PERFORM ROOT CAUSE ANALYSIS FOR PROCESS UPSET

Course Properties

Course date: 05-11-2017
Course End Date: 09-11-2017
Location Sharm El-Sheikh

COURSE DESCRIPTION

   Modern industrial processes are large and complex. This makes problem finding and solving very difficult. Problems often disappear without being solved only to reappear again. So, finding and solving process problems is one of the most important operations and tasks in the industry.

   Root Cause Analysis (RCA) is a structured, team based, analytical approach that when used correctly can alleviate recurring problems within an organization. In this course, participants will learn to apply several practical, systematic methods for analyzing incidents and problems to uncover root causes. Understanding of these techniques will be reinforced by exercises as we explore effective ways of gathering data for root cause analysis and how to determine which problems should be analyzed. We will also discuss how to design, develop, and implement a root cause analysis program for your organization.


COURSE OBJECTIVE

     Upon successful completion of this course, participants should be able to:

              • Enhance problem solving effectiveness by providing a model for more deeply analyzing problem situations.

              • Clarify the difference between analytical and creative thinking, and when each is most useful.

              • Promote the ability to provide problem-solving support in situations where one is not an expert in the process

                  or technology involved.

              • Expand the range of tools available for analysis of problem situations.

              • Learn how to initiate a root cause analysis and gather data for investigating process incidents.

              • Demonstrate how to collect data through interviews and analysis.

              • Apply powerful techniques to identify and know the difference between symptoms and root causes.

              • Learn to know when to use the appropriate technique in root cause identification.

              • Learn how to avoid future incidents by developing appropriate recommendations to address causal factors

                   and root causes.

              • Develop a structured approach to troubleshooting and problem solving which uses a common terminology

                   and shared understanding.

              • Point the way to continuous improvement in the way to run the processes and make incremental efficiency gains.

              • 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.

              • Understand work practices which allow success in troubleshooting and problem solving.

              • Review and verify operational reports to build on in solving problems.

              • Measure equipment/ facility performance and identify discrepancies from the optimum/ design.

WHO SHOULD ATTEND

   This course  is ideal for personnel involved in process plant operations, troubleshooting, process engineers, senior process engineers, technical staff, plant supervisors, maintenance staff who are involved in troubleshooting and problems solving activities, contractor personnel involved in project execution and plant start-up as well as others providing services to the petroleum industry, should also find this program beneficial.

TRAINING METHODOLOGY

   A highly interactive combination of lecture and discussion sessions will be managed to maximize the amount and quality of information, knowledge and experience transfer. The sessions will start by raising the most relevant questions, and motivate everybody finding the right answers. The attendants will also be encouraged to raise more of their own questions and to share developing the right answers using their own analysis and experience.


COURSE OUTLINE

              - Course Opening and Pre-assessment

              -  Introduction and Objectives

                                What is a "Problem?"

                                Why Problems Persist

                                What is A Root Cause?

                                Why Root Causes are important

                                The difference between problem solving and root cause analysis


               - How to Organize for an RCA

                                RCA Roles and Responsibilities

                                Assemble your RCA Team

                                Modes of Communication

                                How to Resolve Conflict

                                Case Study Exercise


               -    Select the Problem to Analyze

                                Define the selection criteria

                                Plan and estimate tasks for the team

                                Finalize the plan and gain agreement among your stakeholders

                                Case Study Exercise


               - The Mental Problem-Solving Process used in Trouble Shooting

                                Problem Solving

                                Problem-Solving Processes Used by Skilled Trouble Shooters

                                Data Collection and Analysis: Approaches Used to Test Hypotheses

                                Overall Summary of Major Skills and a Worksheet

 
               -  Define the Problem

                                What to look for - Problem-as-Given (PAG) vs. Problem-as-Understood (PAU)

                                Developing your problem statement

                                Refining the problem specification

                                Case Study Exercise


               - Identify the Source of the Problem


         Discuss when to use the appropriate analysis technique to determine the problem source

                                Process Diagram

                                Forms & Checklists

                                Statistical Sampling

                                Fishbone Diagram

                                Surveys

                                Charts - Line, Scatter, Bar, & Pie

                                Case Study Exercise


              - Solution Options Analysis and Selecting the “Best Fit”

                                How to approach different solution options

                                                o Brainstorming

                                                o Weighted Evaluation

                                Selecting the appropriate option

                                Hold an Retrospective on your approach

                                Planning the proposal

                                Case Study Exercise


              -  utting RCA into practice

                                Create a Root Cause Analysis program within your organization

                                How to develop appropriate recommendations to address root causes

                                       at various levels to avoid future incidents


               -  Problem solving Technique

                                Gathering information, Facts not views, Data Analysis, Define the problem

                                Root Coues Analysis

                                Suggest alternatives

                                Select Solution

                                Take Action, Back to Normal operation

                                Reporting

                                Troubleshooting & Case Studies:

                                Heat Exchangers (condensers, reboilers, stab-in bundles, exchangers)

                                Separator  Cary over ,Flare Care over


               - Troubleshooting Fractionation Columns

                                Case Study: Distillation Columns


               - Troubleshooting of Hydraulic Systems

                                Case Study: Hydraulic System


               - Troubleshooting of Fired Heaters

                                Energy Saving Ideas

                                Expanding Heater Capacity


               - Course Closing and Final Assessment