Course Objectives

To gain a detailed understanding of the techniques used in troubleshooting in Oil Refineries.

Course Description

This course will cover the practical applications of distributed control systems. Included is the relationship between programmable logic controllers and the DCS. Further included is the importance of Human Computer Interfaces (HMI) and advanced control strategies, which would not be possible without the application of a computer. This course is non-specific but will include a number of manufacturers DCS systems, such as Honeywell TDC rage. Each delegate will receive a comprehensive course manual. The concept of field buses is introduced with some study of Foundation of assets management as a tool for proactive maintenance systems.

Who Should Attend

This course is intended for engineers and technicians requiring knowledge of automation and distributed control. A section on trouble shooting methods is also included. Personnel in operations will also find this an invaluable course.

Pre-Requisites

All Attendees should have a sound power generation and electrical background.

Course Outcome

At the end of this course you will be able to troubleshoot in oil refineries.

Course Outline

Day 1

• Introduction
• Introduction to Troubleshooting
  • Basic Understanding of Troubleshooting
  • Understanding the Types of Problems That Could Occur
  • First steps to be taken in the event of a problem occurring
  • Unusual Noises & Vibrations, Rotating Equipment, Cavitating Pumps,
  • Oversized Pumps, Harmonic Vibrations, Thumping Furnaces,
  • Hydrocarbon Leaks, Water Hammer etc
  • Crude Distillation
  • Atmospheric & Vacuum

Day 2

• Introduction to Troubleshooting
  • Distillation Columns
  • Stripping Columns
  • Tray Fouling
  • Reflux Changes
  • Common Reflux Problems
  • Reflux Rates
  • Operating Parameters
  • Flooding
  • Foaming
  • Identifying Causes
• Reboiler Induced Foaming & Flooding
  • Amine Regeneration & Scrubbing
  • Dirty Amine
  • Reboiler Corrosion
  • Reclaimer Operation
  • Foaming in Scrubbers
  • Loss in Amine Strength
  • Poor Sweetening
  • H2S and Sulphur Recovery
  • Finding Lost Conversion
  • Start-Up Tips
  • Increased Pressure Drop
  • Maximising Plant Capacity

Day 3

• Refrigeration Systems
  • Compressor Problems
  • Refrigeration Compressor Adjustments
  • Evaporator Accumulator Drum
  • Condenser
• Centrifugal Pumps
  • Rough Running
  • Pump Motors
  • Cavitation
  • Capacity Decrease
  • Alarms & Trips
  • Steam Turbines
  • Liquid Levels
  • Pressure
  • Temperature Shutdowns
  • High & Low Flow Trips
  • Elimination of Unnecessary Trips

Day 4

• Vapour/ Liquid Separation
  • Detection of Foaming
  • High Liquid Levels
  • Entrainment
  • Rapid Depressurisation
  • Demisters
• Water Coolers
  • Plugged Tubes
  • Hydrocarbon Leaks
  • High Exchanger Water Outlet Temperatures
  • Water Side Fouling
  • Understanding the Unit Process Control Systems
  • Set Points
  • Auto/ Manual
  • Cascade Control
  • Master & Slave Controls
  • Instrument Air Systems

Day 5

• Process Heaters
  • Insufficient Draught
  • Excessive Draught
  • Controlling Air Supply
  • Energy Saving Ideas
  • Hot Tubes
•  Course Review and Feedback

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