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
For many facilities, cyclic reformers play a pivotal role in refining operations, offering flexibility in upgrading naphtha into high-octane reformate and a continuous source of hydrogen. While cyclic reformers offer a distinct advantage over semi-regen reformers with regards to turnaround timing, this comes at a cost. This presentation tackles key operational challenges and reliability issues, such as iron contamination, ammonium chloride fouling, on-oil exotherms, reactor hot spots, regeneration section corrosion and the functionality of motor-operated valve (MOV) interlocks.
By providing a comprehensive approach to enhancing cyclic reformer reliability, this presentation reinforces the importance of proactive maintenance, process optimization, and robust safety measures. These strategies provide crucial insights to aid operators in maximizing unit performance while minimizing operational risks.
Speakers:
Rhett Finch, Marathon Petroleum Corporation
Matt Hutchinson, Axens North America
Alex Kniuksta, Honeywell UOP
Alex Sabitov, Phillips 66
Russ Wiltse, Valero Energy Corporation
Sustainable Aviation Fuel (SAF) represents a significant breakthrough in the quest for greener aviation. This presentation delves into the operational challenges around SAF production and how the supply chain had to adapt accordingly. SAF producers will lead the discussion sharing their lessons learned and solutions to the challenges they encountered as they embarked on their SAF production journey. The presentation will also address the critical aspects of distribution and supply chain management. Efficiently managing the supply chain is essential for ensuring the widespread availability and adoption of SAF. We will discuss logistics, storage, and transportation challenges, along with strategies to optimize the distribution network and integrate SAF into existing fuel infrastructures.
Moderator:
Eric Legare, Chevron U.S.A. Inc.
Speakers:
Ramin Abhari, Chevron Renewable Energy Group
Daniel Carlson, Calumet Specialty Products
Fouling of Naphtha Hydrotreating Reactors can cause limitations to operation and planned cycle length. This session will present three technologies to effectively mitigate this fouling to hit the cycle:
Catching Scale: Haldor Topsoe and Marathon Petroleum step up to the plate
HeavyTrap: A Top Bed Double Play
Axens' HyRing: A Grand Slam in Pressure Drop Mitigation
This session will introduce an integral part of maintenance and reliability engineers’ responsibilities to capital projects. How this relationship and communication is important to get safe, reliable, and maintainable equipment installed when working with a capital project team.
The intersection of refining and petrochemical manufacturing has never been more significant as industries navigate the dual challenges of efficiency and sustainability. This session will explore the critical role of Perchloroethylene (PERC) in modern refining processes while also highlighting its applications in petrochemical production.
PERC is recognized as one of the safest catalyst activators during normal operations, as well as a regenerator for spent catalysts. Utilizing less efficient materials can necessitate larger quantities of hazardous substances being kept onsite, thus increasing exposure risks. Other chlorinating agents are either restricted by the EPA or are inherently more hazardous, making PERC a preferable option.
Attendees will gain insights into how PERC enhances refining technologies through processes such as isomerization and catalytic reforming, which help ensure compliance with environmental regulations. Industry experts will discuss the extensive benefits of utilizing PERC, emphasizing innovations that contribute to both safety and operational efficiency.
Moreover, we will review advancements in safety protocols that facilitate the effective handling of PERC, ensuring minimal exposure and adherence to rigorous regulatory standards. By fostering dialogue among leaders in refining and petrochemical manufacturing, this session aims to identify collective strategies for driving innovation and achieving sustainability goals within the industry.
In this session, leaders in plant maintenance from two major companies in the fuel and petrochemical manufacturing industry will discuss the advantages of a company-wide standard process for routine maintenance. Gaining alignment on a common work practice across a large and geographically diverse portfolio can be challenging, but the resulting organizational discipline can yield improved efficiency, reliability and decision-making. The speakers will provide a high-level overview of their routine maintenance processes and share key success factors for implementing a common maintenance work practice at multiple facilities.
Participants will:
Learn the major elements of a routine maintenance process
Hear examples of strategies for a successful wide-scale implementation
Ask questions to understand how a common work practice for plant maintenance can be applied at their company
Moderators:
Mike DeHart, Valero Energy Corporation
Speakers:
John Duenckel, Valero Energy Corporation
Tom Golden, LyondellBasell Industries