Advanced Refinery Operation Process Control (Supervisory Level) 17th – 21st March, 2025

Course Overview

This high-level, five-day training program is designed for supervisors and managers responsible for refinery operations. The course equips participants with strategic process control methodologies and advanced decision-making capabilities essential for optimising refinery efficiency and safety. It delves into supervisory control techniques, including model predictive control, real-time optimisation, and system integration, to enhance plant performance. Key focus areas include managing advanced control systems for critical units, implementing proactive diagnostics and maintenance strategies, and fostering leadership in control room operations. The program also emphasises regulatory compliance, safety management, and best practices for handling operational crises.

Course Objectives

By the end of this course, participants will be able to:

1. Apply strategic control methodologies to optimise refinery operations.

2. Supervise the implementation of advanced control techniques, such as model predictive control and real-time optimisation.

3. Manage control systems for critical refinery units, ensuring operational efficiency.

4. Lead control room operations while ensuring adherence to safety and regulatory standards.

5. Implement proactive diagnostics and maintenance strategies to minimise downtime.

6. Develop crisis management plans and effectively respond to operational challenges.

Target Audience

• Refinery supervisors and control room managers.

• Process engineers transitioning to supervisory roles.

• Operations managers overseeing refinery process control systems.

• Senior refinery personnel involved in strategic decision-making.

• Professionals responsible for implementing regulatory and safety standards in refinery operations.

Daily Agenda

Day One: Refinery Process Control for Supervisors

• Overview of Supervisory Control in Refinery Operations.

• Strategic Role of Supervisors in Process Control.

• Refinery Process Control Architecture: Supervisory Perspective.

• Key Performance Indicators (KPIs) for Refinery Operations.

• Supervisory Management of Control Loops.

• Safety and Compliance in Process Control.

Day Two: Advanced Control Techniques and System Integration

• Model Predictive Control (MPC): Theory and Application.

• Real-Time Optimisation in Refinery Operations.

• Supervisory Control of Complex Units: Distillation and Reactors.

• Integrating Advanced Automation Systems with Operations.

• Refinery-wide Monitoring Systems: SCADA and DCS Insights.

• Case Study: Successful Supervisory Control Implementation.

Day Three: Diagnostics, Maintenance, and Risk Mitigation

• Supervisory Approaches to Diagnostics and Troubleshooting.

• Proactive Maintenance Planning for Supervisors.

• Managing System Downtime: Strategies and Tools.

• Risk Identification and Mitigation in Refinery Operations.

• Supervisory Role in Reliability Centred Maintenance (RCM).

• Group Activity: Diagnosing and Solving Control System Issues.

Day Four: Leadership in Refinery Operations

• Supervisory Leadership in Control Room Environments.

• Decision-Making Under Pressure: Techniques and Tools.

• Managing Multi-Disciplinary Teams in Refinery Operations.

• Communication and Coordination in Process Control Supervision.

• Compliance and Regulatory Leadership in Refinery Operations.

• Developing and Mentoring Control Room Operators.

Day Five: Crisis Management and Continuous Improvement

• Crisis Management in Refinery Process Control.

• Developing Emergency Response Plans.

• Supervisory Role in Incident Investigation and Reporting.

• Continuous Improvement in Process Control Operations.

• Optimising Team Performance in Refinery Operations.

• Final Assessment: Supervisory Process Control Strategies.

Why Choose this Course?

This advanced program is tailored to meet the strategic needs of refinery supervisors and managers. It focuses on supervisory leadership, advanced control techniques, and operational optimisation, empowering participants to oversee refinery operations effectively. The course provides actionable insights into diagnostics, proactive maintenance, and crisis management, enabling participants to lead with confidence, ensure operational efficiency, and maintain compliance with safety standards.

Learning Outcomes

Upon completion of the course, participants will:

1. Understand advanced process control strategies from a supervisory perspective.

2. Manage and optimise complex refinery systems and operations.

3. Lead control room teams with a focus on safety, efficiency, and compliance.

4. Diagnose and mitigate risks in refinery operations proactively.

5. Implement crisis management plans and foster continuous operational improvement.