OG90
Course Contents
Module 1: Energy Management Framework and Performance Baselines
Key Topics
- Energy efficiency drivers, cost impacts and carbon benefits
- Energy management principles and ISO 50001 alignment
- Energy audits, walkdowns and opportunity identification
- Energy balances, Sankey diagrams and baseline development
- Metering, submetering and data-quality requirements
- Energy performance indicators (EnPIs) and benchmarking methods
- Prioritising opportunities by value, effort and risk
Module 2: Utility Systems, Steam and Fuel Optimisation
Key Topics
- Boiler efficiency, combustion control and excess air optimisation
- Steam generation, distribution and condensate recovery
- Steam traps, leaks, insulation and pressure management
- Fuel gas systems, flare losses and heat recovery options
- Cooling water, chilled water and refrigeration efficiency
- Compressed air demand, leakage and pressure optimisation
- Utility constraints affecting production and reliability
Module 3: Process Heat Integration and Equipment Efficiency
Key Topics
- Pinch analysis principles and heat recovery targets
- Heat exchanger monitoring, fouling and cleaning strategies
- Fired heater performance, draft control and stack losses
- Pumps, compressors, fans and variable speed drives (VSDs)
- Distillation energy use and column operating pressure
- Process control actions for energy intensity reduction
- Energy efficiency in start-up, shutdown and turndown
Module 4: Digital Monitoring, Analytics and Optimisation Tools
Key Topics
- Energy dashboards, alarms and exception-based reporting
- Historian data, laboratory data and utility metering links
- Advanced process control (APC) and real-time optimisation (RTO) use cases
- Digital twins and simulation for utility system optimisation
- Predictive maintenance effects on energy performance
- AI and analytics for detecting inefficiency patterns
- Cybersecurity and data governance for energy systems
Module 5: Implementation, Economics and Sustained Improvement
Key Topics
- Energy project screening and techno-economic assessment
- CAPEX, OPEX, payback, NPV and carbon value considerations
- Behavioural change, operator engagement and accountability
- Measurement and verification (M&V) of realised savings
- Energy governance, roles and management review routines
- Continuous improvement and opportunity pipeline management
- Practical Workshop: develop an energy optimisation action plan