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Operations Abnormalities and Plant Upset Training

A professional plant engineer wearing safety gear inspecting operations with a tablet inside an industrial facility, representing plant abnormalities and upset management training.
Edoxi’s 5-Day Operations Abnormalities and Plant Upset offers extensive learning for corporate teams across oil and gas, petrochemical, and chemical sectors. Gain hands-on skills in managing operations challenges and plant disturbance. Learn how to improve operational reliability, reduce downtime, and enhance safety protocols. Boost your professional profile with real-world experience and certification. Enrol now!
Course Duration
40 Hours
Corporate Days
5 Days
Learners Enrolled
50+
Modules
14
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Course Rating
4.9
star-rating-4.9
Mode of Delivery
Online
Certification by

What Do You Learn from Edoxi's Operations Abnormalities and Plant Upset Training

Process Plant Operation Fundamentals
You learn to operate equipment using manuals and standard procedures, manage safety devices, and handle capacity limits for reliable plant operations.
Handling Process Upsets and Abnormalities
You learn to monitor critical process parameters, identify early warning signs, and take corrective actions during plant upsets without compromising safety.
Process Control and Safety Systems
You learn to operate advanced control systems such as cascade and feedback mechanisms and manage emergency shutdown protocols and system inhibitions effectively.
Root Cause Analysis Methodologies
You learn to apply structured investigation techniques to identify failure causes and implement preventive measures to improve system reliability.
Optimisation and Maintenance Strategies
You learn to develop reliability-centred maintenance programs for critical equipment and apply risk-based inspection techniques to maximise plant availability.
Equipment Failure Prevention
You learn to conduct fitness-for-service analysis to predict equipment life and apply preventive strategies to reduce unexpected failures in process units.

About Our Operations Abnormalities and Plant Upset Course

Edoxi's 5-day Operations Abnormalities and Plant Upset course is designed to enable organisations to enhance operational reliability through effective handling of process deviations. Throughout the training, you learn to present best practices from High Reliability Organisations (HROs) with respect to both operational excellence and safety protocols. 

The course delivers an interactive learning methodology through lectures, videos, and presentations with interactive group exercises, discussions, and case studies. You also gain practical experience through troubleshooting exercises and workshops, which help strengthen your understanding of Operations Abnormalities and Plant Upset. The training starts with a pre-assessment and ends with a post-assessment to measure learning progress and ensure effective knowledge retention.

During our Operations Abnormalities and Plant Upset course, you learn to present how organisations can systematically learn from failures and near misses, as well as adopt best practices from other industries. The training encourages you to raise more of your own questions and to share in developing the amicable solutions using your own analysis, observations, and real-world knowledge.

By completing the 5-days training program, you receive Edoxi’s course completion certificate that ensures your skills in operations abnormalities and plant upset. You learn to advance your career as a Process Safety Engineer, Plant Operator, Safety Specialist, Maintenance Engineer, enriching your technical profile and contributing to efficient, reliable industrial operations.

Key Features of Edoxi's Operations Abnormalities and Plant Upset Training

Understanding Abnormalities and Upsets

You learn to recognise and manage process deviations from normal operating conditions and maintain stability during unexpected upsets.

Identifying Root Causes

You learn to analyse abnormal operations using root cause analysis techniques to find and eliminate underlying issues.

Progressive Practical Exercises

You learn to handle real-world troubleshooting scenarios, starting from basic alarms and process deviations to complex emergency situations.

Managing Production and Quality Issues

You learn to assess how process variations affect production rates and product quality, and apply corrective measures to restore normal operations.

Immediate Operator Response

You learn to perform quick assessments, implement manual overrides or system restarts, and take timely action to prevent escalation during plant disturbances.

Comprehensive Practical Application

You apply all concepts through hands-on exercises and real-world case studies, gaining complete operational experience in managing plant abnormalities and upsets.

Who Can Join Our Operations Abnormalities and Plant Upset Course?

Operations Management Personnel

If you are an oil and gas professional with 2-3 years of experience in plant operations or the petrochemical industries, you can learn to enhance your understanding and management of plant upset and abnormalities.

Process Engineering Professionals

If you are a process engineer responsible for troubleshooting and process optimization, you can gain the knowledge of operational abnormalities that help you to diagnose and prevent future issues.

Maintenance and Reliability Teams

If you are a team member of maintenance and reliability responsible for equipment performance and system availability, you can enhance skills in assessment and restore equipment functionality.

