Course Profile:

The Process Design Training Course, though an integral one, is split into the following modules. CHEMSYS
offers the option to choose the module. This is done to benefit trainees who have difficulty in getting time to
undergo the full course as well as professionals intending to improve their skills in only one particular area.
a.
b.
b.
c.
d.
e.

Process Plant Design Course Module - Advanced

Process Plant Design Course Module - Basic
Process Equipment Design Course Module
Aspen HYSYS Simulation Training Module
Aspen Plus Simulation Training Module
Heat Exchanger Design & Rating Training

a. Process Plant Design Module - Advanced :

The foundation module, as the name implies, lays the foundation for process design. It gives an overview of
the industry and clarifies the roles and responsibilities of a process engineers in a dynamic real life situation in
the industry. It also lists the process deliverables and trains you regarding the methodology The following
topics are covered here:
CPE 001: PROCESS PLANT DESIGN -Advanced
DURATION: 100 HRS
1
Overview
1.1
Outline of chemical engineering
1.2
General information about courses
1.3
Process Engineering Design Scope
1.4
Role of Process Design Engineer
2
Specific Project Details
2.1
Design Basis of selected project
2.2
Specifications for selected project
2.3
Standards used for selected project
3
Feasibility Studies
3.1
Technical and Economic Feasibility of General & Specific project
4
Preparation of Process Flow Diagram
4.1
General PFD explanation
4.2
Drawing template of PFD
4.3
PFD for specific project
5
Heat and Mass Balance Calculation
5.1
General calculations with example
5.2
HMBT calculation for specific project
6
Process Design and Simulation
6.1
Introduction to HYSYS Software
6.2
HYSYS User Interface
6.3
HYSYS Simulation Tutorial 1
6.4
HYSYS Simulation Tutorial 2
6.5
HYSYS Simulation Tutorial 3
6.6
HYSYS Simulation for Specific Project
6.7
Detailed HMB reports through HYSYS simulation
7
Equipment Design Calculation
7.1
Equipment used in process plants
7.2
Specification and codes & standards
7.3
Design of Storage Tank
7.3.1
Horizontal
7.3.2
Vertical
7.4
Design of Separators
7.4.1
2 ph separators
7.4.2
3 ph separators
7.4.3
Free Water Knock Out Drum (FWKO)
7.4.4
Slug Catchers

7.5
7.5.1
7.5.2
7.5.3
7.6
7.7
7.8
7.9
7.1
7.11
7.11.1
7.11.2
7.11.3
8
9
9.1
9.2
9.3
9.4
9.5
10
11
11.1
11.2
11.3
12
12.1
12.2
13
14
15
16
17
18

Design of Pump
Centrifugal Pump
Gear Pump
Positive Displacement Pump
Design of Reactors
Design of Desalter
Design of Emulsion Treater
Design of Indirect Fired Heater
Design of Heat Exchanger
Design of Columns and Towers
Distillation Column Tray/Packed
Contactor (Absorber) Tray / Packed
Molecular sieves(Adsorbers)
Design of specific project equipments & preparation of datasheet
Piping & Instrumentation Diagram Preparation
Introduction of P&ID
Legends and symbols
Instrument arrangements
General Example of P&ID
Specific project P&ID
Utility Calculations
Hydraulic Calculations
Line sizing criteria
Single phase line size
2 phase line size (liquid & Gas)
Safety Valve calculations
For liquid at various Scenario
For gas/vapor/steam at various condition/scenarios
Control Valve Sizing
3D Plant & Equipment Modeling - introduction
Plot plan & layout
Nozzle Elevation and Orientations
General Arrangement Drawing
Cost Estimation and Economics

b Process Plant Design Module - Basic :

