Course Overview
This training program provides refinery operators and supervisors with comprehensive knowledge and practical skills for the safe and efficient operation of major refinery static and rotating equipment.
The course blends theoretical understanding, operational guidelines, safety practices, and real case studies aligned with refinery industry standards.
Target Audience
- Field Operators
- Panel Operators
- Operations Shift Supervisors
- Operations Engineers
- Maintenance Supervisors (optional)
Course Objectives
Upon completion, participants will be able to:
- Understand the principles and configurations of refinery equipment
- Carry out safe startup, normal operation, shutdown, and emergency handling.
- Identify abnormal conditions and implement corrective actions.
- Monitor and interpret key operating parameters.
- Improve equipment reliability through proper operating practices.
- Ensure compliance with safety standards and refinery procedures.
Course Outlines:
Module 1: Fired Heaters
- Fundamentals
- Heater types
- Draft systems, burners, fuel trains
- Radiant & convection sections
- Tube metallurgy, coking mechanisms
1.2 Operation
- Startup/shutdown procedures
- Draft & excess O₂ control
- Flame monitoring
- Coil outlet temperature optimization
1.3 Safety & Troubleshooting
- Hot spots and tube rupture prevention
- Burner malfunctions
- Emergency heater trip handling
- Case studies of past incidents
Module 2: Air Coolers
- Basics
- Forced vs induced draft
- Fans, louvers, dampers
- Fouling and cleaning requirements
2.2 Operation
- Fan startup and shutdown
- Air flow & temperature control
- Vibration and noise monitoring
2.3 Troubleshooting
- Poor cooling performance
- Motor/electrical issues
- Tube leakage detection
Module 3: Heat Exchangers
- Types & Construction
- Shell & tube, plate, fin-fan, spiral
- Flow arrangements
- Fouling mechanisms
3.2 Operation
- Monitoring temperature profiles
- Identifying heat transfer degradation
- Safe isolation and bypass practices
3.3 Troubleshooting
- Tube leaks/cross-contamination
- High pressure drop
- Bundle issues and inspection methods
Module 4: Pumps
- Fundamentals
- Centrifugal vs positive displacement
- Cavitation and NPSH
- Seals, bearings, alignment basics
4.2 Operation
- Startup/shutdown
- Duty/standby pump changeover
- Seal flush system monitoring
4.3 Troubleshooting
- Cavitation, vibration, overheating
- Loss of prime
- Seal leakage
Module 5: Compressors
- Types & Components
- Centrifugal & reciprocating compressors
- Anti-surge systems
- Lube oil, seal oil systems
5.2 Operation
- Startup and shutdown
- Load control
- Performance monitoring
5.3 Troubleshooting
- High vibration
- Surge events
- Temperature rise and seal failures
Module 6: Pressure Vessels
- Fundamentals
- Types of process vessels
- Internal components (trays, packing, demisters)
- MAWP and design requirements
6.2 Operation
- Monitoring internal performance
- Level/pressure/temperature control
- Safe vessel entry preparations
6.3 Safety
- Overpressure scenarios
- PSV roles & inspection cycles
- Handling leaks or vessel abnormalities
Module 7: Valves
- Types & Functions
- Gate, globe, ball, plug, check valves
- Control valves & actuators
7.2 Operation
- Proper valve handling
- Stroke testing
- Valve isolation and LOTO
7.3 Troubleshooting
- Sticking, leakage, actuator failures
- Cavitation and flashing
8. Practical / Hands-On Sessions (Optional)
- Heater operation simulation
- Pump changeover practice
- Compressor start/stop logic demonstration
- Heat exchanger fouling analysis
- Fault identification using photos/video evidence