HSE (Health, Safety & Environment) Professionals

If you are an HSE professional who ensures all response activities comply with safety and environmental regulations, you can develop skills in monitoring risk levels, implement emergency protocols if necessary, and support safe restart procedures.

Technical Consultants

If you are a technical consultant providing expert advice, analysis, and solutions for technology-related challenges, you can gain practical knowledge for advice on best practices, analyse persistent or complex issues, and recommend long-term improvements.

Cross-functional Team Leaders

If you are a manager coordinating technical activities across multiple organisational departments, you can gain skills in managing and resolving issues that impact plant safety, reliability, and efficiency.

Operations Abnormalities and Plant Upset Course Modules

Module 1: Overview of Process Plant Operation
  • Process overview
  • Operating manuals
  • Location of equipment and pipes
  • Standard operating procedures
  • Equipment capacity
  • Safety devices on equipment
  • Interconnecting stations
  • Communication devices
Module 2: Preparations for Handling Process Plant Upsets
  • Monitoring process parameters
  • Safety first
  • Hazard identification & mitigation
  • Alarms & shutdown system knowledge
  • Control room and field communications and interactions
  • Logging of process parameters and analyzing abnormal readings
  • Abnormal noise, vibrations, and chattering
  • Safety valve pop-up
  • Updating start-up and shutdown procedures
  • Updating and availability of P&IDs
Module 3: Process Control & System Safeguards
  • Process parameters
  • Process parameters measurement
  • Basic control loop
  • Components of control system
  • Feedback control
  • Types of control systems
  • Split range control
  • Cascade control
  • On-off controls
  • Tuning of controllers
  • Shutdown systems
  • ESD testing
Module 4: Documentation & Systems for Follow-Ups
  • Equipment out of service
  • Long-term isolation
  • Inhibitions and overrides
  • Dead-leg flushing
  • LO/LC valves
  • Alarm and shutdown checks
  • Function checks of interlocks
Module 5: Standard Operating Procedures (SOPs)
  • SOPs
  • Testing and updating
  • Training
  • Updating P&IDs
Module 6: Safety Systems & Risk Management
  • Safety first
  • Hazard identification & mitigation
  • Learning from failures
  • Analyzing near misses, incidents & accidents
  • Risk assessment and case studies
  • Types of recommendations
Module 7: Safety Analysis in Design
  • FEED considerations
  • HAZOP (using a selected P&ID)
  • LOPA
  • Management of Change (MOC)
Module 8: Continuity of Operations & Plant Systems Reliability
  • Coping with risks
  • Risk assessment
  • Risk evaluation
  • Defining reliability and resilience
  • Reliability-Centered Maintenance (RCM) techniques
  • Fault Tree Analysis (FTA)
  • Practical examples and case studies
Module 9: Process Plant Optimization Technologies
  • Overview of optimization technologies
  • Elements of process plant optimization procedures
  • Constraints in optimization: production, operation, economy, and environment
  • Correlation between process optimization and process control
Module 10: Root Cause Analysis (RCA)
  • Importance of RCA
  • Different RCA methods
  • Conducting RCA case studies (participant involvement)
Module 11: Maintenance Management System Optimization
  • Utilization optimization of piping systems and pipelines
  • Utilization optimization of pumps, compressors, and fans
  • Optimization of maintenance management systems and frequencies
  • Optimization of spare parts management through predictive maintenance
  • Optimization of repair and alteration programs (as per codes)
Module 12: Minimization of Equipment Failure
  • Risk-Based Inspection (RBI)
  • Procedures for minimizing equipment failure risk
  • Fitness for Service (FFS) analysis & estimating remaining life of equipment
  • Plant economy optimization via planned equipment replacement
Module 13: Reliability, Availability & Effectiveness
  • Relationship between reliability and availability
  • Plant reliability optimization
  • Plant availability optimization through improved maintenance
  • Effectiveness analysis of individual equipment
  • Optimization of overall plant effectiveness
  • Workshop: examples and solutions
Module 14: Best Practices for Energy Consumption
  • Energy consumption reduction strategies
  • World standards & benchmarking guidelines
  • Best practices in industrial energy management
  • Energy conservation checklist for industrial plants
  • Optimization of heat production, steam distribution & consumption

Download Operations Abnormalities and Plant Upset Course Brochure

Operations Abnormalities and Plant Upset Course Outcome and Career Opportunities

Completing Edoxi’s operations abnormalities and plant upset course equips you with practical, hands-on skills to manage plant operations and fundamental safety procedures. You gain the expertise to enhance operational reliability, ensure safety performance, and boost your career and organisation’s performance.

