ADVANCED PROCESS DESIGN
INTRODUCTION
Stepin Engineering offers targeted training for Chemical and Petrochemical Engineers in
the Oil and Gas sector, enhancing skills and fostering career progression. The Advanced
Process Design program focusses on efficient, safe industrial process design, covering
simulation, equipment selection, and sustainability. It equips engineers with essential
knowledge for career advancement and adaptability in the dynamic Oil and Gas Industry.
TRAININGS COVERED
BLOCK FLOW DIAGRAM(BFD), PROCESS FLOW DIAGRAM (PFD),LEGENDS &
SYMBOLS, PROCESS AND INSTRUMENTATION DIAGRAM(P&ID)
MODULE 1
TOPICS COVERED
Definition of BFD, PFD & PID. Typical drawing of BFD. Contents of BFD.
Legends & Symbols. Typical legends and Symbols. Explanation of legends and
symbols with respect to various standards.
PFD: Typical drawing of PFD. Contents of PFD. Representation of legends & symbols
in PFD. H&MB representation and contents on PFD. Requirements of various
standards related to PFD.
P&ID Purpose, Structure, Legends
P&ID: Typical drawing of P&ID. Contents of P&ID. Representation of legends &
symbols in P&ID. Requirements of various standards related to P&ID.
LINE SIZING
MODULE 2
TOPICS COVERED
Pressure drop calculations as per SHELL DEP and various models used for pressure
drop calculations
Pipe schedule, Piping class etc.
Line sizing criteria for liquid lines, Friction factor, Gas lines, liquid lines, steam lines
and Gas-liquid two phase line sizing as per API 14E.
Codes and Standards requirements.
Velocity criteria as per standards for various cases. Demonstration of line sizing
through manual calculations.
Equivalent length definition and explanation with respect to SHELL DEP.
PUMP SIZING & HYDRAULICS
MODULE 3
TOPICS COVERED
Pump suction and discharge line sizing.
Explanation of Pipe sizing segment and line sizing in HYSYS using HYSYS manual.
PIPENET SIMULATION (STANDARD MODULE)
MODULE 4
TOPICS COVERED
Introduction to Pipenet simulation.
Standard, Transient and Spray modules in Pipenet simulation.
Demonstration of Input parameters to build the network for standard module.
Simple network modelling demonstration to carryout Hydraulic calculations.
Complex network modelling demonstration. Discussion on results and Report
preparation.
PIPENET SIMULATION (TRANSIENT MODULE)
MODULE 5
TOPICS COVERED
Introduction to Transient module
Transient Analysis network building & Demonstration
Surge Analysis through Pipenet -Examples. Demonstration of Surge analysis for
water systems.
FIRE WATER & FOAM DEMAND CALCULATIONS
MODULE 6
TOPICS COVERED
Introduction to Firewater Systems
Fire water Demand calculations as per NFPA regulations. Foam application rate for
crude oil storage tanks.
Fire water network, storage, fire water pumps, jockey pumps design calculations.
Hydrants, Monitors and Sprinklers – K factor calculations. Input parameters to
Pipenet simulation.
FIRE WATER NETWORK SIMULATION IN PIPENET
MODULE 7
TOPICS COVERED
Introduction to Firewater Systems
Fire water Demand calculations as per NFPA regulations. Foam application rate for
crude oil storage tanks.
Fire water network, storage, fire water pumps, jockey pumps design calculations.
Hydrants, monitors and sprinklers – K factor calculations. Input parameters to
Pipenet simulation.
PSV - DEFINITIONS, TYPES & SET PRESSURE
MODULE 8
TOPICS COVERED
Various Definitions in Pressure-Relieving and Flare system
Description of various types of Relief valve and installation in Refineries and Oil and
Gas industries
Why do we need to install Relief Valves
Types of Relief Valves to be Installed
Why Rupture Disk is Installed
Set Pressure Calculation Procedure
When do you go for Multiple Relief Valves and set Pressure Calculation of Multiple
Relief Valves
Emergency Depressurizing Valves and the sizing procedure
Surge Relief Valve for Liquid Systems
Surge Relief Valves for Gas System. Analysis and results discussion
PSV SIZING CALCULATIONS
MODULE 9
TOPICS COVERED
Sizing Procedure for Gas, Liquid System with a detailing procedure Disposal
Systems
Atmospheric Discharge Procedure
PSV Discharge to closed Systems
Flare Header Calculations
Horizontal / Vertical KO Drum Sizing Procedure
Flare Header Purge Gas Calculations
Seal Drum Sizing etc.
Flare Radiation Calculation
Flare Stack Sizing Procedure
Flare Ignitors systems.
Description of Burning Pit and Sizing guidelines
PSV FLARE HEADER SIZING
MODULE 10
TOPICS COVERED
Flare Header / Piping / Mach No Calculation and Sizing Procedure for Gas-Liquid
System with a detailing procedure Disposal Systems
Atmospheric Discharge Procedure
PSV Discharge to closed Systems
Flare Header Calculations
Demonstration of Relief Valve Sizing of Gas, Liquid, Steam and Gas-Liquid System
using Manual Calculation
Flare Radiation Calculation
Flare Stack Sizing Procedure
Flare Ignitors Surge Relief Valve Sizing Procedure
Description of Burning Pit and Sizing guidelines
SOFTWARE COVERED
PIPENET
TRAINER
TRAINER NAME : MR. ELAMVALUTHI GANGADARAN
(LEAD TRAINER)
SCHEDULE
Online Assessment
S. No Date Day Description Trainer Time
5PM - 7PM
Elamvaluthi
1 03-May-25 Saturday BFD, PFD, Legends & Symbols, PID 10 am- 1 pm BFD, PFD, Legends & Symbols, PID
Gangadaran
Elamvaluthi
2 04-May-25 Sunday Line Sizing 10 am- 1 pm Line Sizing
Gangadaran
Elamvaluthi
3 10-May-25 Saturday Pump Sizing & Hydraulics 10 am- 1 pm Pump Sizing & Hydraulics
Gangadaran
Pipenet Simulation (Standard Elamvaluthi Pipenet Simulation (Standard
4 11-May-25 Sunday 10 am- 1 pm
Module) Gangadaran Module)
Pipenet Simulation (Transient Elamvaluthi Pipenet Simulation (Transient
5 17-May-25 Saturday 10 am- 1 pm
Module) Gangadaran Module)
Fire water & Foam Demand Elamvaluthi Fire water & Foam Demand
6 18-May-25 Sunday 10 am- 1 pm
calculations Gangadaran calculations
Fire water Network simulation in Elamvaluthi Fire water Network simulation in
7 24-May-25 Saturday 10 am- 1 pm
Pipenet Gangadaran Pipenet
PSV- Definitions, Types & Set Elamvaluthi PSV- Definitions, Types & Set
8 31-May-25 Saturday 10 am- 1 pm
Pressure Gangadaran Pressure
Elamvaluthi
9 01-JUN-25 Sunday PSV sizing calculations 10 am- 1 pm PSV sizing calculations
Gangadaran
Elamvaluthi
10 07-JUN-25 Saturday PSV - Flare header Sizing 10 am- 1 pm PSV - Flare header Sizing
Gangadaran
THANK YOU
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