Console Operator Training

OPE/FBMOCIR-E

Who should attend?

  • Provide the necessary knowledge to adapt quickly and efficiently to the consoliste position.
  • Operate the units in a proactive and optimized way.
  • Analyze complex situations and react quickly, to disturbances and situations of emergency.
Audience :
  • Experienced field operators moving on to panel/console operator positions in transforming and/or separation units processing continuously.

Level : Foundation

Course Content

  • WELCOME-ASSESSMENT

      • Welcome/safety. PPE distribution. Presentation of the training.
      • Continuous learning assessment (including quizzes, case studies and practical exercises using simulators and pedagogical units, included in the various modules).
  • PROCESS CONTROL, AUTOMATION & DCS

      • Process control and automation:
      • Fluid mechanics: pressure, flowrates, fluid flow, pressure drops.
      • Reading of PID/PFD, control schemes and safety logigrams.
      • Safety Instrumented Systems (SIS).
      • DCS and operational support tools:
      • Architecture and system components. Separation between control and safety systems.
      • Use of de safety logic diagrams, cause and effect matrix. Alarming. Fire and gas.
      • Start-up help device.
      • SOE (Sequence Of Event); defaults view (restitution).
      • Report of inhibition. Safety bypass. Safety interface.
      • Awareness to defaults from the system.
      • Application to diagrams and DCS displays from the Pedagogical Unit.
      • Simulators: surfing on DCS; analysis of the behavior of control loops; split-range; PID tuning; impact of P, I and D parameters; typical instrument failures.
  • THERMAL EQUIPMENT

      • Heat exchangers: principles, resistance to heat transfer.
      • Simulator applications: heat transfer in shell/tubes reboiler (fed with steam or hot oil) and air condenser. Heat balance. Follow-up; troubleshooting.
      • Furnaces - Applications on a real furnace and using a generic simulator:
      • Console operator checking: process control scheme monitoring, tuning principles, operation, alarms, safety devices, shunt…
      • Start-up/shutdown: sequence of ignition and shutdown, tripping; role-playing between console/plant operators.
  • ROTATING EQUIPMENT

      • Centrifugal pumps - Simulator applications:
      • Impact of pump suction pressure drop; possible causes.
      • Start-up, trips; console/field operator communication.
      • Centrifugal and reciprocating compressors:
      • Simulator applications: console operator checkings (control, alarm management, operating guidance).
      • Malfunctions/deficiencies: analysis, troubleshooting, diagnostics. Pumping conditions.
      • Start-up and shutdown sequences: full-scale volumetric compressor and generic simulator applications.
  • PRODUCTS - PROCESSES - OPTIMIZATION

      • Products - Processes:
      • Industrial chemistry reminding. Composition and physico-chemical properties of feeds and products.
      • Commercial products quality requirements, specification and standard tests. Scheduling, management and optimization.
      • Generic simulator of a process unit: influence of the main operating parameters on the operation, consequences on process and products. Importance of material and thermal balances. Consequences of a quality deviation or a need for re-routing.
      • Binary and multiple draw-off distillation columns:
      • Liquid-vapor equilibria for pure components and mixtures.
      • Equipment function. Internal reflux, pumparounds. Heat balance.
      • Operating parameters and control loops. Parameters for adjustments and optimization.
      • Awareness of optimization:
      • Analyzers/estimators; benefits, constraints, limitations. Advanced control concepts.
      • Valuation and optimization (feedstocks management, targeted yields, over-quality and off-specification cost). Slop management and origins, interlinked utilities/processes: management of flare and FG networks (SO2 bubble, gas emissions to the atmosphere, environment).
      • Simulator applications: optimization of products qualities, change in feed quality, loss of reboiler, lack of overhead condensation, maximum flow rate increase and bottleneck search, restart after tripping.
  • INTEGRATED PLANT SAFE OPERATION, demonstration unit

      • Safe behavior:
      • Radio communication, responsibility sharing. Shift handover. Transmission of know-how.
      • Console checkings on a stabilized unit, warning thresholds, connection with operating ranges. Inertia and interference.
      • Unit monitoring with anticipation, priority and alarm management.
      • HSE in operation:
      • 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, alarm inhibition/by-pass.
      • Awareness of simultaneous operations management (SIMOPS).
      • Emergency operation and crisis management.
      • Impact of operations on air emissions and water treatment.
      • Start-up and shutdown of the unit:
      • Use of procedures, comprehension/justifications of different steps (initial, steady state and final).
      • Understanding the unit's hold-up and response dynamics.
      • Transient phase management. Start after tripping.
      • Troubleshooting, disturbances:
      • Unexpected behavior during start-up/shutdown steps and steady state: analysis and reaction, mass balance during start up steps.
      • Incidents, malfunctions, wrong information from instruments, blockage of On/Off valve, practice of emergency operations, etc.

Learning Objectives

  • Upon completion of the course, participants will be able to:
  • communicate and work effectively in shifts teams,
  • explain the processes using available documents,
  • identify the risks for the equipment and ensure that the necessary preventive actions are taken,
  • adapt unit tuning to operate safely and optimize production, product quality and operating costs,
  • determine the possible causes of disturbances and alarms, and react appropriately and methodically,
  • prepare, start and stop a unit safely,
  • analyze and handle in a global manner the operation of a generic installation,
  • transpose the acquired method to get ready to operate specific processes.

Ways & Means

  • Training involves on-site (pilot unit) teamwork on a real industrial pedagogical plant.
  • Remindings of theoretical and technical fundamentals, case studies and realistic situation management using generic dynamic simulators or pedagogical units.
  • Quiz to validate the acquisition.
  • Some pedagogical activities of this course will take place in OLEUM’s facilities (subject to availability).