Categories > Technical / Refineries & Petrochemicals Category:

 

 Refinery Troubleshooting

 

Program Duration

:

5 Days
Program Date :

05-09 May, 2012

Program Location

:

Cairo-Egypt

Program Fees

:

US$ 3200  /Per Person

 

PROGRAM OBJECTIVES:

Since day-to-day operation problem solving and optimizing are critical to the profitability of plant operations, troubleshooting is a prime responsibility of refinery and plant engineers. The importance of troubleshooting has grown as plants push to operate at higher and higher throughput levels. Lost profits due to unsolved unit problems can never be recovered.

Consistently maintaining smooth operation, maximum capacity, and acceptable product quality are important goals that can be difficult to achieve. Thus, this program has been developed to provide an in-depth, yet practical review of the art and science of plant troubleshooting

WHO SHOULD ATTEND?

  • Maintenance Senior Technicians 

  • Operation Senior Technicians

PROGRAM OUTLINES:

Module 1: Troubleshooting Process:

  • Objectives and Approach

  • The Skills of Troubleshooters

  • Importance of Troubleshooting

  • Case Examples
     

Module 2: Troubleshooting Concepts And Techniques: 

  • Typical Problems

  • Interaction of Process and Equipment

  • Troubleshooting Techniques

  • Troubleshooting Process

Module 3: Distillation:

  • Practical Distillation Problems:

    • Control Problems

    • Flooding

  • Measuring Tray Pressure Drop

  • High Liquid Level Induces Flooding

  • Vertical Temperature Survey

  • Two-Phase Bottom Level Problem

  • Foaming

  • Expanding Tray Capacity

  • Damaged Trays

  • Liquid Filled Towers

  • Reflux Changes

  • Level Control

  • Reboiler Problems

  • Trapout Pans

  • Leaking Drawoff Trays

Module 4: Heat Exchangers:

  • Application of Exchangers

  • Operation of Exchangers

  • Fouling Deposits

  • Troubleshooting Exchangers

  • Exchanger Cleaning

  • How Reboilers Work

  • Thermosyphon Reboilers

Module 5: Fluid Catalytic Cracking, FCC::

  • Overview of Catalytic Cracking Processes:

    • Conversion Processes

    • Catalytic Cracking

    • Catalytic Cracking Reactions

    • Sulfur, Oxygen, and Nitrogen Compounds

    • Catalytic Cracking Catalysts

    • Process Variables of Catalytic Cracking Processes

    • Fluidized-Bed Catalytic Cracking, FCC

    • Process Description

  • Troubleshooting Process Operations 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 6: Methyl Tertiary Butyl Ether, MTBE:   

  • Use of Alcohols and Ethers

  • HÜLLS Ethers Process for MTBE, ETBE, and TAME

  • MTBE Process Flow

  • Ethers Yields

  • Process Variables and Troubleshooting:

    • Temperature

    • Methanol to Isobutylene Ratio

    • Butene/ Methanol Azeotrope

    • Isobutylene Conversion

    • Catalyst Life

    • MTBE Product Purity

    • Corrosion Prevention

Module 7: Pumps:

  • Problems of Centrifugal Pumps

  • Pump Control Systems:

    • Pressure Control

    • Flow Control

    • Level Control

  • Suction Pressure Limits, Cavitations and NPSH

Module 8 : Fired Heaters :

  • Pass Balancing

  • Average Versus Peak Heat Flux and Coking

  • Heat Integration and Air Preheat

Module  9 Centrifugal Compressors:

  • Compressors

  • Suction Conditions

  • Surge Control

Module 10: Control:

  • Control Systems And Causes of Instability:

    • Surge Volume

    • Types of Surge Volumes

    • Typical Surge Requirement

    • Level Control

    • Pressure Control for Gases

  • The Control Valve

  • Pressure Drop Across Control Valve and Impossible Constraints

  • Valve Action on Air Failure (Unsound Control Schemes)

Module 11: Other Equipment:

  • Process Equipment in Petroleum Refining

  • Refinery Process Vessels

  • Drums

  • Liquid-Liquid Separators

  • Coalescence

  • Gas-Liquid Separators

  • Cyclone Separators

  • Drying

  • Drying Equipment

Module 12: Sulfur recovery unit and Amine unit:

  • Overview of Sulfur Recovery

  • Sources of Refinery H2S

  • Amine Treating Units

  • Fundamentals of Amine Chemistry

  • Sour Water Stripping

  • Sour Water Chemistry

  • Sulfur Recovery (Claus Units)

  • Fundamental Sulfur Plant Chemistry

  • Tail Gas Treating Processes

  • Sulfur Plant Problems

  • Troubleshooting Q&A