This document outlines a training course on developing operational excellence in petroleum refining. The course aims to teach key concepts and techniques to improve various aspects of refinery performance, including safety, reliability, quality, cost, and people development. It covers topics such as refinery processes, equipment, chemistry, and optimization strategies. The target audience includes operations, maintenance, and engineering professionals seeking to broaden their understanding of refinery operations.
Building Operational Excellence in Petroleum Refining Training CourseKarl Kolmetz
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
This document provides an overview of operational excellence and outlines five key areas ("bites") for organizations to focus on: 1) health, safety and environment, 2) reliability of continuity of operations, 3) quality, 4) costs, and 5) people development. It emphasizes that operational excellence is a long-term culture change involving systematic management of business processes. Specific strategies are described for each area, such as developing best practices for operational and maintenance procedures, conducting rigorous audits to identify compliance issues, and incorporating lessons from near misses.
Optimizing Petroleum Refining Unit Operations TrainingKarl Kolmetz
This document provides information about an optimization training course for petroleum refining unit operations. The course aims to help participants develop key concepts and techniques for optimizing refinery operations to improve performance metrics like product recoveries, purities, and energy utilization. The course covers topics like refinery processes, equipment, chemistry, flow sheets, troubleshooting concepts, and strategies for improving reliability, quality, costs, and developing people. It is intended for operations, engineering, maintenance, and support personnel to help close performance gaps between the best and last quartiles of operational ability.
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
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.
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.
Companies often struggle to fully realize the benefits of reducing complexity in their operations. This document discusses how companies can plan from the start to capture these benefits. It recommends explicitly considering benefit capture as part of complexity reduction efforts. Companies should identify which benefits, such as reducing costs or improving customer service, will provide the greatest value. They should also understand what changes are needed internally to achieve these benefits. With a clear plan to convert reduced complexity into financial gains, companies can better ensure the benefits of their efforts materialize.
The document discusses various root cause failure analysis techniques including: 5 Whys method, Ishikawa diagrams, failure mode analysis, statistical analysis, and selecting/prioritizing corrective actions. It provides examples of root cause analyses including issues with Boeing C-17 landing gear sensors, Blue Screen of Death software errors, conveyor drive failures, and mobile hydraulic truck pump leakage. The key lessons are the importance of thorough problem definition, dedicated investigation, not assuming initial causes are correct, and using data to identify root causes and prevent recurrence.
Building Operational Excellence in Petroleum Refining Training CourseKarl Kolmetz
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
This document provides an overview of operational excellence and outlines five key areas ("bites") for organizations to focus on: 1) health, safety and environment, 2) reliability of continuity of operations, 3) quality, 4) costs, and 5) people development. It emphasizes that operational excellence is a long-term culture change involving systematic management of business processes. Specific strategies are described for each area, such as developing best practices for operational and maintenance procedures, conducting rigorous audits to identify compliance issues, and incorporating lessons from near misses.
Optimizing Petroleum Refining Unit Operations TrainingKarl Kolmetz
This document provides information about an optimization training course for petroleum refining unit operations. The course aims to help participants develop key concepts and techniques for optimizing refinery operations to improve performance metrics like product recoveries, purities, and energy utilization. The course covers topics like refinery processes, equipment, chemistry, flow sheets, troubleshooting concepts, and strategies for improving reliability, quality, costs, and developing people. It is intended for operations, engineering, maintenance, and support personnel to help close performance gaps between the best and last quartiles of operational ability.
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
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.
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.
Companies often struggle to fully realize the benefits of reducing complexity in their operations. This document discusses how companies can plan from the start to capture these benefits. It recommends explicitly considering benefit capture as part of complexity reduction efforts. Companies should identify which benefits, such as reducing costs or improving customer service, will provide the greatest value. They should also understand what changes are needed internally to achieve these benefits. With a clear plan to convert reduced complexity into financial gains, companies can better ensure the benefits of their efforts materialize.
The document discusses various root cause failure analysis techniques including: 5 Whys method, Ishikawa diagrams, failure mode analysis, statistical analysis, and selecting/prioritizing corrective actions. It provides examples of root cause analyses including issues with Boeing C-17 landing gear sensors, Blue Screen of Death software errors, conveyor drive failures, and mobile hydraulic truck pump leakage. The key lessons are the importance of thorough problem definition, dedicated investigation, not assuming initial causes are correct, and using data to identify root causes and prevent recurrence.
