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Process Plant Optimization Technology and Continual Improvement

Course Title	Start Date	End Date	Venue	Fees (US $)
Process Plant Optimization Technology and Continual Improvement	18 Oct 2026	22 Oct 2026	Dubai, UAE	$ 3,900	Register
Process Plant Optimization Technology and Continual Improvement	18 Oct 2026	22 Oct 2026	Live-Online	$ 2,500	Register
Process Plant Optimization Technology and Continual Improvement	15 Nov 2026	19 Nov 2026	Dubai, UAE	$ 3,900	Register
Process Plant Optimization Technology and Continual Improvement	22 Nov 2026	26 Nov 2026	Riyadh, KSA	$ 3,900	Register

Process Plant Optimization Technology and Continual Improvement

Course Title	Start Date	End Date	Venue	Fees (US $)
Process Plant Optimization Technology and Continual Improvement	18 Oct 2026	22 Oct 2026	Dubai, UAE	$ 3,900
Process Plant Optimization Technology and Continual Improvement	18 Oct 2026	22 Oct 2026	Live-Online	$ 2,500
Process Plant Optimization Technology and Continual Improvement	15 Nov 2026	19 Nov 2026	Dubai, UAE	$ 3,900
Process Plant Optimization Technology and Continual Improvement	22 Nov 2026	26 Nov 2026	Riyadh, KSA	$ 3,900

Introduction

Process plant optimization plays a central role in the competitiveness of today’s process industries. For optimization benefits to be substantial and sustainable, the total cost of production — including the cost of operational interruptions — must be kept to a minimum. This requires effective management of maintenance operations, optimization of equipment and plant reliability and availability, and sound inspection, maintenance and planning strategies. Applied systematically, plant optimization is an effective route to improved profitability. A further key aspect of process plant optimization is energy management and the reduction of energy consumption. Industrial processes and utility systems offer significant potential for savings, while process changes such as advanced process control and new technologies present additional optimization opportunities. This training course provides a comprehensive review of process plant integrity as the essential foundation for sustainable plant profitability and optimization. It links optimization, reliability, energy efficiency and asset integrity into a single continual-improvement cycle, so that gains achieved are measured, sustained and built upon.

Objectives

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

Explain the main elements of process plant optimization and how potential benefits are identified, quantified and realized.
Apply a business focus to technical decisions and contribute more effectively to sustainable plant profitability.
Select the most appropriate maintenance and inspection methodologies — preventive, predictive, RCM and RBI — for asset decision-making.
Measure and improve equipment and plant performance using reliability, availability and OEE metrics.
Identify and evaluate opportunities to reduce energy consumption using recognized standards and benchmarking practices.
Perform technical and economic evaluations of alternatives (life-cycle cost, NPV, payback) to support repair, alteration and replacement decisions.
Embed continual-improvement principles (Plan–Do–Check–Act) into plant optimization initiatives.

Training Methodology

The course is conducted along workshop principles, combining formal lectures with interactive worked examples. Emphasis is placed on explaining the underlying technical phenomena and on providing answers to problems encountered in everyday industrial practice related to the operation, maintenance, repair and alteration of process equipment. Each learning point is reinforced with practical examples, and there are ample opportunities for active discussion and the exchange of professional experience to consolidate learning. Methods include:

Structured lectures supported by visual presentations
Worked calculation examples (availability, OEE, energy savings, remaining life, economics)
Daily workshops and group problem-solving exercises
Industry case studies and facilitated discussion
Individual action planning to transfer learning to the workplace

Who Should Attend?

This course is designed for technical professionals involved in improving process plant performance, profitability and energy efficiency, including:

Process, mechanical, reliability and maintenance engineers
Operations and maintenance supervisors, technicians and senior operators
Maintenance planners and inspection personnel
Project engineers involved in plant modifications, repairs and alterations
Energy, utilities and process-efficiency specialists
Technical managers responsible for asset performance and plant profitability

Course Outline

DAY 1 Overview of Optimization Technologies
Learning outcome: Describe the plant optimization procedure and frame a real optimization problem with its constraints.
Topic	Key content
Overview of optimization technologies for process plants	Steady-state vs. dynamic optimization; offline studies vs. real-time optimization (RTO); where value is created in a typical plant
Elements of the process plant optimization procedure	Objective function, decision variables, constraints, data validation and reconciliation, implementation and performance monitoring
Constraints in optimization: production, operation, economy and environment	Capacity limits, safe operating envelopes, cost and margin drivers, emissions and regulatory limits
Optimization approaches: mathematical models and physical models (prototype units)	First-principles vs. empirical / data-driven models; pilot and prototype units; model validation and limitations
Correlation between process optimization and process control	The control hierarchy: regulatory control, advanced process control (APC/MPC), RTO, planning and scheduling
Workshop: examples and solutions	Formulating and solving an optimization problem for a typical process unit

