There are many aspects of building operational excellence. Partial list may include;
1. Health, Safety and the Environment
2. Reliability – Continuity of Operations
3. Quality
4. Cost
5. People Development
Guidelines for Safe Pre-commissioning, Commissioning, and Operation of Proces...Karl Kolmetz
This seminar focuses on the core building blocks of the process unit equipment.
This program will emphasize process unit equipment fundamentals, safe
utilization of these fundamentals by operations and maintenance personnel, and
equipment troubleshooting techniques.
Reliability Centered Maintenance (RCM) is a proven, logical, sensible approach that helps companies improve reliability. Yet most companies are not getting the return they expected. They see RCM as too much trouble for too little reward. So that’s why we decided to publish this new report. Find out why RCM doesn't work, what needs to change and how to put RCM to work at your company so it doesn't become another Resource Consuming Monster.
We know RCM works however I wanted to share with you the 5 Biggest Mistakes people make using Reliability Centered Maintenance. Love to hear your comments or tell us what you have seen work and not work.
Optimizing Petroleum Refining FCC Unit Operations TrainingKarl Kolmetz
The success of every company depends of each employee's understanding of
the key business components. Employee training and development will unlock
the companies' profitability and reliability. When people, processes and
technology work together as a team developing practical solutions, companies
can maximize profitability and assets in a sustainable manner. Training and
development is an investment in future success - give yourself and your
employees the keys to success
Optimizing and Troubleshooting Process Equipment Advanced Training CourseKarl Kolmetz
This seminar focuses on the core building blocks of the optimizing and
troubleshooting process systems, equipment and economics. This program will
emphasize the process unit operation fundamentals, safe utilization of these
fundamentals by operations, engineering, maintenance and support personnel.
Guidelines for Safe Pre-commissioning, Commissioning, and Operation of Proces...Karl Kolmetz
This seminar focuses on the core building blocks of the process unit equipment.
This program will emphasize process unit equipment fundamentals, safe
utilization of these fundamentals by operations and maintenance personnel, and
equipment troubleshooting techniques.
Reliability Centered Maintenance (RCM) is a proven, logical, sensible approach that helps companies improve reliability. Yet most companies are not getting the return they expected. They see RCM as too much trouble for too little reward. So that’s why we decided to publish this new report. Find out why RCM doesn't work, what needs to change and how to put RCM to work at your company so it doesn't become another Resource Consuming Monster.
We know RCM works however I wanted to share with you the 5 Biggest Mistakes people make using Reliability Centered Maintenance. Love to hear your comments or tell us what you have seen work and not work.
Optimizing Petroleum Refining FCC Unit Operations TrainingKarl Kolmetz
The success of every company depends of each employee's understanding of
the key business components. Employee training and development will unlock
the companies' profitability and reliability. When people, processes and
technology work together as a team developing practical solutions, companies
can maximize profitability and assets in a sustainable manner. Training and
development is an investment in future success - give yourself and your
employees the keys to success
Optimizing and Troubleshooting Process Equipment Advanced Training CourseKarl Kolmetz
This seminar focuses on the core building blocks of the optimizing and
troubleshooting process systems, equipment and economics. This program will
emphasize the process unit operation fundamentals, safe utilization of these
fundamentals by operations, engineering, maintenance and support personnel.
Introduction to Pressure Relieving and Flaring Systems Training CourseKarl Kolmetz
Each company needs to have people trained in key areas of safety. These
include;
1. Hazard Analysis
2. Relieve Valve Design
3. Reliving Cases Design
4. Flare System Design
This seminar focuses on the core building blocks of the relieving and flaring
process systems, equipment and economics. This program will emphasize the
process unit operation fundamentals, safe utilization of these fundamentals by
operations, engineering, maintenance and support personnel.
Reliability and Maintenance Conference - 7-9 April 2014, Al Khobar, Kingdom o...Ricky Smith CMRP, CMRT
Despite the best efforts and precautions, equipment
failures do occur hampering the equipment performance
and adversly impacting the profitibility of the business.
Rotating Equipment Reliability and Maintenance
Conference aims to create a learning platform for all the
maintenance and reliability professionals to share the
best maintenance practices and discuss the strategies to
improve reliability.
This three day conference will cover all aspects of
reliability and maintenance including reliability centered
maintenance, availability, machinery failures, risk
assessment, spare parts optimization, techniques to
facilitate equipment maintenance, root cause analysis,
condition monitoring, maintenance planning and
scheduling.
