Piping, pump, compressor & control valve Process Engineering from Udemy

This course is curating 4 courses for chemical process engineers in 1 course:

1. Pipe Sizing Calculation for Chemical Process Engineers

2. Pump Hydraulics and Specifications

3. Compressor Principles, Operation and Control

4. Control Valve: Hydraulics, Characteristics and Sizing

Pipe Sizing

Pipe sizing is one of the first major activities a process engineer carries out during the preparation of the P&ID.

Pipe size is an important factor for a well-designed process. It shall affect fluid velocity, pressure drop, flow regime,…etc.

A poorly sized pipe can cause disturbance to the whole process and may lead to plant shutdown in critical cases.

Pipe size also has a lot to do with cost, oversizing a pipe means extra cost, more complex pipe design, more foundation, even sometimes process issues.

In this course, you'll learn how to choose the correct pipe size that works with the corresponding fluid service and compare it with velocity, pressure drop, and two-phase flow regime criteria.

Through this course, you'll see how to calculate the velocity and pressure drop of a fluid in the pipe.

Then after calculating the parameters, we'll see the expected criteria range for each service, so that we can compare them with our calculated parameters.

We'll see also what are the two-phase flow regimes and how we should deal with them.

Finally, I'll give some examples for pipe sizing and I'll give an Excel sheet that can guide you on how to size pipes in the future.

Pump Hydraulics and Specifications

Pumps have been the heart of any plant as they are the main equipment used to guarantee the required process flow or pressure. Pumps are used extensively in oil and gas, chemical and petrochemical industries to pump different fluid types at various pressures and temperatures.

Without a pump or if there is a problem in the pump operation, this can cause a huge process disturbance, and in some cases, this may lead to process shutdown.

Sizing the pumps and their suction and discharge systems is one of the major carried out activities in process design. This course will not just explain the theory of operation of a pump against the process. We will see live examples where we shall calculate main pump requirements with respect to the net positive suction head, differential head, and hydraulic power.

This will be through excel sheets that will be provided in the course to teach you how to calculate these parameters. Calculation sheets will be available to you throughout the course.

In this course, We shall see how the pump curve works and how to plot it against the system curve.

We will see how the pump and process system interact with each other and how the pump responds and interacts with process changes or disturbances.

We shall examine the pump curve for both centrifugal and positive displacement pumps and see how each of them interacts with the discharge system differently.

We shall see different control methods to make sure we are on the required pump operating point.

We shall also see different pump configurations how to operate the pumps in series and in parallel and how this is reflected on pump curves.

Compressor Principles, Operation and Control

Compressors are the main equipment used to transfer gases and raise their pressure. They are used in many different applications. You'll see compressors in the oil and gas industry, whether in midstream or in downstream refineries, in petrochemical plants and in many other chemical processing applications.

Compressors are relatively expensive compared to other pieces of equipment in a process plant. That’s why it is always important to understand their types, how they work, their main issues, and how to overcome them.

This course will try to cover the main compressor principles. We shall see how each of these principles works in the case of both centrifugal and reciprocating compressors.

We shall see how compressing gases which are compressible differs a lot from pumping incompressible liquids.

We shall go through dynamic compressors and their types, then positive displacement compressors and their types. This shall be through comparisons showing the advantages and disadvantages of each type.

In this course, We shall see how the compressor curve works and how to plot it against the system curve for both dynamic and positive displacement types.

We will see how the compressor and the process system interact with each other and how the compressor responds and interacts with process changes or disturbances.

We shall go through compressor surge, its effects, and best practices to avoid it.

We shall see different control methods to make sure we are on the required compressor operating point. This shall also include both centrifugal compressors and reciprocating compressors.

Control Valve: Hydraulics, Characteristics and Sizing

Control valves are an essential part of any process plant. You can hardly see a process plant whether in oil and gas industry or in any chemical processing plant without a control valve as they are used to control more than 95% of process parameters.

Throughout this course, we shall see the main functions of a control valve and how they work,

We shall go in deep on what is a control valve Cv or flow coefficient and how it is important in sizing and rating of a control valve.

We shall go through control valve inherent and installed characteristics and how the process configuration affects the operation of a control valve and what is the difference between inherent and installed characteristics.

Then we shall see when to use a butterfly valve as a control valve and how the valve geometry affects its characteristics.