Multichannel retail, where retailers operate both online and brick-and-mortar stores, is now common but complex to manage effectively. While multichannel provides opportunities like new customers and cost savings, most retailers do not capture all the potential benefits without proper processes. A consulting firm helped a large European retailer improve its multichannel operations by optimizing its online product setup and exit management, reducing out-of-stock items online from 13% to 0% and cancelled online orders while increasing operating profits by 22%.
The document provides an overview of Simple OEE (Overall Equipment Effectiveness) including:
- Simple OEE is calculated based on three metrics: Availability, Performance, and Quality.
- It defines the major loss events that can reduce machine productivity including downtime, speed, and quality losses.
- Implementing Simple OEE involves measuring these losses to identify improvement opportunities and increase equipment efficiency.
Using Safety to Drive Lean ImplementationPhil La Duke
Using safety to drive lean implementation can help organizations gain competitive advantages through greater efficiency while eliminating waste. Implementing lean tools such as standard work, visual management, and empowering workers to stop production for safety issues can simultaneously make workplaces safer and more productive. Many actions that make work safer, such as error proofing equipment and processes, also make operations leaner. Viewing safety as a way to reduce costs from injuries and as a leading indicator of lean implementation can provide benefits across quality, production, and costs.
Achieving Operational Excellence is now more crucial than ever. As competition intensifies and expectations for high
performance rise, companies have increased their focus on achieving higher levels of operational performance. This is why about 80-90% of Fortune 500 companies have
implemented some form of a Lean, Six Sigma, or Operational Excellence program.
Unfortunately, only about 30% achieve their expected results. This is more disappointing when you consider that many have been left with greater levels of bureaucracy and
cost than they started with. In this Vantage Point, we will explore the characteristics of companies that defy this trend by successfully deploying management systems to achieve Operational Excellence while simultaneously removing large chunks of cost and overhead.
Creating a Culture of Operational Discipline that leads to Operational Excell...Wilson Perumal and Company
As the world becomes more complex, the best companies and leaders are beginning to realize that improving culture is their greatest lever for achieving Operational Excellence. Complex systems require a different kind of culture—one with a specific set of guiding principles. In order to instill these principles in your organization, it is necessary to learn what the current culture is and what people think it ought to be like, establish the guiding principles necessary to be successful, align them to every level of the organization, and develop and sustain them through committed leadership and integration into key management system processes.
Wilson Perumal & Company has a long track record of helping companies in all industries transform their cultures and dramatically improve operational results. In this Vantage Point, we will share the most important lessons we have learned through our research and experience working directly with High-Reliability Organizations (HROs) and our clients as they pursue Operational Excellence.
The document discusses issues with maintenance and asset management practices in industry. It questions whether company boards understand the risks associated with poor maintenance. It also asks if insurers are supporting mediocrity in maintenance practices through their underwriting. The presenter has decades of experience consulting on asset management and believes current practices in industry are poor and not supporting reliability.
Yet while the engineers understand the technical aspects of PSM, there can still be formidable difficulties implementing the elements. In countries with high Power Distance and low Individualism, as in many developing economies, engineers look to line management for specific direction, setting of priorities, and resources. Let´s review what need to see to ensure our PSM is up and running
The document provides an overview of a training workshop on becoming a safety trainer. It discusses the purpose of the workshop, which is to provide the basic knowledge and skills needed to plan, prepare, present, and evaluate safety training. The workshop will cover 9 steps in the training development and presentation process. It will address preparing lesson plans, presenting training in the classroom and on the job, and evaluating training effectiveness. The document provides an agenda for the workshop and outlines what will be covered.
This document contains summaries of 25 presentations on lean manufacturing topics from a company called Superfactory. The summaries cover lean concepts and tools such as 5S, kaizen, value streams, mistake proofing, quick changeover, Six Sigma, theory of constraints, and more. Each summary is 1-2 paragraphs long and outlines the main sections or steps covered in the corresponding presentation.
Paul O'Neill, the new CEO of Alcoa, focused his first speech to investors on improving workplace safety instead of discussing typical business topics like profits and growth. Investors were confused by this unusual focus and one advised clients to sell their stock, predicting it would hurt the company's performance. However, within a year profits hit a record high under O'Neill's leadership. By prioritizing safety, O'Neill improved Alcoa's culture and operational performance, leading to significantly higher profits and market value over his tenure. This story shows how focusing on safety can improve business outcomes.
