Practical Process Engineering

Job effectiveness and problem-solving requires multidisciplinary skills that are usually learnt on the job. For timely project delivery and minimum downtimes, industry requires engineers to interact with specialists from different areas of expertise and understand their jargon.
 

Through workshops and live demonstrations in a complex process plant, this course will boost your confidence and expand your practical skills so that you can apply them in your workplace.


The course will take place in October, 7, 8, 18 and 19


Please note that this course will also be running in March and June 2022.

 

Location: Energy and Bioproducts Research Institute, Aston University, Birmingham, UK

Course type

Professional short courses/CPD

Course format

Experiential learning

Duration

4 days

UCAS code(s)

n/a

Start date

Overview
Practical Process Engineering, CPD course
ebri

Practical course to get familiar with plant diagrams, different types of equipment and instrumentation, and the way they are integrated in the control system.

generator

"I found the course very useful and interesting. It provided me with an excellent opportunity to learn about process engineering. Especially, the activities in the EBRI's power plant were fascinating and was great fun too!"

FHEA, MRSC, AMIChemE

"I have looked at P&IDs before, I have visited plants before, but I have never used them both at the same time. This course was really enjoyable and incredibly useful. I learned how to recognise equipment and instrumentation and learn about the practical aspects of plant services, electrical and control systems."

SFHEA, AMIChemE, Committee member of EdSIG

generator

"I found the course very useful and interesting. It provided me with an excellent opportunity to learn about process engineering. Especially, the activities in the EBRI's power plant were fascinating and was great fun too!"

FHEA, MRSC, AMIChemE

"I have looked at P&IDs before, I have visited plants before, but I have never used them both at the same time. This course was really enjoyable and incredibly useful. I learned how to recognise equipment and instrumentation and learn about the practical aspects of plant services, electrical and control systems."

SFHEA, AMIChemE, Committee member of EdSIG

Course outline

An integrated knowledge of mechanical, electrical and control engineering is necessary to liaise with professionals from different disciplines and understand systems common to many industries, such as chemical, petrochemical, energy, pharma and food and beverage. This 4-day course embodies the interdisciplinary nature of these plants, and the broad range of concepts and technical documentation that are always involved.

The course takes place in a 1 MW bioenergy plant for combined heat and power generation. It is a fully instrumented process plant that comprises 10 control panels and approximately 500 instruments, with a broad range of equipment spread across the four-storey building that constitutes the so-called EBRI Pilot Plant (see the Facilities section).

You will be trained by a team of professionals on reading complex schematics, understanding plant documentation, mechanical systems, electrical panels, control systems and some basic troubleshooting. This is achieved by a structured combination of theory, workshops and live demonstrations, including the opportunity to operate the plant in cold mode from the control room.

Join this course to get essential practical skills and boost your confidence in dealing with complex process systems.

Recognition 

ichemeThe Institution of Chemical Engineers (IChemE) has approved and rated this course "outstanding":

"I think this is possibly the best course I've ever reviewed in terms of an overall learning experience. I would have loved to have gone on something like this back in 1990 when I first started in the process safety area!"

"The lecture materials will form a good reference manual, and the practical examples such as diagrams will be very useful for comparative purposes in the delegates 'own facilities."

“From the high-quality material and blend of learning methods, it is evident that this training is provided by a learning institution who understands the learning process as well as the technical content.”

“I can imagine delegates really enjoying and benefiting from this course.”

