CDGA

Process Plant Troubleshooting & Engineering Problem Solving

Modern industrial processes are large, complex and have a high degree of interaction between both dependent and independent variables. This makes problem solving difficult and leads to the “disappearing problem” syndrome. Problems often disappear without being solved only to reappear again. This seminar deals with a unique approach of combining cause and effect problem solving thinking with formulation of theoretically correct working hypotheses to provide rapid and effective problem solving techniques for the process industry. Problem Solving in the process industry is often characterized by either inference based on cause and effect relationships or highly involved theoretical approaches. Neither of these approaches is satisfactory in a modern manufacturing environment. The cause/effect inference approach while being expedient often results in solutions that do not eliminate the problem, but in fact make the problem worse. The more sophisticated highly theoretical approach is rarely expedient enough to satisfy time constraints in a production facility. Thus one of the most frequent industry requests to the academic world is “give us people that can solve problems”. This program presents an approach that emphasizes the classical problem solving approach (defining the sequence of events) with the addition of the steps of formulating a theoretically correct working hypothesis, providing a means to test the hypothesis, and providing a foolproof means to eliminate the problem. The initial part of the seminar focuses on defining the problem that must be solved and obtaining the location, time and quantity based specifications of the problem. The initial part of the seminar is suitable for all engineering disciplines as well as non-engineers. The second part of the seminar deals with the utilization of chemical engineering fundamentals to develop a technically correct working hypothesis that is the key to successful problem solving. The primary emphasis is on pragmatic calculation techniques that are theoretically correct. These techniques have been developed by the Seminar Instructor in 40+ years of industrial experience. Using these techniques, theoretically correct working hypotheses can be developed in an expedient fashion.

The Training Course Will Highlight ?

The objective of this training program of 5 days duration is to impart Training on Trouble Shooting Chemical Plant Problems related to the petroleum / petrochemical / fertilizer and power generation plants. The training covers the basics of common chemical plant equipment such as Pumps, Compressors, Turbines, Heat exchangers, coolers, Distillation columns, static vessels, pipe lines, motors etc and troubleshooting various problems associated with them.

Training Objective

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

Apply and gain an in-depth knowledge on process plant troubleshooting and engineering problems solving through various practical exercises carry out during the course
Enumerate the components of plant problem solving as well as the various troubleshooting techniques on engineering problem solving by familiarizing the potential sources
Specify the limitations to plant problem solving through sources of historical data and become aware of the daily monitoring system guidelines by setting trigger points
Apply the methods of risk analysis particularly HAZOP and MSDC in process plant troubleshooting and practice the process of engineering problem solving through sample problems in troubleshooting
Discuss the scope of applied economics including other valuation forms & methods, and review the guidelines for problem solving temperature, pressure, and level
Employ the simplified approach in solving compressor problems and know distillation, plates & tray stability and discuss clearly the elements of measurements & verifications, and carry-out sample exercise on kinetics, flow, mechanical and designs
Recognize the attributes of equivalent piping lengths, commercial correlations, and fluids by means of practical exercises
Discuss the importance of two phase flow including its attributes and applications and analyze the characteristics of controllers, feedback, feed forward and cascade controls used in process control
Improve knowledge on process control and optimization, process analyzers, distillation multiple control, volume control, condenser control, and control project drawback
Develop an understanding on heat transfer and various troubleshooting techniques and applications in used process plant
Implement several strategies on distillation column packing and identify the different forms of hazards to equip participants with the QRA procedures and demonstration
Carry out the latest methodology of MSDS and discuss if the needed information is good enough or incomplete
Identify various accidents in the process plant and know what a flixborough accident

Target Audience

This training is designed for engineers and operations personnel of process plants, refineries (Oil and Gas) and power plants, involved in operation, maintenance and performance monitoring of Operation.

Process engineers,
Plant managers,
Team leaders,
Section heads,
Plant supervisors and
Technical staffs (Operators and Technicians).

Training Methods

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

30% Lectures
30% Workshops & Work Presentations
20% Case Studies & Practical Exercises
20% Videos, Software & General Discussions

The course instructor may modify the above training methodology before or during the course for technical reasons with no prior notice to participants.

Daily Agenda

Concepts

The nature of problems
Context – Asset based or Business Process based
Structured approaches – 6 Big Losses, 7 Wastes
Techniques introduction
Tools introduction

Tools & Techniques – Practical Experience

Problem Analysis
Practical Use of Tools and Techniques
Case Studies
Project selection methods
Tools & Techniques – selecting the right one

People Issues

Working practices – empowerment or impairment?
Group dynamics
Individual motivators
Developing Troubleshooting and Problem Solving skills
Managing change

Chemical Plant Equipment Trouble Shooting

Fractionators Operation and Trouble Shooting

Principles of Distillation (Fractionation)
Reflux
Reboiling
Fractionators Operation and Trouble Shooting

Heat Exchanges Operation and Trouble Shooting

Shell and Tube Exchangers
Double pipe Exchangers
Indirect Heaters
Air Cooled Exchangers
Heat Exchanger Operation and Trouble Shooting

Fired Heaters Operation and Trouble Shooting

Performance Monitoring
Fired Heater Operation and Trouble Shooting

Pumps Operation and Trouble Shooting

Basic Pump Hydraulics
Calculating Total Head
Horsepower Calculations
Net Positive Suction Head (NPSH)
Pump Performance Curves
System Performance
Operation, Control and Trouble Shooting

Compressors Operation and Trouble Shooting

The Theory of Compression
Centrifugal Compressors Operation, Control and Trouble Shooting
Reciprocating Compressors Operation, Control and Trouble Shooting
Operation, Control and Trouble Shooting

Utilities Systems Operation and Trouble Shooting

Water Treatment Systems

Introduction to Water Treatment
Suspended Solids
Dissolved Solids
Dissolved Gases
Industrial Water Treatment
Primary Water Treatment
Secondary Water Treatment
Potable Water Purification
Disinfections of Water
Sterilization of Water by (Chlorine, Ozone, Chloramines)

Waste Water Systems

Main Sources of Pollution
At the Production
During Transportation
During Refining
De – Oiling of Water
Purpose of De – Oiling
API Interceptor
Parallel Plate Interceptor (PPI) and Corrugated Plate Interceptor (CPI)
Flotation Units
Flocculation Units

Fuel Systems

Typical Fuel Gas System
Typical Problems
Pressure Variation
Liquid in the Gas
Change in Fuel Gas Composition

Air Systems

Instrument Air
Typical Instrument Air Supply Systems
Instrument Air Distribution Systems Operation and Trouble Shooting
Utility Air
Typical Utility Air Supply Systems
Utility Air Distribution Systems Operation and Trouble Shooting

Process Shutdowns (PSD) and Emergency Shutdown (ESD)

Normal Shutdown Procedures

Process Emergency Shutdown

Process Failures
Utility failure

Accreditation

CDGA attendance certificate will be issued to all attendees completing minimum of 80% of the total course duration.

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Course Rounds : (5 -Days)

Code	Date	Venue	Fees
PE208-01	20-04-2025	Cairo	USD 5450
PE208-02	20-07-2025	Dubai	USD 5450
PE208-03	15-09-2025	Kuala-Lumpur	USD 5950
PE208-04	23-11-2025	Dubai	USD 5450

Process Plant Troubleshooting & Engineering Problem Solving

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Course Rounds : (5 -Days)

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