Technical Integrity and Engineered Safety in Petrochemical Plants

Introduction

This course combines current industry practices with engineering methods and applicable codes & standards. Further, participants will gain enough knowledge that will help them to improve their efficiency in managing technical integrity in a professional manner. The course manual will be valuable for future reference.

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.

Training Methodology

This is an interactive course. There will be open question and answer sessions, regular group exercises and activities, videos, case studies and presentations on best practice. Participants will have the opportunity to share with the facilitator and other participants on what works well and not so well for them, as well as work on issues from their own organizations.

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 Outline

Day 1: 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

Workshop I – Failure ConsequencesCase studies and worked examples

Day 2 :

• 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

Workshop II – Failures Due To Design Deficiencies Case studies

Day 3: 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 
• Evaluation of Inspection Data

Workshop III – Failures due to Improper Operation and Maintenance Case studies

Day 4 :        

Hazard Identification and Assessment

Risk Analysis, Assessment and Management

Probability basics 

• Probabilistic risk assessment concepts and methodology 
• Fault tree and event tree analysis 
• Quantitative risk assessment concepts and methodology

Integrated Safety Management Plan

• Hazard and Effect Management Plan 
• Bow-Tie process 
• Risk Matrix 
• Determining acceptability of risk

Hazard and Operability (HAZOP) Reviews Process and guidelines

• Management of Change
• Change Control Policy and Procedures 
• Process Changes 
• Plant Changes 
• Assessment and Authorization 
•  Documentation 
• Illustrative Change Control Procedure

Workshop IV

Case studies - Failures Due to Improper Management of Change System 

• Examples of HAZOP reviews

Day 5 :        

Fitness-For-Service / Engineering Critical Assessments API RP 579 Fitness-For-Service 

• Fracture Mechanics and Mode of Failure of Material 
• Flaw Characterization, Growth, Stability 
•  Factors of Safety 
• Disposition versus Repair
• Maintenance Strategies and Programs Risk-based Inspection 
• Reliability-centered maintenance
• Rerating Piping and Pressure Vessels
• Engineering Information and Systems Management

Troubleshooting Plant equipment and Piping systems Guidelines and best practices 

• Resonance and Vibration 
• Excessive Thrusts and Moments on Connected Equipment 
• Leakage at Joints 
• Excessive Piping Sag, Disengagement of Piping From Supports 
•  Interference With Expansion and Contraction

Technical Integrity Audits

• Guidelines and procedures 
• Checklists 
• Implementation plans

Workshop IV – Examples of HAZOP reviews