Arabian American Center January Training & Development
Program Title:
Prepare Detailed RCA,Take Corrective Actions,Operate CRU-TV Compressors ETC According to Procedures
13.01.2019 - 17.01.2019
$ 3900


Course Overview

   Root cause analysis involves searching backwards from an undesirable effect or outcome to identify its causes. While "root cause" implies that there is a single cause responsible for a given problem, some effects actually have multiple causes that trigger them. Sometimes the multiple effects are independent of each other; other times, causes are interrelated where, if one cause is removed, the problem can no longer occur. We all know that it is important to contain problems as soon as they occur or are discovered. However, what we generally see with problems are symptoms of the problem. The root cause is rarely apparent. While it is important to initiate an interim containment plan as soon as a problem occurs, it is even more important to invest the time and energy to identify and address the root cause or causes of those problems they so that they are less likely to occur in the future.


  This course also provides the participants with an overview of incident investigation. The motivation for this course is to outline a procedure of incident investigation that is objective and satisfies most regulatory requirements. Many organizations fail to learn from their mistakes and near misses, some organizations even fail to learn from their accidents. Often, one can see the same accidents happening over and over again. There are many reasons why organizations do not learn to prevent the recurrence of accidents. When an accident occurs, it is important that it be investigated thoroughly. The results of a comprehensive accident report can help organizations pinpoint the cause of the accident. This information can then be used to prevent future accidents, which is the primary purpose of accident investigation. This course teaches how to lead investigations and root cause analyses using various techniques.

Moreover, the aim of the course is to give an understanding to the technology of gas processing. General concepts are introduced which enable all participants to have a basic comprehension of the needs and requirements of gas compression, processes and condensate recovery operation.

Target Audience

               • This course helps anyone to understand fundamental problem solving processes and

                   examines the basic concept of problem solving, and how to facilitate an effective investigation.

               • In the course, participants will apply everything learned to a prepared scenario.

                   This is to provide 'real world' training, and to show how effective these methods really are.

               • The program is ideal for personnel involved in gas plant process operations, troubleshooting,

                  process engineering, and technical services as well as others providing services to the gas

                  industry, should also find this program beneficial

               • Operators of Production Operations

               • Process Engineers

Course Objectives

              • How to meet regulatory requirements for incident investigations.

              • How to develop and implement a structured program designed for learning from incidents.

              • How to initiate and conduct an investigation.

              • How and when to apply causal factor and root cause analysis for investigating process and

                  non-process incidents.

              • How to develop appropriate recommendations to address root causes at various levels to avoid

                 future incidents.


              • How to structure reports.

              • Via actual industry examples and workshops, learn key points and practice your new skills.

              • Use a structured approach to identifying and defining the problem, determining the root cause

                 through analysis and defining an appropriate solution.

              • Use a range of logical, data, process and root cause analysis tools to develop an understanding

                of the problem and identify a root cause.

              • Understand the importance and approaches to verifying a root cause.


              • Identify, evaluate and develop solutions that address the root cause of the problem.

              • Learn how to establish an effective team environment for root cause analysis. Clarify what the

                  problem is and is not.

               • Using data and investigative tools to identify the root cause.

               • Generate ideas to solve the root cause problem and select the most appropriate solution using

                  decision matrices.

               • Implement measures to ensure the gains made are held.


               • Recognize common barriers to root cause analysis and apply techniques to overcome those


               • Demonstrate knowledge and understanding of the principles of natural gas industry

               • Explain theory behind CRU operation skills

               • Select and implement most adequate techniques for condensate recovery & fractionation

               • Discuss logic in CRU operating procedures


               • Relate the gained knowledge in the area of natural gas utilization to real-life cases

               • Optimize compressor operation

               • Diagnose CRU operating problems

               • Apply troubleshooting to technical difficulties encountered in the field of specialization

Training Methodology

  A highly interactive combination of lectures and discussion sessions will be managed to maximize the amount and quality of information and knowledge transfer. The sessions will start by raising the most relevant questions, and motivate everybody find the right answers. You will also be encouraged to raise your own questions and to share in the development of the right answers using your own analysis and experiences.  Tests of multiple-choice type will be made available on daily basis to examine the effectiveness of delivering the course.

  All presentations are made in excellent colorful power point. Very useful Course Materials will be given.

