Upset Management Engineer: Process Upsets Detection & Troubleshooting

Course Content:

Day 1: Introduction to Process Upsets

• Definition of process upsets and their importance in the industry.
• Difference between emergency failures and performance upsets.
• Practical examples of process upsets.
• Common factors causing operational upsets.

Day 2: Early Detection Techniques for Upsets

• Key performance indicators (KPIs) signaling potential upsets.
• Data analysis and monitoring/control systems (SCADA/DCS).
• Real-time process monitoring and analysis tools.
• Utilizing artificial intelligence and big data analytics for upset detection.

Day 3: Root Cause Problem-Solving Methodologies

• Applying Root Cause Analysis (RCA) tools.
• Techniques like the 5 Whys and Fishbone Diagram (Cause-and-Effect Diagram).
• Fault analysis using FMEA (Failure Modes and Effects Analysis).
• Practical workshop on analyzing a real-world problem.

Day 4: Solutions and Strategies for Handling Upsets

• Developing rapid response plans for faults.
• Preparing standard operating procedures (SOPs) for upset management.
• Risk management and minimizing upset impacts on operations.
• Implementing preventive and proactive maintenance strategies.

Day 5: Continuous Evaluation and Development

• How to build a continuous monitoring and improvement system for operations.
• KPIs for evaluating the effectiveness of detection and response systems.
• Case studies showcasing successful process upset management.
• Final workshop: Analyzing a hypothetical upset and preparing a comprehensive action plan to resolve it.