Topic outline

  • Process Plant Performance & Efficiency

    This course covers systematic techniques on process plant performance and efficiency

    This course is intended for those concerned with the process plant performance and efficiency including planning staff, instrumentation & control staff, production & operation staff, process, electrical, mechanical and project engineers. Management can also appreciate the importance of the new tools available to achieve the plant objectives of today and meet the challenges of tomorrow
    • Training Methodology & Objectives

      Training Methodology

      This Trainee-centered course includes the following training methodologies:-

      • Talking presentation Slides (PPT with audio)
      • Simulation & Animation
      • Exercises
      • Videos
      • Case Studies
      • Gamification (learning through games)
      • Quizzes, Pre-test & Post-test

      Course Objectives

      After completing the course, the employee will:-

      Apply and gain an in-depth knowledge on process plant performance and efficiency Discuss progress charts (time versus depth), chemical product, process plant and its components
      Identify refineries complexity factors and carryout supply chain management, the pareto principle or 80-20 rule, production and improving performance and performance monitoring Employ operating procedures, optimization and managing performance as well as discuss the benefits of performance measurement
      Apply resources / budget justification, ownership and teamwork, communication and benchmarking Identify performance measures, metrics development process, leading and lagging indicators, data collection and quality
      Classify maintenance policies and apply predictive maintenance, comparison of maintenance strategies, proactive maintenance and reliability centered maintenance Define root cause analysis and identify its types as well as implement total productive maintenance and maintenance best practices
      Explain maintenance terms & definitions including reliability, availability and maintainability Discuss the functions of maintenance manager, supervisor and maintenance planner as well as perform motivating strategies, disciplinary action and performance appraisal
      Carryout modern maintenance management, operator best operating practice, maintenance excellence and effective maintenance planning Recognize the various types of schedule, the factors affecting scheduling and the principles of effective scheduling
      Implement maintenance strategies, modern maintenance management and best practices of lubrication storage and handling Apply the various ways to reduce inventory waste/costs and ensure that storage conditions are correct
      Describe system distribution diagrams, typical refinery offsite and utilities and refinery steam system Perform boiler feed water treatment and the recommended PRV installation
      Recognize combustion air preheating, radiation and convection heat loss minimization and variable speed control for fans, blowers and pumps Discuss key performance indicators, fuel efficiency, model validation and back-casting
      Carryout enterprise resource planning, risk management & optimization, risk management methods and HAZOP study Optimize offsites operations and illustrate tank farm layout, tank mixing, storage facilities operation, batch blending and blending optimization
      Apply inventory management, utilities management, boiler management, steam system and fuel gas system conventional control Employ total quality management, lean manufacturing, distillation optimization and MVPC optimization
      • Course Description

        This E-Learning course is designed to provide participants with a detailed and up-to-date overview of process plant performance and efficiency. It covers the progress charts (time versus depth), chemical product, process plant and its components; the refineries complexity factors, supply chain management, pareto principle or 80-20 rule, production and improving performance and performance monitoring; the operating procedures, optimization and managing performance; the benefits of performance measurement; the resources / budget justification, ownership and teamwork, communication and benchmarking; and the performance measures, metrics development process, leading and lagging indicators, data collection and quality
        Further, the course will also discuss the maintenance policies, predictive maintenance, comparison of maintenance strategies, proactive maintenance and reliability centered maintenance; the root cause analysis and its types; the total productive maintenance and maintenance best practices; the maintenance terms & definitions including reliability, availability and maintainability; and the functions of maintenance manager, supervisor and maintenance planner; the motivating strategies, disciplinary action and performance appraisal.
        Moreover, the course will also cover the modern maintenance management, operator best operating practice, maintenance excellence and effective maintenance planning; the various types of schedule, the factors affecting scheduling and the principles of effective scheduling; the maintenance implementation strategies,  modern maintenance management and best practices of lubrication storage and handling; the various ways to reduce inventory waste/costs and ensure that storage conditions are correct; and the system distribution diagrams, typical refinery offsite and utilities and refinery steam system
        During this course, participants will learn the boiler feed water treatment and the recommended PRV installation; the combustion air preheating, radiation, convection heat loss minimization and variable speed control for fans, blowers and pumps; the key performance indicators, fuel efficiency, model validation and back-casting; the enterprise resource planning, risk management methods and HAZOP study; the offsites operations optimization; the tank farm layout, tank mixing,   storage facilities operation, batch blending and blending optimization; the inventory management, utilities management, boiler management, steam system and fuel gas system conventional control; and the total quality management, lean manufacturing, distillation optimization and MVPC optimization
        • Module 1 - Introduction