Arrelic is a predictive analytics startup firm that helps manufacturing industries improve plant productivity, reliability, and reduce costs through approaches like predictive maintenance. It offers predictive analytics services using tools like vibration analysis and infrared thermography. Arrelic also provides consulting services in reliability engineering, asset management, and training to optimize asset performance. Its goal is to create a world-class team through graduate programs, experience transfers, and talent development.
Advanced Maintenance And Reliability (Best Maintenance and Reliability Practi...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. Read this article and see where you stand.
Top Tips for Improving your Quality ManagementClaire Healey
An essential guide to assist you, the Quality Expert in enforcing the standards you expect on a daily basis across the whole manufacturing plant. Improve product quality, traceability and Statistical Process Control (SPC) whilst preventing mix-up and product recalls in manufacturing.
The world is substantially more complex than it was when Lean Six Sigma was first developed. Stephen Wilson and Chris Seifert discuss how to adjust your approach to utilizing Lean Six Sigma to maintain its relevance and increase the success rate of your continuous improvement initiatives.
Do It Right: A Safety Incentive Platform GuideWorkStride
Incentivizing and rewarding workers for safe behaviors is proven to be effective in improving workplace safety. However, there are times when these programs cause more harm than good. How do you know what type of program will work and be compliant with OSHA regulations?
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.
This document provides an introduction to continuous safety improvement (CSI) concepts. It discusses how total quality management (TQM) and continuous quality improvement (CQI) principles can be applied to occupational safety and health. The workshop goals are to familiarize participants with W. Edwards Deming's contributions to quality management, and to apply his 14 Points to workplace safety. Deming's 14 Points are then discussed in detail and related to concepts of proactive safety management versus traditional reactive approaches. The document emphasizes that achieving continuous safety improvement requires changing systems and processes, rather than focusing solely on numerical goals or results.
This white paper discusses the importance of procedure based maintenance in facilities. It argues that relying only on the skills and experience of maintenance staff can lead to failures and inconsistencies. Effective, repeatable procedures are needed to ensure safety, reliability, and sustainable results. The paper recommends making staff aware of issues, training them on procedures, implementing procedures, continuously improving, and monitoring results. Procedure based maintenance can help reduce variation and human error.
“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.
This document outlines the most common mistakes made in containment plans. It discusses that containment plans should involve all stakeholders from the beginning to ensure a clear scope of work. It also notes that inconsistent training methods between experienced and new workers can lead to quality issues. Finally, it stresses that containment is not the final solution, and that the right approach can reduce recurrence and get production back on track faster while also helping prevent future disruptions.
This document discusses the concepts and principles of Continuous Safety Improvement (CSI) and how they relate to Total Quality Management. It provides an overview of two workshop goals: 1) becoming familiar with the origins and contributions of the Total Quality Management movement and W. Edwards Deming, and 2) applying Deming's 14 Points to workplace safety. Several of Deming's 14 Points are then examined in more detail and how they can guide a proactive, systems-based approach to safety management focusing on continuous improvement.
This document provides an overview of Gasco's Ensure Safe Production (ESP) program. It includes:
- An introduction and leadership message supporting ESP.
- Background on ESP and why it's important for process safety.
- Descriptions of the roles and relevance of ESP for different job functions.
- Gasco's ESP methodology and how it ensures operations stay within defined limits.
- Examples of incidents that highlight the importance of different ESP components like abnormal situation management and proactive monitoring.
Multichannel retail, where retailers operate both online and brick-and-mortar stores, is now common but complex to manage effectively. While multichannel provides opportunities like new customers and cost savings, most retailers do not capture all the potential benefits without proper processes. A consulting firm helped a large European retailer improve its multichannel operations by optimizing its online product setup and exit management, reducing out-of-stock items online from 13% to 0% and cancelled online orders while increasing operating profits by 22%.
The document provides an overview of Simple OEE (Overall Equipment Effectiveness) including:
- Simple OEE is calculated based on three metrics: Availability, Performance, and Quality.
- It defines the major loss events that can reduce machine productivity including downtime, speed, and quality losses.
- Implementing Simple OEE involves measuring these losses to identify improvement opportunities and increase equipment efficiency.
Using Safety to Drive Lean ImplementationPhil La Duke
Using safety to drive lean implementation can help organizations gain competitive advantages through greater efficiency while eliminating waste. Implementing lean tools such as standard work, visual management, and empowering workers to stop production for safety issues can simultaneously make workplaces safer and more productive. Many actions that make work safer, such as error proofing equipment and processes, also make operations leaner. Viewing safety as a way to reduce costs from injuries and as a leading indicator of lean implementation can provide benefits across quality, production, and costs.
