Learning Objectives

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

1. Fundamentals of Petrochemical Operating Procedures

• Understand the importance of standardized operating procedures (SOPs) in petrochemical plants.
• Differentiate between Operating Procedures, Standing Instructions, and Work Instructions.
• Identify critical procedures in continuous and batch petrochemical processes.

2. Development and Implementation of Standard Operating Procedures (SOPs)

• Learn the key components of an effective SOP (scope, responsibilities, steps, safety precautions, emergency actions).
• Ensure procedural alignment with industry best practices and regulatory requirements.
• Implement document control and change management procedures for SOP updates.

3. Standing Instructions for Shift and Process Control

• Define standing instructions for plant startup, normal operations, and shutdown procedures.
• Establish guidelines for shift handover and reporting requirements.
• Maintain operational continuity and minimize process variability through effective instructions.

4. Equipment Operation and Maintenance Guidelines

• Develop equipment-specific SOPs for reactors, distillation columns, compressors, heat exchangers, and pumps.
• Implement preventive and predictive maintenance procedures to ensure reliability.
• Use condition monitoring and real-time process data for equipment performance assessment.

5. Safety, Emergency, and Environmental Compliance Procedures

• Ensure compliance with OSHA, API, NFPA, and local safety regulations.
• Implement emergency response plans for fire, gas leaks, spills, and process upsets.
• Develop safety-critical standing instructions for hazardous materials handling (flammable, toxic, corrosive substances).

6. Process Control and Alarm Management

• Define operational setpoints, alarm limits, and control loop tuning parameters.
• Ensure effective alarm management strategies to minimize false alarms and improve response times.
• Integrate DCS (Distributed Control System) and SCADA-based procedural automation.

7. Quality Control and Product Specifications

• Develop process monitoring guidelines to ensure product consistency and quality.
• Establish sampling and laboratory testing procedures for petrochemical products.
• Implement corrective actions for deviations in process parameters.

8. Auditing, Compliance, and Continuous Improvement in SOPs

• Conduct internal audits of SOPs and standing instructions for compliance verification.
• Implement Kaizen, Six Sigma, and Lean principles for process improvement.
• Develop training and competency assessment programs for plant personnel.

9. Case Studies and Practical Applications

• Analyze real-world incidents related to non-compliance with SOPs and lessons learned.
• Participate in hands-on workshops for writing and reviewing operating procedures.
• Develop customized SOPs and standing instructions for a selected process in a petrochemical plant.

Target Audience

• Petrochemical plant operators and process engineers
• Production supervisors and shift controllers
• Safety and environmental officers
• Reliability and maintenance engineers
• Compliance and quality assurance personnel