Generic Models

Process Models

• Fundamental process concepts; working principles of common process equipment

• Equipment performance under different operating conditions

• Hands-on practice on operations such as start-up, shutdown, troubleshooting etc.

• Practice safe operation of the unit; prepare for handling emergencies

Experience in Real-time

• Effects of changes in operating conditions such as flow, pressure, temperature, etc.

• Effects of changes in boundary conditions such as supply & discharge pressure, supply temperature, feed composition, etc.

• Performance of control systems; functioning of different control schemes such as antisurge control, minimum flow control, overpressure control, etc.

• Common problems and the recovery actions

Product Sample List

Separation System

Reactor System

Fluid Transfer Equipment

Heat Transfer System

Boiler and Furnaces

Basic Process Control

Separation System

• Concepts of vapor-liquid separation; bubble and dew points

• Distillation concepts; conditions affecting separation quality and energy consumption

• Absorption concepts; conditions affecting quality of gas-liquid absorption

• Common problems such as transmitter drift, transmitter failure, valve failure, etc.

Flash Drum

• Vertical flash drum; drum safety valve with bypass

• Feed: mixture of light hydrocarbons

• Top product: light vapor; bottom product: heavy liquid

Distillation Column

• Column with 40 Trays; a debutanizer

• Overhead condenser (total condenser)

• Reflux drum: safety valve with bypass, reflux pump

• Reboiler: superheated LP steam heating medium; tray temperature control

• Flooded condenser, variable tube flooding extent, column top pressure control

• Feed: C4s and C5s; top product: C4 rich stream; bottom product: C5 rich stream

• Tray problems such as plugging & weeping and column problems such as flooding

Absorber

• Amine absorber; Tray column

• Gas sweetening, H2S and CO2 removal

• Diethanolamine (DEA) absorbent

• Column level & pressure control

• Lean amine and sour gas flow control

Reactor System

• Reaction kinetics; rate of reaction, heat of reaction, conversion, etc.

• Factors affecting reactions such as temperature, pressure, reactant concentration or partial pressure, residence time, etc.

Fixed Bed Reactor

• Single-bed with nickel catalyst; reactor safeguards

• Feed: Synthesis gas containing carbon oxides

• Gas-phase reaction: methanation; purification of syngas for removal of carbon oxides

• Carbon oxides converted to methane through hydrogenation; equilibrium reaction; exothermic

Continuous Stirred Tank Reactor (CSTR)

• Jacketed reactor with agitator; cooling water in jacket

• Liquid-phase reaction; transesterification of vegetable oil to biodiesel; presence of alkali catalyst

• Second order exothermic reaction

Batch Reactor

• Jacketed reactor with agitator; LP Steam / cooling water in jacket

• Batch addition of feed; withdrawal of product upon reaction completion

• Liquid-phase reaction, reduction of nitro-benzene to aniline; active metal and concentrated hydrochloric acid catalyst

• First order exothermic reaction

Fluid Transfer Equipment

• Working principles; performance under different process conditions

• Safety in operation; common problems such as supply failure, driver failure, loss of load, higher discharge or exhaust pressure, etc., and their recovery

Tank & Pump

• Two tanks with different capacities

• Fluid transfer using centrifugal pumps

• Tank level control

Steam Turbine

• Single-stage steam turbine; drives boiler feed water pump

• MP steam, polytropic expansion to low pressure

• Governor / turbine speed control

• Variable turbine exhaust pressure and user load

Centrifugal Compressor

• Steam turbine driven centrifugal compressor

• Suction and discharge knockout drums

• Antisurge control; performance under load and pressure changes

Reciprocating Compressor

• Motor driven reciprocating compressor

• Three stages with inter-stage cooling; high pressure operation

• Suction, inter-stage and discharge knockout drums

• Capacity control with unloaders; discharge pressure control with spillback

Heat Transfer System

• Heat transfer concepts and equipment dynamics

• Performance under different operating conditions such as flow, temperature & composition

• Common problems such as fouling, tube plugging, tube leak, and their recovery

Process Heat Exchangers

• Shell & tube exchangers with counter-current flow

• Two exchangers with hot-side in series

Air Cooler​

• Single-pass exchanger; cross-flow

• Three motor-driven fans; pitch control

Condenser

• Water-cooled partial condenser

• Single-pass counter-current flow; shell-side condensation

• Vapor and liquid draws from reflux drum

Thermosiphon Reboiler

• Hot oil as heating medium

• Single-pass counter-current flow; vertical configuration

• Tube-side boiling, natural circulation

Vaporizer

• Kettle type exchanger with submerged tube-bundle

• Hot gas as heating medium

• Shell-side boiling, level based heat transfer

Refrigeration

• Two stage propylene (C3) refrigeration

• Motor driven centrifugal compressor

• Compressor safeguards

• Feed gas chillers, suction knockout drums

• Refrigerant cooler and condenser

• Refrigerant surge drum

Boiler and Furnaces

• Performance under different operating conditions such as flow, pressure, temperature and fuel gas composition

• Practice safe operation; prepare for emergencies

• Common problems such as partial & incomplete combustion, coil fouling, coil leak, coil rupture, equipment failure and their recovery

Utility Boiler​​

• D-Type box configuration with steam drum, mud drum and steam super heaters

• Forced draft operation; turbine-driven fan with motor-driven standby

• Boiler feed water; turbine-driven pump with motor-driven standby

• Flue gas heat recovery; economizer and air preheater

• Furnace firing; four burners with individual burner operation

• Boiler drum level control; three-element control

• Boiler pressure control; fuel and air cross-limit controls

• Boiler safeguards

Natural Draft Furnace

• Radiation, convection and heat recovery sections

• Two-pass process coils; individual pass flow control

• Stack damper; arch pressure control; flue gas oxygen and combustibles monitoring

• Four burners with individual burner operation; primary & secondary air registers

• Furnace safeguards

Balanced Draft Furnace​

• Radiation, convection and heat recovery sections

• Two-pass process coils; individual pass flow control

• Forced and Induced draft fans; air preheater

• Stack damper; arch pressure control; flue gas oxygen and combustibles monitoring

• Four burners with individual burner operation; secondary air registers

• Furnace safeguards

Basic Process Control

• Fundamental concepts of basic controls and their functioning

• Merits / performance of a control scheme and comparisons with other schemes

PID Control

• Intermediate storage tank
• Tank level control; water system
• Tank Inlet flow controlled
• PID controller tuning

Feedforward Control

• Intermediate storage tank

• Tank level control; water system

• Tank Inlet, flow controlled; feedforward component

• Tank outlet, level controlled; feedback component

Override Control

• Intermediate storage tank
• Tank level control; water system
• Tank Inlet, flow controlled
• Tank outlet, flow controlled; low and high level overrides

Ratio Control

• Forced draft furnace heating process oil
• Burner system; air to fuel ratio control
• Fuel gas, flow controlled
• Air, ratio controlled

Split Range Control

• Sour gas surge drum
• Drum pressure control
• Gas supply to drum, flow controlled
• Gas exit from drum, pressure controlled; split range
• Gas exit to two destinations, off gas header and flare

pH Control

• Neutralization tank with agitator; process water flow controlled
• Tank outlet pH control; acid and base reagent addition
• Reagent addition, split range control strategy
• Non-linear concentration-pH relation; pH controller tuning