COURSE OVERVIEW

This course provides participants with a comprehensive understanding of the utilities and steam systems used in fertilizer plants, focusing on their design, operation, and integration with production processes. Utilities systems such as boilers, condensate recovery, waste heat recovery, compressed air, cooling water, and gas supply systems play a crucial role in maintaining continuous and efficient plant operation.

Participants will gain practical knowledge of steam generation, distribution, and condensate management, as well as the operation of turbines, compressors, and key process gas systems including natural gas, process air, synthesis gas, ammonia, and carbon dioxide. The course emphasizes operational best practices, troubleshooting, and system optimization using real-world case studies from fertilizer industries.

By combining theoretical instruction with applied operational scenarios, the training enables operators to enhance safety, improve reliability, and optimize performance across utility and steam systems.

COURSE OBJECTIVES

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

1. Understand the function and importance of utilities systems in fertilizer plants.
2. Describe the operation and configuration of steam and condensate systems.
3. Explain the principles of waste heat recovery and boiler feedwater (BFW) management.
4. Operate and monitor steam generation and distribution networks effectively.
5. Understand the role of turbines and compressors in driving process units and utilities systems.
6. Gain knowledge of natural gas, process air, synthesis gas, ammonia, and CO₂ systems and their interrelations.
7. Identify common operational issues and apply troubleshooting techniques to maintain system efficiency.
8. Enhance awareness of safety procedures, pressure management, and maintenance practices.
9. Learn to interpret P&IDs and utility flow diagrams relevant to plant operation.
10. Develop effective coordination between field and control room teams to ensure safe and reliable plant performance.

TARGET AUDIENCE

-Control Room Operators

-Field Operators

-Process Technicians

-Utilities Operators

-Maintenance Technicians

-Mechanical and Process Engineers

-Operations Supervisors

TRAINING COURSE METHODOLOGY

A highly interactive combination of lectures and discussion sessions, as well as case studies, will be managed to maximize the amount and quality of information, knowledge, and experience transfer. The course will be intensive but 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 learning. Course material will be provided in PowerPoint, with necessary animations, learning videos, and general discussions.

The course participants shall be evaluated before, during, and after 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.