process plant troubleshooting & engineering problem solving

COURSE OVERVIEW

Pe0114 : process plant troubleshooting & engineering problem solving.

• Description
• Methodology

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Course description, training methodology.

This interactive training course includes the following training methodologies as a percentage of the total tuition hours

In an unlikely event, the course instructor may modify the above training methodology before or during the course for technical reasons.

VIRTUAL TRAINING (IF APPLICABLE)

If this course is delivered online as a Virtual Training, the following limitations will be applicable

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Process plant troubleshooting and engineering problem solving, introduction:.

This training program aims to equip participants with essential skills and methodologies to effectively diagnose and resolve issues in process plants. This program emphasizes critical thinking, systematic problem-solving approaches, and practical troubleshooting techniques essential for ensuring operational efficiency and reliability.

Program Objectives:

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

Develop proficiency in diagnosing process plant issues.

Acquire systematic problem-solving skills.

Apply root cause analysis techniques effectively.

Implement preventive and corrective actions.

Enhance operational reliability and efficiency.

Foster a culture of continuous improvement in troubleshooting.

Target Audience:

Process engineers and plant operators.

Maintenance and reliability professionals.

Technical staff involved in operations and troubleshooting.

Engineering managers and supervisors.

Professionals seeking to enhance problem-solving capabilities in process industries.

Program Outline:

Fundamentals of process plant troubleshooting:.

Introduction to process plant troubleshooting.

Importance of systematic problem-solving.

Roles and responsibilities in troubleshooting.

Safety considerations in troubleshooting activities.

Regulatory compliance and standards.

Root Cause Analysis Techniques:

Overview of root cause analysis (RCA).

Common RCA methodologies (5 Whys, Fishbone Diagram).

Data collection and analysis for RCA.

Case studies on successful RCA applications.

Implementing preventive measures based on RCA findings.

Equipment and Process Troubleshooting:

Troubleshooting mechanical equipment failures.

Electrical and instrumentation troubleshooting.

Troubleshooting control systems and PLCs.

Process deviations and abnormal operations.

Interpreting equipment performance data.

Implementing Effective Solutions:

Developing action plans for corrective actions.

Monitoring and evaluating effectiveness of solutions.

Documenting troubleshooting processes and outcomes.

Integration of troubleshooting with maintenance strategies.

Continuous improvement in troubleshooting practices.

Case Studies and Practical Applications:

Real-world case studies in process plant troubleshooting.

Simulation exercises and hands-on problem-solving.

Group discussions and peer learning sessions.

Lessons learned and best practices in troubleshooting.

Future trends in process plant troubleshooting and problem-solving techniques.

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Process Plant Troubleshooting & Engineering Problem Solving Workshop

Introduction:.

Excellent troubleshooting skills are essential for Best-in-Class modern industrial companies. Having personnel trained in troubleshooting training and equipped with solid troubleshooting skills minimizes downtime and enhances overall productivity.

This plant troubleshooting and engineering problem-solving workshop is designed to instill maintenance troubleshooting techniques and an engineering approach to problem-solving, ensuring rapid and efficient issue resolution.

Why is Troubleshooting Important?

Plant troubleshooting and engineering problem-solving are critical processes for identifying the cause of a system problem and solving it.

Understanding the importance of troubleshooting must be addressed in industrial and manufacturing settings where downtime can result in significant financial loss and reduced safety.

Through this plant troubleshooting and engineering problem-solving seminar, participants will understand why troubleshooting is necessary and how it can contribute to process continuous improvement.

Targeted Groups:

• Employees are responsible for leading and directing teams to improve productivity.
• Individuals tasked with plant troubleshooting and solving plant-related problems.
• Production, Maintenance Engineering, and Process Engineering personnel.
• Supervisors are involved in the operations or maintenance functions.
• Planners, coordinators, engineers, and technologists are committed to enhancing their troubleshooting skills training.

Workshop Objectives:

By the end of this plant troubleshooting and engineering problem-solving workshop, participants will:

• Understand how to become a Top Gun troubleshooter.
• Develop a structured approach to troubleshooting and problem-solving with common terminology and understanding.
• Learn how to make incremental efficiency gains through continuous improvement practices.
• Distinguish between owning a techniques manual and effectively applying it.
• Identify motivated individuals who should lead troubleshooting efforts.
• Understand work practices that enable success in troubleshooting and problem-solving.

