Course Overview
This advanced training program equips process engineers, operators, and plant personnel with systematic methodologies to detect, diagnose, and resolve process upsets in oil & gas, petrochemical, and industrial facilities. Participants will learn root cause analysis techniques, real-time monitoring strategies, and corrective action implementation to minimize downtime and optimize plant performance.
Course Objectives
By the end of this course, participants will be able to:
✔ Identify early signs of process upsets (pressure surges, temperature deviations, flow instabilities)
✔ Apply structured troubleshooting methodologies (5 Whys, Fishbone Diagrams, Fault Tree Analysis)
✔ Interpret real-time process data (DCS trends, alarm floods, SCADA systems)
✔ Implement corrective actions to stabilize operations
✔ Prevent recurring upsets through process optimization and control system tuning
✔ Enhance safety during abnormal operating conditions
Who Should Attend?
✅ Process Engineers & Operations Engineers
✅ Control Systems Engineers & Instrumentation Technicians
✅ Plant Operators & Shift Supervisors
✅ Process Safety Engineers (PSEs)
✅ Maintenance Planners & Reliability Engineers
Course Outline
Module 1: Fundamentals of Process Upsets
- Definition & types of process upsets
- Common causes (equipment failure, control loop malfunctions, human error)
- Economic & safety impacts of unmanaged upsets
Module 2: Real-Time Monitoring & Early Detection
- Alarm management best practices (ISA-18.2)
- DCS/SCADA trend analysis
- Key performance indicators (KPIs) for upset detection
Module 3: Root Cause Analysis (RCA) Techniques
- 5 Whys Methodology
- Fishbone (Ishikawa) Diagrams
- Fault Tree Analysis (FTA)
- Bowtie Risk Assessment
Module 4: Troubleshooting Process Upsets
- Step-by-step diagnostic approach
- Pressure, temperature, and flow instability cases
- Distillation column & reactor upsets
Module 5: Control System Optimization
- PID tuning for upset recovery
- Cascade & override control strategies
- Anti-surge & compressor control
Module 6: Human Factors in Upset Management
- Operator response effectiveness
- Shift handover communication
- Stress management during emergencies
Module 7: Case Studies & Industry Lessons
- Refinery upset case (pressure swing)
- Gas plant trip analysis
- Pipeline surge event troubleshooting
Module 8: Preventive Measures & Continuous Improvement
- Debottlenecking strategies
- Process hazard analysis (PHA)
- Management of Change (MOC) for stability