By the end of this LPG Plant Processing & Troubleshooting course, participants will be able to:

• Identify and troubleshoot common process issues in LPG plants to ensure optimal operation and minimize off-spec product and production losses.
• Effectively operate and manage Process safety systems, including Burner Management Systems (BMS) and interlocks, to enhance safety performance and prevent process upsets.
• Respond confidently and accurately during normal, abnormal, and emergency operating conditions, thereby increasing operational reliability.
• Recognize potential safety hazards associated with LPG processing, such as fire, explosion, and toxic releases, and implement appropriate safety measures.
• Apply troubleshooting tools and techniques to diagnose equipment malfunctions, process deviations, and control system failures.
• Implement proactive safety and operational practices to reduce risks related to process upsets, equipment failure, and safety system malfunctions.
• Enhance situational awareness and decision-making skills to improve plant safety, reliability, and product quality

Day 1: Introduction to LPG Plant Processing & Basic Troubleshooting

• Overview of LPG Plant Processes:
• Feed gas treatment, LPG fractionation, and product recovery
• Key Process Fluids & Their Characteristics
• Troubleshooting Fundamentals:
• Common operational issues
• Importance of process monitoring and instrumentation
• Safety Hazards & Precautions in LPG Plants:
• Fire, explosion, toxic releases
• Personal protective equipment (PPE) and safety protocols

Day 2: Equipment & Process Control in LPG Plants

• Major Equipment & Their Troubleshooting:
• Compressors, condensers, separators, fractionation columns
• Process Control & Optimization:
• Role of SIS & DCS/BMS
• Interlocks and safety controls
• Troubleshooting Methods:
• Identifying root causes of process deviations
• Use of alarms and logs
• Safety System Management:
• Proper operation of BMS and interlocks
• Preventing false trips and system failures

Day 3: Troubleshooting Techniques & Process Upset Management

• Handling Common Process Upsets:
• Feed variability, temperature, pressure fluctuations
• Equipment Malfunctions:
• Compressor issues, valve failures, blockages
• Troubleshooting for Gas Quality & Off-spec Gas:
• Monitoring, corrective actions
• Practical Troubleshooting Scenarios:
• Case studies and group exercises

Day 4: Safety Hazards & Emergency Response

• Detailed Overview of LPG Safety Hazards:
• Flammable vapors, toxic releases, cryogenic risks
• Managing Safety Systems:
• BMS, interlocks, emergency shutdowns
• Emergency Response Procedures:
• Evacuation, leak control, fire extinguishing
• Operator Role in Safety:
• Maintaining situational awareness
• Reporting and documenting incidents

Day 5: Operational Discipline, Risk Reduction & Continuous Improvement

• Strategies for Improving Plant Reliability & Gas Quality
• Operator Confidence & Response Drills:
• Normal operations, alarms, emergency scenarios
• Cost Reduction & Risk Management:
• Preventive maintenance, process audits
• Cultivating a Safety Culture:
• Behavioral safety, reporting hazards
• Final Review & Practical Exercise:
• Troubleshooting simulation and Q&A

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