About Course
Plant Design Engineering course improves the skills of candidates through its training on fundamental principles of Engineering and Technical concepts which are used in Process Design & Chemical Plant
Design A Process engineer help to transform raw materials into valuable everyday products. They are responsible for designing, implementing, controlling and optimizing industrial processes and machinery in the industry.
This training will cover
Detail process design engineering
Aspen Plus simulation
Aspen HYSYS simulation
Heat exchanger design using Aspen EDR
Distillation column design &
troubleshooting
Our trainers are experienced, leading professionals from top relevant organizations.
Our syllabuses structured as per the Global standards as well the working requirements in various
companies.
What Will You Learn?
- This course will improve your technical skills & enhances your experience by 1 year
- You will become expert in fundamental principles of Engineering and Technical concepts which are used in Process Design & Chemical Plant Design.
- Certificate of completion from ChemKlub India Career growth, Digitalization in chemical industry, Switching career from production to process
- Becoming master in process designing & troubleshooting Cracking any interview
Course Content
Process design engineering
1. Overview of Industry and Role of Process Engineer in various field.
2. Basic Design requirements based on Types of Plants/ Projects
3. Overview: Basic Engineering Package & Detailed Engineering Package
4. Process Design Basis data and its significance
5. Basics of Chemical Engineering required for Process Engineering Definitions,
Unit Conversions, Equations, Laws etc.
6. Introduction to BFD, PFD, UFD and P&ID
7. Types of Valves and Applications: Gate, Ball, Globe, Butterfly, Needle, Angle,
Diaphragm, Check valves etc.
8. Relevant Codes and standards used in Chemical and Process industry API,
ASME, IS, TEMA, IBR, GPSA, ANSI etc
9. Statutory Requirements for Chemical Plants
10. Preparation of Piping Line List and Technical concepts
11. Line Sizing: Liquid, Steam and Compressible Fluid Line Sizing Pressure Drop
calculations and Hydraulics Line Sizing by hand calculations and on PRDR Software
PSV inlet and outlet Line sizing
12. Control Valves(Pneumatic Valves) : Control Valve Sizing and Datasheets,
Types of Control valves, Flow Coefficient Cv, Pressure Drop calculations,
Characteristics of Control Valves, Chokedflow or Critical flow, Cavitation & Flashing
problems in Control valves Pressure drop calculations across Control valve and Cv
calculations
13. Pump Calculations, Sizing and Datasheets:
Types of Pumps, Centrifugal Pumps and Positive Displacement Pumps, Pump
Characteristic Curves, Affinity Laws, NPSH Available, Differential Head, Process
Datasheet, End of Curve operations, Cavitation Problem in Pumps and
Troubleshooting, How to Increase NPSH available, Pump Assembly, Process
datasheets Minimum Circulation Flow, Pump in Series and in Parallel
14. Storage Tanks: Types and Classification of storage Tanks Calculations and
15. Preparation of Process datasheet
16 Heat Exchangers Design and Heat Transfer Operations
17. Air Moisture Separator: Process datasheet and Calculations as per GPSA .OutBreathing flow ratescale Venting requirements as per API2000, Process datasheets
18.Pressure Safety Valves(PSV & PRV) & Rupture Disk (RD): Datasheet and
Calculations, Types of PSV, PSV locations, Relief events, Pressure relieving events,
Pressure setting criteria, External Firecase, Control Valve Open 100% case, Thermal
Expansion, Closed Block out, Tube Rupture case, ln-advertent power failure case
etc PSV Sizing and Calculations on software
19 Instrument Process Datasheets: Flow, Level, Pressure and Temperature
Instruments
20.Cooling Tower: Types of Cooling Tower, Natural draft & Mechanical draft,
Internal components, Dry bulb and wet bulb temperature, Efficiency calculations,
Approach, Range, Losses in Cooling Towers, Makeup water calculations, Tons of
Refrigeration(TOR), Capacity of Control valves, Additives In Cooling towers, Process
datasheet etc.
21.Steam Ejector, Flame Arrestor, StaticMixer
22.De-Superheater and Mass-Enthalpy balance calculations
23.Special Piping Material Datasheets Items: Filters, Strainers, Steam Traps,Sight
Glass and Flexible Hoses
24.Types of Plant Utilities, Preparation of Utility Summary list
25.Utility Balance and Adequacy Check Report and Calculations
26.Hazardous Area Classification (HAC)
27.Other available Software used in Chemical industry and their applications
by Chemklub India
Aspen PLUS & HYSYS
Aspen Plus Training
1. Understanding of Unit operation models in Aspen Plus
Calculation of Bubble Point & Dew Point
Txy - Pxy diagram of a binary mixtures
Simulation of Reactor Models
Reactors-R Stoic, R equilibrium, R Gibbs, CSTR, PFR
Exchangers-Heater, Cooler
Simulation of Distillation Models DSTWU, RadFrac, Petrofac
Simulation of Flash Drum, Mixer/Splitters
2. Flow sheeting option
Design Specification
Calculators
3. Model analysis tool
Sensitivity analysis
Optimization
4. Equipment Sizing
Column Sizing & Rating
Detailed Column Hydraulics study
5. Convergence
Analyze error and warning messages
Convergence Methods
Tear Stream
6. Aspen Plus Certification Exam Guidance
7. Process Plant Case Studies
Case studies
Aspen HYSYS Training
1.Introduction to Aspen Hysys
Property environment & Fluid packages
Petroleum assay
Characterization of crude assay
Oil manager
Simulation environment
2. Understanding of Unit operation models in Aspen Hysys
Simulation of Flash Drum, Mixer/Splitters
Simulation of Reactor Models
Reactors- Conversion, Equilibrium, Gibbs, CSTR.
