Mechanical Integrity & Reliability in Refineries, Petrochemical & Process Plants

Mechanical Integrity & Reliability in Refineries, Petrochemical & Process Plants

Date/Time: Date(s) - 08/08/2022 - 10/08/2022( 8:00 am - 5:00 pm )
Location: Malaysia, Kuala Lumpur


  • To assist participants in clearly understanding and applying the various aspects of engineered safety to ensure mechanical integrity in a responsible and cost-effective manner.
  • To enhance the knowledge and skills of the participants in hazard identification and analysis; and in risk assessment and management.
  • To provide participants with practical and effective methods and tools to perform practical likelihood and consequence analyses.

Who should Attend?

This course is particularly valuable for refinery and petrochemical plant technical managers, engineers, inspectors, maintenance personnel, as well as for project and consulting engineers and engineering and technical personnel involved in plant mechanical integrity and reliability.


Technical integrity, industrial failures and safety in design

Technical Integrity – An Overview
  • 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
  • Learnings
Estimation of Consequences of Pressure and Storage Equipment Failures – vessels, exchangers, heaters, storage tanks, and piping.
  • Types of Hazards – release of hazardous substances, bleves, 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 and availability premises
Integration of operability and maintainability in 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
  • Human factor: training modules, operator training
Workshop 1 – Failure Consequences; Case studies and worked examples

Failures and failure prevention

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 3 – Failures due to Improper Operation and Maintenance

Operation and maintenance aspects of plant integrity

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

Material selection and design of major equipment and piping systems

Design Codes, Standards, Specifications, and Best Practices
  • Fit-for-purpose facilities
  • Business-focused facilities
  • Liability and due diligence
Engineering Materials I
  • Types and application
  • Imperfections and defects
  • Specifications and standards
Engineering Materials II
  • Behaviour of Metals Under Stress
  • Degradation processes
  • Selection methodology and guidelines
Design of Major Plant Equipment – Methodology and 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 2 – Failures Due To Design Deficiencies – Case studies

Hazard and risk identification, assessment & management

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

Training Methodology

  • Case Studies.
  • Individual and group discussions and exercises.
  • Intensive training by using templates, diagrams, and charts.
  • Planning activities and presentations.
  • Self-assessments.
  • Action plan.

Request Booking

Bookings are closed for this course.

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