Learning Objectives

Upon successful completion of this course, participants will be able to:

1. Introduction to Process Engineering

• Understand the fundamentals of process engineering and its role in industrial operations.
• Learn about process design principles, mass balance, and energy balance calculations.
• Differentiate between batch and continuous processing.

2. Process Flow Design and System Integration

• Develop Process Flow Diagrams (PFDs) and Piping & Instrumentation Diagrams (P&IDs).
• Optimize process integration using heat exchangers and pinch technology.
• Select appropriate separation and purification techniques (distillation, absorption, extraction, etc.).

3. Equipment Selection and Sizing

• Identify key process equipment and their operational principles:
• Pumps and compressors.
• Heat exchangers and reactors.
• Separators, columns, and tanks.
• Apply process simulation tools for equipment sizing (Aspen HYSYS, PRO/II, ChemCAD).

4. Process Control and Automation

• Implement Distributed Control Systems (DCS) and Supervisory Control and Data Acquisition (SCADA) systems.
• Understand control loop tuning and process optimization techniques.
• Integrate safety instrumented systems (SIS) and emergency shutdown systems (ESD).

5. Process Safety and Hazard Management

• Conduct HAZOP (Hazard and Operability Study) and risk assessments.
• Implement Layer of Protection Analysis (LOPA) and safety integrity levels (SIL).
• Ensure compliance with OSHA, API, ASME, and environmental regulations.

6. Process Optimization and Energy Efficiency

• Identify bottlenecks and inefficiencies in process operations.
• Apply Lean Six Sigma and continuous improvement methodologies.
• Optimize utility consumption (steam, cooling water, compressed air, and fuel gas).

7. Troubleshooting and Operational Challenges

• Diagnose common operational issues (fouling, scaling, corrosion, pressure drop, efficiency loss).
• Develop problem-solving strategies for process upsets and shutdowns.
• Use root cause analysis (RCA) to improve system reliability.

8. Case Studies and Practical Applications

• Analyze real-world process engineering challenges and optimization solutions.
• Participate in hands-on exercises using simulation and troubleshooting software.
• Develop a process improvement and safety enhancement plan.

Target Audience

• Process and chemical engineers
• Operations and plant managers
• Equipment and maintenance engineers
• HSE and risk management professionals
• Industrial automation and control specialists