Contemporary industrial processes exhibit characteristics such as size, complexity, and extensive interplay among dependent and independent variables. Consequently, problem-solving within these processes becomes challenging, often leading to the phenomenon known as the "disappearing problem" syndrome. Problems tend to vanish without being resolved, only to resurface later. This course introduces a distinctive approach that combines cause-and-effect problem-solving thinking with the development of theoretically sound working hypotheses. This approach offers expedient and efficient problem-solving techniques specifically tailored for the process industry.

Course Objectives:

Upon the successful completion of this course, participants will be able to:-

Enrich knowledge on process plant troubleshooting and engineering problems solving through various practical exercises carry out during the course
Familiarize the components of plant problem solving as well as the various troubleshooting techniques on engineering problem solving by familiarizing the potential sources
Specify the limitations to plant problem solving through sources of historical data and become aware of the daily monitoring system guidelines by setting trigger points
Apply the methods of risk analysis particularly HAZOP and MSDC in process plant troubleshooting and practice the process of engineering problem solving through sample problems in troubleshooting
Know the scope of applied economics including other valuation forms & methods, and review the guidelines for problem solving temperature, pressure, and level
Learn the application of the simplified approach in solving compressor problems and know distillation, plates, and tray stability Explain clearly the elements of measurements and verifications, and carry-out sample exercise on kinetics, flow, mechanical, and designs
Recognize the attributes of equivalent piping lengths, commercial correlations, and fluids by means of practical exercises
Know the importance of two phase flow including its attributes and applications and be able to analyze the characteristics of controllers, feedback, feed forward and cascade controls used in process control
Improve knowledge on process control and optimization, process analyzers, distillation multiple control, volume control, condenser control, and control project drawback
Enhance understanding on heat transfer and various troubleshooting techniques and applications in used process plant
Implement several strategies on distillation column packing
Evaluate the different forms of hazards and be able to equip participants with the QRA procedures and demonstration
Become aware of the methods of MSDS and know if the needed information is good enough or incomplete
Identify various accidents in the process plant and know what a flixborough accident is.

Who Should Attend?

Process Engineers, Plant managers, Team Leaders, Section Heads, Plant Supervisors and technical staff.

Course Outlines:

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
Worst foreseeable credible scenarios, safeguarding, best industry practices.
Codes, Standards, Industry Practices
Safety by Design
Compliance with Regulations and Acts - HS&E requirements and considerations

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 2, 5, 8 and 9.
Worked examples

Storage Tanks
Types and application; cone roof tanks, floating roof tanks
Basic design methodology
Overview of API 650
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
Types and application of pressure relieving devices
Code requirements
Sizing methodology; API 520 and 521
Specific operation and maintenance requirements; API 576
Piping Systems
Overpressure Protection

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
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
Heat Exchangers

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
Types and application
Operation and troubleshooting
Vibration monitoring
lubricating oil analysis
Methodology and guidelines
Reliability improvement

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