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This course will familiarize participants with all aspects of process plant major equipment & piping systems including preliminary sizing & mechanical design of process equipment; equipment configuration; development of plot plans & much more.

Course Outline
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 the plant design field; project engineers; piping fabricators, contractors and suppliers; piping design and analysis personnel; recent engineering graduates in all disciplines.

Program Outline

Faculty: Nabil Al-Khirdaji, Kappa Associates International - EPIC Instructor

Day I
Process Plant Design and Layout Fundamentals
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
€¢ Constructability
€¢ Business-focused facilities (BFF)

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)
€¢ Plot plans, equipment drawings, nozzle specifications
€¢ Piping and Instrument Diagrams (PandIDs) €" symbols,
  conventions and best practices (PIP)
€¢ Considerations for civil, structural, mechanical, electrical,
€¢ Design and layout checklist

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
€¢ Specific requirements - pressure relief and flare header; gas
  piping, heat tracing

9:45     Refreshments and Networking

10:00   Basic Design of Piping Systems
€¢ Hydraulic design
€¢ Pressure integrity
€¢ Mechanical (Structural) integrity

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
€¢ Sizing and Selection
€¢ Location of supports, guides, and anchors
€¢ Worked examples

2:30    Refreshments and Networking

Introduction to Pipe Stress Analysis
€¢ Code requirements (ASME B31.3)
€¢ Best industry practices
€¢ Examples of simplified screening methods

3:45    Workshop II
Demonstration of computer-assisted piping design and
flexibility analysis

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
€¢ Centrifugal
€¢ Reciprocating

3:45   Gas Turbines
€¢ Combined heat and power systems configurations

4:00    Steam Turbines
€¢ Condensing
€¢ Backpressure
€¢ Steam and condensate piping systems

4:30    Concluding Remarks and Final Adjournment

After participating in this course, you will be able to:
  • gain practical working knowledge and skills in process equipment and piping systems layout and design principles, procedures and practices
  • understand the 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.
  • familiarize yourself with the design and construction codes and standards for piping and process equipment including ASME BandPVC, B31.3; API 650; TEMA, etc
  • enhance your knowledge in stress analysis and better appreciate its significant role in avoiding failures.
  • learn from catastrophic incidents that resulted from poor layout design so that you will avoid such incidents.


Nabil Al-Khirdaji
Nabil Al-Khirdaji, M.Eng. and P.Eng., is president of Kappa Associates International, which provides engineering and project services to the petroleum, process, energy, and related industries. Mr. Al-Khirdaji has taught well over 200 technical professional development courses and he specializes in the areas of plant integrity, petroleum refinery, and process plant equipment design and operation. He has taught in Canada, the U.S., Saudi Arabia, Kuwait, Sudan, Yemen, Oman, Abu Dhabi, Dubai and Malaysia, presenting numerous topics on the design, operation, and maintenance of process plant equipment and piping systems. He received his B.Eng. (Mechanical) degree from the American University of Beirut and his M.Eng. degree from the University of Toronto.

A registered professional engineer with the Association of Professional Engineers of Ontario, Mr. Al-Kjirdaji has over 40 years of experience in the petroleum, petrochemical, and related industries both in Canada and the Middle East. During these past 40 years, including 24 years with Shell Canada Limited, he has assumed a number of project, engineering specialist, and engineering management positions with a vast range of responsibilities. He is also mechanical program director with EPIC and holds 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.

Prerequisites & Certificates

Certificates offered

2.1 CEUs / 21 PDHs

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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