At the end of this course participants will be able to:

• Examine the major components of a common PLC system
• Interpret PLC specifications
• Apply troubleshooting techniques
• Convert conventional relay logic to a PLC language
• Operate and program a PLC for a given application

• PLC hardware
• I/O signals and modules
• Memory mapping and addressing
• Programme upload & download procedures and precautions
• Ladder programming
• Case studies and examples in applying PLC from different manufactures
• Installation and practical aspects

Day 1

PLC Hardware

• Introduction to PLC functions
• PLC types
• PLC architectures
• Redundancy

Day 2

I/O signals and modules

• Digital contact/voltage modules
• Digital sinking/sourcing modules
• Analogue 4-20 mA modules
• Analogue hart-field bus modules

Day 3

Memory Mapping and Addressing

• I/O addressing
• Software contact, relays, times, and counters allocation in memory

Day 4

Programme Upload & Download Procedures and Precautions

• Ladder Programming
• Timers’ instructions
• Counters’ instructions
• Comparison instructions
• Moving instructions

Day 5

Case Studies and examples in applying PLC from Different Manufactures

• Installation and Practical Aspects
• PLC sizing and selection
• Safety considerations
• Installing in hazard industries
• Power supply

At the end of this course participants will be able to:

• Understand the heat transfer modes
• Know the function of heat transfer equipment
• Identify the types of heat exchangers and know their components
• Know testing procedures of heat exchangers for leaks
• Identify the heat transfer equipment problems and how to troubleshoot them
• Have informed techniques & hands-on experience with heat transfer equipment
• Understand maintenance, safety and inspection of heat transfer equipment

• Typical process heating & cooling applications
• Fluid properties
• Heat transfer principles
• Shell and tube exchangers
• Compact heat exchangers
• Brazed aluminum exchangers
• Air coolers
• Fired equipment (furnace type & fire-tube)
• Operating problems

Day 1 and 2

Principles of Heat Transfer

• Heat transfer thermodynamics
• Conduction heat transfer
• Convection heat transfer

Types of Heat Exchangers: Parts and Operations

• Shell and tube exchangers
• Double pipe exchangers
• Air-cooled exchangers
• Plate heat exchangers

Types of Evaporators: Parts and Operations

• Horizontal tube film
• Vertical falling film
• Forced circulation
• Combined with hybrid systems

Types of Condensers: Parts and Operations

• 4-1 Air-cooled condensers
• 4-2 Water- cooled condensers
• 4-3 Evaporative condensers

Day 3 and 4

Types of Refrigerators: Parts and Operations

• Vapor compression refrigeration system
• Vapor absorption refrigeration system

Types of Furnaces: Parts and Operations

• Electric furnaces
• Gas furnaces
• Gravity furnaces
• Oils furnaces

Day 5

• Heat Transfer Equipment Troubleshooting
• Safety & Inspection Maintenance of Heat Transfer Equipment

At the end of this course participants will be able to:

• Identify PLC control hardware and installation criteria
• Examine PLC software structure
• Write medium level PLC programs (using ladder logic)
• Troubleshoot a typical PLC control system
• Examine SCADA and PLC control systems
• Know the essentials of SCADA software configuration
• Identify tips and tricks in installation of SCADA control systems
• Know the essentials of telecommunications links
• Identify the use of industrial ethernet in SCADA systems
• Examine PLC and SCADA systems
• Understand SCADA network security issues
• Troubleshoot SCADA control systems

• SCADA control overview
• Fundamentals of PLC control software
• SCADA control systems’ software
• Good programming habits
• Human Machine Interfaces (HMIS)
• Advanced control with PLC
• Landline media
• Introduction to IEC 61131-3
• Building a PLC panel, as well as general commissioning, testing and upgrading
• Industrial communications protocols

Day 1

Introduction

• Purpose
• Scope
• References
• Currency
• SCADA Control Overview

Day 2

Fundamentals of PLC Control Software

• General control
• Discrete control
• Analog control
• Classes of analog controllers
• Control loops
• Type of controllers

Day 3

SCADA Control Systems’ Software

• Supervisory control
• Process control
• Field instrumentation control

Day 4 and 5

Good Programming Habits

• Human Machine Interfaces (HMIS)
• Advanced control with PLC
• Landline media
• Introduction to IEC 61131-3
• Building a PLC panel, as well as general commissioning, testing and upgrading
• Industrial communications protocols

At the end of this course participants will be able to:

• Understand the fundamentals of architecture and operation of Distributed Control Systems
• Know key ergonomic issues in the design of operator displays
• Apply advanced control strategies to the existing plant control system
• Make more effective use of the existing DCS process control capabilities
• Recognize and deal with human problems in interfacing to alarm systems
• Know tricks and tips in installation and use of industrial ethernet in DCS systems

