Advanced GC Process Troubleshooting & Control System (Managing Efficient Shutdowns & Turnarounds)

Introduction

This course is divided into two modules:

Advanced GC Process Troubleshooting & Control System

The course covers the major components and subsystems of a gas chromatographic system and its accessories, including in­lets, columns, and detectors. It presents operating principles, set-up procedures, and failure modes for each along with prac­tical examples. Preventative maintenance is covered with emphasis on maintaining analysis and troubleshooting methods of the inlet, columns, and detectors, data and others. The course discusses the optimization of column lengths, flows, and tempera­tures. It includes the necessary theoreti­cal information in each section. In addi­tion two software programs are applied for quantitative methods.

The course includes the practical mainte­nance where some parts of GC are dem­onstrated i.e. inject system part, different liner and syringes, maintenance kit, differ­ent columns type, and FID detector part. In addition, video films of maintenance methods for different types of GC compo­nents are available in the course.

Managing Efficient Shutdowns & Turnarounds)

The course will cover also the Planning and managing of shutdowns, turnarounds, and outages in the process plant environment as they are a complex and demanding function. If turnarounds are not properly planned, managed and controlled, companies run the risks of serious budget overruns, costly schedule delays and negative impacts on customers.

In this course you will learn:

How to develop a Shutdown/Turnaround strategy

Management of all stages of the shutdown process

Develop the management plan, work plans, resource plans, and budget

How to management related issues such as risk and safety

This course has been developed to specifically respond to the need to help organizations meet their shutdown and turnaround goals. A combination of extensive hands-on experience in turnaround planning and execution, input from turnaround teams, and emerging industry trends were blended together to establish best practice turnaround management approaches. This course is designed to establish a thorough understanding of the fundamentals of effective shutdown and turnaround management.

Objectives

Upon completion of the Course, Participants will be able to:

• The aim is to provide first-hand information to the participants on the optimal use of gas chromatography (GC).
• A special emphasis has been given on the demonstration of applica­tions, maintenance, and trouble­shooting of GC.
• Imparting participants’ fundamen­tal knowledge of Gas Chromatog­raphy as a technique.
• To understand GC maintenance methods as a routine check.
• Knowledge of accessories and con­sumables required for its opera­tion.
• To familiarize participants with the techniques for achieving gas chro­matography analysis, qualitative and quantitative methods, cause and effect diagrams and the standard curve.
• To enhance the company’s turnaround management capabilities, and to ensure a team approach in the planning and execution of plant shutdowns and turnarounds
• Provide a comprehensive understanding of effective turnaround management techniques and implementation
• Create awareness of planning methods and an integrated organizational approach in the execution of successful turnarounds
• Incorporate latest developments in turnaround planning and management techniques and emerging industry trends

Target Audience

• Shutdown or turnaround managers and coordinators
• Planning/scheduling and cost control staff
• Construction superintendents and supervisors
• Operations shutdown/outage coordinators
• Project engineers and contract administrators
• Participation from inspection, materials, safety and maintenance engineering is also encouraged
• All who works in any laboratory, i.e. clinical, industry, gas, petroleum, refinery, phar­macy, etc
  • Laboratory manager and supervisor
  • Laboratory engineers and chemists
  • Laboratory analysts and technicians
  • Instrument engineers/technicians

Instrumentation & Process Outline

The course covers the following topics:

Module 1: Advanced GC Process Troubleshooting & Control System

CHROMATOGRAPHY FUNDAMENTAL AND SEPARATION TECH­NIQUE

THEORY PARAMETERS:

• Plate height (H)
• Retention Time
• Capacity Fac­tor
• Selectivity Factor
• Column Efficiency
• Column Resolution

SAMPLING AND SAMPLE HANDLING ISO 17025:

• Requirements for Gases,
• Liquid and Solid,
• Sample Sampling Methods,
• Sample Registra­tion and Storage,
• Sample Disposal,
• Max Holding Time of Sample,
• Sample Contamination.

SAMPLE PREPARATION AND ANALYTE MANIPULATION TECHNIQUE:

• Solid-phase extraction,
• Static headspace technique,
• Soxhlet extraction,
• Microwave-assisted extraction,
• Supercritical fluid extraction

DERIVATIZATION METHOD:

• Silyl
• Alkyl
• Acylation and Esterification Methods

DESCRIPTION OF GC COMPONENTS

TYPES OF GC:

• Normal GC,
• High-Speed GC and Portable GC

GC SEPARATION AND RETENTION PROCESS:

• Dispersive Interac­tions,
• Dipole-Dipole Interactions,
• Dipole-Induced Dipole Interactions

OPERATING CONDITION AND STANDARD OPERATING PROCE­DURE

CARRIER GAS:

