SUBJECT: Process Engineering Short Course Syllabus

1) Introduction to Various Types of Project Contracts (4 hours)

 Meaning of Engineering Procurement and Construction (EPC)
 Typical Organization Chart of EPC Company
 Work Flow in EPC Companies
 FEED Stage Work Flow
 EPC Contract Types
 Procurement Procedure
 Types of Tenders
 Tender Procurement Process Flow Chart

2) Basic Engineering Design Package (BEDP or FEED Package) (10 hours)

 Scope and Title
 Contents of BEDP
 Contents of Table 1
 General Design Data
 Project Specifications
 Manuals and Drawings
 Contents of Table 2
 General Design Data
 Specifications & Data Sheets
 Drawings
 Developments of Table 1 Contents
 General information
 Basic Engineering Design Data
 Complex/Plant material balance
 Utility summary tables
 Flare Load Summary Tables
 Effluent summary tables
 Winterizing & heat conservation and insulation data
 Safety
 Resins, Chemicals, Solvents and Catalysts
 Hazardous area classification
 Licensor’s Proprietary Items
 Project Specifications
 Different Types of Manuals
 Developments of Table 2 Contents
 General Information
 Unit Design Basis
 Equipment Item Index
 Heat & material balance tables
 Utility Summary Tables
 Review of Detailed Design
 Specifications & Data Sheets
 Fired heaters
 Storage tanks
 Towers, reactors and vessels
  Heat exchangers
 Machinery
 Instruments
 Drawings
 Preliminary unit plot plan
 Piping & instrumentation diagrams (P&IDs)
 Utility distribution flow diagrams (UDFDs)
 Emergency shut-down block diagram and/or logic diagram.
 Cause & effect tables/diagrams.
 Single line diagrams.

3) Detail Design and Engineering (6 hours)

 Scope
 Work Sequence and Procedures
 Process and Utilities Engineering
 Piping Engineering
 Mechanical Engineering
 Instrumentation Engineering
 Electrical Engineering
 Civil and Structural Engineering
 List of Softwares used During Detail Engineering (Name and Application)

4) Introduction to Key Process Engineering Deliverables (5 hours)

5) Preparation of Key Process Engineering Summaries (5 hours)

 Fluid List- Sample
 Line List-Sample
 Line List- Preparation
 Tie-in-Point List-Sample
 Tie-in-Point List-Preparation
 Catalyst Summary-Sample
 Chemicals Summary-Sample
 Catalyst & Chemical Summary-Preparation
 Hazardous Source List-Sample
 Hazardous Source List-Preparation
 Equipment List- Sample
 Equipment List- Preparation
 Utility Consumption Summary – Sample
 Utility Consumption Summary - Preparation
 Preparation of Flare Load Summary
 Effluent Summary-Sample
 Effluent Summary-Preparation

6) Typical Oil and Gas Production Facilities (6 hours)

 Oil Production Facilities
 Artificial Lift
 Crude Oil Treatment
  Produced Water Treatment
 Natural Gas Processing
 Amine Process (Flow Diagram)
 Dehydration using Glycol (Flow Diagram)
 Dehydration using Solid Desiccants (Flow Diagram)
 NGL Recovery
 LNG Supply Chain

7) Introduction to Crude Oil Refinery Processes (6 hours)

 Introduction
 Typical Block Flow Diagram for Refinery
 Various processes PFD.
 Physical Processes
 Thermal Processes
 Catalytic Processes
 Conversion of Heavy Residues
 Treatment of Refinery Streams
 Lube base stock preparation
 Other processes (Common Facilities)

8) Guidelines for Preparation of Majors Process and Piping Drawings (6

hours)
 Process Work Flow
 Process Equipments Symbols for P&ID
 Block Flow Diagram (BFD)
 Process Flow Diagrams (PFD)
 Piping and Instrumentation Diagrams (P&ID)
 Process Control Diagrams (PCD)
 Plot Plan
 Guidelines for Preparation of Plot Plan
 Elevation Drawings
 Guidelines for Preparation of Equipment Layout

9) Fluid Flow and Line Sizing (5 hours)

 Types of Fluid Flow
 Equation of Continuity
 Bernoulli's Equation
 Friction Losses in Pipes
 Minor Losses Calculation
 Equivalent Length of Fittings
 Pressure Drop Formula
 Step Wise Procedure for Single Phase Pipeline Sizing
 Line Sizing Criteria – Allowable Velocity & Pressure Drop
 Line Sizing – Two Phase Flow
 Types of Two Phase Flows
 Flow Regimes
 Pressure Drop Calculation Procedure
10) Pumps and Hydraulic Calculations (8 hours)
Part 1
 Introduction
 Types of Pumps
 Positive Displacement Pumps
 Positive Displacement Pumps (Strengths/Concerns)
 Roto Dynamic Pumps
 Roto Dynamic Pumps (Strengths/Concerns)
 Head & Typical Performance Curves
 Selection Guidelines
 Centrifugal v/s Reciprocating Pumps
 Capacity /Pressure
 Pressure/Flow/ Fluid Handling
 Cost
 Affinity Laws

