Process Troubleshooting & Debottlenecking: Expert 5-Day Training Course

Course Overview

This intensive Process Troubleshooting and Debottlenecking training program delivers practical expertise for operations and engineering professionals across the Kingdom of Saudi Arabia (KSA), Oman, GCC countries (UAE, Qatar, Kuwait, Bahrain), and Africa. The course covers systematic troubleshooting methodologies, root cause analysis, capacity enhancement techniques, process optimization, and problem-solving strategies essential for maximizing plant performance, eliminating bottlenecks, and improving reliability in refineries, petrochemical plants, gas processing facilities, and chemical industries.

With the Middle East operating over $800 billion in refining and petrochemical assets and Africa’s expanding industrial sector, this training addresses critical competencies for professionals at Saudi Aramco, SABIC, PDO (Petroleum Development Oman), ADNOC, Ma’aden, OQ, Dangote, Sasol, and other operators seeking to increase throughput 10-30% without major capital investment, reduce downtime, and enhance operational excellence supporting Saudi Vision 2030 industrial efficiency goals.

Target Audience

• Operations Engineers managing refinery and petrochemical units

• Process Engineers troubleshooting performance issues

• Technical Supervisors leading operational improvement initiatives

• Plant Managers maximizing facility throughput and reliability

• Maintenance Engineers supporting process reliability

• Production Engineers optimizing unit performance

• Technical Consultants conducting plant performance audits

• Project Engineers evaluating debottlenecking investments

Day 1: Systematic Troubleshooting Methodology

Morning Session: Troubleshooting Fundamentals

• Troubleshooting definition: systematic problem identification and resolution

• Common plant problems: capacity limitations, product quality, efficiency losses, reliability issues

• Cost of poor performance: lost production, energy waste, off-spec products, unplanned shutdowns

• Systematic approach: define problem, gather data, analyze, develop hypotheses, test, implement solutions

• Troubleshooting vs. firefighting: proactive vs. reactive approaches

• Data collection: process data, laboratory results, inspection findings, historical trends

• Process variable analysis: temperatures, pressures, flows, levels, compositions

• Statistical methods: control charts, trend analysis, correlation studies

• Tools and techniques: fishbone diagrams, 5-Why analysis, fault trees, Pareto charts

• Case studies: Troubleshooting successes at Saudi Aramco refineries, ADNOC facilities

Afternoon Session: Root Cause Analysis (RCA)

• RCA methodology: identifying underlying causes vs. symptoms

• 5-Why technique: iterative questioning to reach root cause

• Fishbone (Ishikawa) diagrams: categorizing potential causes

• Fault tree analysis: logic diagrams for complex problems

• Apollo RCA: comprehensive causal analysis method

• Event timeline reconstruction for incident investigation

• Common root causes: design flaws, procedural gaps, equipment failures, operator errors, management systems

• Human factors: training, fatigue, communication failures

• RCA tools: Kepner-Tregoe, TapRooT®, Cause Map methodologies

• Documentation and corrective action tracking

• Preventing recurrence: systemic improvements, procedure updates, training programs

• Workshop: RCA exercise on refinery case study

Day 2: Equipment-Specific Troubleshooting

Morning Session: Distillation & Fractionation Troubleshooting

• Common distillation problems: poor separation, flooding, capacity limitations, excessive pressure drop

• Tray problems: damaged trays, plugged holes, fouled downcomers, bent components

• Packing issues: channeling, maldistribution, fouling, breakage

• Temperature profile analysis: identifying tray damage, feed location problems

• Pressure drop analysis: detecting fouling, flooding conditions

• Product quality issues: composition drift, off-spec products, contamination

• Flooding diagnosis: determining flood location (jet flood, downcomer flood, system limit)

• Entrainment problems: excessive carryover, foaming, surging

• Vapor-liquid maldistribution: liquid channeling, vapor bypassing

• Condenser and reboiler problems affecting column performance

• Diagnostic tools: gamma scans, temperature surveys, tray inspection

• Case studies: Crude column troubleshooting (Ras Tanura), FCC fractionator issues (SATORP)

Afternoon Session: Heat Exchanger & Reactor Troubleshooting

• Heat exchanger problems: fouling, tube failures, performance degradation, vibration

