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
Speakers:
Darin Foote, CHS Inc.
Chuck Johnston, Marathon Petroleum Corporation LP
Vidyashankar Kuppuraj, Marathon Petroleum Corporation
Johnny Serafin, Phillips 66
Nic Tognetti, CHS Inc.
Advanced process control (APC) has been employed in FCC applications for 40 years. Despite the similarities of FCC Technology and APC platforms the success of these applications varies widely. In this session we will discuss common threads that lead to poor outcomes and how to build a successful APC program on a modern FCC.
In this session we will discuss in detail the continuous improvement in plant profitability achieved by having a holistic approach for advanced automation where applications such as procedural automation, Artificial Intelligence Plant Control (AIPC), control strategy in distributed control system and safety instrumented system all work together in harmony. AIPC, leveraging Reinforcement Learning (RL), offers a transformative approach to process plant optimization, addressing key limitations of traditional Model Predictive Control (MPC).
While MPC has been a cornerstone of advanced process control for decades, its reliance on linear models and manual tuning often struggles to effectively handle complex, nonlinear process dynamics, particularly in scenarios with frequent disturbances or changing operating conditions. AIPC overcomes these limitations by continuously learning and adapting to the plant's behavior. We will share our motivation to develop this product in-house and how easy it is to maintain the application and sustain the benefits by existing operations staff without the need of any AI or MPC expertise.
Participants will:
Understand the benefits of using AIPC over conventional MPC
Learn how Linde has successfully implemented AIPC on their Air Separation Units that include cryogenic distillation and very complex heat integration and recovery process.
Realize the importance of embracing this cutting-edge technology for improving profitability and safety of their plant and also for their personal and professional growth.
What is basic process control?
How is it done? Why is it important for the refinery engineer to be familiar with the basics?
In this foundational session, the discussion will focus on the workings of everyday loops and instrumentation that a refinery engineer is likely to encounter.
Moderator:
Sriram Ramaganesan, Phillips 66
Speakers:
Joe Boyce, Marathon Petroleum Corporation
Scott Flanagan, Marathon Petroleum Corporation
Tim Olsen, Emerson Automation Solutions
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.
This session covers the complete spectrum of process optimization methods at a refinery or petrochemical plant. From models predictive control to real time optimization via process models and onto machine learning methods via neural networks. The attendee will gain an understanding of when to apply these methods in practice and the organizational support needed to succeed long term.