Panel Operator Certification

Overview:

Program Objectives:

At the end of this program, participants will be able to:

• Communicate and work effectively with shift colleagues.

• Explain in detail the processes using various documents (PFDs, P&IDs, control schemes, logic diagrams).

• Identify risks related to equipment operation and process; to enforce adequate preventive actions.

• Adjust the plant process parameters to optimize production rate, product quality and operating costs, minimize losses and releases.

• Analyze the process key parameters to determine disturbance causes, and take appropriate corrective and preventive actions.

• Prepare, start, and shut down a unit in safe conditions.

• Prepare for the exam.

Target Audience:

• Aspiring panel operators seeking to enhance their skills.

• Current panel operators aiming to refine their expertise.

• Industrial personnel responsible for plant operations and optimization.

Program Outlines:

Unit 1:

Introduction & Operator Responsibilities:

• Welcome and safety procedures introduction.

• Distribution of Personal Protective Equipment (PPE).

• Overview of panel operator role within the operation team.

• Introduction to plant documentation and inventory.

• Understanding basic industrial chemistry principles.

• Study of fluid mechanics and heat exchange mechanisms.

Unit 2:

Process Control & Automation Fundamentals:

• Fundamentals of process control loops and control valves.

• Introduction to sensors, transmitters, and controllers.

• Overview of Distributed Control System (DCS) architecture.

• Study of automation systems including safety instrumented systems and PLCs.

• Simulation exercises on valve characteristic curves and PID tuning.

• Understanding safety logic and cause & effect matrix.

Unit 3:

Equipment Operation & Utilities:

• Operation principles and monitoring of pumps, compressors, and drivers.

• Understanding thermal equipment such as heat exchangers, air coolers, and furnaces.

• Overview of specific equipment relevant to assigned units.

• Study of utilities including flare systems, air production, and effluent treatment.

• Simulation exercises on operation, troubleshooting, and start-up procedures.

• Examination of start-up and shutdown procedures for various process units.

Unit 4:

Product Quality & Process Management:

• Analysis of feed and product properties.

• Understanding commercial product quality requirements and standard tests.

• Study of process units, material balance, and main operating parameters.

• Exploration of distillation, absorption, and stripping processes.

• Overview of mixing rules and influence of operating parameters.

• Simulation exercises on process unit operation and control.

Unit 5:

Safe Plant Operation & Emergency Management:

• Training on panel operator safe behavior and communication protocols.

• Overview of HSE (Health, Safety, and Environment) practices in operation.

• Examination of routine operations, permits to work, and special operations.

• Practice of integrated plant operation including crisis management.

• Preparation of the exam.