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This course will provide a comprehensive review of the various aspects of process plant integrity as the essential foundation for sustainable plant profitability and optimization, and practical approach to effective energy management.

Course Outline
After participating in this course, you will be able to:
  • become familiar with and better understand the elements of plant optimization
  • develop an understanding of the safeguarding of plant integrity over its intended life based on total life cycle cost principles
  • appreciate the significance of asset management and energy management in reducing operating costs and increasing profitability

Plant integrity and reliability is the cornerstone of process plant optimization. For optimization benefits to be sustainable, production interruptions must be kept to a minimum which requires effective management of degradation processes that affect equipment and systems and effective inspection and maintenance strategies, plans and methods. Plant optimization can be an effective way to achieve improved profitability without the large investment associated with building a new plant.

Common industrial processes and systems, such as steam, cooling water, process heating, and electric motors consume most of the energy and offer significant opportunities for savings. Process changes such as advanced controls, new catalysts, and new technologies also present opportunities for plant optimization.

This course will provide a comprehensive review of the various aspects of process plant integrity as the essential foundation for sustainable plant profitability and optimization, and practical approach to effective energy management.

  • 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 participants with managerial tools to effectively optimize plant operations
  • To provide participants with practical and effective methods and tools to perform technical and economic evaluations of the alternatives.
Who Should Attend
  • Technical professionals in the Process, Petroleum, Petrochemical, Power, Mining, and Pulp and Paper industries,
  • Engineers, Supervisors, Operations and Maintenance personnel as well as military personnel involved in facilities management, as well as Project and Consulting Engineers
  • Engineering and Technical personnel involved in improving process plant, petrochemical plant and refinery profitability and energy efficiency.
Program Outline

Welcome, Introduction, Seminar Preview, Learning Outcomes and the Assessment Method

Day 1 - Process Plant Operation, Integrity and Reliability

  • Process plant optimization and energy conservation - overview
  • Plant integrity and reliability - cornerstone of plant optimization and energy management
  • Asset integrity management (aim) and optimization - integrating operation, inspection, maintenance effort
  • Operation and maintenance impacts on plant integrity and reliability
  • Equipment condition monitoring and assessment
  • Establishment of integrity operating windows (iow) - 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 II - Process Plant Optimization
  • Process control basics
  • Elements of process plant optimization
  • Components required to optimize an industrial process
  • Application of simulation technology to plant optimization and control - plant optimization models
  • The basics of heat integration
  • Pinch technology
  • Heat exchanger train optimization
  • Implications of plant optimization activities - impact of optimization activities and technological modifications on the plant and human resources.
Day III - Industrial Energy Management - Energy Efficiency: Good for Business - Good for the Environment
  • Energy use and optimization in process industries
  • Industrial energy management programs, standards and techniques
  • Case studies - examples of energy management programs and standards - CIPEC, UNIDO. Incentives for energy assessment and energy retrofit projects
  • Best practices in process plant energy management
  • Energy conservation opportunities - technology options; checklists
  • Developing and implementing customized energy management program
  • Obstacles that face energy management programs
  • Relating energy efficiency to business outcomes
  • Technical and economic evaluation of potential opportunities
Questions and Answers and Feedback to Participants on Achievement of Learning Outcomes

Daily Schedule:
8:00   Registration and coffee (first day only)
8:30   Session begins
12:00 Lunch
4:30   Adjournment

There will be a one-hour lunch break each day in addition to a refreshment and networking break during each morning and afternoon session.


Nabil Al-Khirdaji
Nabil Al-Khirdaji, M.Eng. and P.Eng., is president of Kappa Associates International, which provides engineering and project services to the petroleum, process, energy, and related industries. Mr. Al-Khirdaji has taught well over 200 technical professional development courses and he specializes in the areas of plant integrity, petroleum refinery, and process plant equipment design and operation. He has taught in Canada, the U.S., Saudi Arabia, Kuwait, Sudan, Yemen, Oman, Abu Dhabi, Dubai and Malaysia, presenting numerous topics on the design, operation, and maintenance of process plant equipment and piping systems. He received his B.Eng. (Mechanical) degree from the American University of Beirut and his M.Eng. degree from the University of Toronto.

A registered professional engineer with the Association of Professional Engineers of Ontario, Mr. Al-Kjirdaji has over 40 years of experience in the petroleum, petrochemical, and related industries both in Canada and the Middle East. During these past 40 years, including 24 years with Shell Canada Limited, he has assumed a number of project, engineering specialist, and engineering management positions with a vast range of responsibilities. He is also mechanical program director with EPIC and holds a senior project management position with an oil and gas engineering company in Milan, Italy. Mr. Al-Khirdaji served for several years on the API committee on refinery equipment, which oversees the development of engineering practices for the design, fabrication, installation, inspection, and use of materials and equipment in refineries and related processing facilities.

Prerequisites & Certificates

Certificates offered

2.1 CEUs / 21 PDHs

Cancellation Policy
To withdraw from a course, you must send a request, in writing, with the official receipt to our office. Fifteen or more business days in advance: full refund less $50.00 administration charge. Five to fifteen business days in advance: non-refundable credit of equal value for any future EPIC seminar within one year. Credits are transferable within your organization. In case of an unexpected event occurring after this time, you may send someone else to take your place without any additional cost.
Map & Reviews
EPIC Educational Program Innovations Center
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Here are some reviews of the training vendor.
The course was very well presented and the course instructor was absolutely amazing.
Reviewed by 2013
Our instructor, Stephen Lamming, was outstanding and a true expert in his field. He was able to complement the technical air monitoring information with practical real life examples which was highly beneficial. He is an excellent communicator and was highly interactive with the course attendees. This course was recommended to me because Stephen Lamming does an outstanding job. I was very impressed with this course and have subsequently recommended it to my colleagues.
Reviewed by 2012
Would have liked more interactive problem solving.
Reviewed by 2011

This course currently does not have any dates scheduled. Please call 1-877-313-8881 to enquire about future dates or scheduling a private, in house course for your team.

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