Advanced Troubleshooting and Engineering Solutions for Refinery Plants

Introduction:

The program entitled “Advanced Portfolio of Refinery Plant Troubleshooting and Engineering Solutions” is devoted to specialists who wish to expand their operations concerning solving refinery problems, particularly involving engineering. In the operational environment of a refinery, challenges such as process troubles, equipment dysfunctions, and operational faults arise frequently.

This course will enable participants to acquire and apply sophisticated troubleshooting techniques. By combining various styles, participants will be able to identify complex issues, implement effective troubleshooting measures, and develop mechanisms to enhance plant performance.

Supporting topics will include troubleshooting tools and techniques for complex problems, advanced troubleshooting implementation, and practitioner-based engineering approaches tailored to refinery processes. Simulated exercises, case studies, and hands-on practice will provide practical exposure to address the myriad challenges faced by participants.

At the end of the course, participants will be equipped with knowledge and skills in advanced troubleshooting techniques and basic engineering fundamentals, significantly improving refinery operations. Attend the course to enhance your skills and make a difference in refinery plant performance.

Objectives:

At the end of this course, participants will be able to:

• Master advanced procedures for Root Cause Analysis related to refinery processes.
• Understand and apply various methods for assessing equipment breakdowns.
• Identify inefficiencies using process analysis techniques.
• Utilize engineering skills to improve operational effectiveness.
• Employ root cause analysis in troubleshooting processes.
• Develop capabilities in process control and optimization.
• Measure and manage performance metrics effectively.
• Integrate safety and compliance into troubleshooting efforts.
• Foster critical reasoning and decision-making skills.
• Apply knowledge through case studies to acquire essential skills.
• Use system integration and improvement techniques.
• Develop maintenance procedures to reduce machinery downtime.
• Write and present technical reports proficiently.
• Implement a structured approach to problem-solving.
• Enhance operational reliability and efficiency in a refinery.

Training Methodology:

• Case Studies
• Group Discussions
• Workshops
• Simulations
• Problem-Solving Sessions
• Interactive Question and Answer

Course Outline:

Unit 1: Advanced Troubleshooting Techniques

• General description of advanced troubleshooting methods.
• Sequence of activities for identifying problems and diagnosing process or equipment issues.
• Features and usage of diagnostic equipment.
• Procedures for diagnostic interpretation and identifying issues.
• Root cause diagnosis procedures.
• Tools for troubleshooting in high-risk operational conditions.
• Practical sessions on using diagnostic tools and software.
• Real troubleshooting practice.
• Formulation of sequential troubleshooting approaches.
• Tools for assessing and reporting troubleshooting outcomes.

Unit 2: Analysis and Optimization of Work Processes

• Familiarization with modern work process analysis.
• Techniques for evaluating and quantifying processes.
• Identification of non-value-added activities or bottlenecks.
• Application of process simulation/models for enhancement.
• Methodologies for improving process dependability and control.
• Case studies on developing new process improvement programs.
• Portfolio of completed optimization projects.
• Participatory practices in process analysis and improvement.
• Approaches for measuring results of process changes.
• Development of action plans for continual work process improvement.

Unit 3: Equipment Failure Diagnosis

• Categories of failing equipment in refinery operations.
• Residual heat diagnosis of equipment and systems.
• Methods for determining root causes of malfunctions.
• Tactics for addressing equipment breakdowns and minimizing downtime.
• FMEA (Failure Mode and Effects Analysis) workshop.
• Examples of successfully managed equipment failures.
• Physical examination and diagnosis of equipment faults.
• Strategies for developing preventive and predictive maintenance programs.
• Techniques for improving equipment reliability and performance.
• Documentation and reporting on equipment failure analysis.

Unit 4: Engineering Solutions and Process Control

• Basic principles of engineering problem-solving for process control.
• Advanced control systems and their applications.
• Managing execution processes of engineering projects and evaluating control systems.
• Incorporating new solutions into existing systems.
• Engineering solutions and their implications for refinery operations.
• Designing, testing, and improving control systems.
• Procedures for assessing technical solutions.
• Directions for enhancing control processes.
• Principles of control systems and their implementation.
• Repair techniques for malfunctioning control systems.

Unit 5: Safety and Compliance, Performance Assessment

• Importance of safety and regulation in refinery operations.
• Laboratory practices related to safety regulations and policies.
• Techniques for tracking and assessing operational performance indicators.
• Integrating safety into engineering and troubleshooting aspects.
• Case studies of safety incidents and compliance management.
• Effective safety management strategies for operational improvement.
• Measures for assessing compliance with operational goals.
• Development of safety and performance programs.
• Approaches for maintaining surveillance and evaluation of safety and performance.