Petrol- and Petrochemical Industry. Competency based qualification program in Factory and Process Automation. Report

Transcription

1 Petrol- and Petrochemical Industry Competency based qualification program in Factory and Process Automation Report

2 Table of Contents Order no.: Description: Designation: Petrol- and Petrochemical Industry Competency based qualification program in Factory and Process Automation Project report Status: 08/2007 Author: Graphics: Layout: Wolfgang Eckart, Festo Didactic GmbH & Co Wolfgang Eckart, Festo Didactic GmbH & Co Festo Didactic GmbH & Co Festo Didactic GmbH & Co., D Denkendorf, 2007 Internet: All rights reserved, including translation rights. No part of this publication may be reproduced or transmitted in any form or by any means, electronic, mechanical, photocopying, or otherwise, without the prior written permission of Festo Didactic.

3 Table of Contents Table of Contents 3 Introduction 6 Introduction 6 Analysis 7 1. Analysis Structure of the project General informations regarding the oil industry Definition of Petrol Industry Petroleum Petroleum composition Petroleum classification Petroleum producing countries Petroleum refinery Refined products transportation Definition of Petrochemical Industry Definition of Petrochemistry Definition of Petrochemical Petrochemical products and their derivates 19 Festo Didactic GmbH & Co. Petrol- and Petrochemical Industry 3

4 1.5 Definition of chemical industries and engineering Definition of chemical industries Definition of chemical engineering Definition of process engineering Definition of process control systems Definition of control engineering Definition of chemical plant operators Summarization 32 Industrial demands Industrial demands Definition of Factory, Process Automation and Mechatronics Definition of Factory Automation Definition of Process Automation Definition of Mechatronics Market survey Industrial interview Evaluation of the industrial interviews Evaluation of the Petrol Industry Comparison between Petrol- and Petrochemical Industry Evaluation of the entire interviews 66 Festo Didactic GmbH & Co. Petrol- and Petrochemical Industry 4

5 Demands driven solution Demand-driven solution Definition of competency based training - CBT Characteristics of CBT Advantages and limitations of CBT Evaluation and assessment in CBT Definition of general competencies Demand-driven solution Basic technologies Partly Automation MPS/PCS Fully Automation Process Manufacturing and Packaging 125 Summary and outlook Summary and outlook Next steps 141 Festo Didactic GmbH & Co. Petrol- and Petrochemical Industry 5

6 Introduction Introduction The main focus of this project step will be on the definition of a further training program to transfer the necessary know-how in the basic technologies of Factory and Process Automation and the combination of it to so called Partly Integrated (automated) or Totally Integrated (automated) systems addressed directly to the Petrol- and Petrochemical Industry. This project report will assist educational institutions to set-up an external shortterm training program in the above mentioned technology creating a higher reputation in the industry and additional income. This know-how transfer is called training for productivity and will help the industry to close the knowledge and especially the skills gaps of graduates and employees. The next logical step should be the definition of a specific curricula for Process Control Engineering to be able to offer specific trained staff to the Petrol- and Petrochemical industry. The definition of the curricula is not part of this project solution. In some countries there is a study program in Process Control Engineering with curricula already available. This project will consist of three phases: 1. Analysis 2. Industrial demands 3. Demand-driven solution The main focus of this project was to define a short term training program for staff or employees already working in the different areas and sectors of Petrol- and Petrochemical industries. There will be and could be a feedback to the occupational training in the different levels vocational, technician and engineer by inserting specific know-how and skills in already existing curricula, or by defining a new study program with new curricula. The project started in January 2007 and has been finished end of August The main objective was to evaluate the technological standards and needs within the Petro- and Petrochemical industry and based on this evaluation, to define the technological know-how and the necessary equipment and training structure and contents which should be trained for that specific areas of industrial processing. This project is not related to a certain country. However, it helps to create easily country-specific projects taking into consideration the respective requirements. The market survey has been done in Saudi Arabia, Iran, Indonesia and Nigeria. Festo Didactic GmbH & Co. Petrol- and Petrochemical Industry 6

7 Analysis 1. Analysis 1.1 Structure of the project This part of the project will cover the definitions of Petrol- and Petrochemical industries, the countries of interest, the product range and the technological structure of the companies. This competencey based qualification program in Automation Technology and Process Control consists of three chapters Generally a master project out of which specific projects can be developed will save money and time. It is not necessary to reinvent the wheel by solving already known recurrent problems. The efforts and resources can be focused on those parts of a project which must be shaped individually according to the specific requirements. The proceeding is predefined and after some project implementations it is fieldtested. The funding institutions gain reliability in the procurement of equipment. And last but not least the monitoring function of the project owner will be significantly easier and more efficient Festo Didactic GmbH & Co. Petrol- and Petrochemical Industry 7