1. Refinery Operations 1 2. Mechanical Maintenance and Inspection 3. Instrumentation and Electrical Maintenance 4. Refinery Management

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2 Content LONG DURATION PROGRAMMES Page No. 1. Refinery Operations 1 2. Mechanical Maintenance and Inspection 3. Instrumentation and Electrical Maintenance 4. Refinery Management SHORT DURATION PROGRAMMES 1. Refinery Technology Development 2 2. Total Productive Maintenance 3 3. Process Optimization 4 4. Turnaround Management 5 5. Power and Utilities 6 6. Quality Control 6 7. Leadership Through Self Discovery 7 8. Personality Development 7 9. Negotiation Skills 7

3 Meru Consulting 1 Long Duration Programmes - Each module two weeks Programme Contents Refinery Operations Oil Industry in General Basic Petroleum Chemistry Crude Atmospheric and Vacuum Distillation Merox and Amine Treating Hydrogen Production and Hydrodesulphurisation Platformer Sulphur production, Hexane and Biturox Units Quality Control in a Refinery Lube Dewaxing and Wax Deoiling Cooling Water Treatment New Generation Base Oil FCC Theory and Operation Heat Exchanger Storage Tanks and Types-Operation Process Optimisation Lube Extraction, NMP and PDA Units Furnace Operations, Efficiency and Calculation Hazards of Air / Steam / Water and Electricity Hydrocracker Theory, Design and Operation Product Blending Wastewater treatment Problem Solving-Case Studies and Discussions Mechanical Maintenance and Inspection Heat, Heat Transfer, Heat Exchanger Design, Operation and Maintenance Refractory s Mechanical Seals On-stream and Shutdown Inspection Protective Coating and Maintenance Vibration Analysis Welding Technology and Inspection Valves, Types, Selection and Maintenance NDT Tools and Techniques Pumps, Selection Basis, Production Techniques, Testing and Performance Corrosion Fouling Material Selection and Cathodic Protection Boiler Operation and Maintenance Compressors-Reciprocating Centrifugal and Trouble Shooting in Compressors Columns and Pressure Vessel Design Thermal Insulation Instrumentation and Electrical Maintenance Total Productivity Maintenance Turbines Area Classification Online Blending Techniques DDC and Electronic Instrumentation Flow Meter Design and Selection Control Valves Transformers Bearing Motors and Generators PLC Interlock System, Furnace and Compressors Process Analyser Safety Valves Plant Communications Process Simulator and Refinery Visit Measurement of Variables Civil foundations For Large Structures Storage Tanks, Design and Maintenance Refinery Management Marketing Management Integrated Materials Management Value Engineering Central Excise, MODVAT and Customs Procedures Turnaround Management R and D Activities Stress Management Law of Contract Investment Analysis and Cost Reduction Overview of Financial Management Corporate Planning Energy Conservation Handling of Waste in Oil Refinery Occupational Health Services Pollution Control Presentation Skills IT Security Income Tax Taxation Project Development Project Execution Problem Solving Case Studies and Discussions # suggestive only. Contents can be modified based on the need analysis of the group

4 2 Meru Consulting Short Duration Programmes Meru has short duration training programmes (1 day or 3 days or 5 days) for different levels of Managerial and Workman categories to enable them to appreciate the need for multi-tasking with multi-responsibilities in the changing environment. These programmes are structured to be highly participative in nature, giving opportunities for the participants to interact with one another. 1. Refinery Technology Development The Refinery Technology Development Programme is designed to expose the basics on the Management of the Refinery in terms of requirement of skills to enable the participants to become full-fledged refinery personnel. It focuses on improving the essential knowledge and skills of the participants in Operations and Maintenance disciplines as to appreciate each other s role in the fulfillment of the organisation s objectives. It provides adequate scope for participants to have a thorough understanding of their responsibilities and duties in a refining environment. Programme Contents DAY 3 DAY 4 DAY 5 Petroleum Chemistry Crude Atmospheric and Vacuum Distillation Merox and Amine Treating FCCU and Hydrocracker Storage Tanks Quality Control Furnace Operation Heat Exchangers Pumps Selection basis Testing and Performance Mechanical seal Vibration Analysis Valves Types Selection-Maintenance NDT Tools and Techniques Thermal Insulation Protective Coating Total Productive Maintenance Boiler Operation and Maintenance Cooling Water Rotating Equipments Turbines Motors and Generators

