Refinery Operations Process Control (Experienced Level) 15th – 19th December, 2025

Course Overview

This advanced-level course is designed for experienced professionals seeking to deepen their expertise in refinery process control systems. Over five days, participants will explore advanced control strategies and optimisation techniques critical for enhancing refinery performance. The curriculum covers dynamic process control, advanced instrumentation, automation technologies, and the integration of data analytics into operational decision-making. Emphasis is placed on controlling critical variables such as pressure, temperature, and flow in essential units like distillation columns, reactors, and heat exchangers. Participants will also refine troubleshooting skills and learn cost-effective approaches to improve operational safety, reliability, and product quality.

Course Objectives

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

1. Analyse and implement advanced process control strategies for refinery operations.

2. Optimise performance by managing key control variables in critical refinery units.

3. Utilise advanced instrumentation and automation technologies effectively.

4. Apply data analytics to refine decision-making in process control operations.

5. Troubleshoot and resolve complex control loop issues.

6. Enhance operational efficiency and ensure compliance with safety and quality standards.

Target Audience

• Process control engineers with prior refinery experience.

• Operations managers overseeing refinery process systems.

• Instrumentation and automation engineers in refineries.

• Professionals in refinery maintenance and reliability.

• Engineers responsible for troubleshooting and process optimisation.

Daily Agenda

Day One: Fundamentals of Advanced Process Control

• Refinery Process Control Overview: An experienced-level recap.

• Control Loop Architecture: Concepts and best practices.

• Overview of Automation Technologies in Refineries.

• Review of Refinery Instrumentation for Process Control.

• Pressure, Temperature, and Flow Rate Control Strategies.

• Dynamic Process Modelling and Simulation for Refinery Applications.

Day Two: Advanced Control Techniques and Optimisation

• Cascade, Feedforward, and Adaptive Control Methods.

• Multi-variable Control Systems and Applications in Refineries.

• Process Optimisation Tools and Software.

• Automation of Distillation Columns and Reactors.

• Integration of Control Systems with Refinery Operations.

• Case Study: Successful Refinery Optimisation Projects.

Day Three: Troubleshooting and Fine-Tuning of Control Loops

• Diagnosing Control Loop Issues: Symptoms and Root Causes.

• Resolving Common Challenges in Process Control.

• Methods for Fine-Tuning Refinery Control Loops.

• Performance Monitoring of Control Systems.

• Data-driven Troubleshooting Approaches.

• Hands-on Simulation: Real-world Troubleshooting Scenarios.

Day Four: Instrumentation, Automation, and Data Analytics

• Advanced Instrumentation for Critical Refinery Units.

• SCADA and Distributed Control Systems (DCS) Integration.

• Leveraging Data Analytics for Refinery Operations.

• Predictive Analysis for Process Control Improvement.

• Automation Upgrades for Aging Refinery Systems.

• Group Activity: Designing a Data-driven Control Strategy.

Day Five: Enhancing Operational Efficiency and Reliability

• Cost-effective Techniques for Process Control Enhancement.

• Ensuring Compliance with Regulatory and Quality Standards.

• Refinery System Reliability and Risk Management.

• Energy Efficiency in Process Control.

• Final Assessment and Interactive Workshop: Control Strategy Optimisation.

• Course Wrap-up and Certificate Distribution.

Why Choose this Course?

This specialised course equips experienced professionals with cutting-edge knowledge and practical skills to manage refinery process control systems effectively. Through an interactive approach combining theoretical concepts and real-world applications, participants will learn to troubleshoot issues, optimise operations, and ensure safety and quality compliance. The course provides actionable insights into managing complex refinery systems, enabling participants to drive efficiency, reliability, and cost reduction.

Learning Outcomes

Upon completion of the course, participants will:

1. Master advanced process control strategies for refinery operations.

2. Be proficient in diagnosing and resolving process control issues.

3. Understand how to leverage automation and data analytics for optimisation.

4. Enhance operational efficiency and reliability in refinery systems.

5. Apply advanced instrumentation techniques for improved control accuracy.