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

What is plant Optimisation?

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

What is the meaning of debottlenecking?

Why is this “Process Plant Optimisation, Revamping and Debottlenecking” training program crucial for effective process plant management? The main aim of a revamp is to improve basic parameters like volume or processing efficiency. Revamping and debottlenecking require flexibility in planning and proficiency in the right engineering gear. Therefore, to optimise and maintain the fundamental performance of a unit, this program is important to take you beyond a surface level of study.

This training course will provide you with a comprehensive view of the process of how to optimise offsite plant operations including design, storage facilities, and inventory management, understand utility management, and expand your knowledge on optimisation, revamping, and debottlenecking process plants.

Upon successful completion of this course, the delegates will be able to:

• Understand plant optimisation and energy conservation in detail
• Describe and practice the managerial tools needed to effectively optimise plant operations
• Evaluate the concept of capacity creep and discuss the methodology of the cost-effective debottlenecking strategies
• Implement systematic methods of optimising plant reliability including root cause failure analysis, logic diagrams, fault trees, etc.
• Identify the role and importance of management and enterprise information systems in plant optimisation
• Acquire knowledge on risk management in process plant optimisation
• Describe utility management and rehabilitation in revamping and debottlenecking
• Assess the maintenance, energy, utilities, environmental, and safety parameters in revamping and debottlenecking
• Analyse economic, planning, and other project management issues

This Process Plant Optimization, Revamping and Debottlenecking training program would be suitable for:

• Process plant technical professionals
• Engineers, technicians, and operators
• Supervisors and maintenance personnel
• Project engineers
• Engineering and technical personnel responsible for improving process and petrochemical plant, and refinery profitability
• Those who are involved in planning, managing, and ensuring energy efficiency

Welcome & Introduction

Pre-Test

Module 1: Overview of Process Plant Operation

• Overview of Optimisation Technologies for Process Plants
• Elements of Process Plant Optimisation Procedure
• Constraints in Optimisation:
  • Production
  • Operation
  • Economy
  • Environment
• Optimisation Approaches
• Mathematical Models and Physical Models
• Correlation between Process Optimisation and Process Control
• Workshop: Examples and Solutions

Module 2: Process Plant Optimisation Basics

• Process Plant Optimisation
• Process Control Basics
• Elements of Process Plant Optimisation
• Components to Optimise Industrial Processes
• Mathematical Model of Process
• Process Variables
• Simulation Technology to Plant and Control
• The Basics of Heat Integration

Module 3: Energy Management for Businesses & The Environment

• Industrial Energy Management
• Energy Efficiency for Businesses and the Environment
• Energy Use and in Process Industry
• Energy Management Standard: Details
• Energy Management Standard: Features
• Obstacles for Energy Management Programs

Module 4: Energy Conservation

• World Standards and Benchmarking Guidelines
• Useful Practices in Process Plant Energy Management
• Energy Conservation Check List for Industrial Plants
• Energy Conservation Opportunities
• Energy Audit
• Energy Audit Types
• Benchmarking Energy Intensity and Usage
• New Energy Efficient Technologies
• Technical Evaluation of Potential Opportunities
• Economic Evaluation of Renewable Energy

Module 5: Plant Optimisation Activities

• Implications of Plant Optimisation Activities
• Technological Modifications to the Plant
• Technology Licenses
• Impact on Human Resources
• Good Safety ‐ Good Business
• Safety Costs: Costs of Injuries

Module 6: Revamping and Debottlenecking Strategies

• Revamping Strategies
• Production Capacity Enhancement
• Maintenance, Energy, Utilities, Environmental and Safety Parameters
• Economic, Planning, and Project Management Issues
• Case Studies:
  • Optimising a Polypropylene Plant
  • Debottlenecking Ethylene & Propylene Plant
  • Revamping an Oil Refinery Plant

Post Test

Presentation of Certificates

A variety of methodologies will be used during the course that includes:

• (30%) Based on Case Studies
• (30%) Techniques 
• (30%) Role Play
• (10%) Concepts
• Pre-test and Post-test
• Variety of Learning Methods
• Lectures
• Case Studies and Self Questionaires
• Group Work
• Discussion
• Presentation

International Center for Training & Development (ICTD) will award an internationally recognized certificate(s) for each delegate on completion of training.

To be advice as per course location. This rate includes participant’s manual, and-Outs, buffet lunch, coffee/tea on arrival, morning & afternoon of each day.

Daily Course Timings:

    08:00 - 08:20       Morning Coffee / Tea

    08:20 - 10:00       First Session

    10:00 - 10:20       Coffee / Tea / Snacks

    10:20 - 12:20       Second Session

    12:20 - 13:30       Lunch Break & Prayer Break

    13:30 - 15:00       Last Session