5 Meru Consulting 3 2. Total Productive Maintenance Maximize overall equipment effectiveness (OEE) Improve the equipment reliability and maintainability Ensure maximum economy in equipment and management Cultivate equipment related expertise and skills Discuss and analyze problems in maintenance Importance of TPM education in the competitive environment Equipment effectiveness a team approach The Six Loss Analysis for discrete manufacturing The Eight Loss Analysis for continuous manufacturing Piloting quality maintenance activity Evaluate and improve maintenance management system Zero-defect Zero-breakdown activity 5-S summary Programme Contents Importance of TPM education in the competitive environment TPM Development Equipment effectiveness a team approach Inspection skills Maintenance prevention design activity The Six Loss Analysis Piloting Quality Maintenance Activity Improve Maintainability, Reliability and Life Span of Existing Equipment Evaluate and Improve Maintenance Management System Maintenance skill a cross training Operation and Maintenance skills - The Eight Loss Analysis DAY 3 Zero-defect Zero-breakdown activity Productive Maintenance Technology Productive Improvement System Overall Systems Performance TPM promotional structure 5-S Summary Tangible results orientation

6 4 Meru Consulting 3. Process Optimization The Refinery Technology Development Programme is designed to expose the basics on the Management of the Refinery in terms of requirement of skills to enable the participants to become full-fledged refinery personnel. It focuses on improving the essential knowledge and skills of the participants in Operations and Maintenance disciplines as to appreciate each other s role in the fulfillment of the organisation s objectives. It provides adequate scope for participants to have a thorough understanding of their responsibilities and duties in a refining environment. Conventional Controls Advanced Regulatory Controls Constraint Controls Multivariable Predictive Control and LP Optimization Database Systems Distributed Control System an overview Concepts of DCS Different types of DCS Short tour on latest DCS offered by major DCS vendors Connectivity to Supervisory Computer Advanced Process Control - concepts Introduction to APC Need for APC Approach to APC Project Process Optimization Levels of Process Control Basics of PID Control Feed Forward Control Ratio Control Nonlinear Control Predictive Control Constraint Control DAY 4 DAY 5 Crude Unit and FCCU Control strategies Model Identification and Commissioning Sustained Performance Short tour on latest MVPC offered by Major APC vendors. Distillation Controls Reactor Regenerator Combustion Control Real Time database Concepts of database Real time data, history and retrieval Advanced Alarm Management Application programming Latest trends in Process Information Technology Short tour on latest RTDB of major international vendors. DAY 3 Multivariable Predictive Control Basics of MVPC Independent and Dependent Variables specification Dynamic Constraints Different MVPC Applications LP Steady State Optimiser Plant Test

7 Meru Consulting 5 4. Turnaround Management Oil Industry plays a crucial role in present day s economic scenario worldwide. To be viable, refineries make all attempts to maximize their utilization of machinery for higher productivity. Towards this, maintenance gains significance in terms of keeping the machinery with lower down time by proper planning and executing schedules of stress free Turnaround Activities periodically for smooth, economical and safe work environment and thereby ensuring effective run length of the plant. Introduction to Turnaround Management. Maximizing overall Equipment effectiveness Identify the Critical and Risk Issues Defining Shut Down Performance Goals Establishing Base Lines for Performance Tracking Documentation for reference and guide lines on Shut-down and Startup Procedure Control of Shut-down schedules, Manpower Cost and Materials MIS on Safety Environment Logistics. Communication Systems. Shut Down Critique Benefits Analysis. Programme Contents DAY 3 Introduction to T/A Management. Scope and Sequence of T/A Management Systems approach Planning the schedules for timely completion Major obstacles for T/A planning, incomplete and poorly defined work scope Shut Down Challenges Establishing methodology for monitoring performances Proper Materials Planning Integrated T/A Management Strategy Systemizing the Designed Activities for successful T/A Shut Down organization interfaces Productivity Tracking and Improvements Quality Control Assurances/ Inspection Plan Logistics and Environmental Plan T/A Communication Meetings - Formatting Developing Risk Management Establishing Work Priorities Expediting Implementation A timely approach Ensuring Quality Inspections Review of Planning and Control system vis-a-vis the actual physical progress Collect Performance Data for future reference Monitoring Measuring and Reporting for timely completion based on quantities.

