Knowledge Management KPE Operations Department

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Knowledge Management KPE Operations Department

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

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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 lt 350 ppm
• 2001 Diesel S-content lt 50 ppm
• 2004 Diesel S-content lt 10 ppm

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Introduction Kuwait Petroleum Europoort ( KPE )
B.V.

• 2 Crude units ( 4 mm t/yr )
• ConversionThermalCracker/ Visbreaker( 0.5 mm
  t/yr )
• Gasoline Plant ( 0.9 mm t/yr )
• Diesel ( lt 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 )

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Introduction Kuwait Petroleum Europoort ( KPE )
B.V.

• Distribution Centre
• 7-8 Million tons per year
• 25 VLCCs/VLPCs
• 120 Coasters
• 6000 Barges
• 8000 Trucks
• 110 Tanks 2 Million M3

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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

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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

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Experience with Eoa during a construction
project

• Gasoline Plant
• Favorable experience with Eoas Knowledge
  Systems department
• Gasoline plant manuals served as a pilot
• Combination of practical experience of KPE
  operators and Eoa expertise
• Complete set of detailed process descriptions and
  extensive operational procedures ( normal,
  start-up, shut-down, emergency )

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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

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Plan realisation

• Eoa 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

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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

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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

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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

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More information

• Hand out presentation at Eoas information stand
• Possibility to view the complete Sulphur Plant
  manual
• Questions?