Safety in Process Equipment Design and Operation Course

This training course provides an overview of important elements of process safety as they are often encountered in today’s industrial practice. The emphasis is on engineering design aspects of Process Safety Management and it will highlight the safeguarding aspects of processing equipment inside the plant. Techniques for analysing and mitigating process safety hazards applicable to Oil and Gas processing will be reviewed.

Integration of the concepts required to achieve an optimum approach to Process Safety Engineering is the main goal of this course. Exercises and useful examples will be utilized throughout the course to emphasize the key learning points.

The training course will feature:

• Importance of the concept of “Inherently Safer Design”
• Design principles based on Standards for safe operation of process equipment
• Selection and sizing of safety valves and pressure relief systems
• Methods for process hazards analysis: HAZOP, LOPA, FMEA
• Detection and prevention methods for fire and explosion accidents
• Plant Equipment Inspection (NDT) and Maintenance Procedures

Training Objectives

• At the end of this training course, the participants will be able to:
• Understanding different aspects of process design that influence process safety
• Appreciate “inherently safer design” for the entire process plant operation
• Evaluate mechanical integrity of process equipment
• Identify hazards associated with process fluids regarding impact on material degradation
• Follow code requirements for sizing relief valves to handle relief streams
• Operate emergency de-pressuring systems (EDP) in case of fire and gas explosions

Target Audience

• This training course is suitable to a wide range of professionals but will greatly benefit:
• Operation, technical service and maintenance professionals
• Technical professionals responsible for maintenance and repair of equipment
• Professionals involved in inspection and maintenance and repair
• Project engineers and HSE professionals
• Technical professionals dealing with risk assessment and integrity analysis

Daily Agenda

Day One: Overview of Safety in Process Design

Competency Description: Familiarization with concept of safety in design

Topics to be covered

• Definition of Safety in Process Design
• Overview of Historical Incidents and Problem Areas
• Components of Process Safety: People, Plant, Process
• Risk Identification and Safety Analysis
• Process Hazard Analysis: HAZOP, LOPA, FMEA
• Hazards Associated with Specific Plant Systems
• Elimination of Hazards through Process Design
• Prevention of Human Error through Process Control and Monitoring

Day Two: Inherently Safer Design

Topics to be covered

• “Inherently Safer Design” Methodology
• Pre-Design and Design Phases
• Materials of Construction and Optimized Fabrication
• Hazard Associated with Process Fluids and Chemical Reactions
• Corrosion, Erosion and Material Degradation
• Leakage and Loss of Primary Containment
• Dispersion of Hydrocarbon Release
• Flammability of Chemicals

Day Three: Safety of Process Equipment

Topics to be covered

• Hazard Associated with Process Equipment
• Safety Considerations in Reactor Design
• Design Procedure for Safety of Pressure Vessels, Storage Tanks, Reactors, Heat Exchangers
• Venting of Tanks and Vessels: Codes, Standards and Best Practices
• Piping System Design and Safety
• Design of Piping System Accessories: Valves, Fittings, Supports
• Assessment of Material Degradation during In-Life Cycle: Fitness for Service
• Monitoring, Testing and Inspection (NDT)

Day Four: Design of Pressure Relief Systems

Topics to be covered

• Design of Safety Valves
• Operation of Pressure Relief System
• Calculation and Sizing of Relief Loads of Pressure Relief Systems
• Pressure Relief Valves vs. Rupture Discs
• Codes, Standards and Best Practices
• Specifics of Pressure Relief Systems for Pumps, Compressors, Turbines
• Process Plant Disposal Systems
• Disposal Hazards, Risk Assessment and Environmental Factors

Day Five: Process Monitoring and Control

Topics to be covered

• Safety Instrumented Systems
• Process Plant Monitoring and Control System: SCADA
• Emergency De-pressuring Systems (EDP)
• Prevention of Fire and Gas or Dust Explosions
• Safety Consideration in Plant Layout and Equipment Spacing
• Management of Change and Integrity Operation Window
• Plant Equipment Inspection and Maintenance Procedures
• Final Conclusions