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Process Equipment Design and Controls for Operators & Engineers

Introduction

Process Equipment Design and Controls for Operators & Engineers

Course Objectives

• Study the different aspects of process design that impact process safety
• Implement a fundamentally safer design for the operation of the entire process plant
• Assess the mechanical reliability of process equipment
• Recognise the hazards related to process fluids in terms of their impact on material degradation
• Abide by the code requirements for sizing relief valves to handle relief streams
• Activate emergency de-pressuring systems (EDP) in case of fire and gas explosions
• Advanced competency in model predictive control (MPC) and advanced process control (APC) systems
• Expertise in hazard and operability studies (HAZOP) and layer of protection analysis (LOPA)
• Enhanced understanding of safety instrumented systems (SIS) and process safety management
• Skills in equipment design optimization and performance monitoring
• Proficiency in regulatory compliance and industry best practices

Who Should Attend?

• Process engineers
• Project engineers and HSE professionals
• Petroleum engineers
• Maintenance & production engineers
• R&D chemists
• Plant chemists
• Technical professionals accountable for maintenance and repair of equipment
• Technical professionals working with risk assessment and integrity analysis
• Specialists involved in inspection and maintenance and repair
• Operations managers and plant supervisors
• Control system engineers and instrumentation specialists
• Safety engineers and process safety professionals

Course Outline

Module 1: Fundamentals of Process Engineering

• Mass and energy balances
• Reactor types
• Process & Engineering Diagrams
• Flammability
• Electrical area classification
• Risk Management and Hazard Studies
• Process design establishing sequence of chemical and physical operations with operating conditions
• Material and energy balance calculations for complete process characterization
• Process flow diagrams (PFD) as schematic representation of overall process and equipment
• Piping and instrumentation diagrams (P&ID) showing detailed piping, instruments, and control systems

Module 2: Overview of Safety in Process Design

• Definition of Safety in Process Design
• The Components of Process Safety
• Risk Identification and Safety Analysis
• Process Hazard Analysis: HAZOP, LOPA, FMEA
• Hazards Associated with Specific Plant Systems
• Elimination of Hazards through Process Design
• Obstruction of Human Error with Process Control and Monitoring Techniques
• Inherently safer design principles for hazard elimination through process modification
• Process hazard analysis methods for systematic risk identification and evaluation
• Safety instrumented systems (SIS) for automated protection and emergency response
• Human error prevention through robust control systems and monitoring techniques

Module 3: Inherently Safer Design

• What is Inherently Safer Design?
• Pre-Design and Design Phases
• Materials of Construction and Optimized Fabrication
• Process Fluids and Chemical Reaction Hazards
• Corrosion, Erosion, and Material Degradation
• Leakage and Loss of Primary Containment
• Dispersion of Hydrocarbon Release
• Flammability of Chemicals
• Material selection considering mechanical properties, chemical resistance, and temperature tolerance
• Process intensification and minimization strategies for hazard reduction
• Corrosion and erosion assessment for material degradation prevention
• Primary containment design for leak prevention and emergency response

Module 4: Crude Oil Processing Equipment Design & Sizing

• Separator’s Technology
• Operating Parameters and Operations Problems
• Elements Of Calculation Standards
• Sizing A 2-Phase And 3-Phase Separator
• Equipment sizing ensuring appropriate handling of required throughput and operating conditions
• Separator design principles for oil, gas, and water separation efficiency
• Operating parameter optimization for separator performance and reliability
• Calculation standards and design codes for pressure vessel sizing

Module 5: Gas Processing Equipment Design & Sizing

• Column’s Technology
• Selection Criteria
• Operating Parameters
• Elements Of Sizing
• Column Troubleshooting
• Distillation and absorption column design with internal optimization
• Equipment sizing balancing capital costs with operating efficiency
• Column troubleshooting for operational problems and performance optimization
• Selection criteria considering process requirements and economic factors

Module 6: Safety of Process Equipment

• 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
• Standards and Best Practices
• Piping System Design and Safety
• Design of Piping System Accessories
• Assessment of Material Degradation
• Monitoring, Testing, and Inspection (NDT)
• Pressure vessel design according to ASME codes and safety standards
• Heat exchanger thermal design with mechanical integrity considerations
• Reactor safety design including emergency systems and containment
• Piping system design with proper sizing, materials, and safety accessories

Module 7: Design of Pressure Relief Systems

• Design of Safety Valves
• Operation of Pressure Relief System
• Sizing of Pressure Relief Systems Relief Loads
• Pressure Relief Valves vs. Rupture Discs
• Codes, Standards and Best Practices
• Specifics of Pressure Relief Systems
• Process Plant Disposal Systems
• Disposal Hazards and Environmental Factors
• Pressure relief valve sizing according to API and ASME standards
• Relief system design for various scenarios including fire, blocked outlets, and runaway reactions
• Disposal system design considering environmental factors and safety requirements
• Emergency pressure relief for vessel and piping protection

Module 8: Process Monitoring And Control

• Safety Instrumented Systems
• Process Plant Monitoring and Control Systems
• Emergency De-pressuring Systems (EDP)
• Prevention of Fire and Gas or Dust Explosions
• Safety Deliberations in Equipment Spacing and Plant Layout
• Supervision of Change and Integrity Operation Window
• Plant Equipment Inspection and Maintenance Procedures
• Advanced process control (APC) systems for optimization and safety enhancement
• Safety instrumented systems (SIS) with proper safety integrity levels
• Emergency depressuring systems for fire protection and explosion prevention
• Plant layout design considering safety spacing and emergency access