               • 30% Lectures

               • 30% Workshops and work presentation

               • 20% Group/individual Work or projects & Practical Exercises

               • 20% Videos& General Discussions, Case studies etc…

Course Contents:

               • Incident and accident investigation

                                Human contribution to accidents

                                The role of root cause Analysis in identifying management system failures

                                Accident investigation techniques I: Fault Tree Analysis 'FTA'

                                Working in small groups on the use of FTA

                                Preparation of action plans

                                Incident investigation techniques II: Events & Causal Factors Analysis 'E&CFA'

                                Group exercise on investigating a multiple-fatalities accident involving offshore

                                     drilling rig

               • Introduction to root cause analysis and techniques

                                Root cause analysis principles

                                Techniques for causal factor identification

                                Root cause mapping

                                Corrective actions

                                Reporting

               • How RCA's Work

                                Key RCA roles

                                NORMS-based analysis of information

                                Development of corrective and preventive actions

                                Review findings, assess, and implement actions

                                Writing a Good Report and lessons to be learned

                                Action plan and follow up

               • Form & Focus the Team

                                Form a Team

                                Focus the Team

                                Understand the Problem

               • Find the Root Cause

                                Create a cause & effect diagram

                                Explore chains of causes

                                Study interrelationships

                                Use data analysis & investigative tools

                                Identify root causes

               • Root Cause Analysis Concepts

                                Root cause analysis is a process

                                Causal factor charting

                                Root cause identification

                                Recommendation generation and implementation

               • The nature of process problems affecting performance

                                Performance defined in terms of generic variables: Speed; Quality; and Cost

                                Effort inputs in context - Asset based or Business Process based

                                Structured approach - The Operations Process redefined

                                Configuration; Operation; and Optimization

                                Maturity Indexing: Planning; Control, Congruence, Empowerment

                                6 Big Losses, 7 Wastes

               • Tools and Techniques - Practical Experience

                                Interactive and Dynamic variable relationships analysis

                                Techniques introduction

                                Tools introduction

                                Problem Analysis

                                Practical Use of Tools and Techniques

                                Case Studies

                                Tools & Techniques - selecting the right one  

               • Fix the Root Cause

                                Propose potential solutions

                                Select the "best" solution

                                Conduct a reality test

                                Develop Action Plan to implement solution

                                Verify the solution

               • Finalize the Solution

                                Validate the solution

                                Update documentation

                                Train

                                Start audits

                                Transfer knowledge

               • Overcoming Barriers

                                Barriers to Root Causes Analysis with potential remedies

               • Basic concepts of natural gas processing

                                Introduction

                                Process modules

                                Scope of natural gas processing

                                Processing objectives

                                Effect of gas type in field processing

                                Location of the gas field

                                Natural gas processing plant

                                Flow sheet

                                Equipment and components

                                Heat exchange in gas processing

                                Heat transfer theory

                                Mechanisms of heat transfer

                                Heat exchangers types

                                Shell and tube

                                Double-pipe

                                Plate and frame

                                Aerial coolers

                                Fired heaters

               • Natural gas liquids recovery

                                Introduction

                                NGL recovery processes

                                Refrigeration processes

                                Lean oil absorption

                                Solid bed absorption

                                Membrane separation process

                                Selection of NGL recovery processes

                                Basic gas laws; characterization of the flow stream;

                                Compressor operation fundamentals.

                                Troubleshooting of compressor operation.

                                (Cover reciprocating, centrifugal and screw compressors)

   Gas Processing – Purpose of condition gas for sales and/or extract and recover NGL’ s; hydrocarbon Dew-point Control (adsorption, Hydrocarbon Recovery Units (HRU’ s), and Short-Cycle Units); absorption/lean oil process; Vapor Compression System; Natural Gas Liquid (NGL) Extraction; NGL products concerns of economic justification; NGL products concerns of extraction processes (absorption/Lean Oil Process, adsorption, condensation, mechanical refrigeration, Turbo-Expanders, and Valve Expanders (LTX, LTS, J-T (Joule Thompson)); Condensate Stabilization (refluxed distillation and non-refluxed distillation); product treatment (contaminants of interest (CO2 , Sulfur, water and removal of CO2 from NGL product and Sulfur compounds from LPG products.


    Natural Gas Liquids (NGL) extraction – Gas liquefaction objectives and method; NGL Process Flow Diagram (PFD); heat transfer and exchanger (heat and enthalpy concept and phase change and P-H diagram); external refrigeration loop; calculation of cryogenic loop used for hydrocarbon liquids extraction from natural gas; Joule-Thompson (JT) expansion; turbo expander; and optimization of the process performances.

                                Design considerations

                                Operational problems

                                Equipment used in gas plant operations

                                Trouble shootings

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