Summary:

This program offers a practical, in-depth review of troubleshooting in plant operations, essential for refinery and plant engineers focused on maximizing profitability and efficiency. It begins with fundamentals—process objectives, equipment behavior, and troubleshooting techniques—then applies a case study approach using real-world examples of pumps, heat exchangers, heaters, vacuum systems, compressors, and more. Participants will learn how to identify and solve complex operational issues, enhancing plant reliability and productivity.

Outline: 

INTRODUCTION

• Objectives and Approach
• Importance of Troubleshooting
• Case Studies

TROUBLESHOOTING CONCEPTS AND TECHNIQUES

• Typical Problems
• Integration of Process and Equipment
• Techniques & Tools

DISTILLATION

• Flooding and Its Detection
• Pressure Surveys
• Saltation
• Entrapment
• Damaged Equipment
•  Entrainment and Product Quality

HEAT EXCHANGERS

• Preheat and Crude Fouling
• Leaks
• Hot Vapor Bypass and Sealing
• Vapor Blanketing
• Heat Integration and Startup
• Heat Flux Limits
• Thermosyphon Reboilers

HYDRAULICS

• Gravity Flow and Open-Channel Flow
• Unstable Systems
• Compressible Flow: Transfer Lines
• Nozzles
• Pressure Balance Systems

PUMPS

• Suction Conditions-NPSH and Suction Specific Speed
• Multiple Pumps in Parallel
• Low Head Applications
• Fan Law Limits

FIRED HEATERS

• Pass Balancing
• Average Versus Peak Heat Flux and Coking
• Heat Integration and Air Preheat
• Environmental Control

VACUUM SYSTEMS

• Ejector Systems
• Suction Constraints
• Excessive Load
• Precondenser Performance
• Plugged Exchangers
• Damaged Equipment
• Liquid-Ring Low-Pressure Operation

CENTRIFUGAL COMPRESSORS

• Suction Conditions
•  Surge Control

RECIPROCATING COMPRESSORS

• Interstage Pressures
• Capacity Restrictions

CONTROL

• Instability
• Impossible Constraints
• Unsound Control Schemes
• Instrument Installation Problems
• Advanced Control Problems

OTHER EQUIPMENT

• Coalescers
• Dryers
• Salt Dryers
• Drums
• Gas Turbines

ADVANCED TECHNIQUES

• Gamma Scans: Uses and Limitations
• Neutron Backscatter
• Thermal Scanning

Who Should Attend: 

Participants will gain a comprehensive understanding of troubleshooting principles and practices, covering both traditional and advanced techniques, and network with industry peers. Ideal for refinery troubleshooting personnel, process engineers, plant operators, and technical service staff, the program also benefits process engineers from operating, design, and construction firms, as well as service providers to the petroleum and petrochemical industries.

Instructor: 

Andrew W. Sloley, an independent consultant with 40+ years of experience in the hydrocarbon processing industry. Specializing in product separation, distillation, and heat integration, he has worked on various petrochemical and refining units, from crude to cryogenic systems. Andrew has authored 400+ publications, holds a B.S. in Chemical Engineering, and is a licensed professional engineer in Texas. Currently a contributing editor for Chemical Processing magazine, his expertise spans crude units, process optimization, equipment design, and troubleshooting.

Venue & Logistics: 

Hotel Booking Link: Book Hotel Here

*Please note this link expires two weeks before the start of the course. Please notify training@becht.com for any issues with the booking link.

Location:  15700 John F Kennedy Blvd, Houston, TX 77032

• Phone:  +12814425100
• Hotel Website
• Parking available on-site - free for all training attendees

For more information on training logistics, see the linked Attendee Info Sheet.