In this session, we will discuss in detail the definition of Normalization of Deviance and how it has contributed to major accidents, including both Space Shuttle disasters. Examples will be provided of Normalization of Deviance in operating and maintaining process plants, as well as in our daily lives.
Participants will:
Gain an understanding of how to stop Normalization of Deviance
Learn how to identify and correct this behavior
Take this concept home to apply with their families
After more than 50 years of root cause analysis (RCA), you might expect problem solving to be a clear and straightforward process. It’s not. You can find yourself caught in unproductive debates. “Is that a contributing factor, or a causal factor?” “That’s a primary cause, but it’s not the main cause.” The result is frustration, inefficiency, and solutions that allow a repeat of the same problems.
A better approach to RCA is one built on evidence-based cause-and-effect relationships. The steps are simple: define the problem, explain why it happened, and identify solutions to reduce risk. Its focus is on having more reliable work processes, learning, and improving, which helps engage the frontline and minimize blame.
This session will explain the pitfalls of drifting from scientific problem solving and features a case study demonstrating how first-principles RCA leads to tangible improvements in reliability and human performance.
Participants will learn:
Four common errors that arise when explaining why an incident occurred
The biggest misconception about RCA
Why effective RCA does not require any proprietary techniques, terminology, or software
How RCA can be scaled for low-risk incidents and expanded as needed for higher-impact events.
How to reduce “human error” by involving those who perform the work
Moderator:
Bill Clark, Phillips 66
Speakers:
Bill Clark, Phillips 66
Mark Galley, ThinkReliability
Refiners and petrochemical manufacturers are proving that using oil and gas while reducing emissions is not a zero-sum game. By integrating cutting-edge technologies and developing lower emissions products, they are enabling global communities to enjoy the benefits of life-enhancing fuels and petrochemicals, all while significantly lowering emissions across the economy. This transformative approach is paving the way for a future where energy efficiency and environmental stewardship go hand in hand.
The presentation aims to delve into the critical aspects of process safety in renewable diesel and Sustainable Aviation Fuel (SAF) manufacturing, addressing the challenges and opportunities inherent to the transition towards sustainable energy solutions. As renewable technologies, particularly renewable diesel and SAF, continue to evolve, ensuring robust process safety mechanisms is paramount to mitigate risks and enhance operational reliability.
We'll explore various incidents and lessons learned shared by leading operating companies in the renewable sector. These real-world examples will illustrate the complexities and potential hazards associated with renewable diesel and SAF operations, emphasizing the importance of stringent safety protocols, proactive risk management strategies and rapid integration of lessons learned.
Moderator:
Eric Legare, Chevron U.S.A. Inc.
Speakers:
Paul J. Dofton, Marathon Petroleum Corporation
Stephanie Hadden, Chevron U.S.A. Inc.
Kamyar Keyvanloo, Phillips66
Maggie McDaniel, Calumet Speciality Products Partners, L.P.
Water is an essential commodity in the refining process, and in many plants as much water can be used as BBL of oil. Increasing water cost and scarcity creates operating expense savings opportunity in an area that may have historically not been given much attention. Some of the historical challenges when addressing water intensity in a refinery are a lack of ownership within the facility, sparse metering, value at system level not often apparent at equipment level, and a mindset that utilities work never outranks other work.
This session will discuss some of the historical challenges in reducing or controlling water intensity in a complex refinery system. We will identify some no cost and low-cost means to help address issues that can reduce water costs and waste. A detailed drill down will be presented into ways to understand and measure a plants water intensity. This discussion will identify techniques around optimization of specific operating components that make up the primary water users, and how to work toward water reduction and resource conservation in a refinery.
Moderator:
Dan Harbs, Veolia
Speakers:
Johnny Dorminey, Chevron U.S.A. Inc.
Dan Harbs, Veolia
While AFPM members continue to produce the traditional fuels and energy essential for our daily lives, they are also at the forefront of creating liquid fuels with lower lifecycle greenhouse gas (GHG) emissions to reduce emissions throughout the transportation sector.
The potential of Small Modular Reactors (SMRs) lies in their ability to revolutionize the energy sector with their modular and scalable design. Unlike traditional reactors, SMRs can be constructed in factories, ensuring uniform quality and reducing construction times. While their compact size allows for easier transportation and installation, with the promise of enhanced safety features, lower initial investment, and flexibility to meet varying energy demands. SMR technologies currently under development will be discussed with how they will provide new options specifically for the needs of the refining and petrochemical industries.
Participants will:
Gain a fundamental understanding of current SMR technologies
Learn about potential Use Cases for SMR’s in refining and petrochemical manufacturing
Panelists:
William Bandy, Marathon Petroleum Corporation
Delbert Grotewold, Veolia Water Technologies & Solutions
Nathan Jannasch, Chevron U.S.A, Inc.
Matthew Kawabe, Topsoe, Inc.
Kamyar Keyvanloo, Phillips 66
Many new facilities were commissioned recently to produce renewable diesel and SAF from renewable feedstocks to reduce the carbon intensity of transportation fuels while taking advantage of state and federal credits. Operating experience in this technology has been gathered by operators and their suppliers. This session will capture some of that expertise and share it with the audience in a traditional Q&A format. An experienced panel of Renewables experts from Operating and Technology companies will answer member supplied questions on operations, technology, reliability and lessons learned. Those in attendance are sure to gain valuable knowledge on this important topic.
Panelists:
William Bandy, Marathon Petroleum Corporation
Delbert Grotewold, Veolia Water Technologies & Solutions
Nathan Jannasch, Chevron U.S.A, Inc.
Matthew Kawabe, Topsoe, Inc.
Kamyar Keyvanloo, Phillips 66
Many new facilities were commissioned recently to produce renewable diesel and SAF from renewable feedstocks to reduce the carbon intensity of transportation fuels while taking advantage of state and federal credits. Operating experience in this technology has been gathered by operators and their suppliers. This session will capture some of that expertise and share it with the audience in a traditional Q&A format. An experienced panel of Renewables experts from Operating and Technology companies will answer member supplied questions on operations, technology, reliability and lessons learned. Those in attendance are sure to gain valuable knowledge on this important topic.
Facilitators:
Cliff Avery, Ketjen Corpotation
CJ Farley, TPM Solutions
1. Commercial Results of 100% Vegetable Oil Processing in an FCCU
Speaker: Andrea de Rezende Pinho, Petróleo Brasileiro S/A - PETROBRAS
In 2023, Petrobras and the Riograndense Refinery (RPR) successfully processed 100% vegetable oil in a Fluid Catalytic Cracking (FCC) Unit. Petrobras' technology is based on three pillars: i) triglycerides, such as soybean oil used in the commercial test, ii) ReNewFCC line catalyst and iii) unique operating conditions compared to conventional FCCUs. Biogenic products such as renewable aromatic hydrocarbons (BTX - benzene, toluene and xylene), renewable LPG, and renewable propylene were produced during the commercial trial. Commercial yields, quality of the products, operational challenges and technical adaptations for the trial will be presented.
2. U.S. HEFA Co-processing – Past, Present, and Future Projects
Speaker: Eamon Cullinane, Turner, Mason & Company
HEFA co-processing at U.S. oil refineries has historically not seen the same success as standalone RD/SAF refinery conversions. So why has co-processing in the U.S. been limited in the past and why might we see more of it in the future? We will explore historical production levels of co-processing, economics vs standalone RD/SAF facilities, the regulatory landscape and credit incentives (RINs, BTC, CFPC/45Z, CA LCFS, etc.) driving these economics, and future prospects of co-processing in the U.S.
