Course Details

This course is appropriate for a wide range of professionals but not limited to:

• Operations and process plant operators
• Field and control room technicians
• Maintenance personnel involved in operations
• Junior process and mechanical engineers
• HSE professionals working closely with operations
• New graduates and trainees in oil, gas, and petrochemical plants
• Anyone involved in plant operations or supervision

• Expert-led sessions with dynamic visual aids
• Comprehensive course manual to support practical application and reinforcement
• Interactive discussions addressing participants’ real-world projects and challenges
• Insightful case studies and proven best practices to enhance learning

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

• Understand the basic components and flow of process facility systems.
• Operate and monitor major equipment and utility systems effectively.
• Apply standard operating procedures (SOPs) and emergency shutdown procedures.
• Interpret process control systems and instrumentation.
• Identify potential operational problems and troubleshoot effectively.
• Promote safety, reliability, and environmental compliance in daily operations.
• Integrate maintenance and operations activities for plant efficiency.

DAY 1

Introduction to Process Facility Operations

• Welcome and introduction
• Pre-test
• Overview of process industries: Oil, Gas, Petrochemical, Chemical
• Key components of a process facility
• Process flow diagrams (PFDs) and piping and instrumentation diagrams (P&IDs)
• Process fluids and their properties
• Basic principles of heat, flow, and pressure
• Facility layouts and operating philosophies

DAY 2

Major Equipment and Systems

• Pumps: types, operations, and troubleshooting
• Compressors and turbines
• Heat exchangers and furnaces
• Separators and vessels
• Valves, pipelines, and utility systems
• Start-up and shutdown procedures for equipment

DAY 3

Process Control and Monitoring

• Control loops and instrumentation basics
• Process control systems (DCS, PLC, SCADA)
• Monitoring tools and operator interfaces
• Alarm management and interpretation
• Normal, abnormal, and emergency conditions
• Process optimization basics

DAY 4

Safety, Environment, and Emergency Handling

• Process safety management (PSM) overview
• Hazard identification and risk analysis (HAZOP, HAZID)
• Permit to work (PTW) system
• Emergency shutdown systems (ESD)
• Firefighting and gas detection systems
• Environmental compliance and waste management

DAY 5

Operations Excellence and Troubleshooting

• Key performance indicators (KPIs) for operations
• Common plant problems and case studies
• Routine inspections and checklists
• Integration with maintenance and reliability
• Communication and teamwork in operations
• Course wrap-up, and Q&A
• Post-test
• Certificate ceremony