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SUSHANT LABHASETWAR MIEAust, CPEng
PROCESS ENGINEER
Contents
1. What do I offer to clients and employers
2. The role I play in Industry
3. Skills and Competencies
4. Samples of Problems Solved
5. Simulation Tools
6. Career Goal
Sushant Labhasetwar 2
What do I offer to clients and employers?
1. 10 years of core process design experience in diverse fields of chemical process industry
2. Help create business opportunities
3. Technical expertise to provide solutions to engineering problems
4. Skills and Competencies
5. In-depth understanding of EPCM business
6. Knowledge of codes and standards
7. Value to workplace
Sushant Labhasetwar 3
The Role I play in Industry
CommunityStandards and Regulations
Stakeholders’Requirements
Procedures
Environmental Considerations
Technology
ME
Safe Operating Procedures
Business Opportunities
Value for Stakeholders
Profits
Design which is Safe Sustainable Cost effective Operable
Sushant Labhasetwar 4
Onshore and offshore MMO contractsSelection and Sizing of EquipmentsTechnical Evaluation and Study ReportsCompliance with international standards and regulations such as API, ASME, NFPA, GPSA and ShellSimulation Tools – HYSYS (steady state and dynamics), HTRI, Aspen Flare Analyzer, PHASTVendor Technical EvaluationHAZOP participation and close outsHazardous area classificationCompliance with Company's Quality Improvement ProgramsMulti-discipline coordinationAssistance in Procurement and Pre-commissioning ActivitiesPreparation of ProposalsOperating Manual Preparation
Process Design and Development for Concept Stage, FEED, Detail Engineering, EPCM Projects
Material and Energy Balance CalculationsDevelopment of Process Flow Diagrams (PFD)Piping and Instrumentation Diagrams (P&ID)Process Design of Centrifugal and Positive Displacement Pumps2-phase, 3-phase separator sizing based on GPSA standardsProcess Design of Heat Exchangers by HTRIRelief valves calculations and specification sheets API tank sizingUtility system design for cooling water, chilled water, instrument air, plant air, steam systems, condensate collection, raw water, filtered water, Demineralized waterPreparation of Instrument Data Sheets e.g. Control ValvesPreparation of Control Logic PhilosophyInterlock Schedule and SAFE charts based on API-14CPreparation of Enquiry Specification for produced water system, water treatment plant (WTP) & technical bid evaluationHazardous area classification Preparation of conceptual plot plan and equipment layout
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Sushant Labhasetwar 5
Skills and Competencies
Is relief device required here? What are consequences?
Sushant Labhasetwar 6
Outcomes
Addition of relief devices made plant safer, deletion met operations requirement in toxic services and made it economical
Samples of Problems Solved
Sushant Labhasetwar 7
Is long piping compromising safety of API tank? What type of relief device will suit the application?
Outcomes
Selected most suitable type of relief device for the application, met local regulations, generated safe design
Sushant Labhasetwar 8
Are operators safe when vent is ignited?
Outcomes
Optimized size of vent boom by critical analysis of most feasible operating/upset scenarios, located vent boom such that operators are safe from thermal radiation and gas concentrations. Also, optimized number of CO2 cylinders at the platform
Sushant Labhasetwar 9
Gas In- 5 to 50 °C
Gas Out
Well Fluid In60-90 °C
Well Fluid Out
Two Sources:Associated Gas/Lift Gas
(Design Temperature: 75 °C Downstream)
Am I exceeding design temperature in any case?
Outcomes
Design produced optimum area, saved space on layout and cost
• 8 Cases for Associated Gas / 8 Cases for Lift Gas• Conventional Approach: 3 °C when Gas T = 50 °C • My final design: 7.5 °C approach
Instrument Gas HeaterDouble Pipe Heat ExchangerPurpose: Provide 10 °C Superheat
Sushant Labhasetwar 10
How can the throughput of batch mixer be increased? Is there anyway to reduce batch time?
Outcomes
Analyzed parameters affecting batch time, set up calculation module to evaluate batch time, validated calculations by comparing with existing batch time, played with parameters to suggest improvement in batch time thereby processing more batches in a day
Sushant Labhasetwar 11
What equations best suit given application?
Selection of heat transfer equations from literature survey
Outcomes
Recommended optimum solution for existing mixer by studying various combinations of cooling media, speed of agitation and jacket design. Also, Utilized optimum configuration for designing new mixer
Sushant Labhasetwar 12
Aspen Hysys (Steady State and Dynamics) for Flow Sheet Simulation
Aspen Flarenet for Designing Relief Systems
Simulation Tools
Data generation for designSizing of equipmentsStudying behavior under different plant conditions
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Sizing of relief headersSelection of type of reliefdevicesData for flare design
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Sushant Labhasetwar 13
HTRI (Heat Transfer Research Institute) for Design of Shell and Tube Heat Exchangers
Sushant Labhasetwar 14
PHAST for dispersion modeling
Modeling of vents dispersing to atmosphere
Locate vents based on safe concentrations and radiation limits at operating platforms
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Sushant Labhasetwar 15
Career Goal
Continue to serve industry to the best of my capabilities
and knowledge achieving sustainable development
THANK YOU
Sushant Labhasetwar 16