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