Transcript
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TROUBLE SHOOTING IN THE PROCESS
INDUSTRIES
A “bread and butter” skill !r all "#e$i"al en%ineers&
Uses s'ste$ati" TS
$et#!d and builds
te"#ni"al kn!(led%e
t#r!u%# e)*erien"e+
N! s'ste$ati" $et#!d+ N!
(a' t! !"us te"#ni"al
kn!(led%e+
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v1
Hot Oil
v2
v3
L1
v7
v5 v6
Hot Oil
F1 T1 T3
T2
F2
T4
T5
F3 T6
T8
F4
L2
v8
T7
P1
F5
F6T9
v4
T#e 'ield ! ,aluable *r!du"t #as de"reased b' -./
!,er t#e last (eek+ 0i) t#e *r!ble$&
D! (e "all t#is an !**!rtunit'1 a "#allen%e
!r a "risis2
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v1
Hot Oil
v2
v3
L1
v7
v5 v6
Hot Oil
F1 T1 T3
T2
F2
T4
T5
F3 T6
T8
F4
L2
v8
T7
P1
F5
F6T9
v4
T#e 'ield ! ,aluable *r!du"t #as de"reased b' -./
!,er t#e last (eek+ 0i) t#e *r!ble$&
Let3s %uess
4!u $ean t#at t#e rea"t!r
isn3t (ell $i)ed2
5#at "!uld %! (r!n%
(it# a *u$*2
5e need a s'ste$ati" (a'
t! tr!uble s#!!t2
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PROCESS TROUBLESHOOTING
5#at d! (e (ant t! learn2
Attitude 6 5e (ant t! distin%uis# n!r$al ,ariati!n
r!$ a se,ere ault and ind t#e r!!t "ause ! a ault.
Skill6 5e "an
a**l' a
s'ste$ati"
Tr!uble S#!!tin%
7et#!d
8n!(led%e6 5e
understand *r!"ess
*rin"i*les ande9ui*$ent
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5#at is Tr!uble S#!!tin%2
• A**li"ati!n ! Pr!ble$ S!l,in% $et#!ds t! t#e dia%n!sisand i$*r!,e$ent ater de,iati!ns !""ur in a s'ste$+
5e d! t#is in !ur e,er':da' li,es all t#e ti$e
5#' d!esn3t t#e *rint!ut l!!k like t#e s"reen
dis*la'2 5e !nl' #a,e ;. $inutes t! #and
in !ur
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PROCESS TROUBLESHOOTING :
A 5ORTH5HILE EDUCATIONAL TOPIC
Can (e tea"# Tr!uble S#!!tin%2
• Pe!*le i$*r!,e (it# e)*erien"e and edu"ati!n
• Students beneit r!$ a s'ste$ati" $et#!d and
earl' e)*erien"e
• TS $!ti,ates and %uides learnin% ! *r!"ess
*rin"i*les and desi%ns t#at "an be easil' $!nit!red
• TS %i,es ne( insi%#ts !r lie:l!n% skill i$*r!,e$ent
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PROCESS TROUBLESHOOTING
-+ En%a%e
=+ Deine
;+ E)*l!re
+ I$*le$ent
?+ E,aluate
S8ILLS
Tail!r (ell kn!(n Pr!ble$
S!l,in% 7et#!d
-+ Build !n *ri!r PS e)*erien"es
=+ Gi,e '!u a *r!"edure t! ada*t t!
$an' situati!ns
;+ C!nsistent (it# $et#!ds used in
en%ineerin% *ra"ti"e
For more detail, see Woods, D., Successful Trouble Shooting for Process
Engineers, Wiley VCH, Weinheim, 2006.
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Ste* - : En%a%eSte* = : Deine
Ste* ; : E)*l!re
Ste* < : Dia%n!sis
Ste* > : I$*le$ent
Ste* ? : L!!kba"k
TROUBLE SHOOTING APPLIES THE
SI@:STEP PROBLE7 SOLING 7ETHODIt3s a "ir"le1 n!t a linear
$et#!d
1
2
34
5
6
5e l!!k ba"k ater ea"# ste*+ Are t#e results ! *re,i!us ste*s uture
state1 *r!"ess understandin%1+ still a**r!*riate2
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TROUBLE SHOOTING APPLIES THE
SI@:STEP PROBLE7 SOLING 7ETHOD
Ste* - : En%a%eSte* = : Deine
Ste* ; : E)*l!re
Ste* < : Dia%n!sis
Ste* > : I$*le$ent
Ste* ? : L!!kba"k
It3s "ir"ular1 n!t linear
1
2
34
5
6
1
2
34
5
6
I ste* is "!$*le)1 "an a**l' all si) ste*s inside !ne $a!r ste*
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Tr!uble S#!!tin% 5!rks#eet
-+ En%a%e
=+ DeineCurrent, desired,deiation
Desired !inal state" #$%&'#
'he (ro)lem *#+*# -'
;+ E)*l!re
a. Fundamentals
). &eleant Chanes
/. (erien/e !a/tors
d. Data /onsisten/y
e. ounds on )ehaior
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PROCESS TROUBLESHOOTING
-+ En%a%e
=+ Deine
;+ E)*l!re
+ I$*le$ent
?+ E,aluate
C!urse Tr!uble:s#!!tin%
5e (ill intr!du"e t#e $et#!d al!n%
(it# %!!d and *!!r a"ti!ns (#ile
s!l,in% a *r!"ess e)a$*le+
T#en1 (e (ill s!l,e a "!u*le $!re
e)a$*les durin% a (!rks#!*+ T#ese
(ill be !n t#e t(!:t!(er distillati!n
*r!"ess+
Naturall'1 (e (ill #a,e a s#!rt eedba"k
sessi!n t! "#e"k !ur learnin% (e als!