• Fouling detection: monitoring heat transfer coefficient decline

• Tube-side vs. shell-side issues: differential diagnosis techniques

• Vibration problems: causes, detection, mitigation strategies

• Temperature approach monitoring: identifying performance loss

• Air-cooled exchanger problems: fan issues, hot spots, recirculation (critical in GCC heat)

• Reactor troubleshooting: conversion loss, selectivity decline, runaway reactions

• Catalyst deactivation: coking, poisoning, sintering, attrition

• Hot spots and cold spots: temperature distribution problems

• Pressure drop increase: catalyst fouling, particle size degradation

• FCC reactor-regenerator issues: catalyst circulation, air distribution, temperature control

• Catalyst loss, afterburn, poor regeneration efficiency

• Furnace problems: flame impingement, tube coking, efficiency loss

• Workshop: Heat exchanger fouling analysis and corrective actions

Day 3: Process Debottlenecking Fundamentals

Morning Session: Identifying and Analyzing Bottlenecks

• Bottleneck definition: limiting factor constraining plant capacity

• Types: equipment capacity, process constraints, utility limitations, operational restrictions

• Bottleneck identification techniques: process mapping, constraint analysis, data review

• Theory of Constraints (TOC): identifying and exploiting bottlenecks

• Capacity analysis: design vs. actual throughput, utilization factors

• Equipment rating: pumps, compressors, columns, heat exchangers, reactors

• Process simulation: modeling current operations, identifying constraints

• Using Aspen HYSYS, Aspen Plus for capacity analysis in GCC facilities

• Utility constraints: steam, power, cooling water, instrument air limitations

• Storage and logistics bottlenecks affecting throughput

• Economic prioritization: high-value vs. low-value debottlenecking opportunities

• Case studies: Capacity analysis at Sohar Refinery, SABIC petrochemical debottlenecking

Afternoon Session: Debottlenecking Strategies

• Low-cost debottlenecking: operational changes, control optimization, procedural improvements

• Medium-cost: minor modifications, equipment additions, process changes

• High-cost options: major equipment replacement, unit expansion, grassroots capacity

• Operational debottlenecking: optimizing parameters, reducing safety margins, improving efficiency

• Feed quality management: preprocessing, blending strategies

• Control system optimization: APC implementation, constraint management

• Pushing operating envelopes safely: temperature, pressure, flow rate increases

• Equipment modifications: larger nozzles, improved internals, additional trays/packing

• Adding parallel equipment: pumps, compressors, heat exchangers

• Hydraulic improvements: reducing pressure drop, improving flow distribution

• Revamp considerations: maintaining operations during modifications

• Quick wins: immediate improvements with minimal investment

• Workshop: Developing debottlenecking options for refinery crude unit

Day 4: Advanced Troubleshooting & Optimization

Morning Session: Compressor & Pump Troubleshooting

• Centrifugal compressor problems: surge, performance degradation, vibration, seal failures

• Compressor performance curves: head-flow characteristics, efficiency

• Surge detection and prevention: anti-surge control, recycle systems

• Fouling effects: reduced capacity, efficiency loss, increased power consumption

• Vibration analysis: mechanical issues, aerodynamic instabilities

• Reciprocating compressor problems: valve failures, capacity loss, pulsation

• Pump troubleshooting: cavitation, low flow, excessive vibration, seal leaks

• NPSH (Net Positive Suction Head) issues: cavitation damage, performance loss

• Impeller wear and damage: reduced performance, efficiency decline

• Alignment and mechanical seal problems affecting reliability

• Performance testing: establishing baselines, monitoring degradation

• Case studies: Compressor troubleshooting at PDO gas plants, pump issues in Saudi refineries

Afternoon Session: Control System & Instrumentation Issues

• Control loop problems: oscillations, sluggish response, instability

• PID tuning issues: proportional, integral, derivative parameter optimization

• Instrumentation failures: transmitter drift, analyzer problems, valve issues

• Control valve problems: sticking, undersizing, poor characteristics

• Cascade control troubleshooting: master-slave loop interactions

• Advanced control issues: MPC controller degradation, model mismatch

• DCS problems: configuration errors, communication failures, hardware issues

• Interlock and safety system troubleshooting

• Analyzer reliability: gas chromatographs, online analyzers, sampling systems

• Common problems in GCC harsh environments: heat, dust, humidity effects

• Process variable selection: ensuring controllability and observability

• Workshop: Control loop troubleshooting simulation exercises

Day 5: Practical Problem-Solving & Performance Optimization

Morning Session: Energy Efficiency Troubleshooting

• Energy inefficiency symptoms: high fuel consumption, utility overuse, heat losses