Finally, we shall go through the valve sizing procedure, how to choose the controlling case, we shall go through more than one example, carry out calculations and you shall have an excel sheet that can guide you in the future.

These examples will teach you not only how to calculate the pressure drop of the control valve or how to choose the cases that shall affect the valve sizing, they shall even show how the whole system hydraulics interact with each other and the means to debottleneck it.

Waiting to see you in the course and let’s start.

Disclaimer:

Please note that the Excel sheets were made just for educational purposes. If you shall use it to validate a process or purchase equipment or piping, then you should validate it yourself, and using it shall be upon your sole responsibility.

What's inside

Learning objectives

Learn how to calculate the main parameters used for pipe sizing for liquid, gas and two phase flow
Know the common velocity criteria used for judging a pipe size for different fluid services
Know the common pressure drop criteria used for judging a pipe size for different fluid services
See how two phase flow regimes affect the pipe
See some examples of choosing the suitable pipe size and how the chosen criteria affects the pipe diameter
How pump curves work and get the operating point against system curve
Calculate pump available npsh and make sure that we are avoiding pump cavitation using solved examples
Estimate pump differential head based on process needs and discharge side resistance using solved examples
Calculate pump power
Difference between the operation of a centrifugal pump and positive displacement
Pump control methods
Operation of pumps in series and in parallel
Main differences between pumps and compressors
Main compressor types

When to use more than one stage of a compressor
Performance curves of both dynamic and positive displacement compressors
Surge scenario and best practices to avoid it
Compressor stonewall
Dynamic compressor methods of control
Reciprocating compressor methods of control
The main functions of a control valve in a process
How a control valve works?
The valve flow coefficient
Valve inherent and installed characteristics
Calculate control valve main parameters and controlling cases
Show more
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Learn how to calculate the main parameters used for pipe sizing for liquid, gas and two phase flow
Know the common velocity criteria used for judging a pipe size for different fluid services
Know the common pressure drop criteria used for judging a pipe size for different fluid services
See how two phase flow regimes affect the pipe
See some examples of choosing the suitable pipe size and how the chosen criteria affects the pipe diameter
How pump curves work and get the operating point against system curve
Calculate pump available npsh and make sure that we are avoiding pump cavitation using solved examples
Estimate pump differential head based on process needs and discharge side resistance using solved examples
Calculate pump power
Difference between the operation of a centrifugal pump and positive displacement
Pump control methods
Operation of pumps in series and in parallel
Main differences between pumps and compressors
Main compressor types
When to use more than one stage of a compressor
Performance curves of both dynamic and positive displacement compressors
Surge scenario and best practices to avoid it
Compressor stonewall
Dynamic compressor methods of control
Reciprocating compressor methods of control
The main functions of a control valve in a process
How a control valve works?
The valve flow coefficient
Valve inherent and installed characteristics
Calculate control valve main parameters and controlling cases
Show more
Show less

Syllabus

Introduction

Before You Start

What does the word "Hydraulics" mean?

Main course Sections

Traffic lights

Read about what's good

what should give you pause

and possible dealbreakers

Covers pipe sizing, pump hydraulics, compressor principles, and control valves, which are essential topics for chemical process engineers

Includes practical examples and Excel sheets for pipe sizing and pump calculations, which can be directly applied in process design

Explores the interaction between pumps/compressors and process systems, which is crucial for understanding and troubleshooting process disturbances

Examines different control methods for pumps and compressors, which is important for maintaining required operating points

Discusses surge and stonewall phenomena in compressors, along with best practices to avoid them, which is critical for compressor operation

The Excel sheets are for educational purposes only, so users should validate them before using them for critical processes or equipment purchasing

Reviews summary

Practical essentials for process engineers

According to learners, this course offers a solid and practical foundation in key process engineering equipment: piping, pumps, compressors, and control valves. Many students find the course highly beneficial for its practical examples and the helpful Excel sheets provided for calculations. The instructor is frequently praised for clear explanations. While widely seen as a valuable resource, particularly for those seeking an overview or refresher, some experienced engineers note that the course could benefit from more depth in certain areas.

Valuable for beginners or engineers needing a review.

"Recommended for anyone starting in process engineering."

"good as a refresher."

"Solid course for understanding the basics and practical application."

Explanations are clear and easy to follow.

"Explained clearly."

