Process Technology Equipment
Chapter 1 Introduction to Process Equipment
Page 1
CHAPTER 1 Introduction to Process Equipment
Table of Contents
Contents
Page
Chapter Overview
2
Class Preparation Checklist
2
Chapter Objectives
2
Agenda
3
Lesson Plan
4
1.0 Introduction
1.1 How Process Industries Operate
5
6
1.2 Process Technician’s Role in Operations and
Maintenance
7
1.3 Equipment
8
1.4 Safety and Environmental Hazards
15
Summary and Wrap-Up
16
Suggested Student Activities
16
End of Chapter Review Questions
17
Clicker Questions
24
Appendix
27
Process Technology Equipment
Chapter 1 Introduction to Process Equipment
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CHAPTER 1 Introduction to Process Equipment
Chapter Overview
This introductory chapter provides an overview of several process industries, the
different types of process equipment and their functions, the role of the process
technician, and the importance of safety and good environmental stewardship.
Process industries use various processes to manufacture products for consumers. A
process can be quite complicated or straightforward but typically involves the
conversion of raw materials into finished or intermediate products.
A process technician’s role might include controlling, monitoring, or maintaining the
process equipment used in the manufacturing process as well as the process itself. The
process technician’s responsibilities include working safely to protect oneself, others,
the process equipment, and the environment.
Class Preparation Checklist
1. Familiarize yourself with the chapter content.
2. Bring cutaways or other hands-on teaching aids if available.
6. Request the appropriate A/V equipment (if needed) and make sure that
your computer is correctly synched with the projector to avoid any delays in
the classroom.
Chapter Objectives
1.1 Describe the process industries and what they produce.
1.2 Describe the process technician’s role in operations and maintenance (North
American Process Technology Alliance [NAPTA] Intro to Tools and Equipment).
1.3 Describe the types of common equipment used in the process industries (NAPTA
Intro to Tools and Equipment).
1.4 Describe safety and environmental hazards associated with equipment usage in the
process industries (NAPTA Intro to Tools and Equipment).
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Chapter 1 Introduction to Process Equipment
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Class Agenda
Activity
Minutes
PPTs
1. Welcome to Class
1
1
2. Introduction and Agenda
2
2
3. Safety Minute
5
3
4. Objectives
3
4
5. Terms
5
5
6. Introduction
1
6
7. How Process Industries Operate
2
7
8. Process Technician’s Role in Operations and
Maintenance
4
8
9. Equipment
1
9
10. Process Drawings and Equipment Standards
1
10
11. Pipes, Tubing, Hoses, and Fittings
1
11
12. Valves
1
12
13. Process Vessels
1
13
14. Pumps
1
14
15. Compressors and Turbines
2
15
16. Motors and Engines
2
16
17. Heat Exchangers
1
17
18. Cooling Towers and Furnaces
2
18
19. Boilers and Auxiliary Equipment
2
19
20. Tools and Separation Equipment
2
20
21. Reactors and Filters, Dryers
2
21
22. Solids Handling Equipment and Environmental
Control Equipment
2
22
23. Mechanical Power Transmission and Lubrication
1
23
24. Safety and Environmental Hazards
1
24
25. Summary and Wrap-Up
4
25
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Chapter 1 Introduction to Process Equipment
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Chapter 1 Lesson Plan
Welcome Everyone to Class
Time: 1 minute
Resources: Slide 1
Sample Instructor Script:
Introduction and Agenda
Time: 2 minutes
Resources: Slide 2
Sample Instructor Script:
You’ve probably driven past large process industries, seen pictures, or possibly worked
in a plant. If so, then you noticed the many pipes, vessels, and different types of
equipment used in the manufacturing process. Each piece of equipment has a specific
role to play in the process and has its unique start-up, shutdown, and operating
procedures. Today’s lesson covers the different types of equipment as well as the
process technician’s involvement in working with and maintaining the equipment.
