Crude Oil Process Plant and Refinery Performance-Based Operations and Maintenance 7th – 11th July, 2025

Course Overview

This 5-day comprehensive training program is designed to enhance the operational efficiency, reliability, and performance of crude oil processing plants and refineries. Focusing on performance-based strategies, the course equips participants with the tools and techniques needed to optimise plant operations, ensure consistent product quality, and maintain high uptime. The course delves into the importance of key performance indicators (KPIs), performance monitoring methods, and predictive maintenance practices to prevent equipment failures and reduce downtime.

Course Objectives

By the end of this course, participants will be able to:

1. Understand the concept of performance-based operations and maintenance in crude oil processing plants and refineries.

2. Identify and apply key performance indicators (KPIs) to monitor and optimise plant performance.

3. Implement predictive maintenance strategies to prevent equipment failures and reduce unplanned downtime.

4. Utilise performance monitoring techniques for continuous improvement in refinery operations.

5. Develop and apply strategies for aligning maintenance activities with operational goals.

6. Understand the impact of process optimization on refining operations and product quality.

Target Audience

• Plant operators and refinery engineers.

• Maintenance engineers and managers.

• Supervisors and team leaders in crude oil processing and refinery operations.

• Process optimization specialists.

• Safety and reliability engineers.

• Professionals involved in performance monitoring and maintenance strategy development.

Daily Agenda

Day One: Introduction to Performance-Based Operations and Maintenance

• Overview of Crude Oil Processing Plants and Refineries: Key components and operations in crude oil refining.

• Performance-Based Maintenance Strategies: Understanding the need for performance-focused operations and how it differs from traditional maintenance approaches.

• Key Performance Indicators (KPIs): Identifying critical KPIs for refinery operations, including capacity utilization, yield, and energy consumption.

• Benchmarking Plant Performance: Methods for comparing plant performance against industry standards and setting realistic performance goals.

• Case Study: Analysing the performance of a refinery and identifying areas for improvement.

• Importance of Data in Performance Monitoring: Collecting, analysing, and using data to drive decision-making in refinery operations.

Day Two: Performance Monitoring and Optimisation Techniques

• Real-Time Monitoring Systems: Overview of digital tools and technologies for real-time performance monitoring.

• Data Analytics for Process Optimisation: Using data analysis to identify trends, inefficiencies, and opportunities for improvement.

• Optimising Process Variables: Methods to optimise temperature, pressure, and flow rates to improve plant performance and product quality.

• Energy Efficiency in Refinery Operations: Techniques for reducing energy consumption without compromising product quality or output.

• Predictive Analytics for Maintenance: Applying predictive analytics to monitor equipment conditions and prevent failures.

• Practical Exercise: Using performance monitoring tools to identify inefficiencies in a refinery simulation.

Day Three: Predictive Maintenance and Reliability Engineering

• Introduction to Predictive Maintenance: Understanding predictive maintenance techniques and their role in improving plant reliability.

• Condition Monitoring Tools: Tools and technologies for monitoring the health of critical equipment in the refinery.

• Failure Modes and Effects Analysis (FMEA): How to assess potential failure modes and plan maintenance to prevent failures.

• Reliability-Centered Maintenance (RCM): Integrating reliability strategies with operational performance goals.

• Root Cause Analysis: Techniques for identifying the root causes of equipment failures and how to implement corrective actions.

• Case Study: Reviewing a real-world failure incident and developing a predictive maintenance strategy.

Day Four: Aligning Maintenance with Operational Goals

• Integrated Maintenance Strategies: Aligning operational and maintenance strategies to achieve business objectives.

• Total Productive Maintenance (TPM): Involving all employees in maintaining equipment to improve performance and reduce downtime.

• Managing Spare Parts and Inventory: Effective strategies for maintaining optimal spare parts inventory to support operational goals.

• Performance-Based Contracting: Understanding the role of performance-based contracts in maintaining refinery operations.

• Continuous Improvement and Lean Principles: Implementing continuous improvement initiatives such as Lean and Six Sigma in refinery operations.

• Workshop: Developing a maintenance strategy that aligns with performance-based operational goals.

Day Five: Continuous Improvement and Advanced Refinery Optimisation Techniques

• Optimising Refinery Operations for High-Performance: Techniques for maximising throughput, reducing energy costs, and improving product quality.

• Advanced Process Control (APC): Implementing advanced control strategies to enhance the stability and performance of refinery processes.

• Process Revamping and Upgrades: Approaches to improving outdated refinery systems to meet modern performance standards.

• Monitoring and Auditing Performance: Best practices for conducting regular audits to ensure compliance with performance standards.

• Future Trends in Refinery Performance Optimisation: Exploring new technologies and trends that will shape the future of refinery operations and maintenance.

• Final Assessment: Reviewing the course material through practical scenarios and discussions.

Why Choose this Course?

This course provides participants with essential tools and strategies for optimising refinery performance through a performance-based approach to operations and maintenance. By focusing on the integration of predictive maintenance, performance monitoring, and continuous improvement, participants will be able to enhance plant efficiency, reduce downtime, and ensure consistent product quality. This course equips professionals with the practical skills necessary to align maintenance activities with operational goals, contributing to the overall profitability and reliability of refinery operations.

Learning Outcomes

Upon completion of this course, participants will:

1. Be proficient in using performance-based strategies to optimise refinery operations.

2. Understand the application of KPIs for monitoring and improving refinery performance.

3. Implement predictive maintenance techniques to prevent equipment failures and reduce downtime.

4. Be able to analyse and optimise operational data for continuous improvement.

5. Align maintenance activities with refinery performance goals and operational targets.