"Instructor knows his stuff."

"The explanations are clear."

Provides a good overview of four main areas.

"good overview of the four main topics."

"A solid foundation in process equipment. Covers the essentials well."

"The combination of pipe, pump, compressor, and control valve content is perfect for plant engineers."

Includes useful Excel sheets and examples.

"The practical examples and the Excel sheets are gold!"

"The practical calculations for pipe sizing and pump hydraulics using the sheets were very useful."

"Very practical and to the point. Loved the examples and the calculation tools."

Some parts felt rushed or materials dense.

"some parts felt rushed. The Excel sheets are okay but could be more robust."

"Some slides were a bit dense..."

May not meet needs of highly experienced engineers.

"Wish some sections went a bit deeper, but overall worthwhile."

"Maybe slightly basic on compressors for someone with experience..."

"Found it too basic. Expected more depth on the hydraulics. ... not experienced engineers."

Activities

Be better prepared before your course. Deepen your understanding during and after it. Supplement your coursework and achieve mastery of the topics covered in Piping, pump, compressor & control valve Process Engineering with these activities:

Review Fluid Mechanics Fundamentals

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Reinforce your understanding of fluid properties, pressure, and flow, which are essential for grasping pipe sizing, pump hydraulics, and compressor principles.

Browse courses on Fluid Mechanics

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Review key concepts like viscosity, density, and pressure.
Solve basic problems related to fluid flow and pressure drop.

Read 'Piping Calculations Manual' by Shashi Menon

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Supplement your understanding of pipe sizing and hydraulics with real-world examples and detailed calculations.

View Alter Ego: A Novel on Amazon

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Read chapters related to pipe sizing and pressure drop.
Work through example problems to reinforce understanding.

Practice Pump NPSH Calculations

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Solidify your ability to calculate Net Positive Suction Head (NPSH) by working through a series of practice problems.

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Find or create 10-15 problems involving NPSH calculations.
Solve each problem, paying attention to units and conversions.
Compare your answers with solutions to identify areas for improvement.

Four other activities

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Show all seven activities

Create a Presentation on Control Valve Characteristics

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Consolidate your understanding of control valve characteristics by preparing and delivering a presentation on the topic.

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Research different control valve characteristics, such as linear, equal percentage, and quick opening.
Prepare slides explaining the advantages and disadvantages of each characteristic.
Include examples of applications where each characteristic is most suitable.
Practice delivering the presentation to ensure clarity and conciseness.

Develop a Pipe Sizing Excel Tool

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Apply your knowledge of pipe sizing principles by creating a practical tool that automates calculations.

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Identify the key equations and criteria for pipe sizing.
Implement these equations in an Excel spreadsheet.
Test the tool with various fluid services and compare results.
Add features to handle different pipe schedules and fittings.

Study 'Compressor Handbook' by Paul Hanlon

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Deepen your understanding of compressor principles and control methods with a comprehensive handbook.

View Melania on Amazon

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Focus on chapters related to compressor types and control.
Review sections on surge and stonewall phenomena.

Design a Pump System for a Specific Application

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Integrate your knowledge of pump hydraulics and system design by creating a detailed pump system design for a real-world application.

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Choose a specific application, such as a water treatment plant or a chemical processing unit.
Determine the required flow rate, pressure, and fluid properties.
Select an appropriate pump type and size based on the application requirements.
Design the suction and discharge piping system, considering NPSH and pressure drop.
Create a detailed system diagram and equipment list.

Career center

Learners who complete Piping, pump, compressor & control valve Process Engineering will develop knowledge and skills that may be useful to these careers:

Process Engineer

As a process engineer, you will design, implement, control, and optimize industrial processes. This course directly aligns with the core responsibilities of a process engineer, particularly in the oil and gas, chemical, and petrochemical industries. The course emphasizes crucial aspects such as pipe sizing, pump hydraulics, compressor principles, and control valve characteristics. Specifically, the sections on pipe sizing calculations and pump specifications will prove invaluable, as process engineers frequently deal with fluid dynamics and ensuring efficient transfer of materials. Furthermore, understanding compressor operation and control valve sizing is essential for managing pressure and flow rates within a process plant, ensuring safe and optimal operation. A process engineer who understands these concepts is an invaluable asset.

