Engineering Essentials for Maintenance and Plant Engineers in a Process Plant

Name: Engineering Essentials for Maintenance and Plant Engineers in a Process Plant
Price: 2695 CAD
Availability: InStock

Course Code: MEC105

This course is divided into 5 sessions. Each session will be 6 hours in duration.

The sessions will be held again on Sep 14,15,16,17&18, 2026
This course will be offered in 2027 on the following date: June 7-8-9-10-11. and will be held again on October 25-26-27-28-29

If you are unable to attend any of the sessions a recording will be made available.

Course Description

This training course is specifically written for engineers who are at the forefront of a process plant. In addition to the need to attend the day-to-day plant activities providing operational support, the engineers also must possess adequate knowledge on material selection, fabrication and testing within the acceptable industry standard. Unfortunately, there is no simple cookbook in mechanical engineering as the subject is very wide. Understanding some basics of engineering design and practice will help the engineers to rapidly repair/modify/trouble-shoot the problem immediately with good engineering judgement, without having to wait for outside help.

Interpreting ASME Process Piping and Pressure Vessel Codes and Engineering Drawings were never easy. On the other hand, self-learning requires long years of engineering and design experience to fully understand both to become a subject matter expert (SME).

The 5 days course is designed to meet the needs of plant level engineers from Design, Construction and Owner Companies who, although qualified in their own discipline, may not have received adequate training on the mechanical engineering design. Course concentration will be focused on ASME B31.3 Process Piping, and ASME Sec VIII Div 1 Pressure Vessels that are widely used in a process plant with addition of few API Recommended Practice and Standards that are regularly encountered in a process plant.

Objective

- Provide an awareness of the code and regulations that governs the design and requirements of piping and vessels in a process plant.
- Provide a basic interpretation and understanding of the design codes (ASME B31.3 and ASME Sec VIII Div 1) in simplified form.
- Provide basic engineering knowledge to young Engineers and plant Maintenance and Operation Engineers for easy decision making.
- Aware of where to look for available resources and data.
- Ample exercises to practice.

Target Audience

Engineers from Engineering and Operating Company who are involved primarily in the Operation & Maintenance of a process plant. Design Engineers who need to add to their current experience and knowledge the basics of the mechanical piping design code. New graduates who want to learn about the piping engineering and engineering drawing will immensely benefit from this course by setting their basics right at the onset of their career.

This course is suitable to a wide range of professionals but will greatly benefit:

Mechanical Engineers – Engineering/Technical
Mechanical Engineers – Design (EPC)
Plant Engineers (O&M)
Reliability Engineers
Non-Mechanical Engineers in charge of a process plant
Inspection Engineers

Level of Course

for Intermediate Level

Learning Objectives

After you attend this course/workshop, you will be able to:

Understand the importance of the code requirement/compliance.
Gain insight of design basis used by the most common Codes.
Learn to deal with piping and pressure vessel design requirement for new or modification work in a plant level.
Gain confidence to work independently.
Expand knowledge to supervise junior engineers.

Material(s) Required

Laptops, Calculator, paper and pen.

Mr. Ganga D. Deka

Mr. Ganga D. Deka, P.Eng is a registered Professional Engineer with APEGA Alberta (Canada) and currently works as a consultant. He brings with him over 30 years of experience in oil and gas industry with diversified experience in both Engineering Design and Operation & Maintenance (O&M). He brings with him the best experience from both the sides – from the drawing office to hands-on.

Ganga had assumed responsible positions in multi-million-dollar projects both in green field and brown field engineering projects. He had led team of engineers both in field level operating plants, turn-arounds, and engineering design that makes him clearly understand the need of engineers and technologists who work in a process/chemical plant. His career includes working with ZADCO (under ADNOC in Abu Dhabi), QATARGAS (in Qatar), Worley and Fluor in Canada.

Ganga’s long years of experience in the oil industry gives him a thorough insight to the basics of pressure testing requirement in process industry. With his versatile knowledge and experience he currently delivers seminars on various mechanical engineering subjects related to a process plant to both young and experienced mechanical and non-mechanical engineers. He had delivered training courses in North America, Malaysia and India.

Program Outline:

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

Day1:

1.0 Understanding Material

Material classification Systems, Specification, Properties
Acceptable Materials for ASME B31.3/ ASME Sec VIII Div 1/Div 2 pressure vessel Codes.
Understanding ASME B31.3 and ASME Sec VIII Div 1/Div 2 Codes Stress Tables.
Temperature Limitations – Brittle Fracture/Toughness Requirement, Creep
Material Selection
Understanding Piping Class/Material Test Report /Certificates

2.0 Understanding Drawings

Process and Instrumentation Diagrams (P&ID)
Orthographic/Isometrics/Spool Drawing
Line Designation Table / Line List

3.0 Understanding Codes/Standards/Specifications

Owner/Company Specification
Local Regulatory Requirements
National Standards
International Standards/Codes/Specifications
Fitness-For Service (FFS) -API 579

Day 2

4.0 Understanding Stresses

Basic Stress Concepts
Failure Theories
Stress Categories
Basis of Allowable Stress -Safety Factors
Fatigue Failure
Case Study

5.0 Design Basics of Piping

Design Conditions – Design Pressure & Design Temperature
Pipe and piping components
How to calculate required Thickness.
Pressure/Temperature Ratings for Valves and Flanges
Standards for Piping Components
How to select and build a piping segment with correct pressure components rating.
Making a good Material Requisition.
Case Study

Day 3

6.0 Design Basics of Pressure Vessels

Design Conditions, MAWP
How to interpret a Vessel Name Plate Data
Design by Rules Thickness Calculation for Vessel Components
Fabrication Requirements – Inspection, NDE and Testing
Weld Joint Categories, Joint Efficiencies
Vessel Openings – what to look for adding an additional nozzle.
Case Study

7.0 Welding, Fabrication and Inspection

Welding Processes
Qualifying a Welding Procedure/Welders
Understanding P & S Group materials (ASME BPVC Section IX)
Destructive/Non-Destructive Tests
Examination Methods/Acceptance Criteria//Extent of Examination required by Construction Codes ASME B31.3 and ASME Sec VIII Div 1
Joint preparation – welding unequal thicknesses.
Socket and Fillet weld requirement

Day 4

8.0 Pressure Testing (Code Requirement)

8.1 Piping Systems (ASME B31.3)

Hydrostatic Test
Pneumatic Test
Initial Service Leak test
Alternative Leak Test
Closure Weld Test
Case Study

8.2 Pressure Vessels

ASME Sec VIII Div 1 and Div 2 Vessels
Testing Tall Pressure Vessels and Horizontal Pressure Vessels
Case Study

9.0 Inspection, Repair and Testing of Shell and Tube Heat Exchangers

10.0 Hot and Half-Bolting Removal Procedure

11.0 Calculation of Bolt Load & Bolt Torque w/Case Study

Day 5

12.0 Hot Tapping w/Case Study

13.0 Centrifugal Pumps (API 610)

14.0 Mechanical Seals (API 682)

15.0 Valve Testing (API 598)

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