COURSE OVERVIEW:

Process utilities are the lifeblood of any refinery or petrochemical complex, providing the energy, cooling, and motive force required for production. This course provides a comprehensive exploration of the design and operation of auxiliary support systems, including steam generation, cooling water, instrument air, and fuel gas. Participants will examine the integration of these systems with the main process units, focusing on the importance of reliability and availability to prevent plant-wide upsets.

The scope of this training involves the detailed analysis of water treatment processes for boiler feed and cooling towers. Attendees will learn about the chemical conditioning required to prevent scale, corrosion, and biological growth within utility networks. The course details the mechanical operation of utility equipment, such as boilers, air compressors, and cooling tower fans, emphasizing the optimization of energy efficiency and the management of utility balances across the facility.

Coverage includes the operational logic of backup and emergency utility systems, such as emergency power generators and nitrogen systems for inerting. Participants will explore the environmental aspects of utility operations, including flue gas emissions and wastewater management. By integrating mechanical reliability with process control strategies, this course equips operators and utility engineers with the skills to maintain a stable and cost-effective utility infrastructure that supports continuous plant operation.

COURSE OBJECTIVES:

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

1.  Identify the critical utility systems required for refinery operations.

2.  Manage Boiler Feed Water (BFW) quality to prevent boiler tube failure.

3.  Optimize the operation of industrial boilers and steam distribution headers.

4.  Control cooling water chemistry to minimize fouling and corrosion.

5.  Manage the efficiency of cooling towers and circulating pumps.

6.  Operate and troubleshoot industrial air compression and drying systems.

7.  Balance the refinery fuel gas system and manage fuel quality.

8.  Execute safe procedures for nitrogen purging and blanketing operations.

9.  Oversee the operation of raw water treatment and demineralization plants.

10.  Manage the distribution and quality of instrument vs. plant air.

11.  Implement energy conservation measures in utility systems.

12.  Coordinate utility supply during unit start-ups and shutdowns.

13.  Troubleshoot utility-wide failures and execute emergency recovery plans.

TARGET AUDIENCE:

Utility Plant Operators, Facility Engineers, Energy Coordinators, and Maintenance Personnel responsible for auxiliary support systems.

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.