:: DEFINE | Management Consultancy & Training Provider In UAE, Abu Dhabi,Dubai,Saudi Arabia ::

APPLY RCA METHODS ON OIL & GAS FACILITIES

Location

Dubai, UAE

Date

From Date: 21-Jul-2025
To Date: 25-Jul-2025

Duration

5 days

Language

ENGLISH

Discipline

PROCESS ENGINEERING, WATER DESALINATION & CHEMICAL ENGINEERING

Introduction

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 includes both sample problems as well as problem working sessions to allow the participants to develop confidence with this approach.

The attendees are encouraged to bring real problems that they are working to use in discussions on the last day of the seminar. These problems should be of a non-confidential nature and can be discussed without violation of any confidentiality restrictions.

Objective

Upon the 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 consequences of accident

Audience

This course is intended for supervisors / Engineers / Senior operators / Operators / Process engineers.

Content

TOPICS COVERED

Preventive, predictive and corrective maintenance on centrifugal pumps; new pump models introduced in KOC; type of pumps, pumps components ,pumps selection , operating philosophy , trouble shooting, service, maintenance and major repair of pumps, review and update equipment clearance data sheet; hands on training on maintenance (overhaul) of single and multistage pumps, repair procedures for pump parts, pump alignment, reconditioning dry seals, bearing technology (including white metal bearing technology).

COURSE OUTLINE

DAY 1

Introduce Process Troubleshooting Philosophy

Trouble Shooting Objective
Problem Solving Concepts
IPO Chart “input-process-output (IPO) model”
What is a PROBLEM
Common process abnormalities
Investigate, identify & apply corrective action
What happens when bad decisions are made?
Six steps to ensure a Best decision in problem solving (PS)
Approaches to solve a problem:
1. Algorithmic 2. Heuristic
Process Troubleshooting Philosophy
Cause Effect Diagram 4M
TROUBLE SHOOTING IN THE PROCESS INDUSTRIES
TROUBLE SHOOTING APPLIES SIX-STEP PROBLEM SOLVING METHOD

CLASS EXAMPLE: Let’s discuss this process with preheat, packed bed reaction, and effluent cooling

DAY 2

Leadership

The Definition of Leadership
What are important Leadership personality traits?
7 Secrets of Leadership Success
HSE MANAGEMENT SYSTEM (HSEMS)
The leadership barriers
What are management and leadership?
Qualities of leadership
Leaders' Top Three Mistakes

Risk Assessment& Management

Definitions
What is a risk assessment?
Why is the risk assessment important?
Hazards Identification (HAZID)
Conduct a preliminary job review Meeting
5 Steps Of Risk Assessment
Likelihood (Probability)& Impact (Severity)
Likelihood Rating Guidance
SEVERITY Rating Guidance
Risk Ranking
Risk Management
Risk Control “Engineering, Administrative& Personal Protective Equipment”

DAY 3

Root Cause Analysis (RCA)

Root Cause analysis Tools:

Ishikawa Charts (Fish Bone)
Design of Experiments
Is / Is not Analysis
5 Why’s
Cause & Effect Diagram.
Statistical Data Analysis (Cpk, Paretto Charts, Anova,etc…)

Failure Mode and Effect Analysis

FMEA Origination
The different types FMEA
FMEA’s Link with Continuous Improvement
FMEA Worksheet
Why we use FMEA.
When to use FMEA
Potential Applications of FMEA
Steps on completing FMEA

Problem Solving& Decision Making

Investigate, identify
6 C’s of Decision Making
Decision Making Process
Decision Making Process Example
Why is Intuition
Decision Making Conditions
Decision Making Style
Common Decision Making Errors
Characteristic of an Decision Making Effectiveness
Apply corrective action

DAY 4

Management Of Change (MOC)

Why we make Changes?
Administrative Change
Organizational Change
Technical Change
MOC Policy
MOC Program
MOC Procedure
Process Modification
Process Change
PFCP “Process & Facilities Change Proposal”
Why MOC is necessary
PSSR “ Pre Startup Safety Review”

Case study: “SPIRAL TO DISASTER”

HAZOP “Hazards& Operability Studies”

Introduction
The HAZOP Concept
The HAZOP team
Team members and responsibilities
When to perform a HAZOP
Types of HAZOP
HAZOP procedure
Modes of operation
Examples of process parameters
The basic HAZOP guide-words
HAZOP Node

Class Example: “Fired Heater”

DAY 5

Maintenance Management

Maintenance Engineering Objectives
Maintenance Terms And Definitions
Preventive Maintenance
Objectives of PM
Failure Of PM Programs In Maintenance Organizations
Why Do Plant Needs Preventive Maintenance Program
Typical Human Behaviors
Maintenance KPI’s

Note:

Pre & Post Tests will be conducted

Case Studies, Group Exercises, Group Discussions, Last Day Review & Assessments will be carried out.

…………………………………………….

Certificate

Define Management Consultancy & Training Certificate of course completion will be issued to all attendees.

Methodology

A highly interactive combination of lectures and discussion sessions will be managed to maximize the amount and quality of information and knowledge transfer. The sessions will start by raising the most relevant questions and motivating everybody to find the right answers. You will also be encouraged to raise your questions and to share in the development of the right answers using your analysis and experiences. Tests of the multiple-choice type will be made available daily to examine the effectiveness of delivering the course.

Very useful Course Materials will be given.

30% Lectures
30% Workshops and work presentation
20% Group Work& Practical Exercises
20% Videos& General Discussions

Course Details