Student Safety Minute
Time: 5 minutes
Resources: Slide 3, Safety Minute handouts
● Safety Minute Topics Sign-Up Sheet
● Safety Minute Example
● Safety Minute Outline that you will present today
Sample Instructor Script:
(Note to Instructor: Hand out Sign-Up Sheet, Example, and Outline.)
I am going to pass around a sign-up sheet for the Safety Minute presentations, along
with a sample Safety Minute Outline.
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Chapter 1 Introduction to Process Equipment
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Objectives
Time: 3 minutes
Resources: Slide 4
Sample Instructor Script:
There are many different types of process industries; however, one common element
among them is the use of process equipment. Pumps, valves, reactors, and distillation
protective gear and follow safety procedures. Much of the equipment used in a
manufacturing process uses liquids or gases at high temperatures. Some equipment
may have rotating parts or pinch points. The process technician must constantly be alert
to potential hazards.
Terms
1.0 Introduction
Time: 1 minute
Resources: Slide 6
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Chapter 1 Introduction to Process Equipment
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Sample Instructor Script:
This introductory chapter provides an overview of several process industries, the
different types of process equipment and their function, the role of the process
technician, and the importance of safety and good environmental stewardship.
1.1 How Process Industries Operate
Time: 2 minutes
Resources: Slide 7
1. Many industries have smaller process units (integrated groups of process
equipment) that convert or refine raw materials, also known as input or
feedstock, into end products.
2. The raw materials are sorted by process requirements.
3. The raw materials are processed. Process technicians monitor and control the
mechanical, physical, and/or chemical changes that occur during the process,
while maintaining safety, health, environmental, quality, and efficiency standards.
4. A product (output), or desired component, is the result of a particular process.
The product can be either an end product for consumers or an intermediate
product used as part of another process to make a different end product. The
end product of one process unit or process industry can become the feedstock of
another.
5. The product then is distributed to consumers, including other businesses that
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might use the product of one industry’s process as the feedstock for their own
(for example, ethylene as the feedstock for polyethylene).
1.2 Process Technician’s Role in Operations and Maintenance
Time: 4 minutes
Resources: Slide 8
Sample Instructor Script:
A process technician is a vital member of a team responsible for safely planning,
equipment, starting/stopping equipment, viewing instrumentation readouts, analyzing
data, making process adjustments, responding to process emergencies or abnormal
conditions, and documenting tasks, issues, and changes.
Minor maintenance tasks include removing equipment from service; isolating, cleaning,
and preparing equipment for maintenance activity; changing or cleaning filters; repairing
techniques and principles to identify an operational issue with a piece of equipment or
an entire process.
Process technicians must have a basic understanding of quality and how it might affect
production and a company’s reputation. Without quality measures, products and
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1.3 Equipment
Time: 1 minute
Resources: Slide 9
Sample Instructor Script:
1.3.1 Process Drawings and Equipment Standards
Time: 1 minute
Resources: Slide 10
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Chapter 1 Introduction to Process Equipment
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Each drawing includes a legend, a title block, and an application block. Each drawing
includes various symbols representing the components of a process. These symbols
are standardized to allow people from different facilities to read the process diagrams.
Standardization reduces confusion and mistakes.
The following are some of the institutions that are responsible for creating these
standardized symbols:
1.3.2 Pipes, Tubing, Hoses, and Fittings
Time: 1 minute
Resources: Slide 11
Sample Instructor Script:
Tubing is small-diameter hose or pipe that can be used to transport fluids or solids.
Tubing is made from a variety of materials and is used in many applications, including
sample systems and instrumentation.
Hoses are larger than tubing and less permanent than piping, and they are more
flexible. Hoses carry fluids and can be made of plastic, rubber, fiber, metal, or a
combination of materials. Many times, they are used to make temporary connections, as
in the case where facility air is used to drive equipment or when a rail car or tank truck is
1.3.3 Valves
Time: 1 minute
Resources: Slide 12
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Valves can be operated either manually or automatically. The most commonly used
type of valve in the process industries is the gate valve. Main valve components include
the handwheel or handle, packing, bonnet, valve body, valve disc, and valve seat.
