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Process Control for Production Operators

Introduction

Process Control for Production Operators

Objectives

Upon the successful completion of this course, each participant will be able to:-

• • Apply the latest methodologies of managing production operations
  • Optimize plant location and layout including capacity planning
  • Measure and improve productivity
  • Manage meetings and teams, solve problems and make correct decisions
  • Create an environment of self-motivation 
  • Recognize the different service systems and their special characteristics
  • Carry out performance appraisals and ensure a positive mutually acceptable outcome
  • Apply the method of line balancing and production capacity planning
  • Use benchmarking as an improvement tool
  • Implement the methodology of continuous business improvement and practice the various techniques of improvement including cause-and-effect diagrams, scattered diagrams, process maps, input-output analysis, Pareto diagrams, and why-why analysis
  • Measure, control, improve and manage performance in their plant

Who Should Attend?

This training course is suitable for a wide range of professionals, but will greatly benefit:

• Petroleum Engineers
• Maintenance & Production Engineers
• Process Engineers 
• R&D Chemists, Plant Chemists
• Economists & Business Managers

Course Outline

Day 1: PROCESS ENGINEERING FUNDAMENTALS

• Introduction
• Basic Concepts to remember
• Flow diagrams
• Piping and Instrumentation Diagrams (P&IDs)
• Process equipment
• Introduction to mass and energy balances
• Batch vs Continuous
• Risk Assessments and Hazard Studies
• Flammability and Electrical Area Classification
• Workshop Session

Day 2: FLUID FLOW

• Pressure and Head
• Bernoulli’s Theorem
• Flow of Liquids
• Reynolds number, the 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
• Pumps and Compressors
• Mixing and Mixers

Day 3:  HEAT TRANSFER

• Thermal conductivity
• Conduction and convection
• Insulation
• Heat transfer coefficients
• Heat exchangers, type and sizing
• Chemical reactions
• Reaction kinetics
• Introduction to catalysis and Green Chemistry

Day 4: INTRODUCTION TO SEPARATION PROCESSES

• Distillation basics
• Phase behavior and vapor/liquid equilibria
• Distillation Equipment
• Distillation Troubleshooting
• Gas/Liquid separation
• Absorption and adsorption
• Solid Liquid separation
• Air and water pollution control
• Effluent treatment

Day 5: PROCESS CONTROL & ECONOMICS BASICS

• Measured variables
• Simple feedback control
• SIS and SIL
• Process Utilities
• Air
• Water and cooling water
• Steam
• Electricity and power generation
• Process Economics
• Preliminary economic analysis
• Fixed and variable costs, break-even
• Calculating raw materials usage
• Scale-up and six-tenths rule
• Estimating the cost of process equipment and plants