Petrol- and Petrochemical Industry Competency based qualification program in Factory and Process Automation Report
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-73770 Denkendorf, 2007 Internet: www.festo.com/didactic e-mail: did@festo.com 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.
Table of Contents Table of Contents 3 Introduction 6 Introduction 6 Analysis 7 1. Analysis 7 1.1 Structure of the project 7 1.2 General informations regarding the oil industry 8 1.3 Definition of Petrol Industry 10 1.3.1 Petroleum 10 1.3.2 Petroleum composition 11 1.3.3 Petroleum classification 12 1.3.4 Petroleum producing countries 13 1.3.5 Petroleum refinery 14 1.3.6 Refined products transportation 17 1.4 Definition of Petrochemical Industry 18 1.4.1 Definition of Petrochemistry 18 1.4.2 Definition of Petrochemical 18 1.4.3 Petrochemical products and their derivates 19 Festo Didactic GmbH & Co. Petrol- and Petrochemical Industry 3
1.5 Definition of chemical industries and engineering 24 1.5.1 Definition of chemical industries 24 1.5.2 Definition of chemical engineering 25 1.5.3 Definition of process engineering 27 1.5.4 Definition of process control systems 28 1.5.5 Definition of control engineering 30 1.5.6 Definition of chemical plant operators 31 1.6 Summarization 32 Industrial demands 33 2. Industrial demands 33 2.1 Definition of Factory, Process Automation and Mechatronics 34 2.1.1 Definition of Factory Automation 34 2.1.2 Definition of Process Automation 36 2.1.3 Definition of Mechatronics 37 2.2 Market survey 40 2.2.1 Industrial interview 41 2.3 Evaluation of the industrial interviews 50 2.3.1 Evaluation of the Petrol Industry 50 2.3.2 Comparison between Petrol- and Petrochemical Industry 58 2.3.3 Evaluation of the entire interviews 66 Festo Didactic GmbH & Co. Petrol- and Petrochemical Industry 4
Demands driven solution 78 3. Demand-driven solution 78 3.1 Definition of competency based training - CBT 89 3.1.1 Characteristics of CBT 90 3.1.2 Advantages and limitations of CBT 91 3.1.3 Evaluation and assessment in CBT 92 3.2 Definition of general competencies 93 3.3 Demand-driven solution 105 3.3.1 Basic technologies 106 3.3.2 Partly Automation MPS/PCS 122 3.3.3 Fully Automation Process Manufacturing and Packaging 125 Summary and outlook 139 4. Summary and outlook 139 4.1 Next steps 141 Festo Didactic GmbH & Co. Petrol- and Petrochemical Industry 5
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 2007. 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
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