Maintenance and Engineering

Process Plant Troubleshooting

Process upsets, off-spec products and equipment problems need fast, systematic troubleshooting. This course teaches a structured troubleshooting method for process plants: defining the problem, gathering data, understanding the process and equipment, generating and testing hypotheses, implementing fixes safely and preventing recurrence.

5 days Classroom or live online English

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Take the course details with you.

Download the full standard outline: why attend, methodology, objectives, audience, competencies, the daily outline and current plans.

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Why attend

From knowledge to real-world impact.

Guesswork in troubleshooting wastes time and can be unsafe. You will learn a disciplined method used by expert troubleshooters.

Workplace challenges

Professional Problems This Course Is Designed to Solve

The programme explores practical approaches to the following challenges. Results depend on how the learning is applied in your organisation.

Difficulty translating subject knowledge into practical workplace decisions.
Inconsistent approaches to the activities covered in the course outline.
Lack of a structured plan for applying and reviewing new skills.

Course methodology

How you will learn.

Plant troubleshooting cases, data analysis exercises, team problem-solving and lessons-learned reviews.

Course objectives

What you'll take away.

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

Apply a structured troubleshooting method
Define problems precisely
Gather and analyse process data
Use process and equipment knowledge to form hypotheses
Test solutions safely
Prevent recurrence and share lessons

Target audience

Who should attend.

This course is suitable for:

Process engineers
Plant operators and supervisors
Maintenance engineers
Technical support engineers
Production managers

Target competencies

Capabilities you will build.

Participants will develop competencies in:

Systematic troubleshooting
Data analysis
Hypothesis testing
Safe implementation
Knowledge sharing

Course outline

Your learning journey.

A focused, practical outline with time to explore, apply and reflect.

Day 1Troubleshooting Method

09:00–10:08Why structure matters
10:08–11:00Troubleshooting steps
11:00–11:30Coffee break
11:30–11:45Troubleshooting steps (continued)
11:45–12:53Common mistakes
12:53–14:00Exercise

Day 2Problem Definition

09:00–10:08Is/is not analysis
10:08–11:00Data gathering
11:00–11:30Coffee break
11:30–11:45Data gathering (continued)
11:45–12:53Process history
12:53–14:00Workshop

Day 3Process Knowledge

09:00–10:08Mass and energy balances
10:08–11:00Equipment behaviour
11:00–11:30Coffee break
11:30–11:45Equipment behaviour (continued)
11:45–12:53Control system effects
12:53–14:00Exercise

Day 4Hypotheses and Tests

09:00–10:08Generating hypotheses
10:08–11:00Safe testing
11:00–11:30Coffee break
11:30–11:45Safe testing (continued)
11:45–12:53Management of change
12:53–14:00Case study

Day 5Prevention

09:00–10:08Root causes
10:08–11:00Documentation
11:00–11:30Coffee break
11:30–11:45Documentation (continued)
11:45–12:53Lessons learned
12:53–14:00Action plan

The timings provided are estimates and may vary depending on the number of participants and the discussions taking place during the sessions. They are indicative only and do not constitute a binding commitment.

Dates & venues

Find a session that works for you.

Confirmed dates accept registration requests. Tentative dates are enquiry only.

Good to know

A few things to know.

How is the course delivered?

Our classroom programmes combine facilitated discussion, case studies, exercises and reflection. The precise format will be confirmed before enrolment.

Can you deliver this programme for our team?

Yes, you can enquire about a tailored programme. Share your goals, group size and preferred dates with our learning team.

Will I receive a certificate?

Participants who complete the programme receive a Smart Horizon certificate of attendance. Smart Horizon programmes are not externally accredited and do not award a professional qualification, licence or designation. Where a course title or outline refers to a professional certification (for example, AACE International's Certified Cost Professional), the programme supports learning and preparation only; the credential itself is awarded solely by the relevant professional body under its own application and examination requirements.

What should I confirm before booking travel?

Please confirm the session, exact venue, accessibility arrangements, fees and any visa requirements with the team before arranging travel. Tentative dates are not confirmed sessions.

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