Part 2
 Terminology in Hydraulics
 NPSHA Calculations
 Hydraulics Calculations Procedure
 Solved Example
 Hydraulic Calculations – Reciprocating Pump
 Rule of Thumb for Pumps
 Excel Calculation Sheet

11) Compressors (5 hours)

 Introduction
 Type of Compressors
 Positive Displacement Compressors
 Centrifugal Compressors
 Compressors
 Lubricating System
 Lube Oil Cooling
 Comparison
 Basic Calculations – Head/Power/Discharge Temperature
 Compressor Operation
 Surge & Anti surge
 Surge Controls
 Thumb Rules for Compressors
 Codes & Standards

12) Introduction to Process Vessel Design (4 hours)

 Process Design Conditions
 Codes and Standards
 Low Temperature Requirements
 Pressure Testing
  Separators / Pressure Vessel Sizing
 Vertical Separator Design
 Separator Sizing
 Horizontal Separator Sizing
 Thumb Rules (Separators)
 Thumb Rules (Storage Tanks)

13) Heat Exchangers and Thermal Design Procedure (12 hours)

Part 1
 Classification of Exchangers
 Exchangers Nomenclature
 Types of Heat Exchangers
 Double Pipe Heat Exchanger
 Shell and Tube Exchanger
 Major Components of Shell and Tube Heat Exchanger
 Plate and Frame Exchanger
 Spiral Plate Exchanger
 Spiral Tube and Helical Flow Exchanger
 Air Cooled Exchanger
 Plate Fin Exchanger
 Categories of Shell and Tube Exchanger
 Fouling Factors
 Log Mean Temperature Difference Correction Factor
 Overall Heat Transfer Coefficients
 Energy Balance and Heat duty
 Pressure Drop Calculations
 Data Required for Thermal Design
 Thermal Design Procedure
 Thermal Design Parameters
 Thumb Rules for Heat Exchangers
 Codes and Standards
Part 2
 Shell and Tube Heat Exchanger
 Allocation of Fluids
 Flow Arrangements
 Problem Statement
 Design of Shell and Tube Heat Exchanger
 General Design Steps
 Thermal Design
 Hydraulic Design
 Part (A) - General Design Steps of Shell and Tube Heat Exchanger
 Part (B) - Thermal Design of Shell and Tube Heat Exchanger
 Physical Properties
 How Should I Start
 How to calculate heat duty of heat exchanger?
 Calculating LMTD
 Calculation Of Heat Transfer Area
  Select A Suitable Size Tube
 1 – 1 Pass Arrangement Calculation
 1 – 4 Pass Arrangement Calculation
 Read jH Factor from Graph-Tube
 Summary of Tube Side Calculation...
 Shell Side Calculations
 Read jH Factor from Graph-Shell
 Calculation Of Overall Heat Transfer Coefficient
 Calculation of LMTD Correction Factor
 Heat Transfer Area Verification
 Part (C) – Hydraulic Design
 Pressure Drop Calculations across Tube side…
 Pressure Drop Calculations across shell side…
 Single Phase Exchanger-Formulas
 Codes & Standards

14) Pressure Safety Valves and Sizing / Calculation Procedures (6 hours)

 Introduction
 PSV Types
 Chattering Problems
 Sizing Calculations
 Example and Procedures
 Codes, Standards and Simulators

15) Control Valves and Sizing Calculations (5 hours)

 Introduction
 Features
 Flow Characteristics
 Cavitation
 Flashing
 Piping Influence & Choked Flow
 Typical Control Valve Data Sheet
 Construction Features
 Classification & Types
 Types of Actuators
 Symbology in P&ID
 Bonnet & Accessories
 Major Vendors
 Interface
 Body & Trim Material
 Codes & Standards
 Sizing & Selection

16) Cost Estimation Methods (4 hours)

 Fixed Capital Investment
 Cost Estimate Types and Accuracy
 Capital Cost Estimate Classifications
  Capital Cost Estimate Definition
 Cost Estimation Methods
 Factors Affecting Capital Cost
 Direct Project Expenses
 Indirect Project Expenses
 Contingency and Fee
 Auxiliary Facilities
 Pumps and Electric Motors
 Fans
 Blowers
 Compressors
 Heat Exchangers
 Fired Heaters
 Pressure Vessels
 Distillation Columns
 Packed Distillation Columns

17) HAZOP Analysis Fundamental (8 hours)

 What is HAZOP?
 Objective of HAZOP
 How and Why HAZOP is used.
 Purpose of HAZOP
 HAZOP – Hazard and Operability Study
 Features of HAZOP Study
 HAZOP Phasing
 HAZOP Study Procedure
 HAZOP Study Flow Chart
 Guidelines for division into Sections (Nodes)
 Guide Words
 HAZOP Study Form
 HAZOP Study
 Strength of HAZOP
 Weakness of HAZOP
 Planning for HAZOP
 Documents to be kept ready
 Team Characteristics
 Responsibility of HAZOP Team Members
 Sample Process Documents
 Sample HAZOP Work Sheet
 Sample HAZOP Close Out Report