CPE 001: PROCESS PLANT DESIGN -Advanced

1
1.1
1.2
1.3
1.4
2
2.1
2.2
2.3
3
3.1
4
4.1
4.2
4.3
5
5.1
5.2
6
6.1
6.2
6.3
6.4
6.5
6.6
6.7
7
7.1
7.2
7.3
7.3.1
7.3.2
7.4
7.4.1
7.4.2
7.4.3
7.4.4
7.5
7.5.1
7.5.2
7.5.3
7.6
7.7
7.8
7.9
7.1
7.11

DURATION: 100 HRS

Overview
Outline of chemical engineering
General information about courses
Process Engineering Design Scope
Role of Process Design Engineer
Specific Project Details
Design Basis of selected project
Specifications for selected project
Standards used for selected project
Feasibility Studies
Technical and Economic Feasibility of General & Specific project
Preparation of Process Flow Diagram
General PFD explanation
Drawing template of PFD
PFD for specific project
Heat and Mass Balance Calculation
General calculations with example
HMBT calculation for specific project
Process Design and Simulation
Introduction to HYSYS Software
HYSYS User Interface
HYSYS Simulation Tutorial 1
HYSYS Simulation Tutorial 2
HYSYS Simulation Tutorial 3
HYSYS Simulation for Specific Project
Detailed HMB reports through HYSYS simulation
Equipment Design Calculation
Equipment used in process plants
Specification and codes & standards
Design of Storage Tank
Horizontal
Vertical
Design of Separators
2 ph separators
3 ph separators
Free Water Knock Out Drum (FWKO)
Slug Catchers
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

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
f.
1.1
1.2
1.4
1.5
1.6
1.7
1.8
1.9

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

Heat Exchanger Design & Rating(20 hrs) :

Introduction to ASPEN EDR Software
Types of Heat Exchangers
TEMA Types and Selection procedures
Heat exchamger specifiction
Shell and Tube dimensional standard
Optimization heat exchanger area
Report generation and TEMA sheet
Linking output to other software

Vessel Voume Calc.

Full Vessel Volume
Following formulas have been used to calculate Vessel Volume:
2:1 Ellipsoidal head vessel full volume
Volume = ( * D )/ 12 + (* D * L )/ 4
where,
= 3.141
D = Inside Diameter of Vessel

L = Length tan to tan

Torispherical head vessel full volume
Volume = (0.1694 * D ) + (* D * L )/ 4
where,
= 3.141
D = Inside Diameter of Vessel
L = Length tan to tan
Hemispherical head vessel full volume
Volume = ( * D )/ 6 + (* D * L )/ 4
where,
= 3.141
D = Inside Diameter of Vessel
L = Length tan to tan

Partial Volume ( Horizontal Vessel)

Following formulas have been used to calculate Horizontal Vessel Partial Volume:
A = 0.0175 COS-1[( D-2 HL)/D]
B = [1-(( D-2 HL)/D)2 ]0.5
HCPV = 0.25DL [ 0.0175AD-B(D-2HL) ]
1. With hemispherical head:
( 1.57DHDE 1.05HDE ) + HCPV
2. With ellipsoidal head:
( 0.785DHDE 0.523HDE) + HCPV
3. With torispherical head:
( 0.508DHDE 0.338HDE) + HCPV
4. With flat head:
HCPV
where,
D = Inside Diameter of Vessel
HDE = Height of liquid in dishend
HL = Height of liquid in shell
A = Constant
B = Constant

Partial Volume ( Horizontal Vessel)

1. With hemispherical head:
( 0.785DHTDE 1.05 HTDE ) + 0.785DHL + ( 1.57D HBDE 1.05 HBDE )
2. With ellipsoidal head:
( 0.785DHTDE 4.188 HTDE ) + 0.785DHL + ( 3.14D HBDE 4.188 HBDE)
3. With torispherical head:
( 0.785DHTDE 7.480 HTDE ) + 0.785DHL + ( 4.841D HBDE 9.96 HBDE )

4. With flat head:

0.785DHL
where,
D = Inside Diameter of Vessel
HTDE = Height of liquid in top dishend
HBDE = Height of liquid in bottom dishend
HL = Height of liquid in shell

