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Institute For Oil & Gas Training
OGI-1244 New

Petroleum Refinery Processes & Operations Training Course

Duration
5 days
CPD hours
15
Language
English
Next date
19 Oct 2026
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Overview

The Petroleum Refinery Processes & Operations Training Course from Institute For Oil & Gas Training develops the technical and operational capabilities required to manage petroleum refining, optimise refinery operations and improve the performance of refinery process units across modern oil and gas facilities. The course addresses the practical skills gap between understanding individual refining processes and managing their interaction within an integrated refinery environment.

Petroleum refining is a complex industrial activity involving the conversion of crude oil into commercially valuable products, including petrol, diesel, aviation fuel, liquefied petroleum gas, naphtha, lubricants and other petroleum derivatives. Efficient refinery operations depend on the coordinated performance of separation, conversion, treating and product-blending systems. Operational teams must understand how these systems interact, how process conditions influence product quality and throughput, and how operating decisions affect energy consumption, equipment reliability and process safety.

The Petroleum Refinery Processes & Operations Training Course provides a structured understanding of the complete refining process, from crude oil receipt and preparation to intermediate processing, final product treatment and storage. It examines the operating principles of major refinery process units, the relationship between feedstock characteristics and product yields, and the methods used to monitor and improve process performance.

For organisations operating refineries, petrochemical complexes and integrated oil and gas facilities, process knowledge directly supports production reliability, asset utilisation and operational decision-making. Refinery personnel must respond effectively to changing crude quality, equipment limitations, fluctuating product demand, process disturbances and increasingly demanding environmental and safety expectations. A clear understanding of refinery process fundamentals enables personnel to identify performance deviations, assess operational risks and coordinate corrective action across interconnected production systems.

The course explores the principal refining processes, including atmospheric and vacuum distillation, catalytic cracking, hydrocracking, catalytic reforming, hydrotreating, desulphurisation and product blending. Participants examine the purpose of each process, its principal operating variables, the characteristics of its feed and products, and the operational factors that influence performance. The programme also considers the importance of process control, heat integration, energy efficiency, equipment condition and operating discipline in achieving stable refinery production.

Institute For Oil & Gas Training connects these technical principles with operational challenges encountered in industrial refining environments. Participants develop a broader understanding of how process units function individually and as part of an integrated production system. This perspective strengthens communication between operations, process engineering, maintenance, inspection, laboratory and technical support teams.

The programme also addresses the practical relationship between process efficiency and process safety. Refinery operations involve high temperatures, elevated pressures, flammable hydrocarbons, corrosive substances and complex process equipment. Understanding normal operating envelopes, recognising abnormal conditions and following established operating procedures are essential to controlling risk and maintaining production continuity.

By combining process fundamentals with practical operating considerations, this course supports professionals who need to interpret operating data, understand process limitations, investigate production problems and contribute to continuous improvement. It is suitable for organisations seeking to strengthen technical competence, improve coordination between operational functions and establish a more consistent approach to refinery performance management.

Objectives

  • Explain the purpose, scope and commercial importance of petroleum refining within the oil and gas value chain.

  • Describe the principal stages of crude oil processing, from feedstock preparation to finished product storage.

  • Differentiate between separation, conversion, treating and blending processes used in modern refineries.

  • Explain the operating principles of atmospheric and vacuum distillation units.

  • Identify the functions and operating considerations of catalytic cracking, hydrocracking and catalytic reforming units.

  • Describe the purpose of hydrotreating, desulphurisation and other product-treatment processes.

  • Interpret simplified refinery process flow diagrams and understand the interaction between interconnected process units.

  • Identify the principal operating variables that influence throughput, product yield, separation efficiency and product quality.

  • Explain how feedstock properties influence process selection, unit performance and product distribution.

  • Recognise common operating deviations and identify the process information required for effective troubleshooting.

  • Evaluate the relationship between energy consumption, heat recovery and refinery operating efficiency.

  • Explain the importance of process monitoring, instrumentation, control systems and operating procedures.

