LNG & Gas Processing
LNG Liquefaction Plant Operations & Troubleshooting
A four-day operations-focused programme for LNG train personnel: refrigerant circuit behaviour, main cryogenic heat exchanger performance, compressor and driver constraints, and structured troubleshooting of production loss.
Industry focus: Petrochemical & Manufacturing Plants
Who Should Attend
Designed for these roles
- LNG plant operations engineers, panel operators and shift supervisors
- Process and technical service engineers supporting liquefaction trains
- Maintenance and reliability engineers on cryogenic and rotating equipment
- Technical authorities reviewing production loss and optimisation studies
Delivery formats
- Customised in-house training at your plant or office
- Public classroom delivery, subject to schedule
- Live online delivery where suitable
- Recommended group size: 8–20 participants
Problems Solved
What this course fixes
Production shortfall accepted as normal because nobody isolates the constraint
Refrigerant composition drift managed by habit rather than by data
Repeat compressor trips and surge events without a closed-out cause
Start-up and cooldown sequences that take longer than they should after outages
Learning Outcomes
What participants can do after the programme
Outcomes are written as tasks, not topics — so managers can verify capability back at work.
- Explain refrigerant loop behaviour and the effect of composition on train capacity
- Diagnose main cryogenic heat exchanger performance loss from operating data
- Identify compressor surge, fouling and driver limits as production constraints
- Manage boil-off gas, fuel gas balance and flaring during upsets
- Run a structured production loss investigation and rank recovery actions
Course Outline
Detailed programme content
Day 1 — Train Configuration & Process Control
- Liquefaction train layout, utilities and interfaces with treating units
- Key control loops and how the train responds to feed and ambient changes
- Refrigerant make-up, composition control and sampling practice
- Operating envelopes, cold box protection and integrity operating windows
Day 2 — Cryogenic Equipment Performance
- Main cryogenic heat exchanger: approach temperatures, distribution and freeze risk
- Performance monitoring: what to trend and what it tells you
- Cold box leak indications, insulation and nitrogen purge systems
- Exercise: assess a train's exchanger performance from operating data
Day 3 — Rotating Equipment & Utilities
- Refrigerant compressors, drivers and anti-surge system behaviour
- Gas turbine performance in tropical ambient conditions and its capacity impact
- Boil-off gas compressors, fuel gas balance and flare minimisation
- Case discussion: repeat trips traced to instrumentation and control causes
Day 4 — Troubleshooting, Start-up & Loss Recovery
- Cooldown, start-up and shutdown sequences and where time is lost
- Structured troubleshooting method applied to production loss scenarios
- Production accounting, loss trees and capacity creep opportunities
- Workshop: build a loss tree for a participant's own plant scenario
Practical Work
Practical exercises and case studies
Sessions are built around calculations, data interpretation and technical decisions. Case material is generic or anonymised — no client-confidential project data is used.
Main cryogenic heat exchanger performance assessment from operating data
Refrigerant composition adjustment exercise against capacity and power targets
Compressor surge and driver limit diagnosis from trend data
Loss tree workshop built on a participant's own production shortfall scenario
Trainer Profile
Delivered by Sathish Kumar
Senior Trainer — Reliability, Maintenance & Rotating Equipment
19 years industry experience
Sathish builds maintenance strategies that survive contact with a real budget. His workshops use participants' own failure history, so teams leave with a revised task list rather than a certificate alone.
Real project exposure
- RCM implementation across critical pumps and compressors at a combined-cycle power plant
- Root cause failure analysis on repeat bearing failures in a boiler feed pump train
- Spare parts and criticality review for a palm oil refinery group
Certifications
- CMRP — Certified Maintenance & Reliability Professional
- Vibration Analyst Category III (ISO 18436-2)
- RCM2 Practitioner
Trainer allocation is confirmed in your proposal. Substitute trainers hold equivalent certification and sector experience.
Next Step
Run this programme for your team
We will confirm available dates, trainer, duration and HRD Corp claimable investment — and adjust the outline to your equipment and standards at no extra cost.
No obligation. Proposals include HRD Corp claim guidance.
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