See salaries and explore the career path for Process Engineer

Piping Engineer

A piping engineer designs and oversees the construction and maintenance of piping systems used to transport fluids and gases. This course is highly relevant to the role. The course content directly relates to the daily tasks of a piping engineer. The sections on pipe sizing calculations, including determining appropriate pipe diameters based on fluid properties and flow rates, are essential knowledge. The comprehensive exploration of pressure drop calculations, velocity criteria for different fluid services, and handling two-phase flow regimes helps build a strong foundation for designing safe and efficient piping systems. Moreover, the practical examples and Excel sheets will allow a piping engineer to immediately apply the learned principles to real-world scenarios. A piping engineer who wants to excel in this field should take this course.

See salaries and explore the career path for Piping Engineer

Chemical Engineer

A chemical engineer applies principles of chemistry, physics, mathematics, and engineering to design, develop, and optimize chemical processes. This course is highly valuable, as it covers core areas of chemical engineering practice. The course content provides practical knowledge directly applicable to designing and operating chemical plants. The in-depth coverage of pipe sizing, pump hydraulics, compressor operation, and control valves helps build a very strong foundation for a chemical engineer. The focus on fluid dynamics, pressure drop calculations, and equipment sizing ensures efficient and safe operation of chemical processes. In particular, the Excel-based calculation sheets and practical examples enable a chemical engineer to apply theoretical concepts to real-world scenarios. This course will give any chemical engineer an edge.

See salaries and explore the career path for Chemical Engineer

Instrumentation and Control Engineer

An instrumentation and control engineer designs, develops, and manages the systems used to monitor and control industrial processes. This course is very helpful for an instrumentation and control engineer, especially the section on control valves. This course offers valuable insights into how instrumentation and control systems interact with process equipment like pumps and compressors. Understanding control valve characteristics, sizing, and how they impact process hydraulics is crucial for designing effective control loops. Furthermore, the course content on pump and compressor control methods provides context for implementing automated control strategies. This course will help an instrumentation and control engineer better understand the overall system dynamics and optimize control system performance.

See salaries and explore the career path for Instrumentation and Control Engineer

Plant Engineer

A plant engineer is responsible for maintaining and improving the infrastructure and equipment within an industrial plant. The course content is directly relevant to the daily tasks of a plant engineer. The knowledge of pipe sizing, pump hydraulics, compressor operation, and control valves empowers a plant engineer to troubleshoot issues, optimize performance, and ensure the reliability of critical equipment. The practical examples and calculation sheets also provide tools for assessing equipment performance and identifying potential problems. Understanding the interactions between different components, such as pumps, compressors, and control valves, is crucial for maintaining a well-functioning plant. This is the perfect course for any plant engineer.

See salaries and explore the career path for Plant Engineer

HVAC Engineer

An HVAC engineer designs, installs, and maintains heating, ventilation, and air conditioning systems in buildings and industrial facilities. Although focused on process engineering, this course remains valuable for aspiring HVAC engineers. Knowledge of fluid dynamics, pipe sizing, and pump hydraulics is pertinent to designing efficient HVAC systems. While the course emphasizes process-specific applications, the underlying principles of fluid mechanics and heat transfer are broadly applicable. Examining pumps and compressors, along with their control methods, helps build a better understanding of the components commonly found in HVAC systems. The pipe sizing component will also be especially useful for an HVAC engineer.

See salaries and explore the career path for HVAC Engineer

Maintenance Engineer

A maintenance engineer oversees the maintenance and repair of equipment and systems. This course may be useful for a maintenance engineer, particularly the modules on pump, compressor, and control valve operation. Understanding the principles behind these systems, common failure modes, and troubleshooting techniques empowers a maintenance engineer to diagnose problems quickly and effectively. The course content on hydraulics and system interactions can help a maintenance engineer develop predictive maintenance strategies and optimize maintenance schedules, keeping the plant in great condition.

See salaries and explore the career path for Maintenance Engineer

Reliability Engineer

A reliability engineer focuses on improving the reliability and maintainability of equipment and processes. The course may be useful, as it touches on aspects relevant to equipment performance and failure modes. The sections on pump hydraulics and compressor operation are particularly relevant, as these components are often critical to process reliability. Acquiring a comprehensive understanding of how these systems work, their potential failure points, and the factors that influence their performance is extremely valuable. This course may help a reliability engineer assess risks, identify potential weaknesses, and implement strategies to improve equipment uptime and reduce maintenance costs.

