Course Details

Objective

By the end of the course, participants will be able to understand

• Understand the basic principles of petrochemical processes.
• Operate, monitor, and control critical equipment in petrochemical plants.
• Implement safety measures and respond effectively to emergencies.
• Troubleshoot and diagnose common operational problems.
• Perform routine plant maintenance tasks and ensure compliance with operational standards.

Content

Day 1: Introduction to Petrochemical Plants & Process Fundamentals

• Overview of petrochemical industry and plant operations
• Types of petrochemical products (e.g., polymers, fertilizers, fuels)
• Key processes in a petrochemical plant (distillation, cracking, polymerization)
• Introduction to process flow diagrams (PFDs) and piping & instrumentation diagrams (P&IDs)
• Basic plant equipment: pumps, compressors, reactors, heat exchangers

Day 2: Operating Principles & Control Systems

• Control systems in petrochemical plants (DCS, SCADA, PLCs)
• Process monitoring: measurements and sensors
• Understanding process variables: pressure, temperature, flow, level
• Control strategies for maintaining stable operations
• Operator’s role in process optimization and troubleshooting

Day 3: Safety, Environmental Considerations & Emergency Response

• Safety principles: HAZOP, PSM, and risk assessments
• Personal Protective Equipment (PPE) and safety gear
• Emergency shutdown systems and procedures
• Fire, gas detection, and leak prevention systems
• Environmental regulations and waste management in petrochemical plants

Day 4: Troubleshooting & Maintenance Procedures

• Identifying common operational problems in petrochemical processes
• Diagnostic tools and techniques for troubleshooting
• Routine maintenance procedures for critical equipment
• Preventive maintenance vs. corrective maintenance
• Effective communication with maintenance teams and supervisors

Day 5: Plant Optimization & Operator Best Practices

• Performance monitoring and KPIs for operators
• Operational efficiency and energy management
• Preventing and minimizing downtime
• Operator best practices for safety, efficiency, and team collaboration

NOTE:

Pre-& Post Tests will be conducted.

Case Studies, Group Exercises, Group Discussions, Last Day reviews, and assessments will be carried out.

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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