Upon the successful completion of this course, participants will be able to:

• Calculate, evaluate and compile basic process data essential for design of process equipment and plant.
• Acquire enhanced skills and knowledge of process design methods and calculation procedures (including use of practical short-cut techniques), application of criteria for sizing and design of process equipment and perform evaluations of existing equipment designs and revamp methods. 
• Prepare comprehensive Process Design Specification document package. 
• Troubleshoot process equipment and solve their related problems

PRE-TEST

 Introduction

• Nature of Design
• Design Constraints
• Design Categories

Petroleum Properties & Definitions 

• Composition of Petroleum streams
• Petroleum Processing – Continuous Process Industry: An Overview
• Hydrocarbon Properties: (Pure Hydrocarbons, Defined Mixtures, Undefined Mixtures)
• Characterization Parameters & Definitions

Development of Process Data 

• Process Design Tasks & Sequence
• Process Calculations Methods: (Empirical Procedure, Rigorous Procedure)
• Process Design Simulation Techniques: (Commercial Packages, Equipment Software, Process Data Packages)
• Data Compilation and Presentation: (Process Flow Diagram, Equipment Data Sheets, Accuracy and Significance)

Equipment Sizing, Selection and Design Process Equipment Categories

• Required vs. Calculated Data

Piping

• Fluid Flow Equations
• Pressure Loss Categories
• Pipe Properties
• Sizing Criteria
• Two-Phase Flow
• Sizing Methods
• Maintenance & Troubleshooting

Pumps

• Categories & Types
• Performance Characteristics
• Key Design Parameters
• Calculation Method/Typical Format and Examples
• Pump Selection Guidelines
• Maintenance & Troubleshooting
• Pumps: Performance, Control and Operation
• Pumps: Selection, Standards, and Specifications
• Pumps: Design, Materials and Seals

 Compressors

• Categories and Types
• Compression Process
• Characteristics & Terminologies
• Key Design Parameters
• Compressor Control Methods
• Calculation Method/Typical Format & Examples
• Selection Guidelines
• Maintenance & Troubleshooting
• Compressors: Design, Materials and Seals

 Heat Exchangers / Air Coolers

• Types of heat exchangers
• Shell-and-Tube Construction – TEMA
• Heat Transfer Relation
• Key Design Considerations, Fouling Factors, Process Applications
• Types of Reboilers
• Calculation Methods – Short-cut with Example
• Rating Existing Exchangers with Example
• Selection Guidelines
• Air cooled exchangers: Types – Forced and Induced flow, Key Design Consideration, Calculation Procedures, Monitoring & Troubleshooting
• Plate type heat exchangers
• Maintenance & Monitoring & Troubleshooting exchanger performance

Direct-Fired Heaters

• Types – Size and Configuration
• Fuel options
• Combustion systems
• Design Considerations – Process & Combustion
• Control Systems
• Troubleshooting

Process Vessels

• Types and Functions, Design Considerations
• Calculation Method and Examples
• Vessel internals – distributors, demisters etc
• Troubleshooting

Fractionators Columns

• Fractionators Types: Simple and Complex Columns
• Design Methods – Process/Hardware
• Process Design Procedure/ Examples: Simple Column-Stabilizer; Complex Column-C2 splitter Column
• Reboiling options – side reboilers etc
• Heat Pumped columns
• Internals: Different type of Trays, random & structured Packings / Grids, Vessel internals – distributors, demisters
• Hydraulic Criteria
• Performance Comparison
• Process Specification Data Sheets
• Maintenance & Troubleshooting

Reactors

• Fixed-Bed Reactors Types
• Gas Phase Reactors (GPR)
• Design Considerations
• Sizing Methods – Press Drop Calc
• Internals
• Maintenance & Troubleshooting

Ancillary Equipment

• Steam Jet Ejectors
• Pressure Relief Devices
• Troubleshooting

Mechanical & Safety Aspects

• Codes, Standards and Specifications
• Materials of Construction – Overview
• Safety in Design – Equipment Spacing

Process Control

• PID Controllers
• Feedback, Feed Forward and Cascade Controls
• DCS
• Advanced Control

Materials of Construction

• Selection Criteria
• Construction Materials
• Code & Standards to avoid Catastrophes
• Material Selection (Ferrous Material, Non Ferrous material, others)
• Corrosion Considerations

Process Risk Analysis

• Risk priority matrix
• Evaluation methods
• HAZOP study
• QRA “Ishikawa” diagrams
• MSDS

 Cost Estimating

• Cost Estimating Methods
• Estimate Types and Accuracy
• Equipment Installation Factors
• Contingency Allowances
• Cost Escalation

Process Design Specifications

• Purpose of Specification Package
• Types of Specification Packages
• Specification Package Contents
• Process Design in Project Cycle
• Cost of Process Design

Q & A Discussion

POST-TEST