Production Facilities Control Room Operation

This course aims to acquire best practices of production facilities control room operation through role-play situations on integrated Oil & Gas production plant dynamic simulator.

 

  • analyze and anticipate the behavior of main control loop structures (DCS and SIS systems architecture and functionalities),
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  • explain production equipment, process operating parameters, and perform troubleshooting,
  • implement proactive, anticipatory control room operation and acquire a safety mindset,
  • react and act in a structured manner to anomalies and plant upsets,
  • enforce safety guidelines during downgraded and critical situations.

 

  • Experienced control room operators and production supervisors looking to advance their know-how in control room operation

  • GETTING STARTED - DCS FUNCTIONALITIES FOR PROPER ANALYSIS
  • Familiarization with HMI functions and operations.
  • DCS tools review.
  • PROCESS CONTROL & SAFETY INSTRUMENTED SYSTEMS
  • Impact of P&ID parameters and simply closed loop tuning.
  • Study of control loop structures: cascade, split-range on the simulator.
  • Programmable logic controllers: introduction to automated sequences.
  • Monitoring of start-up sequence (compressor) through MMI.
  • Safety Instrumented Systems (SIS): PSS, ESD, HIPPS, and F&G systems description.

 

  • WELLS & PRODUCTION LINES OPERATION
  • Well, start-up (ramp-up) and shutdown.
  • Analysis of automatic good control.
  • Well, monitoring and detection of abnormal conditions.
  • ROTATING MACHINERY OPERATION
  • Centrifugal pumps.
  • Centrifugal compressors:
  • Technology review, the study of process and auxiliary lines, protection systems.
  • Start-up and shutdown sequences.
  • Analysis of operating conditions and operating parameters.

 

  • PROCESS UPSET MANAGEMENT
  • Alarms: priorities management and decision making.
  • Becoming aware of the need for anticipation VS on-alarm action.
  • Managing and predicting process disturbances by using trend views. Use of trends to anticipate deviations.
  • Global plant performance checks: identification and implementation of a routine checks roadmap.
  • Shift report and impact of a faulty report through role-play situations.
  • Process upsets: learning to react and act in a structured manner.
  • Identification, analysis, and containment of process upsets according to the learned methodology.
  • Example of simulator exercises performed:
  • Loss of centrifugal compressor.
  • Loss of cooling media.
  • Production rate decrease.
  • Unexpected slugging.
  • ESD activation due to process safety trip.

 

  • SAFETY IN OPERATION
  • Learning to operate the plant in critical situations, to make adequate decisions, to follow-up on actions performed.
  • Example of simulator exercises performed:
  • Gas leakage to the flare.
  • Inhibition and downgraded situation mitigation (faulty pressure transmitter, SDV blocked open…).
  • Manual ESD activation following leakage detection

  • PRODUCTION START-UP
  • Analysis of production facilities start-up philosophy.
  • Safe plant start-up.
  • Implementing the start-up procedure on the simulator:
  • Operating parameters analysis and anticipation of process upset.
  • Generation of several malfunctions (by the instructor) to be fixed.
  • CONTINUOUS ASSESSMENT TEST
  • Weekly tests on the simulator.

 

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