Introduction

Process plants operate under complex and dynamic conditions where unexpected issues can impact safety, production, and profitability. Effective troubleshooting and structured engineering problem-solving are essential to quickly identify root causes, restore operations, and prevent recurrence.

This program, designed by Global Horizon Training Center, equips participants with systematic troubleshooting methodologies, analytical tools, and practical techniques to diagnose and resolve process plant issues efficiently and confidently.

Course Objectives

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

• Apply structured problem-solving methodologies in process environments
• Identify and diagnose process deviations and operational issues
• Perform root cause analysis (RCA) effectively
• Analyze process data and interpret plant performance
• Troubleshoot equipment, control systems, and process units
• Implement corrective and preventive actions
• Improve plant reliability and operational efficiency
• Enhance decision-making under operational constraints

Target Audience

This program is designed for:

• Process and Chemical Engineers
• Plant and Operations Engineers
• Maintenance and Reliability Engineers
• Control and Instrumentation Engineers
• Oil & Gas and Industrial Professionals
• Technical staff involved in plant operations

Outline

Day 1: Fundamentals of Troubleshooting and Problem Solving

• Introduction to troubleshooting methodologies
• Types of process problems
• Problem definition and scoping
• Data collection and analysis basics
• Safety considerations

Day 2: Process Data Analysis and Diagnostics

• Process variables and performance indicators
• Trend analysis and data interpretation
• Identifying abnormal conditions
• Process monitoring tools
• Case examples

Day 3: Equipment and System Troubleshooting

• Troubleshooting pumps, compressors, and valves
• Heat exchangers and reactors
• Piping and flow issues
• Instrumentation and control systems
• Common failure modes

Day 4: Root Cause Analysis and Corrective Actions

• RCA techniques (5 Whys, Fishbone, FMEA)
• Failure analysis methods
• Developing corrective and preventive actions
• Decision-making frameworks
• Documentation and reporting

Day 5: Optimization, Prevention, and Case Studies

• Preventive strategies and best practices
• Continuous improvement approaches
• Performance optimization
• Lessons learned
• Case studies and real-world applications