Thickness Calculation
Cylinder thickness calculation is based on para UG-27 of ASME Section VIII Division 1 2011 edition code
book.
Where in cylinder thickness due to circumferential stress is given by:
t = P * R/(2SE 0.6P)
where,
t = Cylinder thickness in corroded condition
P = Design pressure
R = Cylinder Inside radius in corroded condition
S = Maximum Allowable Stress at design temperature
E= Joint Efficiency

This tool also calculate cylinder thickness on OD basis as per Appendix 1-1 of ASME Section VIII Div. 1, which is
t = P * Ro/(SE + 0.4P)
where,
Ro = Cylinder outside diameter

Ellipsoidal Head thickness calculation is based on para UG-32(d) of ASME Section VIII Division 1 2011
edition code book.
Where in Ellipsoidal Head thickness is given by:
t = P * D/(2SE 0.2P)
where,
t = head thickness in corroded condition
P = Design pressure
D = inside diameter of head skirt
S = Maximum Allowable Stress at design temperature
E= Joint Efficiency

This tool also calculate head thickness on OD basis as per Appendix 1-4(c) of ASME Section VIII Div. 1, which is
t = P * Do*K/(2SE + 2P(K-0.1))
where,

Do = outside diameter of Head

K = a factor for ellipsoidal Head calculation.

Cone thickness calculation is based on para UG-32(g) of ASME Section VIII Division 1 2011 edition code
book.
Where in Cone thickness is given by:
t = P * D/2cos(SE 0.6P)
where,
t = Cone thickness
P = Design pressure
D = Inside diameter
= Apex Angle
S = Maximum Allowable Stress at design temperature
E = Joint Efficiency

This tool also calculate head thickness on OD basis as per Appendix 1-4(e) of ASME Section VIII Div. 1, which is
t = P * Do/(2cos (SE + 0.4P))
where,
Do = Outside diameter of Cone

Torispherical head thickness calculation is based on Appendix 1-4(d) (3) of ASME Section VIII Division 1
2011 edition code book.
Where in Torispherical Head thickness is given by:
t = P*L*M/(2SE 0.2P)
where,
t = Torispherical head thickness
P = Design pressure
L = Crown Radius
M = 0.25*(3+(L/R)0.5)
R = Knuckle Radius
S = Maximum Allowable Stress at design temperature
E = Joint Efficiency
This tool also calculate head thickness on OD basis as per Appendix 1-4(d)(4) of ASME Section VIII Div. 1, which is
t = P * Lo*M/(2SE +P(M-0.2))
where,
Lo = Outside Crown Radius

Flat head thickness calculation is based on para UG-34(c)(2) of ASME Section VIII Division 1 2011 edition
code book.
Where in Flat Head thickness is given by:

t = D (CP/SE)0.5
where,
t = Cone thickness
D = Diameter
C = Factor
P = Design pressure
S = Maximum Allowable Stress at design temperature
E = Joint Efficiency

Spherical head thickness calculation is based on para UG-27(d) of ASME Section VIII Division 1 2011 edition
code book.
Where in Spherical Head thickness is given by:
t = P * R/(2SE 0.2P)
where,
t = head thickness
P = Design pressure
R = Inside Radius
S = Maximum Allowable Stress at design temperature
E = Joint Efficiency
This tool also calculate head thickness on OD basis as per Appendix 1-1(a)(2) of ASME Section VIII Div. 1, which is
t = P * Ro/(2SE +0.8P)
where,
Ro = D/2
D = Diameter

Head Calculation
Ellipsoidal
This K-SECAL small help tool calculates the 2:1 Ellipsoidal Head Blank Diameter. Head is formed from a circular
plate of approximate blank diameter calculated using below empirical formula. This diameter is good for initial
planning and weight estimation.
OD + OD/24 + 2SF +2/3KR + (THK in case head thickness is equal to or greater than 25 mm/1 INCH)
Confirm with Head manufacturer before cutting the blank. Every manufacturer based on forming method have
different diameter requirement.
Along with 2:1 Ellipsoidal Head Blank Diameter this tool also calculates head volume and blank weight. Select
different type of metals from drop down for weight calculation. Select FPS unit to calculate diameter in inch.
Compare above data between different types of heads (Hemispherical and Torispherical) by selecting from drop
down.

