Major Process Equipment Maintenance and Repair Practical Machinery Management for Process Plants

This course presents to the attendees the basics. The course covers description and definition of hydrocarbon mixture properties, characterization parameters and their significance in design of equipment. Basic calculation procedures for design and rating of process equipment are discussed, with examples, to enhance skills in design techniques. Design aspects associated with revamping of existing facilities are also discussed and guidelines provided.

Course Objectives

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

• Gain a comprehensive understanding of process equipment design sizing, and selection concepts and techniques
• Apply practical techniques including short-cut methods for selection, sizing and design of process equipment for refineries, petrochemical and related oil and gas processing plants
• Understand the procedures for preparation of process equipment specifications and evaluation of vendor’s proposals
• Determine the aspects of mechanical design, safety considerations and cost estimating methods to complement background to process design

Who Should Attend?

This course is intended for mechanical, chemical process engineers involved in design, revamp and operation of refineries, petrochemical and related oil and gas plants. The program is also recommended for plant design and equipment engineers working with operating and engineering/construction companies, process licensors, and equipment manufacturers.

Course Outline

Diverse geographical and operating conditions require considerably different types and sizes of heating, cooling, and air-moving equipment to create a desired controlled environment. If improperly sized or selected equipment is used, the desired environment will not be obtainable at all times. Furthermore, improperly selected and/or sized equipment may be more costly -- requiring excess power or energy as well as an unnecessary capital investment.

This course, through a combination of lecture and workshops, explains and demonstrates the state-of-the-art methodology for sizing and selecting heating, ventilating, and air-conditioning (HVAC) equipment for commercial buildings. The common types of HVAC systems are discussed and analyzed as are currently available energy conserving/recovery equipment. The issue of indoor air quality (IAQ), particularly as it relates to variable air volume (VAV) systems, is addressed. An introduction to duct design is also included.

Day 1
Introduction

• Main operating Process equipment
• Design, sizing and selection criteria

Petroleum Properties and Definitions

• • Petroleum Processing: An Overview
  • Piping:
• Sizing Criteria - Velocity and dP
• Two-Phase Flow - Regimes/dP Calculation
• Sizing Methods - Detailed and Short-Cut

Day 2
Pumps

• Categories and Types - Reciprocating and
• Centrifugal
• Performance Characteristics - Curves,
• System/CF Hydraulics
• Calculation Method/Typical Format and Examples
• Pump Selection Guidelines

Compressors

• Categories and Types - Reciprocating and Centrifugal
• Compressor Control Methods
• Calculation Method/Typical Format and Examples
• Selection Guidelines - Technical and Economic Factors

Day 3
Heat Exchangers

• Types - Shell-and-Tube, Double-Pipe, Plate, Other Shell-and-Tube Construction - TEMA
• Classification Calculation Methods - Detailed and Short-Cut with Example Rating Existing Exchangers with Example Selection Guidelines

Air Coolers

• Types - Forced and Induced Air Design Calculation Procedure – Approximate Method

Day 4
Direct-Fired Heaters

• Types - Service, Duty Limits, Shop vs. Field Size Design Considerations - Process and Combustion Sides Fired Heater Control Systems

Day 5
Fractionators (Distillation Columns)

• Fractionator Types - Simple and Complex Columns Design Methods - ‘Process’ and ‘Hardware’ Design
• Process Design Procedures with Examples,
• Simple Column, Complex Column

Course Methodology

A variety of methodologies will be used during the course that includes:

• (30%) Based on Case Studies
• (30%) Techniques
• (30%) Role Play
• (10%) Concepts
• Pre-test and Post-test
• Variety of Learning Methods
• Lectures
• Case Studies and Self Questionaires
• Group Work
• Discussion
• Presentation

Course Fees

This rate includes participant’s manual, Hand-Outs, buffet lunch, coffee/tea on arrival, morning & afternoon of each day.

Course Timings

Daily Course Timings
08:00 - 08:20 Morning Coffee / Tea
08:20 - 10:00 First Session
10:00 - 10:20 Coffee / Tea / Snacks
10:20 - 12:20 Second Session
12:20 - 13:30 Lunch Break & Prayer Break
13:30 - 15:00 Last Session