Certified Petroleum Pump System and Refinery Plant Operator

Why Select this Training Course?

The Certified Petroleum Pump System and Refinery Plant Operator course is meticulously crafted to meet the pressing demands of an energy landscape that combines tradition with technological innovation. Operators are the lifeblood of petroleum refineries, and this intensive course is designed to dramatically enhance operational competencies, ensuring graduates are equipped to excel in contemporary and future refinery environments.

What does the course offer in pump systems?

Practical workshops allow for hands-on experience with the latest pump technologies, such as intelligent control systems and predictive maintenance tools. These sessions will not only demonstrate operation but delve into troubleshooting and efficiency optimisation.

What strategies from the course enhance refinery plant operations?

You’ll engage with industry experts to understand not just the mechanical workings but also the strategic thinking behind successful plant management. This includes studying resource allocation, downstream processing efficiency, and advanced safety protocols.

Who Should Attend?

• Pump system operators in the oil and gas industry
• Maintenance engineers and supervisors in petrochemical plants
• Refinery plant managers and operators
• Safety officers and environmental managers in petroleum refineries
• Process and chemical engineers seeking specialised knowledge in petroleum pump systems

What are the Course Objectives?

• To gain comprehensive knowledge of modern pump system operations
• To enhance technical skills in refinery plant optimisation
• To deepen understanding of safety and environmental practices within refineries
• To equip participants with problem-solving abilities for complex operational challenges
• To ensure up-to-date knowledge on the latest industry trends and technologies

How will this course be presented?

The course combines theory and practical experience:

• Lectures on theoretical principles by industry experts
• Real-world case study analyses
• Hands-on training with simulation models and actual equipment
• Collaborative project work and group discussions
• Site visits to leading refinery operations (where possible)

What are the Topics Covered in this Course?

Module 1: Advanced Pump Technology and Systems

• Centrifugal and positive displacement pump selection
• Hydraulic system design and pump performance curves
• Advanced sealing systems and bearings
• Integration of pump monitoring and control technologies
• Diagnostics, maintenance, and reliability engineering of pump systems
• Energy efficiency measures and system optimisation
• Troubleshooting common pump issues
• Environmental and safety considerations in pump systems

Module 2: Fluid Dynamics and Thermodynamics

• Principles of fluid mechanics in petroleum refining
• Heat transfer and energy conservation in refining processes
• Understanding thermodynamic cycles within pump systems
• Key principles of phase equilibria and separations technology

Module 3: Refinery Safety Practices

• Implementing and maintaining a safety culture
• Key regulations and compliance requirements
• Emergency response protocols and disaster management

Module 4: Crude Oil Distillation and Processing Techniques

• Atmospheric and vacuum distillation operations
• Catalytic cracking, reforming, and treatment processes
• Principles of fluid coking and delayed coking
• Distillate hydrotreating and hydrocracking
• Solvent extraction and dewaxing techniques
• Alkylation and isomerisation process insights
• Tail gas treatment and sulphur recovery
• Integrating petrochemical operations within refineries

Module 5: Corrosion Control and Material Science

• Corrosion mechanisms and prevention strategies
• Advanced materials and alloys for enhanced corrosion resistance
• Non-destructive testing (NDT) methodologies
• Application of corrosion inhibitors and protective coatings
• Cathodic protection systems and their maintenance

Module 6: Digitalisation and Automation in Refinery Operations

• Adoption of Industry 4.0 technologies in refineries
• Digital twinning and its operational advantages
• The role and deployment of robots and drones
• Data analytics for process optimisation
• Integration of refinery information management systems (RIMS)
• The impact of artificial intelligence (AI) and machine learning on operations
• Blockchain for supply chain management and security
• Modern SCADA systems for enhanced plant control
• Cybersecurity measures for critical infrastructure

Module 7: Environmental Management and Compliance

• Environmental impact assessments (EIAs)
• Modern waste treatment technologies
• Air quality management and emission controls
• Water usage, treatment, and recycling techniques
• Implementing environmental management systems (EMS)
• Compliance with local and international environmental regulations
• Developing a carbon footprint reduction strategy
• Sustainable practices and renewable energy integration

Module 8: Maintenance, Reliability, and Equipment Lifecycle Management

• Developing effective maintenance schedules
• Reliability-centred maintenance (RCM) strategies
• Asset integrity management and condition monitoring
• Lifetime extension methods for refinery equipment
• Turnaround management for large-scale refinery operations
• Lean principles in refinery maintenance

Module 9: Economic Aspects of Refinery Operations

• Cost estimation and control in refinery processes
• Economic analysis of new technologies integration
• Efficiency-driven operational budgeting

Module 10: Future Trends in Petroleum Refining

• Renewable energy sources and bio-refineries
• Implications of electric vehicles on refinery production
• Future policies and their impact on the oil and gas sector

Module 11: Advanced Instrumentation and Control Systems

• The role of sensors and actuators in process control
• Advanced process control (APC) strategies
• Distributed control systems (DCS) vs Programmable logic controllers (PLC)
• Integration of wireless instrumentation networks
• Real-time data acquisition and control loop tuning
• Alarm management and fault diagnosis systems
• Human-machine interface (HMI) design and ergonomics
• Ensuring the cybersecurity of control systems

Module 12: Refinery Planning and Turnaround Management

• Strategies for effective refinery planning and scheduling
• Turnaround philosophy and lifecycle approach
• Critical path method (CPM) for turnaround projects
• Shut down management and execution best practices
• Turnaround safety management and contractor control
• Cost-saving strategies for turnarounds
• Post-turnaround analysis and performance measurement
• Innovative tools and technologies driving turnaround efficiency

Module 13: Energy Management and Efficiency Optimisation

• Industry standards for energy performance, such as ISO 50001
• Best practices for energy audit and benchmarking in refineries
• Fuels and combustion efficiency techniques
• Heat exchanger network (HEN) analysis and optimization
• Energy recovery systems and waste-heat utilisation
• Energy management systems (EMS) and integration of renewable energy
• Greenhouse gas (GHG) reduction strategies
• Role of energy efficiency in corporate sustainability

Module 14: Process Modelling and Simulation

• Use of process simulators for design and analysis
• Dynamic simulation for operator training and process improvement
• Case studies on simulation-driven process enhancements
• Predictive modelling for yield and quality control
• Heat and mass balance calculations using simulation software
• Advanced applications: real-time optimisation (RTO) and closed-loop simulation
• Process intensification via simulation studies
• Embracing digital twins for real-time asset management