Course Title

1. Introduction to Chemical Engineering Fundamentals

• Defining chemical engineering and its role in industrial processes including (design, operation, and optimization)

• Applicable international standards and regulatory requirements including (API 750, OSHA 29 CFR 1910.119, and local process safety regulations)

• Overview of common industries applying chemical engineering principles including (oil and gas, petrochemical, and water treatment)

• Overview of process-related incidents and their primary causes including (equipment failure, operator error, and inadequate hazard understanding)

2. Mass and Energy Balance Fundamentals

• Basic mass balance concepts including (conservation of mass and material flow tracking)

• Basic energy balance concepts including (heat input, heat loss, and thermal equilibrium)

• Applying balance concepts to simple process scenarios including (mixing and heating processes)

• Understanding process efficiency and yield concepts

3. Common Unit Operations

• Distillation and separation processes including (basic principles and applications)

• Heat exchange processes including (heat exchangers and thermal transfer principles)

• Fluid flow and pumping fundamentals including (pressure, flow rate, and pipe sizing basics)

• Reaction processes including (basic reactor types and reaction conditions)

4. Process Equipment Overview

• Pumps and compressors including (basic function and common types)

• Heat exchangers and cooling systems including (shell-and-tube and plate exchanger basics)

• Reactors and vessels including (basic design considerations and function)

• Valves and control devices including (isolation, control, and relief valve functions)

5. Reading Process Flow Diagrams and P&IDs

• Interpreting basic process flow diagram (PFD) symbols and flow paths

• Interpreting basic piping and instrumentation diagram (P&ID) symbols

• Identifying instrumentation and control points on a P&ID

• Cross-referencing diagrams with physical plant equipment

6. Process Safety Fundamentals

• Applying OSHA 29 CFR 1910.119 process safety management principles

• Identifying common process hazards including (overpressure, temperature excursions, and chemical incompatibility)

• Understanding the role of safety instrumented systems and relief devices

• Recognizing the importance of operating within defined process parameters

7. Group Discussion and Case Studies

• Case studies from regional process-related incidents including (overpressure events, equipment failure, and process upsets) and lessons learned in prevention

• Group discussion on common process understanding gaps including (misreading diagrams and misunderstanding equipment function)

• Sharing regional best practices including (cross-training and structured process familiarization programs)

• Discussion on the link between basic process knowledge and overall plant safety performance