1.3.4 Process Vessels
Time: 1 minute
Resources: Slide 13
Sample Instructor Script:
1.3.5 Pumps
Time: 1 minute
Resources: Slide 14
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1.3.6 Compressors and Turbines
Time: 2 minutes
Resources: Slide 15
Sample Instructor Script:
1.3.7 Motors and Engines
Time: 2 minutes
Resources: Slide 16
Process Technology Equipment
Chapter 1 Introduction to Process Equipment
Sample Instructor Script:
Motors are mechanical drivers that convert electrical energy into useful mechanical
work and provide power for rotating equipment. Power distribution is crucial to the
function of process industries. Electricity is the most common source of energy for
driving motors, and motors are typically the largest electrical loads in an industrial
manufacturing facility. Thus, the efficiency of the motors and their operations directly
affects the cost structure of the process plant.
1.3.8 Heat Exchangers
Time: 1 minute
Resources: Slide 17
1.3.9 Cooling Towers and Furnaces
Time: 2 minutes
Resources: Slide 18
Sample Instructor Script:
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1.3.10 Boilers and Auxiliary Equipment
Time: 2 minutes
Resources: Slide 19
Sample Instructor Script:
1.3.11 Tools and Separation Equipment
Time: 2 minutes
Resources: Slide 20
Sample Instructor Script:
The selection, knowledge, and use of hand and power tools are essential to the safety
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power tools should be used only after proper training and selection based on the
specific requirements of the task.
Process technicians must know which tools to use for each piece of equipment or task.
1.3.12 Reactors and Filters, Dryers
Time: 2 minutes
Resources: Slide 21
Sample Instructor Script:
Reactors are types of vessels in which a controlled chemical reaction is initiated. Within
1.3.13 Solids Handling Equipment and Environmental Control Equipment
Time: 2 minutes
Resources: Slide 22
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1.3.14 Mechanical Power Transmission and Lubrication
Time: 1 minute
Resources: Slide 23
1.4 Safety and Environmental Hazards
Time: 1 minute
Resources: Slide 24
Sample Instructor Script:
When working with process equipment, process technicians must be aware of the
pressure and temperatures)
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● Not complying with government, industry, or company regulations.
Process technicians also are expected to:
● Summarize today’s lesson.
● Answer questions.
● Announce the next reading assignment and homework.
● Remind the next person who will be doing a Safety Minute.
Suggested Student Activities
(Note to Instructor: Time permitting, do the activities listed below or possibly assign
them as homework. Be sure to remind students what to read for the next class.)
1. Research the process industries in your city or region that might hire you after you
graduate from this program. Place a map of the area in the front of the classroom.
Share names, locations, and information about the various types of process
industries with your classmates.
2. Work with a classmate to list the various responsibilities or tasks related to the
following areas of the process technician role:
a) Process monitoring and control
b) Preparing plant equipment for maintenance tasks
Process Technology Equipment
Chapter 1 Introduction to Process Equipment
g) Product quality
h) Teamwork
3. List and describe process equipment included in the following equipment types:
a) Movers
b) Power sources
c) Processors
d) Heating/cooling units
4. List and describe some of the safety concerns in the process industries and what you
can do to prevent a personal injury.
End of Chapter Review Questions
1. Which of the following industries is NOT classified as a process industry?
A. Mining
B. Power generation
C. Computer processing
D. Pharmaceutical manufacturing
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2. What are raw materials called?
A. Assets
B. Output
C. Feedstock
D. Resources
3. What standards must a process technician maintain when processing raw
materials?
A. Quality
B. Quantity
C. Efficacy
D. Strength
4. What might be required of a process technician while monitoring and
controlling a process?
A. Analyze data
B. Make process adjustments
C. Evaluate processes for improvement
D. All of the above
Answers:
Process Technology Equipment
Chapter 1 Introduction to Process Equipment
Process Technology Equipment
Chapter 1 Introduction to Process Equipment