Layout and Design of Process Plant Equipment and Piping Systems

Mississauga, Ontario /
Aug 12 - 15, 2019 /
Course Code: 10-0808-2365

The confirmation of a course and venue depends on early registration; Register early to avoid the postponement or cancellation of a course.
  • Overview
  • Syllabus
  • Instructor
  • Location


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

  • develop practical working knowledge and skills in process equipment and piping systems layout and design principles, procedures and best practices
  • determine the impact of layout and pipe routings options
  • familiarize yourself with the design and construction codes and standards for piping and process equipment
  • enhance your knowledge in stress analysis and better appreciate its role in avoiding failures
  • learn from catastrophic incidents that resulted from poor layout and design so that you will avoid such incidents

Designing process plants is a complex and demanding process. The design of plant layout is one of the most important tasks before plant construction. A good plant layout can not only reduce capitalized cost, but also helps to improve the safety of the plant and reduce its environmental impact. Additionally, fast, uncomplicated and adequate access to individual items of plant and equipment is essential for effective operation and maintenance which means higher plant availability and longer time between failures.

This course will familiarize participants with all aspects of process plant major equipment and piping systems.

Course Outline:

  • Design and Layout Fundamentals
  • Process Plant Design
  • Layout Design and planning
  • Workshops - Case Studies - Catastrophic Incidents Caused by Poor Layout
  • Process Equipment – Sizing and Design Methodologies and Considerations
  • Basic Design of Piping Systems
  • Layout and Design Requirements of Piping Systems
  • Piping Thermal Expansion and Flexibility
  • Introduction to Pipe Stress Analysis and Demonstration of Software Application
  • Equipment Piping Layout Considerations and Best Practices

Who Should Attend:
Engineers and Designers Involved In Plant Design Activities • Project Engineers • Process Engineers • Piping Fabricators •Contractors and Suppliers • Piping Design and Analysis Personnel• Recent Engineering Graduates In All Disciplines

More Information


Daily Schedule
8:00 Registration and Coffee (Day I only)
8:30 Session begins
12:00 Lunch
4:30 Adjournment

There will be a one-hour lunch break each day in addition to a refreshment and networking break during each morning and afternoon session.

Day I - Process Plant Design and Layout Fundamentals

Welcome, Introduction, Seminar Preview, Learning Outcomes and the Assessment Method

Design and Layout Fundamentals

  • Overview
  • Project scope and definition – project management overview, PMI, AMA
  • Design methodologies and guidelines
  • Applicable design codes, standards, recommended practices and regulations – CSA, ASME, MSS-SP, PIP
  • Compliance and due diligence – Regulations, designers responsibilities

Process Plant Design

  • Objectives and principles
  • Design methodology and guidelines
  • Inherent safety
  • Process Flow Diagrams (PFDs) – symbols, conventions and best practices

Layout Design - General Philosophy and Principles

  • Goals of plant layout design
  • Site location, layout and conditions
  • Separation distances – standards and best practices, API, CCPS, GE-GAP

Key Considerations Affecting Plant Process Design and Layout

  • HSEC (Health; Safety; Environment; Community)
  • Safety aspects of plant layout - methodology for hazardous area classification; plant layout safety index; fire, explosions and toxic release
  • Operability and maintainability
  • Constructability
  • Business-focused facilities (BFF) – Life cycle costs

Layout Planning and Procedures

  • Plant layout and plot plans - best practice and guidelines - NFPA, CCPS, PIP
  • Plot plans, equipment drawings, nozzle specifications
  • Piping and Instrument Diagrams (P&IDs) - symbols, conventions, best practices PIP
  • Considerations for civil, structural, mechanical, electrical, instrumentation
  • Design and layout checklist

Workshop I

  • Case Studies - Catastrophic Incidents Caused by Poor Layout – Root causes and learnings.

Day II –Process Equipment and Piping Systems – Sizing and Design Methodologies and Considerations

Process Equipment – Sizing and Design

  • Design methodology and recommended practices – safety by design
  • Preliminary sizing and mechanical design of major equipment– Pressure vessels, storage tanks, heat exchangers, process heaters, boilers, and pumps.
  • Estimating costs of major equipment and piping
  • Standard specifications and data sheets for process equipment
  • Worked examples

Piping Fundamentals

  • Pipe types, manufacture and quality; materials; standard and custom sizes
  • Piping system components, standards, dimensions, materials, regulations
  • Fabrication and installation, piping joints, code requirements

Layout and Design Requirements of Piping Systems

  • Optimization of process plant layout with pipe routing
  • Isolation and blinding
  • Vents, drains, slopes, injection points and sample connections
  • Configuration of spared equipment – testing and operating philosophy
  • Specific requirements - pressure relief and flare header; gas piping; heat tracing