Day one

A practical introduction to process plant

  • Process plant implementation
  • Bioenergy process plant for the production of CHP generation (plant tour)
  • How to read complex P&IDs (workshop)
  • Identifying components in a process plant (workshop)
Day two

Mechanical systems

  • Rotating equipment: pumps and compressors
  • Industrial utilities (workshop)
  • Systems for the transport of solids and fluids (live demonstration in the plant)
  • Operating utilities in a process plant (live demonstration in the control room)
Day three

Electrical systems

  • Basic electrical concepts
  • Elements in power distribution
  • Electrical schematics
  • Working with electrical schematics (workshop)
  • Industrial control panels (live documentation)
  • Understanding your building electrical system (live demonstration)
Day four

Control systems

  • Introduction to Programmable Logic Controllers
  • Introduction to Siemens software (live demonstration)
  • Tracing signals through the process plant (live demonstration)
  • Basic concepts in communications
  • Control systems integration


Interactive practical sessions will follow on from technical lectures. Collaborative work and open discussion is encouraged to benefit from the experience of others.

Target audience

If you are working in the engineering sector and would like to gain some hands-on experience in a 1 MW process plant, then this course is for you. This course is also for:

  • Recent graduates and early-career professionals with design, operation, maintenance and safety responsibilities.
     
  • Experienced professionals and scientists who are new to process engineering.
     
  • Anyone with a theoretical engineering background seeking to gain more hands-on, practical experience in a safe environment.

Learning outcomes

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

  • Liaise with mechanical, electrical and control engineers using their jargon
  • Apply your multidisciplinary skills in troubleshooting engineering systems
  • Read complex piping and instrumentation diagrams
  • Identify instruments and equipment
  • Work with equipment lists, I/O lists and control operating philosophies
  • Read the utility layouts and their operation
  • Start and stop different actuators and rotating equipment for the transport of solids and fluids
  • Isolate panels in an industrial plant and basic fault finding on power failure
  • Read simple single-line diagrams and electrical schematics
  • Understand the jargon of control engineers and programmers
  • Use a functional design specification to perform functionality tests
  • Follow a signal from the process to the SCADA and vice versa for basic troubleshooting
  • Identify the main components in control industrial panels
  • Operate a process plant with an integrated knowledge of the different disciplines involved

Key information and fees

The course takes place at Aston University (Birmingham, UK). It lasts four days and is delivered in two separate weeks.

Professional accreditation: Approved by the IChemE

CPD hours: 25

Fee: £1950

A fee discount is available for certain groups, please feel free to enquire.

All training materials, a certificate of completion and personal protective equipment will be provided.

Cancellation policy

Delegates can transfer to a later course date at any stage without incurring a cancellation fee.

Parking and transport

There is parking available, but you can also travel by public transport using one of the three train stations nearby. Ask us for more details on how to get here.

 

Instructors

You will learn from a multidisciplinary team of instructors who have worked in WSP, BP Shipping, BAE Systems, Rolls-Royce, Sterling Power Group, Couch Perry & Wilkes, Schneider Electric, and Emerson Automation Solutions.

Day one

patricia-thornleyPatricia Thornley

Patricia has been a chartered physicist since 2001 and has over 25 years of experience working in bioenergy in industry and academia. She has a PhD in the performance of gasification plants and worked as Lender Engineer in Parsons Brinckerhoff (now WSP) for seven years, where she was involved with the practical construction, commissioning and testing of around 20 different UK bioenergy and waste plants. She is currently participating in a £1M Innovate UK project, supporting the demonstration of a pilot rice straw conversion plant in the Philippines.

Since 2012 Patricia has led the UK's national bioenergy research programme (the £6M Supergen Bioenergy Hub), bringing together over 40 academic, industrial and policy partners to focus on sustainable bioenergy implementation. She is Director of theEnergy and Bioproducts Research Institute and was previously Professor of Sustainable Energy Systems at the University of Manchester.

claraClara Serrano

Clara is PhD CEng with 11 years of experience in the commissioning and operation of bioenergy process plants. She led the Bioenergy Department in the Science and Technology Park of Albacete (2007 –2012, Spain), leading the commissioning of various pilot plants and delivering consultancy services at a national level.

Since 2013, she works in the Energy and Bioproducts Research Institute, where she is the Plant Manager of the bioenergy pilot plant for combined heat and power generation.

