|Day 1: Wednesday 24 October 2018|
|09:00 - 13:30 : Registration and lunch snacks|
|13:30||Welcome and Introduction||EEPC Chairman, Paul Broekaart|
|Chair: Jos Vankevelaer, BASF|
|13:40||Introduction to EEPC||Philip de Smedt, PetrochemEU|
|13:50||Keynote presentation on "refinery versus Petrochemical Integration" – global perspective||George Gale, Naphtha Information Services|
|14:20||Keynote presentation on "refinery versus Petrochemical Integration" – focusing on Europe||Marta Yugo, Concawe|
|14:50||Panel discussion||Marta Yugo, Concawe
George Gale, Naphtha Information Services
Mary-Jane Hogg, Dow
Ralph Croes, Dow, LOSG Chair
Jens Utecht, BASF, LOSG Vice-Chair
Martin Harvey, Sabic (facilitator)
|15:50||High selectivity "runaway – resistant" 4th generation front-end acetylene hydrogenation catalyst in world scale unit||Jon Lunn, Dow
Uwe Duerr, Clariant
|16:20||The Value of Multiplexed TDLAS Monitoring and Diagnostic Technology in Fired Heaters and Furnaces||Philippe Van Den Bussche, BASF
Eric Huelson, John Zink
|16:45||Working Group 1: general introduction of activities
||Pascal Coenen, Shell
|17:45||Workshop 2019 – Safety Culture||Pascal Coenen, Shell|
|18:00||Environmental issues: GHG emissions, emissions from decoking||Philip de Smedt, Cefic|
|19:15||Cocktail reception at the hotel|
|Day 2: Thursday 25 October 2018|
|Chair: Paul Broekaart, Dow|
|08:30||Introduction to the break-out session||Paul Broekaart, Dow
Jos Vankevelaer, BASF
|08:45||Break-out sessions on "Training of New Staff".
|11:30||Condition based recoiling||Stef Luijten, Dow|
|11:55||Digital 4.0 and implementation in industry||Hans-Guenter Wagner, BASF|
|12:25||Use of digital twin technology to drive cracker furnaces improvements||Sreekumar Maroor, PS Enterprise
Steve Hall, PS Enterprise
|Chair: Martin Harvey, Sabic|
|14:00||Turnaround Workshop feedback||Jos Vankevelaer, BASF|
|14:20||Primary fractionator fundamentals and flexibility to feedstock||André Bernard, Nova Chemicals|
|14:50||Olefin Plant cost down, Capex & Plant Performance well balanced||Gunther Kracker, Linde|
|15:15||Thermal decomposition of sulfur compounds and their role in coke formation during steam cracking of hydrocarbons||Kevin van Geem, UGent|
|16:15||Working Group 2:
||Ferran Cortes, Dow
|17:15||Protection of brazed aluminium heat exchangers employed in ethylene plant cold boxes||Peter Feld, Dow
Emmanuelle Biadi, Pall
|17:45||Process safety for steam crackers||Patrick van der Gulik, Shell|
|18:15||End of second day|
|18:50||Gathering in the hotel lobby
|19:00||Departure for the visit of the city (45' walk) and dinner
|22:30||End of dinner|
|Day 3: Friday 26 October 2018|
|Chair: Gunther Kracker, Linde|
|08:30||Issue Group Turbo Machinery Safety & Reliability
|09:30||Issue Group Reactive Chemicals||Anne Spindelndreher, Linde
Steven Leen, Sabic
|09:50||Issue Group Maintenance report
|11:50||Issue Group Furnace Safety
|11:55||Feedback from breakout sessions|
|12:30||Conclusions||EEPC Vice-Chair, Pascal Coenen|
|12:45||End of the conference, followed by lunch|
EEPC Break-out sessions on "Training of Young Engineers"
Thursday 25 October 2018 at 08:45
What to do at trip and start-up after trip
facilitated by Gunther Kracker, Linde
The operating environment for European steam crackers has changed in the recent years. The increased degree of automation and the trimming of plants for maximized reliability have resulted in excellent availability of European steam crackers, with intervals between trips continuously extending.