  • Identify process hazards associated with high-temperature, high-pressure and hydrocarbon-handling operations.

  • Explain the role of recognised process safety and engineering standards in supporting refinery integrity and operational control.

  • Contribute to structured investigations of production losses, equipment constraints and process performance deterioration.

  • Apply a systematic approach to operational decision-making, technical communication and continuous improvement.

Training methodology

Institute For Oil & Gas Training delivers the Petroleum Refinery Processes & Operations Training Course through a practical, industry-focused methodology that connects technical principles with operational responsibilities. The learning approach emphasises process understanding, interpretation of operating information, structured problem-solving and the application of established refinery practices.

Instructor-Led Technical Sessions

Structured technical sessions explain the purpose, operating principles and industrial applications of the principal refinery process units. Participants examine how crude oil properties, process conditions, equipment characteristics and product specifications influence refining performance. Technical explanations focus on operational relevance rather than purely theoretical detail.

Refinery Process Case Studies

Industry-based case studies explore common operational challenges, including reduced distillation efficiency, unstable process conditions, excessive energy consumption, catalyst performance deterioration and product-quality deviations. Participants evaluate the symptoms, identify possible contributing factors and consider suitable investigation and corrective-action approaches.

Process Flow and Unit Interaction Exercises

Participants interpret refinery process flow diagrams and simplified process descriptions to understand material movement between major units. These exercises demonstrate how changes in one process unit affect upstream and downstream operations, product recovery, intermediate inventories and overall refinery throughput.

Operational Scenario Analysis

Practical scenarios examine responses to changing feedstock characteristics, equipment constraints, process upsets and departures from normal operating conditions. Participants consider available operating information, identify priorities and assess the implications of alternative responses for safety, product quality and production continuity.

Process Data Interpretation

Exercises introduce participants to the interpretation of operating variables such as temperature, pressure, flow rate, level, differential pressure and product-quality indicators. Participants examine trends, distinguish normal variation from potential process deterioration and identify when further investigation or technical escalation is appropriate.

Group Problem-Solving Activities

Cross-functional exercises encourage participants to approach refinery problems from operations, process engineering, maintenance and production management perspectives. These activities strengthen technical communication and demonstrate the importance of sharing accurate process information before implementing operational changes.

Application to Workplace Responsibilities

Throughout the programme, participants relate course concepts to their organisational procedures, operating responsibilities and production objectives. The methodology supports the transfer of learning into daily operations, shift handovers, troubleshooting activities, performance reviews and continuous improvement initiatives.

The overall approach develops practical understanding while reinforcing the importance of approved operating procedures, technical discipline and established safety controls. It also enables participants with different levels of refinery experience to build a common understanding of process behaviour and operational performance.

Organisational impact

The Petroleum Refinery Processes & Operations Training Course supports organisational performance by improving the ability of refinery personnel to understand process behaviour, recognise operating problems and coordinate technical responses. Its benefits extend across production, engineering, maintenance, quality assurance and process safety functions.

Improved Process Efficiency

A stronger understanding of refining processes helps personnel recognise conditions that affect separation performance, conversion efficiency, energy consumption and product recovery. Participants become better equipped to identify performance deviations, communicate their implications and support investigations into avoidable operating losses.

For sponsoring organisations, this capability supports more informed process reviews and more consistent evaluation of opportunities to improve unit performance. It also strengthens the ability to distinguish between operating issues, equipment limitations and feedstock-related constraints.

More Reliable Refinery Operations

Refinery reliability depends on the effective coordination of process units, equipment systems and operating teams. Training helps personnel understand the consequences of process disturbances and the importance of maintaining stable operating conditions within approved limits.

Improved process awareness supports earlier recognition of abnormal trends, better escalation of technical concerns and more effective coordination between shift operations, engineering and maintenance teams. These practices contribute to the prevention of avoidable disruptions and support production continuity.

Stronger Process Safety Awareness

Refinery personnel work with hazardous substances and operating systems that demand disciplined process control. The course reinforces understanding of operating envelopes, process deviations, hazard awareness and the importance of following established procedures.

