Introduction

The optimisation of process plants requires effective management of maintenance operations and equipment, along with plant reliability and durability.

What is plant Optimisation

 

The vital aspects of process plant optimisation are related to system energy management and the reduction of energy consumption. Many industrial processes and systems currently offer significant potentials for savings. However, bringing significant process changes such as modern controls and newer technologies can also enhance the opportunities for plant optimisation. This Zoe course will discuss the importance of monitoring and adjusting process plant operations. You will learn to do this in a way that sustains optimum levels of efficiency his is done while maintaining safe and reliable operational procedures

Course Objective

·        Understand plant optimisation and energy conservation in detail.

·        Describe and practice the managerial tools needed to effectively optimise plant operations.

·        Evaluate the concept of capacity creep and discuss the methodology of the cost-effective debottlenecking strategies.

·        Implement systematic methods of optimising plant reliability including root cause failure analysis, logic diagrams, fault trees, etc.

·        Identify the role and importance of management and enterprise information systems in plant optimization.

·        Acquire knowledge on risk management in process plant optimization.

·        Describe utility management and rehabilitation in revamping and debottlenecking.

·        Assess the maintenance, energy, utilities, environmental, and safety parameters in revamping and debottlenecking.

·        Analyse economic, planning, and other project management issues.

Training Methodology

 A highly interactive combination of lecture and discussion sessions will be managed to maximize the amount and quality of information, knowledge and experience transfer. The sessions will start by raising the most relevant questions, and motivate everybody finding the right answers. The attendants will also be encouraged to raise more of their own questions and to share developing the right answers using their own analysis and experience.

Percentage of Delivery Methodologies

• 35% Presentation
• 30% Group & Individual Exercises
• 25% Case Studies
• 10% Active Movies and Simulation

 

 

Course Outline

 

Day 1:

Overview of Process Plant Operation

·        Overview of Optimisation Technologies for Process Plants.

·        Elements of Process Plant Optimisation Procedure.

·        Constraints in Optimisation:

o   Production.

o   Operation.

o   Economy.

o   Environment.

·        Optimisation Approaches.

·        Mathematical Models and Physical Models.

·        Correlation between Process Optimisation and Process Control.

·        Workshop: Examples and Solutions.

Day 2:

 Process Plant Optimisation Basics

·        Process Plant Optimisation.

·        Process Control Basics.

·        Elements of Process Plant Optimisation.

·        Components to Optimise Industrial Processes.

·        Mathematical Model of Process.

·        Process Variables.

·        Simulation Technology to Plant and Control.

 ·       The Basics of Heat Integration.

 Day 3:

 Energy Management for Businesses & The Environment

·        Industrial Energy Management.

·        Energy Efficiency for Businesses and the Environment.

·        Energy Use and in Process Industry.

·        Energy Management Standard: Details.

·        Energy Management Standard: Features.

·        Obstacles for Energy Management Programs.

Day 4:

  

Energy Conservation

·        World Standards and Benchmarking Guidelines.

·        Useful Practices in Process Plant Energy Management.

·        Energy Conservation Check List for Industrial Plants.

·        Energy Conservation Opportunities.

·        Energy Audit.

·        Energy Audit Types.

·        Benchmarking Energy Intensity and Usage.

·        New Energy Efficient Technologies.

·        Technical Evaluation of Potential Opportunities.

 ·       Economic Evaluation of Renewable Energy.

Plant Optimisation Activities

·        Implications of Plant Optimisation Activities.

·        Technological Modifications to the Plant.

·        Technology Licenses.

·        Impact on Human Resources.

·        Good Safety ‐ Good Business.

 ·       Safety Costs: Costs of Injuries.

Day 5:

 

 Revamping and Debottlenecking Strategies

·        Revamping Strategies.

·        Production Capacity Enhancement.

·        Maintenance, Energy, Utilities, Environmental and Safety Parameters.

 ·       Economic, Planning, and Project Management Issues.