Zawiya Oil Refinery Unlocks New Levels of Productivity

Dynamic and reciprocating compressors are crucial to numerous refinery processes, including hydrocracking, fluid catalytic cracking, gas sweetening, sulphur recovery, and vapour recovery systems, at Zawiya Oil Refinery. Recognising the significant gains achievable through optimised maintenance and advanced configurations—such as enhanced energy efficiency, improved safety, and increased reliability—Zawiya Oil Refinery engaged Qabas to deliver a deep capacity-building initiative to elevate the expertise of their teams in managing these critical systems.

The Situation

In the highly complex environment of an oil refinery, the performance of compressors directly impacts overall productivity, safety, and cost efficiency. Compressors are integral to maintaining optimal conditions across multiple high-pressure processes. Any inefficiency in their operation can lead to increased energy consumption, unplanned downtime, and significant financial losses. The refinery’s leadership identified a critical need to upskill a broad spectrum of roles, including process engineers, maintenance and reliability engineers, operations technicians, instrumentation and control engineers, project managers, and plant supervisors.

The challenge was to provide these professionals with the knowledge to enhance compressor performance, implement predictive maintenance strategies, and integrate operational improvements with broader plant management objectives. The initiative aimed to ensure that every level of the team—from newly graduated engineers to seasoned managers—could contribute to maximising output, reducing operational risks, and supporting the refinery’s long-term goals.

Our Approach

Qabas designed an ambitious and comprehensive training programme tailored to meet the diverse needs of Zawiya Oil Refinery’s multidisciplinary teams. The programme focused on bridging the gap between technical expertise and strategic operational objectives, offering advanced training across key areas:

1. Optimised Compressor Operations: Delivered expert instruction on configuring and operating dynamic and reciprocating compressors for maximum efficiency, with a focus on reducing energy consumption and extending equipment lifespan.
2. Predictive Maintenance and Reliability Engineering: Equipped participants with advanced techniques for predictive maintenance, utilising data-driven insights to prevent failures, minimise unplanned downtime, and enhance long-term reliability.
3. Safety and Risk Management in High-Pressure Systems: Provided comprehensive training on maintaining rigorous safety standards, including hazard analysis, failure mode identification, and risk management in high-pressure environments.
4. Instrumentation and Control Integration: Focused on aligning compressor operations with instrumentation and control systems to enable real-time monitoring and seamless performance adjustments, ensuring consistency and safety.
5. Strategic Project and Plant Management: Empowered managers with the tools to align compressor performance with overall plant objectives, optimising cost control, project timelines, and operational efficiency.
6. Advanced Troubleshooting and Technical Support: Trained teams to quickly diagnose and resolve issues, ensuring minimal disruption to operations and maintaining high levels of productivity.
7. Adopting Industry Best Practices and Emerging Technologies: Introduced cutting-edge advancements in compressor technology, preparing teams to adopt innovative solutions that enhance competitiveness and efficiency.

Implementation

The programme was delivered through targeted workshops combining theoretical knowledge with hands-on simulations. Participants engaged in real-world scenario exercises reflecting the operational challenges faced at the refinery. Cross-functional group activities promoted collaboration, enabling teams to integrate their skills and develop comprehensive strategies for optimising compressor performance.

Results

The initiative significantly uplifted the technical and strategic capabilities across Zawiya Oil Refinery’s workforce. Teams are now equipped to drive improvements in compressor efficiency, reduce operational costs, and enhance safety. The integration of predictive maintenance has led to fewer disruptions, while the adoption of advanced operational techniques has streamlined processes, resulting in greater overall productivity.

This capacity-building programme has positioned Zawiya Oil Refinery to excel in a competitive market, with a more resilient, knowledgeable, and strategically aligned workforce capable of sustaining long-term operational excellence.