Course details

Overview ?

Introduction

Safety in Process Design includes a wide range of subjects with many applications in Oil & Gas, Chemical and Process industries, related to hydrocarbons and chemical processing. This 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 analyzing 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.

Upon completion of this course, the delegates will learn:

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

Objectives

Comprehensive understanding of different aspects of process design that influence process safety
Ability to select an “inherently safer design” for the entire process plant operation
Knowledge on the mechanical structure integrity of process equipment
Familiarity with hazards associated with process fluids regarding material degradation
Experience with the Code requirements for sizing relief valves, methodology for determining the relief flows and handling the relief streams
Knowledge of how to operate with emergency depressuring systems (EDP) system for prevention of fire and gas explosions

Training Methodology

The seminar will be conducted along workshop principles with formal lectures and interactive examples, which will result in the active participation of all delegates in discussions and teamwork. Real life examples will be selected to illustrate the efficient operation and potential technical failures as well as their root causes. The emphasis will be on troubleshooting the problems and maintaining plant safety. There will be ample opportunities for active, open discussion and sharing professional experiences on various safety issues. All course materials will be provided.

Organizational Impact

On completion of this seminar the delegate will be able to critically analyse the safety methodologies employed within the organisation and instigate improvements where required.

The knowledge gained in this seminar will:

Enable the delegate to optimise the operation of various components of equipment while maintaining safety of the plant
Give the delegate confidence to carry out risk minimization analyses on process equipment thereby avoiding failures
Enable measures to enhance equipment status for the given operating conditions
Give better handling of pressure relief system
Enable better specification of new and replacement of old elements of piping system
Allow tighter control of maintenance budgets by the avoidance of unplanned equipment failures in service

Personal Impact

Improved confidence when considering safety issues
Better understanding of how the process design impacts safety of the plant
Better grasp of maintenance and instrumentation on incident prevention
Improved personal knowledge of risk and hazard analysis
Better ability to troubleshoot difficult and hazardous situations
Confidence and ability to select the appropriate depressuring plan thereby improving reliability and personal profile to senior management

Who Should Attend?

Engineers and technicians in oil & gas, chemical and process industries
Process, mechanical and chemical engineers
Engineers and technicians who deal with reactors and piping systems
Design engineers, project engineers and HSE managers
Control, automation and instrumentation engineers
Operators and maintenance personnel

Seminar outline

Overview of Safety in Process Design

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

Inherently Safer Design

“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

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: 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)