Changes are inevitable during the life cycle of any manufacturing facility. Changes occur design, construction, operation, decommissioning, mothballing and demolition. MOC is a critical success factor of any Process Safety Management (PSM) Program. It ensures that each proposed change undergoes the appropriate level of technical and EHS review any change does not inadvertently introduce new hazards or unknowingly increase the risk of existing hazards.
This document discusses the factors involved in the decision to outsource your environmental, health and safety compliance requirements and how to go about selecting a firm that can support your needs.
Using Safety to Drive Lean ImplementationPhil La Duke
This presentation was made during the Society of Manufacturing (SME) EASTEC Conference as part of the Lean and Green Symposium. May 19, 2008 by Phil La Duke. For more information on this topic contact Phil La Duke (Pladuke@oe.com) or visit www.safety-impact.com
Exec Presentation on Achieving Enterprise Resiliency and Corporate CertificationThomas Bronack
Provides an explanation of how Enterprise Resiliency can help your company combine recovery services into one organization speaking the same language and utilizing a common toolset, while adhering to the Compliance Laws of countries you do business in.
Contractor Safety Verification, Learning & Improvementmyosh team
12.30pm Wed 6th April
Presented by Amelia Simony, HSE Manager, Spaceframe
How well is your team self-reflecting to learn and improve?
This webinar will outline how to apply critical control management and examples of how to reflect, learn and improve when working with contractors
Key takeaways:
-Confirming critical controls when working with contractors
-WHS Governance and control effectiveness
-Methods to collaborate, benchmark performance, learn and improve.
This presentaiton on Overall Equipment Effectiveness, Down Time Analytics and Assett Utilization was developed by me and a coleague during my tenure at ISS. Presentation was given to the Chattanooga, TN Chapter of the SME.
Human Performance improvement for the Turkish Energy SectorGSE Systems, Inc.
This presentation was given by GSE Systems at the 2015 Energy Istanbul conference. For more information, go to www.gses.com or follow GSE Systems on Twitter @GSESystems. Thanks for viewing!
“My maintenance staff is highly trained and do not like using procedures.” If the statement is valid, and the cost of asset failure is not important to our operation, then your staff must have an unlimited and infallible memory – congratulations!
Did you know that the most complex equipment ever built was a nuclear submarine and that the first nuclear submarines experienced failures due to lack of effective procedures, thus ending in catastrophic failure?
If safety is number one in your organization, then repeatable, effective work procedures should be as well.
The slides that Carl and Fred present at the 2014 RAMS conference (www.rams.org).
An overview of tasks, approaches, and structure to creating a proactive and effective reliability program in your organization.
Optimizing Petroleum Refining Unit Operations Training CourseKarl Kolmetz
Many aspects of petroleum refining operations management can be improved
including, product recoveries, purities and energy utilization, and safety. This
cannot be achieved without first an understanding of basic fundamental
principles of design and operation. These principles need to be understood in
advance of operating and trouble shooting a process unit operation for the
manager or problem solving to be effective.
This seminar focuses on the core building blocks of the petroleum refining
process systems, equipment and economics. This program will emphasize the
refining process unit operation fundamentals, safe utilization of these
fundamentals by operations, engineering, maintenance and support personnel.
When properly implemented and supplemented with a digital inspection plan, containment can actually add value to your organization. Here's how to avoid mistakes.
Dear students get fully solved assignments
Send your semester & Specialization name to our mail id :
help.mbaassignments@gmail.com
or
call us at : 08263069601
The challenges facing in pharmaceutical maintenanceMANUEL PACINI
Maintenance strategies for the pharmaceutical industry.
Maintenance and service-related items are often the second-largest budget element in a laboratory after salaries and benefits
Introduction to Pressure Relieving and Flaring Systems Training CourseKarl Kolmetz
Each company needs to have people trained in key areas of safety. These
include;
1. Hazard Analysis
2. Relieve Valve Design
3. Reliving Cases Design
4. Flare System Design
This seminar focuses on the core building blocks of the relieving and flaring
process systems, equipment and economics. This program will emphasize the
process unit operation fundamentals, safe utilization of these fundamentals by
operations, engineering, maintenance and support personnel.
Reliability and Maintenance Conference - 7-9 April 2014, Al Khobar, Kingdom o...Ricky Smith CMRP, CMRT
Despite the best efforts and precautions, equipment
failures do occur hampering the equipment performance
and adversly impacting the profitibility of the business.
Rotating Equipment Reliability and Maintenance
Conference aims to create a learning platform for all the
maintenance and reliability professionals to share the
best maintenance practices and discuss the strategies to
improve reliability.
This three day conference will cover all aspects of
reliability and maintenance including reliability centered
maintenance, availability, machinery failures, risk
assessment, spare parts optimization, techniques to
facilitate equipment maintenance, root cause analysis,
condition monitoring, maintenance planning and
scheduling.
