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Refinery Foremen Training Course

50 days OPE/MTRAF-E
Level
Proficiency
Audience
  • Foremen, shift leaders, panelists and technicians (maintenance, inspection, laboratory, analysis, research department), with no previous vocational certificate.
Purpose
  • This course provides a comprehensive training on products, processes, equipment and safety, to enhance competencies and develop skills for a safe and efficient management of refinery operations.
Learning Objectives
  • Upon completion of the course, participants will be able to:
  • supervise the production of petroleum products in specifications,
  • analyze and criticize the operating conditions of processes and equipment in order to optimize their use,
  • manage the inherent risks of products, equipment and human behavior; thus contributing to operational safety,
  • communicate efficiently with shift and day colleagues, to enforce compliance with instructions.
Prerequisite
  • Knowledge of the group of units in charge, including field and panel activities.
Ways and means
  • Practical applications, case studies and manipulations on dynamic simulators. Role plays.
  • Review and wrap-up session at the end of each phase of the course.
  • Site visits.

BASIC TRAINING 11 days
  • Physico-chemical properties of hydrocarbons and petroleum cuts.
  • Properties of fluids. Liquid/vapor equilibria.
  • Fluid flow. Heat, energy, heat transfer.
  • Industrial and catalytic chemical reactions.
  • The basic training is illustrated by many practical applications of actual examples from refineries.
SAFETY & ENVIRONMENT IN OPERATIONS 6 days
  • Hazards related to products and equipment.
  • Safety in operations. Integrated safety systems and process safety.
  • Work related hazards. Managing contractors and subcontractors.
  • Environmental issues and related constraints.
  • Case studies. Group work.
EQUIPMENT 13.5 days
  • Metal and corrosion processes. Preventive measures.
  • Static equipment, vessels, storage tanks.
  • Rotating machinery (centrifugal and volumetric pumps, centrifugal and volumetric compressors, steam turbines): workings and technology; operation and disturbed situations; constraints and limits on equipment operation.
  • Heat exchangers and air coolers: operation, test and monitoring.
  • Furnaces and boilers: operating conditions, firing control, typical problems, typical start-up procedures.
  • Instrumentation and control: operation and instrumentation, working of control loops.
  • Advanced process control.
  • Practical control exercises on a dynamic simulator.
  • Technical visits to manufacturer's factories or industrial plants complete the lessons.
PRODUCTS & PROCESSES 11.5 days
  • Crude oil and petroleum products: characteristics, blending rules, reception and shipping, quality control tests, sampling.
  • Distillation operation: binary and multiple draw off.
  • Workshop on a dynamic simulator.
  • Refinery processes: characteristics of the feeds and products, analysis of operations, tuning parameters, performance criteria and optimization, study of operating disturbances:
  • Atmospheric distillation (study on a simulator), desalting, vacuum distillation.
  • Catalytic reforming.
  • Hydrotreatment, hydrodesulfuration and H2 production.
  • Conversion processes: hydrocracker, FCC, coker.
  • Finishing processes.
  • Sulfur recovery and tail gas treatment.
  • Bitumen manufacturing.
  • Manufacturing process diagram.
  • Material balance.
  • Utilities: energy production, distribution and consumption, flares, cooling water, waste waters treatment, boiler feed water.
  • Energy management. Production optimization.
INTEGRATED PLANT SAFE OPERATION - TEAM MANAGEMENT 5 days
  • Team management. Management of change.
  • Radio communication, other communication equipment. Teamwork, responsibilities sharing. Transmission of know-how.
  • Alertness, forward thinking plant operation. Alarms management.
  • Application: role plays.
  • 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.
  • Steady state runs: routine checks, integrated plant behavior (inertia, interferences), global performances.
  • Identification, analysis and reaction to upsets and equipment failures; stabilization.
CONTINUOUS EVALUATION 3 days