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Layout and Design of Process Plant Equipment and Piping Systems
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When: June 24-26, 2013
Course Code: 04-0604-2271
Where: EPIC Learning Centre
5660 McAdam Rd
Mississauga, Ontario  L4Z 1T2
Contact: Farah Eftekhari 416-223-9961 x 228

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Course Fee:

Early-bird registration:
OSPE Members: $1705.50 + HST
Non Members: $1895 + HST

After May 24, 2013:
OSPE Members: $1858.50 + HST
 Non member: $2065 + HST

1.8 CEUs / 18 PDHs

After participating in this course, you will be able to:
•developpractical working knowledge and skills in process equipment and piping systems layout and design principles, procedures and practices
•determinethe impact of layout and pipe routing options on installed costs, operability, maintainability and safety of the plant and how
you can achieve business focused facilities while complying with regulatory requirements and high plant availability.
•familiarizeyourself with the design and construction codes and standards for piping and process equipment including ASME BPVC, B31.3; API 650; TEMA, etc
•enhanceyour knowledge in stress analysis and better appreciate its significant role in avoiding failures.
•discovercatastrophic incidents that resulted from poor layout design so that you will avoid such incidents.

Designing process plants is a complex and demanding process. The design of plant layout is one of the most important tasks before plant construction. A good plant layout can not only reduce capitalized cost, but also helps to improve the safety of the plant and reduce its environmental impact. Additionally, fast, uncomplicated and adequate access to individual items of plant and equipment is essential for effective operation and maintenance which means higher plant availability and longer time between failures

This course will familiarize participants with all aspects of process plant major equipment and piping systems including preliminary sizing and mechanical design of process equipment; equipment configuration; development of plot plans; multi-objectives and optimization of plant layout; layout, design procedures and practices involved in the location of equipment and layout of associated piping systems;

Key considerations in the layout and design of process equipment and piping systems include operability and maintainability as well as safety and environmental implications and compliance with applicable regulations, codes and standards.

One of the main objectives of process plant layout and design is to achieve a business focused facility whereby total life cycle cost which is comprised of the capital investment and on-going operating and maintenance costs is minimized. This is influenced by several factors including separation distances between equipment, piping routings. Significant cost savings can therefore be achieved by minimizing the plot area providing safety, operational and maintenance requirements are met.

Effective interaction between the various engineering disciplines (civil, electrical, mechanical, instrumentation and control) is required to achieve robust and cost-effective layout of piping systems and process equipment.

This course is intended to familiarize the participants with the key aspects of layout and design of process equipment and piping systems and to provide them with practical working knowledge in this very important field.

Who Should Attend
Engineers and designers involved in plant design activities; project engineers; process engineers, piping fabricators, contractors and suppliers; piping design and analysis personnel; recent engineering graduates in all disciplines.

Program Outline

Day I - Process Plant Design and Layout Fundamentals

Welcome, Introduction,Course Preview, Learning Outcomes and the Assessment Method

8:30 Design and Layout Fundamentals
•Scope and definitions
•Design methodologies and guidelines
•Applicable design codes, standards, recommended practices and regulations

9:30 Process Plant Design
•Objectives and principles
•Methodology and guidelines
•Process Flow Diagrams (PFDs) – symbols, conventions and best practices

10:00 Refreshments and Networking

10:15 Key Considerations Affecting Plant Process Design and Layout
•HSEC (Health; Safety; Environment; Community)
•Safety aspects of plant layout - methodology for hazardous area classification; plant layout safety index
•Operability and maintainability
•Business-focused facilities (BFF) – Life cycle cost

11:30 Layout Design -General Philosophy and Principles
•Goals of plant layout design
•Site location, layout and conditions
•Separation distances

12:00 Lunch

1:00 Process Equipment Sizing and Design
•Preliminary sizing and mechanical design of major equipment
•Estimating costs of major equipment and piping
•Standard specifications and data sheets for process equipments

2:30 Refreshments and Networking

2:45 Layout Planning and Procedures
•Plant layout and plot plans - codes of practice relating to plant layout (PIP, NFPA)
•Plot plans, equipment drawings, nozzle specifications
•Piping and Instrument Diagrams (P&IDs) – symbols, conventions and best practices (PIP)
•Considerations for civil, structural, mechanical, electrical, instrumentation
•Design and layout checklist

4:00 Workshop 1
Case Studies - Catastrophic Incidents Caused by Poor Layout

Day II - Piping Systems – Design Methodology and Considerations

8:30 Piping Fundamentals
Pipe system components; dimensions; pipe data; materials; regulations; codes, standards and specifications; fabrication and installation; piping joints; design bases and documents.

