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Free Download Plant Modification & Turnaround Engineering Masterclass
Published 8/2026
MP4 | Video: h264, 1920x1080 | Audio: AAC, 44.1 KHz, 2 Ch
Language: English | Duration: 11h 56m | Size: 7.31 GB
Repair to ASME PCC-2, hot tapping and stopples, tie-ins, spooling, bolted joints and management of change
What you'll learn
Choose between run, repair, rerate and replace, and defend the decision with engineering
Select a repair method to ASME PCC-2 and judge a contractor's proposal critically
Assess a hot tap or in-service weld - burn-through, hydrogen cracking, material and service
Plan a tie-in from scope through permit and execution to reinstatement and close-out
Decide spool breaks and understand what each field weld costs in schedule and quality
Control fabrication through material traceability, fit-up, welding qualification and NDE
Break and remake a bolted joint properly - gasket selection, bolt load and tightening pattern
Recognise where a modification creates a small-bore vibration risk, and brace it correctly
Build a test pack, test safely, and close out a fabrication data book the client will accept
Run management of change on a modification, from authorisation through to drawing update
Judge which live interventions should not proceed at all, and say so with the evidence
Build turnaround modification scope from inspection, survey and monitoring findings
Requirements
No fabrication, welding or turnaround experience is required - the workflow is built up from the start
Any engineering, technical, construction or operations background is enough to follow the programme
No mathematics beyond arithmetic - this is an execution, decision and governance programme
Helpful but not essential: access to an isometric, a permit system or a turnaround scope from your own site
No software or purchases needed. Copies of ASME PCC-2 and B31.3 are useful alongside the course but not required
This is engineering training, not authorisation - site procedures and qualified personnel always govern
Description
Every other masterclass in this catalogue is about designing, inspecting or maintaining equipment. None of them is about changing it while it is running and full of hydrocarbon.
That is most of the work. New plants are rare; modifications are constant. A tie-in for a new unit, a corroded spool replaced in a shutdown window, a clamp on a leaking flange, a hot tap because the alternative is taking the whole train down, an instrument connection added last year that nobody assessed.
And it is where the incidents are. Loss of containment on an operating plant is far more often a consequence of a change than of a design error.
WHY THESE MODULES BELONG TOGETHER
A modification is one chain of decisions. Whether to repair, replace or rerate. Whether to intervene live or wait for a shutdown. Where the spool breaks and how the new pipework is fabricated. How the joints are broken and remade. What the change does to the small-bore connections hanging off the line. And whether the whole thing is authorised, recorded and closed out.
Taught separately, each of those is somebody else's job. Taught together, they are the job - and the engineer who can see the whole chain is the one who spots where it will fail.
WHAT IS INSIDE - SIX COMPLETE MODULESASME PCC-2 Repair, Clamps & Hot Tapping. The repair decision against run, replace and rerate; weld repair and excavation verification; temper bead and controlled deposition; weld overlay and clad restoration; composite repair; mechanical clamps and leak sealing; in-service welding and hot tapping; and the control of temporary repairs that quietly become permanent.
Hot Tapping & In-Service Modification.The decision to tap rather than shut down; the full sequence from fitting to coupon retrieval; burn-through and hydrogen cracking as the two controlling mechanisms; branch fittings, isolation valves and tapping machines; the assessment that must precede approval; services where it must never be used; and stopples, line stops and freeze plugs as the wider intervention set.
Piping Fabrication, Erection & Spooling. From isometric to installed pipework - spool break selection and what each break costs; material control and traceability; cutting, bevelling and fit-up; welding processes, qualification and control; purging, preheat and PWHT; NDE by fluid service; erection, supports and spring setting; test packs, pressure testing, cleaning and the fabrication data book.
Flanges, Gaskets & Bolted Joint Integrity.The joint that gets broken and remade every time anything changes: flange types and facings, gasket selection and behaviour, bolt load and the relationship between torque and preload, tightening patterns and controlled bolting, joint assembly quality to ASME PCC-1, and troubleshooting the joints that keep leaking.
Small-Bore Piping & Vibration-Induced Fatigue.Where modifications go wrong quietly: the connections added during previous changes, excitation from flow, acoustic energy and machinery, resonance in an unsupported branch with a valve on the end, screening and assessment on an operating plant, bracing that works in two planes, and eliminating the connections nobody needs.
Mechanical Integrity Programmes.The governance layer around all of it - the regulatory framework and what it actually requires, equipment scope and programme boundaries, data and systems, management of change and authorisation, deficiency management, and the assurance that proves the programme is working rather than merely documented.
THE PART NOBODY TEACHES
Management of change. It appears in four of the six modules and it is the thread connecting all of them. A hot tap adds a branch that has to enter the inspection programme. A replacement spool in a different material has to be verified and recorded. A clamp fitted as a temporary repair needs a date on it. Most modification failures are not engineering failures; they are close-out failures.
TWO FULL MOCK EXAMINATIONS
Timed, scored and retakeable, covering repair selection and live-plant intervention, and fabrication, joints, testing and handover. Not video walkthroughs - actual examinations you can sit under conditions.
WHO THIS IS FOR
Turnaround and shutdown engineers building and executing scope. Brownfield and modification project engineers changing plants that are already running. Maintenance and integrity engineers deciding repair against replacement and authorising live-plant work. Construction and commissioning engineers executing tie-ins and taking systems back. Operations engineers holding the permit. And process safety engineers who own management of change.
WHAT YOU GET
Around 19 hours of structured video across 120 lessons and 30 sections, two full mock examinations, downloadable presentations, lifetime access on mobile and TV and a certificate of completion.
No fabrication, welding or turnaround background is required - the workflow is built from the isometric onwards and the welding metallurgy is explained for engineers rather than for welders. This is not authorisation to perform live-plant work; site procedures, qualified personnel and the owner's approval process always govern.
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 the engineer who can change a running plant without breaking it.
Who this course is for
Turnaround and shutdown engineers developing and executing modification scope
Brownfield and modification project engineers working on operating plant
Maintenance and integrity engineers deciding repair against replacement and authorising live work
Piping and mechanical engineers moving from design into execution
Construction, fabrication and commissioning engineers delivering tie-ins and test packs
Operations engineers and supervisors holding permits and process conditions during intervention
Process safety and mechanical integrity engineers who own management of change
Graduate and early-career engineers heading to site or into a turnaround team for the first time
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