• understanding the elements of plant optimization
• systematic and coordinated efforts by engineering, operations, and maintenance functions
• maximisation of plant availability, reliability and productivity
• minimising operational costs
• safeguarding of plant integrity over its intended life based on total life cycle cost principles

• To assist participants in clearly understanding what plant optimization and energy conservation is all about – the drivers, the potential benefits, and how to realize them
• To enhance the business focus of participants and equip them to make more contributions to sustainable plant profitability
• Learn how to identify the most attractive opportunities for energy savings
• Provide the delegate with managerial tools to effectively optimise plant operations
• To provide participants with practical and effective methods and tools to perform technical and economic evaluations of the alternatives

This course is particularly valuable for:

• Process Plant, Petroleum Refinery, and Petrochemical Plant Technical Professionals
• Engineers, Supervisors, Operations and Maintenance personnel, as well as for Project and Consulting Engineers
• Engineering and Technical personnel 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 learnings with Case Studies and Question & Answer workshops to maximize the benefits to the participants.

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.

Day One

Process Plant Operation, Integrity and Reliability

• Process Plant Optimization and Energy Conservation – Overview
• Asset Integrity Management (AIM) and Optimization - Integrating operation, inspection, maintenance effort
• Plant Integrity and Reliability – Cornerstone of Plant Optimization and Energy Management
• Operation and Maintenance Impacts on Plant Integrity and Reliability
• Equipment condition monitoring and assessment
• Establishment of Operating Windows (OW) - Maximize throughput within the limits defined by mechanical-structural integrity over the expected life of the asset components
• Effective management of change (MOC) program – On-going link between engineering, operations and maintenance
• Process Plant Economics

Day Two

Process Plant Optimization

• Process Control Basics
• Elements of Process Plant Optimization
• Components Required To Optimize An Industrial Process
• Process or a mathematical model of the process, and process variables which can be manipulated and controlled
• Application Of Simulation Technology To Plant Optimization And Control - Plant Optimization Models
• The Basics Of Heat Integration
• Pinch technology
• Heat exchanger train optimization
• Optimization procedure
• Application Of Simulation Technology To Plant Optimization And Control - Plant Optimization Models

Day Three

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

• Energy Use and Optimization in Process industries
• Industrial Energy Management Techniques
• Industrial Energy Management and System Standards
• Industry Program for Energy Conservation
• Best Practices in Process Plant Energy Management
• Developing Customized Energy Management Program
• Obstacle that Face Energy Management Programs
• Workshop - Examples of energy management programs and standards – CIPEC, UNIDO. Incentives for energy assessment and energy retrofit projects

Day Four

Energy Conservation Opportunities

• Implementing an Energy Management Program
• Benchmarking Energy Intensity and Usage
• Technology Options - New energy-efficient technologies. Examples include Corrosion analyzer for advanced materials and fabricated components Fiber optic sensor for combustion measurement and control
• Energy Conservation Checklist
• Plant processes
• Mechanical Systems
• Electric Power
• Technical and Economic Evaluation of Potential Opportunities

Day Five

The Implications of Plant Optimization Activities

• Relating Energy Efficiency To Business Outcomes
• Impact of optimization activities and technological modifications to the plant
• Plant integrity and safety
• Technology licenses
• Financing agreements
• Impact on Human Resources – The human factor

CDGA attendance certificate will be issued to all attendees completing minimum of 80% of the total course duration.