Participants develop a clearer understanding of how changes in temperature, pressure, flow and equipment condition influence process risk. This supports stronger communication of emerging concerns and reinforces the role of operational discipline in preventing incidents.

Better Product Quality Management

Finished product quality depends on the performance of multiple process units and treatment stages. Training improves understanding of the factors that influence product characteristics, including feedstock composition, process severity, contaminant removal and blending decisions.

This knowledge supports more effective collaboration between production teams and laboratory or quality assurance functions. It also helps personnel understand the operational consequences of off-specification products, reprocessing requirements and deviations from customer specifications.

Improved Energy and Resource Utilisation

Energy consumption is a significant operational consideration in petroleum refining. A clearer understanding of heat transfer, furnace operation, distillation requirements and process integration enables participants to contribute more effectively to energy performance reviews.

The course supports the identification of potential improvement areas involving heat recovery, operating conditions and avoidable process inefficiencies. Any resulting savings depend on the facility, the available improvement opportunities and the implementation of appropriate technical measures.

More Effective Troubleshooting

Structured troubleshooting reduces dependence on assumptions and encourages decisions based on operating evidence. Participants learn to examine process trends, assess relationships between operating variables and identify the information needed to investigate performance deviations.

This capability improves the quality of technical discussions and supports more consistent communication between operational and engineering personnel. It also helps organisations develop clearer problem statements and more focused corrective-action plans.

Stronger Cross-Functional Coordination

Refinery performance depends on cooperation between operations, process engineering, maintenance, inspection, instrumentation, laboratory and production planning teams. A shared understanding of refining processes improves communication across these functions.

Participants gain a clearer appreciation of how decisions in one area affect other parts of the production system. This supports better coordination during troubleshooting, operating changes, maintenance planning and product-quality investigations.

Support for Compliance and Operational Governance

The programme reinforces the importance of documented procedures, technical standards, equipment integrity, process safety management and environmental controls. It helps personnel understand how established frameworks support consistent decision-making and the management of operational risk.

Training does not replace formal compliance assessments, specialist engineering reviews or site-specific competency requirements. Instead, it strengthens the process knowledge needed to apply organisational procedures and contribute to effective operational governance.

Personal impact

The Petroleum Refinery Processes & Operations Training Course strengthens participants' ability to understand industrial refining systems and make informed contributions to day-to-day operations.

Broader Technical Understanding

Participants develop an integrated view of petroleum refining, including the purpose of individual process units, their operating requirements and their contribution to finished product production. This understanding helps them connect routine operating activities with wider production objectives.

Improved Operational Decision-Making

Participants learn to consider process conditions, equipment limitations, product requirements and safety implications when evaluating operational issues. They develop a more structured approach to recognising deviations, gathering relevant information and communicating concerns to appropriate technical personnel.

Stronger Troubleshooting Capability

The course improves participants' ability to interpret operating trends and understand potential causes of process deterioration. They gain a practical framework for distinguishing symptoms from possible underlying causes and supporting systematic investigations.

Enhanced Professional Communication

A stronger technical vocabulary enables participants to communicate more effectively with process engineers, control room operators, maintenance specialists and production managers. This is particularly valuable when explaining process deviations, discussing unit performance or preparing operational handovers.

Greater Awareness of Process Safety

Participants strengthen their understanding of refinery hazards, normal operating limits, process deviations and the importance of procedural compliance. This awareness supports more disciplined workplace behaviour and more effective reporting of operational concerns.

Increased Contribution to Performance Improvement

Participants become better prepared to contribute to discussions about throughput, yield, energy consumption, product quality and equipment reliability. They gain a clearer understanding of how technical observations translate into opportunities for operational improvement.

Career and Professional Development

The programme supports the professional development of personnel working in refinery operations, process engineering, production supervision, technical services and related functions. It provides a foundation for taking on broader operational responsibilities and collaborating more effectively across refinery departments.

