Process Equipment Design, Applications, Maintenance & Troubleshooting Rules of Thumb For Process Engineers

This five-day course is designed to provide chemical and process engineers with a lot of common sense techniques, shortcuts and calculations to quickly and accurately solve day-to-day design, operations and equipment problems.  The practical tips, handy formulas, correlations, curves, charts, tables, and shortcut methods presented in this course will save engineers valuable time and effort.

This course covers rules of thumb applicable to fluid flow, heat exchangers, fractionators, absorbers, pumps, drivers, separators/accumulators, boilers & cooling towers.

Course Objectives

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

• Apply the rules of thumb for chemical and process engineering including fluid flow, gas flow, velocity head, piping pressure, compressible flow, sonic velocity, metering and valves
• Employ the rules of thumb for heat exchangers and command the TEMA standards and selection guides
• Perform rules of thumb for fractionators & absorbers and explain their design, control schemes & optimization techniques
• Use the rules of thumb for pumps including affinity laws, horsepower, efficiency minimum flow & suction system and recognize the various construction materials used in pumps
• Implement the rules of thumb for drivers and determine their ranges of application, efficiency & service factors
• Apply rules of thumb for separators/accumulators such as liquid & vapour residence time, calculation methods, pressure drop, vessel thickness, gas scrubbers & reflux drums and employ the general vessel design tips
• Carry out the rules of thumb for boilers and acquire knowledge on thermal efficiency, stack gas enthalpy & quantity, steam drum stability, blowdown control, caustic embrittlement, etc.
• Perform rules of thumb for cooling towers and analyze its system balances, temperature data & transfer units

Who Should Attend?

This course is intended for process, maintenance, production, operations, plant and field managers, superintendents, supervisors, engineers, technicians and operators.  This is also applicable to plant and shift foremen as well as to other technical staff.

Course Outline

Day 1
Introduction
Equipment Design

• Fluid Flow
• Heat Exchangers
• Fractionators
• Absorbers
• Pumps
• Compressors
• Drivers
• Separators/Accumulators
• Boilers
• Cooling Towers

Day 2
Process Design

• Refrigeration
• Gasification
• Gas Treating
• Vacuum Systems
• Pneumatic Conveying
• Blending

Day 3
Plant Design

• Process Evaluation
• Reliability
• Metallurgy
• Safety
• Controls

Day 4
Operations

• Troubleshooting
• Startup
• Energy Conservation

Day 5
Operations (continuation)

• Shortcut Methods for Decisions
• Process Modeling Using Linear Programming
• Properties
• Approximate Conversion Factors
• RECAP

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