Course Catalogue.

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

• Understand equipment design methods based on existing world standards
• Apply HAZOP, LOPA, and FMEA analysis during design and operation
• Perform Risk-Based Inspection and analyze results
• Perform fitness for Service (FFS) analysis
• Make the run/repair/replace decisions

Description
Components of process equipment and piping systems are subjected to hazardous service conditions and damage mechanisms. This course will enable technical personnel to become familiar with suitable design methods, the selection of quality engineering materials, and the procedures for monitoring and inspecting equipment to detect and assess any damage and malfunction in operation.

The course will present the approach based on a criticality list, including risk-based inspection and corresponding tests focusing on failure mechanisms and prevention techniques. This course will also cover practical aspects of equipment safe and efficient operation, maintenance, and repair techniques, as well as the method of calculation of equipment remaining life.

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

Who Should Attend
Professional and technical personnel in petrochemical, process, power, and other industries • Mechanical engineers • Process engineers • Project engineers • Technical personnel involved in the operation, inspection, and maintenance of the plant.

Course Syllabus

DAY 1: Process Equipment Design Methods and Standards

• Safety in the Design of Process Equipment
• Design Standards: CSA, ASME, API, ISO
• Estimate of Hazard and Risk of Equipment: HAZOP, LOPA, FMEA
• Optimization in Design and Operation of Equipment: Constraints
• Safety Conditions in Operation and Maintenance
• Reliability and Availability Analysis of Process Equipment
• Workshop: Case Studies, Examples and Solutions

DAY 2: Design and Safe Operation of Stationary Pressure and Thermal Equipment

• Pressure Vessels
• Aboveground Storage Tanks
• Piping Systems and Pipelines
• Pressure Safety Devices
• Heat Exchangers
• Industrial Boilers and Process Heaters
• Workshop: Case Studies, Examples and Solutions

DAY 3: Design and Efficient Operation of Fluid Moving Equipment

• Centrifugal and Positive Displacement Pumps
• Centrifugal and Reciprocating Compressors
• Fans and Blowers
• Gas and Steam Turbines
• Condition Monitoring and Maintenance of Rotating Machinery
• Workshop: Case Studies, Examples and Solutions

DAY 4: Equipment Degradation and Failure Analysis

• Material Degradation Mechanisms and Consequences
• Equipment Failure Analysis
• Best Industrial Practices for Failure Prevention
• Risk-Based Inspection and Testing
• Fitness for Service (FSS) Analysis as per API 579
• Maintenance and Repair Strategies and Best Practices
• Workshop: Case Studies, Examples and Solutions