The knowledge gained also supports ongoing professional development in areas such as process optimisation, refinery troubleshooting, production planning, process safety and asset performance management.

Who should attend

  • Refinery Operations Managers: Strengthen oversight of process performance, production continuity, operating discipline and coordination between refinery units.

  • Production Managers and Superintendents: Improve understanding of unit interactions, product yields, operational constraints and production planning decisions.

  • Process Engineers: Develop broader knowledge of refining technologies, process variables, unit performance and troubleshooting methods.

  • Control Room Operators: Improve interpretation of process indicators, operating trends, abnormal conditions and interactions between process units.

  • Field Operators: Strengthen understanding of equipment functions, process flow, operating procedures and the significance of field observations.

  • Shift Supervisors and Team Leaders: Improve technical decision-making, shift communication, operational coordination and the escalation of process concerns.

  • Chemical and Petroleum Engineers: Expand practical knowledge of refinery configurations, feedstock processing, conversion technologies and finished product requirements.

  • Maintenance and Reliability Engineers: Understand how process conditions influence equipment performance, maintenance priorities and the reliability of refinery assets.

  • Instrumentation and Control Engineers: Develop a stronger understanding of process variables, control requirements and the operational significance of instrumentation readings.

  • Process Safety Professionals: Improve understanding of refinery process hazards, operating envelopes, process deviations and the technical context of risk management.

  • Inspection and Asset Integrity Personnel: Strengthen awareness of refining environments, equipment operating conditions and the relationship between process deterioration and asset integrity.

  • Laboratory and Quality Assurance Personnel: Understand how refinery operating conditions and treatment processes influence intermediate streams and finished product quality.

  • Technical Services and Performance Improvement Specialists: Build the process knowledge required to evaluate production losses, energy performance and opportunities for optimisation.

  • Refinery Project and Commissioning Engineers: Develop a clearer understanding of process unit functions, operating interfaces and the requirements for integrating new or modified facilities.

  • Oil and Gas Professionals Transitioning into Refining: Establish a practical foundation in refinery processes and operations when moving from upstream, midstream or other downstream functions.

  • Senior Technical and Operations Executives: Improve the technical perspective needed to evaluate production performance, operating risks, resource utilisation and improvement priorities.

Course outline

This module introduces the structure of the refining industry, the characteristics of crude oil and the principles governing the conversion of crude feedstock into valuable petroleum products. Participants examine the relationship between crude composition, refinery configuration, product demand and processing requirements.

The module establishes the technical foundation for understanding refinery process units and their interactions. It also examines crude oil receipt, storage, preparation, desalting and the importance of maintaining appropriate feed conditions before processing.

  1. API 2350

    • API Standard 2350 addresses overfill prevention for petroleum storage tanks in applicable petroleum facilities.

    • It provides a recognised framework for managing tank overfill risk through defined operating practices, procedures and safeguards.

    • Participants examine the relevance of tank inventory management, operating limits and coordinated controls during crude oil receipt and storage.

    • Application depends on the facility, tank configuration and the standard's scope.

    Learning Outcomes

    • Explain the purpose and commercial role of a petroleum refinery.

    • Describe the principal properties of crude oil that influence refining operations.

    • Explain the relationship between crude characteristics and refinery processing requirements.

    • Outline the stages involved in crude receipt, preparation and initial processing.

    • Describe the purpose of desalting and preheating systems.

    • Interpret simplified refinery process flow diagrams.

    • Explain how feedstock preparation supports stable downstream operations.

    • Recognise the importance of controlled storage, documented procedures and appropriate operating limits.

This module examines atmospheric and vacuum distillation as the principal separation processes used to divide crude oil into fractions for further processing. Participants explore the relationship between temperature, pressure, vapour-liquid behaviour and fractionation performance, with emphasis on operating conditions and product recovery.

The module also considers the factors that affect distillation stability, including feed conditions, heat input, column pressure, reflux, stripping steam and equipment performance. Participants develop an understanding of how separation efficiency influences downstream unit operation and overall refinery economics.

