INTRODUCTION:

This intensive training course will provide delegates with the required skills to ensure cost effective operation and maintenance for their process plant.  Optimum modes that produce the most efficient results, consistent with safe and reliable operation will be studied in detail.

Plant energy consumption and reliability is the foundation of process plant optimisation. For optimisation benefits to be sustainable, production interruptions must be kept to a minimum, which requires effective management of degradation processes that affect equipment and systems and effective inspection and maintenance strategies, plans and methods. Plant optimisation can be an effective way to achieve improved profitability without the large investment associated with building a new plant.

Objectives

By the end of this Process Plant Optimisation & Energy Conservation training course, participants will be able to:

Recognize and understand overall plant effectiveness (OPE)

Apply the business focus to ensure sustainable plant profitability

Appraise the most cost-effective operation and energy saving methods

Describe the managerial tools needed to effectively optimize plant operations

Implement the most appropriate operation and maintenance strategies

Determine and measure key performance indicators (KPIs) for their plant

Identify and apply effective procedures to improve those KPIs

Course Outline

DAY 1

Appreciation of Process Plant Effectiveness

The Concept of Overall Plant Effectiveness (OPE)

Constraints in Optimization Operation, Economy and Environment

Relationship Between Business and Plant Effectiveness

Effects of Equipment Failures on Business

Impacts of Operation and Maintenance on Plant Effectiveness

Determination of Process Plant Availability

Practical Case Study

DAY 2

Process Plant Reliability and Improvement Techniques

Process Plant Reliability (PPR) and Effectiveness (PPE)

Calculation of Process Plant Reliability

Determination of Process Plant Effectiveness

Parameters Influence Plant Reliability

Parameters Influence Plant Effectiveness

Plant Reliability and Effectiveness Improvement Methods

Case Study

DAY 3

Energy Savings Opportunities and Strategies

Energy Use in Process Plant and Petrochemical Industry

Best Practices in Process Plant Energy Management

Heat Integration Methods

Pinch Method and Improvement Procedure

Thermal Power Plants Energy Saving Options

Obstacles for Energy Management Programs

Case Study

DAY 4

Monitoring and Failure Prevention Methods

Methods for Minimizing Static Equipment Failure

Strategies for Mitigating Rotating Equipment Down Time

Condition Monitoring Methods

None Destructive Examination (NDE) Techniques

Determination of Equipment Life Time and Remaining Life

Methods for Extending Equipment Cycle and Service Time

Detailed Case Study

DAY 5

Best Practices in Operation & Maintenance Methods

Cost-effective Operation and Maintenance Strategies

Piping System, Tanks and Pressure Vessels

Heat Exchangers, Boilers and Cooling Towers

Turbomachinery: Pumps and Compressors

Project and Spare Parts Management and Budgeting

Practical Case Study