Course Objective : • Understanding different aspects of process design that influence process safety • Appreciate “inherently safer design” for the entire process plant operation • Evaluate mechanical integrity of process equipment • Identify hazards associated with process fluids regarding impact on material degradation • Follow code requirements for sizing relief valves to handle relief streams • Operate Emergency De-Pressuring Systems (EDP) in case of fire and gas explosions Course Outline Overview of Safety in Process Design • Definition of Safety in Process Design • Overview of Historical Incidents and Problem Areas • Components of Process Safety: People, Plant, Process • Risk Identification and Safety Analysis • Process Hazard Analysis: HAZOP, LOPA, FMEA • Hazards Associated with Specific Plant Systems • Elimination of Hazards through Process Design • Prevention of Human Error through Process Control and Monitoring Inherently Safer Design • Inherently Safer Design Methodology • Pre-Design and Design Phases • Materials of Construction and Optimized Fabrication • Hazard 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 Safety of Process Equipment • Hazard Associated with Process Equipment • Safety Considerations in Reactor Design • Design Procedure for Safety of Pressure Vessels, Storage Tanks, Reactors, Heat Exchangers • Venting of Tanks and Vessels: Codes, Standards and Best Practices • Piping System Design and Safety • Design of Piping System Accessories: Valves, Fittings, Supports • Assessment of Material Degradation during In-Life Cycle: Fitness for Service • Monitoring, Testing and Inspection (NDT) Design of Pressure Relief Systems • Design of Safety Valves • Operation of Pressure Relief System • Calculation and Sizing of Relief Loads of Pressure Relief Systems • Pressure Relief Valves vs. Rupture Discs • Codes, Standards and Best Practices • Specifics of Pressure Relief Systems for Pumps, Compressors, Turbines • Process Plant Disposal Systems • Disposal Hazards, Risk Assessment and Environmental Factors Process Monitoring and Control • Safety Instrumented Systems • Process Plant Monitoring and Control System: SCADA • Emergency De-Pressurig Systems (EDP) • Prevention of Fire and Gas or Dust Explosions • Safety Consideration in Plant Layout and Equipment Spacing • Management of Change and Integrity Operation Window • Plant Equipment Inspection and Maintenance Procedures • Final Conclusions