COURSE OVERVIEW:

The Crude Distillation Unit (CDU) is the primary gateway for all refinery operations, performing the initial separation of crude oil into its functional boiling fractions. This course provides a comprehensive technical examination of the CDU, focusing on the atmospheric distillation process that yields naphtha, kerosene, diesel, and atmospheric residue. Participants will explore the fundamental principles of vapor-liquid equilibrium and mass transfer that govern the separation efficiency within the main fractionation column and its associated side strippers.

The scope of this training encompasses the entire CDU flowsheet, from the pre-heat train and desalting section to the atmospheric tower and product stabilizers. Attendees will analyze the mechanical design and operational logic of critical equipment, including the crude furnace, tower internals (trays and packing), and pump-around circuits. The course emphasizes the importance of heat integration and energy optimization, detailing how complex heat exchange networks are utilized to minimize fuel consumption while maximizing the pre-heat temperature of the crude feed.

A significant focus is placed on the operational challenges of maintaining product quality and unit reliability. Participants will learn to troubleshoot common issues such as tower flooding, tray damage, and corrosion in the overhead systems caused by salt and acid formation. By integrating process control strategies with practical field insights, the course equips operators and engineers with the skills to optimize cut points, manage changing crude slates, and ensure the steady-state performance of this cornerstone refinery unit.

COURSE OBJECTIVES:

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

1.  Explain the fundamental physics of multi-component distillation in a CDU.

2.  Optimize the performance of the crude pre-heat train for maximum energy efficiency.

3.  Manage the desalting process to minimize salt carryover and corrosion.

4.  Interpret atmospheric tower pressure and temperature profiles for stable operation.

5.  Adjust product cut points to meet specific distillation and flash point targets.

6.  Evaluate the impact of stripping steam on product separation and quality.

7.  Manage pump-around rates to optimize heat removal and column loading.

8.  Identify the causes of column flooding, weeping, and entrainment.

9.  Monitor and control overhead system corrosion using chemical inhibitors and wash water.

10.  Execute safe procedures for unit start-up, shutdown, and emergency cooling.

11.  Analyze the impact of different crude slates on CDU hydraulic capacity.

12.  Troubleshoot furnace performance and burner combustion issues.

13.  Utilize process data to perform heat and mass balances across the unit.

TARGET AUDIENCE:

CDU Operators, Process Engineers, Production Supervisors, and Technical Managers responsible for primary refinery distillation.

TRAINING COURSE METHODOLOGY:

A highly interactive combination of lectures, discussion sessions, and case studies will be employed to maximise 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.