  1. API 560

    • API Standard 560 covers fired heaters for general refinery service within its defined scope.

    • It provides recognised engineering requirements for the design and construction of applicable refinery fired heaters.

    • Participants examine the relationship between furnace operation, heat input, process feed conditions and safe equipment performance.

    • The standard provides an engineering reference rather than a substitute for site-specific operating procedures.

    Learning Outcomes

    • Explain the operating principles of atmospheric and vacuum distillation.

    • Distinguish between the principal product fractions recovered from crude oil.

    • Describe how temperature and pressure influence fractionation.

    • Identify important operating variables affecting distillation performance.

    • Explain the role of furnaces, heat exchangers, reflux and stripping systems.

    • Recognise common symptoms of distillation inefficiency and operating instability.

    • Interpret basic process trends to support operational troubleshooting.

    • Explain how primary separation performance affects downstream process units.

This module explores the conversion technologies used to transform lower-value or heavier hydrocarbon streams into products with greater commercial value. Participants examine catalytic cracking, hydrocracking, catalytic reforming and associated process considerations, including the functions of catalysts, hydrogen and reaction conditions.

The module also addresses the relationship between conversion severity, product distribution, energy consumption and equipment constraints. Participants investigate the operational factors that influence conversion performance and understand why changes to one unit can affect the operation of other refinery systems.

  1. API 521

    • API Standard 521 addresses pressure-relieving and depressuring systems.

    • It provides engineering guidance for evaluating overpressure scenarios and designing appropriate pressure-relief and depressuring arrangements within its scope.

    • Participants examine the significance of pressure protection in process systems operating under demanding conditions.

    • The standard supports understanding of the engineering safeguards associated with abnormal pressure conditions; it does not establish site-specific operating instructions.

    Learning Outcomes

    • Explain the purpose of major refinery conversion processes.

    • Differentiate between catalytic cracking, hydrocracking and catalytic reforming.

    • Describe the influence of catalysts, hydrogen and operating conditions on conversion performance.

    • Identify important variables affecting product yield and quality.

    • Explain the relationship between conversion processes and downstream treatment requirements.

    • Recognise operational symptoms associated with reduced conversion performance.

    • Evaluate how changes in one unit affect connected refinery systems.

    • Contribute to discussions about yield improvement, operating constraints and process optimisation.

This module examines the processes used to remove contaminants, improve product characteristics and prepare refinery streams for final use. Participants explore hydrotreating, sulphur removal, hydrogen utilisation and the importance of controlling product properties throughout the refining process.

The module also considers product blending, specification management, laboratory testing and the operational consequences of producing off-specification material. Participants develop a practical understanding of how treatment efficiency and blending decisions influence product quality, storage requirements and commercial value.

  1. ISO 4259

    • ISO 4259 addresses the determination and application of precision data in relation to petroleum product test methods.

    • It provides a recognised statistical framework for interpreting test results and understanding the precision of petroleum product measurements.

    • Participants examine the importance of test-method precision when assessing product conformity and investigating differences between laboratory results.

    • The standard supports informed interpretation of test data but does not replace the product specification or the applicable test method.

    Learning Outcomes

    • Explain the purpose of hydrotreating and desulphurisation processes.

    • Describe how treatment operations influence petroleum product characteristics.

    • Identify important factors affecting treatment efficiency and product quality.

    • Explain the contribution of hydrogen and catalysts to selected treatment processes.

    • Describe the principles of refinery product blending.

    • Interpret the operational significance of common petroleum product quality indicators.

    • Explain how laboratory results support production and quality decisions.

    • Identify appropriate considerations when investigating off-specification products.

    • Recognise the importance of product segregation, storage controls and accurate quality documentation.

This module integrates the technical knowledge developed throughout the programme and examines how refinery units operate as a coordinated production system. Participants explore process monitoring, operating discipline, equipment reliability, energy efficiency and the management of abnormal operating conditions.