"all a eedba"k sessi!n a 9ui+
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CLASS E@A7PLE6 Let3s dis"uss t#is *r!"ess (it#
*re#eat1 *a"ked bed rea"ti!n1 and eluent "!!lin%
Feed tank
FC
1
P3
V 3 0 0
TC
3
T4
Fuel
oil
F
2T7
Produt
tank
C!"!
F
7
#ir
$ntake
FC
5
L-
L=
P-
P;
T>
T?
0C-
0=
TC-
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CLASS E@A7PLE6 0ired Heater S"enari!
9ou are :or;in at your !irst t loo; usual to you, and she )eliees that it is
/aused )y im(ro(er )ehaior o! the sta/; dam(er.
Fortunately, you learned trou)le?shootin s;ills in uniersity. o:, you /an
/om)ine your s;ills :ith the o(erator>s insihts to sole the (ro)lem.
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Feed tank
FC
1
P3
V 3
0 0
TC
3
T4
Fuel
oil
F
2T7
Produt
tank
C!"!
F
7
#ir
$ntake
FC
5
L-
L=
P-
P;
T>
T?
'ime →
'em(
'C1
Fuel !lo:
F2
Feed rate
FC1
CLASS E@A7PLE6 Tr!uble S#!!tin%
T#e !*erat!r d!es n!t like t#ese trends
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Deal (it# e$!ti!ns
7ana%e stress
0irst e( ti$es (e (!n3t a"#ie,e *ere"ti!n
PROCESS TROUBLESHOOTING
-+ En%a%e
=+ Deine
;+ E)*l!re
+ I$*le$ent
?+ E,aluate
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'ime →
'em(
'C?1
Fuel !lo:F2
Feed rate
FC1
CLASS
E@A7PLE
T#is is t#e *l!t !sele"ted data t#at
is "!n"ernin% t#e
!*erat!r+
PROCESS TROUBLESHOOTING
ui"k1 (#at is t#e *r!ble$2
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'ime→
'em(
'C1
Fuel !lo:
F2
Feed rate
FC1
Feedtank
FC
1
P3
V
3
0
0
TC
3
T4
Fuel
oil
F
2T7
Produt
tank
C!"!
F
7
#ir
$ntake
FC
5
T#e *u$* is
"a,itatin%
T#e rea"t!r
is leakin% T#e "!ntr!l
s'ste$ is unstable
Aliens #a,e
landed&
D!n3t %uess&
ENGAGE
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S!$e initialattitudes t#at are
n!t #el*ul+
• 5#at1 (#' #a,en3t '!u d!ne
s!$et#in%2
• I d!n3t understand1 but I better
d! s!$et#in% ast+
• O# dear1 run&&
• JI #!*e n! !ne kn!(s t#at I
d!n3t kn!( t#e ans(er+ I #a,e
n! "!niden"eK
PROCESS TROUBLESHOOTING
-+ En%a%e
=+ Deine
;+ E)*l!re
+ I$*le$ent
?+ E,aluate
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S!$e initial attitudes
t#at are #el*ul+
• Listen and read "areull'+ D!
n!t e)*e"t t#e ans(er t! be!b,i!us+
• 5!rk (it# !t#ers in s!l,in% t#e
*r!ble$+
• Use t#e standard TS $et#!d&
• A**l' *r!"ess *rin"i*les+
PROCESS TROUBLESHOOTING
-+ En%a%e
=+ Deine
;+ E)*l!re
+ I$*le$ent
?+ E,aluate
I (ant t!1
and I "an&&
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PROCESS TROUBLESHOOTING
-+ En%a%e
=+ Deine
;+ E)*l!re
+ I$*le$ent
?+ E,aluate
TS IS GOAL:DIRECTED
Dra( a sket"# and n!te ke' ,ariables+
5#at s#!uld be is a"tuall' #a**enin%2
T#ere!re1 t#e de,iati!n is6 ))))))))
Current
stateUn*r!itable
and *er#a*s1
unsae
0inal
stateEi"ient1
$a' take
ti$e
Initial
stateSae and
a"#ie,ed
9ui"kl'
Safety, major equipment damage and large $ loss takeprecedence.
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PROCESS TROUBLESHOOTING
-+ En%a%e
=+ Deine
;+ E)*l!re
+ I$*le$ent
?+ E,aluate
Current
stateUn*r!itable
and *er#a*s1
unsae
0inal
stateEi"ient1
$a' take
ti$e
Initial
stateSae and
a"#ie,ed
9ui"kl'
DE0INE STATES6 S7ARTS:M
• S*e"ii" and 7easurable
• Attainable• R eliable• Ti$el' "an be a"#ie,ed in t#e a**r!*riate ti$e• Sael'
• M C!st:Ee"ti,e
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'ime →
-utlet 'em(
Fuel !lo: rate
Feed rate
CLASS E@A7PLE
S#!uld be6
A"tuall'6
Initial state6
0inal State6
Feed tank
FC
1
P3
V 3 0 0
TC
3
T4
Fuel
oil
F
2T7
Produt
tank
C!"!
