Process Technology Course

Lesson 1 • Introduction to Process Industries

Covers the scope, history, and economic significance of process industries. Establishes the industrial context that frames all subsequent technical content.

Lesson 2 • Process Flow and System Overview

Explains how raw materials transform into products through sequential unit operations. Students trace material flow from feed to final product.

Lesson 3 • Core Process Terminology

Introduces standardised vocabulary used across process facilities. Accurate terminology use is essential for reading procedures, P&IDs, and safety documents.

Lesson 1 • Heat Transfer Equipment

Examines shell-and-tube, plate, and fired heaters used to add or remove heat. Heat transfer equipment appears in nearly every process unit covered later.

Lesson 2 • Vessels and Tanks

Covers storage tanks, pressure vessels, and reactors as primary containment equipment. Understanding vessel types is prerequisite to studying fluid handling and reactions.

Lesson 3 • Pumps, Compressors, and Drivers

Identifies centrifugal and positive-displacement pumps, compressors, and their drivers. Fluid movement equipment is central to understanding process flow control.

Lesson 4 • Valves, Piping, and Fittings

Covers valve types, piping materials, and fitting configurations used to direct flow. Correct valve and piping knowledge is required for safe isolation and lineup procedures.

Lesson 1 • Measurement of Process Variables

Introduces instruments that measure temperature, pressure, flow, and level. Accurate measurement is the foundation of all process monitoring and control actions.

Lesson 2 • Analysers and Quality Instruments

Covers online analysers for composition, pH, and density used to verify product quality. Analyser outputs feed directly into quality control and process optimisation decisions.

Lesson 3 • Distributed Control Systems Overview

Introduces DCS architecture, operator interface screens, and alarm management. DCS interaction is the primary means by which operators monitor and adjust process conditions.

Lesson 4 • Basic Control Loop Principles

Explains feedback control loops including sensors, controllers, and final control elements. Loop understanding enables operators to recognise normal and abnormal control behaviour.

Lesson 1 • Personal Protective Equipment and Exposure Control

Covers selection, use, and limitations of PPE for chemical and physical hazards. Proper PPE use reduces personal exposure risk during routine and non-routine tasks.

Lesson 2 • Protective Systems and Safety Instrumented Systems

Explains pressure relief devices, safety instrumented systems, and emergency shutdown logic. These systems are the last line of defence before a process hazard becomes an incident.

Lesson 3 • Hazard Identification and Risk Assessment

Covers hazard types, risk matrices, and structured identification methods such as HAZOP. Risk assessment skills underpin every safe operating decision made by technicians.

Lesson 4 • Permit-to-Work and Isolation Procedures

Teaches hot work, confined space, and lockout/tagout permit systems. Permit compliance prevents accidental energy release and unauthorised equipment activation.

Lesson 1 • Heat Transfer Principles

Covers conduction, convection, and radiation as mechanisms of industrial heat transfer. Understanding heat transfer explains exchanger performance and temperature control responses.

Lesson 2 • Pressure and Flow Fundamentals

Explains Bernoulli's principle, head pressure, and flow resistance in piping systems. These concepts explain why pressure and flow readings change during normal operations.

Lesson 3 • Thermodynamic Concepts for Process Operations

Introduces enthalpy, energy balances, and phase change thermodynamics at an operator level. These concepts explain steam systems, condensers, and reboiler behaviour.

Lesson 1 • Distillation Column Operation

Explains vapour-liquid equilibrium, tray efficiency, and reflux ratio in distillation. Column operation is the most common separation technique in process industries.

Lesson 2 • Reaction Kinetics and Reactor Types

Introduces reaction rate, conversion, selectivity, and the operating characteristics of reactor types. Reactor knowledge enables operators to optimise yield and manage exothermic runaway risk.

Lesson 3 • Solids Handling and Drying Operations

Addresses conveying, screening, drying, and size reduction of solid process materials. Solids handling is critical in polymer, mineral, and food processing applications.

Lesson 4 • Absorption and Stripping Operations

Covers solvent-based gas absorption and thermal or steam stripping for component removal. These operations are widely used in gas treating and environmental control systems.

Lesson 1 • Normal Shutdown Procedures

Covers planned shutdown sequencing, depressurisation, and equipment isolation steps. Proper shutdown prevents equipment damage and prepares units safely for maintenance.

Lesson 2 • Reading and Using Operating Procedures

Teaches procedure format, step verification, and deviation documentation practices. Strict procedure adherence is the primary defence against human-error-driven incidents.

Lesson 3 • Unit Startup Procedures

Covers pre-startup checks, equipment lineup, and controlled introduction of feed. Startup is the highest-risk phase of operations and requires disciplined sequential execution.

Lesson 4 • Shift Handover and Communication

Addresses structured shift handover protocols, verbal briefings, and log documentation. Effective handover prevents information loss that causes incidents during shift transitions.

Lesson 1 • Systematic Troubleshooting Methodology

Introduces structured problem-solving frameworks for diagnosing process deviations. A systematic approach reduces diagnostic time and prevents incorrect corrective actions.

Lesson 2 • Continuous Improvement in Process Operations

Introduces improvement methodologies applied to process operations for sustained performance gains. Operators who apply improvement tools contribute directly to plant reliability and profitability.

Lesson 3 • Process Data Analysis for Optimisation

Covers trend analysis, key performance indicators, and mass and energy balance checks. Data-driven analysis identifies efficiency losses and guides targeted process improvements.

Lesson 4 • Instrument and Equipment Failure Diagnosis

Teaches how to distinguish true process changes from instrument malfunctions. Misdiagnosing instrument failure as a process upset leads to incorrect and potentially dangerous responses.