COURSE NAME:Troubleshooting in Chemical Plants


This course can be scheduled at your convenience, to request this course please click here


Upon completion of this course, participants will be able to:

  • Enrich knowledge on troubleshooting through various practical exercises carry out during the course (Specify the limitations to plant problem solving)
  • Apply the methods of risk analysis particularly in process plant troubleshooting
  • Identify various accidents in the process plant and know the causes, actions taken & lessons learned
  • Discuss the risks associated with process troubleshooting and the applicable safety procedures to be followed.
  • Describe how Heat Exchangers function
  • Recognize typical problems and identify possible causes of Heat Exchangers
  • Describe how fired heaters function
  • Recognize typical problems and identify possible causes fired heaters
  • Know Fuel and Air Systems and their operating problems.
  • Identify the components of Flare System and its operating problems.
  •   Identifying physical principles and forces that occur in rotating equipment, focusing on pumps and compressors
  • Using operating and troubleshooting techniques for pumps and compressors
  • Identify the Impurities in Water.
  • Know the Different Methods for Water Treatment.
  • How to Control Cooling Water Quality.
  • How to Control Potable Water Quality.
  • How to Control Boiler Water Quality.
  • How to Control Waste Water Quality.
  • Understand and Identify the Operating Problems.
  • Know the Different Types of Storage Tanks.
  • Know how to Operate Storage Tanks.
  • Identify the Hazardous Conditions and Safety Procedures for Storage Tanks.
  • Define abnormal conditions such as high liquid level, heat loss, tanks getting dry, plugged outlets
  • Handle abnormal conditions such as loss of power, loss of control, loss of air, shortage of man power.
  • Chemical plant Equipment Trouble Shooting:
    • Heat Exchanges Operation and Trouble Shooting
      • Shell and Tube Exchangers
      • Double pipe Exchangers
      • Indirect Heaters
      • Air Cooled Exchangers
      • Heat Exchanger Operation and Trouble Shooting


  • Fired Heaters Operation and Trouble Shooting
    • Performance Monitoring
    • Fired Heater Operation and Trouble Shooting


  • Gravity Separators Operation and Trouble Shooting
    • Separation Process
    • Principles of Separation
    • Gravity Separation
    • Phases of Separation 
    • Separation System Problems
    • Factors Affecting Separation
    • Separators Operation and Trouble Shooting


  • Fractionators Operation and Trouble Shooting
    • Principles of Distillation (Fractionation)
    • Reflux
    • Re-boiling
    • Fractionators Operation and Trouble Shooting


  • De-salter
    • De-salter Operation
    • De-salter Troubleshooting


  • Pumps Operation and Trouble Shooting
    • Basic Pump Hydraulics
    • Calculating Total Head
    • Horsepower Calculations
    • Net Positive Suction Head (NPSH)
    • Pump Performance Curves
    • System Performance
    • Operation, Control and Trouble Shooting


  • Compressors Operation and Trouble Shooting
    • The Theory of Compression
    • Centrifugal Compressors Operation, Control and Trouble Shooting
    • Reciprocating Compressors Operation, Control and Trouble Shooting
    • Operation, Control and Trouble Shooting


  • Utilities Systems Operation and Trouble Shooting
    • Water Treatment Systems
      • Introduction to Water Treatment
        • Suspended Solids
        • Dissolved Solids
        • Dissolved Gases
      • Industrial Water Treatment
        • Primary Water Treatment
        • Secondary Water Treatment
      • Potable Water Purification
        • Disinfections of Water
        • Sterilization of Water by (Chlorine, Ozone, Chloramines)


  • Waste Water Systems
    • Main Sources of Pollution
      • At the Production
      • During Transportation
      • During Refining
      • De – Oiling of Water
        • Purpose of De – Oiling
        • API Interceptor
        • Parallel Plate Interceptor (PPI) and Corrugated Plate Interceptor (CPI)
        • Flotation Units
        • Flocculation Units


  • Fuel Systems
    • Typical Fuel Gas System
    • Typical Problems
      • Pressure Variation
      • Liquid in the Gas
      • Change in Fuel Gas Composition




  • Air Systems
    • Instrument Air
      • Typical Instrument Air Supply Systems
      • Instrument Air Distribution Systems Operation and Trouble Shooting
      • Utility Air
        • Typical Utility Air Supply Systems
        • Utility Air Distribution Systems Operation and Trouble Shooting


  • Process Shutdown (PSD) and Emergency Shutdown (ESD)
    • Normal Shutdown Procedures


  • Process Emergency Shutdown
    • Process Failures
    • Utility failure


  • Emergency Shutdown 
    • Fire
    • Power Failure
    • Instrument Air Failure
    • Cooling Water Failure



  • Process Engineers, Plant Forman, Section Heads, Plant Supervisors & technical staff involved in Chemical plant operations.
    • 5 Day(s)

    The presentation is generally appealing to me. The dedication & devotion of the instructor are both laudable & admirable.
    Mohammed F. Alotaibi

    Really this course is important for any inspector, so I will recommended it for our employees. And thanks a lot!
    Ahmed Al-Yami

    You are doing excellent bringing such very talented instructor. Please keep it up.
    Ahmed Afifi
    Al-Zamil CoolCare

    I would like to appreciate you as well as the instructor for a good training due to the fact that the helping to gain new information about the types of valve with advantages and disadvantage as well. Many thinking.
    Zaki Ali Aldawood

    This course was very beneficial and helpful to understand one of the Major NDT method. I encourage ITC to continue with this performance.
    Talal Saad AlHasawi

    ITC service was in overall excellent. Thanks.
    Wael M. Morsy

    This course was good and a nice guide to the PMP exam. Thanks.
    Yazeed Mohamed Mreki
    General Authority of Civil Aviation (GACA)

    It was good course & good preparation with excellent instructor. Thanks a lot.
    Faisal Mahdi Al-Qahtani

    It was a nice course to have. I suggest taking this course with the same instructor to other people. Thanks for the instructor for his kindness & helfull during the course.
    Abdul-Moniem Al-Humoud

    It is very important course, which enable us to improve our knowledge to work approaching our big account and can be recall us the key account. This is will support us to active result for the best of the Co.
    Mohammed Amjad
    Al-Suwadi Services

    The instructor is highly and technical knowledgeable in explaining all the subject in the course taken.
    Noel V. Garan
    Coldstorec Group Of Saudi Arabia

    Instructor was well prepared and knowledgeable I gain lot of useful information.
    Gulam Khan
    Saudi Aramco

    It was a good learning experience. Got to know the concept involved in key account.
    Muthuraman Nachiappan
    Al-Suwadi Services

    The instructor Mr. Ahmed Sabry has a very nice spirit.
    Salam Fakhoury
    Al Khodari Company

    It is very useful to us and increase our knowledge.
    Mohammed Rashed Afifi
    Al Khodari Company

    The course is excellent and helpful. It help me in organizing the work in more safe manner.
    Muzammil Hayat
    Al Khodari Company

    The instructor is very knowledge and hard working, his way of teaching is very good.
    Ibrahim Darwish
    Al Khodari Company