Course Catalogue.

By the end of this course, you will be able to:

• Apply industry-standard design principles and codes to process equipment and piping systems
• Evaluate equipment risk using HAZOP, LOPA, and FMEA methodologies
• Implement risk-based inspection (RBI) and interpret inspection results to inform decisions
• Assess equipment integrity using fitness-for-service (FFS) approaches
• Make defensible run, repair, or replace decisions based on technical and risk factors

Description

Process equipment and piping systems operate under demanding conditions where material degradation, mechanical failure, and process risks can compromise safety, reliability, and performance. Inconsistent design practices, limited visibility into damage mechanisms, and reactive maintenance strategies can lead to increased downtime, unplanned failures, and elevated risk exposure.

This course addresses these challenges by providing a structured approach to equipment design, risk assessment, and operational integrity. It integrates established engineering standards with practical methods for evaluating risk, monitoring equipment condition, and managing degradation mechanisms throughout the asset lifecycle. Key frameworks such as risk-based inspection and fitness-for-service are applied to support informed, evidence-based decision-making.

Through practical examples, case-based workshops, and real-world scenarios, this course provides the tools and methodologies required to improve equipment reliability, extend asset life, and optimize maintenance and inspection strategies in complex industrial environments.

Who Should Attend

This course is designed for:

• Mechanical, process, and project engineers
• Technical professionals involved in equipment design, inspection, and maintenance
• Professionals working in petrochemical, process, power, and related industries
• Early-career to senior practitioners responsible for equipment reliability and asset integrity

Course Syllabus

DAY I

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 II

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 III

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 IV

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