F
7
#ir
$ntake
FC
5
Let3s "!$*lete t#e
deiniti!n+
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'ime →
-utlet 'em(
Fuel !lo: rate
Feed rate
S#!uld be6 "!ntr!llin% te$*erature
A"tuall'6 te$*erature is allin% ast1 but uel
is in"reasin%2
Initial state6 a"#ie,e sae !*erati!n ast&
0inal State6 Pr!du"e desired a$!unt !
*r!du"t
F e e d t a n k
F C
1
P 3
V
3
0
0
T C
3
T 4
F u e l
o i l
F
2T 7
P r o d u t
t a n k
C ! " !
F
7
# i r
$ n t a k e
F C
5
DE0INE
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PROCESS TROUBLESHOOTING
-+ En%a%e
=+ Deine
;+ E)*l!re
+ I$*le$ent
?+ E,aluate
Ri"# understandin%
• 0unda$entals
• C#e"k in!r$ati!n and data&&&
• Rele,ant "#an%es
• Startu*
• Trends
• ui"k b!unds
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• 0unda$entals: 7FE Balan"es1 Se"!nd La(1 St!i"#i!$etr'
: 5#at ae"ts t#e ke' ,ariables2
: C!uld “n!r$al” *lant ,ariati!n "ause t#is
be#a,i!r2
: Causalit'1 (#at "a$e irst2 5#at (as "ause2
CLASS E@A7PLE
-+ En%a%e
=+ Deine
;+ E)*l!re
+ I$*le$ent
?+ E,aluate
PROCESS TROUBLESHOOTING
Let3s deter$ine rele,ant
"ausal relati!ns#i*s+
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22
5#at !t#er "auses
inluen"e t#e ee"t2
-+ En%a%e
=+ Deine
;+ E)*l!re
+ I$*le$ent
?+ E,aluate
PROCESS TROUBLESHOOTING
Ti$e
CAUSE E00ECT
0eed
l!(
0eedte$*era:
ture
Heater !utlet te$*erature
↓ 2
5#i"# dire"ti!n (!uld "ause t#e ee"t2
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-+ En%a%e
=+ Deine
;+ E)*l!re
+ I$*le$ent
?+ E,aluate
PROCESS TROUBLESHOOTING
• C#e"k in!r$ati!n and data&&&
: Is t#e te$*erature a"tuall' de"reasin%2: Is uel a"tuall' in"reasin%2
: 5#at *rin"i*les "an be used t! "#e"k data2
• 0unda$ental Balan"es
• Du*li"ate sens!rs !n t#e sa$e ,ariable
• C!nsisten"' in rate *r!"esses
: *ressure and l!(
: te$*eratures in #eat transer
• C!nsisten"' in e9uilibriu$ *r!"ess: te$*erature and *ressure in e9uilibriu$ *r!"ess
• Trends ! related ,ariables
: te$*erature and "!$*!siti!ns in rea"t!r
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-+ En%a%e
=+ Deine
;+ E)*l!re
+ I$*le$ent
?+ E,aluate
PROCESS TROUBLESHOOTING
• C#e"k in!r$ati!n and data&&&
: Is t#e te$*erature a"tuall' de"reasin%2: Is uel a"tuall' in"reasin%2
: 5#at *rin"i*les "an be used t! "#e"k data2
CLASS E@A7PLE
H!( "an (e ,eri' t#e data and in!r$ati!n
in t#e !ri%inal *r!ble$ state$ent2
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-+ En%a%e
=+ Deine
;+ E)*l!re
+ I$*le$ent
?+ E,aluate
PROCESS TROUBLESHOOTING
• C#e"k in!r$ati!n and data&&&
: Is t#e te$*erature a"tuall' de"reasin%2: Is uel a"tuall' in"reasin%2
: 5#at *rin"i*les "an be used t! "#e"k data2
-+ Te$*erature sens!rs !r "!nsisten"'1 es*e"iall'
TC:- and T
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• Rele,ant "#an%es $aintenan"e1 et"+
5e s#!uld "!nsider t#e ti$e se9uen"e in tr!uble
s#!!tin% #!(e,er1 a ti$e se9uen"e d!es n!t *r!,e
"ause:ee"t+
• Startu* e9ui*$ent irst *la"ed in ser,i"e
5e $ust "!nsider a (ider ran%e ! r!!t "auses
(#en e9ui*$ent is bein% started u*+
• Trends:5#at is dire"ti!n and rate ! "#an%e ! ,ariables2
-+ En%a%e
=+ Deine
;+ E)*l!re
+ I$*le$ent
?+ E,aluate
PROCESS TROUBLESHOOTING
Let3s e)*l!re t#ese issues in t#e
"lass e)a$*le+
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CLASS E@ERCISE
• Rele,ant "#an%es
a+ Calibrated T and an instru$ent in an!t#er *lant
b+ C#an%ed eed tank re9uired !*enin%"l!sin% bl!"k
,al,es
• Startu* : n!t a**li"able
• Trends
a+ 0!r a l!n% ti$e1 t#e TC:- see$ed t! un"ti!n1
#!ldin% T near its set *!int
b+ T#e eed l!( is in"reasin%+
"+ er' re"entl'1 TC:- is de"reasin% ra*idl'
d+ er' re"entl'1 0= is in"reasin% ra*idl'
-+ En%a%e
=+ Deine
;+ E)*l!re
+ I$*le$ent
?+ E,aluate
PROCESS TROUBLESHOOTING
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• 5#at is kn!(n and (#at is !*ini!n2
5e $ust "!nsider t#e state$ents ! !t#ers+ 5e
s#!uld seek ,alidati!n !r t#e state$ents+
• Use %uidelines and e)*erien"e a"t!rs
5e (ill build t#ese t#r!u%#!ut !ur "areers+
: H!( d!es data "!$*are (it# t'*i"al ran%e2
: Is t#at a t'*i"al *u$* !utlet *ressure2
: 5#at is a t'*i"al a**r!a"# te$*erature2: 5#at #a,e (e learned r!$ *ri!r aults2
-+ En%a%e
=+ Deine
;+ E)*l!re
+ I$*le$ent
?+ E,aluate
PROCESS TROUBLESHOOTING