As name suggest this modules is shorter version of advanced modules in which emphasys on PFD, P&ID ,
siumaltion and equipment design is given.
CPE 002: PROCESS PLANT DESIGN - Basic
DURATION: 50 HRS
1
Overview
2
Specific Project Details - Distillation column unit
3
Feasibility Studies - Introduction
4
Preparation of Process Flow Diagram
5
Heat and Mass Balance Calculation
6
Process Design and Simulation
6.1
Introduction to HYSYS Software
6.2
HYSYS User Interface
6.3
HYSYS Simulation Tutorial 1
6.4
HYSYS Simulation Tutorial 2
7
Equipment Design Calculation
7.1
Equipment used in process plants
7.2
Specification and codes & standards
7.3
Design of Heat Exchanger

7.4
8
9
10
11

Design of Columns and Towers

Piping & Instrumentation Diagram Preparation - Basic
Plot plan & layout
Nozzle Elevation and Orientations
Cost Estimation and Economics

C. Process Equipment Design Module :

The Detailed Process Design Module helps you to understand the basic concept and criteria for the design of
process equipment. We deal with design in a practical way referring the relevant codes and standards
wherever required. You get a chance to work on live projects as well. At the end of this module you will design
all the equipment in the project you are associated with. This module covers:
CPE 003: PROCESS EQUIPMENT DESIGN
1.1

Equipment used in process plants

1.2

Specification and codes & standards

1.3

Design of Storage Tank

1.3.1

Horizontal

1.3.2

Vertical

7.4

Design of Separators

1.4.1

2 ph separators

1.4.2

3 ph separators

1.4.3

Free Water Knock Out Drum (FWKO)

1.4.4

Slug Catchers

1.5

Design of Pump

1.5.1

Centrifugal Pump

1.5.2

Gear Pump

1.5.3

Positive Displacement Pump

1.6

Design of Reactors

1.1

Design of Desalter

1.8

Design of Emulsion Treater

1.9

Design of Indirect Fired Heater

1.10

Design of Heat Exchanger

1.11

Design of Columns and Towers

1.11.1

Distillation Column Tray/Packed

1.11.2

Contactor (Absorber) Tray / Packed

1.11.3

Molecular sieves(Adsorbers)

DURATION: 40 HRS

d. Aspep HYSYS Simulation Module :

Simulation is the tool every process engineer should be conversant with. CHEMSYS provides the necessary
training for you to understand the simulation tool and help you to gain confidence to use it yourself. You can
spent sufficient time learning and practicing the tool with guidance from CHEMSYS. Here again, you work on
a live project. The topics covered in this module are:
CPE 004: ASPEN HYSYS SIMULATION

DURATION: 30 HRS

1.1

Introduction to HYSYS Software

1.2

HYSYS User Interface

1.3

Defining the Simulation Basis.

1.4

Selecting a Unit Set.

1.5

Adding a Stream

1.6

Flash Calculations

1.7

Adding Utilities

1.8

The Stream Property Value

1.9

Flash Calculations of a Ethanol-Water Mixture

1.10

Gas-Plant Example

1.11

Optimization in HYSYS

1.12

Set and Adjust Logic Operations

1.13

Flash Calculation

1.14

PFD Preparation

1.15

Sizing of Columns.

1.16

Oil Manager / Characterization

1.17

Pipe Sizing and Pressure Drop in HYSYS

1.18

Simulation of live Project

e. Aspen Plus Simulation (30 hrs):

1.1
Introduction to ASPEN PLUS Software
1.2
ASPEN PLUS User Interface
1.3
Property / Simulation Environment
1.4
Unit operaton Models
1.5
Modelling of distilation tower
1.6
Modelling Reactors
1.7
Selecting physical property models
1.8
Flowsheet Results
1.9
Modeling of heat exchnagers
1.10 Modelling of pump,compressor , pipes
1.11 Calculation blocks
1.12 IMproving computation Performance

f. Heat Exchanger Design & Rating(20 hrs) :

1.1
Introduction to ASPEN EDR Software
1.2
Types of Heat Exchangers
1.4
TEMA Types and Selection procedures
1.5
Heat exchamger specifiction
1.6
Shell and Tube dimensional standard
1.7
Optimization heat exchanger area
1.8
Report generation and TEMA sheet
1.9
Linking output to other software