Training Safety in Process Design

Training Safety in Process Design

Introduction

Safety in Process Design includes a wide range of subjects with many applications in Oil & Gas, Chemical and Process industries, related to hydrocarbons and chemical processing. This seminar provides an overview of important elements of process safety as they are often encountered in today’s industrial practice. The emphasis is on engineering design aspects of Process Safety Management and it will highlight the safeguarding aspects of processing equipment inside the plant. Techniques for analyzing and mitigating process safety hazards applicable to oil and gas processing will be reviewed. Integration of the concepts required to achieve an optimum approach to Process Safety Engineering is the main goal of this seminar. Exercises and useful examples will be utilized throughout the seminar to emphasize the key learning points.

Upon completion of this seminar, the delegates will learn:

• Importance of the concept of “Inherently Safer Design”
• Design principles based on Codes and Standards for safe operation of process equipment
• Selection and sizing of safety valves and pressure relief systems
• Common process hazards analysis methods: HAZOP, LOPA, FMEA
• Detection and prevention methods for fire and explosion accidents
• Plant Equipment Inspection (NDT) and Maintenance Procedures

Seminar Objectives

• Comprehensive understanding of different aspects of process design that influence process safety
• Ability to select an “inherently safer design” for the entire process plant operation
• Knowledge on the mechanical structure integrity of process equipment
• Familiarity with hazards associated with process fluids regarding material degradation
• Experience with the Code requirements for sizing relief valves, methodology for determining the relief flows and handling the relief streams.
• Knowledge of how to operate with emergency depressuring systems (EDP) system for prevention of fire and gas explosions

  Training Methodology

 The seminar will be conducted along workshop principles with formal lectures and interactive examples, which will result in the active participation of all delegates in discussions and teamwork. Real life examples will be selected to illustrate the efficient operation and potential technical failures as well as their root causes. The emphasis will be on troubleshooting the problems and maintaining plant safety. There will be ample opportunities for active, open discussion and sharing professional experiences on various safety issues. All seminar materials will be provided.

 Organizational Impact

On completion of this seminar the delegate will be able to critically analyse the safety methodologies employed within the organisation and instigate improvements where required. The knowledge gained in this seminar will:

• Enable the delegate to optimise the operation of various components of equipment while maintaining safety of the plant
• Give the delegate confidence to carry out risk minimization analyses on process equipment thereby avoiding failures
• Enable measures to enhance equipment status for the given operating conditions
• Give better handling of pressure relief system
• Enable better specification of new and replacement of old elements of piping system
• Allow tighter control of maintenance budgets by the avoidance of unplanned equipment failures in service

Personal Impact

• Improved confidence when considering safety issues
• Better understanding of how the process design impacts safety of the plant
• Better grasp of maintenance and instrumentation on incident prevention
• Improved personal knowledge of risk and hazard analysis
• Better ability to troubleshoot difficult and hazardous situations
• Confidence and ability to select the appropriate depressuring plan thereby improving reliability and personal profile to senior management

Who Should Attend?

• Engineers and technicians in oil & gas, chemical and process industries
• Process, mechanical and chemical engineers
• Engineers and technicians who deal with reactors and piping systems
• Design engineers, project engineers and HSE managers
• Control, automation and instrumentation engineers
• Operators and maintenance personnel

Programme Outline

Overview of Safety in Process Design Definition of Safety in Process Design Overview of Historical Incidents and Problem Areas Components of Process Safety: People, Plant, Process Risk Identification and Safety Analysis Process Hazard Analysis: HAZOP, LOPA, FMEA Hazards Associated with Specific Plant Systems Elimination of Hazards through Process Design Prevention of Human Error through Process Control and Monitoring

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

Safety of Process Equipment Hazard Associated with Process Equipment Safety Considerations 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 Design of Piping System Accessories: Valves, Fittings, Supports Assessment  of Material Degradation during In-Life Cycle: Fitness for Service Monitoring, Testing and Inspection (NDT)

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

Process Monitoring and Control Safety Instrumented Systems Process Plant Monitoring and Control System: SCADA Emergency Depressuring 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

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