INTRODUCTION TO PROCESS ENGINEERING

Transcription

1 Training Title INTRODUCTION TO PROCESS ENGINEERING Training Duration 5 days Training Venue and Dates Introduction to Process Engineering May $3,750 Abu Dhabi, UAE In any of the 5 star hotel. The exact venue will be intimated prior to course commencement. Training Fees 3,750 US$ per participant includes Training Materials/Handouts, Tea/Coffee breaks, Refreshments and International Buffet Lunch. Training Certificate Define Management Consultants Certificate of course completion will be issued to all attendees. TRAINING OVERVIEW INTRODUCTION & DESCRIPTION Society in its daily endeavors has become so dependent on automation that it is difficult to imagine life without automation engineering. In addition to the industrial production with which it is popularly associated, it now covers a number of unexpected areas. Trade, environmental protection engineering, traffic engineering, agriculture, building engineering, and medical engineering are but some of the areas where automation is playing a prominent role. Automation engineering is a cross sectional discipline that requires proportional knowledge in hardware and software development and their applications. In the past, automation engineering was mainly understood as control engineering dealing with a number of electrical and electronic components. This picture has changed since computers and software have made their way into every component and element of communications and automation. Industrial automation engineers carry a lot of responsibility in their profession. No other domain demands so much quality from so many perspectives of the function, yet with significant restrictions on the budget. The project managers of industrial automation projects have significant resource constraint, considering the ever changing demands of its management, trying to adopt the rapid acceleration of the technological changes and

2 simultaneously trying to maintain the reliability and unbreakable security of the plant and its instruments. TRAINING OBJECTIVES Define and use process flow diagrams PFD, P&IDs, instrument lists, specification forms, logic diagrams, location plans, installation details and loop diagrams Understand process control devices and the symbols used to define them Define and specify vendor criteria for the production of plant documentation to the order of the company Use specifications to control the design scope of the project Understand the purpose of a HAZOP in the development of a plant Implement and manage drawing plant modifications from conception to completion Be aware of the ISA standards available to assist you in developing and understanding instrument and control documents Understand the scope, responsibility and interaction of each discipline in the completion of a project or plant modification TRAINING METHODOLOGY A highly interactive combination of lectures and discussion sessions will be managed to maximize the amount and quality of information and knowledge transfer. The sessions will start by raising the most relevant questions, and motivate everybody find the right answers. You will also be encouraged to raise your own questions and to share in the development of the right answers using your own analysis and experiences. Tests of multiple-choice type will be made available on daily basis to examine the effectiveness of delivering the course. Microsoft Power Point with colourful slides packed with information Real life P&ID exercises Highly interactive with total involvement of the participants. Interesting and Interactive Quiz Sessions and Group Tasks for better assimilation 30% Lectures 30% Workshops and work presentation 20% Group Work& Practical Exercises 20% Videos& General Discussions WORKSHOP This course hands-on workshop concentrates on demonstrating how a thorough Knowledge and understanding of how the plant works from a drawing and documentation perspective will greatly enhance your ability to maintain and enhance the operation of the plant.

3 You will learn to diagnose problems and suggest solutions on a plant you have never seen. Too often plant modifications that are instituted fix the symptom instead of the underlying problem, this course will show you why it is so important to keep looking at the plant documentation as a whole in order to solve the problem. You will also learn how to create documentation using simple standards and specifications as well as custom design a solution for your own plant. Disciplines covered include process, electrical and instrumentation and numerous practical exercise sessions allow the application of knowledge gained to reinforce the principles. This is not an advanced course but focusing on the basic practical principles 1) Organizational Impact The company will be able to achieve measurable improvement in process and control Integrity through effective interaction between engineering, operation and Maintenance functions. The company will be able to enhance its loss prevention, production and Safety performance. The company will be able to enhance its ability to use applicable processing and Maintenance resulting in lower life cycle costs while complying with codes and Standards and other regulatory requirements. PERSONAL IMPACT Participant's successfully completing this course will demonstrate the following outcomes: define the terms "measurement and process instrumentation interpret and draw instrumentation symbols used in process and instrumentation drawings describe the basic principles of operation of pressure,flow,level and temperature measuring elements being familiar with process control terminology and different modes of control actions an ability to analyzing and solving the control systems problems COMPETENCIES EMPHASIZED Participants will enhance their competencies in the following areas: Working knowledge in design, operation and maintenance of process & instrument equipments in oil and gas plants Understanding and reading PFD AND P&ID drawing documentations WHO SHOULD ATTEND? Instrumentation and Control Engineers and Technicians Electrical Engineers and Electricians Project Engineers