• Introduction
• Summary of typical distributed control systems
• DCS versus SCADA versus PLCs
• DCS elements
• Data communications in DCS
• Programming of DCS
• The operator interface
• Distributed Control System reporting
• Distributed Control System configuration

Day 1

Introduction

Summary of Typical Distributed Control Systems

DCS versus SCADA versus PLCs

• Comparison
• The smart instrument; the main component in a Distributed Control System

DCS Elements

• Main difference between a DCS and SCADA/PLC system
• Requirement of the operator interface within DCS
• Redundancy in the DCS
• Day 2 and 3
• Data Communications in DCS
• Overview of DCS and SCADA
• Network topology
• Foundation fieldbus
• Industrial ethernet
• TCP/IP

Programming of DCS Systems

• Block configuration
• Tips and tricks in programming

The Operator Interface

• The operators’ process “window”
• The various operator display configurations

Day 4 and 5

Alarm System Management for DCS

• Philosophies alarm management
• Human and ergonomic factors
• Safety integrity levels

Distributed Control System Reporting

• Alarm reporting, types of alarms generated
• Data history use in logs and trend displays

Distributed Control System Configuration

• The organization of system data files
• Data configuration procedures

At the end of this course participants will be able to:

• Understand sources of refinery feedstock; crude or synthetic
• Understand the composition of the feeds, their characteristics, desirable properties and selection
• Identify the effects of crude types on a refinery, and how a refinery matches crude composition to product market demand by selection of process units
• Know the fundamentals of individual refinery processes, engineering, materials and construction/operational challenges

• Classification and properties of oil
• Description of the processes
• Desalting of crude oil
• Overview of the distillation process
• Atmospheric distillation of crude oil
• Vacuum distillation
• Introduction to advanced processes
• Process monitoring and control/special safety issues

Day 1

Classification and Properties of Oil

• Paraffin base
• Asphaltic base
• Mix base
• Hybrid base
• API gravity
• Viscosity
• Chemical and physical prosperities

Description of the Processes

• Fractionation
• Conversion process
• Treatment process
• Blending
• Other refinery processes

Day 2

Desalting of Crude Oil

• Dilution water injection and dispersion
• Emulsification of diluted water in oil
• Distribution of emulsion in the electrostatic field
• Electrostatic coalescence
• Water droplet settling
• Overview of the Distillation Process
• Definition
• System components:
• 1 Columns parts
• 2 Trays devices
• 3 Reboilers
• 4 Condensers
• 5 Heaters/coolers
• 6 Pumps
• Description of the distillation process diagram

Day 3 and 4

Atmospheric Distillation of Crude Oil

• Crude distillation
• Crude distillation operation
• Operating difficulties
• Troubleshooting

Vacuum Distillation

• VDU feed/product
• Different types of vacuum distillation
• VDU flow diagram
• Process equipment
• Troubleshooting

Day 5

Introduction to Advanced Processes

• Vice breaking
• Catalytic cracking
• Hydro cracking
• Coking
• Isomerization
• Hydro reforming
• Process monitoring and control/special safety issues

At the end of this course participants will be able to:

• Understand corrosion ramifications in oil production operations
• Recognize the various forms of corrosion attacks
• Carry out a corrosion failure analysis
• Utilize the most appropriate method for corrosion control
• Adopt the most appropriate monitoring techniques
• Utilize information sources

• Corrosion principles and forms
• Corrosion aspects and design
• Cathoding protection
• Corrosion failures, analysis procedures, and samples
• Oil refinery and pipelines

Day 1

Corrosion Principles and Forms

• Overview
• Economics
• Corrosion fundamentals
• Basic corrosion principles
• Forms of corrosion

Day 2

Corrosion Aspects and Design

• Corrosion aspects – oxygen
• Hydrogen sulphide
• Carbon dioxide, bacterial
• Corrosion control – design

Day 3

Cathoding Protection

• Cathodic protection
• Materials selection
• Coatings and linings
• Corrosion management

Day 4

Corrosion Failures, Analysis Procedures, and Samples

• Corrosion failure analysis
• Water chemistry
• Quality assurance
• Corrosion samples

Day 5

Oil Refinery and Pipelines

• Corrosion under insulation
• Pipelines and risers
• Oil refining
• Corrosion films

At the end of this course participants will be able to:

• Understand the basic principles of flow diagrams
• Understand piping & instrument diagrams P&ID, PFD
• Read oil & gas plant piping & instrument diagrams
• Identify the fundamentals of the process control
• Understand control loop systems (opens & closed loop systems)
• Understand basic control systems (pressure, level, temperature, flow, etc 1)1
• Know process control basics and automatic control
• Read interlock logic diagrams

• What is process modeling and process controlling?
• Control strategy and practical examples
• Control loop systems (opens & closed loop systems)
• Process control basics and control valves, and other devices

Day 1 and 2

Piping & Instrument Diagram, P&ID, PFD

• Process engineering fundamentals
• Preliminary engineering drawings PFD, P&ID and PBD P&ID symbols
• Drawing and interpretation for P&ID – valves, transmitters, equipment
• Working with basic design requirements
• Control systems in P&ID:

1. Identifying points of measurement and control
2. Drawing and interpretation P&ID control and safety systems
3. Interpretating basic P&ID with control systems
4. Interpretating a detailed diagram

• Developing P&ID drawing (flow station/production facilities)
• Engineering drawings’ documentation (as-built drawings)

Day 2

What is Process Modeling and Process Controlling?

