Layout and Design of Process Plant Equipment and Piping Systems

After participating in this course, you will be able to:

• Develop a practical working knowledge of process equipment and piping systems layout
• Become familiar with design principles, procedures and best practices
• Determine the impact of layout and pipe routings options
• Understand design and construction codes and standards for piping and process equipment
• Enhance your knowledge of stress analysis and better appreciate its role in avoiding failures
• Learn from catastrophic incidents that resulted from poor layout and design

Description
Designing process plants is a complex and demanding process. The plant layout design is one of the most important tasks before plant construction. A good plant layout can not only reduce capital costs but also help improve the plant’s safety and reduce its environmental impact. Additionally, fast and easy access to the parts of the plant and the equipment is essential for effective operation and maintenance, which means higher plant availability and a longer time between failures. This course will familiarize participants with the technical characteristics of process plant equipment and piping systems.

This course will include several class workshops consisting of case studies and selected practical, real-world examples to solve in teamwork.

Who Should Attend
Engineers & Designers involved in Plant Design and Operation Activities • Project Engineers • Process and Piping Engineers • Contractors & Suppliers • Piping Design & Analysis Personnel • Recent Engineering Graduates.

DAY-1 Process Plant Layout and Design Principles

• Principles of process plant design and layout
• Design codes: CSA, ASME, ANSI, NFPA, CFPA
• Concept of safety by design (Inherent Safety)
• Process Flow diagram (PFD) & Piping & Instrument diagram (P&ID)
• Layout planning and design requirements
• Site location, traffic, utilities and business criteria
• Safety considerations and HSE regulations and codes
• Structural, mechanical and electrical aspects of the layout plan

DAY-2: Process Equipment Layout and Design Approach

• Process equipment selection and sizing
• Design methodologies as recommended by standards
• HAZOP, LOPA, FMEA Analysis
• Design and layout of pressure vessels and storage tanks
• Design and layout of heat exchangers
• Design and layout of industrial boilers and industrial heaters
• Pressure relief valves (PRV) and other safety devices
• Control systems and instrumentation

DAY-3 – Piping Systems Layout and Design Strategies

• Pipe sizes and schedules
• Piping design codes and standards: ASME B31.1 & B31.3
• Hydraulic design - fluid flow and pressure drop: pumping power
• Mechanical (structural) design: pressure integrity
• Selection of materials, fabrication and welding techniques
• Pipe support selection and optimization
• Piping thermal expansion design options: expansion loops & bellows
• Pipes in the oil and gas industry: fluid gathering and transport systems
• Pipes in HVAC systems
• Piping installation and inspection

Day 4 – Optimization of Process Plant Equipment

• Optimization of plant layout & equipment spacing
• Prediction of potential failures of process equipment
• Root cause analysis (RCA) of common failures
• Risk management & mitigation technologies: ALARP
• Equipment inspection and repair technologies
• Fitness for service (FFS) analysis, per API 579