Asset Integrity & Reliability Masterclass

API 580/581 risk-based inspection, API 579 fitness-for-service, API 571, 583 & 584 & corrosion management
What you'll learn

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Conduct a risk-based inspection study to API 580 and 581, from screening through to a defensible inspection plan
Perform a fitness-for-service assessment to API 579 - metal loss, pitting, crack-like flaws and the Failure Assessment Diagram
Build a damage mechanism review for any circuit from material, service and temperature
Establish and govern integrity operating windows to API 584, including exceedance response
Manage corrosion under insulation to API 583 - prioritisation, inspection strategy and prevention by design
Write and maintain a corrosion control document and define corrosion circuits
Build a mechanical integrity programme that satisfies PSM Requirements

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and survives audit
Apply RCM logic to select maintenance tasks and eliminate bad actors
Calculate probability and consequence of failure, and understand how inspection effectiveness modifies risk
Select a repair method to ASME PCC-2 and control temporary repairs properly
Set KPIs and leading indicators that tell you the programme is working before something fails
Present an integrity case to an owner, a regulator or an insurer with evidence behind it
Requirements

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No prior integrity or inspection experience is required - every module builds from first principles
Any engineering, inspection, maintenance or technical background is enough to follow the programme
Comfortable with basic algebra - the RBI and FFS calculations are worked step by step
No software or licence needed. The calculations are done by hand so the methodology is visible rather than hidden in a tool
Helpful but not essential: familiarity with pressure equipment, piping or plant inspection
Suitable both as a complete programme and as a reference to return to module by module
Description

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Every operating plant is getting older, and somebody has to be able to say - with evidence - that it is still safe to run.
That person is not usually the designer. The design was finished years ago and the assumptions in it stopped being true somewhere around the third turnaround. What matters now is what the equipment has actually experienced, what is degrading, how fast, and whether the inspection programme is looking in the right places.
This masterclass is the discipline of answering that question and being able to defend the answer.
WHAT ASSET INTEGRITY ACTUALLY IS
Not inspection. Inspection is a data-gathering activity inside a much larger system. Asset integrity is the programme that decides what to inspect, when, using which technique, on the basis of what could credibly go wrong - and then does something useful with the result.
It is also, increasingly, a regulated obligation. Mechanical integrity is a named element of process safety management, and a competent authority or an insurer will ask to see the programme rather than the reports.
WHAT IS INSIDE - TEN COMPLETE MODULESAPI 580 & 581 Risk-Based Inspection.The RBI methodology from qualitative screening to fully quantitative assessment, probability and consequence of failure, damage factor calculation, inspection effectiveness and how it modifies the outcome, risk targets and plan generation, and the documentation an RBI study must produce to be defensible.
API 579 Fitness-for-Service. Assessment levels and when each applies, the Remaining Strength Factor, general and local metal loss, pitting and laminations, HIC and SOHIC assessment, crack-like flaws and the Failure Assessment Diagram, creep and fire damage, and the run, repair, rerate or replace decision the assessment feeds.
API 571 Damage Mechanisms. The mechanism catalogue underpinning everything else - thinning, environment-assisted cracking, high-temperature mechanisms and metallurgical damage, matched to material, service and temperature so that a credible damage mechanism review can be built for any circuit.
API 584 Integrity Operating Windows. Establishing critical, standard and informational limits, linking process parameters to damage mechanism rates, exceedance response and escalation, integration with the control system and operator awareness, and the governance that keeps IOWs alive rather than filed.
API 583 Corrosion Under Insulation. The most expensive damage mechanism in refining. Susceptible temperature ranges and services, insulation and cladding as the cause rather than the protection, inspection strategy and its difficulty, prioritisation and de-insulation decisions, and prevention by design.
Corrosion Management & Control Documents. The corrosion control document and corrosion circuit definition, corrosion monitoring by probe, coupon and inspection data, chemical treatment and inhibition programmes, data management and trending, and building a corrosion management system that survives audit.
Mechanical Integrity Programmes.The PSM mechanical integrity element and its Requirements

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, equipment criticality and coverage, written procedures and training, quality assurance for maintenance materials, deficiency management, KPIs and leading indicators, and the audit findings that recur across the industry.
Reliability-Centred Maintenance. Functions and functional failure, failure modes and effects analysis, consequence categories, the RCM decision logic, maintenance task selection, bad actor identification and elimination, and the interface between reliability and integrity.
Materials, Metallurgy & Corrosion.The metallurgy layer beneath every damage mechanism - why the mechanisms behave as they do, and how material selection prevents them.
ASME PCC-2 Repair.What you do about what you found. The repair decision, welded and non-welded methods, in-service welding, and temporary repair control with expiry tracking.
THE THREAD RUNNING THROUGH IT
Every module answers one of four questions. What could credibly degrade this equipment. How fast. How would I know. And what do I do when I find it.
An integrity programme that cannot answer all four is a set of inspection reports rather than a system, and that distinction is exactly what a regulator, an insurer or an incoming asset owner will probe.
BUILT FOR THE CORPORATE FUNCTION
This programme is aimed at the engineer who owns the integrity of a plant rather than a single item of equipment. The emphasis throughout is on programmes, governance, documentation and defensibility as much as on technique - because that is what the role actually consists of, and it is the part no other training covers.
TWO FULL MOCK EXAMINATIONS
Timed, scored and retakeable, covering damage mechanisms, risk-based inspection and fitness-for-service, and programme management.
WHO THIS IS FOR
Integrity and inspection engineers who own or contribute to an integrity management programme. Reliability engineers working on equipment strategy and bad actor elimination. Corrosion and materials engineers supporting integrity decisions. Process safety and compliance professionals responsible for the mechanical integrity element. Asset managers and plant engineers accountable for continued operation. And consultants delivering RBI, FFS or integrity programme work.
WHAT YOU GET
Around 31 hours of structured video across 200 lessons and 50 sections, two full mock examinations, all presentations downloadable, lifetime access on mobile and TV and a certificate of completion.
No prior integrity experience is required - every module builds from first principles. No software or licence needed; the RBI and FFS calculations are worked by hand so the methodology is visible.
STILL GROWING
This masterclass is actively extended. New modules are added at no extra cost to everyone already enrolled.
Built by a practising Chartered Engineer (CEng MIMechE) with over fifteen years delivering safety-critical projects across oil, gas and energy infrastructure.
Enrol now and be able to defend the answer, not just produce it.
Who this course is for

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Integrity and inspection engineers who own or contribute to an asset integrity management programme
Reliability engineers responsible for equipment strategy and bad actor elimination
Corrosion and materials engineers supporting integrity and inspection decisions
Process safety and compliance professionals responsible for the mechanical integrity element of PSM
Asset managers and plant engineers accountable for continued safe operation of ageing equipment
Consultants and contractors delivering RBI studies, FFS assessments or integrity programmes
API 510, 570 and 653 holders extending from inspection into programme ownership
Engineers preparing an integrity case for a regulator, insurer or incoming asset owner
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