Let3s "!$*lete buildin% !ur understandin%
! t#e "lass e)a$*le (it# t#ese issue+
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CLASS E@ERCISE
• 5#at is kn!(n and (#at is !*ini!n28n!(n
Data *l!tted
0eed tank "#an%ed 5as it2 5as it d!ne "!rre"tl'2
T "alibrated
O*ini!ns
An unusual s$ell is *resent
T#e "ause is t#e sta"k da$*er
• Use %uidelines and e)*erien"e a"t!rsa+ Are t#e ,alues ! t#e *r!"ess ,ariables t'*i"al2
b+ H!( l!n% d!es t#e TC:- ,ar' be!re it “settles
d!(n” ater a l!( "#an%e
"+ 5#at is a t'*i"al disturban"e t! TC:-2
-+ En%a%e
=+ Deine
;+ E)*l!re
+ I$*le$ent
?+ E,aluate
PROCESS TROUBLESHOOTING
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PROCESS TROUBLESHOOTING
-+ En%a%e
=+ Deine
;+ E)*l!re
+ I$*le$ent
?+ E,aluate
“T#e s!luti!n t! a *r!"ess *r!ble$ isn3t
!und b' sittin% be#ind '!ur desk1 but b'
%!in% t! t#e *lant and "arr'in% !ut tests
and e,aluatin% t#e data+”
b' Laird1 et al1 C#e$+ En%r+ Pr!%ress1 =...
5e #a,e t! anal'e t#e initial data and
!r$ulate (!rkin% #'*!t#eses+ T#ese#'*!t#eses %i,e us a basis !r
in,esti%ati!ns6 t#e' !"us !ur
in,esti%ati!ns+
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PROCESS TROUBLESHOOTING
-+ En%a%e
=+ Deine
;+ E)*l!re
+ I$*le$ent
?+ E,aluate
INITIAL EIDENCE
Su((ort, Dis(roe,
Neutral
DIAGNOSTIC ACTIONS
Su((ort, Dis(roe, NeutralOR8ING H4POTHESES
a ) / d e % C D
Brainst!r$ "auses Su**!rtNeutraldis*r!,e
C!nsider ti$e1 "!st1 and se9uen"e+
Ne(1 dia%n!sti"
a"ti!ns
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PROCESS TROUBLESHOOTING
-+ En%a%e
=+ Deine
;+ E)*l!re
+ I$*le$ent
?+ E,aluate
STEPS IN “PLAN”
A+ Brainst!r$ *!ssible r!!t "auses t#at $i%#t
e)*lain t#e initial e,iden"e
B+ Careull' "!$*are t#e "andidate #'*!t#eses
(it# t#e initial data and dis*r!,e
#'*!t#eses1 i *!ssible+
C+ De,el!* a list ! dia%n!sti" a"ti!ns t#at (ill
#a,e dierent !ut"!$es !r ea"# re$ainin%(!rkin% #'*!t#esis+
D+ Order t#e dia%n!sti" a"ti!ns a""!rdin% t!
!ll!(in%6 - #i%# i$*a"t !r redu"in%
#aards1 = l!( "!st and ; s#!rt ti$e+
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PROCESS TROUBLESHOOTING
-+ En%a%e
=+ Deine
;+ E)*l!re
+ I$*le$ent
?+ E,aluate
GENERATING THE CANDIDATE ROOT
CAUSES
C#allen%e t#e"!n,enti!nal (isd!$
@@@@ ust "!uld n!t#a**en+
• D! n!t be"!nr!ntati!nal
• based !n *rin"i*les
• *r!*!se dia%n!sti"
a"ti!n
• Bl!"ked *i*e• 0alse $easure$ent
• C#an%e in e9ui*$ent
*er!r$an"e
• C#an%e is "!n,ersi!n
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PROCESS TROUBLESHOOTING
-+ En%a%e
=+ Deine
;+ E)*l!re
+ I$*le$ent
?+ E,aluate
INITIAL EIDENCE
Su((ort, Dis(roe,
Neutral
DIAGNOSTIC ACTIONS
Su((ort, Dis(roe, NeutralOR8ING H4POTHESES
a ) / d e % C D
Brainst!r$ "auses Su**!rtNeutraldis*r!,e
C!nsider ti$e1 "!st1 and se9uen"e+
Ne(1 dia%n!sti"
a"ti!ns
H!( d! (e kn!( t#e entries6 #'*!t#eses1 initial e,iden"e
and dia%n!sti" a"ti!ns2
T#e' are based !n t#e understandin% de,el!*ed
durin% t#e “E)*l!re” ste*1 (#i"# is "ru"ial
!r %!!d tr!uble s#!!tin%+
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PROCESS TROUBLESHOOTING
-+ En%a%e
=+ Deine
;+ E)*l!re
+ I$*le$ent
?+ E,aluate
INITIAL EIDENCE
Su((ort, Dis(roe,
Neutral
DIAGNOSTIC ACTIONS
Su((ort, Dis(roe, NeutralOR8ING H4POTHESES
a ) / d e % C D
Brainst!r$ "auses Su**!rtNeutraldis*r!,e
C!nsider ti$e1 "!st1 and se9uen"e+
Ne(1 dia%n!sti"
a"ti!ns
CLASS E@A7PLE
• De,el!* a set ! (!rkin% #'*!t#eses!r t#e ired #eater *r!ble$+
• E,aluate ea"# usin% t#e initial e,iden"e
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PROCESS TROUBLESHOOTING
-+ En%a%e
=+ Deine
;+ E)*l!re
+ I$*le$ent
?+ E,aluate
LIST O0 T4PICAL 5OR8ING H4POTHESESn!t ne"essaril' "!$*lete
• TC:- "!ntr!l l!!* is unstable
• Pa"ked bed rea"t!r is *lu%%ed
• TC:- sens!r is ault' readin% l!(er t#at a"tual T
• 0uel ,al,e ;.. is ault'
• 0eed tank is runnin% dr'1 "ausin% ,!rte)
• Sta"k da$*er is t!! ar "l!sed
• 0eed l!( rate is t!! #i%#
Are t#ese r!!t
"auses2
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PROCESS TROUBLESHOOTING
-+ En%a%e
=+ Deine
;+ E)*l!re
+ I$*le$ent
?+ E,aluate
Use "urrent in!r$ati!n t! dierentiate
a$!n% "andidates
D!es initial e,iden"e su**!rt1 is it neutral1
!r d!es it dis*r!,e2
Re$e$ber t#at initial e,iden"e is sube"t t!