Achieving Operational Excellence is now more crucial than ever. As competition intensifies and expectations for high
performance rise, companies have increased their focus on achieving higher levels of operational performance. This is why about 80-90% of Fortune 500 companies have
implemented some form of a Lean, Six Sigma, or Operational Excellence program.
Unfortunately, only about 30% achieve their expected results. This is more disappointing when you consider that many have been left with greater levels of bureaucracy and
cost than they started with. In this Vantage Point, we will explore the characteristics of companies that defy this trend by successfully deploying management systems to achieve Operational Excellence while simultaneously removing large chunks of cost and overhead.
Creating a Culture of Operational Discipline that leads to Operational Excell...Wilson Perumal and Company
As the world becomes more complex, the best companies and leaders are beginning to realize that improving culture is their greatest lever for achieving Operational Excellence. Complex systems require a different kind of culture—one with a specific set of guiding principles. In order to instill these principles in your organization, it is necessary to learn what the current culture is and what people think it ought to be like, establish the guiding principles necessary to be successful, align them to every level of the organization, and develop and sustain them through committed leadership and integration into key management system processes.
Wilson Perumal & Company has a long track record of helping companies in all industries transform their cultures and dramatically improve operational results. In this Vantage Point, we will share the most important lessons we have learned through our research and experience working directly with High-Reliability Organizations (HROs) and our clients as they pursue Operational Excellence.
The document discusses issues with maintenance and asset management practices in industry. It questions whether company boards understand the risks associated with poor maintenance. It also asks if insurers are supporting mediocrity in maintenance practices through their underwriting. The presenter has decades of experience consulting on asset management and believes current practices in industry are poor and not supporting reliability.
Yet while the engineers understand the technical aspects of PSM, there can still be formidable difficulties implementing the elements. In countries with high Power Distance and low Individualism, as in many developing economies, engineers look to line management for specific direction, setting of priorities, and resources. Let´s review what need to see to ensure our PSM is up and running
The document provides an overview of a training workshop on becoming a safety trainer. It discusses the purpose of the workshop, which is to provide the basic knowledge and skills needed to plan, prepare, present, and evaluate safety training. The workshop will cover 9 steps in the training development and presentation process. It will address preparing lesson plans, presenting training in the classroom and on the job, and evaluating training effectiveness. The document provides an agenda for the workshop and outlines what will be covered.
This document contains summaries of 25 presentations on lean manufacturing topics from a company called Superfactory. The summaries cover lean concepts and tools such as 5S, kaizen, value streams, mistake proofing, quick changeover, Six Sigma, theory of constraints, and more. Each summary is 1-2 paragraphs long and outlines the main sections or steps covered in the corresponding presentation.
Paul O'Neill, the new CEO of Alcoa, focused his first speech to investors on improving workplace safety instead of discussing typical business topics like profits and growth. Investors were confused by this unusual focus and one advised clients to sell their stock, predicting it would hurt the company's performance. However, within a year profits hit a record high under O'Neill's leadership. By prioritizing safety, O'Neill improved Alcoa's culture and operational performance, leading to significantly higher profits and market value over his tenure. This story shows how focusing on safety can improve business outcomes.
Arrelic is a predictive analytics startup firm that helps manufacturing industries improve plant productivity, reliability, and reduce costs through approaches like predictive maintenance. It offers predictive analytics services using tools like vibration analysis and infrared thermography. Arrelic also provides consulting services in reliability engineering, asset management, and training to optimize asset performance. Its goal is to create a world-class team through graduate programs, experience transfers, and talent development.
Advanced Maintenance And Reliability (Best Maintenance and Reliability Practi...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. Read this article and see where you stand.
Top Tips for Improving your Quality ManagementClaire Healey
An essential guide to assist you, the Quality Expert in enforcing the standards you expect on a daily basis across the whole manufacturing plant. Improve product quality, traceability and Statistical Process Control (SPC) whilst preventing mix-up and product recalls in manufacturing.
The world is substantially more complex than it was when Lean Six Sigma was first developed. Stephen Wilson and Chris Seifert discuss how to adjust your approach to utilizing Lean Six Sigma to maintain its relevance and increase the success rate of your continuous improvement initiatives.
Do It Right: A Safety Incentive Platform GuideWorkStride
Incentivizing and rewarding workers for safe behaviors is proven to be effective in improving workplace safety. However, there are times when these programs cause more harm than good. How do you know what type of program will work and be compliant with OSHA regulations?
