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Training Program On Basic Process Engineering Practices

Process engineers play an important role throughout the project life cycle from concept to commissioning and operations. Their responsibilities include selecting the technology, performing feasibility studies and heat and mass balances, engineering design, monitoring construction, starting up the plant, and ensuring optimal operations. Process engineers also contribute to technical services, plant modifications, efficiency improvements, and research and development of new technologies and products.

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Nguyen Anh Tung
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321 views14 pages

Training Program On Basic Process Engineering Practices

Process engineers play an important role throughout the project life cycle from concept to commissioning and operations. Their responsibilities include selecting the technology, performing feasibility studies and heat and mass balances, engineering design, monitoring construction, starting up the plant, and ensuring optimal operations. Process engineers also contribute to technical services, plant modifications, efficiency improvements, and research and development of new technologies and products.

Uploaded by

Nguyen Anh Tung
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PPT, PDF, TXT or read online on Scribd
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Module - 2 Process Engineer’s Role

Training Program on
Basic Process Engineering Practices
Project Life Cycle - Recapitulation

 Let us recapitulate the project life cycle.


 Process Engineers have very important role to play in each
of the stages.

Basic Engineering
Design Construction

Feasibility Operation
Concept
Study Maintenance

Concept Revamp
Process Engineers Role – EPC – Phase I

• Project Leader – Process Engineer


- Dream Plant built & Operated as per his dream !
• Conceptual
- Definition
• Naphtha cracker
• Bhopal Pesticide Plant
• ONGC LPG Recovery Plant
- Market Information
• Plastics IPCL case
• Bhopal Pesticides Plant
• ONGC Uran Plant
- Technology Selection
• LPG Recovery
- Oil Absorption Process
- Refrigeration Process
- Expanded Cycle
Process Engineers Role – EPC– Phase I

• Feasibility Study
- Capex
- Opex
- Economic viability
- Sensitivity Parameters
• Capex
• Taxation Parameters
• Raw Material Cost
• Opex
• Utility Cost
- Sensitivity Analysis
Process Engineers Role – EPC– Phase I

• Key Parameters / Process Package

- Process Optimization
- Heat & Mass Balance
- Translate to Process Package
• Process Flow Diagram
• P&I Diagram
• Plot layout
• Equipment specification, etc.
Process Engineers Role – EPC– Phase II

Engineering (Support role)

• Equipment Selection
- Compressors
- Column Packing
- Package Units
• Tender enquiry
• Receive offers
• Comparative Statement
• Evaluation
Process Engineers Role – EPC – Phase II
Engineering (Support role)

Fabricated Equipment
Pressure Vessels, Columns
• Mechanical
- Nozzle size, orientation
- Nozzle location
- Reboiler type – skirt height
Heat Exchanger
• Mechanical Drawing
- Type
- # of passes
- nozzle orientation
Fired Heater/Furnaces
- Configuration
- General arrangement
Process Engineers Role – EPC– Phase II

Engineering (Support role)

• Piping Design
- Lay out drawing
- Model Review
- Isometric check
• Stress Analysis
• Supports
- Hydraulic check – critical loops
• Revise P&I Diagrams as necessary
• Other Disciplines
- Support as required
Essentially monitoring & hand holding
Process Engineers Role – EPC– Phase II

Plant Check out and Pre-commissioning

• P & I Check
• Pipe /Equipment

- Flushing, Cleaning, Purging and Testing


• System identification

• Equipment Running in
• Refractory Drying
• Catalyst Reduction

• Chill Down
Process Engineers Role – EPC– Phase II

Commissioning

• Check plant operating parameters


• Quality of Product Streams

- Specifications met?
- If not?

• Equipment Performance
- Compressors
- Furnace

• Trim operations to ensure performance test


- Dream come true !
Process Engineers Role – Operating Company–Phase III

General Plant Management

* * *

Production Plant Engineering Technical R&D


Services

- Keep plant - Maintenance - Efficiency - Support


running - Modifications - SHE innovations
- Innovations - Technology
development

* Checks & Balances


Process Engineers Role – Operating Company– Phase III

• Plant Operations

- Ensure desired / optimum level of production


• Shift Supervision
• Technical Services

- Plant house keeping


- Plant efficiency
- Plant capacity
• Debottlenecking

• Modifications

• SHE
- Technology monitoring and application
- Interface with R&D

• R&D tech. Developer


Process Engineers Role – Operating Company– Phase III

Research & Development

• Who is best suited?

• New Technology
- Same Products (Fundamental)

• Catalyst Development

• Reactor design
(Reaction kinetics and the Thermodynamics)

- Engineering modifications
• Heat Recovery Systems

• New methodology allows higher temperatures


• New types of packing

- New & Related products

Example: Refining companies, (UOP) etc.


Process Engineers Role – Consulting & Operating

SUMMARY

• Chemical Engineer by education


• Process Engineer by experience
- Vast canvas

• Process Engineering skill can contribute in many ways:


- Concept to commissioning

- Plant performance
Continuity

Efficiency
• R&D

- Technology Development (Equipment / Catalyst / Reactor)

• Cracking Furnace
Reactor yield

• New Product

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