Process Plant Troubleshooting & Engineering Problem Solving

ICTD International Centre for Training and Development

How long?

  • 5 days
  • in person

ICTD International Centre for Training and Development

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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.

About the course

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

Course Outline

Day 1

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

Day 2

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

Day 3

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)
  • HFACS Level 1: Unsafe Acts
  • HFACS Level 2: Preconditions for Unsafe Acts
  • HFACS Level 3: Unsafe Supervision
  • HFACS Level 4: Organizational Influences
  • Developing Leadership Competence
  • Managing change via the Transition Matrix

Day 4

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

Day 5

OPEN FORUM

  • 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

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Process Plant Troubleshooting & Engineering Problem Solving at ICTD International Centre for Training and Development

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