In today’s industrial realm, Process Plant Optimization holds a pivotal role. Achieving substantial optimization benefits requires minimizing production costs, including interruptions in operations. This entails proficiently managing maintenance operations and optimizing equipment, plant reliability, and availability. Moreover, it involves deploying effective inspection and maintenance strategies, coupled with meticulous planning methods. The optimization of the plant emerges as a highly efficacious approach for attaining heightened profitability.

A crucial facet of process plant optimization revolves around system energy management and curtailing energy consumption. Industrial processes and systems present significant potentials for cost savings. Adjustments in processes, such as incorporating advanced controls and embracing novel technologies, also open avenues for optimizing the plant.

This training course, presented by STRATEDGE and focusing on Process Plant Optimization Technology and Continual Improvement, will furnish a thorough examination of diverse aspects related to process plant integrity. It stands as an indispensable cornerstone for ensuring enduring plant profitability and optimization.

• Facilitating participants’ comprehension of the fundamental components of plant optimization and guiding them in achieving and actualizing potential benefits.
• Strengthening the business-oriented perspective of participants, empowering them to make greater contributions to the enduring profitability of the plant.
• Providing maintenance professionals, planners, and engineers with the expertise to choose the most suitable methodologies for their decision-making in maintenance.
• Instructing participants on the identification of opportunities for reducing energy consumption.
• Furnishing participants with pragmatic and efficient approaches, along with tools, for conducting technical and economic evaluations of various alternatives.

In the STRATEDGE Process Plant Optimization Technology and Continual Improvement training course, a workshop approach will be adopted, integrating formal lectures and interactive worked examples. The central emphasis in this STRATEDGE course will be to clarify various technical aspects and provide resolutions for challenges commonly faced in day-to-day industrial operations related to the maintenance, repair, and modifications of process equipment. Practical examples will be employed to underscore each educational point. The course will actively promote discussions, fostering the exchange of professional experiences and insights to enhance the assimilation of knowledge. Comprehensive course materials will be provided.

• Process plant technical professionals: engineers, technicians, and operators
• Engineers, supervisors, operations, and maintenance personnel
• Project engineers
• Engineering and technical personnel dedicated to enhancing process plant profitability
• Professionals focused on improving energy efficiency in process plants

Day 1: Overview of Optimization Technologies

• Exploration of Optimization Technologies for Process Plants
• Examination of the Elements within the Process Plant Optimization Procedure
• Addressing Constraints in Optimization: Production, Operation, Economy, and Environment
• Evaluation of Optimization Approaches: Mathematical Models and Physical Models (prototype units)
• Understanding the Correlation between Process Optimization and Process Control in Typical Process Plants
• Workshop Session: Illustrative Examples and Resolutions

Day 2: Reliability, Availability, and Effectiveness

• Insight into the Relationship between Plant Reliability and Availability
• Strategies for Optimizing Plant Reliability
• Enhancing Plant Availability through Improved Maintenance Practices
• Analysis of the Effectiveness of Individual Equipment
• Overall Plant Effectiveness Optimization
• Workshop Session: Practical Examples and Solutions

Day 3: Best Practices for Energy Consumption

• Optimization Strategies Targeting Energy Consumption Reduction
• Compliance with World Standards and Benchmarking Guidelines
• Best Practices in Energy Management for Process Plants
• Energy Conservation Checklist for Typical Industrial Plants
• Optimization of Heat Production, Steam Distribution, and Consumption
• Workshop Session: Application of Examples and Solutions

Day 4: Maintenance Management System

• Optimization of Piping Systems and Pipelines Utilization
• Maximizing the Utilization of Pumps, Compressors, and Fans
• Enhancing Maintenance Management Systems and Determining Maintenance Frequency
• Optimizing Spare Parts Management through Predictive Maintenance
• Aligning Repair and Alteration Programs with Existing Codes
• Workshop Session: Case Studies and Solutions

Day 5: Minimization of Equipment Failure

• Implementation of Risk-Based Inspection (RBI)
• Procedures for Minimizing the Risk of Equipment Failure
• Fitness for Service (FFS) Analysis and Estimation of Remaining Equipment Life
• Optimization of Plant Economy through Planned Equipment Replacement
• Summary and Course Review