COURSE OVERVIEW:

The meaning of this course lies in the successful translation of laboratory-grade analytical science to the demanding environment of the industrial process floor. In a chemical plant or refinery, analytical data is the primary driver for process optimization, safety, and product quality. This program provides the technical competencies required to manage the analyzers that operate in real-time, providing continuous feedback to control systems and plant operators.

The scope of the training addresses the unique challenges of Process Analytical Chemistry (PAC), including sample conditioning, analyzer shelter design, and instrument-to-PLC communication. It covers a diverse range of process technologies, such as On-line Gas Chromatography, Near-Infrared (NIR) spectroscopy, and Continuous Emissions Monitoring Systems (CEMS). Participants will explore the maintenance and calibration of analyzers that must function reliably 24/7 in harsh, outdoor, and potentially explosive atmospheres.

The coverage includes a comprehensive look at representative sampling probes, fast-loop engineering, and the role of process analyzers in environmental compliance. The course emphasizes the importance of analyzer availability, data validity, and the integration of analytical results into the plant’s Distributed Control System (DCS). By mastering these industrial analytical protocols, participants will be able to improve process yield, reduce off-spec production, and ensure the safety of large-scale chemical operations.

COURSE OBJECTIVES:

After completion of this course, the participants will be able to:

• Define the core principles of Process Analytical Chemistry (PAC).
• Design representative sample conditioning systems for process streams.
• Operate and maintain On-line Gas Chromatographs (PGC).
• Utilize Near-Infrared (NIR) for real-time process monitoring.
• Manage Continuous Emissions Monitoring Systems (CEMS) for compliance.
• Implement calibration and validation protocols for field analyzers.
• Configure analyzer interfaces with DCS and PLC control systems.
• Troubleshoot sample lag time and conditioning system failures.
• Manage the safety requirements for analyzers in hazardous areas (ATEX).
• Perform routine maintenance on process-aligned spectroscopic probes.
• Utilize analyzer data for real-time process optimization and control.
• Document analyzer performance and availability for management review.

TARGET AUDIENCE:

This course is intended for Process Instrument Technicians, Analyzer Engineers, Chemical Plant Operators, and Industrial Quality Control Supervisors.

TRAINING COURSE METHODOLOGY:

A highly interactive combination of lectures, discussion sessions, and case studies will be employed to maximize the transfer of information, knowledge, and experience. The course will be intensive, practical, and highly interactive. The sessions will start by raising the most relevant questions and motivating everybody to find the right answers. The attendants will also be encouraged to raise more of their questions and to share in developing the right answers using their analysis and experience. There will also be some indoor experiential activities to enhance the learning experience. Course material will be provided in PowerPoint, with necessary animations, learning videos, and general discussions.

The course participants shall be evaluated before, during, and at the end of the course.

COURSE CERTIFICATE:

National Consultant Centre for Training LLC (NCC) will issue an Attendance Certificate to all participants completing a minimum of 80% of the total attendance time requirement.