Day-1:

1. Introduction

• Basic Concepts to remember
• Properties of produced fluids
• Production Surface Facilities
• Flow diagrams
• Piping and Instrumentation Diagrams (P&IDs)
• Process equipment
• Introduction to mass and energy balances
• Risk Assessments and Hazard Studies
• Flammability and Electrical Area Classification
• Workshop Session

2. 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

Day-2:

3. LINE SIZING CRITERIA

• Design Basis
• Sizing of Liquid Lines
• Sizing of Gas Lines
• Sizing of Gas/Liquid Two-or Multi-Phase Lines
• Sizing of Gas Relief Lines
• Maximum allowable velocities due to reaction forces

4. Separation / treating:

• Two and three phase separation
• Free water removal
• Treatment of emulsions
• Hydrate prevention and treatment
• Vapor recovery
• Gas conditioning for sales

5. Heat Transfer

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

Day-3:

6. 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

7. Control systems

• Introduction
• Main process variables in the refinery
• Control of refinery process
• Open loop system
• Closed loop system
• Fundamentals of process control
• The feedback control loop
• On – off controller
• Proportional controller
• Proportional &integral controller
• Proportional &integral & derivative controller
• Description of key points in the operation of control systems like:  DCS, PLC, UPS, SCADA, etc.
• Logic, integration and loops in control systems.
• Control system response and best practices in ESD.
• Key points in emergency response action plan (ERAP).
• Identification of control systems’ discrepancies.
• Monitoring and evaluation of equipment performance.
• Complex and detailed root cause analysis both within and outside the GC.
•  Optimization of corrective actions.
• Advanced control techniques
• Fail safe

Day-4:

8. Operational Responsibility for 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
• Process Control Software
• Nonroutine Operations
•  Abnormal Operations
• Standby Operations
• Emergency Operations
• Management of Change
• Safety Protective Systems
• Safety Shutdown Systems
• Pressure Relief Equipment
• Operator Training
• Refresher Training
• Playing “What-if” Games
• Incident Investigation

Day-4:

• Recognizing and Reporting Incidents
• The Investigation
• Investigation Results and Followup
• Human Factors
• Human-process Interfaces
• Behavioral Issues
• Spontaneous Response
• Audits, Inspections, Compliance Reviews
• Accident Investigation
• Accident Reporting & Recordkeeping
• Working safely in confined spaces
• Hazardous (classified) locations
• Risk management process