• Control Srategy and Practical Examples

Day 4 and 5

Control Loop Systems (Opens & Closed Loop Systems)

• Automatic control
• Control and safety valves
• Process Control Basics and Control Valves, and Other Devices

At the end of this course participants will be able to:

• This course presents a comprehensive summary of oil desalting
• systems. For each technique, theoretical and practical aspects
• are discussed in detail; including oil desalting operation,
• equipment and troubleshooting, and separator troubleshooting.
• This course is designed for new process engineers and
• personnel working in operation, troubleshooting and
• maintenance of crude oil dehydration and desalting systems.

• Overview about crude oil origin
• Oil & gas separation
• Crude oil emulsions
• Oil emulsion treatment technology
• Oil desalting systems

Day 1 and 2

Overview of Crude Oil Origin, Chemistry, and its Properties

• Different theories of oil origin
• Chemical components and impurities
• Oil classification

Oil & Gas Separation/Fundamentals of Separation in Vessels

• Separator types
• Factors effecting separation
• 3-two phases separation

Oil & Gas Separator Operation and Troubleshooting

• Inadequate vapor capacity
• Liquid flow capacity
• Pressure drops
• Separation efficiency

Day 3 and 4

Crude Oil Emulsions

• Definition
• Types of emulations
• Emulsion stability and effecting factors
• Measurement of emulsions

Oil Emulsion Treatment Technology and Equipment

• Chemical selection/free-water knockouts
• Gunbarrel tanks/horizontal flow treaters
• Indirect fired heaters/direct fired heaters
• Horizontal heater-treaters/electrostatic heater-treaters

Day 5

Oil Desalting Systems

• Single-stage dehydration
• Single-stage desalters
• Two-stage desalters
• Three-stage desalters
• Typical operating conditions and performance
• Factors that affect desalter operation and performance
• Oil desalter operation and troubleshooting
• Practical Considerations

At the end of this course participants will be able to:

• Select, size and operate oil & gas equipment
• Understand practical equipment sizing methods for major process equipment.
• Apply hydrate prevention techniques
• Select an appropriate storage tank and maintenance

• Basics of fluid flow
• Pressure loses in pipelines
• Valves types and parts
• Separation processes
• Crude oil dehydration & desalting
• Hydrates and hydrates’ prevention techniques
• Glycol dehydration
• Stabilization by pressure reduction
• Distillation
• Storage tanks

Day 1

Basics of Fluid Flow

• Viscocity
• Laminar flow theory
• Turbulant flow

Pressure Loses in Pipelines

• Calculation friction factor

Valve Types and Parts

• Valves types
• Gate valves
• 1-2 Globe and angle valves
• 1-3 Check valves
• Ball valves
• Butterfly valves
• Y-strainer
• Valves parts: body, bonnet, disc, valve trim and seat rings

Day 2

Selection and Application of Valves

• Classification of Valves based on:
• Mechanical motion
• Valve size
• Pressure – temperature rating

Valve Categories

• 2-1 Isolation valves
• 2-2 Regulating valves
• 2-3 Pressure – relief devices

Separation Process: Principles, Terminology, Application & Main Parts

• Separation process
• Thermodynamics of separation operations
• Mass transfer and diffusion
• Single equilibrium stages
• Cascade and hybrid systems

Separation Troubleshooting

• Inadequate vapor capacity
• Liquid flow capacity
• Pressure dop
• Separation efficiency

Day 3 and 4

Crude Oil Dehydration & Desalting

• Free water separation
• Emulsion
• Heater treater
• Electrostatic treater process plant description

Hydrates and Hydrates Prevention Techniques

• Definition
• Chemical structures
• Crystal types of gas hydrate
• Depressurization process
• Thermal stimulation process
• Chemical inhibitor injection process

Glycol Dehydration

• Glycol dehydration plant description and equipment

NGL Recovery Methods

• Single stage turbo expander technology
• Self refrigeration method

Day 5

Stabilization by Pressure Reduction

• Distillation Type Stabilizers; Stabilizer Equipment Operations & Control
• Storage Tanks; Types, Operation Safe Cleaning & Maintenance
• Fixed roof
• Floating roof
• Storage Tanks, Sampling Measurements & Export Systems

