Learning Objectives

Upon successful completion of this course, participants will be able to:

1. Fundamentals of Chemical Handling and Injection Systems

• Understand the role of chemicals in industrial processes (corrosion inhibitors, demulsifiers, scale inhibitors, biocides, drag-reducing agents, etc.).
• Identify chemical properties (toxicity, reactivity, flammability, pH, volatility, solubility, etc.).
• Learn about Material Safety Data Sheets (MSDS), Global Harmonized System (GHS) labeling, and Personal Protective Equipment (PPE) requirements.

2. Chemical Injection System Components and Functionality

• Understand key components in chemical injection systems:
• Chemical storage tanks and drums.
• Chemical injection pumps (diaphragm, plunger, peristaltic, electric metering pumps, etc.).
• Flow control valves, injection quills, and static mixers.
• Instrumentation and monitoring systems (flow meters, pressure regulators, level indicators, alarms, and control panels).
• Learn about manual vs. automated dosing systems.

3. Chemical Injection System Startup Procedures

• Perform pre-startup inspections of chemical tanks, pumps, and injection lines.
• Verify chemical inventory levels, compatibility, and flow path integrity.
• Ensure all safety interlocks and pressure relief systems are operational.
• Follow step-by-step startup procedures for different types of chemical injection systems.
• Conduct system priming and flow calibration checks.

4. Normal Operating Procedures and Performance Optimization

• Monitor chemical flow rates and dosing accuracy.
• Adjust dosing parameters based on process requirements and real-time data.
• Implement remote monitoring and automated control strategies for optimized operation.
• Conduct regular sampling and analysis to verify chemical effectiveness.

5. Chemical Injection System Shutdown Procedures

• Follow gradual shutdown sequences to avoid system pressure surges.
• Flush chemical injection lines to prevent clogging and chemical degradation.
• Isolate storage tanks and injection pumps safely.
• Document shutdown logs and maintenance records.

6. Troubleshooting Common Chemical Injection System Issues

• Identify and resolve:
• Pump failures and inconsistent dosing rates.
• Clogging and scaling in injection lines.
• Loss of prime or vapor lock in pumps.
• Corrosion issues due to improper chemical selection.
• Pressure imbalances affecting dosing accuracy.
• Instrumentation and control failures.
• Use diagnostic tools and data analysis for efficient troubleshooting.

7. Safety and Environmental Considerations in Chemical Handling

• Ensure safe handling and storage of hazardous chemicals.
• Implement emergency response plans for leaks, spills, and exposure incidents.
• Follow best practices for chemical disposal and waste minimization.
• Ensure compliance with OSHA, EPA, NFPA, REACH, and other industry-specific safety regulations.

8. Case Studies and Practical Applications

• Review real-world case studies on chemical handling and injection system failures and optimizations.
• Participate in hands-on exercises for safe startup, shutdown, and troubleshooting.
• Develop a customized Standard Operating Procedure (SOP) for chemical injection systems in a specific facility.

Target Audience

• Process and operations engineers
• Chemical handling and maintenance personnel
• Safety and environmental officers (HSE)
• Oil & gas, water treatment, and industrial plant operators
• Field service technicians involved in chemical injection systems