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Knowledge Management KPE Operations Department

Knowledge Management KPE Operations Department. Introduction Kuwait Petroleum Europoort B.V. Start situation Experience with Elsevier opleiding & advies (Eo&a) during a construction project Development of a plan / goal Plan realisation Example Sulphur Plant Experiences

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Knowledge Management KPE Operations Department

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  1. Knowledge Management KPE Operations Department • Introduction Kuwait Petroleum Europoort B.V. • Start situation • Experience with Elsevier opleiding & advies (Eo&a) during a construction project • Development of a plan / goal • Plan realisation • Example Sulphur Plant • Experiences • Control, updating and ownership of procedures

  2. Introduction Kuwait Petroleum Europoort ( KPE ) B.V. • Fuels, Lube Base Oils , Bitumen • Original owner Gulf Oil Corporation ( 1963 ) • Taken over by Kuwait Petroleum Corp. 1983 • 1986 : Modernisation Lube Oil Plant • 1987 : Upgrade tankfarm ( VLPC project ) • 1990 : New Gasoline Plant ( lead/sulphur free ) • 1994 : Diesel S-content < 350 ppm • 2001 : Diesel S-content < 50 ppm • 2004 : Diesel S-content < 10 ppm

  3. Introduction Kuwait Petroleum Europoort ( KPE ) B.V. • 2 Crude units ( 4 mm t/yr ) • Conversion:ThermalCracker/ Visbreaker( 0.5 mm t/yr ) • Gasoline Plant ( 0.9 mm t/yr ) • Diesel ( < 10 ppm S ; 1 mm t/yr ) • Jet Fuel ( 0.5 mm t/yr ) • 8 Base Oil Grades ( 0.25 mm t/yr ) • Bitumen ( 0.35 mm t/yr )

  4. Introduction Kuwait Petroleum Europoort ( KPE ) B.V. • Distribution Centre • 7-8 Million tons per year • 25 VLCC’s/VLPC’s • 120 Coasters • 6000 Barges • 8000 Trucks • 110 Tanks ; 2 Million M3

  5. Introduction Kuwait Petroleum Europoort ( KPE ) B.V. • Organisation • 325 Employees • Operations : 185 • Engineering & Maintenance : 85 • Finance, Human Resources , Logistics • Operations • 170 Shift personnel • 15 Day personnel • Manager Operations : Rob van der Velden

  6. Start situation • Knowledge fragmented in the heads of experienced employees • Production process described in original design manuals ; operational procedures general and not up to date • Foreseen rejuvenation of the operator staffing

  7. Experience with Eo&a during a construction project • Gasoline Plant • Favorable experience with Eo&a’s Knowledge Systems department • Gasoline plant manuals served as a pilot • Combination of practical experience of KPE operators and Eo&a expertise • Complete set of detailed process descriptions and extensive operational procedures ( normal, start-up, shut-down, emergency )

  8. Development of a Plan / Goal • Complete detailed process- and procedure manuals for all first line production processes based on Gasoline plant system • Quicker and more effective training of new employees • Establish uniform operating practices across the various production plants

  9. Plan realisation • Eo&a team on the refinery • 3-4 Operators full time • Structure via Top Down method • Overview total process • Detailed drawings for each paragraph • User friendly • Quick access to required information • Only relevant information • Structure according to sequential phases of production process

  10. Sulphur Plant Example • Process Description • General ( approval,legend,symbols ) • Plant ( plot plan, theory, equipment ) • Storage and Utilities • Normal Operation • General , Plant , Storage and Utilities • Procedures • General • Start-up • Special • Shutdown • Emergency

  11. Experiences • Outsourcing • Other priorities , workload own force • Specialism • High quality end product • Involvement own employees increases basis ; acceptation • Uniform training requirements; operator exams • Direct availability ; no fragmentation • More effective training new employees • Less mistakes ; quicker start-ups ( less shift change delays ) • Requirement for ISO certification ; demonstration of good control of production process • Knowledge drain avoided

  12. Control,Updating,Ownership • Each manual has owner • No modifications allowed without authorization Operations and Technology Section Heads • Scheme for periodic updates • Electronic availability ( Intranet ) • Limited number of hard copies • One overall administrator for all manuals • ( intranet + hard copies ) • System to make sure that operators are being trained in modifications

  13. More information • Hand out presentation at Eo&a’s information stand • Possibility to view the complete Sulphur Plant manual • Questions?

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