DAY 2 Reliability, Availability and Effectiveness
Learning outcome: Quantify reliability, availability and equipment effectiveness and identify the largest sources of loss.
Topic	Key content
Relationship between plant reliability and availability	MTBF, MTTR and failure rate; inherent vs. operational availability
Optimization of plant reliability	Failure modes and effects (FMEA), the bathtub curve, introduction to Weibull analysis, redundancy and design for reliability
Optimization of plant availability through improved maintenance	Reactive, preventive, predictive and condition-based maintenance; reliability-centred maintenance (RCM) strategy selection
Analysis of effectiveness of individual equipment	Overall Equipment Effectiveness (OEE = availability × performance × quality); loss identification
Optimization of overall plant effectiveness	Bottleneck analysis, loss trees and plant-level performance KPIs
Workshop: examples and solutions	Calculating availability and OEE for a process unit and ranking the top losses

DAY 3 Best Practices for Energy Consumption
Learning outcome: Identify, benchmark and evaluate energy-saving opportunities across process and utility systems.
Topic	Key content
Optimization strategies aimed at energy consumption reduction	Energy balances, heat integration and introduction to pinch analysis, process modifications
World standards and benchmarking guidelines	ISO 50001 energy management systems; energy performance indicators (EnPIs) and baselines per ISO 50006; industry energy-intensity benchmarking
Best practices in process plant energy management	Metering, monitoring and targeting; energy reviews; organisational roles and accountability
Energy conservation checklist for typical industrial plants	Motors and variable-speed drives, compressed air, insulation, leak management, fired heaters, lighting
Optimization of heat production and steam distribution and consumption	Boiler efficiency and combustion control, steam trap management, condensate and flash-steam recovery
Workshop: examples and solutions	Plant energy audit exercise with savings and payback calculation

DAY 4 Maintenance Management System
Learning outcome: Optimize rotating and static equipment utilization and the maintenance system that supports it.
Topic	Key content
Optimization of utilization of piping systems and pipelines	Integrity operating windows (API 584), corrosion management, hydraulics and pressure-drop reduction
Optimization of utilization of pumps, compressors and fans	Operating near best efficiency point (BEP), affinity laws, flow control by VSD vs. throttling, condition monitoring (vibration, thermography, oil analysis)
Optimization of maintenance management system and frequency of maintenance	CMMS and the work management cycle, PM interval optimization, backlog and schedule-compliance KPIs
Optimization of spare parts management through predictive maintenance	Criticality-based stocking, ABC / VED analysis, using condition-monitoring data to plan inventory
Optimization of repair and alteration programs in accordance with existing codes	API 510, API 570, API 653, ASME PCC-2 and NBIC requirements; management of change (MOC)
Workshop: examples and solutions	Building an optimized maintenance and spares plan for a critical equipment set

DAY 5 Minimization of Equipment Failure and Continual Improvement
Learning outcome: Apply risk-based methods to minimize equipment failure and build a continual-improvement roadmap.
Topic	Key content
Risk Based Inspection (RBI)	API 580 / API 581 methodology; probability and consequence of failure; risk matrices; risk-based inspection planning
Procedures for minimizing risk of equipment failure	Damage mechanisms (API 571), integrity operating windows, root cause analysis (RCA)
Fitness For Service (FFS) analysis and estimate of remaining life of equipment	API 579-1/ASME FFS-1 assessment levels; corrosion-rate and remaining-life calculation
Optimization of plant economy through planned equipment replacement	Life-cycle cost, repair-vs-replace decisions, economic life, NPV and payback evaluation
Continual improvement: building a plant optimization roadmap	Plan–Do–Check–Act (PDCA) cycle, prioritizing initiatives, sustaining gains through KPIs and reviews
Workshop, course review and assessment	Integrated case study, individual action plans, post-course assessment

BENEFITS

For participants

A structured, practical toolkit for diagnosing and optimizing plant performance
Confidence in applying reliability, energy and integrity methods and the codes that govern them
Ability to build a sound technical and economic case for improvement proposals

For organizations

Staff equipped to reduce unplanned downtime and improve plant availability
Identified opportunities to lower energy consumption and operating cost
Better-informed, risk-based inspection, maintenance and replacement decisions
A continual-improvement mindset that sustains optimization gains

Professional Recognition & Accreditations

ASSESSMENT AND CERTIFICATION

Participant learning is evaluated through daily workshop exercises and a post-course assessment. Participants who attend the full programme and complete the assessment receive a Certificate of Completion.