• Van Demeter equation,
• Optimal Practical Gas Velocity (OPGV),
• Average Linear Velocity,
• Flow Rate,
• Carrier Gas Selection,
• Pressure Regulator,
• Gas Purification

SAMPLE INJECTION SYSTEM:

• Sample Introduction Technique,
• Manual Injection,
• Solvent Flush Injection,
• Septa,
• Inlet Liner
• Split/Splitless Inlets System
• Spit Ratio
• Purge Delay Time,
• Cool On-Column Inlets,
• Programmed Temperature Vaporization,
• Headspace Technique,
• Injection Problems,
• Hot Vaporizing Injector

COLUMN CONFIGURATIONS:

• Stationary Phase of Packed and Capillary Column,
• Packed Columns,
• Temperature programming,
• Gas-Liquid and Gas-Solid Columns,
• Polarity and Selectivity,
• Column Coating

DETECTORS:

• Ideal Characteristics
• Column Position
• Gases
• Flame Ionization Detector
• Thermal Conductivity Detector,
• Flame Photometric Detector,
• Nitrogen Phosphorous Detector,
• Photo Ionization Detector,
• Electron Capture Detector,
• Mass Spectrometry (Fragmentation and identify technique with software training),
• Chemiluminescent Detector,
• Mass Analyzer – Time of Flight,
• Ion Trap and Quadruple Technique.

MAINTENANCE AND INSTALLATION METHODS:

• Clean and Condition Septa,
• Cleaning Injector Liners,
• Silylating Liners,
• Column Conditioning,
• Installation Fused Silica Capillary Columns,
• Column Placement in the oven,
• Column Installation,
• Leak Detection,
• Bleed Test,
• FidJet Cleaning Procedure,
• TCD Clean Detector Cell,
• Cleaning Of ECD,
• FPD Mainte­nance,
• Cleaning MS and Change the Filament

INSTRUMENT PROBLEMS AND TROUBLESHOOTING:

• Approaches to Solve GC Problems
• Troubleshooting Tests
• Band Broadening
• Broadening Initial Peak Bandwidths
• Retention Gap Sampling
• Sampling By Solute Fo­cusing
• Retention Gaps Tube
• Baseline Deviation
• Noisy Baseline
• Spikes in Baseline
• Peak Shape Problems
• Flat Top Peaks
• Split Peaks
• Negative Peaks
• Retention Changes
• Ghost Peak
• Causes and Prevention of Column Damage
• Column Contamination
• Needle Discrimination
• Change in Detec­tors Sensitivity
• Difficulty in Lighting Fid Flame
• Loss of Detectors Linear Range
• Leaks in MS
• Excessive Noise or High Background in MS

PRACTICAL DEMONSTRATION:

• Introduction and familiarization with GC
• Preparation of sample test
• Preparation of standards
• Setting the methods program
• Inject the sample and standards
• Print the chromatograms
• Check all GC components and how to do the preventive maintenance

QUALITY CONTROL AND VALIDATION METHOD:

• Specificity
• Linear­ity
• Selectivity
• Accuracy
• Precision
• Bias
• Linearity
• Range
• Limit of De­tection
• Limit of Quantification
• Robustness
• Ruggedness
• Stability

QUANTITATIVE METHODS:

• Interpolated Graph Calibration by Using External and Internal Standards
• Standard Addition Method
• Calibration Methods
• Correlation Coefficient
• Outliers Test of Repeated Measure­ments
• Outliers in the Calibration Curve
• Errors in Quantitative Analysis
• Distribution of Errors
• Confidence Limit
• Limit of Detection
• Repeatabil­ity
• Reproducibility
• Optimization Methods

Module 2: Managing Efficient Shutdowns & Turnarounds

Introduction to Shutdowns and Turnarounds

• Introduction to Shutdown and Turnaround Management
• The Shutdown Management Process
• Organization and Roles

Shutdown/Turnaround Preparation

• Plant Shutdown and Preparation for Maintenance
• Scope of Work Development and Work Breakdown Structures
• Preparation and Execution Issues
• Logistics, infrastructure and materials management

Shutdowns/Turnaround Planning Techniques

• Developing Shutdown and Turnaround Plans
• The Critical Path Planning Method
• “Short Cut” Planning Methods
• Developing the overall Shutdown Plan

Progress Monitoring and Control

• Progress Monitoring and Control
• Budgeting and Cost Control
• Earned Value, Earned Hours and Key Performance Indicators
• Finalization, Post-Audit and Improvement planning
• Contractors and Contractor Management
• Managing Safety

Safety, Quality and Risk Management

• Managing Safety and Quality
• Risk Management
• Overview of Computerized Tools
• Conclusion