Changes are inevitable during the life cycle of any manufacturing facility. Changes occur design, construction, operation, decommissioning, mothballing and demolition. MOC is a critical success factor of any Process Safety Management (PSM) Program. It ensures that each proposed change undergoes the appropriate level of technical and EHS review any change does not inadvertently introduce new hazards or unknowingly increase the risk of existing hazards.
This document discusses the factors involved in the decision to outsource your environmental, health and safety compliance requirements and how to go about selecting a firm that can support your needs.
Using Safety to Drive Lean ImplementationPhil La Duke
This presentation was made during the Society of Manufacturing (SME) EASTEC Conference as part of the Lean and Green Symposium. May 19, 2008 by Phil La Duke. For more information on this topic contact Phil La Duke (Pladuke@oe.com) or visit www.safety-impact.com
Exec Presentation on Achieving Enterprise Resiliency and Corporate CertificationThomas Bronack
Provides an explanation of how Enterprise Resiliency can help your company combine recovery services into one organization speaking the same language and utilizing a common toolset, while adhering to the Compliance Laws of countries you do business in.
Contractor Safety Verification, Learning & Improvementmyosh team
12.30pm Wed 6th April
Presented by Amelia Simony, HSE Manager, Spaceframe
How well is your team self-reflecting to learn and improve?
This webinar will outline how to apply critical control management and examples of how to reflect, learn and improve when working with contractors
Key takeaways:
-Confirming critical controls when working with contractors
-WHS Governance and control effectiveness
-Methods to collaborate, benchmark performance, learn and improve.
This presentaiton on Overall Equipment Effectiveness, Down Time Analytics and Assett Utilization was developed by me and a coleague during my tenure at ISS. Presentation was given to the Chattanooga, TN Chapter of the SME.
Human Performance improvement for the Turkish Energy SectorGSE Systems, Inc.
This presentation was given by GSE Systems at the 2015 Energy Istanbul conference. For more information, go to www.gses.com or follow GSE Systems on Twitter @GSESystems. Thanks for viewing!
“My maintenance staff is highly trained and do not like using procedures.” If the statement is valid, and the cost of asset failure is not important to our operation, then your staff must have an unlimited and infallible memory – congratulations!
Did you know that the most complex equipment ever built was a nuclear submarine and that the first nuclear submarines experienced failures due to lack of effective procedures, thus ending in catastrophic failure?
If safety is number one in your organization, then repeatable, effective work procedures should be as well.
The slides that Carl and Fred present at the 2014 RAMS conference (www.rams.org).
An overview of tasks, approaches, and structure to creating a proactive and effective reliability program in your organization.
Optimizing Petroleum Refining Unit Operations Training CourseKarl Kolmetz
Many aspects of petroleum refining operations management can be improved
including, product recoveries, purities and energy utilization, and safety. This
cannot be achieved without first an understanding of basic fundamental
principles of design and operation. These principles need to be understood in
advance of operating and trouble shooting a process unit operation for the
manager or problem solving to be effective.
This seminar focuses on the core building blocks of the petroleum refining
process systems, equipment and economics. This program will emphasize the
refining process unit operation fundamentals, safe utilization of these
fundamentals by operations, engineering, maintenance and support personnel.
When properly implemented and supplemented with a digital inspection plan, containment can actually add value to your organization. Here's how to avoid mistakes.
Dear students get fully solved assignments
Send your semester & Specialization name to our mail id :
help.mbaassignments@gmail.com
or
call us at : 08263069601
The challenges facing in pharmaceutical maintenanceMANUEL PACINI
Maintenance strategies for the pharmaceutical industry.
Maintenance and service-related items are often the second-largest budget element in a laboratory after salaries and benefits
Infodream Articles about Continuous Improvement, Aerospace, Quality Control a...Infodream
Articles include: 1. Lack of Training to Blame for Slow Up-take of Continuous Improvement Tools in Aerospace -- 2. SPC Vision Reduces Inspection Stages and Empowers Operators at Turbomeca UK -- 3. Real time SPC & Quality Control at Mölnlycke Health Care supports FDA’s PAT
Advanced Training for Pressure Relieving and Flaring SystemsKarl Kolmetz
Each company needs to have people trained in key areas of safety. These
include;
1. Hazard Analysis
2. Relief Valve Design
3. Reliving Cases Design
4. Flare System Design
This seminar focuses on the core building blocks of the relieving and flaring
process systems, equipment and economics. This program will emphasize the
process unit operation fundamentals, safe utilization of these fundamentals by
operations, engineering, maintenance and support personnel.
