Process Equipment Design and Controls for Operators & Engineers

Upon completing this Process Equipment Design and Controls for Operators & Engineers training program successfully, participants will be able to:
• Study the different aspects of process design that impact process safety
• Implement a fundamentally safer design for the operation of the entire process plant
• Assess the mechanical reliability of process equipment
• Recognise the hazards related to process fluids in terms of their impact on material degradation
• Abide by the code requirements for sizing relief valves to handle relief streams
• Activate emergency de-pressuring systems (EDP) in case of fire and gas explosions
Course Content
Fundamentals of Process Engineering
• Mass and energy balances
• Reactor types
• Process & Engineering Diagrams
• Flammability
• Electrical area classification
• Risk Management and Hazard Studies
Overview of Safety in Process Design
• Definition of Safety in Process Design
• The Components of Process Safety
• Risk Identification and Safety Analysis
• Process Hazard Analysis: HAZOP, LOPA, FMEA
• Hazards Associated with Specific Plant Systems
• Elimination of Hazards through Process Design
• Obstruction of Human Error with Process Control and Monitoring Techniques
Inherently Safer Design
• What is Inherently Safer Design?
• Pre-Design and Design Phases
• Materials of Construction and Optimised Fabrication
• Process Fluids and Chemical Reaction Hazards
• Corrosion, Erosion, and Material Degradation
• Leakage and Loss of Primary Containment
• Dispersion of Hydrocarbon Release
• Flammability of Chemicals
Crude Oil Processing Equipment Design & Sizing
• Separator’s Technology
• Operating Parameters and Operations Problems
• Elements Of Calculation Standards
• Sizing A 2-Phase And 3-Phase Separator
Gas Processing Equipment Design & Sizing
• Column’s Technology
• Selection Criteria
• Operating Parameters
• Elements Of Sizing
• Column Troubleshooting
Safety of Process Equipment
• Hazard Associated with Process Equipment
• Safety Considerations in Reactor Design
• Design Procedure for Safety of:
o Pressure Vessels
o Storage Tanks
o Reactors
o Heat Exchangers
• Venting of Tanks and Vessels
• Standards and Best Practices
• Piping System Design and Safety
• Design of Piping System Accessories
• Assessment of Material Degradation
• Monitoring, Testing, and Inspection (NDT)
Design of Pressure Relief Systems
• Design of Safety Valves
• Operation of Pressure Relief System
• Sizing of Pressure Relief Systems Relief Loads
• Pressure Relief Valves vs. Rupture Discs
• Codes, Standards and Best Practices
• Specifics of Pressure Relief Systems
• Process Plant Disposal Systems
• Disposal Hazards and Environmental Factors
Process Monitoring And Control
• Safety Instrumented Systems
• Process Plant Monitoring and Control Systems
• Emergency De-pressuring Systems (EDP)
• Prevention of Fire and Gas or Dust Explosions
• Safety Deliberations in Equipment Spacing and Plant Layout
• Supervision of Change and Integrity Operation Window
• Plant Equipment Inspection and Maintenance Procedures

Methodology
The training methodology integrates lectures, interactive discussions, collaborative group exercises, and illustrative examples. Participants will acquire a blend of theoretical insights and hands-on practical experience, emphasizing the application of learned techniques. This approach ensures that attendees return to their professional environments equipped with both the competence and self-assurance to effectively implement the acquired skills in their responsibilities.

DATE:

1ST BATCH:        21st – 24th Jan, 2025     

2ND BATCH:       24th – 27th June, 2025