Process Design Engineering


»Overview of EPC Sector for various Industries .
»Introduction to Front End Engineering Design (FEED).
»Fundamental of Process Plant Engineering.
»Internal departmental coordination Reference documentation.
»Relevant Code & Standards for Process Design Engineering.
»Use of International Standard for Design Basis, Std Practices/Procedure & specification.
»Introduction to Oil & Gas Industry for Onshore & Offshore Petroleum.
»Understanding client requirement & specific Inputs for project.
»Knowing various phase of Project Execution.
»Introduction of Process Design Engineering
»Process Fluids Phase Behavior
»Pipe Hydraulics & Line Sizing
»Process Equipment Detail Design
»Process Safety & Protection
»Preparation of Drawings & Documents.
»Technical Specification & Vendor Catalog.
»Process Symbols & Abbreviation.
»Piping & Instrumentation diagram(P&ID).
»Process flow diagram(PFD)
»Process Data Sheet.
»Role & Responsibilities of Chemical Engineer in various Domains.

Module: 1

Fundamental of Process Plant Engineering

•    Overview of EPC & Process Industries and Scopes.
•    Designing Methodology of EPC Industry.
•    Overview of Basic Engineering Packages.
•    Overview of an Engineering Organization.
•    Flare System in Process Engineering.
•    Relevant Code & Standard For Plant Processing.
•    Process Control & Optimization Code.
•    Process Development & Case Analysis.
•    Detail of Various Process Condition by Client side & their documents.
•    Role of Process Engineer in various Industries.
Introduction of Process Design Engineering
•    Development of PFD,P&ID,PDS
•    MFD,UFD,FFD,BFD of Equipment.
•    Line List, Equipment List, Equipment Data Sheet.
•    Heat & mass Transfer & Recovery.
•    Fundamental of Material Balance.
•    Fundamental of Energy Balance.
•    HMBT Calculation of Specific Process.
•    Equipment Selection & Specification.
•    Process Block Diagram.
•    Control Valve & Pressure Safety Valve.
•    Pressure Relief Valve & level of over Pressure Protection.
•    Newtonian Fluids Analysis for Single  & 2 Phase Flows.
•    Selection of Material & Corrosion Study.
•    Distillation Binary System Calculations.
•    Cause & Effect Diagram.
•    E.T.P Design.
•    MOC
•    Design of Indirect Fired Heater
•    Design of Desalter
•    Slug Catchers
•    Free Water Knock Out Drum (FWKO)
•    Design of Separators.

Process Fluids Phase Behavior

•    Fluid Flow Operation.
•    Flow Rate & Velocity Calculation
•    Flow Property Analysis –Reynolds Number.
•    Composition of Well Fluids.
•    Well Fluid Determination.
•    Well Fluid Phase Behavior & Terminologies.
•    Nature of Wells.
•    Slenderness Ratio.
•    Reservoir Component.
•    Equation of State.
•    Molecular sieves(Adsorbers)
•    Contactor (Absorber)

Pipe Hydraulics & Line Sizing

•    Hydraulics & Pump Hydraulics Calculation.
•    Line Sizing & Pressure Drop Calculation.
•    Nozzle Sizing
•    Darcy Weisbach & Hazen William Equation.
•    Pipe Separation

Process Equipment Detail Design

•    Process Equipment
 •   Distillation Column Definition, Classification, Selection & Sizing.
•    Cooling Tower Heat Exchanger Definition, Classification, Selection & Sizing.
•    Vessel Definition, Classification, Selection & Sizing.
•    Furnace Definition, Classification, Selection & Sizing.
•    Reactor Definition, Classification, Selection & Sizing.
•    Mechanical Equipment
•    Pump Definition, Classification, Selection & Sizing.
•    Pump Cavitations & NPSH Calculation.
•    Compressor Definition, Classification, Selection & Sizing.
•    Storage Tank Definition, Classification, Selection & Sizing.

Process Safety & Protection

•    Introduction of Safety Environment in Process Industry.
•    Explosion prevention techniques.
•    Risk assessments as per IEC 62305-2.
•    Explosion Triangle and Mode of Safety.
•    Explosion prevention techniques
•    Relevant Codes and Standards for Hazardous.
•    Hazardous Area of Classification.
•    Hazardous Analysis.
•    Hazardous Operation.
•    Hazardous Identification.
•    Concept of Group, Zones and Classes.
•    The ATEX requirements
•    Type of Process Equipment Suitable for use in Potentially Explosive Atmospheres.
•    Types Of Protection For different Hazardous.
•    Hazardous source List Preparation.
•    Marking Of Equipment Nameplates.
•    Hazardous Area Drawings / Layouts.

Module: 2

SYSTEM STUDIES ON ASPEN-HYSYS

•    Introduction to HYSYS Software
•    Propane Refrigeration Loop
•    Refrigerated Gas Plant
•    NGL Fractionation Train
•    Oil Characterization
•    Gas Gathering System
•    Two-Stage Compression
•    Compressor and Pump Curves
•    Water Content & Natural Gas Hydrates
•    Natural Gas Dehydration with TEG
•    Rating Heat Exchangers
•    CO2 Capture with MEA
•    Acid Gas Sweetening
•    Flash Calculations
•    Stream Property Flash Value Calculations of a Ethanol-Water Mixture
•    Gas-Plant Example
•    Optimization in HYSYS
•    Set and Adjust Logic Operations
•    PFD Preparation
•    Sizing of LPC Columns.
•    Sizing of CO2 Absorber.
•    Analysis of Butane, Light Neptha
•    Striper Design.
•    Oil Manager / Characterization
•    Pipe Sizing and Pressure Drop in HYSYS
•    Aspen Simulation Workbook and Reporting in Aspen HYSYS.

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