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Course Code
OGCM-052
Process Plant Operations & Troubleshooting
- The Training Course provides professionals with the advanced analytical skills, structured methodologies, and engineering insight necessary to address operational issues with confidence and precision. Organizations require more than technical knowledge, they need teams capable of identifying root causes quickly, preventing recurring failures, and sustaining safe and stable operations. The course covers the various process control, operations and instrumentation methods such as pressure measurement, level measurement, temperature measurement, flow measurement, basic principles of control systems, wiring schematics & diagrams, control valves and process considerations.
Learning Outcomes
- Apply structured troubleshooting methodologies for recurring and complex engineering problems
- Develop a structured approach to Troubleshooting and Problem Solving this uses a common terminology and shared understanding
- Use analytical tools to identify failure patterns, performance gaps, and operational risks
- Strengthen continuous improvement practices to optimize equipment reliability and process stability
- Apply teamwork, communication, and leadership principles that support collaborative problem solving
- Distinguish clearly between proactive and reactive approaches and understand their operational consequences
- Recognize human-factor influences that affect troubleshooting quality and operational outcomes
- Understand work practices which allow success in Troubleshooting and Problem Solving through reducing the variability of your process?
- Translate engineering problem-solving techniques into actionable, plant-focused solutions
- Understand the difference between having a techniques manual on the bookshelf and actually making it work
- Identify the motivated people who should be the champions of Troubleshooting and Problem Solving and who should just follow
Course Contents
- Process plant and machinery specific issues
- Performance (impacting factors, performance defined in terms of speed, quality, and cost)
- Cross functional problem solving
- Development of maintenance strategy
- Life cycle analysis, design for operation, design for maintenance
- Leadership Development and Motivation of Operations Employees
- Strategies, planning, and protocols
- Organization and Roles
- Supplementary Topics
- Cost Estimation
- Spare Parts Planning
- Commissioning Strategy
- Mechanical Completion and Integrity Checking
- Pre-commissioning and Operational Testing
- Start-up Initial Operation, Testing and Acceptance
- Process Plant and Machinery Specific Issues
- Process Plant and Machinery Commissioning
- Instrumentation and Control Systems
- Preparing and Isolating Process Plant
- Management, Planning and Control
- A Short-cut Approaches to Planning
- Progress Monitoring and Control
- Earned Value Analysis
- Managing Risks during Commissioning
- Trouble Shooting and Problem Solving
- Risk Management
- Managing Safety and Quality
- The nature of process problems affecting performance
- Performance defined in terms of generic variables: Speed, Quality and Cost
- Effort inputs in context – Asset based or Business Process based
- Structured approach – The Operations Process redefined
- Configuration; Operation; and Optimization
- Maturity Indexing: Planning, Control, Congruence, Empowerment
- Tools and Techniques – Practical Experience
- Interactive and Dynamic variable relationships analysis
- Techniques introduction
- Introduction to the Theory of Inventive Problem Solving
- Auditing your process to a dynamic standard
- Effect of Maintenance Operations strategy
- Development of Standards and Key Performance Indicators
- Life Cycle Costing, Design for Operation, Design for Maintenance
- Problem Analysis
- Practical Use of Tools and Techniques
- Tools and Techniques – selecting the right one
- Working practices – empowerment or impairment?
- Group dynamics
- Individual motivators
- Developing Troubleshooting and Problem Solving skills
- Operator, Maintainer, Designer Interface
Our Methodology
- Make coaching and monitoring innovative and using modern
- Media training also using on the go training by using interactive means and focusing on
- The exercises, practical applications and real situations study
- Live delivery method, instructor-led training
- Experienced consultant, trainers, and professional
- Qualified trainer with high-level experience
Attendance Reports
- Send daily attendance reports to training departments
- Send full attendance report to training dep. by the end of the course
- Attend 100 % from the course days also provide daily
- Issue attendance certificate for participant who attend minimum 80% from the course duration
Pre/Post Reports
- Pre- assessment before starting training
- Post assessment after finishing training
- Full report for the difference between Pre-& Post assessment
Who Should Attend
- Supervisors who are involved in the Operations & Maintenance function
- Supervisors and team leaders managing day-to-day plant operations
- Engineers involved in troubleshooting, analysis, and performance optimization
- Production and process engineering personnel
- Maintenance Planners and Coordinators
- All technical staff supporting plant reliability
