Course Details
Course Outline
5 days course
Fundamentals of Safety in Process Design
- Defining safety in process design and its role in preventing accidents and hazards
- Reviewing historical incidents and real-world industrial disasters to identify key safety lessons
- Exploring the core elements of process safety: People, plant, and process
- Discovering risk identification and safety analysis tools and techniques
- Comparing between different hazard analysis methods and their application in process safety:
- HAZOP
- LOPA
- FMEA
- Describing how the process design eliminates hazards, and how the process control and monitoring prevent human error
Principles of Inherently Safer Design (ISD)
- Describing the Inherently Safer Design (ISD) approach and how it reduces hazards at the design stage
- Strategies for designing inherently safer processes:
- Substitute
- Minimize
- Moderate
- Simplify
- Describing process design phases and the role of inherently safer design in the process design life cycle
- Guidelines for selecting materials of construction and optimized fabrication
- Identifying hazards associated with process fluids and chemical reactions:
- Corrosion, erosion and material degradation
- Leakage and loss of primary containment
- Dispersion of hydrocarbon release
- Flammability of chemicals
- Discussing ISD limitations and concerns
Safety Considerations in Process Equipment
- Identifying and analyzing different hazards associated with process equipment
- Discussing safety considerations in reactor design
- Exploring design procedures for safe equipment design: Pressure vessels, storage tanks and heat exchangers
- Codes and standards related to tanks and vessels venting: ASME, API, OSHA, and other regulatory bodies
- Guidelines for designing piping system and piping system accessories
- Techniques for assessing material degradation during the in-life cycle
- Exploring monitoring, testing and inspection (NDT) methods to assess equipment integrity.
Design and Operation of Pressure Relief Systems
- Understanding the principles of designing safety valves and pressure relief systems
- Describing the operation of the pressure relief system during overpressure events
- Formulas and tools for calculating and sizing relief loads of pressure relief systems
- Comparing between different overpressure protection devices: Pressure Relief vs. Rupture Discs
- Reviewing codes and standards related to pressure relief systems: ASME, API, OSHA, and other regulatory bodies
- Understanding the specifics of pressure relief systems for pumps, compressors, and turbines
- Exploring different plant disposal systems and associated environmental considerations
Process Monitoring and Control
- Understanding the role of safety instrumented systems (SIS) in preventing accidents
- Discovering process plant monitoring and control systems:
- SCADA
- PLCs
- Guidelines for designing emergency de-ressuring systems (EDP)
- Strategies to prevent fire, gas, and dust explosions in hazardous environments
- Discussing safety considerations in plant layout and equipment spacing
- Understanding the role of management of change (MOC) and integrity operation window (IOW) in ensuring ongoing safety compliance during operational changes
- Exploring plant equipment inspection techniques and maintenance procedures
