Heat exchange: exchange mechanisms, resistance to heat transfer.
Liquid-vapor equilibrium of pure substances and mixtures.
Simulators: impact of operating parameters on the chemical reaction performances, heat exchanges through various types of heat exchangers, separation in a flash drum.
PROCESS CONTROL, AUTOMATION & DCS USAGE
Process control:
Constitution of a control loop, symbols used. Sensors and transmitters. Control valves.
Controllers operating principles, inputs/outputs, internal parameters, and tuning.
Complex control loops (cascade, split range, multiple calculation blocks). Advanced control basics.
Simulators: Valves characteristic curves. PID parameters tuning. Heat exchanger duty control. Split range configuration. Behavior analysis of complex control loops.
Distributed Control System (DCS):
Architecture and system components. Man-Machine Interface (MMI). Trends tools. Information flux between site and control room.
Automation:
Safety instrumented systems: PSS, ESD, HIPPS, EDP; architecture and relationship with DCS. Safety logic and cause & effect matrix.
PLCs and automation: graft analysis, the study of specific sequences.
Simulators: furnace safety logics.
EQUIPMENT OPERATION
For each: working principles, technology, ancillary systems, process control scheme monitoring, operation, alarms, safety devices.
Pumps, compressors, drivers:
Simulators: filters switch, operation of pumps; changes in operating conditions, capacity control of compressors, troubleshooting of a compressor; start-up of a steam turbine driven centrifugal compressor.
Thermal equipment: heat exchangers, air coolers, furnaces, boilers:
Simulators: fouling of a heat exchanger; changing fuel supplied to burners, coil fouling, start-up and shutdown of a furnace.
Specific equipment for a given assignment unit (gas turbines, solid handling, extruders…).
PRODUCTS & PROCESSES
Composition and Physico-chemical properties of feeds and products.
Commercial product quality requirements, specifications, and standard tests. Mixing rules.
Process units: role, principles, main equipment, specific hazards. Influence of the main operating parameters on the operation, consequences on process, and products. Material balance.
Distillation, absorption, stripping.
Utilities: flare systems, air production, effluent treatment units, steam, water treatments…:
Simulators: start-up and shutdown, operation and control of various process units (for instance: two-product distillation columns, multi draw-off distillation column, amine absorption, and regeneration, sulfur recovery unit, hydrotreatment unit).
INTEGRATED PLANT SAFE OPERATION
Panel operator safe behavior:
Radio communication, other communication equipment. Teamwork, responsibility sharing. Transmission of know-how.
Global performances, margin optimization/impact of quality gaps.
Identification, analysis and reaction to upsets and equipment failures; stabilization.
Simulators: field round on a running process unit; commissioning, start-up and shutdown procedures, justifications of different steps; inhibition management; operations in downgraded situations; practice of emergency operations.
ASSESSMENT
Continuous assessment (including practical exercises on simulators).
Final test with real-life situation simulation exercises to validate objectives.
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