          Contents:

            • Today's External Environment
            • Chemical Product
            • Products
            • Chemical Product
            • Process Plant
            • Components of the Process Plant
            • Refineries Complexity Factors
            • Supply Chain Management
            • Cost, Size & Complexity Impact ROI
            • How is the Pie Sliced?
            • Items Contributing to the Optimum
            • The Pareto Principle or 80-20 Rule
            • The Pareto Principle
            • The Pareto Principle in Action
            • Video: Pareto Principle - 80/20 Rule
            • Process Plant
            • Components of the Process Plant
            • Production and Improving Performance
            • Performance Monitoring
            • What is Optimization?
            • Optimization Characteristics
            • Maxima and Minima
            • What can Optimization Achieve?
            • How Big is the Pie?
            • As Cost, Size & Capacity Increase the Pie Gets Bigger
            • Module Quiz
          • Module 2 - Managing Performance

            Contents:
              • Managing Performance
              • The Benefits of Performance Measurement
              • Key Terms and Definitions
              • Goals
              • World-Class
              • Accountability
              • Resources / Budget Justification
              • Ownership and Teamwork
              • Communication - A Common Language
              • Benchmarking
              • Benchmarking - Definition
              • Benchmarking - An Improvement Tool
              • Benchmarking - Benefits
              • Benchmarking - Types
              • Benchmarking - Process
              • Benchmarking Methodology
              • Video: Different Types of Benchmarking
              • Identifying Performance Measures
              • Metric
              • Metrics Development Process
              • Leading and Lagging Indicators
              • lack of Standardized Definitions
              • Data Collection and Quality
              • Module Quiz
            • Module 3 - Understanding Maintenance

              Contents:
                • Understanding Maintenance
                • Maintenance Objectives in Plant
                • How Maintenance Achieve Objectives
                • Facts & Figures
                • Understanding Maintenance
                • Maintenance Development Over Time
                • Maintenance Policies
                • Classification of Maintenance Policies
                • Maintenance Policies
                • Comparison of Maintenance Strategies
                • Maintenance Policies
                • Proactive Maintenance
                • Understanding Reliability
                • Reliability Centered Maintenance
                • Maintenance & Reliability - Importance
                • Proactive vs. Preventive/Predictive
                • Maintenance & Reliability
                • Maintenance & Reliability Objectives
                • Equipment Reliability - Responsibility?
                • Top Management View of Maintenance
                • Maintenance & Reliability - Facts & Figures
                • What is Root Cause Analysis?
                • Types of RCA
                • FMEA/FMECA
                • Total Productive Maintenance
                • Maintenance Best Practices
                • Total Productive Maintenance
                • Maintenance Best Practices
                • Maintenance Terms & Definitions
                • Video: Plant Maintenance of Process Equipment
                • Module Quiz
              • Module 4 - Works Execution Management

                Contents:
                  • Organization Structures
                  • Vocabulary
                  • The Practical Result of Planning 
                  • Functions of Maintenance Manager
                  • What Maintenance Managers Do?
                  • Reaching Organisational Goals by Managing Resources 
                  • Management & Supervisor Functions 
                  • Planning Activities 
                  • Management & Supervisor Functions 
                  • Organising Activities 
                  • Management & Supervisor Functions 
                  • Leading Activities 
                  • Management & Supervisor Functions 
                  • Controlling Activities 
                  • What Resources Are Available and Should be Managed by the Supervisor? 
                  • Financial 
                  • Human/People 
                  • Physical 
                  • Information 
                  • Resources 
                  • Management Roles
                  • Management Skills
                  • Managerial Activities Study
                  • Allocation of Activities by Time
                  • Coping with “Temporariness”
                  • Declining Employee Loyalty
                  • Managers Dilemma
                  • Motivation, Employee Absenteeism
                  • Motivation
                  • Style of Management
                  • Motivating Strategies
                  • Disciplinary Action
                  • Procedure
                  • Performance Appraisal
                  • Steps in Appraisal
                  • Appraisal Force Distribution Method
                  • Message
                  • Human Resources
                  • Modern Maintenance Management
                  • Roles & Responsibilities of Maintenance Planner
                  • Maintenance Planners Attributes
                  • Maintenance Excellence
                  • Levels of Planning
                  • Long Range 
                  • Short Range
                  • Annual Budget
                  • Day to Day 
                  • Development of a Planning Package Includes
                  • Work Order
                  • Planner’s Attributes
                  • Principles of Effective Maintenance Planning 
                  • Failures of Planning
                  • Maintenance Planner Does NOT
                  • Schedule
                  • Types of Schedule
                  • Factors Affecting Scheduling
                  • Principles of Effective Scheduling
                  • Types of Schedule
                  • Scheduling
                  • Scheduling Team (Planner/Maintenance/Production)
                  • Principles of Effective Scheduling
                  • Types of Schedule
                  • Reliability Engineer
                  • The Importance of Teams
                  • Meeting
                  • Tips for Effective Group Meeting 
                  • Maintenance Implementation Strategies
                  • Communication
                  • Modern Maintenance Management
                  • The Maintenance Organization
                  • Vocabulary
                  • Video: Leading Effective Execution for Making Strategy Work
                  • Module Quiz
                • Module 5 - Materials, Repair, Operations Store Management

