This course is designed to enhance the capabilities of refinery operation supervisors and future team leaders by providing advanced troubleshooting techniques along with practical, hands-on data analysis tools. Through real-world case studies and tailored workshops, participants will build the confidence to diagnose process deviations and make data-driven decisions that improve reliability, safety, and performance in operations.

• Process Operation Supervisors
• Senior Operators preparing for supervisory roles
• Process and Production Engineer

Advanced Troubleshooting Techniques for Operations

1. Developing a Troubleshooting Mindset & Structured Thinking

• Learn how to shift from a “firefighting” mindset to a root-cause problem-solving approach.
• Understand structured analytical thinking for solving field problems.
• Explore logical steps in problem assessment, investigation, and communication.

2. Common Equipment & Process Failures in Refinery Operations

• Explore frequent failure symptoms in key refinery equipment such as pumps, distillation columns, and heaters.
• Link operational issues to incorrect usage, environmental changes, or upstream process abnormalities.
• Understand recurring failure patterns observed in refineries.

3. Advanced Problem Analysis Techniques

• Apply Root Cause Analysis (RCA) methodologies to real-world cases.
• Use tools such as the 5 Why’s and Fishbone (Ishikawa) Diagram for structured problem analysis.
• Practice analyzing real plant failures through guided exercises.

4. Process Troubleshooting Case Study (Group Based Workshop) __ Case is subjected to be adjusted as appropriate

4.1 Workshop 1: Process Line Problem related to manual valves

• Case study + Presentation + Conclusion

4.2 Workshop 2: Process Line Problem related to control valves

• Case study + Presentation + Conclusion

4.3 Workshop 3: Pumps Operation Problem

• Case study + Presentation + Conclusion

4.4 Workshop 4: Pumps Cavitation Problem

• Case study + Presentation + Conclusion

4.5 Workshop 5: Heat Exchanger Performance Problem

• Case study + Presentation + Conclusion

Advanced Troubleshooting Techniques for Refinery Operations (Continue) + Process Data Handling via Excel Tool

1. (Continue) Process Troubleshooting Case Study (Group Based Workshop) including

1.1 Workshop 6: BFW control system + control valve failure

• Case study + Presentation + Conclusion

1.2 Workshop 7: Gas Dehydration Process Problem

• Case study + Presentation + Conclusion

1.3 Workshop 8: Heat Exchanger Block Outlet and Explosion

• Case study + Presentation + Conclusion

2. Basic Excel Tools for Daily Data Handling + Practice

• Sorting and filtering data for quick access and insights
• Essential formulas for data analysis:
  • AVERAGE
  • MIN/MAX
  • COUNT
• Highlighting critical data using Conditional Formatting

3. Advanced Excel Tools for Supervisory Analysis + Practice

• Using Analysis ToolPak for basic statistical summaries
• Creating Histograms for distribution insights
• Generating Pivot Tables to summarize large datasets effectively
• Visualizing with Pivot Charts for better decision-making

4. Process Data Handling Techniques + Practice

• Trend analysis using time-series data
• Identifying abnormal values and outliers
• Choosing the right graphs for analysis:
  • Line Chart (trend detection)
  • Scatter Plot (correlation analysis)
  • Bar Chart (comparison across units or time)