Process Plant Performance & Efficiency

Introduction: 

This comprehensive course is designed to equip participants with the knowledge and tools to optimize process plant performance and efficiency. It covers a wide range of topics, from process fundamentals to advanced optimization techniques, enabling attendees to identify and implement strategies for improving plant operations

This course provides participants with a specified overview of process plant performance and efficiency. It includes the characterization of catalyst and reactor performance; separation processes; efficient pipelines, pumps, and compressors; the efficiency of off-site utilities such as energy, cooling water, steam, and refrigeration; and the importance of proper waste disposal and its impact on plant performance and efficiency.

Course Objectives:      

Applicants will be able to understand the best  method in measurements and control technology and their major role in plant performance and efficiency; identify the various optimization tools used in process plant performance; determine the refinery and process plant optimization trends; discuss the continuous improvement, benchmarking and best practices for process plant performance and efficiency; carryout troubleshooting procedures and identify the different performance analysis software used in process plant performance in relation to process optimization and performance monitoring.

After the delegates complete the course will be able to:

• Develop a deep understanding of process plant operations and key performance indicators (KPIs)
• Master process modeling, simulation, and optimization techniques
• Apply advanced process control strategies for improved efficiency
• Implement energy efficiency and waste minimization initiatives
• Utilize data analytics and process monitoring tools for performance enhancement
• Conduct root cause analysis and troubleshooting to address process issues
• Develop a continuous improvement culture within the organization

Course Content:

Day 1: Process Fundamentals and Performance Metrics

• Introduction to process plants and their operations
• Process flow diagrams (PFDs) and process flow sheets (P&IDs)
• Key performance indicators (KPIs) for process plants
• Mass and energy balances
• Process simulation software overview

Day 2: Unit Operations and Process Intensification

• Characterization of catalysts and reactors
• Performance evaluation of separation processes (distillation, absorption, filtration, etc.)
• Performance analysis of pumps, compressors, and heat exchangers
• Process intensification techniques (microreactors, membrane separation)
• Energy integration and efficiency in unit operations

Day 3: Advanced Process Control and Optimization

• Process control fundamentals (PID controllers, advanced control)
• Model predictive control (MPC)
• Real-time optimization (RTO)
• Process data analytics and visualization
• Statistical process control (SPC)

Day 4: Data Analytics and Process Improvement

• Data collection and management in process plants
• Process modeling using data analytics
• Root cause analysis and problem-solving techniques
• Six Sigma and Lean methodologies for process improvement
• Benchmarking and best practices in process industries

Day 5: Case Studies and Industry Trends

• Case studies of successful process optimization projects
• Industry trends and emerging technologies (digitalization, Industry 4.0)
• Life cycle assessment (LCA) and sustainability
• Economic analysis of process improvements
• Continuous improvement culture and organizational change

Training Methodology:

This interactive training course includes: Lectures, Presentations, Case Studies & Practical Exercises and Videos

Who Should Attend?

This course is proposed for all those work with the process plant performance and efficiency including process staff, operation and maintenance, planning staff, instrumentation & control staff, production & operation staff, process, electrical, mechanical and project engineers

• Process engineers
• Plant operators
• Maintenance engineers
• Production supervisors
• Quality control personnel
• Process optimization specialists