                  Contents:
                    • Course Perspective & Approach
                    • Manager’s View of MRO Storerooms
                    • Typical Look of MRO Stores
                    • Typical Look of MRO Storeroom
                    • MRO to be
                    • RMO to be
                    • MRO to be
                    • Lubrication Storage and Handling 
                    • How do we go from pictures A to B
                    • Organization Chart of MRO’s
                    • Organization Chart of MRO Storeroom
                    • Storekeeper Attributes
                    • Procurement
                    • Cutting Inventory Costs 
                    • Definitions
                    • Lead Time
                    • Economic Order Quantity (EOQ)
                    • Open or Closed Storeroom?
                    • Physical Storage
                    • Housekeeping
                    • Receiving, Inspection and Shipping
                    • Servicing of Stored Items
                    • Racks and Bins
                    • Satellite Storage
                    • Free-Issue Stores
                    • Vendor-Managed Storage
                    • Video: MRO Stockroom Management
                    • Module Quiz
                  • Module 6 - Energy Supply

                    Contents:
                      • System Distribution Diagrams
                      • Steam 
                      • Definition of Terms
                      • Dry Steam & Its Fraction
                      • Heat Recovery Steam Generation
                      • Boiler Equipment
                      • Heat Transfer Fundamentals to Boilers
                      • How are Boilers Classified?
                      • Water Tube Boiler
                      • Boiler Feed Water Treatment
                      • PRV Types
                      • Pilot Operated Pressure Relief Valves
                      • Safety Valves - Field Example
                      • Spring Force
                      • Basic Principles Associated with Steam Traps
                      • Common Return Lines
                      • Basic Principles Associated with Steam Traps
                      • Steam Flow Quality & Condensate
                      • Steam Traps Types
                      • Boiler & Fired heater Heat Exchange Efficiency
                      • Boiler Heat Exchange Efficiency/2
                      • Boiler Heat Exchange Efficiency/3
                      • Improve Plant By Increasing Efficiency 
                      • Typical Air Pre-Heating System 
                      • Types of Combustion
                      • Stack Temperature/ Efficiency
                      • Energy Efficiency Opportunities/1
                      • Energy Efficiency Opportunities/2
                      • Energy Efficiency Opportunities/3
                      • Energy Efficiency Opportunities/4
                      • Energy Efficiency Opportunities/5
                      • Cooling Water
                      • Direct-Contact Exchangers
                      • Types of Wet-cooling Towers
                      • Background
                      • Mechanical Draft Cooling Towers
                      • Cooling Water
                      • Condensers
                      • Electrical Energy
                      • Refrigeration
                      • Compressed Air
                      • Video: How a Watertube Boiler Works - Boiling Point
                      • Module Quiz
                    • Module 7 - Benchmarking & Best Practices

                      Contents:
                        • Performance Measures & Profitability 
                        • Key Performance Indicators  
                        • Relative Energy Intensity Index – Example
                        • Relative Maintenance Index US $/EDC 
                        • Key Performance Indicators 
                        • Key Performance Indicators Refinery Example 
                        • Key Performance Indicators 
                        • Best Practices 
                        • Model Validation 
                        • Back-Casting 
                        • Model Validation & Back-Casting 
                        • Other Considerations 
                        • Plant Optimization versus Supply Chain Optimization 
                        • Manufacturing Process Supply Chain 
                        • Supply Chain Management
                        • Supply Chain Optimization 
                        • Supply Chain Optimization - Schematic 
                        • Refinery & Process Plant Optimization Trends 
                        • Optimization Trends 
                        • The Overall Goal 
                        • Crude Unit Optimization Case Study 
                        • Crude Unit Expansion - Background 
                        • Crude/Vacuum Unit Original Design 
                        • Crude/Vacuum Unit Revamp Before 
                        • CDU Revamp Philosophy 
                        • Crude/Vacuum Unit Revamp After 
                        • CDU Loadings at Original Design 
                        • CDU Loadings by Adding a Pumparound Increases Capacity by 15% 
                        • Potential Revamp Capacity Increase = 85% 
                        • Actual Revamp Adds 40% Capacity 
                        • VDU Revamp Philosophy 
                        • Flashed Crude Composite Curves 
                        • MVPC Optimization 
                        • CDU/VDU Yields Before & After 
                        • Benefits – Margin & Capture 
                        • Module Quiz
                      • Module 8 - Management & Information Systems