err!rs1 !r e)a$*le1 a sens!r "!uld be ault'
!r an !*ini!n "!uld be (r!n%+
T#is t#!u%#t *r!"ess (ill #el* t! ideni'
dia%n!sti" a"ti!ns t! "!$*lete tr!uble
s#!!tin%+
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PROCESS TROUBLESHOOTING
-+ En%a%e
=+ Deine
;+ E)*l!re
+ I$*le$ent
?+ E,aluate
Dia%n!sti" A"ti!ns t! dierentiate a$!n%
re$ainin% "andidates
G!!d a**r!a"#es
: S*e"ii" and desi%ned t! test #'*!t#esis: C!nir$ data F in!r$ati!n
: C!$*are (it# re"entt'*i"al data
: D! s$all e)*eri$ents
• ariables "an be $easured• Seek "!nir$in% in!r$ati!n• Retrie,e useul #ist!ri"al data• Anal'e "ause:ee"ts
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PROCESS TROUBLESHOOTING
-+ En%a%e
=+ Deine
;+ E)*l!re
+ I$*le$ent
?+ E,aluate
Dia%n!sti" A"ti!ns
P!!r A"ti!ns
: “C#e"k t#e ,al,e”: “5#at is t#e #eat transer "!ei"ient2”
: “5#at is t#e uel te$*erature2”
: “S#utd!(n *lant and !*en rea"t!r”
T#ese a"ti!ns9uesti!ns are t!! ,a%ue !r "ann!t
be d!ne+ H!( (!uld '!u *er!r$ t#e a"ti!n
and *r!,ide t#e results t! an en%ineer2
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Feed tank
FC
1
P3
V 3 0 0
TC
3
T4
Fuel
oil
F
2T7
Produt
tank
C!"!
F
7
#ir
$ntake
FC
5
L-
L=
P-
P;
T>
T?
Hypothesis Initial information Diagnostic ActionTC sens!r drit
0uel ,al,e is stu"k !*en
0eed rate "ausin% T de"rease
TC t!! sl!(
Let3s "!$*lete t#e table !r t#ese
#'*!t#eses
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Hypothesis Initial information Diagnostic ActionT sens!r drit Neutral C#e"k (it# te$*erature at
e)it ! rea"t!r
0uel ,al,e is stu"k !*en Dis*r!,e
Te$*erature (!uldin"rease
Pla"e l!( "!ntr!ller in
$anual and $ake s$all"#an%e t! "!ntr!ller !ut*ut
0eed rate "ausin% T de"rease
TC t!! sl!(
Dis*r!,e
*re,i!us "#an%es (ere
"!ntr!lled
Feed tank
FC
1
P3
V 3 0 0
TC
3
T4
Fuel
oil
F
2T7
Produt
tank
C!"!
F
7
#ir
$ntake
FC
5
L-
L=
P-
P;
T>
T?