Precision Maintenance is talked about in many companies and implemented at many companies, many with great success, however most companies do not understand Precision Maintenance. In this paper I will clear up some misconceptions and untruths concerning it.
Precision Maintenance is talked about in many companies and implemented at many companies, many with great success, however most companies do not understand Precision Maintenance. In this paper I will clear up some misconceptions and untruths concerning it.
Four steps to an audit proof measurement system by PQ SystemsBlackberry&Cross
Cuatro pasos para lograr un sistema de medición a "prueba de balas".
Mejore sus sistema de medición, asegure su calidad.
Gracias a PQ Systems, aliado de Blackberry&Cross desde 2006.
Más información: http://www.blackberycross.com
Advanced Maintenance And Reliability (Maintenance and Reliability Best Pract...Ricky Smith CMRP, CMRT
Maintenance and reliability has taken great strides toward managing asset reliability by applying known best practices in maintenance and reliability finding that they can optimize reliability and reduce total cost and reduce risk by applying known best practices. However, if not most organizations are still trapped in the old way of thinking.
As Albert Einstein once said: "the significant problems we face cannot be solved with the same level of thinking we were at when we created them".
Similar to Building Operational Excellence in Petroleum Refining Training Course (20)
Water Treatment Unit Selection, Sizing and Troubleshooting Karl Kolmetz
Freshwater uses for manufacturing, food production, domestic and public needs,
recreation, hydroelectric power production, and flood control. The primary sources of
freshwater are rainfall in cisterns and water jars; groundwater from springs, artesian
wells, and drilled or dug wells; surface water from lakes, rivers, and streams;
desalinized seawater or brackish groundwater; and reclaimed wastewater.
Some water supplies may also contain disinfections by-products, inorganic
chemicals, organic chemicals, and radionuclides. Specialized methods for controlling
formation or removing them can also be part of water treatment.
Water treatment processes are applied to surface water sources. Typically, a water
treatment plant (WTP) undergoes a series of processes which include the units
presedimentation, rapid mix, flocculation, sedimentation, filtration, adsorption, and
disinfection, with appropriate chemical feeds and residual treatment processes
Ammonia Plant Selection Sizing and Troubleshooting Karl Kolmetz
Ammonia is produced basically from water, air, and energy. The energy source is
usually hydrocarbons, thus providing hydrogen as well, but may also be coal or
electricity. Steam reforming of light hydrocarbons is the most efficient route, with
about 77% of world ammonia capacity being based on natural gas.
The total energy consumption for the production of ammonia in a modern steam
reforming plant is 40-50% above the thermodynamic minimum. More than half of the
excess consumption is due to compression losses. The practical minimum
consumption is assumed to be 130% of the theoretical minimum.
This guideline covers items in making an ammonia plant. Starting from the raw
material, equipment, manufacturing process and the economics of ammonia plant.
Process Equipment Malfunctions offers the chance to develop proven techniques for
finding and fixing process plant problems and contains details on failure identification.
One of the most important traits that process operators, maintenance personnel, and
engineers can have is the ability to diagnose equipment and process upsets and
respond accordingly quickly and accurately.
Troubleshooting is a step-by-step procedure whose purpose is to identify a problem
quickly and easily in a system or process. Troubleshooting is an art, but a good portion
is a learned skill, which is enhanced by experience and operator capability. A good
operator will work at developing troubleshooting skills and abilities. A good
troubleshooter is worth his or her weight in gold to a company.
Pressure Vessel Selection Sizing and Troubleshooting Karl Kolmetz
Vessels are a vital part of the operational units in the process industries. A vessel is
a container in which materials are processed, treated, or stored. Without this type of
equipment, the process industries would be unable to create and store large
amounts of Product. Pressure vessels used in industry are leak-tight pressure
containers, usually cylindrical or spherical in shape, with different head
configurations.
The process engineer should have some knowledge of the mechanical design of
vessels. For example, the process engineer may have to make a preliminary design
of vessels for a cost estimate. A vessel consists of a cylindrical shell and end caps,
called heads. For safety, vessel design is governed by codes.
Hydrotreating Technology Training CourseKarl Kolmetz
This seminar focuses on the core building blocks of the Hydrotreater process unit
equipment. The program will emphasize process unit equipment fundamentals,
safe utilization of these fundamentals by operations and maintenance personnel,
and equipment troubleshooting techniques.
