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Course Code
OGCM-023
Process Plant Optimization Technology and Continual Improvement
- This course will feature the importance and relevance of the constant need to monitor and adjust Process Plant operation to maintain the optimum mode that produces the most efficient results, consistent with safe and reliable operation. Plant integrity and reliability is the cornerstone of process plant optimization.
- 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 optimization can be an effective way to achieve improved profitability without the large investment associated with building a new plant.
Learning Outcomes
- Recognize and understand what plant optimization and energy conservation is
- Apply the business focus and equip them to make sustainable plant profitability
- Appraise the most attractive opportunities to identify energy savings
- Describe the managerial tools needed to effectively optimize plant operations
- Improved & Continual process plant parameters and energy conversion techniques & methodology
- Utilize Key Performance Indicators (KPIs) for performance monitoring.
- Implement continuous improvement frameworks.
- Develop optimization and improvement action plans.
After completion of this course, the attendees will be able to understand the following:
Course Contents
- Introduction to Process Plant Optimization
- Plant Performance Fundamentals
- Production Efficiency Concepts
- Process Constraints and Bottlenecks
- Operating Windows and Process Variability
- Process Flow Diagrams (PFDs) and Piping & Instrumentation Diagrams (P&IDs)
- Optimization Opportunities Across Plant Operations
- Practice cases & Application for process optimization.
- Implications of Plant continual improvement techniques & methodology
- Operational Excellence models
- Overall Equipment Effectiveness (OEE)
- Process KPI metrices
- Develop a continuous improvement roadmap.
- Practice cases & Application for continual improvement
- 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
- 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
- Post assessment
Introduction (Icebreaker, Sharing Expectations, Pre-Assessment)
Process Plant Operation & Optimization
Advanced Process Optimization Technologies
Components Required to Optimize Industrial Processes
Process Monitoring Techniques
Key Performance Indicators (KPIs)
Process or Mathematical Model of Process and Process Variables
Advanced Process Control (APC)
Real-Time Optimization (RTO)
Predictive analytics
Machine Learning for operations improvement
Practice cases & Application for process optimization to Plant and Control
Process continual improvement Implications of Plant Optimization Activities
Maintenance Management System
Minimization of Equipment Failure
Our Methodology
- Make coaching and monitoring innovative and using modern
- Media training also using on the go training by using interactive means and focusing on
- The exercises, practical applications and real situations study
- Live delivery method, instructor-led training
- Experienced consultant, trainers, and professional
- Qualified trainer with high-level experience
Attendance Reports
- Send daily attendance reports to training departments
- Send full attendance report to training dep. by the end of the course
- Attend 100 % from the course days also provide daily
- Issue attendance certificate for participant who attend minimum 80% from the course duration
Pre/Post Reports
- Pre- assessment before starting training
- Post assessment after finishing training
- Full report for the difference between Pre-& Post assessment
Who Should Attend
- Process plant engineers, operators & technicians
- Operations managers and plant supervisors
- Project engineers
- Maintenance planners and reliability engineers
- Supervisors and maintenance personnel
- Engineering and technical personnel for process plant
