Process Plant Troubleshooting & Engineering Problem Solving

Course Introduction

This 5-day training program is designed to equip participants with the tools and techniques required to troubleshoot complex process plant systems and apply effective problem-solving strategies in engineering. It will cover various process plant operations, the common issues faced, and methods for diagnosing and resolving problems. Participants will also gain insight into systematic troubleshooting methodologies, root cause analysis (RCA), and how to apply engineering principles to improve process efficiency and safety.

Objectives

By the end of this course, participants will be able to:

•     Identify common problems in process plant operations and understand their root causes.
•     Apply structured troubleshooting methodologies to solve engineering issues in process plants.
•     Use process simulation tools and real-time data to diagnose plant issues.
•     Develop effective strategies to prevent recurring problems and improve process reliability.
•     Utilize problem-solving tools like root cause analysis (RCA) and failure mode analysis.
•     Understand the importance of safety and compliance in troubleshooting activities.
•     Improve communication and teamwork in addressing plant issues.

Target Audience

•     Process Engineers and Technicians
•     Operations Managers
•     Maintenance Engineers
•     Reliability Engineers
•     Plant Supervisors
•     System Engineers
•     Control Engineers

Daily Topics

Day 1: Introduction to Process Plant Troubleshooting

    Course Overview and Objectives

        Introduction to the course goals, structure, and expected outcomes.

    Understanding Process Plant Systems

        Overview of common process plant systems: Piping, pumps, compressors, heat exchangers, and reactors.

        Process flow diagrams (PFDs) and piping and instrumentation diagrams (P&IDs).

        Key process variables: Flow, pressure, temperature, level, and composition.

    Types of Plant Problems and Their Causes

        Mechanical, electrical, and control system issues.

        Operational problems such as deviations in temperature, pressure, and flow.

        Common failure modes: Equipment wear, corrosion, scaling, fouling, and misalignment.

    Introduction to Troubleshooting Methodologies

        Systematic approach to troubleshooting: Observation, hypothesis, testing, and correction.

        Importance of safety and shutdown procedures during troubleshooting.

Hands-on Activity: Review real-world examples of process flow diagrams (PFDs) and identify potential problem areas in a plant setup.

Day 2: Root Cause Analysis (RCA) and Failure Mode Analysis

Understanding Root Cause Analysis (RCA)

        Definition and principles of RCA.

        Steps involved in performing an RCA: Data collection, identifying root causes, corrective actions, and verification.

        Tools for RCA: Fishbone diagram (Ishikawa), 5 Whys, Failure Mode and Effect Analysis (FMEA).

    Failure Mode Analysis (FMA)

        What is FMA and its role in preventing system failures.

        Using FMA to prioritize failure modes based on severity, occurrence, and detectability.

        How to create a failure mode matrix and take corrective action.

    Applying RCA and FMA to Process Plant Problems

        Case studies of process plant issues and how RCA and FMA are used to identify and solve them.

        How to prioritize problems based on their impact on production and safety.

Hands-on Activity: Participants will conduct an RCA and FMA on a selected process plant issue (e.g., pump failure, temperature deviation).

Day 3: Process Simulation and Troubleshooting Tools

    Using Process Simulation for Troubleshooting

        Introduction to process simulation software (e.g., Aspen Plus, HYSYS).

        How to use process simulation to model and diagnose process issues.

        Performing "what-if" scenarios to test different troubleshooting strategies.

    Data-Driven Troubleshooting

        Using real-time process data for diagnostics: SCADA, DCS, and PLC systems.

        Analyzing plant data trends to identify abnormal conditions or performance degradation.

        Utilizing alarms, trending, and diagnostics tools to monitor plant performance.

    Control System Troubleshooting

        Common issues in control systems: Sensor faults, valve sticking, loop issues, and controller tuning problems.

        Diagnosing and troubleshooting control system faults using control system diagnostic tools.

Hands-on Activity:Using a process simulation tool to simulate and troubleshoot a process plant issue (e.g., flow rate reduction, pressure drop).

Day 4: Engineering Problem-Solving Tools and Techniques

    Problem-Solving Techniques

        Introduction to problem-solving frameworks: PDCA (Plan-Do-Check-Act), DMAIC (Define-Measure-Analyze-Improve-Control), and 8D Problem Solving.

        Identifying and defining the problem clearly to ensure the right solution is applied.

        Creative problem-solving techniques: Brainstorming, mind mapping, and lateral thinking.

    Decision-Making Techniques for Engineers

        Decision-making tools: Pareto analysis, cost-benefit analysis, and risk assessment.

        Balancing technical, operational, and financial constraints during problem-solving.

    Optimizing Engineering Solutions

        Applying optimization techniques to improve process plant performance.

        Design of experiments (DOE) for analyzing process changes and optimizing performance.

Hands-on Activity:Participants will work in groups to solve a real-world plant engineering problem using a structured problem-solving approach and decision-making tools.

Day 5: Preventing Recurring Issues and Improving Plant Reliability

    Preventive and Predictive Maintenance Strategies

        Overview of preventive maintenance (PM) vs. predictive maintenance (PdM).

        Utilizing condition monitoring tools (vibration analysis, thermal imaging, oil analysis) to predict failures before they occur.

        Creating a reliability-centered maintenance (RCM) strategy for process plants.

    Improving Plant Reliability

        How to design systems with reliability in mind to prevent common issues.

        Using reliability analysis tools such as Reliability Block Diagrams (RBD) and Fault Tree Analysis (FTA).

    Continuous Improvement and Feedback Loops

        The role of continuous improvement (CI) in maintaining plant efficiency.

        Establishing a feedback loop to learn from past failures and improve systems.

        Implementing corrective actions and best practices across the plant.

Hands-on Activity: Develop a reliability-centered maintenance (RCM) plan for a process plant system and present it to the group.

Course Review and Certification:

    Final review of the key concepts, problem-solving techniques, and tools covered during the course.

    Practical and theoretical assessments to test knowledge and skills gained.

    Issuance of Process Plant Troubleshooting & Engineering Problem Solving Certification for successful participants.

Assessment:

    Daily quizzes to assess understanding of key concepts and troubleshooting techniques.

    Practical assessments on applying RCA, FMA, and process simulation tools to real-world scenarios.

Certification:

Upon successful completion of the course, participants will receive a Process Plant Troubleshooting & Engineering Problem Solving Certification.

For registration, & more information please contact

NAYEL Training Centre 

Tel: +971 4 5587735 | Mob: +971 54 7962098 |WhatsApp: +971 54 7962098

Email:  [email protected]