Upon successful completion of this course, students will acquire the following course learning outcomes:
Course Level Learning Outcomes (ACGM or WECM)Core Objectives Associated Course Activities/Assignments/Projects
Core Objectives
Suggested Prerequisite: PTAC 1x32; PTAC 2x20
Course Level: Advanced
Course Description: Instruction in the different types of troubleshooting techniques, procedures, and methods used to solve process problems.
End-of-Course Outcomes: Collect data and identify techniques for troubleshooting and utilize applicable troubleshooting methods to solve process problems.
Lab Recommended
CIP Code Description: 41.0301 (Chemical Technology/Technician)
Effective Date: September 1, 2022
TOPIC OBJECTIVES
Overview 1. Discuss why we need to troubleshoot.
ï‚· Murphy’s Law
2. Brainstorm and identify things that could go wrong within a process.
3. Define proactive and reactive and give examples of each.
4. Discuss the consequences of proactive and reactive.
Safety and health
Process upset
Equipment damage
Environmental compliance issues
Downtime
Loss of production
Financial impact
Monitoring
Instruments and Equipment 1.
2.
3. Discuss the importance of monitoring instruments and equipment as it relates to troubleshooting
Discuss ways monitoring instruments and equipment will aid in troubleshooting a process Discuss instrument indicators when a process is operating abnormally
Process variables
Alarms
Controller output
Trends
4. Discuss equipment indicators when a process is operating abnormally
Pressures (pump suction/discharge)
Differential pressure (across filters)
Leaks
Abnormal sounds
Abnormal temperatures
Abnormal vibrations
Abnormal smells
Cavitation of a pump
Surging on a compressor, etc.
Relationships between Equipment and Instruments 1.
2.
3. Discuss the basic parts of a control loop and how they relay information
Discuss how failure of one instrument in a control loop would affect another
Discuss how a control loop will respond to change in set point
4. Discuss how a control loop will respond to an upset such as:
Loss of pump
Loss of instrument air
Plugged filter
Steam trap failure
TOPIC OBJECTIVES
Fouled exchanger
Power failure
5. Discuss how instrument or equipment failure may affect systems.
Loss of a reflux pump on a distillation column
Level indicator on a condensate pot
Control valve failure on a feed line to a reactor
Loss of temperature indication on a reactor
Relationships between Systems 1. Discuss the domino effect among interrelated systems (i.e., how one system affects another)
Product of one system is feed stock for the next
Thermal interconnectivity (i.e., hot fluid from one system used to preheat feed to another)
2. Given a scenario, explain how a problem in one system can affect other systems:
Reformer in a refinery provides hydrogen for other processes
Reactors producing a mixture of products that need to be separated by distillation (feed composition change) ï‚· Heat from reactor product stream used in a waste heat boiler to generate steam
Troubleshooting Tools 1. Given a process scenario, use tools provided to explain how each would be used in troubleshooting a problem ï‚· Process Flow diagrams
Process & Instrument Diagrams
Material balance
Statistical Process Control charts
Historical trends
Energy balance
Lab analysis / on-stream analyzers
How instruments, equipment and systems inter-relate
Field verification
Hand-held devices such as temperature sensors, vibration monitors, etc.
Baseline information
Operating procedures/training manuals
Engineering and equipment specifications
Cause and Effect diagram
What is it supposed to do
What is it doing
What would cause it to do what it is doing
Troubleshooting Steps 1. Identify and document the symptoms of a problem:
Recognize normal conditions
Recognize abnormal conditions
Collect and document applicable data
Identify potential problems and the magnitude and urgency of the problem based on the data collected
TOPIC OBJECTIVES
2. Communicate the problem
Determine what communication is needed
Discuss with team members to help troubleshoot the problem and identify the possible causes
3. Identify the most likely cause:
Eliminate causes that do not fit the data
Evaluate and prioritize remaining possible causes
Determine the most likely causes(s)
4. Collect additional data to confirm most likely cause
5. Develop a plan to take corrective action(s) based on priorities
Short-term solution (compensating action to keep plant/unit running)
Intermediate term solution (temporary action to prevent extended downtime) ï‚· Long-term solution (action to eliminate problem(s))
6. Document incident
Upset
Troubleshooting steps
Corrective action(s)
Cause
Troubleshooting
Exercises or Scenarios
(Guidelines)
Apply troubleshooting steps to an everyday problem (for example, car engine failure, washing machine runs over, car brake failure, remote for VCR fails, etc.)
Given a scenario, preferably that reflects an industry within your area, use troubleshooting steps to identify symptom(s), identify cause(s) and develop corrective action(s) for a process upset.
Note to Instructor: The following list suggests potential problems.
Equipment problems
Pump cavitation
Filter plugging
Loss of heat transfer
Tube failure
Agitator failure
Power failure to equipment
Coupling failure
Loss of cooling
Etc.
Instrument problems
Loss of instrument air
Plugged air filter
TOPIC OBJECTIVES
Wet instrument air supply
Computer failure
Loss of power to transmitter
Calibration problems with transmitter
Break in thermocouple
Short in thermocouple
Incorrect valve position
I/P calibration and/or failure
Blocked in transmitter
Etc.
c) Process problems
Composition change
Contamination
Inhibitor present or absent
Change in feed ratio
Bad or spent catalyst
Loss of feed
Weather-related changes
Incorrect valve alignment
Etc.