Objectives

At the end of this course the participants will be able to:

• Understanding different aspects of process design that influence process safety
• Appreciate inherently safer design for the entire process plant operation
• Evaluate mechanical integrity of process equipment
• Identify hazards associated with process fluids regarding impact on material degradation
• Follow code requirments for sizing relief valves to handle relief stream
• Operate emergency de-pressuring systems (EDP) in case of fire and gas explosion.

Course Outlines

DAY 1

Overview of Safety in Process Design

• Definitions
• Overview of historical Incidents
• Elements of Process Safety
• Risk Identification and Safety Analysis
• Process Hazard Analysis
• Elimination of Hazard through Process Design
• Prevention of Human Error though Process Control and Monitoring

DAY 2

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

DAY 3

Safety of Process Equipment

• Hazard Associated with Process Equipment
• Safety Consideration 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
• Assessment of Material Degradation during In-Life Cycle
• Monitoring, Testing and Inspection.

DAY 4

Design of Pressure Relief Systems

• Design of Safety Valves
• Operation of Pressure Relief System
• Calculation and Sizing of Relief Loads of Pressure Relief Systems
• Pressure Relief Valves vs. Rupture Discs
• Codes, Standards and Best Practices
• Specifics of Pressure Relief Systems for Pumps, Compressors, Turbines
• Process Plant Disposal Systems
• Disposal Hazards, Risk Assessment and Environmental Factors

DAY 5

Process Monitoring and Control

• Safety Instrumented Systems
• Process Plant Monitoring and Control System: SCADA
• Emergency De-Pressuring Systems (EDP)
• Prevention of Fire and Gas or Dust Explosions
• Safety Consideration in Plant Layout and Equipment Spacing
• Management of Change and Integrity Operation Window
• Plant Equipment Inspection and Maintenance Procedures
• Final Conclusions