Introduction to Process Troubleshooting and Systematic Approaches

Session 1: Overview of Process Plant Operations

• Introduction to process plants and key operational parameters.
• Common challenges and issues encountered in plant operations.

Session 2: Systematic Troubleshooting Methodologies

• The importance of a structured approach to troubleshooting.
• Step-by-step diagnostic process: observation, analysis, and solution.
• Tools and techniques for effective problem identification.

Session 3: Root Cause Analysis (RCA)

• Introduction to RCA and its significance in troubleshooting.
• Methods for performing RCA in process environments.
• Techniques for gathering process data and using it for failure analysis.

Session 4: Case Study: Troubleshooting Process Inefficiencies

• Real-life case studies focused on diagnosing process inefficiencies.
• Group discussion and exercise on identifying root causes

Troubleshooting Equipment and Process Failures

Session 1: Troubleshooting Common Equipment Failures

• Identifying issues in pumps, compressors, heat exchangers, and valves.
• Common symptoms and failure modes of process equipment.
• Techniques for resolving equipment-related issues in process plants.

Session 2: Process Flow and Control Issues

• Troubleshooting flow inconsistencies, pressure imbalances, and control loop failures.
• Diagnosing control valve issues and instrumentation problems.
• Understanding process upsets and their impact on plant operations.

Session 3: Troubleshooting Process Variables

• Examining temperature, pressure, flow, and composition variances.
• Analyzing deviations from process setpoints and their root causes.
• Practical techniques for correcting abnormal process conditions.

Session 4: Case Study: Equipment and Process Troubleshooting

• Analysis of real-world cases where process and equipment failures occurred.
• Participants work in groups to identify and resolve the issues.

Advanced Troubleshooting Techniques and Preventive Measures

Session 1: Advanced Troubleshooting Tools and Software

• Overview of diagnostic tools and software used in modern process plants.
• Using predictive analytics and data-driven approaches to prevent failures.
• Applying advanced monitoring systems to enhance troubleshooting efficiency.

Session 2: Preventive and Predictive Maintenance Practices

• Implementing preventive maintenance to reduce plant downtime.
• Integrating predictive maintenance with troubleshooting efforts.
• Monitoring equipment health and performance trends.

Session 3: Best Practices in Plant Troubleshooting

• Guidelines for developing a troubleshooting culture in the workplace.
• Continuous improvement strategies for enhancing plant reliability.
• Building effective communication between operations and maintenance teams.

Session 4: Final Case Study and Troubleshooting Exercises

• Participants apply the course concepts to a comprehensive troubleshooting scenario.
• Group presentations and peer evaluations.
• Final Q&A session and course wrap-up.