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Refinery Foremen Training Course

50 jours OPE/MTRAF-E
Niveau
Perfectionnement
Public
  • Foremen, shift leaders, panelists and technicians (maintenance, inspection, laboratory, analysis, research department), with no previous vocational certificate.
Finalité
  • 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.
Objectifs
  • 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.
Pré-requis
  • Knowledge of the group of units in charge, including field and panel activities.
Les + pédagogiques
  • 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 jours
  • 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 jours
  • 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 jours
  • 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 jours
  • 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 jours
  • 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 jours