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Objectives

• By the end of this Course participants will be able to:
• Apply and gain an in-depth knowledge of process upsets, troubleshooting, and optimization.
• Identify the types, common causes, and examples of process upsets across various industries.
• Discuss the safety implications, environmental impact, and economic consequences of process upsets.
• Implement a systematic approach to problem-solving, effective data collection, and data analysis.
• Identify common issues with pumps, compressors, and heat exchangers, and utilize diagnostic techniques and tools.
• Discuss control loops and instrumentation, diagnose control system issues, and recognize common issues in chemical reactions and separation processes.
• Diagnose chemical process issues and apply root cause analysis (RCA) and fault tree analysis (FTA).
• Discuss the impact of human error on process upsets and various strategies to mitigate human error.
• Apply process optimization, cost-benefit analysis, economic optimization, and techniques for optimizing energy use in processes.
• Explain Six Sigma methodology and Lean principles and their application to process optimization.
• Recognize statistical process control (SPC), design of experiments (DOE), and optimization of chemical reactions.
• Apply heat integration, energy recovery and reuse, process intensification, and sustainability in process optimization.
• Develop an integrated troubleshooting and optimization plan, identify and manage risks, and create contingency plans for process upsets.
• Employ strategies for successful implementation, monitor and measure improvements, and utilize tools and techniques for maintaining process gains.
• Discuss the importance of teamwork in troubleshooting and optimization and apply effective communication strategies.

The Delegates

• Process engineers, production engineers, plant engineers, and planning engineers.
• Engineering and Technical Managers and Supervisors from any industry .
• Maintenance Planners and Coordinators .
• Operations and Manufacturing Managers and Supervisors .
• Foremen and Team Leaders .
• Plant Engineers and Process System Managers .
• Section Engineers and Planners .
• However, anyone involved in process upsets, troubleshooting and optimization such as managers, leaders, section heads, superintendents and supervisors can highly benefit from this training too .

The Contents

• Introduction to Process Upsets & Troubleshooting
• Fundamentals of Process Upsets
• Definition & Types of Process Upsets
• Common Causes & Examples of Process Upsets in Various Industries
• Impact of Process Upsets
• Safety Implications
• Environmental Impact
• Economic Consequences
• Troubleshooting
• Basic Principles of Troubleshooting
• Systematic Approach to Problem-Solving
• Data Collection & Analysis
• Importance of Data in Troubleshooting
• Techniques for Effective Data Collection
• Tools for Data Analysis (e.g., Statistical Methods, Root Cause Analysis)
• Case Studies: Real-World Examples of Process Upsets
• Analysis of Past Incidents
• Lessons Learned & Best Practices
• Troubleshooting Process Equipment
• Identifying Common Issues with Pumps, Compressors, & Heat Exchangers
• Diagnostic Techniques & Tools
• Troubleshooting Process Control Systems
• Understanding Control Loops & Instrumentation
• Techniques for Diagnosing Control System Issues
• Troubleshooting Chemical Processes
• Common Issues in Chemical Reactions & Separation Processes
• Techniques for Diagnosing Chemical Process Issues
• Root Cause Analysis (RCA)
• Introduction to RCA Methodologies (e.g., Fishbone Diagram, 5 Whys)
• Practical Application of RCA
• Fault Tree Analysis (FTA)
• Understanding FTA & Its Applications
• Building & Analyzing Fault Trees
• Human Factors in Troubleshooting
• Impact of Human Error on Process Upsets
• Strategies to Mitigate Human Error
• Process Optimization
• Definition & Objectives of Process Optimization
• Key Concepts & Principles
• Economic Optimization
• Understanding Cost-Benefit Analysis
• Techniques for Economic Optimization (e.g., Break-Even Analysis,Marginal Cost Analysis)
• Energy Optimization
• Importance of Energy Efficiency
• Techniques for Optimizing Energy Use in Processes
• Six Sigma & Lean Principles
• Overview of Six Sigma Methodology
• Lean Principles & their Application to Process Optimization
• Case Studies: Successful Process Optimization Projects
• Review of Real-World Optimization Projects
• Analysis of Strategies & Outcomes
• Statistical Process Control (SPC)
• Introduction to SPC & Control Charts
• Application of SPC in Process Optimization
• Design of Experiments (DOE)
• Understanding DOE Methodology
• Application of DOE for Process Optimization
• Optimization of Chemical Reactions
• Techniques for Optimizing Reaction Conditions
• Catalysts & their Role in Process Optimization
• Heat Integration & Energy Recovery
• Principles of Heat Integration
• Techniques for Energy Recovery & Reuse
• Process Intensification
• Introduction to Process Intensification
• Techniques & Technologies for Intensifying Processes
• Sustainability & Green Chemistry
• Principles of Sustainability in Process Optimization
• Application of Green Chemistry Principles
• Developing an Integrated Troubleshooting & Optimization Plan
• Combining Troubleshooting & Optimization Techniques
• Steps to Develop a Comprehensive Plan
• Risk Management & Contingency Planning
• Identifying & Managing Risks
• Developing Contingency Plans for Process Upsets
• Implementing Process Improvements
• Strategies for Successful Implementation
• Monitoring & Measuring Improvements
• Continuous Improvement
• Principles of Continuous Improvement
• Tools & Techniques for Maintaining Process Gains
• Team Collaboration & Communication
• Importance of Teamwork in Troubleshooting & Optimization
• Effective Communication Strategies

Course assessment  .

The Discount

Free Seats Are Offered