The purpose of this seminar is to improve and update the participant’s personal
knowledge of Hydro treating technologies and will include:
Naphtha HT
Kerosene HT
Diesel HT
Monitoring unit operations
Troubleshooting
Latest developments
Areas of concern
Petroleum Refining Processes and Economics for Non Technical Personal Trainin...Karl Kolmetz
Many aspects of petroleum refining operations and management can be
improved including, product recoveries, purities and energy utilization, and
safety. This cannot be achieved without first an understanding of basic
fundamental principles of design and operation. These principles need to be
understood in advance of operating and trouble shooting a process unit operation
for the manager or problem solving to be effective.
This seminar focuses on the core building blocks of the refining process systems,
equipment and economics.
Improving the Performance and Reliability of Fired Heaters and Boilers Traini...Karl Kolmetz
Many aspects of fried heaters operations and management can be improved
including, energy utilization, product improvements, furnace tube life, and safety.
This cannot be achieved without first an understanding of basic fundamental
principles of design and operation. These principles need to be understood in
advance of operating and trouble shooting a process unit operation for the
manager or problem solving to be effective.
Advances in Ethylene Unit Pyrolysis Furnace Design and Optimization Training ...Karl Kolmetz
This course will guide the participates to develop key concepts and techniques
for the optimization of Ethylene Unit Pyrolysis Furnace Design and Optimization.
These key concepts can be utilized to make operating decisions that can improve
your unit’s performance.
Many aspects of fired heaters operations and management can be improved
including, energy utilization, product improvements, furnace tube life, and safety.
This cannot be achieved without first an understanding of basic fundamental
principles of design and operation. These principles need to be understood in
advance of operating and trouble shooting a process unit operation for the
manager or problem solving to be effective.
Water scarcity is the lack of fresh water resources to meet the standard water demand. There are two type of water scarcity. One is physical. The other is economic water scarcity.
Welcome to WIPAC Monthly the magazine brought to you by the LinkedIn Group Water Industry Process Automation & Control.
In this month's edition, along with this month's industry news to celebrate the 13 years since the group was created we have articles including
A case study of the used of Advanced Process Control at the Wastewater Treatment works at Lleida in Spain
A look back on an article on smart wastewater networks in order to see how the industry has measured up in the interim around the adoption of Digital Transformation in the Water Industry.
Hierarchical Digital Twin of a Naval Power SystemKerry Sado
A hierarchical digital twin of a Naval DC power system has been developed and experimentally verified. Similar to other state-of-the-art digital twins, this technology creates a digital replica of the physical system executed in real-time or faster, which can modify hardware controls. However, its advantage stems from distributing computational efforts by utilizing a hierarchical structure composed of lower-level digital twin blocks and a higher-level system digital twin. Each digital twin block is associated with a physical subsystem of the hardware and communicates with a singular system digital twin, which creates a system-level response. By extracting information from each level of the hierarchy, power system controls of the hardware were reconfigured autonomously. This hierarchical digital twin development offers several advantages over other digital twins, particularly in the field of naval power systems. The hierarchical structure allows for greater computational efficiency and scalability while the ability to autonomously reconfigure hardware controls offers increased flexibility and responsiveness. The hierarchical decomposition and models utilized were well aligned with the physical twin, as indicated by the maximum deviations between the developed digital twin hierarchy and the hardware.
About
Indigenized remote control interface card suitable for MAFI system CCR equipment. Compatible for IDM8000 CCR. Backplane mounted serial and TCP/Ethernet communication module for CCR remote access. IDM 8000 CCR remote control on serial and TCP protocol.
• Remote control: Parallel or serial interface.
• Compatible with MAFI CCR system.
• Compatible with IDM8000 CCR.
• Compatible with Backplane mount serial communication.
• Compatible with commercial and Defence aviation CCR system.
• Remote control system for accessing CCR and allied system over serial or TCP.
• Indigenized local Support/presence in India.
• Easy in configuration using DIP switches.
Technical Specifications
Indigenized remote control interface card suitable for MAFI system CCR equipment. Compatible for IDM8000 CCR. Backplane mounted serial and TCP/Ethernet communication module for CCR remote access. IDM 8000 CCR remote control on serial and TCP protocol.
Key Features
Indigenized remote control interface card suitable for MAFI system CCR equipment. Compatible for IDM8000 CCR. Backplane mounted serial and TCP/Ethernet communication module for CCR remote access. IDM 8000 CCR remote control on serial and TCP protocol.
• Remote control: Parallel or serial interface
• Compatible with MAFI CCR system
• Copatiable with IDM8000 CCR
• Compatible with Backplane mount serial communication.
• Compatible with commercial and Defence aviation CCR system.
• Remote control system for accessing CCR and allied system over serial or TCP.
• Indigenized local Support/presence in India.
Application
• Remote control: Parallel or serial interface.
• Compatible with MAFI CCR system.
• Compatible with IDM8000 CCR.
