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This course builds on a focused & practical coverage of engineering materials properties & selection method & provides structured procedures & applicable formulas & methods for the mechanical design of pressure equipment, thermal equipment, piping system

Course Outline

After participating in this seminar, you will be able to:
• Size and select major process equipment for specific applications with the understanding of equipment design gained from this course
• Improve plant availability and productivity by applying industry standards and best practices in designing business focused facilities
• Identify key requirements of relevant design and operation standards and industry practices
• Design, operate and maintain pressure, thermal, and fluid handling equipment
• Assess the degradation and condition of process equipment as well as make the run/repair/replace decision
• Achieve measurable improvement in the mechanical reliability level in the plant and a reduction in the failure rates


Engineers in process plants need an integrated and practical understanding of the key design, operation and maintenance aspects of major process equipment. This course aims at providing participants with the skills to design and build business-focused facilities that can be safely and effectively operated and maintained while complying with all applicable regulatory requirements and company policies and procedures. To achieve this end, the process equipment and piping systems must have the required level of reliability to perform their intended function, at the least life cycle cost, over their specified life.

This course builds on a focused and practical coverage of engineering materials properties and selection method and provides structured procedures and applicable formulae and methods for the mechanical design of pressure equipment, thermal equipment, piping systems and machinery – pumps, compressors and drives. It also emphasizes the importance of interactions and common understanding by engineering, operations and maintenance groups of the equipment design aspects and envelopes and the criticality of operating and maintaining the equipment within its design envelopes.


To provide a clear understanding that appropriately designed and constructed equipment and associated piping are essential for safe, reliable and cost-effective plant operation; and that they must be operated and maintained within their respective design envelopes to safeguard plant integrity.

To enhance participants’ awareness of key requirements of relevant design and operation standards and industry practices such as ASME B&PVC, B31.1 and B31.3; API 560, 530, 660, 661, 610, 650; API 571, 580, 581 and 579, and others.

To provide guidelines to participants to identify and locate in-service degradation and appropriate tools for condition assessment and making sound run/repair/replace decisions. 

To make participants aware that although all flaws detected by inspection must be evaluated, not all flaws may need to be repaired. The proper application of API Std 579-1/ASME FFS-1 for fitness-for-service assessment may obviate the need for some repairs and result in reduced maintenance cost and downtime.

Who Should Attend

Professional and technical personnel in the petroleum, process, power, manufacturing, and other related industries. Mechanical engineers and designers as well as process engineers, project engineers, and other discipline engineers will benefit from this course. It is a “must take” course for recent engineering graduates who want to advance in their career by learning from others’ industrial experience.  Inspectors and other operations and maintenance technical personnel involved in the operation and maintenance of process equipment and piping systems will also benefit from this course.

Program Outline

Faculty:  Nabil Al-Khirdaji, President, Kappa Associates International

Day I

Registration and Coffee

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

Key Design Considerations, Guidelines and Practices

1.1 Process Equipment - An Overview

1.2 Plant Integrity and Reliability
• Interdependence of engineering, operation and maintenance
• Management of change

1.3 Equipment Design Bases and Methodology
• Service conditions and fitness for purpose
• Equipment sizing and functional performance

1.4 Business-Focused-Facilities – Appropriate quality at lowest life cycle cost

1.5 Safety by Design
• Worst foreseeable credible scenarios, safeguarding, best industry practices.
• Codes, standards, industry practices

1.6 Compliance with Regulations and Acts - HS&E requirements and considerations


Day II

Design and Operation of Pressure Equipment

2.1 Pressure Vessels and Reactors

• Materials of construction and standards
• Basic design methodology
• ASME boiler and pressure vessel code sections II, V, VIII and IX.
• Worked examples

2.2 Liquid Storage Tanks
• Types and application; cone roof tanks, floating roof tanks
• Basic design methodology
• Overview of API 650

2.3 Piping Systems
• Materials of construction and standards
• Basic design methodology – hydraulic design, pressure integrity, mechanical integrity.
• ASME B31.1 and B31.3
• Piping flexibility and support
• Piping system components – valves and fittings; classes, ratings
• Worked examples

2.4 Overpressure Protection
• Types and application of pressure relieving devices
• Code requirements
• Sizing methodology; API 520 and 521
• Specific operation and maintenance requirements; API 576


Design and Operation of Thermal and Fluid Handling Equipment

3.1 Process Heaters
• Types and configuration; box type, vertical cylindrical type
• Thermal and mechanical design
• API 560, API 530

3.2 Boilers
• Types and configuration; watertube, firetube and waste heat recovery boilers
• Fundamentals of design and operation
• Operating efficiency and testing
• ASME B&PVC Section 1 and Section 4, ASME PTC-4

3.3 Heat Exchangers
• Types and application; shell and tube heat exchangers, plate heat
• Exchangers, air cooled heat exchangers
• Thermal and mechanical design
• Overview of TEMA standards, API 660, API 661
• Operation, fouling, and effectiveness

3.4 Pumps
• Types and application; centrifugal, positive displacement
• Performance characteristics
• Selection and design considerations and standards; ANSI, API 610
• Worked examples

3.5 Compressors
• Types and application; centrifugal, screw, reciprocating
• Design considerations and standards
• Operation and troubleshooting

3.6 Electric motors
• Types and application
• Operation and troubleshooting


Day IV

Degradation and Condition Assessment of Process Equipment

4.1 Degradation processes in Fixed Equipment

• Corrosion, erosion, fatigue, hydrogen attack
• Overview of API 571

4.2 Industrial Failures and Failure Prevention

4.3 Inspection and Testing
• Inspection strategies, plans and coverage – Real function of inspection
• Nondestructive Testing (NDT) methods and their characteristics and applicability
• Risk Based Inspection (RBI) - Overview of API 580 and API 581

4.4 Fitness-For-Service Assessment
• Overview of API 579
• Worked examples

4.5 Machinery Condition Monitoring
• Vibration monitoring
• Lubricating oil analysis
• Troubleshooting  - Methodology and guidelines
• Reliability improvement
Questions and Answers and Feedback to Participants on Achievement of Learning Outcomes

Concluding Remarks and Final Adjournment

There will be a one-hour lunch break each day in addition to a refreshment and networking break during each morning and afternoon session.

Daily Schedule:
    Registration and Coffee (Day I only)
8:30    Session begins
12:00  Lunch
4:30    Adjournment

Prerequisites & Certificates

Certificates offered

2.4 CEU / 24 PDH

Cancellation Policy
To withdraw from a course, you must send a 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 fifteen 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.
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Here are some reviews of the training vendor.
The course was very well presented and the course instructor was absolutely amazing.
Reviewed by 2013
Our instructor, Stephen Lamming, was outstanding and a true expert in his field. He was able to complement the technical air monitoring information with practical real life examples which was highly beneficial. He is an excellent communicator and was highly interactive with the course attendees. This course was recommended to me because Stephen Lamming does an outstanding job. I was very impressed with this course and have subsequently recommended it to my colleagues.
Reviewed by 2012
Would have liked more interactive problem solving.
Reviewed by 2011

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