Targeted Competencies:

By the end of this plant troubleshooting and engineering problem-solving conference, participants will:

• Problem-solving terminology.
• Tools and techniques for maintenance troubleshooting.
• A standard blueprint for problem analysis and resolution.
• Strategies, planning, and protocols for effective problem-solving.
• Variability analysis for anticipating and mitigating issues.
• Human factor analysis as a source of error in troubleshooting.

Conference Content:

Unit 1: introductory concepts:.

• Understanding the nature of problems.
• Establishing a common terminology for plant troubleshooting.
• Contextualizing problems: asset-based vs. business process-based approaches.
• Structured approaches such as 6 Big Losses and 7 Wastes.
• Introduction to various troubleshooting techniques and tools.
• Setting a Six-Level Performance Standard.
• Recognizing critical relationships in problem-solving.

Unit 2: Tools and Techniques:

• Applying decision logic to troubleshooting.
• Understanding maturity indexing in problem-solving.
• Analyzing relationships to identify problem sources.
• Synthesizing problem analysis for effective resolution.
• Making practical use of tools and techniques for troubleshooting.
• Selecting appropriate project selection methods.
• Choosing the correct tools and techniques for each troubleshooting scenario.

Unit 3: People Issues:

• Investigating how work practices impact troubleshooting effectiveness.
• Exploring group dynamics in problem-solving.
• Delving into individual motivators for effective troubleshooting.
• External vs. Internal Motivation.
• Developing troubleshooting and mechanical engineering problem-solving skills.
• Managing change associated with problem-solving initiatives.
• Implementing a Transition Matrix to aid in troubleshooting efforts.

Unit 4: Operator, Maintainer, Designer Interface:

• Encouraging cross-functional working for troubleshooting.
• Examining the effect of maintenance strategy on troubleshooting efforts.
• Analyzing functional contributions to problem-solving.
• Considering Life Cycle Analysis and designing for operation and maintenance.
• Conducting variability analyses to anticipate potential issues.
• Strategies, planning, and protocols for enhanced troubleshooting.
• Improving the fit between critical parameters in operations.
• Continuous improvement.

Unit 5: Review of Concepts, Tools, and Techniques:

• Creating an action plan for troubleshooting and problem resolution.
• Understanding configuration management in the context of troubleshooting.
• Considering commercial programs that support troubleshooting efforts.
• Applying standard questions as a structured approach to troubleshooting.
• Reviewing the four critical stages of Data Maturity for engineering problem-solving.

Conclusion:

Through this structured troubleshooting workshop, participants will gain engineering problem-solving skills crucial for effectively addressing and preventing issues within process plants.

Oil and Gas Engineering Training Courses Process Plant Troubleshooting & Engineering Problem Solving Workshop (EO)

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• Problem Solving and Troubleshooting i...

Problem Solving and Troubleshooting in Process Operations

Topic Process and plant operations

CPD Hours 14

This is an IChemE   approved training course   and not delivered directly by the Institution. For more information about the course,   contact the training provider   directly.

IChemE members get a 10% discount when they enter their membership number at the time of booking.

This highly interactive course is challenging and interesting and will appeal to both engineers and operators, especially those with some 'hands-on' experience in a process operations environment. The course uses a variety of simulation models to give delegates the chance to solve many challenging and realistic problems in a safe environment.

Who will benefit

Engineers and operations personnel who work in chemical plants, process plants of any kind, and oil and gas processing facilities including offshore, onshore, refineries, gas plants, petrochemical plants, FPSOs and LNG plants.

Course outline

• What is problem solving and troubleshooting?
• Methodology
• Respond correctly to abnormal operating conditions
• Exercises to practice solving realistic problems

Upcoming dates

Process Plant Troubleshooting & Engineering Problem Solving

• Course Description
• Course Objective
• Course Outline

Course Introduction:

This five-day course is a must if your company’s goals include reducing costs and preserving the lives of your employees because it delivers a wide range of pro-active, efficient troubleshooting skills. It has been proven that technical competence alone is no longer enough to ensure consistent operational performance. Excellent troubleshooting skills are considered a core competency for 'Best-in-Class' modern industrial companies. In the competitive world that we are living in, it is essential that we optimize our efforts to secure the desired outcomes, and this course will equip the delegate with the basic tools and understanding to make that happen.