Accreditation

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Course Details

Documentation :

Quality material has been prepared by the seminar leader for distribution to delegates in addition a special note pad to facilitate note talking will be provided

Schedule :

Starting Time Ending Time Action

07:45 08:00 Breakfast

08:00 10:45 First Session

10:45 11:00 Coffee Break

11:00 12:45 Second Session

12:45 13:15 Coffee Break

13:15 14:45 Third Session

14:45 15:30 Lunch

15:30 16:30 Open Session

Certificates :

A certificate of attendance will be issued to those who attended and successful complete the program

Hotel Accommodation :

IFM Consultants has negotiated special rates for a limited number of rooms in the hotel .Early registration will help to secure a room at the reduced rate.

For further Information :

IFM Consultants Consultancy & Training Company L.L.C

P.O.Box: 31441 Abu Dhbai – U.A.E

Tel: +9712-6986000

Fax: +9712-6262350

E-mail: info@ifmconsultants.com

website: www.ifmconsultants.com

5 Ways to Register:

1. Call +97126911868 to provisionally reserve your place

2. Fax your completed registration form to +97126262350

3. Email your registration form to info@ifmconsultants.com

4. Send your registration form to P.O. Box 31441 Abu Dhabi-U.A.E.

5. Visit our website www.ifmconsultants.com and fill up the Registration On-Line

Cancellation Policy :

If a confirmed registration is cancelled less than 10 calendar days prior to the program start date, a substitute participant may be nominated to attend the same program, or a 20% cancellation charge is applied. The same 20% cancellation fee will be charged in case the participant is a no-show. For more information regarding administrative policies such as refund and complaint, please contact IFM Consultants Training & Consulting Head Office at +971 2 6986000

Disclaimer :

IFM Consultants reserves the right to alter the content, location of the seminar or the identity of the speakers in case of events beyond our control
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Policies & Discounts

Frequent Nomination Plan :

In recognition of those clients who frequently nominate participants on public programs offered by IFM Consultants, a special frequent nomination discount of 10% on paid fees will be given if 10 or more candidates are nominated per year.

This special discount will apply to the 10th paid nomination onwards on programs offered during this year. Moreover, clients who nominated 10 or more participants in the previous year will be eligible for the 10% discount for every nomination this year.

Several Nominations on the Same Program :

In addition to the above plan, one extra free place is offered to any organization that makes 2 paid nominations for the same program and dates.

Registration Terms :

All nominations to our public events are to be processed by the client's HR/Training department.

Self-Nominations to our public events are to be paid in advance using the payment by self option on the online registration form. A refund will be issued back to the client in the event of program cancellation or seat unavailability.

Registration confirmation is subject to IFM Consultants review of registration request and seat availability.

Cancellation Terms

If a confirmed registration is cancelled less than 10 calendar days prior to the program start date, a substitute participant may be nominated to attend the same program, or a 20% cancellation charge is applied. The same 20% cancellation fee will be charged in case the participant is a no-show.

Program Refund & Complaint Resolution Policies

For more information regarding administrative policies such as refund and complaint, please contact IFM Consultants Training & Consulting Head Office at +971 2 626 33 26

By facilitating the structure and contents of its training programs as well as its processes for assessment, IFM Consultants will exploit reasonable effort to:

Ensure delegates/candidates receive fair and equal opportunities in order to help and encourage them to reach their full potential through training and development while safeguarding the integrity of its training programs.

Prevent unnecessary barriers to achievement (including but not limited to arrangements for access, assessment of training needs, reasonable adjustment and special consideration).

Guarantee fair assessment to all delegates/candidates, including those with particular assessment arrangements;

Comply with all existing legislative requirements in relation to equal opportunity (If IFM Consultants is delivering programs in another country, due consideration is given to any geographical variations in equal opportunity legislative requirements).
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Hotline: +9712 -6986000
info@ifmconsultants.com

Starting Time	Ending Time	Action
07:45	08:00	Breakfast
08:00	10:45	First Session
10:45	11:00	Coffee Break
11:00	12:45	Second Session
12:45	13:15	Coffee Break
13:15	14:45	Third Session
14:45	15:30	Lunch
15:30	16:30	Open Session

Process Plant Optimization Technology and Continual Improvement

Process Plant Optimization Technology and Continual Improvement

Introduction

Objectives

Training Methodology

Who Should Attend?

Course Outline

Professional Recognition & Accreditations

Accreditation

Related Courses

Find a Course

Fees

Quick Inquiry

Downloads

2026 IFM Training Plan

IFM Corporate Profile

Laboratory Systems ISO17025 Consulting

Competency Solutions Brochure

Know More..

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