Elements of Applied Process Engineering

Course Duration/Credits

Five days/3.0 CEUs/30 PDHs

Course Description

This hands-on, highly-interactive course includes various practical sessions and exercises. Theorylearnt will be applied using our state-of-the-art simulators.

The course covers the application of chemical engineering theory to the practical demands of applied process engineering. The course will be presented in interactive format with many industrial examples and case studies. Participants will have the opportunity to solve sample problems with the help of the instructor.

The first part of the course will cover the basics of unit operations and the development of an effective process. Topics included are the preparation of process flow diagrams (PFDs) and P&IDs. These diagrams represent the organization and control of equipment in a petrochemical plant or refinery.

This is followed by the calculation of material flows and the concept of a material balance. Included are techniques on the sizing and evaluation of piping networks (including pipe segments, fittings, parallel piping systems, valves and controls equipment).

Pressure drop calculations are presented for a variety of systems – ordinary Newtonian liquids, vapors and mixed phase systems, reacting systems, packed beds and fluidized beds.

Next, the design and evaluation of major fluid flow equipment is presented. This includes pumps (all types) and compressors as well as fans, vacuum pumps, ejectors and eductors. The associated drivers for these machines are discussed, especially steam turbines and the steam-power cycle found in all petrochemical plants and refineries.

The materials portion of the course is followed by a presentation on energy balances and heat transfer equipment. Refrigeration energy balance, compressor selection, and power requirements are covered. Focus is on the cycles typically found in refineries and petrochemical plants, including cascaded and open systems.

In the next section of the class, materials of construction (MOC) are discussed and selection guidelines presented. Finally, heat transfer equipment selection, design and rating are discussed.

On completion of this course, participants will have the ability to understand and prepare PFDs and P&IDs, perform material/heat balance and fluid flow calculations. Participants will also be able to design, rate and select the major process equipment which accounts for most of the capital investment in refineries and petrochemical plants.

During the class, participants will be given detailed procedures and worksheets for performing the appropriate calculations. Many of the examples have been developed on EXCEL; these programs will be given to the participants on a CD. The tools provided should aid in the design and operation of chemical systems. This is an interactive course with numerous case studies and a CD with solved problems, worksheet and shortcut techniques.

Course Objectives

Upon the successful completion of this course, each participant will be able to: –

  • Apply and gain an in-depth knowledge on process engineering and discuss the chemical & physical aspects as well as the processes and process variables used in applied process engineering
  • Prepare PFDs and P&IDs in a professional manner
  • Perform material/heat balance and fluid flow calculations
  • Acquire knowledge with the various process development including process sketch, diagrams and unit operations
  • Employ the application of fluid dynamics specifically its piping system design and flow systems and determine the different flow equipment used in process engineering
  • Enumerate heat transfer components by explaining the elements of energy balances, heat exchangers, air coolers and fired heaters
  • Develop an understanding on mass transfer attributes including distillation, tray performance & constraints, humification and refrigeration
  • Identify the different types of chemical reactors and describe petroleum processing reactions including hydro treating, catalytic reforming & hydro cracking
  • Discuss the process control applied in process engineering and identify the various construction materials as well as the method of selecting the materials to be used
  • Carryout process risk analysis particularly the various evaluation methods and HAZOP study

Who Should Attend

This course provides an overview of the major elements of applied process engineering for process and project engineers as well as piping designers. The course will also be valuable as a refresher for experienced chemical engineers and those who are not familiar with some aspects of applied process engineering. Additionally, managers and supervisors who have no formal training in chemical engineering should find value in this course.

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