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PROCESS TROUBLESHOOTING
-+ En%a%e
=+ Deine
;+ E)*l!re
+ I$*le$ent
?+ E,aluate
INITIAL EIDENCE
Su((ort, Dis(roe,
Neutral
DIAGNOSTIC ACTIONS
Su((ort, Dis(roe, NeutralOR8ING H4POTHESES
a ) / d e % C D
Brainst!r$ "auses Su**!rtNeutraldis*r!,e
C!nsider ti$e1 "!st1 and se9uen"e+
Ne(1 dia%n!sti"
a"ti!nsCLASS E@A7PLE
• De,el!* a set ! dia%n!sti" a"ti!ns+
• C!ntinue until t#e r!!t "ause #as been identiied+
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PROCESS TROUBLESHOOTING
5!rkin% #'*!t#esis Initial data SND
'C?1 unsta)le , transient /ould )e start o! lare
os/illation
8a/;ed )ed (lued D, !lo: a((ears normal in F1 and F@'C?1 sensor lo: , a/tual tem(erature /ould )e hih
Vale 300 !aulty D, the !uel !lo: is in/reasin
Feed tan; lo: D, the !eed !lo: is normal
#ta/; dam(er /losed #, /ould a!!e/t the /om)ustion
Feed !lo: rate too hih
'his is not a root /ause. 7et>s assume that
the (ro(osed root /ause is not enouh !uel
, !uel ale not !ully o(ened
EALUATE THE 5OR8ING H4POTHESES
S = Support, N = Neutral, D = Disprove
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PROCESS TROUBLESHOOTING
EALUATE THE 5OR8ING H4POTHESES
5!rkin% #'*!t#esis Dia%n!sti" data SND
'C?1 unsta)le 8la/e /ontroller 'C?1 in maual andin/rease /ontroller out(ut slo:ly
8a/;ed )ed (lued +%'C?1 sensor lo: Com(are the tem(eratures !rom '4 and '@
Vale 300 !aulty +%
Feed tan; lo: +a
#ta/; dam(er /losed *n/rease the dam(er o(enin
Feed !lo: rate too hih
'his is not a root /ause. 7et>s assume thatthe (ro(osed root /ause is not enouh !uel
+%
S = Support, N = Neutral, D = Disprove
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PARETO PLOT
Esti$ate t#e beneit r!$ ea"# "!rre"ti,e a"ti!n1 and
i$*le$ent t#!se ustiied.
ene!it
Corre/tie a/tion
PROCESS TROUBLESHOOTING
-+ En%a%e
=+ Deine
;+ E)*l!re
+ I$*le$ent
?+ E,aluate
D! it&
7an' a"ti!ns $a' be *!ssible+ 5e sele"t
t#!se ustiied b' beneits+
A Paret! *l!t *r!,ides a ,isual dis*la' !
relati,e beneits+
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PROCESS TROUBLESHOOTING
-+ En%a%e
=+ Deine
;+ E)*l!re
+ I$*le$ent
?+ E,aluate
INITIAL EIDENCE
Su((ort, Dis(roe,
Neutral
DIAGNOSTIC ACTIONS
Su((ort, Dis(roe, NeutralOR8ING H4POTHESES
a ) / d e % C D
Brainst!r$ "auses Su**!rtNeutraldis*r!,e
C!nsider ti$e1 "!st1 and se9uen"e+
Ne(1 dia%n!sti"
a"ti!ns
5e (ill "!ntinue dia%n!sti" a"ti!ns until !nl'
!ne #'*!t#esis re$ains t#at #as n!t been
dis*r!,ed+ At t#at *!int1 (e (ill %enerall'
"!n"lude t#at t#e re$ainin% #'*!t#esis is true+
5e (ill "all it t#e “r!!t "ause”+
N!te t#at (e #a,e n!t *r!,ed t#e #'*!t#esis
(e #a,e n!t dis*r!,ed it+
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PROCESS TROUBLESHOOTING
-+ En%a%e
=+ Deine
;+ E)*l!re
+ I$*le$ent
?+ E,aluate
D! it&
A"#ie,e t#e
Initial state 9ui"kl'
: Return t! sae !*erati!n
: A""e*table *r!du"t 9ualit'
: Pr!te"t *r!"ess e9ui*$ent
0inal state reliabl': Ei"ient*r!itable !*erati!n
: Desired *r!du"ti!n rate1 i easible
: A"#ie,ed (it#!ut undue $!nit!rin%
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PROCESS TROUBLESHOOTING
-+ En%a%e
=+ Deine
;+ E)*l!re
+ I$*le$ent
?+ E,aluate
P!ssible s!luti!n s"!res
7usts 1 AA 4
1. #a!ety 4 9
2. $eet (rodu/tion /ontra/ts 9 9
5ants :eiht1. DCF B 15 10
2. nery E 2 =+; 5 @
'otal :eihted s/ore 115
5e t'*i"all' (ill NOT "!$*lete Paret!
"#arts !r 7ust5ant tables (#en s!l,in%a *lant *r!ble$+
But1 (e need t! use t#ese $et#!ds (it#!ut
!r$al d!"u$entati!n&
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Let3s *re*are t#e ste*s!r a"#ie,in% t#e
desired states+
-+ En%a%e
=+ Deine
;+ E)*l!re
+ I$*le$ent
?+ E,aluate
CLASS E@A7PLE
Feed tank
FC
1
P3
V 3 0 0
TC
3
T4
Fuel
oil
F
2T7
Produt
tank
C!"!
F
7
#ir
$ntake
FC
5
L-
L=
P-
P;
T>
T?
T>
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R!!t "ause
• In"rease eed⇒
l!(er T
• L!(er T⇒
"!ntr!ller in"reases uel
• De"reased airuel air"!nstant
• Insui"ient air⇒
l!(er T
8e' C!n"e*t
T#e *r!"ess %ain in
t#e eedba"k l!!*
"#an%ed si%n&
Feed tank
FC
1
P3
V 3 0 0
TC
3
T4
Fuel
oil
F
2
T7
Produt
tank
C!"!
F
7
#ir
$ntake
FC
5
L-
L=
P-
P;
T>
T?
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PROCESS TROUBLESHOOTINGPROCESS TROUBLESHOOTING
-+ En%a%e
=+ Deine
;+ E)*l!re
+ I$*le$ent
?+ E,aluate
A"#ie,e t#e irst desired state ra*idl'&
• Pla"e TC:- in $anual1 st!* t#e in"rease ! uel t!
