Applied Science and Mathematics for Process Operators

Overview

Process operators make decisions every shift that depend on basic science and mathematics: reading gauges in different units, estimating flows and levels, understanding why pressure rises when a vessel heats up, or calculating how long a tank will take to fill. Weak skills in these areas lead to errors in readings, poor judgement during upsets and difficulty following technical training on process equipment. Many operators joined the industry from varied backgrounds and need a practical refresher that connects science and maths directly to the equipment and situations they meet on site.

This course builds the applied science and mathematics skills that process operators need in refineries, gas plants and petrochemical facilities. Participants review arithmetic, percentages, ratios, algebra and the use of formulas, then apply them to units and conversions, areas and volumes, flow rates and mass balances. It explains the physical principles behind operation, including pressure, temperature, heat and energy, the gas laws, fluid flow, phase changes and basic electricity. It also covers reading graphs, trends and data sheets, using examples from pumps, tanks, heat exchangers, compressors and columns to show how science and maths support safe and efficient operation.

Objectives

• Apply arithmetic, percentages, ratios and simple algebra to plant calculations
• Convert confidently between metric, imperial and oilfield units
• Calculate areas, volumes, tank contents and flow rates accurately
• Explain pressure, temperature, heat and energy in process equipment
• Use the gas laws and basic fluid flow principles to predict behaviour
• Understand phase changes, vapour pressure and boiling in process systems
• Read graphs, trends and data sheets to support operating decisions

Who should attend

Training methodology

The course uses a step-by-step approach that starts from basic skills and builds towards realistic plant problems. Each topic is explained with simple examples, followed by worked calculations and practice exercises based on real tanks, pumps, exchangers and columns. Participants use calculators and plant data sheets, read trend charts and solve problems in pairs and small groups. Short demonstrations and videos illustrate physical principles such as pressure, boiling and gas expansion. Trainers give individual support to participants who need extra help, and each day ends with a short quiz and review of common mistakes.

Programme outline

Dates and fees

Certificate

Frequently asked questions