Process/Chemical Engineering 101 - Preparing you for the Job

Define the process design basis by compiling discipline-specific and general design basis inputs and outputs, including site conditions, pressures, gas and liquid streams, and equipment limits, then simulate with HYSYS.

Simulations generate heat material balances from gas, hydrocarbon, and water streams, using Hysis and 550,000 standard meter cubed per hour flow data to evaluate cases and guide design decisions.

Learn to markup process flow diagrams and isometrics with red additions, green dilution, and blue comments, manage rev changes, equipment numbers, and new scope like pumps and ESD valves.

Learn how mechanical equipment lists and data sheets capture pumps and vessels, design criteria, and revisions from IFR to IFC, with practical examples.

Learn to size pumps and hydraulics by sizing pipes, accounting for pressure drop, back pressure, and equivalent length, while evaluating NPSH to avoid cavitation.

Explore net positive suction head (npsh) to prevent cavitation by ensuring sufficient suction pressure, and compare npsh required versus available for water and hydrocarbon drums.

Map system curves to centrifugal and PD pump curves to determine operating points, noting when to use PD or metering pumps and how VFDs and valves control flow.

Explore how minimum flow recycle uses a pressure transmitter and flow control valve to keep system pressure stable, while balancing level control and end-user requirements in a distribution-like setup.

Learn to size control valves using minimum, maximum, and normal CV points, evaluate delta P and back pressure, and document with data sheets for reliable valve selection.

Explore how client-driven scope changes force rapid redesign in process engineering, using simulations to stabilize gas and determine vapor pressure, heating, heat exchangers, and new equipment options.

Learn how fouling factors drive cleaning of heat exchangers, as solids, salts, and biology insulate tubes, alter velocity, and push in-place or bundle cleaning with CIP, acids, and anti-corrosion treatments.

Compare glycol and steam heat medium packages, their heat exchangers, and natural gas heating, while noting water treatment, blowdown, condensate recovery, and CO2 considerations in heat integration.

This lecture explains updating a process design after a client scope change, detailing stabilization, glycol heating, heat integration, and a revised flash drum with updated valves and data sheets.

Walk through actual PFDs and FDs from the Sable offshore energy project, highlighting pad legends, symbols, heat material balances, and how cryogenic and utility systems are documented.

Master emergency shutdown and blowdown of pressurized hydrocarbon systems, using ESD valves, SVS, rupture discs, flare blocks, and API 521 guidance, with fire eye sensors and red-button triggers.

Size a pump PSV using the pump data sheet, mawp, and the pump curve. Account for high liquid level and choose external vs internal PSV for PD or centrifugal pumps.

Learn how to size thermal relief pressure safety valves for sun-heated pipes, account for liquid expansion, potential flashing, and orifice sizing with Excel-based calculations.

Assess and size pressure safety valves for a vessel under natural gas blanketing, loss of cooling, and fire scenarios using API 521 guidance.

Master psv sizing for heat exchangers in thermal runaway scenarios, using time-sliced heat input, flashing flow, and shell or condenser side considerations.

Document and verify SVS and PSV lists after sizing, including vendor calculations and two-phase flow considerations. Assess overpressure risk, Hazop, and design choices to minimize SVS and improve safety.