BPCL Advanced Process Design & Simulation – Aspen HYSYS, Dynamics, EDR, PSV Sizing & FlareNet

By chemklub Categories: 2025
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About Course

This comprehensive training program is designed for BPCL engineers to enhance their expertise in process design and simulation. The course covers the complete workflow from steady-state modeling to dynamic analysis, integrating industry-standard AspenTech tools. Participants will gain hands-on experience in Aspen HYSYS for steady-state process simulation, HYSYS Dynamics for transient operations, and EDR for heat exchanger design and rating. The program also includes practical modules on PSV sizing and Aspen FlareNet for flare system analysis, ensuring compliance with safety and operational standards. By the end of the course, participants will be equipped with the technical skills and best practices to design, evaluate, and optimize process systems with high accuracy and efficiency.

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What Will You Learn?

  • Process Simulation Mastery – Develop proficiency in steady-state process modeling using Aspen HYSYS for various refinery and petrochemical applications.
  • Dynamic Process Analysis – Learn to model and analyze transient plant behavior using HYSYS Dynamics for startup, shutdown, and upset conditions.
  • Heat Exchanger Design & Rating – Gain expertise in using Aspen EDR for thermal and mechanical design of shell-and-tube and air-cooled heat exchangers.
  • Relief Device Sizing – Understand API and industry standards for PSV sizing and application in different process scenarios.
  • Flare System Design & Analysis – Use Aspen FlareNet to model, evaluate, and optimize flare and relief header systems for safe plant operation.
  • Integration of Simulation Tools – Learn how to transfer data seamlessly between Aspen HYSYS, Dynamics, EDR, and FlareNet for end-to-end process design.
  • Compliance with Safety Standards – Apply simulation results to meet regulatory and safety compliance in process and relief system design.
  • Optimization Techniques – Explore methods for improving process efficiency, energy usage, and operational reliability through simulation.
  • Case Study Application – Work on real-world refinery and petrochemical case studies for practical understanding.
  • Enhanced Problem-Solving Skills – Strengthen analytical skills to troubleshoot, modify, and optimize process systems effectively.

Course Content

Process Design Engineering

  • Session 1: Introduction, Project scope and types, Basic & detail engineering.
    04:00:00
  • Session 2: Relevant codes and standards used in industry
    02:06:40
  • Session 3: Introduction to BFD, PFD, P&ID and Conceptual Layout
    02:02:29
  • Session 4 : PFD and P&ID’s (Piping & Instrumentation Diagram) Preparation, Line List
    01:59:47
  • Session 5 : Line Sizing Hydraulics and Pressure Drop Calculation
    02:27:17
  • Session 6 : Line Sizing Hydraulics, Pressure Drop Calculation Part 2
    02:28:00
  • Session 7 : Pumps : Classification, Selection, Sizing, Rating and Datasheet Preparation
    03:51:00
  • Session 8 : Pump Datasheet Preparation and Pump Curves
    02:57:00
  • Session 9 : Control Valve : Sizing, Rating and Datasheet Preparation
    02:43:00
  • 10. Control Valve Sizing, Rating and Datasheet Preparation
    01:30:14
  • 13. Heat Exchangers: Classification, Selection, Thermal Design and Datasheet Preparation
    02:19:31
  • 13. Heat Exchanger Thermal Design & Datasheet prep PART 2
    03:21:56
  • 13. Heat Exhangers Classification, Selection, Thermal Design and Datasheet Preparation PART 3
    02:52:02
  • 15. Distillation Column Design and Datasheet Preparation PART-1
    01:59:48
  • 15. Distillation Column Design and Datasheet Preparation PART 2
    01:57:50
  • 14. 2 Phase & 3 Phase Separators, KOD Design and Datasheet Preparation PART 1
    01:59:38
  • 7. Product scale up 8. Material & Energy Balance
    01:45:55
  • 9. Capex & Opex Preparation 19. Cooling Tower Concepts, Sizing and Datasheet Preparation
    01:41:39
  • Scrubber Design and Datasheet Preparation
    02:05:00

Aspen HYSYS

HYSYS dynamics

PSV Sizing and flarenet

Aspen EDR

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