*Unit Specific* - Training and Troubleshooting Workshop

Course Length:Determined by unit size & complexity (est. 2-3 days)

Course Purpose:

This workshop is specifically designed to teach operations personnel to apply the K&S 3-step methodology, for troubleshooting and determining root cause of an upset to their specific process. This training will enhance employees understanding of the logic of their specific process, giving them the ability to use multiple data points to evaluate the accuracy of control data. The function of each piece of equipment associated with your specific process is discussed and the control factors for each identified. Practical application of the K&S 3-step troubleshooting method is accomplished by using unit specific problem scenarios ranging from simple to very complex. Specific emphasis is also placed on developing appropriate (safe & economical) corrective action plans that return your process to normal without creating additional problems. Pro-active monitoring and control of your process is also stressed as a way to recognize abnormal conditions early on and prevent losing control of the process. Your operations personnel are more confident and workplace morale is positively impacted as a result of the training.

Added Benefits:

The pre-selection and involvement of your subject matter expert will ensure your ability to continue this process specific training. The format used to develop and deliver the process specific training allows your company to capture all related data from future upsets and create additional scenarios for on-going internal training. This provides an excellent framework for initial and refresher training for your operations personnel as well as complies with all of the requirements of OSHA’s PSM standard related to training.

Course Objectives:

After course completion your employees will be able to:

  • Solve complex process problems (determine root cause) using the K&S 3-step troubleshooting method
  • Describe the functions of the specific equipment within your process
  • List the process control factors associated with each specific piece of equipment in your process
  • Use the process control factors to develop a punch list for troubleshooting your process
  • Determine if a process upset is the result of a instrument control problem or a mechanical problem
  • Identify items that will reduce the cost of product manufacturing
  • Recognize abnormal conditions in your process early on and minimize the effects of the upset
  • Develop and implement safe and economical corrective action plans that return your process back to normal based on unit logic
  • Take better control of your process to minimize environmental upsets
  • Improve communications with co-workers using a common language for problem solving in your process
  • Operate your process with increased confidence
  • Increase the on-stream time of your process
  • Train others in a common method for troubleshooting upsets/problems in your process

Who should attend?

This course is intended for anyone with day to day responsibilities for operating your process or improving the process. This includes Outside Operators, Console Operators, Supervisors, Engineers, Electrical and Instrument Technicians. Any level of experience will benefit.


The K&S Process Systems Surveillance & Troubleshooting Workshop is recommended as a prerequisite to this course

Topical Outline:

  • Introductions & Objectives
    1. Importance of the good troubleshooter
    2. Team work
    3. System logic
  • Production Person’s Job Model
    1. Data gathering
    2. Monitoring
  • Introduction of your Specific Process Unit & Logic
  • Review the 3-Step Method of Determining Root Cause
  • Discuss in Detail each of the Processes that make up their Specific Unit
    1. Discuss Function & Factors for each piece of Equipment
  • Use the 3-Step Method to solve 12 – 14 Specific Process Problems
  • Develop Safe and Economical Corrective Action Plan for each Problem Worked.

Course Development Instructions:

Once your operations personnel have the skills to use the 3-step method taught during the K&S Process Systems Surveillance & Troubleshooting Workshop, the next step in their learning and application of that method is through a Unit Specific Workshop developed using your specific process. During the workshop, we teach the function and control factors for the specific equipment that makes up your process and solve problem scenarios using the K&S 3-step Method. Since operators require troubleshooting practice on events that are as realistic as possible to draw them into the intricate operation of their processes, every scenario created and used is as realistic as possible. All developed scenarios will challenge their knowledge and skills and help them identify opportunities for improvement of the process.

Pre-Course Development:

To keep our development costs as low as possible, K&S Associates requests that the following items be prepared in advance of the arrival of our consultant:

  • Identify the process to be taught in the Unit Specific Workshop
  • Develop and provide a simplified flow diagram of the process with complete instrumentation
  • The diagram must include controller logic (point of reading and corresponding control valve or component)
  • Provide "normal" data for controllers (set-points) and indicators
  • Provide function statements for all equipment in the process. These function statements will be used as we work together to develop the Function / Factor forms for the workshop
  • Assign a resident process expert to work with us as we develop the classroom materials and handouts, including problem scenarios

Additional Considerations:

  • You resident process expert will become the in-house trainer for the developed process. That expert should adjust his/her schedule to attend all of the Unit Specific Workshops taught for your personnel to further ensure his/her competency in delivering the materials.
  • All developed materials remain on your site.
  • Workbooks and handouts will be provided as part of the Unit Specific Package and master copies of each will be provided to your personnel for future in-house training.

Additional Benefits:

Our specifically designed Unit Specific Training provides focused troubleshooting support for your process unit and is based on the unique logic of your system. Using the created materials from the workshop and compliance with OSHA's PSM Standard under section (g) training will be made easier because:

  • You will be able to capture data from incidents or upsets and instantly update employees that may have been on days-off.
  • You can recreate any incidentfrom data archives and expand the unit specific training and troubleshooting skills.
  • All materials used in the Unit Specific Package can be used in the initial training process of newly assigned operators.
  • All materials used in the Unit Specific Package can be used for operator refresher training as mandated by OSHA.
  • The troubleshooting method can be applied to process simulation training of new control room operators.
  • Operators demonstrate greater confidence in using their operations-based skills.


This Workshop can be presented at your facility. Contact K&S Associates
for more information