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 Process Plant Optimization amp Energy Conservation E6064 QR Code
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Process Plant Optimization & Energy Conservation



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 the safe and reliable operation will be studied in detail.

Plant energy consumption and reliability are the foundation 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.

Course Objectives:

At the end of this course the 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

Targeted Audience:

  • Process Plant Supervisors
  • Plant Engineers and Operators
  • Production and Operation Engineers
  • Maintenance Engineers and Technicians

Course Outlines:

Unit 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

Unit 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 of Improvement Methods
  • Case Study

Unit 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

Unit 4: Monitoring and Failure Prevention Methods:

  • Methods for Minimizing Static Equipment Failure
  • Strategies for Mitigating Rotating Equipment Down Time
  • Condition Monitoring Methods
  • Non Destructive Examination (NDE) Techniques
  • Determination of Equipment Life Time and Remaining Life 
  • Methods for Extending Equipment Cycle and Service Time
  • Detailed Case Study          

Unit 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
  • Summary and Course Closure

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