Normalization of Deviance — The Pathway to Disaster
Reliability and Maintenance Bootcamp
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
Moderator:
Dean Roberts, Ergon Refining, Inc.
Speaker:
Rick Hoffman, Becht
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A First-Principles Approach to Root Cause Analysis and Human Error
Reliability and Maintenance Bootcamp
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
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Maintenance Practices Specific to HF Alkylation Units
Alkylation, FCC
Moderator:
Bill Clark, Phillips 66
Speaker:
Sheila Bottjen, Valero Corporation
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101 Series: HF Alkylation — HF & H₂SO₄ Uncovered: Fundamentals You Need to Know
101 Series, Alkylation
Moderator:
Sheila Bottjen, Valero Energy Corporation
Speaker:
Mike Teders, Becht
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Acid Runaway (HF and Sulfuric Acid)
Alkylation
In this session we will discuss symptoms, causes, and consequences of an Acid Runaway in an Alkylation Unit and how to recognize and respond to an acid runaway. This track will also discuss lessons learned from acid runaway incidents across the industry.
Participants will: Gain an understanding of what’s an acid runaway, Develop acid runaway monitoring parameters, Develop acid runaway response guidance.
Moderator:
Wade Hollman, Phillips 66
Presenters:
Wade Hollman, Phillips 66
Liza Pacheco, Marathon Petroleum Corporation
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Emerging Technologies for Alkylation
Alkylation
Today’s refiners are looking for newer technologies to product better quality alkylate. This session will review innovative processes, including:
- The K-SAAT® process, which produces higher quality alkylate using an engineered non-corrosive solid-acid catalyst. The K-SAAT® process eliminates the need for liquid acid catalyst, and is an ideal low cost solution for refiners looking to upgrade their existing Alkylation process. Participants will gain an understanding of how refiners can revamp an existing Alkylation unit to produce better quality alkylate through case studies that illustrate examples of such a conversion and the benefits achieved.
- The ISOALKY™ Technology, commercialized by Chevron and UOP, which offers benefits (product quality and yields) and economics compared to traditional alkylation technologies. The ISOALKY™ Catalyst is a non-volatile ionic liquid that does not require offsite regeneration. ISOALKY™ Technology can be used for green field plants or retrofit/expansion of existing alkylation units. The first commercial ISOALKY™ Unit has been successfully operating at the Chevron Salt Lake Refinery since January 2021, and the first unit turnaround was completed in October 2024. Participants will gain information on the ISOALKY™ Technology as well as the commercial operation, including turnaround learnings.
Moderator:
Liana Siegel, Marathon Petroleum Corporation
Speakers:
Bhavdip Kalaria, KBR
Jon Keuler, Honeywell UOP
Mark Rasmussen, Chevron U.S.A. Inc.
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Capital Projects: Project Life Cycle Costs
Reliability and Maintenance Bootcamp
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.
Participants will learn:
- What a project life cycle is
- What influences cost the most, and
- Industry standards for analysis
Moderator:
Bill Clark, Phillips 66
Speaker:
Dean Roberts, Ergon Refining, Inc.
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Contaminants from FCC to Alky
Alkylation, FCC
Units in the refinery are interconnected and operational changes to an upstream often create challenges for downstream units. We will review how normal and abnormal FCC operations impact Alky feeds. We will also discuss Alky feed specifications and the impact to acid consumption and alkylate quality.
Moderator:
Tyner Devine, Flint Hills Resources, LLC
Speakers:
Javier Rios, Honeywell UOP
Liana Siegel, Marathon Petroleum Corporation
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