• Compatible with Backplane mount serial communication.
• Compatible with commercial and Defence aviation CCR system.
• Remote control system for accessing CCR and allied system over serial or TCP.
• Indigenized local Support/presence in India.
• Easy in configuration using DIP switches.
Overview of the fundamental roles in Hydropower generation and the components involved in wider Electrical Engineering.
This paper presents the design and construction of hydroelectric dams from the hydrologist’s survey of the valley before construction, all aspects and involved disciplines, fluid dynamics, structural engineering, generation and mains frequency regulation to the very transmission of power through the network in the United Kingdom.
Author: Robbie Edward Sayers
Collaborators and co editors: Charlie Sims and Connor Healey.
(C) 2024 Robbie E. Sayers
Pile Foundation by Venkatesh Taduvai (Sub Geotechnical Engineering II)-conver...
Building Operational Excellence in Petroleum Refining Training Course
1. KLM
Technology Group
Practical Engineering
Guidelines
for Processing Plant
Solutions
Engineering Solutions
www.klmtechgroup.com
Page 1 of 13
Rev 1.0
Building Operational Excellence
in Petroleum Refining
Training Course
Introduction
The success of every company depends of each employee's understanding of
the key business components. Employee training and development will unlock
the companies' profitability and reliability. When people, processes and
technology work together as a team developing practical solutions, companies
can maximize profitability and assets in a sustainable manner. Training and
development is an investment in future success - give yourself and your
employees the keys to success
It is strategically important that your team understands the fundamentals of
building operational excellence. This is the difference between being in the best
quartile of operational ability and being in the last quartile. There is vast
difference in the operational ability of operating companies and most
benchmarking studies have confirmed this gap in operational abilities.
Whether you have a team of new or seasoned employees, an introduction or
review of these concepts are greatly beneficial in closing the gap if you are not in
the best quartile or maintaining a leadership position. Most studies show that a
continuous reinforcement of best practices in operational principles is the most
effective way to obtain the desired results. Training and learning should be an
ongoing continuous lifelong goal.
2. KLM
Technology Group
Practical Engineering
Guidelines
for Processing Plant
Solutions
Engineering Solutions
www.klmtechgroup.com
Page 2 of 13
Rev 1.0
Course Objective
This course will guide the participates to develop key concepts and techniques
for building operational excellence petroleum refining units. These key concepts
can be utilized to make operating and maintenance decisions that can improve
your unit’s performance.
Many aspects of petroleum refining management can be improved including,
product recoveries, purities, energy utilization, cost, quality, and safety. This
cannot be achieved without first an understanding of basic fundamental
principles of these concepts. These principles need to be understood in advance
of operating and troubleshooting a process unit for the manager or problem
solving to be effective.
This seminar focuses on the core building blocks of the petroleum refining
process systems, operation, maintenance, equipment, and economics. This
program will emphasize the refining process unit operation fundamentals, safe
utilization of these fundamentals by operations, engineering, maintenance, and
support personnel.
There are many aspects of building operational excellence. Partial list may
include;
1. Health, Safety and the Environment
2. Reliability – Continuity of Operations
3. Quality
4. Cost
5. People Development
3. KLM
Technology Group
Practical Engineering
Guidelines
for Processing Plant
Solutions
Engineering Solutions
www.klmtechgroup.com
Page 3 of 13
Rev 1.0
1. Safety
HSE is the number one concern. No project or operation can be classified as
optimized or excellent unless it is done safely (HSE). There are many
benchmark studies that show a strong culture of HSE awareness has economic
benefits as well as the social and human benefits. Improving your safety comes
with an economic cost, but a direct cost benefit of improving your safety is lower
insurance rates and improved corporate branding. Many companies with poor
HSE records are no longer in business.
A. The health of your employees and neighbors is especially important.
Limiting the exposure of hazardous materials is the key to increasing
the health of your team.
B. Safety has at least four parts.
1. Construction Safety: This improves over time with the
greatest benefit being a reduction in construction deaths.
2. Industrial Safety: Mostly thought of as PPE, ladder safety,
etc.
3. Process Safety Management (PSM) as required by OSHA:
Great progress has been made in PSM, but many
companies still do not meet the minimum requirements
published by OSHA.
4. Risk Management: Due to the large number of annual
major incidents across the industry limiting risk is critical.
OEI’s senior consultants have a special focus in risk
management to assist in this critical area.
C. We live, work, and play on this earth. Moving forward we need to
do a better job of preserving the earth. We are improving and
polluting less, but we still have work that we can do to reduce our
footprint.
