An intensive professional development training course on

Process Plant Optimisation

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Why Choose this Training Course?

The Course

Plant integrity and reliability is the cornerstone of process plant optimization. For optimization benefits to be sustainable, production interruptions must be kept to a minimum which requires effective management of degradation processes that affect equipment and systems and effective inspection and maintenance strategies, plans and methods. Plant optimization can be an effective way to achieve improved profitability without the large investment associated with building a new plant.

Common industrial processes and systems, such as steam, cooling water, process heating, and electric motors consume   most of the energy and offer significant opportunities for savings. Process changes such as advanced controls, new catalysts, and new technologies also present opportunities for plant optimization. This course will provide a comprehensive review of the various aspects of process plant integrity as the essential foundation for sustainable plant profitability and optimization.

Principal emphasis is placed on:

  • Understanding the elements of plant optimization
  • Systematic and coordinated efforts by engineering, operations, and maintenance functions
  • Maximization of plant availability, reliability and productivity
  • Minimizing operational costs
  • Safeguarding of plant integrity over its intended life based on total life cycle cost principles


 The Goals

  • To assist participants in recognizing and clearly understanding what plant optimization and energy conservation is all about – the drivers, the potential benefits, and how to realize them
  • To apply the business focus of participants and equip them to make more contributions to sustainable plant profitability
  • Appraise the most attractive opportunities to identify energy savings
  • Describe the managerial tools the delegates can utilize to effectively optimize plant operations
  • Demonstrate practical and effective methods and tools to provide participants with the skills to perform technical and economic evaluations of the alternatives


 The Delegates

This course is particularly valuable for:

  • Process Plant, Petroleum Refinery, and Gas  Plant Technical Professionals
  • Engineers, Operations and Maintenance professionals, as well as for Project and Consulting Engineers
  • Engineering and Technical professionals involved in improving process plant, petrochemical plant and refinery profitability and energy efficiency


 The Process

The course combines presentations and discussions of topics covered with relevant practical examples. It combines sound engineering and economic principles, methods, and best industry practices and enforces the learning with Case Studies and Question & Answer workshops to maximize the benefits to the participants.


 The Benefits

Delegates will:   

  • Gain a sound understanding of the main elements of plant integrity and reliability and why this is the cornerstone of sustainable plant optimization and energy efficiency.
  • Improve their understanding of the business aspects of the process plant which will help them focus on improving the economic performance.
  • Learn how to perform key project analyses including technical, economic, and environmental evaluations.
  • Enhance their competence and productivity thereby enhancing their competence and performance level and making additional value added contributions to their organization.
  • Develop technical and analytical skills necessary for conducting technical evaluations.
  • Have skills necessary to participate in plant energy audits.
  • Be able to apply risk-based methodologies in inspection and maintenance.


 The Results

  • Through effective management of energy use, the plant can minimize the overall cost of energy.
  • By diligent use of process optimization techniques, the company can improve production rates while maintaining best safety practices.
  • Management can lessen the risk associated with production operations while realizing direct measurable bottom line savings.
  • The company will be able to enhance its plant reliability and integrity by using improved maintenance strategies and methods based on risk-based inspection and maintenance.
  • Lower life cycle costs can be achieved while complying with codes and standards, and other regulatory requirements.
  • The company will have personnel who will have the economic and analytical skills necessary for performing credible economic evaluations.


The Course Content

Day One

Process Plant Operation, Integrity and Reliability

  • Process Plant Optimization and Energy Conservation – Overview
  • Asset Integrity Management (AIM)
  • Plant Integrity and Reliability
  • Risk Based Integrity (RBI) Approach
  • Operation and Maintenance Impacts on Plant Integrity and Reliability
  • Asset Management and Maintenance Management: Process Improvement
  • Process Plant Economics
Day Two

Process Plant Optimization

  • Process Control Basics
  • Elements of Process Plant Optimization
  • Components Required to Optimize Industrial Processes
  • Process or Mathematical Model of Process and Process Variables    
  • Application of Simulation Technology to Plant Optimization and Control 
  • The Basics of Heat Integration
  • Pinch Technology
Day Three

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

  • Energy Use and Optimization in Process Industry                                   
  • Industrial Energy Management Techniques: Energy Efficiency                   
  • Industrial Energy Management Techniques
  • Energy Management Standard: Details
  • Energy Management Standard: Features
  • Obstacles for Energy Management Programs
Day Four

Energy Conservation Opportunities

  • Energy Audit
  • Energy Audit Types
  • Benchmarking Energy Intensity and Usage
  • Technology Options – New Energy Efficient Technologies
  • Technical and Economic Evaluation of Potential Opportunities:   Renewable Energy
Day Five

Implications of Plant Optimization Activities

  • Relating Energy Efficiency to Business Outcome
  • Impact of Optimization Activities and Technological Modifications to the Plant
  • Technology Licenses
  • Impact on Human Resource
  • Good Safety - Good Business
  • Safety Costs: Costs of Injuries
  • Lessons from Disasters

The Certificate

  • AZTech Certificate of Completion for delegates who attend and complete the course.


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