#1210 – Process Design for Process Plant Equipment

Course Objective

This course is designed to provide participants with a comprehensive understanding of process plant equipment design concepts and techniques. Attendees completing this course will enhance their understanding of process design and gain practical skills and knowledge in the design of process plant equipment.

Who Should Attend?

Process engineers involved in the design, revamp, and operation of refineries, petrochemical, and related oil and gas processing plants. The program is also recommended for plant design and equipment engineers working with engineering companies, process licensors, and equipment manufacturers.

Course Description

Design methods and criteria are presented and discussed to familiarize process engineers with practical techniques (including short-cut methods) for sizing, design, and selection of the main types of process equipment for refineries, petrochemical, and related process plants. The course covers description and definition of hydrocarbons and mixture properties, characterization parameters and their significance in design of equipment. Basic calculation procedures for design of process equipment, with sample examples, are presented and discussed to enhance skills in design techniques. Procedures for preparation of process data and equipment design specification requirements, evaluation of proposals and interaction with equipment manufacturers are discussed. Brief sessions are included on mechanical design aspects and on cost estimating methods to complement background to process design and equipment evaluation and selection aspects.

Course Outline

Introduction

Nature of Design
Design Constraints
Design Categories

New Design
Revamp Design

Petroleum Properties & Definitions

Composition of Petroleum
Petroleum Processing: An Overview
Hydrocarbon Properties

Pure Hydrocarbons
Defined Mixtures
Undefined Mixtures

Characterization Parameters & Definitions

Development of Process Data

Process Design Tasks & Sequence
Process Calculation Methods

Empirical Procedure
Rigorous Procedure

Process Design Simulation Techniques

Commercial Packages
Equipment Software
Process Data Packages

Data Compilation and Presentation

Process Flow Diagram
Equipment Data Sheets
Accuracy and Significance

Equipment Sizing, Selection, and Design

Process Equipment Categories

Proprietary Type Equipment
Non-Proprietary Equipment
Required vs. Calculated Data
Piping

Fluid Flow Equations
Pressure Loss Categories
Pipe Properties – Class and Schedule
Sizing Criteria – Velocity and dP
Two-Phase Flow – Regimes/dP Calculation
Sizing Methods – Detailed & Short-Cut

Pumps

Categories & Types – Reciprocating & Centrifugal
Performance Characteristics – Curves, System/CV
Key Design Parameters – Capacity Factors, Properties, Head, NPSH, Efficiency, Horsepower
Calculation Method/Typical Format and Examples
Pump Selection Guidelines
Compressors

Categories and Types – Reciprocating & Centrifugal
Compression Process – Adiabatic, Isothermal, & Polytropic
Characteristics & Terminologies – Clearance, Surge, Stonewall, Speed, Turndown, etc.
Key Design Parameters – Capacity, Properties, Compression Ratio, Head, Temperature Rise, Efficiencies, Multi-Staging

Compressor Control Methods
Calculation Method/Typical Format and Examples
Selection Guidelines – Technical and Economic Factors
Heat Exchangers

Types – Shell-and-Tube, Double-Pipe, Plate, Other
Shell-and-Tube Construction – TEMA Classification
Heat Transfer Relation – Heat Transfer Coefficients, Mean Temperature Difference, Correction Factors, etc.
Key Design Considerations – Fluid Routing, Pressure, Temperature, Viscosity, Fouling
Fouling Factors, Variables and Prevention
Process Applications – No Phase Change & Phase Change
Reboilers – Types, Feed System, Calculation Method
Calculation Methods – Detailed and Short-Cut with Example
Rating Existing Exchangers with Example
Selection Guidelines

Air Coolers

Types – Forced and Induced Air Design
Key Design Considerations – Heat Transfer Coefficient, Air Temperature and Rise, Tubes & Layout, Air Fans
Air vs. Water Cooling Comparison
Calculation Procedure – Approximate Method

Direct-Fired Heaters

Types – Service, Duty Limits, Shop vs. Field Size
Design Considerations – Sizing, Vapor Velocity, Liquid Residence, Entrainment, Internals, Connections
Vessel Calculation Method and Examples
Fractionators (Distillation Columns)

Fractionator Types – Simple and Complex Columns
Design Methods – ‘Process’ and ‘Hardware’ Design
Process Design Procedure with Examples

Simple Column – Stabilizer
Complex Column – Crude Distillation

Internals: Trays, Packing/Grids, Drawoff, Distributors

Types and Selection
Hydraulic Criteria
Performance Comparison

Reactors

Fixed-Bed Reactors Types – Downflow and Radial Flow
Design Considerations – L/D, Catalyst Bed, Fouling
Sizing Methods – Press Drop Calculation
Internals

Ancillary Equipment

Steam Jet Ejectors for Vacuum Columns
Pressure Relief Devices

Mechanical & Safety Aspects

Codes, Standards and Specifications
Materials of Construction – Overview
Safety in Design – Equipment Spacing

Cost Estimating

Cost Estimating Methods

Capacity/Scale Ratio
Equipment/Modular Factors
Detailed Quotes

Estimate Types and Accuracy
Equipment Installation Cost Factors
Contingency Allowances
Cost Escalation

Process Design Specifications

Purpose of Specification Package
Types of Specification Packages
Specification Package Contents

Q&A Discussion

Course Texts