35 days OPE/FBMOC-E
- Experienced field operators moving to panel operator positions in refining and petrochemical plants.
- This course provides a deeper knowledge and know-how necessary to become a panel operator.
- Upon completion of the course, participants will be able to:
- describe the specific duties of their position and the control room organization,
- explain in detail the processes using various documents (PFDs, P&IDs, control schemes, logic diagrams),
- identify risks related to equipment operation and process; to enforce adequate preventive actions,
- adjust the plant process parameters to optimize production rate, product quality and operating costs,
- analyze the process to determine disturbance causes, and take appropriate corrective and preventive actions.
- Excellent technical knowledge of the assigned unit or group of units (field experience).
Ways and means
- Training involves on-site work and supervision from mentors in the plant.
- Case studies and applications on generic dynamic simulators: half of the course takes place in the training center.
- Interactive delivery method.
Customized simulators may be used as a complement to this training program.
PANEL OPERATOR DUTIES & CONTROL ROOM ACTIVITIES 2 days
- Panel operator role within the operation team; control room staff. Reporting and handover duties.
- Plant documentation: inventory, content, usage, role and duties of the panel operator.
BASIC PROFESSIONAL TRAINING 4 days
- Notions of industrial chemistry. Fluid mechanics: pressure, flowrates, fluid flow, pressure drops.
- Heat exchange: exchange mechanisms, resistance to heat transfer.
- Liquid-vapor equilibrium of pure substances and mixtures.
- Simulators: impact of operating parameters on the chemical reaction, heat exchanges, flash drum.
PROCESS CONTROL, AUTOMATION & DCS USAGE 6 days
- Process control:
- Constitution of a control loop, symbols used. Sensors and transmitters. Control valves.
- Controllers operating principles, inputs/outputs, internal parameters and tuning.
- Complex control loops (cascade, split range, multiple calculation blocks).
- Simulators: Valves characteristic curves. PID parameters tuning. Heat exchanger duty control. Split range configuration. Behavior analysis of complex control loops.
- Distributed Control System (DCS):
- Architecture and system components. Man - Machine Interface (MMI). Trends tools. Information flux between site and control room.
- Safety instrumented systems: PSS, ESD, HIPPS, EDP; architecture and relationship with DCS. Safety logics and cause & effect matrix.
- PLCs and automation: grafcet analysis, study of specific sequences.
- Simulators: structure of the ESD system on a two-phase drum; furnace safety logics.
EQUIPMENT OPERATION 8 days
- For each: working principles, technology, ancillary systems, process control scheme monitoring, operation, alarms, safety devices.
- Pumps, compressors, drivers:
- Simulators: operation of two pumps in parallel, pumps switch; changes in operating conditions, capacity control, troubleshooting of a compressor; start-up of a steam turbine driven centrifugal compressor.
- Thermal equipment: heat exchangers, air coolers, furnaces, boilers:
- Simulators: fouling of a heat exchanger; changing fuel supplied to burners, coil fouling, …
- Specific equipment for a given assignment unit (gas turbines, solid handling, extruders, …).
PRODUCTS & PROCESSES 6 days
- Composition and physico-chemical properties of feeds and products.
- Commercial product quality requirements, specification and standard tests. Mixing rules.
- Process units: role, principles, main equipment, specific hazards. Influence of the main operating parameters on the operation, consequences on process and products. Material balance.
- Distillation, absorption, stripping.
- Utilities: flare systems, air production, effluent treatment units, steam, water treatments, …:
- Simulators: start-up and shutdown, operation and control of various process units (for instance: two-product distillation columns, multi draw-off distillation column, amine absorption and regeneration, sulfur recovery unit, hydrotreatment unit).
INTEGRATED PLANT SAFE OPERATION 6 days
- Panel Operator safe behavior:
- Radio communication, other communication equipment. Teamwork, responsibility sharing. Transmission of know-how.
- Alertness, forward thinking plant operation. Alarm management.
- Application: role plays using the simulators (with panel operator views and FODs).
- HSE in operation:
- Product, equipment and process-related risks; prevention and protection.
- Risks related to operation of equipment, to decommissioning-commissioning and start-up of equipment, specific prevention measures.
- Routine operations. Permit to work, work order, consignations and isolations.
- Special operations: SIMOPS, black start. Emergency operation and crisis management.
- Impact of plant operation on gas release into the atmosphere and on the waste water treatment unit.
- Integrated plant operation:
- Steady state runs: routine checks, integrated plant behavior (inertia, interferences), global performances.
- Identification, analysis and reaction to upsets and equipment failures; stabilization.
- Simulators: field round on a running process unit; commissioning, start-up and shutdown procedures, justifications of different steps; inhibition management; operations in downgraded situations; practice of emergency operations.
ASSESSMENT 3 days
- Continuous assessment (including practical exercises on simulators).
- Final test with real-life situation simulation exercises to validate objectives.