Mechanical Integrity and Reliability in Refineries Petrochemical and Process Plants
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Mechanical Integrity and Reliability in Refineries Petrochemical and Process Plants Course
Introduction:
In this course, participants will receive a thorough examination of the different facets of engineered safety and mechanical integrity within refineries, oil & gas plants, and petrochemical plants.
The primary focus of the course is on the key approaches to ensure plant integrity, with particular emphasis on preventing failures in pressure equipment and piping systems. The course will specifically address failures that have the potential to result in significant consequences.
Course Objectives:
The key objectives of this course are as follows:
- To assist participants in clearly understanding and applying the various aspects of engineered safety to ensure mechanical integrity in a responsible and cost-effective manner.
- To enhance the knowledge and skills of the participants in hazard identification and analysis, and in risk assessment and management.
- To provide participants with practical and effective methods and tools to perform practical likelihood and consequence analyses.
Who Should Attend?
This course is particularly valuable for refinery and petrochemical plant technical managers, engineers, inspectors, maintenance personnel, as well as for project and consulting engineers and engineering and technical personnel involved in plant mechanical integrity and reliability.
Course Outlines:
Technical integrity, industrial failures, and safety in design
Technical Integrity ¡V An Overview
- Definition, scope, and key elements
- Potential threats to technical integrity in a hazardous environment
- Regulatory requirements ¡V SH&E, OSHA, SEVESO II
- Life cycle implications ¡V design/operation/maintenance, regulatory/industrial interface, training/staff development, networking.
Industrial Failures
- Statistics
- Typical examples
- Causes and implications
Estimation of Consequences of Pressure and Storage Equipment Failures - vessels, exchangers, heaters, storage tanks, and piping.
- Types of Hazards ¡V release of hazardous substances, bleves, fractures, explosions, vapor cloud explosions,
- Guidelines and Procedures for quantifying consequences
Safety in Design I
- Project development and design bases
- Appropriate Codes, Standards, Specifications, Industrial Practices
- Safeguarding premises
- Calculation methods, heuristics
Safety in Design II
- Quality Control in Design
- Inherent Safety
- Reliability and availability premises
Integration of operability and maintainability in design
- Health, Safety and Environmental Considerations
- Roles and responsibilities of Engineering/Operation/Maintenance
- Operating Strategies ¡V Run Length, shifts
- Startup, Shutdown, Emergency Operating Procedures
- Steam-out and Flushing procedures
- Isolation, blanking, vents and drains
- The human factor: training modules, operator training
Workshop 1 ¡V Failure Consequences; Case studies and worked examples
¡V Material selection and design of major equipment and piping systems
Design Codes, Standards, Specifications, and Best Practices
- Fit-for-purpose facilities
- Business-focused facilities
- Liability and due diligence
Engineering Materials I
- Types and application
- Imperfections and defects
- Specifications and standards
Engineering Materials II
- The behavior of Metals Under Stress
- Degradation processes
- Selection methodology and guidelines
Design of Major Plant Equipment ¡V Methodology and key considerations
- Pressure Vessels
- Heat Exchangers
- Fired heaters and boilers
Design of Piping Systems I ¡V Pressure Integrity
- Methodology and key considerations
Design of Piping Systems II ¡V Mechanical Integrity
- Special design considerations ¡V dynamic and transients loadings
- Piping flexibility and supports
Workshop 2 ¡V Failures Due To Design Deficiencies - Case studies
¡V Failures and failure prevention
Safeguarding Systems I - Guidelines and Best Practices
- Principles
- Guidelines and Best Practices
- Documentation
- safeguarding systems integrity ¡V design
Safeguarding Systems II ¡V Safety Systems Key Design Considerations
- safeguarding safety systems - SIL
- Relief and depressuring systems
- Safeguarding systems integrity and effectiveness
Failures in Piping and equipment Pressure Vessels, Piping and Boilers
- Degradation processes