See salaries and explore the career path for Reliability Engineer

Consulting Engineer

A consulting engineer provides expert advice and guidance to clients on engineering-related issues. This course may be useful for consulting engineers, especially those specializing in process engineering or related fields. The in-depth knowledge of pipe sizing, pump hydraulics, compressor operation, and control valves is valuable for assessing existing systems, identifying potential improvements, and recommending solutions. The course content provides a consulting engineer with the technical expertise to address complex challenges and deliver value to their clients. The consulting engineer can use what they learn to offer guidance.

See salaries and explore the career path for Consulting Engineer

Project Engineer

A project engineer manages and coordinates engineering projects from conception to completion. While this course focuses on specific technical areas, it remains relevant to a project engineer. The understanding of pipe sizing, pump specifications, compressor principles, and control valves may allow a project engineer to oversee projects involving these components. The course content provides the project engineer with the technical acumen to effectively communicate with other members of the team, track project progress, and ensure projects are completed successfully. This course may be useful for project engineers who want to broaden their understanding.

See salaries and explore the career path for Project Engineer

Sales Engineer

A sales engineer sells complex technical products or services to businesses. While not directly focused on sales, this course can be quite beneficial for a sales engineer. The detailed knowledge of pipe sizing, pump hydraulics, compressor operation, and control valves is valuable for understanding the products they sell. The course content enables a sales engineer to communicate effectively with clients, understand their technical needs, and recommend appropriate solutions. This may allow for a sales engineer to build trust with customers and increase sales. A sales engineer who wants to add to their technical knowledge should give this course a look.

See salaries and explore the career path for Sales Engineer

Energy Engineer

An energy engineer works to improve energy efficiency and reduce energy consumption in various industries. This course may be useful for an energy engineer, as it discusses key components used in energy systems. An energy engineer might find the course useful. The sections covering pumps, compressors, and control valves are relevant to optimizing energy usage in fluid transport and process control. Understanding how these systems operate and how to improve their efficiency could have implications for energy savings. This could also lead to sustainable operations within industrial facilities.

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Manufacturing Engineer

A manufacturing engineer improves manufacturing processes and systems to enhance efficiency and product quality. The course may be useful for a manufacturing engineer, especially if their role involves working with fluid handling systems or process equipment. The understanding of pipe sizing, pump hydraulics, and control valves could contribute to optimizing manufacturing processes and reducing waste. The course may help a manufacturing engineer identify areas for improvement in fluid transport and process control, leading to increased efficiency and cost savings.

See salaries and explore the career path for Manufacturing Engineer

Quality Assurance Engineer

A quality assurance engineer ensures that products and processes meet certain standards of quality. While not directly focused on quality assurance, this course may be useful for an engineer in this field. The understanding of pipe sizing, pump specifications, compressor principles, and control valves could help a quality assurance engineer assess the performance and reliability of process equipment. The course may provide insights into potential failure modes and factors that affect equipment quality, potentially streamlining the manufacturing process so that it is more efficient.

See salaries and explore the career path for Quality Assurance Engineer

Environmental Engineer

An environmental engineer works to protect the environment and human health through the design of solutions to environmental problems. This course may be useful for an environmental engineer focused on industrial processes. The knowledge of fluid dynamics, pipe sizing, and equipment operation could contribute to designing more efficient and environmentally friendly systems. The course may help an environmental engineer understand how industrial processes impact the environment and develop strategies to minimize pollution and reduce resource consumption.

See salaries and explore the career path for Environmental Engineer

Reading list

We've selected two books that we think will supplement your learning. Use these to develop background knowledge, enrich your coursework, and gain a deeper understanding of the topics covered in Piping, pump, compressor & control valve Process Engineering.

Alter Ego

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Provides comprehensive coverage of piping system design and calculations. It valuable reference for understanding pipe sizing, pressure drop calculations, and two-phase flow regimes. The book offers practical examples and guidelines that complement the course material, making it a useful resource for both current learning and future reference. It is commonly used by industry professionals.

Alter Ego: A Novel

Paperback

Piping, pump, compressor & control valve Process Engineering

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What's inside

Learning objectives

Syllabus

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Reviews summary

Practical essentials for process engineers

Activities

Career center

Reading list

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