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E-567 - Production Facilities Control Room Operation

10 days FOPS/ADVCCRGB
Level
Proficiency
Audience
  • Experienced control room operators and production supervisors looking to advance their know-how in control room operation.
Purpose
  • To acquire best practices of production facilities control room operation through role-play situations on integrated Oil & Gas production plant dynamic simulator.
Learning Objectives
  • Upon completion of the course, participants will be able to:
  • analyze and anticipate behavior of main control loop structures,
  • describe DCS and SIS systems architecture and functionalities,
  • explain production equipment, process operating parameters and perform troubleshooting,
  • implement proactive, anticipatory control room operation and acquire a safety mindset,
  • react and act in a structured manner to anomalies and plant upsets,
  • enforce safety guidelines during downgraded and critical situations.
Prerequisite
  • No prerequisites for this course.
Ways and means
  • Extensive practice on integrated Oil & Gas production plant dynamic simulator.
  • Numerous case studies and role-play situations.

Getting started – DCS functionalities for proper analysis 1 day
  • Familiarization with HMI functions and operation.
  • DCS tools review.
process control & safety instrumented systems 1 day
  • Impact of P, I, D parameters and simple closed loop tuning.
  • Study of control loop structures: cascade, split-range on simulator.
  • Programmable logic controllers: Introduction to automated sequences.
  • Monitoring of start-up sequence (compressor) through MMI.
  • Safety Instrumented Systems (SIS): PSS, ESD, HIPPS and F&G systems description.
Wells & production lines operation 1 day
  • Well start-up (ramp-up) and shut-down.
  • Analysis of automatic well control.
  • Well monitoring and detection of abnormal conditions.
Rotating machinery operation 1.5 days
  • Centrifugal pumps.
  • Centrifugal compressors:
  • Technology review; study of process and auxiliary lines; protection systems.
  • Start-up and shutdown sequences.
  • Analysis of operating conditions and operating parameters.
Process upset management 2.5 days
  • Alarms: priorities management and decision making.
  • Becoming aware of the need for anticipation VS on-alarm action.
  • Managing and predicting process disturbances by using trend views. Use of trends to anticipate deviations.
  • Global plant performance checks: identification and implementation of a routine checks roadmap.
  • Shift report and impact of a faulty report through role play situations.
  • Process upsets: learning to react and act in a structured manner.
  • Identification, analysis and containment of process upsets according to the learnt methodology.
  • Example of simulator exercises performed:
  • Loss of centrifugal compressor.
  • Loss of cooling media.
  • Production rate decrease.
  • Unexpected slugging.
  • ESD activation due to process safety trip.
Safety in operation 1 day
  • Learning to operate the plant in critical situation, to make adequate decision, to follow-up on actions performed.
  • Example of simulator exercises performed:
  • Gas leakage to the flare.
  • Inhibition and downgraded situation mitigation (faulty pressure transmitter, SDV blocked open, …).
  • Manual ESD activation following leakage detection.
Production start-up 1 day
  • Analysis of production facilities start-up philosophy.
  • Safe plant start-up.
  • Implementing start-up procedure on simulator:
  • Operating parameters analysis and anticipation of process upset.
  • Generation of several malfunctions (by the instructor) to be fixed.
Continuous assessment test 1 day
  • Weekly tests on simulator.