Process Plant Optimization Technology & Continuous Improvement (Energy & Reliability Indicators)

Plant Optimization plays very important role in today’s industrial world. For optimization benefits to be substantial, cost of production including operation interruptions must be kept to a minimum. This requires effective management of maintenance operations and optimization of equipment and plant reliability and availability. This also involves effective inspection and maintenance strategies, planning methods. Plant optimization can be an effective way to achieve improved profitability & sustainability.

Important aspect of process plant optimization is related to system energy management and energy consumption reduction. Industrial processes and systems offer significant potentials for savings. Process changes such as advanced controls and new technologies also present opportunities for plant optimization.

Audience

This course is designed for:

Process plant technical professionals: engineers, technicians and operators
Engineers, supervisors, production, operations and maintenance personnel, as well as for project engineers
Engineering and technical personnel involved in improving process plant profitability and energy efficiency
R&D staff of all technical disciplines

Course objectives

The course objectives are:

To assist participants in understanding the main elements of plant optimization the way how to achieve and realize potential benefits
To enhance the business focus of participants and equip them to make more contributions to sustainable plant profitability
To equip maintenance professionals, planners and engineers with the knowledge to select the most appropriate methodologies for their maintenance decision-making
To learn how to identify the potential for reduction of energy consumption
To provide participants with practical and effective methods and tools to perform technical and economic evaluations of the alternatives

Course contents

Day-1

Pretest
Overview of Optimization Technologies
Overview of Optimization Technologies for Process Plants
Elements of Process Plant Optimization Procedure
Constraints in Optimization: Production, Operation, Economy and Environment
Optimization Approaches: Mathematical Models and Physical Models – prototype units
Correlation between Process Optimization and Process Control in Typical Process Plant
Workshop: Examples and Solutions

Day-2

Reliability, Availability and Effectiveness
Relationship between Plant Reliability and Availability
Optimization of Plant Reliability
Optimization of Plant Availability through Improved Maintenance
Analysis of Effectiveness of Individual Equipment
Optimization of Overall Plant Effectiveness
Workshop: Examples and Solutions

Day-3

Best Practices for Energy Consumption
Optimization Strategies Aimed at Energy Consumption Reduction
World Standards and Benchmarking Guidelines
Best Practices in Process Plant Energy Management
Energy Conservation Check List in Typical Industrial Plants
Optimization of Heat Production and Steam Distribution and Consumption
Workshop: Examples and Solutions

Day-4

Maintenance Management System
Optimization of Utilization of Piping Systems and Pipelines
Optimization of Utilization of Pumps, Compressors and Fans
Optimization of Maintenance Management System and Frequency of Maintenance
Optimization of Spare Parts Management through Predictive Maintenance
Optimization of Repair and Alteration Programs in Accordance to Existing Codes
Workshop: Examples and Solutions

Day-5

Minimization of Equipment Failure

Risk Based Inspection (RBI)

Procedures for Minimizing Risk of Equipment Failure
Fitness For Service (FFS) Analysis and Estimate of Remaining Life of Equipment
Optimization of Plant Economy through Planned Equipment Replacement
Summary and Course Review
Posttest

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