Process Equipment & Piping Systems: Application, Design & Operation

Introduction:

The mechanical integrity and reliability of process equipment and piping systems can only be achieved if they are designed by competent engineers and operated and maintained effectively within the design envelope, namely, the integrity operating window (IOW).

This conference provides the appropriate mix of fundamentals, methodologies, best industry practices, and practical tools to enhance the competencies and improve the performance of design, operation, and maintenance technical professionals individually and collectively to add value to the organization and improve the plant safety and reliability.

Targeted Groups:

Process, Mechanical and Chemical Engineers
Operation and Maintenance Engineers
Project Engineers
Supervisors and Managers
Technical Personnel involved in inspection

Conference Objectives:

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

Increase the awareness and understanding of mechanical integrity of process equipment and piping systems depends jointly on the proper design, operation, condition assessment, and maintenance of the equipment, underscoring their vital individual and team roles in managing change.
Get practical and sound methods and tools to enable them to carry out basic design calculations for pressure equipment following applicable industrial codes, standards, and best practices.
Get a clear understanding of the degradation mechanisms that process equipment could be subjected to over their operating life, how to identify them, predict and determine their impact, and what appropriate measures can be taken to prevent and control the resultant damage.
Gain the knowledge and failure analysis skills they need to conduct damage and failure analysis to prevent similar failures from happening.
Enhance the knowledge and skills in hazard identification and analysis, and risk assessment and management.

Targeted Competencies:

Working knowledge in mechanical design of pressure equipment and piping systems in compliance with applicable codes, standards, and regulations - ASME B&PVC Section VIII, B31.3
The inter-dependence of design, operation, and maintenance for achieving mechanical integrity of pressure equipment and piping systems
Understanding, prediction and Identification and assessment of active degradation mechanisms and the failures they may cause
Failure investigation techniques and root cause analysis
Application of risk-based methodologies in inspection and maintenance - API 580
NDT methods and their effective application - ASMEB&PVC Section V
Performing Level 1 fitness-for-service assessments - API 579
Engineering materials properties and selection criteria for specific applications
Hazard identification and risk analysis and management

Conference Content:
Unit 1: Key Design Considerations, Guidelines, and Practices:

Process Equipment - An Overview
Plant Integrity and Reliability
Interdependence of engineering, operation and maintenance
Management of change
Fitness for Purpose
Service conditions, equipment sizing, and functional performance
Business-Focused-Facilities – Appropriate quality at lowest life cycle cost
Safety by Design
Worst foreseeable credible scenarios, safeguarding, best industry practices
Codes, Standards, Industry Practices
Compliance with Regulations and Acts - HS&E requirements and considerations

Unit 2: Design and Operation of Pressure Equipment:

Pressure Vessels and Reactors
Materials of construction and standards
Basic Design Methodology
ASME Boiler and Pressure Vessel Code Sections
Storage Tanks
Types and application; cone roof tanks, floating roof tanks
Basic design methodology
Overview of API 650
Piping Systems
Materials of construction and standards
Basic Design Methodology – hydraulic design, pressure integrity, mechanical integrity
ASME B31.1 and B31.3
Piping flexibility and support
Piping system components – valves and fittings; classes, ratings
Worked Examples
Overpressure Protection
Types and application of pressure-relieving devices
Code requirements
Sizing methodology: API 520 and 521
Specific operation and maintenance requirements: API 576

Unit 3: Design and Operation of Thermal Equipment:

Process Heaters
Types and configuration; box type, vertical cylindrical type
Thermal and mechanical design
API 560, API 530
Boilers
Types and configuration; water tube, firetube and waste heat recovery boilers
Fundamentals of design and operation
Operating efficiency and testing
ASME B&PVC Section 1 and Section 4, ASME PTC-4
Heat Exchangers
Types and application; Shell & Tube Heat Exchangers, Plate Heat Exchangers, Air Cooled Heat Exchangers
Thermal and mechanical design
Overview of TEMA standards, API 660, API 661
Operation, fouling, and effectiveness

Unit 4: Design and Operation of Fluid Handling Equipment:

Pumps
- Types and application; Centrifugal, Positive Displacement
- Performance characteristics
- Selection and design considerations and standards; ANSI, API 610
- Worked examples
Compressors
- Types and application; Centrifugal, Screw, Reciprocating
- Design considerations and standards
- Operation and troubleshooting
Electric motors
- Types and application
- Operation and troubleshooting
Condition Monitoring
- Vibration monitoring
- Lubricating oil analysis
Troubleshooting
- Methodology and guidelines
- Reliability improvement

Unit 5: Degradation and Condition Assessment of Process Equipment:

Degradation processes
Corrosion, erosion, fatigue, hydrogen attack
Overview of API 571
Industrial Failures and Failure Prevention
Inspection and Testing
Inspection strategies, plans, and coverage – The real function of inspection
Nondestructive Testing (NDT) methods and their characteristics and applicability
Risk-Based Inspection (RBI )
Overview of API 580 and API 581
Fitness-For-Service Assessment
Overview of API 579
Worked examples
Maintenance Strategies and Best Practices
Optimum mix of reactive, preventive and predictive methods
Reliability Centered Maintenance (RCM)