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.
This document provides an introduction to continuous safety improvement (CSI) concepts. It discusses how total quality management (TQM) and continuous quality improvement (CQI) principles can be applied to occupational safety and health. The workshop goals are to familiarize participants with W. Edwards Deming's contributions to quality management, and to apply his 14 Points to workplace safety. Deming's 14 Points are then discussed in detail and related to concepts of proactive safety management versus traditional reactive approaches. The document emphasizes that achieving continuous safety improvement requires changing systems and processes, rather than focusing solely on numerical goals or results.
This white paper discusses the importance of procedure based maintenance in facilities. It argues that relying only on the skills and experience of maintenance staff can lead to failures and inconsistencies. Effective, repeatable procedures are needed to ensure safety, reliability, and sustainable results. The paper recommends making staff aware of issues, training them on procedures, implementing procedures, continuously improving, and monitoring results. Procedure based maintenance can help reduce variation and human error.
“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.
This document outlines the most common mistakes made in containment plans. It discusses that containment plans should involve all stakeholders from the beginning to ensure a clear scope of work. It also notes that inconsistent training methods between experienced and new workers can lead to quality issues. Finally, it stresses that containment is not the final solution, and that the right approach can reduce recurrence and get production back on track faster while also helping prevent future disruptions.
This document discusses the concepts and principles of Continuous Safety Improvement (CSI) and how they relate to Total Quality Management. It provides an overview of two workshop goals: 1) becoming familiar with the origins and contributions of the Total Quality Management movement and W. Edwards Deming, and 2) applying Deming's 14 Points to workplace safety. Several of Deming's 14 Points are then examined in more detail and how they can guide a proactive, systems-based approach to safety management focusing on continuous improvement.
This document provides an overview of Gasco's Ensure Safe Production (ESP) program. It includes:
- An introduction and leadership message supporting ESP.
- Background on ESP and why it's important for process safety.
- Descriptions of the roles and relevance of ESP for different job functions.
- Gasco's ESP methodology and how it ensures operations stay within defined limits.
- Examples of incidents that highlight the importance of different ESP components like abnormal situation management and proactive monitoring.
Auditor Training 2023 _ Safety General.pptxAngad45
Germano D'Arasmo will present on general safety at PSCI's 2023 Online Auditor Training. The presentation will cover understanding laws and regulations, EH&S functions, risk assessment, incident management, personal protective equipment, and health and safety documentation. It will provide auditors with key information to ensure facilities are operating safely and in compliance with relevant safety standards.
An oil production company identified two areas for improvement: lack of management training and poor communication between company staff and third parties. To address this, Check-6 developed a Training and Engagement Program that provided on-the-job leadership training for supervisors and daily walkabouts pairing company, third party, and Check-6 personnel to break down barriers and share best practices. The program resulted in improved meeting effectiveness, communication, and operational culture as well as enhanced briefing/debriefing skills and overall morale.
This document presents an approach to developing a framework for successfully implementing and using standard operating procedures (SOPs). It identifies common causes for SOP failures, such as human/quality factors and lack of employee involvement. It also outlines a three-phase SOP implementation process: 1) identifying the right team, 2) documenting SOPs appropriately, and 3) sustaining improvements through review and benefits tracking. The goal is to distinguish guidelines, operating instructions, and mandatory instructions to maximize efficiency and minimize errors.
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.
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.
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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.
Benchmarking is the continuous process of comparing one’s business processes and performance metrics to industry bests and/or best practices from other industries. Dimensions typically measured are quality, time, and cost.
Improvements from learning mean doing things better, faster, and cheaper.
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
The document describes a process called PM Optimisation (PMO) for improving maintenance programs. PMO aims to rationalize preventive maintenance tasks by identifying useless or duplicative tasks. It is a more efficient alternative to Reliability Centered Maintenance for mature assets. PMO involves compiling existing maintenance tasks, analyzing failure modes, evaluating consequences of failures, and determining optimized maintenance policies. Applying PMO can eliminate 40-60% of unnecessary tasks and improve asset performance and productivity.
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.
Chapter 11_ The role of quality in performance management.pdfRemaketse
This document discusses quality management and performance. It defines key terms like quality management, quality control, quality assurance and total quality management. It describes approaches like Six Sigma, Japanese practices of kaizen costing and target costing, just-in-time and total quality management. Quality certification standards like ISO 9000 are explained. The importance of quality costs and continuous improvement are discussed. Specific techniques like kaizen and total quality management are described along with examples of successes and failures in their implementation.