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

• Determine water content and hydrate formation conditions.
• Have techniques to prevent hydrate formation1
• Create preliminary designs and evaluation of TEG dehydration
• Control the hydrocarbon dew point of sales gas
• Use techniques to optimize mechanical refrigeration systems
• Use the process simulator for sizing process equipment
• Understand the key principles of gas dehydration and the fractionation process
• Understand the principles of absorption, dehydration, and the sweetening process

• Gas processing systems
• Physical properties of hydrocarbons
• Qualitative phase behavior
• Vapor-liquid equilibrium
• Water-hydrocarbon equilibrium
• Basic thermodynamic concepts
• Separation equipment
• Heat transfer
• Pumps, compressors, refrigeration
• Fractionation/distillation
• Glycol dehydration and absorption systems
• Absorption dehydration and sweetening

Day 1

Introduction

• Fundamental technology
• Basic units of management
• Physical properties

Quantitative Phase Behavior

• Single component systems
• Multi-component systems
• Application of phase envelopes

Vapor-Liquid Equilibrium

• Equilibrium vaporization ratio
• Some conversion calculations
• Product specification

Water-Hydrocarbon Phase Behavior

• Water content of gases
• Water content application
• Gas hydrate
• Hydrate inhibition

Day 2 and 3

Basic Thermodynamic Concepts

• Basic thermodynamics
• Energy balance
• Second law of thermodynamics

Process Control and Instrumentation

• Control objectives and concepts
• Control modes
• Flow and temperature measurement and control

Separation Equipment

• Fabrication specification
• Vapor-liquid – separation
• Three-phase separation

Heat Transfer

• Mechanism
• Basic balance
• Determination of heat exchanger
• Heat exchanger types

Pumps

• General characterization
• Pump types

Day 4 and 5

Compressors

• Compressor power requirements
• Compressors types

Refrigerator Systems

• Ammonia absorption system
• Compression refrigeration
• Expansion turbine refrigeration
• Valve expansion refrigeration

Fractionation and Absorption

• Tray types towers
• Fractionation and control
• Absorption

Glycol Dehydration

• Basic glycol dehydration unit
• TEG regeneration

Absorption Dehydration and Sweetening

• Basic systems
• Nature of absorption
• Liquid dehydration
• Gas and liquid sweetening

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

• Understand the basics of the HAZOP technique
• Fulfill roles as competent HAZOP team members
• Use a risk ranking matrix
• Understand how hazard identification can predict accidents and incidents
• Understand how HAZOP complements other hazard identification tools

• The foreseeability of process accidents
• Overview of hazard identification techniques
• Background to HAZOP
• HAZOP guidewords and parameters
• The basic HAZOP methodology
• Selection of the study node
• Recording the study
• HAZOP recommendations follow-up and sign-off
• Risk ranking methods
• The HAZOP team and its members; team selection
• Setting up a HAZOP study: planning, resources and duration
• Additional features of batch processes
• Other forms of the HAZOP study: procedural, control systems

Day 1

Introduction

• Process safety vs
• Industry metrics

HAZOP Background and Terminology

• Origins of HAZOP
• Explanation of terminology – parameter, deviation, guideword, study node, design intent, etc...

Mechanics of the HAZOP Process

• Application of a deviation to a study node
• Examination of all possible causes
• Evaluation of the consequences of each cause
• Evaluation of the safeguards against each consequence
• Conclusions and recommendations

Day 2 and 3

Causes, Consequences, and Safeguards

• Brainstorming causes
• Logical development and extension of consequences
• Critical assessment of the adequacy of existing hard, soft and procedural safeguards

Recording the Study

• Role of the recorder
• Recording format
• Full and exception recording
• Simultaneous recording and team consensus
• P & I mark up and sign-off

Syndicate Exercise 1

• Selection of study node
• Application of deviations
• Recording syndicates’ findings
• Debrief of syndicates’ HAZOP studies

Other HAZOP Deviations

• Basic 10 deviations
• Additional commonly used deviations

Day 4 and 5

The HAZOP Team

• Members and Responsibilities
• Depth and breadth of experience
• Availability and continuity of the study

Syndicate Exercise 2

• Selection of study nodes
• Application of deviations
• Recording syndicates’ findings
• Debrief of syndicates’ HAZOP studies

Preparing for a HAZOP Study

• When should a HAZOP be undertaken
• P & I drawing status
• Identifying the team
• Supporting documents
• Venue, timing, duration
• Writing HAZOP Recommendations
• Type of recommendations
• Quality of recommendations: what, why, where
• Traceability, follow-up, sign-off

Risk Ranking

• Frequency and consequence matrices
• Ranking recommendations – why, when & who