The module also addresses the relationship between process safety management and production performance. Participants examine the importance of operating procedures, management of change, incident investigation, equipment protection and effective communication between operational and technical teams. The focus is on applying process knowledge to improve reliability, control operational risk and support continuous improvement.

  1. OSHA Process Safety Management

    • OSHA's Process Safety Management of Highly Hazardous Chemicals standard, 29 CFR 1910.119, establishes requirements for covered processes within its United States regulatory scope.

    • It addresses process safety information, process hazard analysis, operating procedures, training, mechanical integrity and management of change.

    • The standard also covers incident investigation, emergency planning and other elements of process safety management for applicable facilities.

    • Participants examine how these elements support disciplined refinery operations and the prevention of major process incidents.

    • Its legal applicability depends on the facility and jurisdiction. Other locations apply their own regulatory requirements and recognised process safety frameworks.

    Learning Outcomes

    • Explain the operational relationships between major refinery process units.

    • Interpret basic process indicators to identify abnormal operating conditions.

    • Describe how process control and operating discipline support stable production.

    • Recognise the importance of process hazard identification and risk management.

    • Explain the role of operating procedures, management of change and mechanical integrity.

    • Identify opportunities to improve energy utilisation and process performance.

    • Apply a structured approach to refinery troubleshooting and performance investigations.

    • Explain how incident learning and corrective actions contribute to operational improvement.

    • Strengthen communication between operations, engineering, maintenance and process safety teams.

    • Contribute to practical improvement initiatives addressing reliability, product quality and production efficiency.

Certificate

Upon successful completion of the Petroleum Refinery Processes & Operations Training Course, attendees receive a Certificate of Completion from Institute For Oil & Gas Training.

The certificate recognises participation in the training programme and completion of its learning requirements. Attendees must meet the institute's applicable attendance requirement and participate in the required course activities to qualify for the certificate. The certificate does not represent a professional licence or an independently accredited engineering qualification.

Course dates

  • Europe

    Middle East

    Asia

    Africa

    North America

    Online

    Fee: £4,400

  • Europe

    Middle East

    Asia

    Africa

    North America

    Online

    Fee: £4,400

  • Europe

    Middle East

    Asia

    Africa

    North America

    Online

    Fee: £4,400

  • Europe

    Middle East

    Asia

    Africa

    North America

    Online

    Fee: £4,400

Fees include tuition, course materials and refreshments. Need different dates or a different city? Ask about your preferred date.

Frequently asked questions

What does the Petroleum Refinery Processes & Operations Training Course cover?

The course covers the main stages of petroleum refining, including crude oil preparation, atmospheric and vacuum distillation, catalytic cracking, hydrocracking, catalytic reforming, hydrotreating, desulphurisation, product blending and integrated refinery operations. It also addresses process monitoring, troubleshooting, energy efficiency, product quality and process safety.

Who should attend this refinery operations training course?

The course is suitable for refinery operators, process engineers, production supervisors, operations managers, maintenance and reliability engineers, instrumentation specialists, process safety professionals, laboratory personnel and other oil and gas professionals involved in refining activities. It also benefits technical personnel transitioning into downstream operations.

How is the Petroleum Refinery Processes & Operations Training Course delivered?

Institute For Oil & Gas Training uses instructor-led technical sessions, refinery case studies, process flow exercises, operational scenarios, process data interpretation and group problem-solving activities. The delivery approach connects refining principles with practical workplace responsibilities and operational challenges.

How long is the course, and will attendees receive a certificate?

The total course duration is 15–20 hours. Attendees who complete the programme and meet the applicable attendance requirement receive a Certificate of Completion from Institute For Oil & Gas Training.

How will this course benefit refinery operations and performance?

The course strengthens participants' understanding of process units, operating variables, product quality and the relationship between refinery systems. This knowledge supports more effective troubleshooting, improved operational communication, better identification of process inefficiencies and stronger awareness of process safety requirements. Organisational results depend on how the learning is applied to actual operating conditions and improvement initiatives.

Next: 19 Oct 2026

4 dates available

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