Similar to Oei building operational excellence in petroleum refining (20)
Engineering Practice Magazine January 2021 Karl Kolmetz
This document is the newsletter from the International Association of Certified Practicing Engineers (IACPE). It contains various articles on engineering topics such as ethylene margins, gas dehydration unit operations, compressor non-metallic piston and rider ring design, molecular investigation of an air flow blocked condenser, key properties of light crude oils, mist elimination equipment selection and sizing, and megaproject scope development. The newsletter provides industry news, technical articles, and insights for practicing engineers.
Refining Process Equipment Troubleshooting Karl Kolmetz
This document provides an overview of a training course on petroleum refining process equipment troubleshooting. The course aims to help operations teams understand fundamental process unit operations concepts in order to improve unit performance and on-stream time. It covers topics like distillation, furnaces, boilers, rotating equipment, piping, heat exchangers, and process control systems. Through lectures and case studies, participants will gain knowledge of troubleshooting principles, techniques, and best practices to identify and resolve issues in refineries and petrochemical plants. The course is intended for personnel involved in plant operations, maintenance, engineering, and technical services.
Introduction to Unit Operation Fundamentals and Troubleshooting Training CourseKarl Kolmetz
This document describes an introductory training course on unit operations fundamentals and troubleshooting. The course aims to help processing plant engineers and operators understand key concepts to improve safety, reliability, reduce costs and increase profits. It is taught over 3 to 5 days by a senior instructor and covers topics like mass transfer, fluid dynamics, heat transfer, reactions, and case studies. Attendees include operations and maintenance personnel who want to broaden their skills and apply concepts to optimize their facilities. The goal is for participants to leave with strategies to troubleshoot issues and increase operational excellence.
Optimizing Paper Mill Operations Training Course Karl Kolmetz
This document provides information about an Optimizing Paper Mill Operations training course. The course aims to teach engineers and production professionals practical skills for increasing safety, reliability, reducing costs and improving profits at pulp and paper mills. Over the course of several days, topics will include fiber sources, pulping processes, black liquor recovery, white liquor production, byproduct recovery, and mill optimization strategies. Attendees will gain an understanding of key operational parameters and methods to improve processes and profits. The instructor has over 25 years of engineering experience in the industry and will share case studies to illustrate optimization approaches.
This document provides information about a Management of Change (MOC) Training Course. The 3-5 day course, led by a senior instructor with over 25 years experience, aims to help participants understand how to develop, implement, and maintain an effective MOC program. The course covers topics such as defining MOC, categorizing changes, conducting MOC reviews, monitoring the MOC program, and incorporating legal/regulatory requirements. It is intended for operations, maintenance, engineering, and safety personnel who are involved in reviewing and approving changes or overseeing process safety. The goal is to refresh or build knowledge of MOC techniques to help companies safely manage changes to their processes and facilities over the lifecycle from design to decommissioning
Water Treatment Unit Selection, Sizing and Troubleshooting Karl Kolmetz
This document provides an overview and guidelines for water treatment unit selection, sizing, and troubleshooting. It discusses various water treatment processes including intake and screening, aeration, coagulation, flocculation, sedimentation, dual media filtration, disinfection, and membrane processes. Tables are provided to help select appropriate treatment methods based on water quality parameters and design considerations like hydraulic criteria and chemical treatment alternatives. Diagrams illustrate common unit operations and configurations. The document aims to assist engineers in preliminary design and specification of water treatment systems.
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.
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.
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.
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.
Advanced Relief Valve and Process Flare Systems TrainingKarl Kolmetz
This document provides information about an advanced training course on pressure relieving and flaring systems. The course aims to develop key concepts and techniques for optimizing these systems. It will cover topics such as flare headers, relief valves, knock out drums, flares, and safety guidelines. The target audience includes operations, engineering, and maintenance personnel who are involved in decision making for processing plants. Attendees will gain an in-depth overview of flaring systems and learn about equipment design, operations, environmental concerns, and troubleshooting techniques.
Introduction to Distillation TroubleshootingKarl Kolmetz
KLM Technology Group is a technical consultancy group based in the USA since 1995 that provides services and equipment to improve process plant efficiency. They offer training courses on various process units and simulation software. The document discusses an introduction to distillation troubleshooting training course. It outlines the steps to troubleshoot a distillation column which include performing simple checks like verifying levels, measuring pressure drops, and taking temperature profiles. If issues are found, further steps include sampling feeds, building mass balances, and running simulations. The goal is to identify potential problems in the distillation column.
