(Click Category to List Courses)
14 - CHM - Chemical and Process Engineering
CHM 182 - Operation Excellence & Optimizing Petrochemicals Process Plants & Refineries
| Code | Start Date | Duration | Venue | |
|---|---|---|---|---|
| CHM 182 | 23 June 2025 | 5 Days | Istanbul | Registration Form Link |
| CHM 182 | 18 August 2025 | 5 Days | Istanbul | Registration Form Link |
| CHM 182 | 13 October 2025 | 5 Days | Istanbul | Registration Form Link |
| CHM 182 | 08 December 2025 | 5 Days | Istanbul | Registration Form Link |
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Course Description
Plant integrity and reliability is the cornerstone of process plant operation. For optimization 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 operation can be an effective way to achieve improved profitability without the large investment associated with building a new plant.
Common industrial processes and systems, such as steam, cooling water, process heating, and electric motors consume most of the energy and offer significant opportunities for savings. Process changes such as advanced controls, new catalysts, and new technologies also present opportunities for plant operations optimization. This course will provide a comprehensive review of the various aspects of process plant integrity as the essential foundation for sustainable plant profitability and optimization.
Course Objectives
- Recognize the elements of plant optimization
- Identify the Systematic and Coordinated Efforts by engineering, operations, and maintenance functions
- Maximize the plant availability, reliability and productivity
- Maximize operational costs
- Safeguard plant integrity over its intended life based on total life cycle cost principles
- Apply the business focus of participants and equip them to make more contributions to sustainable plant profitability
- Appraise the most attractive opportunities to identify energy savings
- Describe the managerial tools the delegates can utilize to effectively optimize plant operations
- Gain a sound understanding of the main elements of plant integrity and reliability and why this is the cornerstone of sustainable plant operation optimization and energy efficiency.
- Develop technical and analytical skills necessary for conducting technical evaluations.
- Be able to apply risk-based methodologies in inspection and maintenance.
Who Should Attend?
- Process Plant, Petroleum Refinery, and Gas Plant Technical Professionals
- 1st Line Operations personnel,
- Operation Supervisors,
- Engineers, Operations and Maintenance professionals, as well as for Project and Consulting Engineers
- Engineering and Technical professionals involved in improving process plant, petrochemical plant and refinery profitability and energy efficiency
Course Details/Schedule
Day 1
- Safety Systems and Risk Management
- Process Safety Fundamentals
- Learning from failures
- Analyzing near misses, incidents & accidents
- Taxonomy of theories
- Risk assessment, Choice of case studies
- Types of recommendations
Day 2
- Continuity of Operations – Plant Systems Reliability
- Coping with risks
- Defining reliability and resilience
- Reliability Centered Maintenance (RCM) techniques
- Fault Tree Analysis (FTA)
- Reliability Blok Diagram (RBD)
- Practical examples and case studies
Day 3
- Case Studies from High Reliability Organizations (HROs)
- Case from Process industry PB Texas City Texas
- Case from Oil and Gas industry
- Cases from Petrochemicals industry
- Group work and group presentations
Day 4
- The Concept of Generic Lessons & Benchmarking
- Best practice of learning from failures from different industries
- Best practice can be learned from worst practice
- The ten generic lessons and the three underpinning factors
- What is benchmarking? History of benchmarking
- Different methods of benchmarking and how they relate to each other
Day 5
- A Model of Learning and Unlearning Excellence
- Adaptive organizational learning
- Routine dynamics
- The Decision-Making Grid (DMG) model
- A framework for analyzing near-misses and failures
- High severity with low frequency versus high severity with high frequency