8 6 Meru Consulting 5. Power Utilities The programme aims at imparting the principles of operations in Power and Utilities section of a refinery. Reliable operation of Power and Utilities system is a vital link to safe, continuous and stable operation of the process. Efficient operation in Power and Utilities also leads to lesser energy consumption. The programme provides a deep insight into the operation and systems focusing on equipment reliability and energy conservation. Introduction to systems in Power and Utilities Raw Water and Drinking Water Systems Demineralised Water Treatment Plants Cooling Towers Compressed Air Systems DAY 3 Electrical Power Generation and Distribution UPS and Battery Systems DCS Gas Turbines and its System. Inert Gas Systems Fuel Oil and Fuel Gas Systems Steam Generation and Distribution Stream Distribution System Turbo Generators 6. Quality Control Quality control is a key activity in Refinery Operation and Product Certification, Quality Control will ensure the products, suitability for intended use by the consumer and efficient operation of Process Units. The Programme focuses on appreciation of quality control procedures and effective use of the inputs for the process. The programme explains the significance of the product specifications. Introduction to Quality Control Refinery Input Analysis Unit Control Analysis Finished Product Specification/Certification Test Procedures Products Product Specification Significance of Specification Test Procedures The Role of Quality Control Unit Control Sample Analysis Crude Assay Desalter Samples Distillation Unit Samples Vacuum Distillation Unit Samples FCCU Samples Fuel Upgradation Unit Samples Lube Plant Samples Wax Plant Samples

9 Meru Consulting 7 7. Leadership Thorugh Self Discovery (For Middle and Sr. Mgt) Programme Overview Leadership is a quality, which exists between people. Essentially Leadership is the relationship between the leader and his team. It is, therefore, the combination of Who you are: your values, beliefs and goals Your skills, capabilities and talents The relationship you create with others and Your situation or your environment We have mentioned the word AND in capital because that is the key word; it is not any one or more of these qualities which make a leader, but all of them in combination and congruence. Your personality is a system, consisting of these parts in congruence. The focus of this programme is on understanding these parts of your personality; enhance their congruence as a system and building leadership capabilities. The programme will take the participants on a journey of change and is based on the assumption that each individual is unique and everyone has the capacity to face his/ her challenges and take appropriate decisions Impact Deeply held values, beliefs and existing level of capabilities. The change process is learned through focusing on his inherent capabilities, enhancing their effectiveness and learning to use these capabilities effectively through the tools available in Neuro Linguistic Programming. 8. Personality Development Programme Overview The programme enables participants to gain awareness into the various personality attributes, which have a major role to play in superior job performance. It provides an opportunity to participants to develop their personality by gaining self-insight and getting feedback from others. It facilitates realization of fell potential, which will lead to improved organizational performance and personal effectiveness. Impact Understanding Self. Managing Relationships. Effective Communication and Presentation. Work-Life Balance. 9. Negotiation Skills Programme Overview In the present era of competitive business environment, profitability and benefits depend, highly, on the negotiation skills of the involved stakeholders. In addition to business conditions, we do negotiate, all the time, with colleagues, family members, friends and many others. In the contemporary world, understanding of negotiation process is important for achieving the desired and expected results. Individual skill in understanding and establishing relationship is crucial in his / her success or failure. The negotiating skills help individual in selling ideas, determining the price and other terms within and outside the organization. A person with good negotiation skills would resolve differences and promote collaboration. Negotiation process is widening its coverage and currently there are multiple national and international for a for effective negotiations. Impact Facilitate understanding the individual role in negotiation process. Help in developing effective and successful negotiation strategies. Create a sense of mutuality while negotiating with others. Emphasise the need to identify the bargaining zones.

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