#eater
• Cl!se uel ,al,e ,;.. until T:- starts t! in"rease
N!te6 D! n!t in"rease t#e air t! t#e uel ri"#
#eater en,ir!n$ent&
• Ensure t#at !)'%en is in e)"ess in lue %as n!s$!ke1 ,ie( la$e1 sa$*le lue %as t! lab
• Pla"e TC:- in aut!
• C!ntinue t! in"rease eed1 but in"rease air l!(
be!re eed& 7!nit!r sta"k %as+
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PROCESS TROUBLESHOOTINGPROCESS TROUBLESHOOTING
-+ En%a%e
=+ Deine
;+ E)*l!re
+ I$*le$ent
?+ E,aluate
A"#ie,e t#e inal desired state+
• Install !n:strea$ lue %as anal'er
• Set desired e)"ess !)'%en b' e)*erien"e t! be -+>:
=/• Pr!,ide l!( !)'%en alar$ t'*i"al ,alue ! -/
• Train !*erat!rs t! adust air l!( t! a"#ie,e
desired e)"ess !)'%en
• Aut!$ate t#e "!ntr!l ! !)'%en b' adustin% t#eair l!( rate+ T#is (!uld be a "as"ade "!ntr!l
desi%n+
OC SS O S OO G
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PROCESS TROUBLESHOOTING
-+ En%a%e
=+ Deine
;+ E)*l!re
+ I$*le$ent
?+ E,aluate
Create a “L!!kba"k”
• Did (e s!l,e t#e R!!t Cause2
• Did (e %enerate $!re "!nir$in%
in!r$ati!n2• H!( "an (e *re,ent in t#e uture
: trainin%
: $!nit!rin% *r!%ra$s
: $!dii"ati!ns t! "urrent *lant e9ui*$ent F!r
*r!"edures: desi%n %uidelines !r uture *lants
• En#an"e !ur *ers!nal e)*erien"e a"t!rs
•C#e"k et#i"s and le%al !ne $!re ti$e
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Let3s *re*are a l!!k
ba"k (it# ste*s t!
*re,ent uture in"idents
-+ En%a%e
=+ Deine
;+ E)*l!re
+ I$*le$ent
?+ E,aluate
CLASS E@A7PLE
Feed tank
FC
1
P3
V 3 0 0
TC
3
T4
Fuel
oil
F
2T7
Produt
tank
C!"!
F
7
#ir
$ntake
FC
5
L-
L=
P-
P;
T>
T?
PROCESS TROUBLESHOOTING
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PROCESS TROUBLESHOOTING
SO7E T4PICAL STRATEGIES THAT DO NOT 5OR8
-+ I '!u d!n3t understand1 %uess+
=+ C!nuse s'$*t!$s (it# r!!t "ause+
;+ Get tunnel ,isi!n+
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T r ! u b l e s # ! ! t i n %
Attitude C#e"k
I #ate tr!uble s#!!tin%+
T#e !r$s are t!! l!n%1
I d!n3t kn!( en!u%#ab!ut e9ui*$ent1 and
I d!n3t like t#e *ressure+4ea#1 'ea#1 I kn!(
t#at I3ll #a,e t!
tr!uble s#!!t+
I3ll (ait until it
reall' $atters+• N! $e$!riati!n1 '!u (ill #a,e
t#e !r$
• G!!d1 “*r!ble$:based” (a' t!
learn ab!ut e9ui*$ent
•Pressure1 tr' (#en MM $atters&
• 5#en it $atters1 (e #a,e t!
*r!du"e i$$ediatel'+
PROCESS TROUBLESHOOTING
PROCESS TROUBLESHOOTING
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PROCESS TROUBLESHOOTING
8e' additi!nal less!n6 5e $ust build *lants t#at "an be
$!nit!red and dia%n!sed& T#is re9uires $an' e)tra sens!rsl!"al and re$!te1 sa$*le *!ints !r lab!rat!r'1 and
s!$eti$es1 ,isual !bser,ati!n %lass *!rts+
5#at (!uld '!u
add t! t#is desi%n
t! i$*r!,e
tr!ubles#!!tin%2
Feed tank
FC
1
P3
V 3 0 0
TC
3
T4
Fuel
oil
F
2T7
Produt
tank
C!"!
F
7
#ir
$ntake
FC
5
L-
L=
P-
P;
T>
T?
PROCESS TROUBLESHOOTING
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0urt#er Ste*s t! Reine Tr!uble S#!!tin% Skills
• Re,ie( atta"#ed table (it# enri"#in% and detra"tin%
be#a,i!rs !r a tr!uble s#!!ter• Ski$ reeren"es !n t#e ne)t slide and l!"ate #ints $!st
#el*ul t! '!u
• Per!r$ t#e (!rks#!*s in"luded in t#is less!n
• Pra"ti"e t#e tr!uble s#!!tin% $et#!d !n *r!ble$s '!u
en"!unter in '!u studies lab!rat!r'1 inde*endent
resear"#1 !*erabilit' *r!e"t in t#is "!urse1 et"+
PROCESS TROUBLESHOOTING
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Reeren"es !r Tr!uble S#!!tin%
'he !ollo:in three resour/es (roide e/ellent a((roa/hes and use!ul re!eren/es !or !urther
study.
Foler, H. #/ott and #tee 7elan/, Strategies for Creative Problem Solving , 8renti/e Hall 8'&,
G((er #addle &ier, 15.
Ie(ner, Charles and en
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• Deelo( a mental imae o! the (ro)lem
Various leels o! a//ura/y to s/reen ideas, Jsu//essie a((roimationK
For eam(le,
? in(ut+out(ut only, no details o! me/hanisms :ithin system
? order o! manitude on system )ehaior
? limits on )ehaior se/ond la:, euili)rium, et/.
