Process Equipment, Application, Design and Operation
Design methods and criteria are presented and discussed to familiarize process engineers with practical techniques (including short-cut methods) for sizing, design, and selection of the main types of process equipment for refineries, petrochemical, and related process plants. The course covers description and definition of hydrocarbons and mixture properties, characterization parameters, and their significance in design of equipment. Basic calculation procedures for design of process equipment with sample examples are presented and discussed to enhance skills in design techniques. Procedures for preparation of process data and equipment design specification requirements, evaluation of proposals, and interaction with equipment manufacturers are discussed. Brief sessions are included on mechanical design aspects and on cost estimating methods to complement background to process design and equipment evaluation and selection aspects.
This course is designed to provide participants with a comprehensive understanding of process plant equipment design concepts and techniques. Participants completing this course will enhance their understanding of process design and gain practical skills and knowledge in the design of process plant equipment.
Process engineers plant design ,equipment engineers , process licensors.
This interactive training course includes the following training methodologies as a percentage of total tuition hours:
- Lectures
- Workshops, work presentations,
- Group Work in case study & Practical Exercises.
- Videos and general discussions
- Pre Test and Post Test
Course Outline
I. Introduction
- Process Engineering
- Refining Overview
- Hydrocarbon Process Examples
- Typical Refinery Block Diagram
- Typical Refinery Processes
- Process Engineering
- Nature of Design
- Process Engineering Applications
- Design
- Operation
- New Plant
- Revamp
- Process Equipment
- Resources/Tools
- Process Work Flow
- Process Calculations
- Rigorous
- Empirical
- Short-cuts
- Simulation Software
- Engineering Flow Diagrams
- Block Flow Diagram
- PFD
- P&ID
- Process Control Diagram
- System Distribution Diagram
- Plot Plan and Elevation Drawings
II. Hydrocarbon Properties
- Hydrocarbon Mixtures
- Hydrocarbon Types
- Hydrocarbon Characterization
- Properties and Definitions
- Property Estimation Methods
- Laboratory Distillations
- Pseudo-Components
- Combustion Properties
- Properties of Materials
- Corrosion
- Hydrogen Induced Attack
- Corrosion Monitoring and Control Techniques
- Coatings
- Electrochemical Techniques
III. Thermo-VLE General Introduction
- Vapor-Liquid Equilibrium
- Equation of State
- Ideal and Non-Ideal Systems
- Fugacities & Activity Coefficients
- Non-Ideal Mixtures of Non-Ideal Gases
- Bubble Point Calculation
- Dew Point Calculation
- Equilibrium Flash Calculation
- Tools
IV. Fluid Flow and Heat Transfer
- Fluid Flow in Piping
- Fluid Flow Basics
- Incompressible Flow
- Compressible Flow
- Two-Phase Flow
- Line Sizing Criteria
- Heat Transfer
- Conduction
- Thermal Conductivity
- Two-Dimensional Steady State
- Transient
- Convection
- Internal Flow
- Condensation
- Two-Phase Flow
- Boiling
- Conduction
- Radiation
V. Pumps and Pumping Systems
- Types of Pumps
- Reciprocating
- Rotary
- Centrifugal
- Performance Characteristics – Curves, System Hydraulics, Affinity Laws, Capacity, Turndown, Sparing
- Key Design Parameters – Capacity Factors, Properties, Head, NPSH, Horsepower
- Calculation Methods and Examples
- Impellor
VI. Compressors
- Compressor Categories and Types
- Positive Displacement – Reciprocating, Rotary Screw
- Dynamic – Centrifugal, Axial
- Compression Process – Adiabatic, Isothermal, Polytropic
- Compressor Characteristics – Performance, Terminology, System Curves
- Key Compressor Parameters – Capacity, Gas Properties, Head, Compression Exponent, Temperature Rise, Efficiency, Power Requirements, Affinity Laws
- Compressor Control
- Surge
- Staging
- Drivers
- Design Issues
- Performance
- Specification
- Rotary Compressors
VII. Process Vessels
- Mechanical Design
- Code Safety Factors
- Design Pressure and Temperature, MAWP
- Codes, Laws, Standards and Practices
- Simple Calculations
- Types and Functions
- Drums – Design Considerations, Orientation, L/D Ratio, Connections, Separation, Settling, Liquid Surge, Sizing, Internals
- Fractionators – Types, Equilibrium Stages, Reflux Ratio, Key Components, Relative Volatility, Minimum Number of Stages
- Crude Distillation Examples
- Fractionator Internals
- Tray Types
- Tray Selection Criteria
- Packing
- Liquid and Vapor Distributors
- Vacuum Towers
- Trayed Towers
- Reboilers
- Reactors
- Common Reactor Types: Fixed-Bed, Axial Flow, Radial Flow
- Design Considerations
- Catalyst Requirements
- Pressure Drop Considerations
- Reactor Internals
- Fixed-Bed Reactor
VIII. Heat Exchangers
- Basic Principles of Heat Exchanger Design
- Factors that Affect Heat Transfer
- Fouling Factors
- Weighted MTD Calculations
- Predicting Heat Exchanger Performance
- Shell and Tube Heat Exchangers
- Mechanical Design
- TEMA Classifications
- Tubes
- Other Exchanger Components
- Factors that Affect Heat Transfer
- Heat Exchanger Operating Parameters and Problems
- Energy Conservation Overview and Methods
- Selection of Heat Exchanger Type
- Shell and Tube
- Plate and Frame
- Spiral
- Air Coolers
- Types
- Main Components
- Header Options
- Reviewing Vendor Options
- Process and Overall Performance
- Mechanical Details
- Vibration Analysis
- Data Sheets
- Drawings
IX. Fired Heaters and Heat Recovery
- Types
- Combustion Basics
- Efficiency
- Heat Transfer – Basics
- Operational Issues – Air Leaks, Burner Problems, Instrumentation, Flooding, Etc.
- Design and Operation
- Fired Heater Duties
- Selection and Design Issues
- Special Units
X. Ancillary Equipment
- Steam Surface Condensers
- Steam Jet Ejectors
- Components
- Advantages and Limitations
- Pressure Relief
- Overpressure Causes
- Relief Load Calculation
- Pressure Relief Devices
- ASME Section VIII Requirements
XI. Control Valves
- Purpose
- Flow Characteristics – Vortices, Separation
- Pressure to Flow Relationships
- Choked Flow Conditions (Critical Flow)
- Cavitation
- Flashing
- Typical Control Valve Applications
- Flow Resistance Model Diagram
- Design Requirements
- Flow Characteristics
- Design Equations
- Examples
XII. Cost Estimating
- Cost Estimating Methods
- Capacity/Scale Ratio
- Equipment/Modular Factors
- Detailed Quotes
- Estimate Types and Accuracy
- Equipment Installation Cost Factors
- Contingency Allowances
- Cost Escalation
XIII. Process Design Specifications
- Purpose of Specification Package
- Types of Specification Packages
- Specification Package Contents