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Process Design Practices is an intensive course for young process engineers to bridge the gap between university education and practical process design and troubleshooting in a short time of five days.


 
Course Outline

After Participating in the Seminar, you will be able to perform the following calculations:
• Vaporizer and steam drum heat balance
• Design pressure, temperature and flange class for all equipment in Stripper system
• Size all pipes and nozzles in Stripper feed circuit and list hydraulic cases
• Pressures at all points between a high and low pressure separator
• Size the Stripper feed flow meter, and permanent pressure drop
• steam consumption in ejector
• Flashing liquid flow rate through a hole in a vessel
• Control valve size in the Stripper feed circuit
• Size and layout of recycle compressor suction drum
• Feed drum elevation from pump NPSH
• Feed pump motor size
• Compressor head, horsepower and outlet temperature
• Number of Stripper feed-bottoms exchangers
• Relief loads for the following cases: Fire case, Blocked liquid outlet, Inlet control valve fails open, Steam reboiler tube failure, Fractionator power failure

Description

It typically takes several years for young university graduate engineers to master practical methods used in the process industry to solve problems. Process Design Practices is an intensive course for young process engineers to bridge the gap between university education and practical process design and troubleshooting in a short time of five days. After participating in the seminar, you will know the most important design practices and will be able to perform the necessary calculations to design and troubleshoot process units.

Objective

Fast track approach for acquiring practical process design and troubleshooting skills

Who Should Attend

Process Design Practices is aimed at chemical engineers employed in the petroleum and chemical industry engaged in designing or operating process units.

Text Book
Concise, high quality write-up with all the necessary equations and numerous sketches

Special Feature
The seminar will be interactive involving all participants. The instructor illustrates the concepts with the following examples from his practical experience that he weaves into his lectures appropriately.  
• Toluene tower bottom thermal conditions
• Condensate header thermal conditions
• Relief header condition differences between simulators
• Hydrotreater hydrogen solubility
• Tower feed circuit design conditions
• Hydrocracker minimum pressurization temperature
• Hydraulics cases for sulphur recovery unit
• Flare pulsation
• Sewer system flooding
• Stopple/freezing of BFW pipes
• Impact of missing blank and plugged drain
• Ejector steam flow
• Leakage through tray holes
• Flashing choke flow in condensate header
• Unstable level in steam/hydrocarbon system
• Liquid backup in water condenser with sealed inlet
• Warmup system for hot hydrocarbon pumps
• Pump losing suction due to gas seal
• Seal system cyclone blockage
• Sootblower spacing and driver type

Faculty: Cilliers Kruger, Korf Technology Ltd.

Program Outline Day 1

Simulation
• Methods for performing mass, enthalpy and entropy balances
• Flash calculation principles and common simulation pitfalls

Workshop
• Vaporizer and steam drum heat balance

Refreshments and Networking

Design Conditions
• Proven and consistent approach in determining design pressure and temperature, and typical mistakes made by inexperienced engineers

Lunch

Case Study
• Incinerator blockage and flooding

Workshop
• Design pressure, temperature and flange class for all equipment in Stripper system

Refreshments and Networking

Hydraulics
• Structured approach for performing fluid flow calculations to determine all pipe, instrument and equipment sizes, including reasonable
   assumptions used during front end design

Workshop
Size all pipes and nozzles in Stripper feed circuit and list hydraulic cases

Adjournment

Day II

Piping
• Pressure drop methods for liquids, gases and two-phase flow, including flow regimes
• Criteria and methods used for insulation, tracing, hot taps and valving

Workshop
• Determine pressures at all points between a high and low pressure separator.

Refreshments and Networking

Flow Meters
• Orifice and nozzle sizing and installation, including liquid, gas, two phase flow, permanent pressure drop and flow rate correction methods

Lunch

Case Study
• Cat gasoline rundown line sizing
• Degassing system blockage

Workshop
• Size the Stripper feed flow meter, and determine permanent pressure drop
• Calculate steam consumption in ejector
• Determine flashing liquid flow rate through a hole in a vessel

Refreshments and Networking

Control Valves
• Control valve sizing and installation, including gas, liquid and two phase flow, positioners, actuators and failure modes

Workshop
• Determine the control valve size in the Stripper feed circuit

Adjournment

Day III

Vessels
• Vessel types, sizing and rating, including level configuration, inlet piping and vessel support

Workshop
• Determine size and layout of recycle compressor suction drum

Refreshments and Networking

Towers
• Typical tower simulation, efficiency and flooding criteria, including derating factors
• Tray layout and clearances at feeds and draws, including reboiler types and configuration

Lunch

Case Study
• Vacuum bottoms pumps loosing suction

Pumps
• Typical pump piping, spillback options, seal and warm-up systems, stuffing box pressure and NPSH requirements

Refreshments and Networking

Pump Drivers
• Pump and motor efficiency, current and horsepower calculations and motor sizing

Workshop
• Determine feed drum elevation from pump NPSH. Determine feed pump motor size

Adjournment

Day IV

Compressors
• Compressor types, capacity control methods, anti-surge controls and head/power calculation methods

Workshop
• Determine compressor head, horsepower and outlet temperature

Refreshments and Networking

Exchangers
•  TEMA types and guidelines, typical pressure drops and U values, effective and approach temperature, winterization and typical layouts

Lunch

Case Study
• Condensate system backup

Workshop
• Estimate number of Stripper feed-bottoms exchangers

Refreshments and Networking

Heaters
• Simulation practices, including inlet piping, excess air, approach temperature and flue gas corrosion
• Heater components, startup and shutdown, dryout, decoking, sootblowing, and typical fuel gas/oil piping layout

Adjournment

Day V

Relief Valves
• Relief valve types, ASME 1 and 8 criteria for determining set and accumulated pressure and API 520/521 methodology for determining relief
    cases, including double jeopardy and instrumentation credit

Break

Workshop
• Determine relief loads for the following cases: fire case, blocked liquid outlet, inlet control valve fails open, steam reboiler tube failure,
  fractionator power failure

Lunch

Case Study
• Surging ejector system

Metallurgy
• Common materials of construction, ASTM designations, refinery corrosion mechanisms and design criteria, including CUI, temper embrittlement
   and high temperature H2, H2S and sulphur corrosion

Concluding Remarks and Final Adjournment

There will be a one-hour lunch break each day in addition to a refreshment and networking break during each morning and afternoon session.

Daily Schedule:
8:00    Registration and coffee (first day only)
8:30    Session begins
12:00  Lunch
4:30    Adjournment


Prerequisites & Certificates
Pre-Requisites

Certificates offered

3 CEU / 30 PDH


Cancellation Policy
To withdraw from a course, you must send a request, in writing, with the official receipt to our office. Fifteen or more business days in advance: full refund less $50.00 administration charge. Five to fifteen business days in advance: non-refundable credit of equal value for any future EPIC seminar within one year. Credits are transferable within your organization. In case of an unexpected event occurring after this time, you may send someone else to take your place without any additional cost.
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EPIC Educational Program Innovations Center
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Here are some reviews of the training vendor.
The course was very well presented and the course instructor was absolutely amazing.
Reviewed by 2013
Our instructor, Stephen Lamming, was outstanding and a true expert in his field. He was able to complement the technical air monitoring information with practical real life examples which was highly beneficial. He is an excellent communicator and was highly interactive with the course attendees. This course was recommended to me because Stephen Lamming does an outstanding job. I was very impressed with this course and have subsequently recommended it to my colleagues.
Reviewed by 2012
Would have liked more interactive problem solving.
Reviewed by 2011
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