This combined course focuses on the central areas of Process and Mechanical Engineering and guides the delegates in developing both fundamental and practical understandings of key issues. Process engineering is at the heart of much of the chemical, oil, gas, and petrochemical industries.

Process and Mechanical engineers are interested in the safe containment, transportation and transformation of solids, liquids and gases. Of specific importance are separation processes including distillation, heat transfer, hydraulics and fluid flow, reaction engineering, process control and economics. It also focuses on sound mechanical engineering principles, together with other engineering techniques including inspection, monitoring and condition evaluation, that enable mechanical engineers to design and maintain the equipment required by process engineers.

This course will feature:

·         Practical introduction to the fundamentals of process engineering

·         Practical introduction to the fundamentals of Mechanical Engineering, Equipment and Materials

·         Key areas applicable to major process industries especially oil, gas & petrochemical

·         Process and Mechanical Engineering influence on Safety and Risk, Failure Modes and Maintenance

·         The links between the two engineering disciplines

By the end of this course, participants will be able to:

·         Apply practical understanding of central issues in process & mechanical engineering in oil, gas, petrochemical, chemical, and allied facilities

·         Understand fundamental principles used in processes & facilities & apply practical understanding of essential process units & classes of units involved in separations, heat exchange & reactions.

·         Apply practical understanding to static & rotating mechanical equipment & related condition mentoring & inspection techniques.

·         Understand mechanical testing methods, Failure Mechanisms & Fitness for Service, NDT & principles of corrosion & corrosion protection.

·         Perform relevant calculations & analyses to assist in operation, sizing, & troubleshooting of chemical processes & mechanical equipment.

This course is suitable to a wide range of professionals but will greatly benefit technical and non-technical personnel in the chemical, petrochemical, oil and process and mechanical industries with a need to understand and discuss fundamental process and mechanical engineering:

·         Petroleum Engineers

·         Maintenance & Production Engineers

·         Process Engineers

·         R&D Chemists, Plant Chemists

·         Economists & Business Managers

Module 1: Process Engineering Essentials: Upstream & Downstream Process Control & Optimization

Introduction and Fundamentals of Process Engineering

• Mass and energy balances
• Reactor types
• Process & Engineering Diagrams
• Flammability
• Electrical area classification
• Risk Management and Hazard Studies

Hydraulics and Fluid flow

• Pressure and head & Bernoulli's theorem
• Flow of liquids, Reynolds number and pressure drop in pipes
• Two-phase and multi-phase flow
• Enthalpy and thermodynamics
• Principle of process relief devices and process design of relief systems
• Mechanical Equipment – Pumps, Compressors & Mixers

Heat Transfer and Reaction Engineering

• Heat Transfer Mechanisms 
• Heat transfer coefficients and calculation
• Heat exchangers, type and sizing  
• Catalysis and Reaction Engineering
• Chemical reactions & kinetics
• Green Chemistry & Engineering and Sustainability

Distillation Processes and Equipment

• Phase behavior and vapour/liquid equilibria
• Gas/Liquid separation
• Distillation equipment - Columns and vessels 
• Troubleshooting of process equipment
• Overview of Other Separation Processes 
• Effluent treatment [in refinery and petrochemical] industries

Process Control and Economics

• Classification of control systems
• Measured variables
• Simple feedback control
• Preliminary economic analysis
• Fixed and variable costs, break even analysis
• Estimating the cost of process equipment and plants

Module 2: Mechanical Engineering Essentials: Rotating & Static Equipment & Structural Integrity

Introduction & Fundamentals of Materials Selection, Types & Failures

• Engineering Material Properties and Selection
• Materials Testing
• Types of Metals
• Static Strength and Fitness For Service
• Materials Failure Mechanisms
• Mechanical Design, Standards and Codes

Static Equipment, Valves, Piping & Fitness for Service

• Valves Types and Characteristics
• Valve Selection
• Valve Actuators
• Piping Systems and Pipe Supports
• Overview of API 570 - Inspection & repair of Pipelines & Piping
• Fitness for Service, API 579 overview

Rotating Equipment, Pumps & Compressors

• Pump Types, Positive Displacement and Dynamic
• Pump curves
• Pump Selection
• Types of Compressors
• Compressor Performance Curves

Corrosion & Corrosion Protection

• Corrosion Fundamentals
• Types of Corrosion
• Corrosion Inspection and Monitoring
• Corrosion Minimization
• Corrosion Protection

Mechanical Maintenance

• Strategies & Philosophies
• Code and Standards
• Condition Monitoring
• Non Destructive Inspection techniques

A variety of methodologies will be used during the course that includes:

·         (30%) Based on Case Studies

·         (30%) Techniques 

·         (30%) Role Play

·         (10%) Concepts

·         Pre-test and Post-test

·         Variety of Learning Methods

·         Lectures

·         Case Studies and Self Questionaires

·         Group Work

·         Discussion

·         Presentation

To be advised as per course locations. This rate includes participant’s manual, Hand-Outs, buffet lunch, coffee/tea on arrival, morning & afternoon of each day.

Daily Course Timings:

    08:00 - 08:20       Morning Coffee / Tea

    08:20 - 10:00       First Session

    10:00 - 10:20       Coffee / Tea / Snacks

    10:20 - 12:20       Second Session

    12:20 - 13:30       Lunch Break & Prayer Break

    13:30 - 15:00       Last Session