4. KLM
Technology Group
Practical Engineering
Guidelines
for Processing Plant
Solutions
Engineering Solutions
www.klmtechgroup.com
Page 4 of 13
Rev 1.0
2. Reliability - Continuity of Operations
A stable, reliable plant is the largest revenue source. A reliable high-cost plant
will generate more revenue than a low-cost plant with multiple outages. The on-
stream factor is a benchmark of reliability. Industry average is 97%, but the top
quartile approaches 100%. This three percent increased production is a
significant difference in revenue.
Operations Group is the first part of reliability.
a. Best in-class operation procedures need to be developed. Of the
operational procedures reviewed by OEI most would rate as poor
and do not meet OSHA minimum standards. OSHA has published
typical operating procedures on their web site. Most operation
procedures are not as comprehensive as OSHA and many
operation procedures reviewed are only a few pages in length.
b. The risk of not developing best in-class operation procedures is
poor operator training based on existing substandard procedures.
OEI can provide senior consultants to assist with building best in-
class operating procedures and then assist with operations training.
c. Verifying operation procedures were followed is key. If you have
traveled in an airplane you have most likely heard the term “Arm
Doors and Cross Check.” The “cross-check” part of this operational
procedure is particularly important because it verifies that the doors
were armed. There are several ways operating procedures can be
verified as followed such as a check list or an independent set of
eyes to verify the procedure was followed, like in the airplane.
d. Incorporating any near misses or actual incidents into the operating
procedures allows companies to correct errors that were made
going forward. Hiding near misses or team management flaws
does not fix the issue and prevent future incidents.
5. KLM
Technology Group
Practical Engineering
Guidelines
for Processing Plant
Solutions
Engineering Solutions
www.klmtechgroup.com
Page 5 of 13
Rev 1.0
Maintenance Group is the second part of operational reliability.
If you survey any group of maintenance managers, they will acknowledge a large
percentage of maintenance cost is caused by mis-operation. A way to reduce
your maintenance cost is to improve your operations group. Reliability of the
Operations Group has a cost, but this cost can be offset by lower maintenance
and lower insurance rates.
a. Best in-class maintenance procedures need to be developed. Most of
the companies that we have reviewed do not have codified
maintenance procedures. Instead they rely on equipment data books
as their maintenance procedures. I would rate this as poor and they
do not meet OSHA minimum standards.
b. The challenge of not codifying good maintenance procedures it that the
maintenance training is based on your existing procedures. Without
good procedures one cannot have good technician training. OEI can
provide senior consultants to assist with building best in-class
maintenance procedures and then assist with maintenance training.
c. Verifying procedures were followed is key. If you have traveled in an
airplane you have most likely heard the term “Arm Doors and Cross
Check.” The “cross-check” part of this procedure is particularly
important because it verifies that the doors were armed. There are
several ways procedures can be verified as followed such as a check
list or an independent set of eyes to verify the procedure was followed,
like in the airplane.
d. Incorporating any near misses or actual incidents into the procedures
allows companies to correct errors that were made going forward.
Hiding near misses or team management flaws does not fix the issue
and prevent future incidents.
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3. Quality
A company’s quality is reflective of external and internal aspects.
a. External aspects: By developing and maintaining the company
reputation of producing quality products will allow you to charge a
premium during economic up turns and maintain your key customers in
a downturn.
b. Internal aspects: There is an added cost of non-quality production.
Sometime the product can be reprocessed, with an added energy
debit. If the product cannot be reprocessed it will need to be sold with
a cost debit.
Most companies have quality audits for the sole purpose of receiving a quality
certification. This is certainly a good reason, but a better reason would be to
utilize the audit to improve the product quality. Most audit finding are above 90%
compliance – amazing – and not true. They are going through the motions of an
audit.
If one audited diligently, what would be a reasonable compliance percentage?
75% would probably be a high number, but companies consistently audit above
90%. Many audits are time consuming and unproductive, when in reality they
could be made very productive by a rigorous independent audit team.
One of our senior consultants was on a safety audit team. The previous audit
team found four noncompliance items. Our team found 40+ noncompliance
items that should have been previously identified. This senior consultant thought
this was a great audit that made the plant considerably safer. A safety colleague
asked me how we was going to deal with the political implications from the
stricter audit. The senior consultant replied there should be no political
implications, everyone should understand that we made the plant considerably
safer.
The political implications were that within three months the senior consultant
was no longer on the audit team for that company. If your audit teams are not
7. KLM
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Page 7 of 13
Rev 1.0
finding compliance items, they are not really looking therefore you are not
allowing your plant to have higher quality or safety.
At one safety audit the senior management team instructed our audit team to do
a rigorous audit, which is great and will lead to higher safety, and lower incidents.
