:: DEFINE | Management Consultancy & Training Provider In UAE, Abu Dhabi,Dubai,Saudi Arabia ::

PROCESS PLANT START-UP, SHUTDOWN, TROUBLESHOOTING & PROBLEM SOLVING

Location

London, UK

Date

From Date: 30-Sep-2024
To Date: 04-Oct-2024

Duration

5 days

Language

ENGLISH

Discipline

PROCESS ENGINEERING

Introduction

Many accidents occur during the start-up or shutdown of process plants. . In addition, several accidents, which occur during the normal working conditions of the plant, are caused by either thermal or mechanical stresses as a consequence of these operations. •

The hazards that are most frequently encountered during the start-up/shutdown procedures are:

Mixing of air and hydrocarbons
Contact of water with hot oil
Freezing of residual water in equipment
Corrosive and poisonous liquids and gases
Thermal and mechanical stresses

This course is designed to give the attendees the requirements and understanding of the process plant operation, process, control system and safeguarding, thereafter will proceed towards the step-by-step methods of plant start-up and shutdowns. Monitoring of normal operation, taking actions at upset conditions, various trouble shooting and risk assessment are included.

Course will be more practically oriented with interactive discussions and experience transfers. Operation and troubleshooting of main equipment will be discussed too.

This will enable the participants to enhance their knowledge on process operation, troubleshooting and take corrective actions at different upset conditions to maintain production with quality requirements, without compromising safety.

More emphasis will be given to practical exercises, experience transfer and safety incident case studies.

Objective

On completion of the course candidates will get good understanding and knowledge on the following:

• Advanced the plant process operating technique

• Understanding of the process trouble shooting at different scenarios.

• Utilization of the proper tools / equipment.

• Equipment common operating parameters & controls.

• Equipment& process start-up / shutdown from / to different modes.

• (Vessel start-up after major maintenance job, power failure, stand by, different ESD levels,)

• Oil & gas production overview from well head to tank farm and gas export.

• Different process equipment’s- Operation & trouble shooting techniques.

• Process parameters measurement principles and commonly used devices.

• Working control loops and ASD system

• Quality requirement for exporting of oil and gas.

• Collection and reporting of process parameters

• Review lab reports

• Take corrective actions to avoid process upset, off-spec qualities

• Review daily production reports

• Review chemical, lube oil and other utilities consumptions.

• Hazards identifications & control measures (Safety in operation.)

• More confidently guide freshers and those who with less experience.

Audience

Production mangers, Supervisor / Engineers and Operators
Mechanical, Instrument and Electrical Engineers, Supervisors and Technicians

Content

Day 1: Knowledge of the process and Control system

1.1 Process plant operation- Requirements

Introduction
Entry Test
Knowledge on Facility Operation-Overview
Knowledge and experience on the respective process plant
Good understanding of safety philosophy & design
Familiar rise with the major static and rotating equipment
Process control system knowledge
Control room and field operation interactions
Location of valves, switches, sampling points. Etc.
ESD, F&G system knowledge.

1.2 Process/ production Management functions

Make available updated process operation & vendor manuals

Updated SOPs
Updated copy of P& ID and C&E doc.
Keeping audited override register

Emergency operation Procedure
Training and assessment of Operation team.

1.3 Process Control

Process parameters
Process parameters measurement
Basic control loop
Components of control system
Feedback control
Different types of control system
Split range control
Cascade control
On-off controls
Tuning of controllers

Day 2: Process Plant start-up

Different types of plant start-ups
Pre-checks and preparations for:
Initial start-up followed by commissioning
Start up after a unit shutdown
Start up after ESD
Line walk and check Isolations/de-isolation
Methods of purging
Hydro carbon Introduction
Immediate actions after shutdown
Giving clearance for re-start
Ramp up operations
Monitoring and control of running plant

Day 3 Process Plant Shutdown

Different types of plant shutdown
Shutdown of a major equipment or unit
Emergency shutdowns
Automatic actions of control and safe guarding system of different levels of ESD
Identify the cause of shutdown
Resetting of shutdown switches and valves
Control room and field activities during shutdowns
Shut down of equipment or unit doe maintenance
Work permit procedures
Process Isolations and gas freeing
Mechanical Isolations
Positive isolations
Gas testing

Day 4 Process plant Troubleshooting Techniques

Basic requirement for troubleshooting
Regulating Process Conditions
Troubleshooting and Debottlenecking
Examples of Trouble shooting table
Seven-Step Troubleshooting Philosophy
Symptom recognition
Symptom elaboration
Listing of probable faulty functions
Localizing the faulty function
Localizing the trouble to a faulty component
Failure analysis

Day 5: Problem solving Techniques

5.1 Problem solving & follow up on following equipment

Separators
Scrubbers
Columns
Centrifugal Gas compressors
Reciprocation Gas Compressors
Heat Exchangers
Flow meters
Storage tanks

5.2 Problem solving & follow up on following process unit

Well head operation
3 phase oil & gas separator train
Desalter
TEG dehydration- Glycol loss
Gas Compression train

5.3 Abnormal situation management

NOTE:

Pre & Post Tests will be conducted.

Case Studies, Group Exercises, Group Discussions, Last Day Review &Assessments will

be carried out.

………………………………….

Certificate

Define Management Consultancy & Training Certificate of course completion will be issued to all attendees.

Methodology

A highly interactive combination of lectures and discussion sessions will be managed to maximize the amount and quality of information and knowledge transfer. The sessions will start by raising the most relevant questions and motivating everybody to find the right answers. You will also be encouraged to raise your questions and to share in the development of the right answers using your analysis and experiences. Tests of the multiple-choice type will be made available daily to examine the effectiveness of delivering the course.

Very useful Course Materials will be given.

30% Lectures
30% Workshops and work presentation
20% Group Work& Practical Exercises
20% Videos& General Discussions

Course Details