Oil and Gas Process Troubleshooting and Problem Solving

This course provides the participants with the means to properly operate and support the facilities of process operations in a way based on the good acquaintance with the modern technologies applied in this field. Trouble‐shooting & forecasting break downs are inclusive.

Audience

This course is intended for professionals working in risk management, process safety, operations, and safety leadership roles, including:

Petroleum refining engineers ,
Chemist who interest in oil and gas industry
Mechanical engineers.
Operators in oil and gas industry ( refining, gas processing, oil treatment , oil production
Operators in petrochemicals and fertilizers refining, gas processing, oil treatment , oil production
Supervisors in oil and gas industry refining, gas processing, oil treatment , oil production
Supervisors oil and gas industry refining, gas processing, oil treatment , oil production

Course objectives

To enhance the delegate knowledge, skills, and abilities necessary to give him some practical exposures to help maintain the facilities of process operations in good operational conditions and cope with the emergency cases of breakdown

By the end of this course, participants will be able to:

Monitor instrumentation and the operation of equipment.
To detect potential and actual problems and take corrective action to prevent the interruption of system operations.
To analyze operational trends and take corrective actions.
To use standard operating procedures to start/stop production equipment
Define troubleshooting.
Identify the steps of troubleshooting.
Understand the process of elimination

Course contents

Day-1:

Characterizing Hydrocarbon

Single-Component Systems
Two-Component Systems
Three-Component Systems
Multicomponent Systems
Classification of Reservoirs and Reservoir Fluids
Phase Rule
PVT Properties of Crude Oils
Crude Oil Gravity
Specific Gravity of the Solution Gas
Crude Oil Density
Crude Oil API
Effect of pressure on API
Effect of temperature on API
Effect of GOR on API
Bubble-Point Pressure
Oil Formation Volume Factor
Crude Oil Viscosity

Basic process Concepts

Basic Concepts to remember
Introduction to Base Oil Refining
Flow diagrams
Piping and Instrumentation Diagrams (P&IDs)
Process equipment
Introduction to mass and energy balances

Introduction to Plant troubleshooting

Definition of troubleshooting.
Steps of troubleshooting.
Identify the problem.
Determine the cause of the problem.
Correct the problem.
Return the process to service.
Sources of information.

Day-2:

Process Plant And Machinery Specific Issues

Process Plant and Machinery Commissioning
Instrumentation and Control Systems
Preparing and Isolating Process Plant

Centrifugal pumps Operating

Operating characteristics
Priming, cavitation
NPSH, NPSH margin
Power requirement for pumping
Pump performance curves
Head – capacity curve [H – Q]
Power – capacity curve [P – Q]
Efficiency – capacity curve [η – Q]
Specific speeds
Operating point of centrifugal pump

Compressor working principles, types, operational aspects

Classification, Types of compressors
Operational principles and constructional features
Compressor operation
Performance characteristics curves
Minimum and maximum flow, constraints
Surge, significance and control
Compressor selection and specification, criteria for drive rating selection
Performance testing
Standards and acceptance criteria for performance testing

Day-3:

Fluid Flow

Pressure and Head
Bernoulli’s Theorem
Flow of Liquids
Reynolds number, pressure drop in pipes
Compressible flow
Introduction to Thermodynamics
Principle of process relief devices and process design of relief systems
Two-phase and Multi-phase Flow

Basic Boilers and Facility Auxiliaries

Steam Boilers
Boiler Systems
Steam System Fittings
Steam System Accessories
Feedwater Systems
Water Treatment
Combustion Equipment
Fuels and Combustion
Combustion and Boiler Controls
Draft Systems
Instrumentation and Control Systems
Steam Boiler Operation

Heat exchangers troubleshooting

Thermal conductivity
Conduction and convection
Insulation
Heat transfer coefficients
Heat exchangers, type and sizing
Heat exchangers troubleshooting

Day-4:

Fluid measurement and instrumentation:

Liquid and gas metering using positive displacement meters
Orifices
Sonic meters
Mass measurement meters
Three phase flow measurement
New metering devices

Troubleshooting Of Process Control

Introduction
Open loop system
Closed loop system
Fundamentals of process control
On – off controller
Description of key points in the operation of control systems like: DCS, PLC, UPS, SCADA, etc.
Process Control Troubleshooting
Fail safe

Pipe line valves

Introduction to valves
Various types of valves
Gate
Expanding gate
Plug
Ball
Check
Valve Maintenance

Operational Safety

Roles and Responsibilities
Routine Operations
Operating within Process and Equipment Limits
Written Procedures
Communication
Communication during Shift Changes
Special Safety Considerations of Batch Processes
Standby Operations
Emergency Operations
Management of Change
Safety Protective Systems
Safety Shutdown Systems
Pressure Relief Equipment
Training
Incident Investigation
Recognizing and Reporting Incidents
Investigation Results and Followup
Human Factors
Human-process Interfaces
Behavioral Issues
Audits, Inspections, Compliance Reviews
Accident Investigation
Accident Reporting & Recordkeeping
Working safely in confined spaces
Hazardous (classified) locations
Risk management process

Day-5:

Hydrogen Sulfide and Propane

Intro to OSHA. OSHA & API regulations specific to H2S
Chemical and Physical Properties
Occupational Exposure Limits
Health Hazards
Respiratory Protective Equipment
Detection of gas
Initial Response Strategy

Start- Up Troubleshooting

Technical Issues, Solutions, Implementing Changes, Introduction
to troubleshooting procedures and techniques, Troubleshooting
during start-up, Technical Issues and solutions,
Problem Analysis, Practical Use of Tools and Techniques, Developing
Troubleshooting and Problem Solving skills, Implementing
Changes, Start- up and process simulation (Hands-
On Demonstration) Shutdown and Decommissioning, Case
studies discussions

Shutdown and Decommissioning

Normal Shutdown, Decommissioning and demolition, Case

Shopping cart