Exchangers-Heater, Cooler.
Simulation of Distillation Models
Piping Operations
3. Logical Operations
Use of balance, adjust, set, recycle and spreadsheet.
Stream cutter, transfer function
4. Simulation Tools
Stream analysis, Data tables
Model summary, Utility manager
5. Equipment Sizing
Column Sizing & Rating
Detailed Column Hydraulics study
6. Introduction to Hysys Dynamics
Example on dynamic simulation
7. Convergence
Analyze error and warning messages
Convergence Methods
Tear Stream
8. Common Reporting options & Hysys workbook
9. Aspen Hysys Certification Exam Guidance
10. Hysys case studies, Compressor surge analysis
Heat exchanger designing using Aspen EDR
General Options: Identifying the available calculation modes Identify where in the
UI to select/change the calculation mode Design mode Identify required inputs and
expected outputs Identify the two options for optimization (area or cost) Define
area ratio Identify key variables considered in the design algorithm (area ratio,
pressure ratio, TEMA limits for rho-V2 and unsupported length, vibration) Identify
how to enter process and/or geometry limits Rating Mode Identify required inputs
and expected outputs Interpret area ratio results Simulation Mode Identify
required inputs and expected outputs Interpret area ratio results Find Fouling
Identify required inputs and expected outputs Interpret area ratio results Overall
Identify, for a given problem statement, the applicable calculation mode, and the
required input
Physical Property Packages: Identifying the different physical property packages
options (B-JAC, COMThermo, Aspen Properties, User Specified) Property Methods
Identify categories of property methods (Ideal, EOS, Activity models) and general
application for each
Overall: Explain the importance of the temperature range of points and pressure
levels in physical properties calculation Identifying, for a given problem statement,
the applicable physical property package, and the appropriate property method
Basic configuration Identify key options that are always selected by the user
(not changed by EDR): TEMA type, hot fluid location, exchanger orientation, baffle
type, etc. Identify applications for different shell types Identify arguments to be
considered during hot fluid location selection (high pressure, hazardous fluid,
fouling)
Geometry: Recognize key geometry (tube ID/OD, shell ID/OD, # of tubes, # passes,
tube pitch, pattern, tube length, baffle type) Recognize the types of tube layout
available Identify EDR standards for geometry (TEMA, ASME, most common
commercial dimensions) Identify Non-TEMA configurations (double pipe, hairpin)
General Options: Identifying the available calculation modes Identify where in the
UI to select/change the calculation mode Design mode Identify required inputs and
expected outputs Identify the two options for optimization (area or cost) Define
area ratio Identify key variables considered in the design algorithm (area ratio,
pressure ratio, TEMA limits for rho-V2 and unsupported length, vibration) Identify
how to enter process and/or geometry limits Rating Mode Identify required inputs
and expected outputs Interpret area ratio results Simulation Mode Identify
required inputs and expected outputs Interpret area ratio results Find Fouling
Identify required inputs and expected outputs Interpret area ratio results Overall
Identify, for a given problem statement, the applicable calculation mode, and the
required input
Physical Property Packages: Identifying the different physical property packages
options (B-JAC, COMThermo, Aspen Properties, User Specified) Property Methods
Identify categories of property methods (Ideal, EOS, Activity models) and general
application for each
Overall: Explain the importance of the temperature range of points and pressure
levels in physical properties calculation Identifying, for a given problem statement,
the applicable physical property package, and the appropriate property method
Basic configuration Identify key options that are always selected by the user
(not changed by EDR): TEMA type, hot fluid location, exchanger orientation, baffle
type, etc. Identify applications for different shell types Identify arguments to be
considered during hot fluid location selection (high pressure, hazardous fluid,
fouling)
Geometry: Recognize key geometry (tube ID/OD, shell ID/OD, # of tubes, # passes,
tube pitch, pattern, tube length, baffle type) Recognize the types of tube layout
available Identify EDR standards for geometry (TEMA, ASME, most common
commercial dimensions) Identify Non-TEMA configurations (double pipe, hairpin)
General Options: Identifying the available calculation modes Identify where in the
UI to select/change the calculation mode Design mode Identify required inputs and
expected outputs Identify the two options for optimization (area or cost) Define
area ratio Identify key variables considered in the design algorithm (area ratio,
pressure ratio, TEMA limits for rho-V2 and unsupported length, vibration) Identify
how to enter process and/or geometry limits Rating Mode Identify required inputs
and expected outputs Interpret area ratio results Simulation Mode Identify
required inputs and expected outputs Interpret area ratio results Find Fouling
Identify required inputs and expected outputs Interpret area ratio results Overall
Identify, for a given problem statement, the applicable calculation mode, and the
required input
