50 days OPE/MTRAF-E
- Foremen, shift leaders, panelists and technicians (maintenance, inspection, laboratory, analysis, research department), with no previous vocational certificate.
- To provide comprehensive training on products, processes, equipment and safety, to enhance competencies and develop skills for a safe and efficient management of refinery operations.
- To supervise the production of petroleum products in specifications.
- To analyze and criticize the operating conditions of processes and equipment in order to optimize their use.
- To manage the inherent risks of products, equipment and human behavior; thus contributing to operational safety.
- To communicate efficiently with shift and day colleagues, to enforce compliance with instructions.
- 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 AND 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 AND 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