Technical Integrity and Engineered Safety in Petrochemical Plants
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Technical Integrity and Engineered Safety in Petrochemical Plants Course
Introduction:
Course Objectives:
Upon the successful completion of this course, participants will have a comprehensive understanding of the various aspects of technical integrity and engineered safety in petrochemical plants, refineries and oil & gas plants.
Who Should Attend?
Technical Managers, Safety Managers, Engineers, Superintendents, Supervisors, Foremen and Safety Staff in refineries, petrochemical plants and oil/gas process plants who are engaged, directly or in directly
Course Outlines:
Overview of Technical Integrity
- Definition, scope, and key elements - hardware and software issues, peopleware- sound people management
- Potential threats to technical integrity in a hazardous environment
- Regulatory requirements – SH&E, OSHA, SEVESO II
- Life cycle implications – design/operation / maintenance, regulatory / industrial interface, training/staff development, networking.
- Industrial Failures – Catastrophic failures do happen
- Statistics
- Typical examples
- Causes and implications
- Learning
Estimation of Consequences of Pressure and Storage Equipment Failures – vessels, exchangers, heaters, storage tanks, and piping
Types of Hazards – the release of hazardous substances, believes, 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 & availability of premises
Integration of operability and maintainability in the design
Health, Safety and Environmental Considerations
- Roles and responsibilities of Engineering/Operation/Maintenance
- Operating Strategies – 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
Failure Consequences Case studies and worked examples
- Design Codes, Standards, Specifications, and Best Practices
- Fit-for-purpose facilities
- Business-focused facilities
- Liability & 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 Methodology & key considerations Pressure Vessels
- Heat Exchangers
- Fired heaters and boilers
Design of Piping Systems I – Pressure Integrity
- Methodology and key considerations
Design of Piping Systems II – Mechanical Integrity
Special design considerations – dynamic and transients loadings
- Piping flexibility and supports
Failures Due To Design Deficiencies Case studies
Safeguarding Systems I - Guidelines and Best Practices Principles
- Guidelines and Best Practices
- Documentation
- Safeguarding systems integrity – design
Safeguarding Systems II – 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
- Failures in pressure equipment
- Piping System Vibration and Failure
Failures in Rotating Equipment Causes
- Monitoring and analysis
- Reliability improvement
Failure Prevention
- FMEA
- Causal analysis
Testing and Monitoring
- NDT methods
- Inspection, Testing and Repair Regulations, Codes, and Practices