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Problem Solving & Troubleshooting in Process Operations

This two-day intensive course teaches engineers and operators how to effectively troubleshoot problems in process plants using simulation exercises. The course is highly interactive, using dynamic simulation models to create realistic operational scenarios. Delegates will practice monitoring processes, identifying issues, determining solutions, and learning from mistakes in a safe environment. The course is taught by experienced industry professionals and focuses on key areas like valves, pumps, compressors and distillation columns. Through a series of challenging problems, delegates will enhance their ability to solve issues and improve productivity. Suitable for personnel with less than 10 years of hands-on experience in chemical, oil/gas and other process facilities.

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344 views

Problem Solving & Troubleshooting in Process Operations

This two-day intensive course teaches engineers and operators how to effectively troubleshoot problems in process plants using simulation exercises. The course is highly interactive, using dynamic simulation models to create realistic operational scenarios. Delegates will practice monitoring processes, identifying issues, determining solutions, and learning from mistakes in a safe environment. The course is taught by experienced industry professionals and focuses on key areas like valves, pumps, compressors and distillation columns. Through a series of challenging problems, delegates will enhance their ability to solve issues and improve productivity. Suitable for personnel with less than 10 years of hands-on experience in chemical, oil/gas and other process facilities.

Uploaded by

Anonymous qPt2MHzXT
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© © All Rights Reserved
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Problem Solving & Troubleshooting in Process Operations

A Practical Introduction

ESD Simulation Training uses dynamic simulation models to deliver hands-on training that
will help you make better decisions in the operation and maintenance of equipment and in
the design of systems. The capacity to create real scenarios in real time provides an
engaging learning environment and measurable results. Our courses are taught by a highly
qualified faculty of experienced engineers and operations professionals and are broken
into 40-minute sessions, comprised of lectures, simulation model exercises, videos, CBT,
multi-media training and group discussions. With a firm focus on hands-on training and
interaction, these courses will keep you engaged and result in a deeper and more lasting
understanding of process operations.

Summary: Intensive, two day course comprising of a mixture of short lectures, workshop
exercises and dynamic process simulation exercises. This course will provide operators with a
good understanding of troubleshooting and problem solving in process plants. Using a series of
simulated practical examples, delegates will be challenged to identify and correct real-life
process problems. These examples will include: equipment malfunctions, instrumentation
faults, and issues with the control systems. The examples will focus on key plant process
equipment such as valves, pumps, compressors and columns. For each example, delegates will
be briefed on the process and control system, and challenged to monitor the process and
identify and correct any faults that develop during the exercise. Briefings will be given to allow
the delegates to understand the process and control system before the exercise starts.
Note: This course can be extended to allow for additional process examples to be investigated.
Pre-requisites: None. Some personal experience with non-typical situations in process areas
will be helpful.

Participant Profile: Engineers and Operations personnel working on any process plant. This
course is suitable for new engineers and operators as well as experienced ones.

Learning Outcomes:
At the end of the course delegates will:
• Understand what problem solving and troubleshooting is and how to do it.
• Be able to identify and respond to abnormal conditions on a process plant including:
 Unstable operation
 Process alarms
 Process trips.
• Be aware of how to monitor an operating process.
• Understand what to look for to be able to identify abnormal situations and correct them
before they become more serious
• Gain personal experience and confidence troubleshooting several process condition
change problems using process simulation model exercises.

Course Curriculum:
This course will be split into a series of sessions. The first session will introduce troubleshooting
and explain the technique to be used with each exercise. After each exercise a comprehensive
de-brief will be held and lessons learnt will be discussed.

