CASE STUDY: Improving Operational Agility While Mitigating ...
Improving Operational Performance With Smarter, Cost-Effective Training Programs
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Transcript of Improving Operational Performance With Smarter, Cost-Effective Training Programs
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Improving Operational Performance with Smarter, Cost-Effective Training Programs
GSE EnVision1332 Londontown Blvd., Suite 200, Sykesville, Maryland 21784, USA
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Why We Are in Business
The importance of oil to the world economy and way of life
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Factors Impacting Your Plant
Employee:Education
Experience Attitude
Daily Emotional State
Equipment:Age
MaintenanceFailures
Plant Operations:
CultureManagement style
Environmental Conditions
Design:
Ease of OperationControls Effectiveness
Information Effectiveness
Impacting Factors
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Your People Your Systems
What has a greater variability in performance?
Understanding the Problem
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How agile is your workforce?
Agility
Do you get consistent performance across the entire fleet of plants?
Are your engineers and operators prepared for operational challenges?
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Worldwide Survey Results(By Society of Petroleum Engineers)
25% believe the current lack of training and development is detrimental to their career
37% felt that a lack of training in previous roles has held them back in their career
More than 50% of the oil and gas industry's employees would consider leaving an employer due to a lack of training and development
+50%
37%
25%
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Worldwide Survey Results(By Society of Petroleum Engineers)
Only 11% expect their employer to provide all of their training
56% of respondents believe that the employer should provide all or some training to new hires56%
11%
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Importance of Competency
• Competence:
Knowledge, skills & attitudes (behaviors)(We cannot observe attitude, but we can observe behavior)
• A competent console operator can:
• Troubleshoot, diagnose & recover from abnormal conditions
• Maintain on-spec products
• Minimize energy, utility & catalyst costs
• Avoid hazardous situations
• Minimize wear & tear on the plant
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Importance of Competency
• An engineer and console operator’s competence is critical to safe and reliable operation of a plant.
• It is indirectly related to the profitability of the plant, the shareholder value and the public perception of the company.
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How Training is Typically Done
• Some level of classroom instruction
• Mentoring or on-job-training program using your most knowledgeable & experienced console operator or engineer
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How Training is Typically Done
Classroom InstructionStudents can interact with instructorResource limitedPace set by slowest student
Mentoring ProgramPlant specific knowledge is transferredCan waste time and $ on answering fundamental questions
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Full-scope custom operator training simulators (OTS) are used to:
• Teach new console operators
• Improve the skills of experienced staff members
How Training is Typically Done
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How Do You Ensure…
• Valuable mentoring time is spent transferring critical knowledge & experience?
• Optimal use of high-value assets such as OTS and other training & development resources?
• You are spending money wisely?
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The Training Process
Industries that have no room for failure have adopted the systematic approach to training, following the ADDIE process.
Analyze
Design
DevelopImplement
Evaluate
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Failure is not an option
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Learn process fundamentals with self-paced tutorials
Practice operations and troubleshooting with generic dynamic simulations
The Flip/Reverse Learning Model
Any new knowledge not utilized within 72 hours is likely to be lost, unless it is used…
TUTORIALS SIMULATIONS
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Distillation Tutorial Example
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Simulation Example
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GSE provides the right solution for the right step in the learning process
Process Fundamentals
Self Paced Tutorial
Cost of Training Asset
Valu
e o
f A
sset
Applied Learning through Generic
SimulationInstructor Led
Real World Knowledge
TransferMentoring
Unit Specific Experiential Learning
Custom Operator Training Simulators
Process ControlSelf Paced Tutorial
Learn the “Why” Before the “How”
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Modular Training Progression
• Start with basics of process equipment and instrumentation & controls
• Move to unit operations & complex processes
Processes
• Practice controls and normal operations
• Move to advanced/emergency
Procedures• Learn to troubleshoot
• Analyze cause and effect and take corrective actions
Analysis
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SIULATIONSProcess Overview
Equipment and Process Configuration
Key Control and Operating Variables
Typical Startup / Shutdown
Troubleshooting
Shorter Learning Curve
Consistent Performance
Understand Cause and Effect
Effective Use of Training Assets
Revenue-Risk-Cost-Agility
Learn process fundamentals with self-paced tutorials
80% of the Learning – 20% of the Cost
TUTORIALS
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Revenue-Risk-Cost-Agility
Smoother Startup
Fewer Outages
Minimize Off-Spec Products
Less Equipment Wear & Tear
SIULATIONSLearn to Control Process
Practice Procedures
Examine Cause & Effect
Make Mistakes in Safe Environment
Gain ConfidencePractice operations and
troubleshooting with generic dynamic simulations
80% of the Learning – 20% of the Cost
Any new knowledge not utilized within 72 hours is likely to be lost, unless it is used…
SIMULATIONS
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Results
Workers with enhanced competence are more confident, effective and efficient, which results in:
• Smoother startups with less flaring
• Fewer shutdowns with shorter durations
• Reduced risk of equipment damage
• Improved safety awareness
In the long term: Your Plant will see financial improvements to the bottom line.