9:00 Additional Layout and Design Requirements of Piping Systems
•Optimization of process plant layout with pipe routing
•Isolation and blinding
•Vents, drains, slopes, injection points and sample connections
•Configuration of spared equipment – testing and operating philosophy
•Specific requirements - pressure relief and flare header; gas piping, heat tracing

9:45 Refreshments and Networking

10:00 Basic Design of Piping Systems
•Design basis and constraints
•Hydraulic design
•Pressure integrity
•Mechanical (structural) integrity
•Worked examples

11:00 Piping Thermal Expansion and Flexibility
•Expansion bends, loops, and expansion joints
•Piping loads on load-sensitive equipment

12:00 Lunch

1:00 Pipe Supports and Restraints
•Types and Application, MSS standards
•Sizing and Selection
•Location of supports, guides, and anchors
•Worked examples

2:30 Refreshments and Networking

2:45 Introduction to Pipe Stress Analysis
•Code requirements (ASME B31.3)
•Best industry practices
•Examples of simplified screening methods
•Demonstration of computer-assisted piping design and flexibility analysis

3:45 Workshop II
•Case studies – Piping failures resulting from improper design and layout

Day III - Equipment Piping Layout Considerations and Best Practices

8:30 Pressure Vessels and Reactors
•Vertical vessels and towers
•Horizontal vessels

9:30 Atmospheric Storage Tanks
•Fixed roof
•Floating roof

10:00 Refreshments and Networking

10:15 Fired Heaters
•Natural draft
•Forced draft

11:00 Heat Exchangers
•Shell and tube
•Reboilers and condensers
•Plate type
•Air-cooled heat exchangers

12:00 Lunch

1:00 Pumps
•Types - centrifugal; vertical in-line; positive displacement
•Applications – process; boiler feedwater; firewater

2:30 Refreshments and Networking

2:45 Compressors, Blowers and Fans

3:45 Gas Turbines
•Combined heat and power systems configurations

4:00 Steam Turbines
•Steam and condensate piping systems

Questions and Answers and Feedback to Participants on Achievement of Learning Outcomes

4:30 Concluding Remarks and Final Adjournment

1.8 CEU / 18 PDH


Nabil Al-Khirdaji
Nabil Al-Khirdaji, M. Eng., P. Eng. is president of Kappa Associates International, which provides engineering and project services to the petroleum, process, energy, and related industries. Nabil has taught many professional development courses, and he specializes in the areas of plant integrity and petroleum refinery and process plant equipment design and operation. Mr. Al-Khirdaji holds B.Eng. (Mechanical) degree from the American University of Beirut and M. Eng. degree from the University of Toronto. He is a registered professional engineer with the Association of Professional Engineers of Ontario, Canada.

Nabil has over 35 years of professional experience mainly in the petroleum, petrochemical and related industries, both in Canada and the Middle East, including 24 years with Shell Canada Limited. He assumed a number of project, engineering specialist, and engineering management positions with responsibilities covering design & construction; pressure equipment & piping; combustion & heat transfer equipment; mechanical equipment & drives; materials, corrosion & inspection; utilities & energy systems; and engineered safety. He also assumed the position of mechanical program director with EPIC, a primary provider of professional development training in Canada, and a senior project management position with an oil and gas engineering company in Milan, Italy. Mr. Al-Khirdaji served for several years on the API Committee on Refinery Equipment which oversees the development of engineering practices for the design, fabrication, installation, inspection, and use of materials and equipment in refineries and related processing facilities.

Nabil has developed and delivered well over a hundred technical professional development courses covering design, operation and maintenance of process plant equipment and piping systems. He has taught in Canada, USA, Saudi Arabia, Kuwait, Sudan, Yemen, Oman, Abu Dhabi, Dubai and Malaysia, on topics including API 579 Fitness-For-Service, Mechanical integrity in refineries and petrochemical plants, and Layout design of equipment and piping systems.

 To withdraw from a course, you must send your request in writing with the official receipt to our office: 
     • Fifteen or more business days in advance: full refund less $50.00 administration charge. 
     • Five to fourteen business days in advance: non-refundable credit of equal value for any future EPIC seminar within one year. 
       Credits are transferable within your organization. 

In case of an unexpected event occurring after this time, you may send someone else to take your place without any additional cost. If a speaker is not available due to unforeseen circumstances, another speaker of equal ability will be substituted. EPIC reserves the right to cancel or change the date or location of its events. EPIC's responsibility will, under no circumstances, exceed the amount of the fee collected. EPIC is not responsible for the purchase of non-refundable travel arrangements or accommodation or any associated cancellation/ change fees. To avoid any fees or charges, please call to confirm that the course is running before confirming travel arrangements and accommodations.

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