Physical Property Packages: Identifying the different physical property packages
options (B-JAC, COMThermo, Aspen Properties, User Specified) Property Methods
Identify categories of property methods (Ideal, EOS, Activity models) and general
application for each
Overall: Explain the importance of the temperature range of points and pressure
levels in physical properties calculation Identifying, for a given problem statement,
the applicable physical property package, and the appropriate property method
Basic configuration Identify key options that are always selected by the user
(not changed by EDR): TEMA type, hot fluid location, exchanger orientation, baffle
type, etc. Identify applications for different shell types Identify arguments to be
considered during hot fluid location selection (high pressure, hazardous fluid,
fouling)
Geometry: Recognize key geometry (tube ID/OD, shell ID/OD, # of tubes, # passes,
tube pitch, pattern, tube length, baffle type) Recognize the types of tube layout
available Identify EDR standards for geometry (TEMA, ASME, most common
commercial dimensions) Identify Non-TEMA configurations (double pipe, hairpin)
Warning/Messages: Identifying the types of messages displayed by EDR and
its importance (errors, warnings, advisories, notes) Interpret, given a particular
file, the error/warning messages Develop, given your previous interpretation,
some modifications that could potentially help fixing the error/warning
messages TEMA sheet Recognize, from a list of outputs, which could be found
in the TEMA sheet Explain how to export TEMA sheet to Excel Thermal
Interpret, for a given simulation, area ratio value, heat transfer area of the unit
Thermal: State, for a given simulation, the effective mean temperature
difference State, for a given simulation, the tube side and shell side overall film
coefficients Interpret, given a simulation, which side represents the greater
contribution to the overall HTC State, for a given simulation, the tube side and
shell side resistance distribution Interpret, given a simulation, how much the
fouling resistances from both sides contributing to the heat transfer resistance
Hydraulic: Identifying the three contributions to the overall pressure drop
(frictional, momentum change, gravitational) State, given a simulation, pressure
drop on each side Identify, given the same file, which pressure drop
mechanism has the greater contribution on each side Identify, given the same
file, which part of the exchanger represents the greater contribution to
pressure on each side Identify on which part of the exchanger the highest
velocity is achieved on each side Identify, given a simulation, if there are Rho-V2
TEMA limits violations
Hydraulic: Identifying the three contributions to the overall pressure drop
(frictional, momentum change, gravitational) State, given a simulation, pressure
drop on each side Identify, given the same file, which pressure drop
mechanism has the greater contribution on each side Identify, given the same
file, which part of the exchanger represents the greater contribution to
pressure on each side Identify on which part of the exchanger the highest
velocity is achieved on each side Identify, given a simulation, if there are Rho-V2
TEMA limits violations
State the definition of a given concept by searching it in the Help Guide
Distillation column design & troubleshooting
Introduction to Distillation Unit Operation
"Fundamental of vapor-liquid equilibrium
Volatility of pure components : boiling point, vapor pressure
Concept of Sensible and Latent Heat
Behavior of mixtures in distillation : dew and bubble points, vaporization curves, total/partial
condensation and vaporization, liquid-vapor separation and distribution of components
according to their volatility
Relation between temperature, pressure and composition of distillate"
Distillation column internals
Column Internals, Types of Packing & Trays.
Different types of contacting systems for the active area : bubble caps, fixed or floating valves
Liquid or vapor distributors, collectors and redistributors"
Separating power : number of stages, liquid and vapor traffics, feed inlet location
"Material balance of the column: concepts of cut point, separation quality and fractionation
capability
Heat balance : condenser and reboiler duties, Reflux and Boil-up ratios and industrial
configurations"
Distillation Column Designing
Tray Design, Pressure drop calculations, Efficiency calculations, McCabe Thiele method, Column
Performance
Condenser & Reboilers
"Different types of condensers.
Distilling column overhead operations. "
Different types of Rebuilder's & their operation
Batch Distillation ,Short Path Distillation
"Batch Distillation Theory - Concepts and Principles, Material and Energy Balances for Batch
Systems, Equipment for Batch Systems such as Batch Distillators, Design & Operation of Batch
Distillation Systems
Distillation Column Controlling
Operating parameters of a distillation column (Pressure, Temperature, Flow rates, Reflux Ratio...)
Column pressure Controlling : pressure control and pressure profile along the column
Column Temperature Controllers
Different controller configurations used in industry, Instrumentation and process control loops
around the column
Distillation Column Troubleshooting
Flooding, Weeping, Entrainments etc. concepts with real industrial examples, optimizing column
performance
Column internal sizing using Aspen Plus/HYSYS
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