Process Plant Troubleshooting & Optimisation

Introduction

Process plants in petrochemical, chemical, and refining industries operate under complex conditions where equipment behaviour, process deviations, and operational changes can significantly impact safety, efficiency, and product quality. Engineers and operators must be able to diagnose problems quickly, understand root causes, and implement corrective actions that restore stability and optimise performance.

This course equips participants with structured troubleshooting methodologies, process deviation analysis, equipment behaviour interpretation, optimisation strategies, and real‑world case studies. It is designed to build strong operational judgement and enhance plant reliability.

The GTMCS Process Plant Troubleshooting & Optimisation course delivers a practical, industry‑aligned, and competency‑focused learning experience.

This Training Course Will Highlight

Troubleshooting logic models

Process deviation analysis

Root cause analysis

Equipment behaviour under upset conditions

Process optimisation strategies

Heat & mass transfer issues

Reaction & separation problems

Operational discipline

Course Benefits

Strengthen troubleshooting capability

Improve process stability & reliability

Enhance operational decision‑making

Build confidence in diagnosing equipment & process deviations

Support optimisation of throughput, energy, and product quality

Align workforce with best practices in process operations

Tools & Techniques Covered

Troubleshooting frameworks

RCA tools (5 Whys, Fishbone, Fault Tree)

Process data interpretation

Heat/mass transfer diagnostic tools

Reaction & separation performance analysis

Optimisation methodologies

Practical Workshops

Troubleshooting simulation

Process deviation analysis

Equipment behaviour interpretation

Heat/mass transfer case studies

Optimisation strategy development

Real‑World Case Studies

Distillation column flooding due to tray damage

Reactor conversion drop caused by catalyst deactivation

Heat exchanger fouling reducing throughput

Compressor surge affecting downstream units

Pump cavitation due to improper flow conditions

Industry Relevance

This course is essential for:

Process engineers

Operations & production teams

Maintenance & reliability professionals

HSSE & process safety teams

Supervisors & technical leaders

Future Skills Alignment

Troubleshooting competency

Process optimisation

Operational discipline

Equipment behaviour understanding

Industrial problem‑solving

Objectives

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

Apply structured troubleshooting methodologies

Analyse process deviations & abnormal conditions

Interpret equipment behaviour under upset scenarios

Diagnose heat/mass transfer, reaction & separation issues

Implement optimisation strategies for improved performance

Support safe & efficient plant operations

Certificates

Upon successful completion of this training course, participants will receive a GTMCS Certificate of Completion.