Following formula has been used for calculating the Ellipsoidal head blank diameter:
For plate thickness less than 25 mm / 1.0 inch

Blank Diameter = D + (D/42) + (2*S.F)+ ((2/3) * Kr)

For plate thickness equal or more than 25 mm / 1.0 inch
Blank Diameter = D + (D/42) + (2*S.F) + ((2/3) * Kr)+ thk
where,
D = Outside Diameter of Ellipsoidal Head
S.F. = Straight Face
Kr = 0.17*D = Knuckle Radius
thk = Thickness of Head

HEAD VOLUME

Ellipsoidal Head Volume = ( * D )/ 24 + (* D * S.F )/ 4

where,
= 3.141
D = Inside Diameter of Ellipsoidal Head
S.F. = Straight Face
HEAD BLANK WEIGHT

Blank Weight = ( * BD * thk * )/ 4

where,
= 3.141
BD = Blank Diameter
thk = Thickness of Head
= Density of Material

Torispherical
K-secal small help tool calculates the Torispherical Head Blank Diameter. Diameter is required for the fabrication of
head from plate. Along with diameter this tool also calculates head blank weight and Volume. For weight you have
the option to select different type of metals. Select FPS unit to calculate diameter in inch.
This tool also has the option to select different type of heads (2:1 Ellipsoidal and Hemispherical) thus instantly
comparing the data between three different type of head.
For torispherical head the knuckle radius =0.6 times the vessel diameter has been considered.

Following formula has been used for calculating the torispherical head blank diameter:
For plate thickness less than 25 mm / 1.0 inch
Blank Diameter = D + (D/42) + (2*S.F)+ ((2/3) * Kr)
For plate thickness equal or more than 25 mm / 1.0 inch
Blank Diameter = D + (D/42) + (2*S.F) + ((2/3) * Kr)+ thk
where,
D = Outside Diameter of Torispherical Head
S.F. = Straight Face
Kr = 0.06*D = Knuckle Radius
thk = Thickness of Head

HEAD VOLUME

Torispherical Head Volume = (0.0847 * D ) + ( * D * S.F )/ 4

where,
= 3.141
D = Inside Diameter of Torispherical Head
S.F. = Straight Face
HEAD BLANK WEIGHT

Blank Weight = ( * BD * thk * )/ 4

where,
= 3.141
BD = Blank Diameter
thk = Thickness of Head
= Density of Material

Hemispherical
K-secal small help tool calculates the Hemispherical Head Blank Diameter. Diameter is required for the fabrication of
head from plate. Along with diameter this tool also calculates head blank weight and Volume. For weight you have
the option to select different type of metals. Select FPS unit to calculate diameter in inch.
This tool also has the option to select different type of heads (2:1 Ellipsoidal and Torispherical) thus instantly
comparing the data between three different types of head.

Following formula has been used for calculating the hemispherical head blank diameter:
Blank Diameter = ( * D)/2
where,
= 3.141
D = Outside Diameter of Hemispherical Head

HEAD VOLUME

Hemispherical Head Volume = ( * D )/12

where,
= 3.141
D = Inside Diameter of Hemispherical Head
HEAD BLANK WEIGHT

Blank Weight = ( * D * thk * )/ 16

where,
= 3.141
D = Outside Diameter of Hemispherical Head

thk = Thickness of Head

= Density of Material

Cone
From many tools that you would find on this portal this tools helps to create development of a Cone. This tool also
instantly calculates and gives you the volume and finished weight of the cone.
For weight you have the option to select different type of metals. Select FPS unit to get dimension in inch.
Following formulas have been used for creating development of cone.
R = D[h + 0.25 (D - d)]0.5 / (D - d)
E = R - [h + 0.25 (D - d)]0.5
Angle = D/R * 180
where,
h = Height of cone
D = Larger inner diameter of cone
d = Small inner diameter of cone

CONE VOLUME

Cone Volume = 0.262 * h(D + d + Dd )

where,
h = Height of cone
D = Larger inner diameter of cone
d = Small inner diameter of cone
CONE WEIGHT

*Blank Weight = A * B * thk *

Length A = 2 * R sin(/2) + C
Width B = R - E cos(/2) + C
where,
C = 25 (In mm)
C = 1 (In inch)
thk = Thickness of Cone
= Density of Material

* Subject Cone weight is the weight of rectangular plate from which the cone development would be cut out.

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