KLM Technology Group provides engineering consulting services and training. It has been operating since 1995 based in the USA. It offers various training courses related to process simulation and chapters from its Kolmetz Handbook of Process Equipment Design on topics like distillation design. The presentation discusses an introduction to process simulation including guidelines for using simulation effectively and a case study on simulating an ethylene depentanizer column.
This document discusses KLM Technology Group, which provides training and consulting services related to process plant equipment and operations. It focuses on training courses for process flares, including an introduction to process flares, advanced flare design/operation/troubleshooting courses, and a syllabus for an advanced flare systems course. The document provides information on flare types (elevated and ground), system components, design factors and considerations, and safety, environmental, and social requirements related to flare system design.
This document discusses design guidelines for propylene splitters. It begins with an introduction to factors that affect tower efficiency like pressure, geometry, flow rates, and compositions. It then discusses typical field efficiencies for different tower types based on published data. The document reviews how pressure, viscosity, and volatility affect efficiency based on O'Connell correlations. It also discusses the effects of pressure on tray and packing efficiencies. The document concludes with discussions on best practices for tray and splitter design and considerations for high versus low pressure splitters.
Redefining brain tumor segmentation: a cutting-edge convolutional neural netw...IJECEIAES
Medical image analysis has witnessed significant advancements with deep learning techniques. In the domain of brain tumor segmentation, the ability to
precisely delineate tumor boundaries from magnetic resonance imaging (MRI)
scans holds profound implications for diagnosis. This study presents an ensemble convolutional neural network (CNN) with transfer learning, integrating
the state-of-the-art Deeplabv3+ architecture with the ResNet18 backbone. The
model is rigorously trained and evaluated, exhibiting remarkable performance
metrics, including an impressive global accuracy of 99.286%, a high-class accuracy of 82.191%, a mean intersection over union (IoU) of 79.900%, a weighted
IoU of 98.620%, and a Boundary F1 (BF) score of 83.303%. Notably, a detailed comparative analysis with existing methods showcases the superiority of
our proposed model. These findings underscore the model’s competence in precise brain tumor localization, underscoring its potential to revolutionize medical
image analysis and enhance healthcare outcomes. This research paves the way
for future exploration and optimization of advanced CNN models in medical
imaging, emphasizing addressing false positives and resource efficiency.
Embedded machine learning-based road conditions and driving behavior monitoringIJECEIAES
Car accident rates have increased in recent years, resulting in losses in human lives, properties, and other financial costs. An embedded machine learning-based system is developed to address this critical issue. The system can monitor road conditions, detect driving patterns, and identify aggressive driving behaviors. The system is based on neural networks trained on a comprehensive dataset of driving events, driving styles, and road conditions. The system effectively detects potential risks and helps mitigate the frequency and impact of accidents. The primary goal is to ensure the safety of drivers and vehicles. Collecting data involved gathering information on three key road events: normal street and normal drive, speed bumps, circular yellow speed bumps, and three aggressive driving actions: sudden start, sudden stop, and sudden entry. The gathered data is processed and analyzed using a machine learning system designed for limited power and memory devices. The developed system resulted in 91.9% accuracy, 93.6% precision, and 92% recall. The achieved inference time on an Arduino Nano 33 BLE Sense with a 32-bit CPU running at 64 MHz is 34 ms and requires 2.6 kB peak RAM and 139.9 kB program flash memory, making it suitable for resource-constrained embedded systems.
Using recycled concrete aggregates (RCA) for pavements is crucial to achieving sustainability. Implementing RCA for new pavement can minimize carbon footprint, conserve natural resources, reduce harmful emissions, and lower life cycle costs. Compared to natural aggregate (NA), RCA pavement has fewer comprehensive studies and sustainability assessments.
Batteries -Introduction – Types of Batteries – discharging and charging of battery - characteristics of battery –battery rating- various tests on battery- – Primary battery: silver button cell- Secondary battery :Ni-Cd battery-modern battery: lithium ion battery-maintenance of batteries-choices of batteries for electric vehicle applications.
Fuel Cells: Introduction- importance and classification of fuel cells - description, principle, components, applications of fuel cells: H2-O2 fuel cell, alkaline fuel cell, molten carbonate fuel cell and direct methanol fuel cells.