Basic Design of Piping Systems

  • Design basis and constraints
  • Hydraulic design – pumping systems, fluid flow and pressure drop
  • Design codes and standards – ASME B31.1 and B31.3
  • Pressure integrity – ASME B31.1 and B31.3
  • Mechanical (structural) integrity
  • Worked examples

Piping Thermal Expansion and Flexibility

  • Basics of pipe thermal expansion
  • Stresses induced by thermal expansion
  • Appropriate methods to absorb thermal expansion - Expansion bends, loops, and expansion joints
  • Piping loads on load-sensitive equipment- Requirements and best practices

Workshop II

  • Case studies – Piping failures resulting from improper design and layout – Root causes and learnings

Day III – Piping Systems – Pipe Supports and Stress Analysis; Underground Piping Systems and Services

Pipe Supports and Restraints

  • Code requirements (ASME B31.3)
  • Types and Application, MSS-SP standards
  • Sizing and Selection
  • Location of supports, guides, and anchors

Workshop III

  • Worked example – Pipe supports

Optimization of Pipe Support Spacing

  • Worked example

Introduction to Pipe Stress Analysis

  • Failure theories, stress categories, stress limits, and fatigue
  • Code requirements (ASME B31.3) – empirical methods, need for formal stress analysis
  • Best industry practices
  • Worked examples - simplified screening methods

Underground Piping Systems and Services

  • Firewater system
  • Effluent collection and treatment
  • Sewer systems – contaminated storm water; oily water; equipment drainage to slop tank
  • Electrical and instrument cables

Workshop IV

  • Demonstration of computer-assisted piping stress analysis (CAEPIPE)

Day IV - Equipment Piping Layout Considerations and Best Practices

Pressure Vessels

  • Vertical vessels and towers
  • Horizontal vessels

Aboveground Storage Tanks

  • Vertical tanks - Fixed roof, Floating roof
  • Horizontal tanks

Fired Heaters and Boilers

  • Fired heater - Natural draft; Forced draft
  • Boilers - Firetube; watertube

Heat Exchangers

  • Shell and tube
  • Reboilers and condensers
  • Plate-type heat exchangers
  • Air-cooled heat exchangers


  • Types - centrifugal; vertical in-line; positive displacement
  • Applications – process; boiler feed water; firewater

Compressors, Blowers and Fans

  • Centrifugal compressors
  • Reciprocating compressors
  • Blowers and fans

Gas Turbines

  • Combined heat and power systems configurations

Steam Turbines

  • Condensing
  • Backpressure
  • Steam and condensate piping systems

Questions and Answers and Feedback to Participants on Achievement of Learning Outcomes

Concluding Remarks and Final Adjournment


Nabil Al-Khirdaji, M.Eng., P.Eng.

Nabil is president of Kappa Associates International, which provides engineering and project services to the petroleum, process, energy, and related industries.

Mr. Al-Khirdaji has taught well over 200 technical professional development courses in Canada and internationally. He has over 40 years of experience in the petroleum, petrochemical, and related industries both in Canada and the Middle East, including 24 years with Shell Canada Limited, where he assumed a number of project, engineering specialist, and engineering management positions. He also held the position of mechanical program director with EPIC and a number of senior international positions including project management with an oil and gas engineering company in Milan, Italy. Mr. Al-Khirdaji served for several years on the API committee on refinery equipment.


EPIC Learning Center
5670 McAdam Rd
Mississauga, ON L4Z 1T2

Other Venue InformationFor hotels close to EPIC/Special room rates, please email

We always want to improve the quality of our courses. Please select any reasons why you feel this course is inadequate (check all that apply).

Please check this box:
Course Rating
4.6 out of 5

Overall rating of this course by its previous attendees!

Fee & Credits
Early Registration Fee:

$2545 + taxes

Fee after July 5, 2019:

$2695 + taxes

  • 2.8 Continuing Education Units (CEUs)
  • 28 Professional Development Hours (PDHs)
  • ECAA Annual Professional Development Points

Canada Job Grant
The cost of this course could be covered by Canada Job Grant.

Your company may be eligible for funding! LEARN MORE
On-Site Training
This course can be customized and delivered to your group of staff at your facility, saving time and money.
Layout and Design of Process Plant Equipment and Piping Systems   Winnipeg | Aug 17 - 20, 2020 _________________________________
EPIC's email newsletter is a great source of information for:

  • course updates
  • surveys
  • informative articles/papers
  • exclusive discounts