Process Plant Optimisation & Energy Conservation

Introduction:

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.

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 optimization. This training will provide a comprehensive review of the various aspects of process plant integrity as an essential foundation for sustainable plant profitability and optimization

Targeted Groups:

• Process Plant Supervisors
• Plant Engineers and Operators
• Production and Operation Engineers
• Maintenance Engineers and Technicians
• Engineering and Technical personnel involved in improving process plant, petrochemical plant and refinery profitability and energy efficiency

Conference Objectives:

At the end of this conference the participants will be able to:

• Understand what plant optimization and energy conservation is all about – the drivers, the potential benefits, and how to realize them
• Enhance the business focus and to make more contributions to sustainable plant profitability
• Learn how to identify the most attractive opportunities for energy savings
• Gain managerial tools to effectively optimize plant operations
• Learn practical and effective methods and tools to perform technical and economic evaluations of the alternatives
• Understand the elements of plant optimization
• Maximize the plant availability, reliability, and productivity
• Minimize the operational costs

Targeted Competencies:

• Process Overall Plant Effectiveness (OPE)
• Best Practices in Operation and Maintenance
• Business Sustainability and Related Factors
• Energy Conservation Opportunities
• Strategies for Improving Plant Profitability

Course Content:
Unit 1: Process Plant Operation, Integrity, and Reliability:

• Process Plant Optimization and Energy Conservation – Overview
• Asset Integrity Management (AIM) and Optimization - Integrating operation, inspection, maintenance effort
• Plant Integrity and Reliability – Cornerstone of Plant Optimization and Energy Management
• Operation and Maintenance Impacts on Plant Integrity and Reliability
• Equipment condition monitoring and assessment
• Establishment of Operating Windows (OW) - Maximize throughput within the limits defined by mechanical-structural integrity over the expected life of the asset components
• Effective management of change (MOC) program – On-going link between engineering, operations and maintenance
• Process Plant Economics

Unit 2: Process Plant Optimization:

• Process Control Basics
• Elements of Process Plant Optimization
• Components Required To Optimize An Industrial Process
• Process or a mathematical model of the process, and process variables which can be manipulated and controlled
• Application Of Simulation Technology To Plant Optimization And Control - Plant Optimization Models
• The Basics Of Heat Integration
• Pinch technology
• Heat exchanger train optimization
• Optimization procedure
• Application Of Simulation Technology To Plant Optimization And Control - Plant Optimization Models

Unit 3: Industrial Energy Management – Energy Efficiency: Good for Business – Good for the Environment:

• Energy Use and Optimization in Process industries
• Industrial Energy Management Techniques
• Industrial Energy Management and System Standards
• Industry Program for Energy Conservation
• Best Practices in Process Plant Energy Management
• Developing Customized Energy Management Program
• Obstacle that Face Energy Management Programs
• Examples of energy management programs and standards CIPEC, UNIDO
• Incentives for energy assessment and energy retrofit projects

Unit 4: Energy Conservation Opportunities:

• Implementing an Energy Management Program
• Benchmarking Energy Intensity and Usage
• Technology Options - New energy-efficient technologies. Examples include Corrosion analyzer for advanced materials and fabricated components Fiber optic sensor for combustion measurement and control
• Energy Conservation Checklist
• Plant processes
• Mechanical Systems
• Electric Power
• Technical and Economic Evaluation of Potential Opportunities

Unit 5: The Implications of Plant Optimization Activities:

• Relating Energy Efficiency To Business Outcomes
• Impact of optimization activities and technological modifications to the plant
• Plant integrity and safety
• Technology licenses
• Financing agreements
• Impact on Human Resources – The human factor