In contrary to these positive aspects, the more seldom occurrence of trips is resulting in a decreasing level of experience with how to cope with these operational upsets. The general trend of decreasing operating staff and the retirement of experienced personnel further contribute to the fading of practical experience with trip situations and the re-establishment of normal operation after plant upsets.
The breakout session will focus on possibilities to train young and less experienced engineers/operators to handle plant upset conditions and to re-startup the plant after trip. Apart from the exchange of general experience with the topic, concrete training methods and training targets shall be shared and discussed from the perspective of plant operating companies. Different approaches shall be compared and best practices collected. To round up the complete picture, the possibilities and training concepts already available during the engineering phase of new or revamped plants shall be shared and discussed.
Start-up after TA
facilitated by Martin Harvey, Sabic
Moving an ethylene plant from the maintenance execution phase of a turnaround to stable, full rate operation is a complex transition. It requires the coordination of multi-functional resources and the diligent execution of many non-routine tasks if it is to be achieved efficiently and without EHS incident.
The chemical industry has a history of an increased major incident rate occurring at start-up in comparison to normal running with probably Texas City as the most widely recognized incident worldwide. The ethylene industry has its own examples where lessons have been learned. As our industry has matured, improved design standards and process designs have evolved to eliminate some risks. There has also been a general move to automate control and safety related actions to eliminate the unreliability of the human element. This has resulted in a drop of incident rates.
However, the average period between ethylene plant major turnarounds has increased (European average ~ 5 yr) and the experience operating staff have of plant start-ups has reduced over the last 2 decades. This emphasizes the need for robust management systems and effective training programs to ensure that known risks are controlled.
This break out session will share some historic incidents and then explore the issues to be considered when developing management systems and training programs.
Start-up after revamp
facilitated by Geert Vercruysse, BASF
Compared with a normal restart after trip or turn around, start up after revamp or implementation of major projects has its specific challenges. Operators not only have to deal with completely new or modified parts of the plant for which no operational experience is present. Also, the way existing parts of the plant have to be handled can be different as before due to interactions with new parts.
Furthermore, for revamp project managers, it may be a challenge to understand and to be fully aware of the operational impact of the project execution, (pre)commissioning and modified start-up procedures.
In the break out session, "start-up after revamp" discussion will cover topics such as :
- Integrating "start-up" in the engineering phase of a project
- Integration of (pre)commissioning and start up into planning of both project and turn around
- Training and involvement of operators in preparation for restart after revamp.
Sustainable results from trainings and knowledge management
acilitated by Philip de Smedt, Petrochemicals Europe
In the coming years, several crackers in Europe will be faced with a lot of operators will retire. In this breakout session, we intend to discuss and share experience how we can avoid the loss of the experience and knowhow that has been built up over time in operating ethylene crackers. This will requires good management systems to ensure that knowhow is stored and transmitted in a way that the important information is not lost. Complicating factor in this transfer is the fact that periods between turnarounds has increased over the years so that some operations such as start-up and shutdown are becoming very infrequent operations and newly hired operators may not have had to chance to experience such operations before very experienced people have left the company.
Another topic that will be discussed is how to learn from incidents. Most companies have systems in place to record and analyze incidents but how do we ensure that relevant and important lessons learned are incorporated into company culture, especially those incidents where human error was a contributing factor.
Elements that can be discussed in this workshop are training programs, training simulators, knowledge databases, management systems, safety culture.
Use of Operator Training Simulators to aid with training for start-up
facilitated by Johan Adriaenssens, BASF
Due to technological progress (e.g. APC) and more reliable cracker operations, operators and engineers are losing hands-on experience on how to optimally start-up a cracker and how to respond properly to upsets.
In this breakout session, we want to discuss how to incorporate a state-of-the art simulator based training within our overall training-program by sharing experiences on topics such as :
- What are the advantages and disadvantages of an OTS for start-up training?
- What type of simulator-trainings, -modules, -exercises are best practice to increase hands on-experience.
- How do we organize (time-intensive) simulator training within our overall training-program and normal operations?
- Start-up after revamp; when do we revamp our OTS?
- Should an OTS also be able to simulate the manual actions that must take place in the field?
- Besides training, are there other area’s in plant operations or maintenance, where an OTS can be useful?