Course Description

This practical and highly-interactive course includes various practical sessions and exercises. Theory learnt will be applied using our state-of-the-art simulators. Process plants are normally designed to nameplate capacities stipulated at the commencement of design. However, this can be misleading. Usually plants have an inbuilt design margin that is not visible to the owner, leading to false operating constraints that cost you lost revenue. On the other hand, bottlenecks are often introduced due to poor design or as a result of incomplete commissioning and poor control. These tend to result in your facility having reduced throughputs coupled with poor uptime. Not too long ago, it was generally conceded that a new plant could produce at least 10% more than its nameplate capacity. In some instances, owners would oversize certain pieces of critical equipment to assure this and possibly more. Today, however, we see plants being expanded too much higher capacities due to a combination of new technology and improved ways to operate and control them.Correctly identifying both limits and opportunities provides the lowest investment revamp. Processes include more than just equipment. Processes include specific linkages between equipment to achieve the operating plant objectives. Revamps must examine both the capabilities of the equipment and the opportunities available from changing the process sequence (or operating conditions). Correctly integrating equipment and process evaluation requires good field test data, an accurate analysis of the data, and putting together a proper team for a given revamp. No revamp is the same as any other. Every plant is different. All equipment and every process have different limits and different opportunities.This course is designed to provide a good overview of the process plant optimization, rehabilitation, revamping and debottlenecking. It covers process plant overview, optimization & profitability, basic and advanced optimization tools, optimizing the design, capacity creep & plant debottlenecking, cost-effective debottlenecking strategy and action plan, optimizing process operations, process controls, optimizing reliability, management & enterprise information systems, risk management & optimization, optimizing offsites operations, utilities management, rehabilitation philosophy and mechanism, revamping strategy and options, r&d role in new product development and production capacity enhancement, safety & environmental considerations, and project management issues. The course includes many case studies that will be discussed within the 5 days. However, participants are encouraged to bring their own problems and case studies to the course. These problems should be of a non-confidential nature that can be discussed without violation of any confidentiality restrictions.

link to course overview PDF

TRAINING METHODOLOGY

This interactive training course includes the following training methodologies:

30 % Lectures
20 % Workshops & Work Presentations
20 % Case Studies & Practical Exercises
30 % Videos, Software & Simulators

In an unlikely event, the course instructor may modify the above training methodology for technical reasons.

VIRTUAL TRAINING (IF APPLICABLE)

If this course is delivered online as a Virtual Training, the following limitations will be applicable:

Certificates	:	Only soft copy certificates will be issued
Training Materials	:	Only soft copy materials will be issued
Training Methodology	:	80% theory, 20% practical
Training Program	:	4 hours per day, from 09:30 to 13:30