• Furnace efficiency problems: excess air, stack losses, burner issues

• Steam system inefficiencies: leaks, steam traps, condensate recovery

• Heat exchanger network optimization: improving integration, reducing utilities

• Cooling water system issues: fouling, corrosion, biological growth (critical in GCC)

• Air-cooled exchanger optimization in high ambient temperatures (50°C+)

• Compressor efficiency: intercooler fouling, valve problems, performance degradation

• Power consumption analysis: identifying high consumers, optimization opportunities

• Flare minimization: reducing hydrocarbon losses, emissions, wasted energy

• Insulation problems: heat loss, personnel safety, economics

• Energy monitoring systems: identifying anomalies, trending efficiency

• Case studies: Energy optimization at YASREF, ADNOC Ruwais efficiency improvements

Afternoon Session: Integrated Problem-Solving Workshop

• Real-world troubleshooting scenarios: refinery, petrochemical, gas processing cases

• Team-based problem-solving exercises simulating actual GCC operations

• Case 1: Crude distillation unit capacity limitation - Saudi Arabia refinery

• Analyzing symptoms, identifying root causes, proposing solutions

• Case 2: FCC unit performance decline - UAE petrochemical complex

• Product quality issues, catalyst problems, operational optimization

• Case 3: Gas compression train surge problems - Oman gas processing

• Operational constraints, control issues, mechanical factors

• Case 4: Heat exchanger network fouling - African refinery

• Energy efficiency loss, cleaning strategies, prevention measures

• Debottlenecking economics: cost-benefit analysis, prioritization, implementation planning

• Presenting recommendations: technical justification, economic evaluation, risk assessment

• Continuous improvement culture: sustaining gains, performance monitoring, knowledge management

• Best practices from Saudi Aramco operational excellence, ADNOC performance management

• Group presentations: Teams present troubleshooting analyses and recommendations

• Expert feedback and discussion of alternative approaches

Learning Outcomes

Upon completion, participants will be able to:

• Apply systematic troubleshooting methodologies solving complex operational problems

• Conduct root cause analysis identifying underlying issues vs. symptoms

• Diagnose equipment-specific problems in distillation, heat exchangers, reactors, rotating equipment

• Identify process bottlenecks constraining plant capacity and throughput

• Develop debottlenecking strategies achieving 10-30% capacity increases cost-effectively

• Optimize energy efficiency reducing fuel consumption and utility costs

• Troubleshoot control systems and instrumentation issues affecting performance

• Conduct economic analysis prioritizing improvement projects for maximum ROI

• Build troubleshooting capability within operations teams

Course Delivery & Certification

• Format: Interactive lectures, case studies, hands-on workshops, team exercises, simulation tools

• Real cases: Actual troubleshooting examples from Saudi Aramco, ADNOC, PDO, SABIC facilities

• Materials: Comprehensive manual, troubleshooting checklists, diagnostic flowcharts, case study library

• Certification: Professional certificate recognized across KSA, Oman, UAE, Qatar, Kuwait, Bahrain, Africa

• Language: English (Arabic support available)

• CPD Credits: Continuing professional development for operations and process engineers

• Locations: Riyadh, Dhahran, Jubail, Yanbu (KSA), Muscat, Sohar (Oman), Dubai, Abu Dhabi, Doha, Lagos, Cairo

Why This Course is Essential

GCC refineries and petrochemical plants operate at high utilization rates with minimal spare capacity. Even 5-10% throughput increases through debottlenecking generate millions in additional revenue. Saudi Aramco’s refineries process 2.9 million bpd—capturing lost capacity through troubleshooting delivers massive value. Unplanned downtime costs $500,000-$5 million per day. Effective troubleshooting reduces incidents, improves reliability, enhances safety.

This training delivers battle-tested methodologies from world-class operators, incorporating Saudi Aramco operational excellence, ADNOC best practices, addressing specific GCC challenges: extreme heat effects, heavy crude processing, sour gas handling, aging assets, supporting Saudi Vision 2030 industrial competitiveness through operational efficiency and reliability.

Solve problems faster. Increase capacity. Maximize profitability.