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Quest Training

Process Technology Fundamentals for Plant Operators Training Course

Teaches plant operators process flow diagrams, material and energy balances, fluid flow, heat transfer and pressure and temperature control for safe operation.

PRO · Process EngineeringAll Levels#2835ClassroomEnglish , Arabic
Duration
5 Days
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Free substitution at any time · 30+ days' notice: full refund minus 10%. Cancellation policy

Sectors:Industrial Engineering, Maintenance & OperationsCategories:Process Engineering

Course Overview

Process technology fundamentals are essential for plant operators responsible for maintaining safe, stable, and efficient industrial operations. Understanding how process equipment functions, how materials move through production systems, and how operating variables affect product quality and equipment performance enables operators to respond effectively to routine operating conditions and abnormal situations. This course introduces the core principles of industrial process technology, including process flow diagrams, material and energy balances, fluid flow, heat transfer, pressure and temperature control, separation processes, and the operation of pumps, compressors, heat exchangers, vessels, and process control systems. Participants will also explore operating procedures, process monitoring, equipment start-up and shutdown, alarm response, and the relationship between operating parameters and process safety. Through practical exercises and plant-based scenarios, participants will strengthen their ability to interpret process documentation, monitor equipment performance, identify abnormal operating conditions, and apply systematic troubleshooting techniques. The programme supports consistent operating practices, improved process reliability, effective communication between control room and field operators, and safer day-to-day plant operations.

Learning Objectives

  • Explain the fundamental principles of industrial process technology and plant operations.
  • Interpret process flow diagrams (PFDs) and piping and instrumentation diagrams (P&IDs).
  • Understand material and energy balances and their application to process monitoring.
  • Explain the operating principles of common process equipment and industrial systems.
  • Identify the effects of pressure, temperature, flow, and level variations on process performance.
  • Apply basic principles of heat transfer, fluid flow, and separation processes.
  • Monitor process variables and recognise deviations from normal operating conditions.
  • Apply safe operating procedures during equipment start-up, shutdown, and routine operation.
  • Identify common equipment and process problems and apply systematic troubleshooting methods.
  • Improve operational communication, process safety awareness, and compliance with plant procedures.

Who Should Attend

Plant operators working in oil and gas, petrochemical, chemical, and process manufacturing facilities. Field operators and control room operators. Junior process technicians and production technicians. Newly appointed operators preparing for plant operating responsibilities. Shift supervisors and production team leaders. Operations personnel involved in equipment monitoring and routine process troubleshooting. Technical personnel seeking a practical foundation in industrial process operations.

Learning Outcomes

  • Explain the main stages of an industrial process and the function of major process units.
  • Read and interpret basic process flow diagrams and piping and instrumentation diagrams.
  • Describe material and energy flows through common process systems.
  • Identify the purpose and operating principles of pumps, compressors, heat exchangers, vessels, and separation equipment.
  • Explain the relationship between process variables and operating stability.
  • Recognise abnormal process conditions through trends, alarms, and field observations.
  • Follow established operating procedures for routine tasks and equipment transitions.
  • Identify common causes of process disturbances and equipment performance problems.
  • Apply structured troubleshooting and communicate operating abnormalities effectively.
  • Demonstrate greater awareness of process hazards, operating limits, and safe work practices.

Course Outline

Day 1

Introduction to Process Technology and Plant Operations

  • Overview of industrial process plants and the role of operators in safe and efficient production.
  • Fundamentals of process systems, unit operations, and production sequences.
  • Understanding raw materials, intermediate products, final products, and process streams.
  • Reading process flow diagrams (PFDs) and identifying major process units.
  • Introduction to piping and instrumentation diagrams (P&IDs), equipment symbols, and line identification.
  • Basic material balances, process inputs and outputs, and stream flow calculations.
  • Operating documentation, standard operating procedures, and shift handover requirements.
  • Practical Exercise: Interpret a simplified process flow diagram, trace material streams through the plant, and identify the main operating units and process flow paths.
Day 2

Process Equipment and Fluid Handling Systems

  • Principles of fluid flow, pressure, velocity, flow resistance, and pressure drop.
  • Centrifugal and positive displacement pumps: operating principles, performance, and common problems.
  • Compressors, their applications, and basic operating considerations.
  • Heat exchangers: heat transfer principles, operating variables, and performance monitoring.
  • Pressure vessels, separators, filters, and other common process equipment.
  • Valves, control valves, actuators, and basic piping system components.
  • Equipment operating limits, routine checks, abnormal conditions, and basic troubleshooting.
  • Practical Exercise: Analyse a process equipment scenario involving abnormal flow or pressure, identify possible causes, and determine the appropriate operator checks and escalation steps.
Day 3

Heat Transfer, Separation, and Process Control Fundamentals

  • Fundamentals of heat transfer by conduction, convection, and radiation.
  • Temperature control, heating and cooling systems, and heat exchanger performance.
  • Principles of phase separation, liquid-liquid separation, and gas-liquid separation.
  • Introduction to distillation, filtration, and other common separation operations.
  • Fundamentals of pressure, temperature, flow, and level measurement.
  • Process control loops, sensors, transmitters, controllers, and final control elements.
  • Understanding set points, process trends, control deviations, and alarm indications.
  • Practical Exercise: Review a process trend involving temperature, pressure, and flow variations, then identify potential causes of instability and the appropriate monitoring actions.
Day 4

Operating Procedures, Start-Up, Shutdown, and Troubleshooting

  • Pre-start-up checks and readiness verification for process equipment and systems.
  • Normal start-up, shutdown, and equipment changeover procedures.
  • Monitoring operating parameters during changes in process conditions.
  • Recognising abnormal situations, process upsets, and early warning indicators.
  • Alarm response, operating limits, and escalation procedures.
  • Common operational problems, including leakage, vibration, overheating, unstable flow, and pressure fluctuations.
  • Coordination between field operators, control room operators, maintenance personnel, and shift supervisors.
  • Practical Exercise: Work through a simulated equipment start-up and process disturbance scenario, identify deviations from normal conditions, and establish a safe sequence of operator responses.
Day 5

Process Safety, Operational Reliability, and Performance Improvement

  • Process hazards, operating envelopes, and the importance of maintaining safe operating limits.
  • Introduction to process hazard analysis and management of change.
  • Permit-to-work systems, isolation principles, and lockout/tagout (LOTO) awareness.
  • Identifying leaks, spills, abnormal emissions, and other indicators of potential process hazards.
  • Routine equipment monitoring, operating logs, and shift reporting.
  • Introduction to operational performance indicators, energy efficiency, and process loss reduction.
  • Learning from operating incidents, near misses, and recurring equipment problems.
  • Practical Exercise: Evaluate a simulated plant operating incident, identify contributing process and equipment factors, and prepare an operator action plan covering immediate response, communication, and prevention of recurrence.

Upcoming Dates

Selected date

Kigali · 4 – 8 Jan 2027 · Classroom

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