Optimizing Gradle Builds - Gradle DPE Tour Berlin 2024Sinan KOZAK
Sinan from the Delivery Hero mobile infrastructure engineering team shares a deep dive into performance acceleration with Gradle build cache optimizations. Sinan shares their journey into solving complex build-cache problems that affect Gradle builds. By understanding the challenges and solutions found in our journey, we aim to demonstrate the possibilities for faster builds. The case study reveals how overlapping outputs and cache misconfigurations led to significant increases in build times, especially as the project scaled up with numerous modules using Paparazzi tests. The journey from diagnosing to defeating cache issues offers invaluable lessons on maintaining cache integrity without sacrificing functionality.
DEEP LEARNING FOR SMART GRID INTRUSION DETECTION: A HYBRID CNN-LSTM-BASED MODELgerogepatton
As digital technology becomes more deeply embedded in power systems, protecting the communication
networks of Smart Grids (SG) has emerged as a critical concern. Distributed Network Protocol 3 (DNP3)
represents a multi-tiered application layer protocol extensively utilized in Supervisory Control and Data
Acquisition (SCADA)-based smart grids to facilitate real-time data gathering and control functionalities.
Robust Intrusion Detection Systems (IDS) are necessary for early threat detection and mitigation because
of the interconnection of these networks, which makes them vulnerable to a variety of cyberattacks. To
solve this issue, this paper develops a hybrid Deep Learning (DL) model specifically designed for intrusion
detection in smart grids. The proposed approach is a combination of the Convolutional Neural Network
(CNN) and the Long-Short-Term Memory algorithms (LSTM). We employed a recent intrusion detection
dataset (DNP3), which focuses on unauthorized commands and Denial of Service (DoS) cyberattacks, to
train and test our model. The results of our experiments show that our CNN-LSTM method is much better
at finding smart grid intrusions than other deep learning algorithms used for classification. In addition,
our proposed approach improves accuracy, precision, recall, and F1 score, achieving a high detection
accuracy rate of 99.50%.
Literature Review Basics and Understanding Reference Management.pptxDr Ramhari Poudyal
Three-day training on academic research focuses on analytical tools at United Technical College, supported by the University Grant Commission, Nepal. 24-26 May 2024
Using recycled concrete aggregates (RCA) for pavements is crucial to achieving sustainability. Implementing RCA for new pavement can minimize carbon footprint, conserve natural resources, reduce harmful emissions, and lower life cycle costs. Compared to natural aggregate (NA), RCA pavement has fewer comprehensive studies and sustainability assessments.
Advanced control scheme of doubly fed induction generator for wind turbine us...IJECEIAES
This paper describes a speed control device for generating electrical energy on an electricity network based on the doubly fed induction generator (DFIG) used for wind power conversion systems. At first, a double-fed induction generator model was constructed. A control law is formulated to govern the flow of energy between the stator of a DFIG and the energy network using three types of controllers: proportional integral (PI), sliding mode controller (SMC) and second order sliding mode controller (SOSMC). Their different results in terms of power reference tracking, reaction to unexpected speed fluctuations, sensitivity to perturbations, and resilience against machine parameter alterations are compared. MATLAB/Simulink was used to conduct the simulations for the preceding study. Multiple simulations have shown very satisfying results, and the investigations demonstrate the efficacy and power-enhancing capabilities of the suggested control system.
Presentation of IEEE Slovenia CIS (Computational Intelligence Society) Chapte...University of Maribor
Slides from talk presenting:
Aleš Zamuda: Presentation of IEEE Slovenia CIS (Computational Intelligence Society) Chapter and Networking.
Presentation at IcETRAN 2024 session:
"Inter-Society Networking Panel GRSS/MTT-S/CIS
Panel Session: Promoting Connection and Cooperation"
IEEE Slovenia GRSS
IEEE Serbia and Montenegro MTT-S
IEEE Slovenia CIS
11TH INTERNATIONAL CONFERENCE ON ELECTRICAL, ELECTRONIC AND COMPUTING ENGINEERING
3-6 June 2024, Niš, Serbia
Presentation of IEEE Slovenia CIS (Computational Intelligence Society) Chapte...
Oei building operational excellence in petroleum refining
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Building Operational Excellence in Petroleum Refining
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.
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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.
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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
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.
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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.
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
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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.
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
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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.
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.
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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
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.
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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.
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.
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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
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Process Equipment Troubleshooting
Troubleshooting concepts and techniques
Typical Problems
Interaction of Process and Equipment
Tower Scan Case Study
Tower Inspection Case Study
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
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People Development
People Development
Team Building
Training
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
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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