4 Telecommunications Engineers and Technicians Process Control Engineers Consulting Engineers Maintenance Engineers and Technicians Production Controllers Drawing Office Staff TOPICS COVERED 1. Basics of chemical engineering review: Chemical processes & reactions Thermodynamics laws Fluid mechanics Heat transfer Exothermic & Endothermic reactions Equilibrium & Balance Materials & heat balance 2. Typical processes system in oil & gas Separation oil/water/gas industry system Gas dehydration systems Desalter operation system Refrigeration system Fractionation system Gas treatment system Gas liquefaction process Day Two 3. Typical Process Equipment Desorption & Function Separators Absorbers (liquid/solid) Columns & reactors Heat Exchange Equipment Compressors & pumps Turbo Expanders Drivers & Turbines Pipelines & flow control 4. Process Measurements and Control Process Variables Measurements of temperature, flow, pressure & level. Fundamentals of process control Elements of control system

5 ON/OFF control system Cascade control system Feed forward control Types of controllers Final control elements types Control valve sizing Control application 5. Process simulation Simulator Mathematical modeling Data base structure Model testing Sensitivity Typical Simulators for processes Day Three 6. P&I and Flow Diagrams reading & Interpretation: Pipe work symbols Valve symbols Equipment symbols o Pumps o Compressors o Heat exchangers o Filters o Valves & actuators o Miscellaneous Standard abbreviations Loop diagrams Function block symbols Color codes Tag numbers Heat & material balance on the P&I diagrams Equipment designation o Standard alphanumeric coding o Numbering of major items o Numbering of minor items Vendor references Typical case studies/exercises Typical case studies/exercises (Reading & Interpretation of P&I and PF Diagrams)

6 COURSE OUTLINE DAY ONE The basic concepts introduction Instrumentation and control Drawings and Documentation Introduction to Plant Design Process diagrams Instrumentation documentation Electrical documentation Generic Symbols and Numbering Systems: Symbols Piping Valve Control Valve and Actuator Instruments Notation, Numbering and Tag System Equipment Instrument Pipelines Instrumentation and Control Combining Process and Hardware Piping Specialty Code Understanding PFDs: Why PFD Relating PFD Information to P&ID Relevance of Heat and Mass Balance Relevance of Operating Conditions Relevance of Physical Property Information Understanding and Developing P&ID: Equipment and System P&ID and Datasheets Development of a Simple Basic P&ID Valves Type and Application Development of Control Loops Need and Location of Measuring Instruments Piping and Insulation Information Safety System in P&ID Depiction of DCS and RTU Incorporation of Miscellaneous Information in P&ID

7 P&ID evolution and changes in plant life. DAY Two Process Control Systems Basic Control Concepts Principles of Control Systems Control modes in closed loop control Tuning of Closed Loop Control Cascade Control Initialization of a cascade system Feed forward Control Manual feed forward control Automatic feed forward control Time matching as feed forward control Overcoming Process dead time First term explanation(disturbance free PV) Second term explanation(predicted PV) Latest Instrumentation and Valve Developments Basic Measurement performance terms and Specifications Advanced Measurement Performance terms and Specifications Pressure Measurement Level Measurement Temperature Measurement Thermocouples Resistance Temperature Detectors (RTD s) Flow Measurement Differential Pressure Flow meters Control Valves DAY Three Process Equipment and Operation Principles Heat transfer Thermal conductivity Conduction and convection Insulation Heat transfer coefficients and calculation 1- Heat Exchangers Overview of Heat Exchanger Equipment Safe operation of Heat Exchanger Equipment

8 Economics Heat Exchanger Monitoring 2-Furnaces Overview of Process Furnace Efficient and safe Operation of a Process Furnace Economics Excess Air Control, Flame Pattern DAY Four Process Equipment and Operation Principles 1-Boilers and Steam Systems Overview of Boilers and Steam Systems Safe Operation of Boilers and Steam Systems Economics Excess Air Control, Demin Water and Condensate 2-Pumps & Compressors and Steam Turbines Overview of Rotating Equipment Safe operation of Rotating Equipment DAY Five Process Equipment and Operation Principles 1- Separation A-Separation in vessels -Two and three phase separators. - Description and Operation B-Separation in towers Overview of towers Description &functions Safe operation of Towers Economics Reflux Optimization, Rebuilder Optimization, Tray Efficiency Case Studies and Group Exercises: Read a Simple P&ID Identify Control Loops Read a Detailed P&ID Case Studies Specific to Debutanizer and Turbo expander Case Studies, Group Exercises, Group Discussions, Last Day Review & Assessments will be carried out.