Process Design Engineering
Process Design Engineering plays a crucial role in transforming raw materials into valuable products through optimized and efficient processes. This discipline focuses on the conceptual development, design, operation, and optimization of chemical, petrochemical, pharmaceutical, and other industrial processes. Our Process Design Engineering course is designed to equip engineers with practical knowledge and industry-relevant skills, covering essential topics like PFDs, P&IDs, equipment sizing, process simulation, utility design, and safety standards. Whether you’re a fresh graduate or a working professional, this course provides a strong foundation to excel in the EPC sector and meet real-world project requirements with confidence.
Course Duration: 120 Hours
Training: Online / Offline
Batch: Regular / Weekend
Fee: ₹ 35,000/-
Course Contents
Introduction to Process Plant
- Basic Concepts Of Chemical Engineering
- Process Engineers And Their Roles In Different Fields Including – EPC / Production / R&D / Lectureship / QA / QC / Project Management
- Thorough Understanding Of Physical Properties Of Fluids
- Overview Of Unit Operations Encountered In Chemical / Petrochemical Plants
- Industry Codes And Standards
Basic Engineering Package
- Design basis Plant/ Project
- Introduction to PFD, P& ID, and PDS, Equipment List, Line List, Equipment Data Sheets
- Process Instrument Data Sheets
- Process Block & Concept Flow Diagram
- Development of PFD, PFD specification
- Development of P& ID
- Fundamentals of Material Balance
- Fundamentals of Energy Balance
Line Sizing
- Terms & Definitions
- Line sizing using velocity criteria for liquids
- Line sizing using velocity criteria for gases
- Pressure drop calculations for liquids using darcy’s equation, manning’s equation and Hagen Williams equation
- Example for line sizing for gases and liquids using velocity criteria as well as pressure drop criteria
Pressure Relief Valve
- Introduction
- Function of Relief Valve
- Types of Relief Valves
- Terms and Definition
- Overpressure Scenarios
- Thermal or Hydraulic Expansion
- Gas Blow by & Tube Rupture
- Utility Failure
- Relief Valve Sizing
- Sizing Methodology
- Calculation Procedure
- Codes & Standards
Separator
- Introduction
- Separation Principles
- Types of Separators
- Typical Separator
- Separator Internals
- Operating Zones
- Separator Classification
- Residence Time
- Sizing Methodology
- Design Parameters
- Codes and Standards
- Case Study & Calculation
Control Valve
- Introduction to Control Valves
- Function and Importance
- Types of Control Valves
- Control Valve Components
- Flow Characteristics
- Valve Sizing Basics
- Cv and Flow Calculations
- Actuators and Positioners
- Control Valve Accessories
- Installation Guidelines
- Standards and Specifications
- Troubleshooting and Maintenance
Distillation Column
- Basic Principles of Distillation
- Types of Distillation Columns (Function & Service)
- Key Components and Design Considerations
- Detailed Study of Column Internals
- Selection & Optimization of Internals
- Tray Hydraulics and Efficiency
- No. of Trays Calculation & Feasibility Analysis
- Packed Column Design and Considerations
- Process Control of Distillation Columns
- Startup and Shutdown Procedures
Heat Exchanger
- Factors that affect heat transfer.
- Fouling factors.
- Weighted MTD calculations.
- Predicting heat exchanger performance
- TEMA classifications
Shell and tube heat exchangers
- Other exchanger components.
- Factors that affect heat transfer.
- Heat exchanger operating parameters and problems.
- Energy conservation overview & methods.
Pump Hydraulics & Fluid Phase Behavior
- Composition of Well Fluid
- Determination of Well Fluid Composition
- Well Fluid Phase Behavior
- Equations of State
- Definition of Pump
- Classification of Pumps
- Selection of Pumps
- Pump Material of Selection
- Steps Involved in the Pump System Design
- Steps involved in the Pump Hydraulic
- Calculations
- Pump Characteristic Curves
Introduction to Simulation
- History of Simulation Software
- Development of Simulation software
- Various Simulation Software available in the market
- Concept of Degree of Freedom
- Difference between Steady State Simulation Vs Dynamic Simulation
- Application of Degree of Freedom in Simulation
- Application of Steady State Simulation
- Application of Dynamic Simulation
- Demonstration of Simulation Software
- Demonstration of Various Modules available
Fluid Package Selection
- Introduction of Thermodynamics
- Introduction to Equation of State Models available in Simulation Software
- Introduction to Activity Co-efficient Models available in Simulation Software
- Selection guidelines for selecting correct type of Thermodynamic Model for various applications pertaining to Refinery, Oil & Gas, Hydro-carbon Processing, Chemical Sectors etc.
- Validation of Thermodynamics
Steady State Simulation
- Modeling Pumps, Compressors, etc.
- Fitting performance characteristic curves
- Modeling multiple curves for VFD-driven equipment
- Analyzing simulation results – rotary equip
- Tutorials on rotary equipment simulation
- Modeling of unit operations: flash vessels, heat exchangers, and distillation columns
- Modeling of absorption, extraction, and azeotropic/extractive distillation operations
- Analysis of simulation results for unit operations
- Tutorials on unit operation simulations
Simulation of Unit Operations and Column
- Modeling CSTR, PFR and Generic Reactors like Gibbs Reactor, Conversion Reactor, Equilibrium Reactor. Analysis of Simulated Results
- Modeling & Simulation of Reactive Distillation Column
- Modeling & Simulation of Case Study Problem with using Optimization Tool
- Modeling & Simulation of Crude Distillation Unit comprising of Characterization of Crude, modeling of CDU unit along with side stream options
Note: For distillation column modeling, short cut method i.e. Fenske, Underwood & Gilliland method as well as rigorous column simulation shall be discussed along with respective caste study examples
Utility Engineering
- Cooling Tower
- Boiler
- Instrument Air Generation Unit
- Chilling Plant
- Nitrogen Generation Unit
- Fire Fighting System Design
Safety Engineering
- Importance of safety in process industries
- Basics of hazardous area classification
- Zone classification for flammable gases/vapors
- Key standards: IEC, NEC, etc.
- Introduction to HAZOP study
- Role of HAZOP in risk identification