This course will feature the following topics:

• The understanding of terminologies; tools and techniques
• Enumerate the components of plant problem solving as well as the various troubleshooting techniques on engineering problem solving by familiarizing the potential source
• Apply the methods of risk analysis particularly HAZOP and MSDS in process plant troubleshooting and practice the process of engineering problem solving through sample problems in troubleshooting
• Apply a standard “Blue-Print” for problem analysis and resolution
• How to utilize Maturity Indexing; Planning; and Protocols
• Useful Case Studies; Exercises and Analysis
• Learning the “Human Factors” as a Source of Error

Course Objectives:

Upon successful completion of this course, the delegates will be able to:

• Appreciate the difference and consequences between pro-active and reactive problem solving
• Develop a structured approach to troubleshooting and problem solving
• Understand continuous improvement in the way you run your processes
• Implement teamwork and leadership principles; support and cooperation practices
• Understand work practices which "allow" success in troubleshooting and problem solving

Who Should Attend?

This course is intended for all employees who are responsible for leading and directing people to achieve and improve productivity levels, those faced with the challenge of solving plant related problems such as; Production, Maintenance Engineering and Process Engineering personnel, Supervisors who are involved in the Operations / Maintenance function, Planners, Coordinators, Engineers and Technologists.

Course Outline:

INTRODUCTORY CONCEPTS

·         Defining the Nature of Problems

·         Utilizing a Common Terminology

·         Structured approaches – 6 Big Losses, 7 Wastes

·         Engineering Problem Solving

·         Components of Plant Problem Solving

·         Daily Monitoring System Guidelines

·         Techniques introduction

·         Tools introduction

·         Levels of Performance Standard

·         Critical Relationship  

TOOLS & TECHNIQUES – PRACTICAL EXPERIENCE

·         Application of Decision Logic

·         Risk Analysis – HAZOP – MSDS

·         Troubleshooting Techniques and Applications on plant equipment’s

·         Practical Maturity Indexing

·         Relationships Analysis

·         Problem Analysis and Synthesis

·         Practical Use of Tools and Techniques

·         Project selection methods

PEOPLE ISSUES

·         Working practices – Empowerment or Impairment?

·         Group dynamics

·         Individual motivators: External vs. Internal Motivation

·         Developing Troubleshooting and Problem Solving Skills

·         Learning the “Human Factors” as a Source of Error

·         The Human Factors Analysis and Classification System (HFACS)

·         The HFACS taxonomy (Four Level)

o   HFACS Level 1: Unsafe Acts

o   HFACS Level 2: Preconditions for Unsafe Acts

o   HFACS Level 3: Unsafe Supervision

o   HFACS Level 4: Organizational Influences

·         Developing Leadership Competence

·         Managing change via the Transition Matrix

OPERATOR, MAINTAINER, DESIGNER INTERFACE

·         Cross functional problem solving

·         Development of Maintenance strategy

·         Life Cycle Analysis, Design for Operation, Design for Maintenance

·         Variability Analysis

·         Strategies; Planning; and Protocols

·         Effect of improved “Fit” between critical parameters in Operations

·         Concepts, Tools and Techniques applied to problems

·         Configuration Management

·         Commercial Programs

·         The Critical stages of Data Maturity

·         Case Studies and Action Plans

·         Wrap up

Course Methodology:

A variety of methodologies will be used during the course that includes:

·         (30%) Based on Case Studies

·         (30%) Techniques 

·         (30%) Role Play

·         (10%) Concepts

·         Pre-test and Post-test

·         Variety of Learning Methods

·         Lectures

·         Case Studies and Self Questionaires

·         Group Work

·         Discussion

·         Presentation

Course Fees:

To be advised as per course location. This rate includes participant’s manual, and-Outs, buffet lunch, coffee/tea on arrival, morning & afternoon of each day.

Course Timings:

Daily Course Timings:

    08:00 - 08:20       Morning Coffee / Tea

    08:20 - 10:00       First Session

    10:00 - 10:20       Recess (Coffee/Tea/Snacks)

    10:20 - 12:20       Second Session

    12:20 - 13:30       Recess (Prayer Break & Lunch)

    13:30 - 15:00       Last Session

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H.H. Sheikh Sultan Bin Zayed Al Nahyan Building Mezzanine-(0) Floor Corniche Street, Abu Dhabi U.A.E

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