Course Outcome Image
You learn to handle how process plants function under normal and abnormal operating conditions.
You gain knowledge to identify critical process equipment, their locations, and interconnections, as well as key operational documents such as P&IDs and SOPs.
You gain skills to evaluate alarms, shutdown systems, and safety device activations to determine appropriate responses.
You learn to use proper communication channels and protocols during emergencies or abnormal events.
You gain techniques to update SOPs in response to process changes, incident findings, or plant modifications.
You learn to apply best practices in risk communication, documentation, and safety recommendations.

Career Opportunities After Our Operations Abnormalities and Plant Upset Certification

  • Process Operator
  • Control Room Operator
  • Process Engineer
  • Operations Engineer
  • Plant Engineer
  • Reliability Engineer
  • Production Supervisor
  • Health, Safety & Environment (HSE) Officer
  • Loss Prevention Engineer
  • Safety Systems Engineer

Operations Abnormalities and Plant Upset Training Options

Corporate Online Training

  • 5 days of intensive, team-focused Operations Abnormalities and Plant Upset learning delivered online.

  • Customised training designed to match your organisation’s specific needs.

  • Expert trainers available for tailored online sessions.

  • Fly Me A Trainer option for tailored on-site training anywhere in the world

Do You Want a Customised Training for Operations Abnormalities and Plant Upset?

Get expert assistance in getting you Operations Abnormalities and Plant Upset Course customised!

How To Get Operations Abnormalities and Plant Upset Certified?

Here’s a four-step guide to becoming a certified Operations Abnormalities and Plant Upset professional.

Do You Want to be a Certified Professional in Operations Abnormalities and Plant Upset?

Join Edoxi’s Operations Abnormalities and Plant Upset Course

Why Choose Edoxi for Operations Abnormalities and Plant Upset Course?

Edoxi’s Operations Abnormalities and Plant Upset Training equips you with practical skills, hands-on experience, and recognised certification to succeed in industrial automation and process control roles. Our training is designed for professionals and corporate teams worldwide seeking to enhance operational efficiency, safety, and technical expertise. Here’s why you may choose us:

Global Presence with Strategic Locations

You benefit from our training institute’s offices in the UAE, Qatar, London, and Kuwait, ensuring consistent quality and support for clients worldwide.

Elite Client Portfolio

You gain training trusted by leading global companies and government organisations to upskill their teams in instrumentation and control systems.

Comprehensive Corporate Training Package

You can focus fully on learning while we manage logistics, accommodation, and catering for your team.

Pre and Post Assessment Methodology

You start with a pre-test to benchmark existing knowledge and complete a post-test to measure learning outcomes.

Customised Training Solutions

You receive a corporate programme tailored to your team’s needs, industry requirements, and specific challenges in process control and instrumentation.

Expert Instructors with Industry Experience

You learn from our certified trainers and industry professionals who bring real-world insights, practical examples, and decades of field experience to every session.

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Edoxi is Recommended by 95% of our Students

FAQ

Is Edoxi’s Operations Abnormalities and Plant Upset course suitable for non-engineers working in operations?

Yes, especially those with process experience.Edoxi’s Operations Abnormalities and Plant Upset course is designed to benefit professionals from various disciplines, with content tailored to different knowledge levels within the same organization.

Can Edoxi’s Operations Abnormalities and Plant Upset training be conducted in phases for different teams?

Absolutely. Edoxi’s team can arrange phased training to ensure operational continuity while maximizing participation across different shifts and departments.

How does Edoxi’s Operations Abnormalities and Plant Upset course address critical safety concerns during plant upsets?

Edoxi’s Operations Abnormalities and Plant Upset training covers comprehensive safety protocols, emergency shutdown procedures, and risk assessment methodologies specifically designed for abnormal operating conditions.

What pre-assessment is conducted before Edoxi’s Operations Abnormalities and Plant Upset Training?

Yes, Edoxi conducts a pre-test to evaluate participants' knowledge levels, which helps us adjust the training program to best meet your team's specific needs and knowledge gaps.

How do you measure Edoxi’s Operations Abnormalities and Plant Upset training effectiveness?

Edoxi’s team implements pre- and post-training assessments to measure knowledge gain, collect participant feedback, and offer follow-up implementation support to ensure practical application.