Course Description

This 5-day course is designed to provide a structured approach to diagnosing and resolving technical and operational issues within process plants. The program emphasizes systematic troubleshooting techniques, root cause analysis, and engineering-based problem solving for complex industrial systems. Participants will develop the analytical thinking skills needed to identify and resolve process inefficiencies, equipment malfunctions, and system bottlenecks, all within the framework of safety, productivity, and reliability. The course delivers best practices and conceptual methods ideal for engineering and operations teams looking to strengthen their problem-solving capabilities.

Course Objectives

Upon the successful completion of this course, each participant will be able to:

  • Understand structured methodologies for troubleshooting process plant issues
  • Apply root cause analysis (RCA) techniques to diagnose recurring problems
  • Use systems-thinking approaches to assess engineering problems holistically
  • Analyze typical process-related failures in fluid systems, heat exchangers, pumps, and valves
  • Interpret process data and trends to detect abnormal conditions
  • Propose corrective and preventive measures based on theoretical frameworks
  • Enhance collaboration between engineering, operations, and maintenance teams through a shared problem-solving approach

Who Should Attend?

This course is designed for professionals involved in the design, operation, and maintenance of process plants.

Course Agenda

Day 1

Registration, Welcome & Introduction

Pre-Test

Foundations of Troubleshooting in Process Plants

  • Nature and complexity of plant troubleshooting
  • Principles of structured problem-solving
  • Common causes of plant failures and upsets
  • Difference between symptoms and root causes
  • Importance of historical data and system knowledge

Day 2

Root Cause Analysis & Diagnostic Techniques

  • Introduction to RCA tools: 5 Whys, Fishbone Diagrams, Fault Tree Analysis
  • Failure Modes and Effects Analysis (FMEA)
  • Use of logic trees and event chains in analysis
  • Troubleshooting under uncertainty and time constraints
  • Team-based problem solving vs. individual troubleshooting

Day 3

Process Equipment Troubleshooting

  • Conceptual failure analysis of pumps, compressors, valves, and piping
  • Heat exchanger issues: fouling, flow restrictions, temperature imbalance
  • Flow-related problems: cavitation, surging, slugging
  • Vibration, noise, and thermal anomalies — diagnostic perspectives
  • Interpreting process indicators and trends (temperature, pressure, flow)

Day 4

Systematic Problem Solving in Operations

  • Systems thinking in engineering problem solving
  • Case-based examples from chemical, oil & gas, and power plants
  • Troubleshooting continuous vs. batch processes
  • Process control-related troubleshooting (loops, sensors, controllers)
  • Human factors and decision-making in plant incidents

Day 5

Preventive Strategies & Lessons Learned

  • How to design out common failures (engineering prevention approaches)
  • Knowledge retention and incident reporting systems
  • Using theoretical case studies to drive continuous improvement
  • Troubleshooting process documentation and communication
  • Course review, Q&A, and development of personal action plans

Post-Test

End of the Course

Assessment Methodology

All courses conducted by EdTech will begin with a Pre-evaluation and end with a Post-evaluation. The instructor will evaluate the knowledge and skills of the participants according to the feedback given by participants. This will help to recognize the benefits and the level of knowledge gained by participants through the course.

Training Methodology

Facilitated by a highly qualified specialist, who has extensive knowledge and experience; this program will be conducted using extensively interactive methods, encouraging participants to share their own experiences and apply the program material to real-life work situations in order to stimulate group discussions and improve the efficiency of the subject coverage.

Percentages of the total course hour classification are:

  • ​40% Theoretical lectures, Concepts and approach
  • 20% Motivation to develop individual skill and Techniques
  • 20% Case Studies and Practical Exercises
  • 20% Topic General Discussions and interaction

Course Manual

Participants will be provided with comprehensive presentation material as reference manual. This presentation material is a compilation of core valuable information, references, presentation methods and inspiring reading which will be used as a part of the material guide.

Course Certificate

At the completion of the course, all participants who successfully accomplished the required contact hours will receive an EdTech Training Participation Certificate as a testimony to their commitment to professional development and further education.

Why Edtech ?

  • Industry Experienced; Internationally Qualified Trainers
  • Hands-on Practical Sessions & Assignments
  • Intensive Study materials
  • Flexible Schedules
  • Realistic training methodology
  • High-Quality Training in Affordable Course Fees
  • Achievement Certificate, as approved by the Ministry of Education (Abu Dhabi Center for Technical and Vocational Education Training - ACTVET), HABC, AWS, IAOSHE, SHRM, etc.