COURSE OVERVIEW:

Dynamic simulation is a powerful engineering tool used to model the time-dependent behavior of chemical processes, providing insights that steady-state modeling cannot capture. This course focuses on the application of dynamic simulation to evaluate the complex transitions that occur during plant start-up and shutdown phases. Participants will explore how to build high-fidelity models that incorporate equipment holdups, control system response, and thermal inertia to predict the real-time trajectory of pressure, temperature, and flow during critical operations.

The scope of this training details the development of rigorous procedures for bringing units online and offline safely. Attendees will learn how to use dynamic models to verify the adequacy of control loops and safety interlocks during non-routine events, such as the initial filling of a distillation column or the rapid depressurization of a reactor. The course emphasizes the importance of understanding the "transient state," teaching engineers how to identify potential hazards like vacuum formation, thermal shock, or compressor surge that may only appear during these unstable phases.

Coverage includes the integration of the Basic Process Control System (BPCS) and Safety Instrumented Systems (SIS) within the simulation environment. Participants will examine how to perform "virtual start-ups" to train operators and validate standard operating procedures (SOPs) before actual plant implementation. By mastering dynamic simulation techniques, professionals will be equipped to minimize unit downtime, prevent equipment damage, and enhance the overall safety and reliability of complex industrial systems during their most vulnerable periods.

COURSE OBJECTIVES:

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

1. Explain the fundamental differences between steady-state and dynamic process simulation.
2. Develop dynamic models that accurately account for vessel holdups and equipment geometry.
3. Configure PID controllers and safety logic within a dynamic simulation environment.
4. Simulate the step-by-step sequence of a cold start-up for a refinery or petrochemical unit.
5. Analyze the impact of thermal stresses and expansion rates during equipment warm-up.
6. Predict the risk of vacuum formation during liquid drainage and shutdown.
7. Evaluate the performance of compressor anti-surge systems during transient events.
8. Validate emergency shutdown (ESD) sequences and timing using dynamic data.
9. Optimize the consumption of utilities like steam and nitrogen during start-up.
10. Identify potential overpressure scenarios that occur only during transient states.
11. Train operators using a "Digital Twin" approach to enhance situational awareness.
12. Verify the adequacy of relief systems for dynamic loading during a plant trip.
13. Formulate a comprehensive report documenting simulated start-up and shutdown results.

TARGET AUDIENCE:

Process Engineers, Control Systems Engineers, Operations Managers, and Simulation Specialists involved in process design and plant operations.

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.