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Results
Using a consistent training program and set of learning tools across the organization allows:
• Better understanding of the process
• Better confidence between operators and engineers
• Better communication and mutual respect for one another
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Process Fundamentals & Controls
Process Fundamentals-I• Gas and Liquid Flow• Pipe Flow Network• Single Phase Heat Exchanger
• Single Phase Exchanger with Bypass Control
• Air Cooler• Tank and Pump• Tank, Pumps and a Heat Exchanger
Process Fundamentals-II• Centrifugal Compressor• Condensing Heat Exchanger• Flash Drum• Three Phase Separator• Kettle Type Reboiler Heat Exchanger• Mixer with Heating Jacket• Reciprocating Compressor • Steam Turbine with Condenser• Reflux Drum with Overhead Condenser
Process Control Fundamentals• Feed Forward Control• Override Control• Ratio & Cascade Control • Split Range Control
Basic Process Control
Advanced Process Control
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Basic Unit Operations
• Amine Treating for Refineries
• Steam Boiler
• Steam & Power Generation Boiler
• Compressor
• Cooling Tower
• Distillation: Depropanizer
• Distillation: Water-Methanol
• Furnace
• Pump
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• Alkylation: HF• Alkylation: H2SO4 • Blending: Gasoline
and Fuel Oil • CDU Atm. & Vacuum • Delayed Coker • FCC: Fluidized
Catalytic Cracker • HCU: Hydrocracker Unit • HDS: Diesel Hydrotreater
• Hydrogen Unit (SMR) with PSA
• Hydrogen Unit (SMR) with Methanator
• Reformer-CCR • Reformer- Fixed Bed • SRU: Claus• SRU: SCOT (Tail Gas Treating Unit) • Visbreaker
Refineries
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Petrochemicals (for Ethylene Plants)
• Acetylene Converter Reactor
• Boiler
• Compressor
• Ethylene Cracking Heater
• Ethylene Refrigeration Unit
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Upstream (Gas Plant/NGL & LNG)
• Amine Treating Unit for Upstream
• Glycol Dehydration Unit
• GOSP: Gas Oil Separation Process
• NGL/LNG Fundamental Simulation Models:• Feed Gas Conditioning
(Filters, Molecular Sieves Dehydration and Mercury Removal)
• Propane Refrigeration• Separation / NGL Gas Plant• Methane Liquefaction and with Nitrogen Removal
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• Operators are competent to reduce risk
• Improve abnormal situation management
• Learn to identify low frequency events, leading to abnormal/emergency situations
• Single global learning platform for enterprise implementation, multiple languages
• Build operator self-confidence
TRAINING OBJECTIVES VENDOR SELECTION
• Technical merits
• Extensive review by the experienced console operators
• Experience with Simulators, e-Learning, multiple languages
• Deeper understanding of Refinery, Petrochemicals and Oil & Gas processes
• Customer focus and after sales support
Case Study 1: Major Oil Co. Training Program
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• Safety through composure
• Build the ability to cope with stressful experiences
• Regain “feel” for process and cause & effect relationships
• Ensuring engineers appreciate operational issues
TRAINING OBJECTIVES
Process Specific Generic Vs. Custom Simulation
Investing in custom simulation, but…
• Cannot afford to wait 5-8 years for the build out
• Not practical to have custom simulation for every process at every site
Case Study 2: Major Oil Co. Training Program
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Conclusions
Avoid RISK and DECREASE COST
Protect REVENUE
Increase workforce AGILITY
Spend less–get better results
80% of the learning at 20% of the cost
More information at www.envision-training.com