The audit team found many non-compliant issues
At the end of the audit the senior management team then ask the plant that was
being audited what they thought of the audit team. Of course, we were rated
poorly by the plant where we just found many non-compliance issues. You can
instruct a team to audit rigorously, and when they do it is not required to ask the
audited plant what they think of the team – you already know the answer to this
question.
If your company is experiencing high rates of incidents, your audit team is
potentially laboring under the politically correct method resulting in incidents,
higher injuries and insurance cost.
4. Cost
Cost control is a particularly important aspect of operational optimization. The
two largest costs are feedstock and energy. An exceedingly small feedstock
reduction can lead to an exceptionally large profit improvement. A feedstock
reduction team should be developed to review feedstock utilization.
In 2002 at Titan Petrochemicals in Malaysia, a feedstock reduction team was
able to reduce feedstock cost over USD 10.0 million dollars while increasing
production. In 2008 at PT Chandra Asri in Indonesia, a feedstock reduction team
a was able to reduce feedstock cost USD 10.0 Million and in 2009 feedstock and
energy optimization increased plant margin greater than USD 20.0 million, while
increasing production rates.
The industry averages three percent energy improvement per year. The top
quartile will improve more than three percent. If you are maintaining your energy
usage year after year, you are falling behind. KLM Technology Group can
provide senior consultants to review your feedstock and energy utilization.
8. KLM
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Sometime just the increased focus in feedstock and energy can bring a very
large Return on Investment (ROI) from a Process Study.
There is also the timeliness of production. To overproduce and store finished or
intermediate products many are not the best use of capital. A supply chain plan
can provide cost savings.
5. People Development
Most people might rate this higher than fifth. It is an especially important aspect
of operational excellent, but talent can be acquired for a price. The best plan is
to hire talented people, train them well, pay them well, and retain them, but few
companies seem to be capable of accomplishing this task. People Development
will insure that items one through four are optimized.
9. KLM
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Page 9 of 13
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Outline
Introduction to Petroleum Refining
Overview of the Chemical Processing Industry
Review of Process Incidents
Safety for the Chemical Processing Industry
Fundamentals of Petroleum Chemistry
Description of a Hydrocarbon Molecule
Types of Hydrocarbon Molecules
Definition and Function of a Catalyst
Introduction to Petrochemical Key Concepts
Unit Operations
Process Flow Diagrams
Mass Balance
Introduction to Refinery Equipment
Distillation
Absorption
Heat Exchange
Reactors
Pumps
Compressors
Furnaces
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Overview of a Refinery
Refinery Flow Sheet
Gasoline Processing Options
Bottoms Heavy Oil Processing Options
Alkylation
Hydrotreating
Reforming
Gas Sweeting
Sulfur Recovery
Characteristics of Crude Oil
Sources of Crude
Composition of Crude
Description of Crude Oil Fractions
Definition of Physical and Chemical Processes
Crude Oil Testing
Crude Assays
Crude Oil Distillation
Designing for Fouling Service
Description of the Distillation Process
Cut Points of the Various Fractions
Crude Tower Design
Vacuum Tower Design
Process Equipment Troubleshooting
Troubleshooting concepts and techniques
Typical Problems
Interaction of Process and Equipment
Tower Scan Case Study
Tower Inspection Case Study
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Plant Reliability
Introduction to Plant Reliability
Equipment Design for improved Reliability
Benchmarking for Plant Reliability
Best in Class Procedures
Best in Class Training
Incident and Near Miss
Quality
Introduction to Quality
Overview of Statistical Process Control
Cost Control
Introduction to Cost Control
Feedstock
Energy
Develop Key Performance Indicators
Managing Projects
People Development
People Development
Team Building
Training
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Who Should Attend:
People who are making day to day decisions regarding operation, design,
and economics of processing plants;
1. 1st Line Operations personnel,
2. Operation Supervisors,
3. 1st Line Maintenance personnel,
4. Maintenance Supervisors,
5. Senior Plant Supervisors,
6. Operations Engineers
7. Process Support Engineers,
8. Design Engineers,
9. Cost Engineers
Ideal for veterans and those with only a few years of experience who want
to review or broaden their understanding in Processing Plant Operations.
Other professionals who desire a better understanding of subject matter
13. KLM
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Practical Engineering
Guidelines
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Engineering Solutions
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Page 13 of 13
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What you can expect to gain:
An detailed overview of refinery operations, processes and economics
Gain an understanding of the equipment of a refinery
Gain an understanding of the refinery flow sheets
Gain an understanding of refinery chemistry and catalyst
Gain an understating of refinery margins
Troubleshooting Techniques
Gain an insight to optimization strategies