Hands-on Exercise: Building an Appropriate Operating Log

Choosing Your Focus: Select Your Petrochemical Unit

For this workshop, we’ll provide guidance on building OLs for a variety of petrochemical units. Here are some examples:

• Cracking Unit: Responsible for breaking down larger hydrocarbon molecules from naphtha into smaller, more valuable products like ethylene, propylene, and gasoline blending components.
• Aromatics Complex: Converts various feedstocks into aromatic hydrocarbons like benzene, toluene, and xylene, essential for producing plastics, synthetic fibers, and solvents.
• Polymerization Unit: Transforms monomers (like ethylene or propylene) into high-molecular-weight polymers used in plastics, synthetic fibers, and various industrial applications.

Workshop Structure: A Step-by-Step Guide

We’ll guide you through the process of building your customized OL, focusing on the following key steps:

1. Unit Description: Start by providing a brief overview of the chosen petrochemical unit, outlining its function and the main products it generates.
2. Process Flowchart: Include a clear flowchart that illustrates the major stages involved in the unit’s operation. This flowchart should visually represent the sequence of steps the operators will follow during their shifts.
3. Raw Materials & Feedstocks: Specify the type and quality of raw materials or feedstocks used in the process. Define any critical pre-treatment steps required before feeding the material into the unit.
4. Operational Parameters: Define the critical operational parameters that need to be monitored and recorded during operation. This might include temperatures, pressures, flow rates, levels, and reaction times for key equipment within the unit.
5. Control Procedures: Outline the standard operating procedures for controlling these critical parameters. Specify the desired setpoints, acceptable ranges, and any corrective actions to be taken if deviations occur.
6. Product Quality Control: Define the key quality control procedures for the final products, including sampling frequency, analytical methods, and acceptable product specifications.
7. Alarms & Events: List the critical alarms associated with the unit and the corresponding actions operators should take in response to each alarm. Additionally, include procedures for documenting abnormal events or equipment malfunctions.
8. Record Keeping: Specify the format and frequency of recording operational data. This could involve manual entries in a logbook or electronic data recording systems.
9. Waste Management: Outline procedures for handling and disposing of any waste products or byproducts generated during the process, ensuring compliance with environmental regulations.
10. Shift Handoff: Define the procedures for effective shift handoff, ensuring critical information and current unit status are communicated seamlessly between operational teams.

Workshop Activities

• Participants will be divided into small groups, each focusing on building an OL for a specific petrochemical unit chosen from the provided options or one they bring to the workshop.
• We will provide templates and resources to guide participants through the process.
• Facilitators will be available to answer questions and offer guidance throughout the exercise.
• Each group will present their customized OL to the workshop audience, highlighting key elements and their rationale.

Learning Outcomes

By the end of this workshop, you will be able to:

• Understand the purpose and importance of an Operation Log (OL) in petrochemical operations.
• Differentiate the key operational aspects of various petrochemical units.
• Apply a step-by-step approach to build a customized OL specific to your chosen petrochemical unit.
• Identify critical operational parameters, control procedures, and alarm responses for efficient and safe unit operation.
• Develop clear record-keeping practices for operational data and product quality control.
• Outline procedures for waste management and shift handoff, ensuring smooth operational continuity and environmental compliance.