1. What is Problem Solving and Troubleshooting?


• Monitor normal conditions.
• Respond to abnormal operating conditions.
• Principle operating parameters.
 Examine why and how they are controlled.
• Troubleshooting theory.
 Fault analysis and diagnosis.
 Methodology (recognise - gather and analyse data - pinpoint case -
confirm diagnosis - respond and rectify).
2. Exercise 1 - Valve Issues:
• Identify and correct problems associated with a malfunctioning valve:
 Monitor process.
 Record information.
 Identify problem.
 Determine solution.
 Review and discussion.
3. Exercise 2 – Pump Issues:
• Identify and correct problems associated with a malfunctioning pump:
 Monitor process.
 Record information.
 Identify problem.
 Determine solution.
 Review and discussion.
4. Exercise 3 – Compressor Issues:
 Identify and correct problems associated with a malfunctioning compressor:
 Monitor process.
 Record information.
 Identify problem.
 Determine solution.
 Review and discussion.
5. Exercise 4 – Column Issues:
• Identify and correct problems associated with a malfunctioning column:
 Monitor process.
 Record information.
 Identify problem.
 Determine solution.
 Review and discussion.
6. Exercise 5 – Instrumentation Issues.
7. Exercise 6 – ESD System Issues.
8. Exercise 7 – Upstream Process Issues.
9. Summary and Conclusions.

This two-day course is designed to teach engineers and process operations


personnel how to effectively troubleshoot problems on process plants. Solving
problems quickly and effectively leads to increased productivity and saves
money. This highly interactive course is challenging and interesting and will
appeal to both engineers and operators. It will appeal especially to engineers
and operators will less than 10 years experience "hands-on" 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.
Suitable for: Engineers and operations personnel who work in chemical
plants, process plants of any kind and oil and gas processing
facilties; offshore, onshore, refineries, gas plants, petrochemical plants,
FPSOs and LNG plants.

Key Topics:

 What is problem solving and troubleshooting?


 Methodology
 Respond correctly to abnormal operating conditions
 Exercises to practice solving realistic problems
Faculty:

In addition to leading edge computer models and simulation tools, ESD Simulation Training has
a highly qualified faculty of experienced engineers and operations professionals who have
undergone extensive training within their areas of expertise. The depth of their knowledge in
the process industries has won the trust and respect of over 30,000 delegates over the past 20
years.

Mark Dixon, B.Sc. (Hons) C.Eng. MIChemE, MIGasE


Managing Director of ESD and a Chartered Chemical Engineer, Mark has been working as a
Chemical Engineer and delivering training courses for 28 years. He is a member of the
Institution of Chemical Engineers (IChemE) and the Institution of Gas Engineers.

Colin Baker, ONC Science


With 47 years’ experience in operation in the oil, gas, chemical and petrochemical industries,
Colin is one of the most knowledgeable simulator trainers in the world. His expertise extends to
the operation of ethylene plants, LNG production, oil refineries and oil and gas production
facilities.

Robert Hodder, MAIChE


Robert is a member of the American Institute of Chemical Engineers and has 45 years of
practical experience working as a Process Engineer, Operations Supervisor, and Training
Manager on oil refineries, LNG plants, offshore and onshore oil and gas production facilities.

David Llewellyn, B.Sc. (Hons) C.Eng.


A fellow of the Institution of Chemical Engineers and the Institution of Gas Engineers, David is a
process engineer with 47 years’ experience in the energy industry with a wealth of experience
working in the production, storage and transportation of LNG, natural gas, LPG and ammonia
industries.

Peter Watson, B.Sc. (Hons), C.Eng


Peter is a fellow of the Institution of Chemical Engineers (Eur. Ing.MEI) and a Chartered
Engineer with 40 years’ experience in the oil and gas processing business, including many senior
management positions around the world.
Roger Edward, Power Engineer, First Class
Roger brings 36 years of training experience as a consultant to the industry in a wide range of
process facilities on several continents, specialising in implementing site-specific training, safety
and emergency response procedures.

Gareth Pemberton, B.Sc. (Hons) A.M.I. Mech.E


Gareth has over 35 years’ experience in the Rotating Equipment Industry as a design engineer,
project manager and general manager. He has worked principally in the oil and gas,
petrochemical and power generation sectors and most recently in the LNG industry with direct
involvement in many of the latest LNG projects.

Edward Dilley, B.Sc. (Hons) C.Eng.


A member of the Institution of Chemical Engineers with over 40 years of experience in process
control, process engineering and planning within the oil refining, petrochemical, synthetic
rubber and power industries. Edward brings a wealth of practical knowledge to the classroom.

Mike Tolstyko, HNC MECH Eng., ONC Bus.


Mike has over 36 years of industry experience in drilling operations worldwide. He is fully
accredited by the IWCF, and is a member of the Society of Petroleum Engineers.

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