Categories >> Maintenance

 

Advanced  Refinery Troubleshooting

 

 

 

PROGRAM INTRODUCTION:

The importance of troubleshooting has grown as plants push to operate at higher and higher throughput levels. Consistently maintaining smooth operation, maximum capacity, and acceptable product quality are important goals that can be difficult to achieve. Thus, this training program illustrates general refinery troubleshooting concepts with specific examples. This program has been designed to provide some practical review of the art and science of plant troubleshooting. A case examples study approach covers major processing units found in refineries.

This program represents the essential orientation required to prepare participants for advanced topics of troubleshooting techniques, analysis, and problem solving. Participants will have the opportunity to obtain some working knowledge of troubleshooting principles and practice, to gain insight into major troubleshooting steps should apply to almost any refinery plants process, and to interact with others working in plants. The module also covers the general duties of operation persons for their responsibilities, as team member and refinery representative, in the areas of plant problems, abnormal, and emergency situations.

The Training Program is divided into “Nine Modules” covers major refinery processing units.

This course is designed to help develop trainee skill and confidence. This course is tailored to help and improve trainee’s skill no matter where trainees are in work journey to become an outstanding trouble shooter. There are a number of case studies for describes a wide range of problems that the fault discovered and the corrective action taken.

PROGRAM OBJECTIVES:

Program's Participants will have the opportunity to obtain a broad working knowledge of troubleshooting principles and practice, to gain insight into both traditional and advanced techniques, and to interact with others working in plants. Also, this program has been to give a broader technical understanding of the approach demonstrates the complexity of actual plant operations and how to simplify and identify solvable problems. Finally, better view of the potential origins of troubles and their respective remedies.

Those in attendance will receive a comprehensive manual covering all topics of modules mentioned below. 

PROGRAM OUTLINES:

Module 1: Troubleshooting

• What is Troubleshooting

• Characterization of Troubleshooting Problem

• Similarities Among Troubleshooting Problems

• Differences Between Troubleshooting Problems

• Characterization of the Process used to solve Troubleshooting Problems

• Effective Troubleshooters

Module 2: Two Case Examples of Troubleshooting Problems: 

• The case of the Cycling Column

• The case of the Platformer Fires

Module 3: Crude Oil Desalting Unit Troubleshooting:

• High Salt Content in Desalted Crude

• Water Content of Desalted Crude too high

• Dirty Effluent Water Bleed

• Appreciable Continuous Variations in Voltmeter

• Voltage Continuously too low and weak Burning of Pilot Lights or completely out

Module 4: Crude Distillation Unit Troubleshooting:

• Inadequate Fractionation and Stripping

• Overhead and Reflux Problems

• Preflash Tower

• Tray Capacity

• Reboiler

Module 5: Vacuum Distillation unit troubleshooting:

• Bottom Pump NPSH

• High Flash Zone Pressure

• Ejector Problems

• Transfer-line Failures

• Black Gas Oil and improving its Recovery

Module 6: Troubleshooting of Fluid Catalytic Cracking Unit, FCC:   

•  Cracking Processes

•  Catalyst Steam Stripping

•  Raise Riser Temperature

•  Catalyst Poisoning Effect on Gas Compressor

•  Catalyst Deactivation

•  Reducing Regenerator Temperature

•  Cyclone Malfunctions

•  Catalyst Regeneration Problems

•  Air Blower Problems

Module 7: Troubleshooting of Visbreaking Unit:

• Low Conversion %

• Coke Deposits

• Sulfur Content

• Decoking Problems

Module 8: Troubleshooting of Amine Systems:

• Dirty Amine

• Reboiler Corrosion

• Foaming in Scrubbers

• Reclaimer Operation

• Energy Reduction

• Poor Sweetening

Module 9: Troubleshooting of Sulfur recovery unit:

• Pressure Drop

• Plugged Seal Legs

• Disintegrated Catalyst

• Carbon Deposits

• Boiler Leaks

• Inadequate Conversion of H₂S to Liquid Sulfur

• Maximizing Sulfur Plant Capacity

 

Who Should Attend?

This training program is designed for engineers, operations superintendents and supervisors’ staff, and all categories from the technical and process department of refinery involved in “Refinery Troubleshooting”.