Course Schedules

Classroom 9 Sessions
Online / Live
Live

Introduction

Process Plant Optimisation & Energy Conservation Training Course focuses on improving industrial performance by reducing energy consumption and maintenance costs. Modern process plants must go beyond traditional practices to achieve higher efficiency, lower emissions, and greater operational reliability.

This Process Plant Optimisation & Energy Conservation Training Course explores how digital tools, advanced analytics, and integrated energy management strategies transform plant performance. Participants will learn how real-time data, predictive intelligence, and optimized processes contribute to improved stability and profitability.

The training course also highlights the direct link between energy savings, maintenance efficiency, and financial outcomes. By combining engineering expertise with practical optimisation techniques, participants will gain the knowledge required to enhance plant performance, reduce operational costs, and support sustainable industrial operations.

What are the Goals?

Process Plant Optimisation & Energy Conservation Course objectives are designed to help participants apply modern engineering and energy-efficiency strategies to improve reliability and cost performance. The training course emphasizes translating technical improvements into measurable operational and financial benefits.

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

  • Apply digitalization tools and real-time data to improve overall plant effectiveness
  • Identify energy-saving opportunities aligned with sustainability and efficiency goals
  • Implement predictive and prescriptive maintenance strategies
  • Optimize heat and power systems using advanced integration techniques
  • Evaluate equipment condition and remaining useful life using modern diagnostics
  • Link operational performance with financial outcomes and cost reduction strategies

Who is this Training Course for?

Process Plant Optimisation & Energy Conservation Training Course is designed for professionals responsible for improving plant efficiency, reliability, and energy performance. It supports individuals aiming to reduce costs, enhance sustainability, and strengthen operational resilience.

This training course will benefit:

  • Process and plant managers focused on improving performance and productivity
  • Energy managers and sustainability professionals working on energy reduction initiatives
  • Maintenance and reliability engineers transitioning to predictive maintenance approaches
  • Operations supervisors seeking to minimize downtime and energy waste
  • Technical personnel from refineries, petrochemical plants, and power generation facilities

How will this Training Course be Presented?

Process Plant Optimisation & Energy Conservation Course uses a practical and industry-focused learning approach to ensure participants gain actionable skills. The training course combines technical knowledge with real-world applications to enhance decision-making and operational improvement.

Participants will engage in instructor-led sessions covering optimisation techniques, energy management, and reliability strategies. Case studies and real-world scenarios help demonstrate how digital tools, predictive analytics, and heat integration improve plant performance.

Interactive discussions and group exercises allow participants to analyze system inefficiencies, identify hidden losses, and evaluate improvement opportunities. The course also emphasizes linking engineering decisions with financial performance, ensuring participants can implement cost-effective and sustainable solutions. This approach ensures practical learning outcomes that support long-term operational excellence.

Course Content

Day 1

The Modern Framework of Plant Effectiveness

  • The New Standard: Defining Overall Plant Effectiveness (OPE) in the Digital Age.
  • Beyond the P&ID: Understanding the link between Plant Physics and Business Profitability.
  • Energy-Maintenance Nexus: How poor maintenance cascades into massive energy losses.
  • Constraints Management: Balancing Production, Environment (ESG), and Economy.
  • Case Study: Analyzing the "Hidden Factory"—identifying lost capacity in a standard refinery setup.
Day 2

Reliability 4.0 & Advanced Improvement Techniques

  • PPR & PPE: Modernizing Process Plant Reliability and Effectiveness metrics.
  • From Reactive to Prescriptive: The evolution of maintenance strategies.
  • The Impact of Variability: How process fluctuations destroy equipment longevity.
  • Root Cause Analysis (RCA) 2.0: Utilizing data logs to prevent recurring failures.
  • Reliability Centered Maintenance (RCM): A business-focused approach to asset care.
Day 3

Energy Transition & Decarbonization Strategies

  • Net-Zero Integration: Aligning process plants with global energy transition goals.
  • Advanced Heat Integration: Moving beyond basic Pinch—Total Site Integration.
  • Circular Energy: Waste heat recovery and the "Hydrogen Ready" plant.
  • Utility System Optimisation: Steam, Compressed Air, and Cooling Water best practices.
  • Overcoming Barriers: Managing the human and technical obstacles to energy programs.
  • Case Study: Retrofitting an existing plant for a 20% reduction in carbon intensity.
Day 4

Digital Monitoring & Failure Prevention

  • Smart Inspection: Leveraging IoT sensors and Wireless Condition Monitoring.
  • Digital Twins: Using virtual models to predict equipment failure and remaining life.
  • Advanced NDT: Next-gen Non-Destructive Examination for static and rotating equipment.
  • Mitigating "The Big Three": Corrosion, Fatigue, and Erosion in high-pressure systems.
  • Asset Health Indexing: Creating a real-time dashboard for plant-wide health.
Day 5

Strategic Operations & The Future of Maintenance

  • Total Productive Maintenance (TPM): Creating a culture of ownership on the shop floor.
  • Best Practices for Critical Assets: Boilers, Turbomachinery, and Heat Exchangers.
  • Spare Parts & 3D Printing: Modernizing inventory management to reduce CAPEX.
  • Life Cycle Costing (LCC): Making the "Repair vs. Replace" decision with financial data.
  • Course Summary: Developing a 90-day action plan for your facility.

The Certificate

Recognition
  • Anderson Certificate of Completion for delegates who attend and complete the training course
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