Fundamentals of Process Plant & Equipment Control

The Course

Process engineering is at the heart of much of the chemical, oil, gas, and petrochemical industries. It requires familiarity with chemical engineering principles, but also with many of the other engineering disciplines including mechanical, electrical and instrumentation. The process engineer is interested in the transportation and transformation of solids, liquids and gases. Of specific importance are separation processes including distillation, heat transfer, hydraulics and fluid flow, reaction engineering, but also process control and economics

The Goals

This seminar focuses on the central areas of process engineering and guides the delegates in developing both fundamental and practical understandings of key issues. Workshop examples will be drawn from the oil and gas processing, petrochemicals and chemical manufacturing industries.

The Process

In addition to formal lectures and discussions, the delegates will learn by active participation through the use of problem-solving exercises, group discussions, analysis of real-life case studies, and focused training videos.

The Results

The seminar provides a practical introduction to the fundamentals of process engineering thereby developing perspective and focus from a company viewpoint.

The Benefits

Upon completion of this workshop, the delegates will develop both fundamental and practical understanding of central issues in processes used in oil, gas, petrochemical, chemical, and allied facilities.

The Core Competencies

Key competencies include practical understanding of essential process units and classes of units involved in separations, heat exchange, and reactions as well as hydraulics and fluid flow. Delegates will be able to perform relevant calculations and analyses to assist in operation, sizing, and troubleshooting.

The Programme Content

Module 1—Fundamentals And Hydraulics

Basics

Process equipment and flow diagrams
P&IDs
Mass and energy balances

Hydraulics and Fluid Flow

Pressure and head
Bernoulli’s theorem and its field applications
Flow of liquids
Reynolds number and pressure drop in pipes
Two-phase and multi-phase flow
Pumps and compressors
Mixing and mixers

Module 2—Heat Transfer And Reaction Engineering

Heat Transfer

Thermal conductivity
Conduction and convection
Insulation
Heat transfer coefficients and calculation
Heat exchangers, type and sizing
Steam reboilers
Condensers and sub-cooling
Introduction to energy recovery

Catalysts and Reaction Engineering

Chemical reactions
Reaction kinetics
Introduction to catalysis
Reactor design and operation

Module 3—Catalysis And Distillation

Distillation and Other Separation Processes

Distillation basics
Phase behavior and vapor/liquid equilibria
Gas/Liquid separation
Trays: function, pressure drop, efficiency, flooding, operations, and damage
Bubble and dew points: calculation and application
Foam: formation, detection, cause
Packed v. trayed columns

Module 4—Separation Processes

Distillation and Other Separation Processes

Trays: function, pressure drop, efficiency, flooding, operations, and damage
Bubble and dew points: calculation and application
Foam: formation, detection, cause
Packed v. trayed columns
Tower capacity: factors, calculation, modification
Absorption and adsorption
Solid Liquid separation

Module 5—Process Control and Economics

Process Control Basics

Measured variables
Simple feedback control

Process Economics

Preliminary economic analysis
Fixed and variable costs, break even
Calculating raw materials usage
Scale up and six tenths rule