Day two

david-smithDavid J Smith

David has sixteen years of industrial experience, initially as a seagoing Marine Engineer Officer with BP Shipping Ltd. He has worked on BP oil tankers, responsible for all aspects of operation, maintenance and safety associated with plants found on foreign-going ships carrying crude oil and petroleum products.

David then joined what is now BAE Systems as a Senior Design Engineer, responsible for designing and developing platform systems on a variety of nuclear and conventional submarines and surface ships. Systems included chilled water, air conditioning, refrigeration, air purification, ICBM missile environment and other related environmental systems.

He is now a Teaching Fellow at Aston University, lecturing in thermodynamics, fluid mechanics, turbo machinery, heat transfer and Engineering Design.

Day three

steve-lukeStephen Luke

Steve is a Chartered Engineer with corporate membership of the Institution of Electrical Engineers (now IET) (1992), the Institute of Measurement and Control (1993) and the Energy Institute (2005).

With 15 years of industrial experience, Steve has worked in Rolls-Royce Plc, offering internal consultancy in all aspects of electrical, instrumentation and control systems. He led a Rolls-Royce Fuel Cell Systems Ltd. team to develop electrical, instrumentation, control and safety systems applied to solid-oxide fuel cell systems. He worked as Senior Design & Development Engineer in Plessey Naval Systems, designing and developing circuit boards and sub-assemblies for submarine-based sonar and command systems.

Steve has held managerial positions working in different universities for 30years (Head of Engineering & Automotive in Cornwall College, Programme Director in the University of Exeter). He is currently Director within the Aston Professional Engineering Centre and responsible for developing and operating work-based programmes and degree apprenticeships.

lee-jenkinsLee Jenkins

Lee is a Senior Fellow of the Higher Education Academy (2017) and Eng-Tech member of the Institute of Engineering and Technology (2003).

He worked for ten years as Electrical Power Engineer in Sterling Power Group andBritish Power International. Since 2014 he works in the Aston Professional Engineering Centre, where he is Program Director in Electrical Power Engineering. This program takes students from National Grid, Western Power Distribution and Scottish and Southern Energy.

Day four

Tim Osgerby

Tim started working in the 80’s as Instrument Technician (Albright & Wilson Ltd, Insertech Ltd) and then as Systems Engineer (Electro link Services), designing and commissioning PLC and PC based control systems.

Since 1990 he is Technical Director of Genesis Control Systems Ltd, providing the design, manufacture, integration, and assembly of a wide range of applications, serving customers within the Automotive, Utilities, Building Management and Chemical and Pharmaceutical Industries.

sam-thiaraSam Thiara

Sam has been involved in the Industrial and Process automation sector for over 30 years. He has worked across the UK and in international markets, supporting clients in automotive, food & beverage, FMCG, chemical & petrochemical, utilities, oil & gas, sugar, pulp and paper and steel industries. Sam has extensive experience in working with UK based and Global System Integrators.

Sam has worked for Schneider Electric as a Senior Applications Engineer, Automation Solutions Consultant and Business Development Manager. he also worked as Business Development Manager for the Operational Certainty Group within Emerson Process Automation.

He is currently the UK sales director for MCS Control Systems Ltd.

 

Facilities

The training takes place in the EBRI Pilot Plant, which is situated in the Energy and Bioproducts Research Institute. It is a fully instrumented process plant built in a four-storey building at Aston University (Birmingham)

exchangers

Some of the operating units are: reactor, cyclone, gas scrubber, nitrogen membranes, heat exchangers, gas filters and engine.

panel

The plant comprises 10 control panels and approximately 500 instruments.

sensors

Through workshops and live demonstrations, you will learn about plant documentation, mechanical systems, electrical panels, control systems and some basic troubleshooting

screws

You will also start and stop different actuators and rotating equipment for the transport of solids and fluids, running the plant in cold mode.

control

And everything in a fully equipped process plant where health and safety are kept at the forefront.


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