                        Contents:
                          • Management Information Systems 
                          • Management Information System (MIS) 
                          • Enterprise Resource Planning (ERP) 
                          • Risk Management & Optimization 
                          • Optimization & Risk Management 
                          • Risk Management Methods 
                          • HAZOP Study 
                          • HAZOP Objectives 
                          • Consequences to be Considered 
                          • HAZOP Guide Words 
                          • HAZOP Team Review Process 
                          • Successful HAZOP Criteria 
                          • Hedging 
                          • Optimizing Offsites Operations 
                          • Tank Farm Layout 
                          • Optimum Storage Volume 
                          • Tank Mixing 
                          • Tank Blending with Fixed Angle Mixer 
                          • Sludge Build-up in Tank with Fixed Angle Mixer 
                          • No Sludge Build-up in Tank with Variable Angle Mixer 
                          • Storage Facilities Operation 
                          • Batch Blending 
                          • In-Line Blending 
                          • Blending Optimization 
                          • Inventory Management 
                          • Utilities Management 
                          • Boiler Management 
                          • Steam System Conventional Control 
                          • Steam System Control 
                          • Steam System Advanced Control 
                          • Fuel Gas System Conventional Control 
                          • Fuel System Control 
                          • Fuel Gas System Advanced Control 
                          • Video: Boiler Fuel Oil Systems
                          • Module Quiz
                        • Module 9 - Module 9 Refinery & Process Plant Optimization Trends

                          Contents:
                            • Optimization Trends
                            • The Overall Goal: Decrease or Increase? 
                            • Optimise Distillation
                            • Introduction - Distillation  Definition
                            • Optimise Distillation
                            • Optimise Reactors
                            • Crude Unit Optimization Case Study
                            • Crude Unit Expansion - Background
                            • Original Design
                            • Crude/Vacuum Unit Revamp - Before
                            • Crude Distillation U. Revamp Philosophy
                            • Crude/Vacuum Unit Revamp - After
                            • VacuumDist.U. Revamp Philosophy
                            • MVPC Optimization
                            • CDU/VDU Yields Before & After
                            • Module Quiz
                          • Module 10 - Continuous Improvement

                            Contents:
                              • Continuous Improvement
                              • Video: Continuous Improvement
                              • Total Quality Management
                              • Deming Cycle For TQM
                              • Continuous Improvement
                              • Kaizen
                              • Lean Manufacturing
                              • Just in Time
                              • Six Sigma
                              • Statistical Six Sigma Definition
                              • The Balanced Scorecard
                              • Comments on Continuous Improvement
                              • Some Inconsistencies & Contradictions
                              • Improvement Slows Down
                              • Continuous Improvement
                              • Module Quiz
                            • Module 11 - Case Studies

                              Contents:
                                • Crude Unit Optimization Case Study 1
                                • Crude Unit Expansion - Background
                                • Original Design
                                • Crude/Vacuum Unit Revamp - Before
                                • Crude Distillation U. Revamp Philosophy
                                • Crude/Vacuum Unit Revamp - After
                                • VacuumDist.U. Revamp Philosophy
                                • MVPC Optimization
                                • CDU/VDU Yields Before & After
                                • Case Study 2
                                • Case Study 3
                                • PMO - Case Study
                                • Case Study 4: Piper Alpha
                                • Case Study 5: Energy Outlook
                                • Case Study 6: Reduce Energy Demand
                                • Case Study 7: Owens-Corning Energy Efficiency Program
                                • Case Study 8: Energy Management 
                                • Case 8, Energy Management 
                                • Case Study 9: RCA Case Study of a Tetra Pak Filler Line
                                • RCFA Methodology
                                • Tetra-Pak Filler Line
                                • Tetra-Pak Filler Line Fishbone Analysis
                                • Tetra-Pak Line Action Plan
                                • Tetra-Pak Line Accountability
                              • Post-Test

                                Kindly complete the post-test to assess your knowledge about the topic after the course.