? ty(i/al results !rom similar /al/ulations or data
? sim(li!ied analysis /onstant (ro(erties, (er!e/t eui(ment, et/.
? detailed /al/ulations !lo:sheetin
? thorouh data e(erimentation see Chem. n. 4C03 !or methods
• *nitially, remoe some /onstraints !rom the (ro)lem.
? *! * /ould loo; at the /atalyst sur!a/e, A
? *! * /ould ;no: the a/tual rate o! rea/tion, A
? *! * /ould loo; at the internal !lo:s in the essel, A.
• e o(en to an unli;ely )ut not im(ossi)le root /ause
• Deelo( the Jnothin ha((enedK hy(othesis. Could the situation arise :ithout a (ro)lem )ut :ith a !ault in some dataL *s this
really a (ro)lemL
• 'a;e a ris; :ith a J!ar outK idea
• Don>t
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A**endi) B+ E)tra t!*i"s !r PLAN
#hort term
• to moe ui/;ly to a sa!e and enironmentally a//e(ta)le /ondition
• to aoid damae to eui(ment
• to maintain the (lant in a /ondition to reain o(eration ui/;ly i! (ossi)le
• to !urther eri!y the dianosis i! needed
• to maintain (rodu/t uality i! (ossi)le• to a/hiee as near as (ossi)le the desired (rodu/tion rate
7oner term
• to shutdo:n eui(ment, i! needed !or re(air, sa!ety, et/.
• to (roide time !or detailed analysis and /al/ulations or la)oratory inestiations
• to (er!orm dianosis (ossi)le only on (lant a!ter shutdo:n
• to im(roe the o(eratin (oli/y used )y (lant (ersonnel
• to im(roe the maintenan/e (oli/y o! the (lant
• to (roide im(roed eui(ment !or the (lant
e. Continue to 'rou)le #hoot
• Ho: /an :e monitor the solution to eri!y that the dianosis :as /orre/tL
• Ho: /an :e )e alert !or other (otential (ro)lemsL
!. Communi/ate and see; su((ort and /ritiues !rom others• aturally, this de(ends on the time aaila)le and /ost o! the solution
• Do not relate the history o! your (ro)lem solinM ie a summary o! the situation, dianosis ta)le, )asis !or root /ause dianosis
and (ro(osed solution.• Clearly relate the im(li/ations !or sa!ety, enironment, (rodu/t uality, (rodu/tion and /ost
• e /on/ise
• e honestM e(lain any remainin un/ertainty
. When areement has )een rea/hed and authority ien
• Do/ument the analysis and solution /learly and (re/isely
• 8roide a /lear (lan o! ee/ution :ith measura)le /he/; (oints
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A**endi) C+ E)tra t!*i"s !r EALUATE
a. Did :e sole the (ro)lemL Com(are the results :ith (redi/tions
). What are the )ene!i/ial /ollateral /onseuen/es o! solin the (ro)lemL
? Ho: /an :e )e sure to sustain theseL
/. What are (otential (ro)lems /aused )y your solution ethi/al, leal, sa!ety, (ro!it et/.L
? 8re(are /orre/tie a/tions i! they should o//ur
d. Ho: /an :e (reent this (ro)lem !rom re/urrinL
e. Ho: /an you hel( your /olleaues !rom your learnin e(erien/eL
!. Ho: /an :e add to our e(erien/e !a/torsL
. Ho: /an :e identi!y a similar (otential (ro)lem at an early stae in its deelo(mentL
nineers esta)lish (ro/ess $!nit!rin% and dia%n!sis (ro/edures that are (er!ormed routinely to (roide early indi/ation o!
(lant (er!orman/e. Ho: /an the (ro)lem solin e(erien/e )e used to im(roe monitorin o! this (lantL For eam(le,
• *m(roed trainin o! o(eratin (ersonnel• %dditional sensors or (eriodi/ la)oratory analysis• %dditional /al/ulations to summariNe (lant (er!orman/e yields, enery+;, e!!i/ien/y, heat trans!er eui(ment, et/.
• 7o/al monitorin o! eui(ment
• *m(roed maintenan/e (ro/edures that are (er!ormed immediately u(on a s(e/i!i/ /ondition in the (lant
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TROUBLE SHOOTING 5OR8SHOP
5e (ill i$*r!,e !ur TS skills b' a**l'in% t#e standard
$et#!d t! a *r!"ess (it# (#i"# (e are all a$iliar1
distillati!n+ T#e *r!"ess is %i,en in t#e !ll!(in% i%ure+
N!te t#at t#e distillati!n *r!"ess in"ludes #eat transer1luid l!(1 *r!"ess "!ntr!l and saet' e9ui*$ent+
5e "ann!t "!$*art$entalie !ur kn!(led%e (#en s!l,in%
realisti" *r!ble$s&
0!ur *r!ble$s are *r!,ided+ 4!u (ill (!rk in %r!u*s t!
s!l,e t#ese+ T#e instru"t!r (ill *r!,ide eedba"k t! '!ur
9uesti!ns and dia%n!sti" a"ti!ns+
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T(!:distillati!n
*r!"ess used in t#e
Tr!uble S#!!tin%
5!rks#!*
• De*r!*anier
• Debutanier
See larger co"# in the lecture notes$
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TROUBLE SHOOTING 5OR8SHOP E@ERCISE -
'he ne: t:o?distillation to:er (lant in the !iure :as
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TROUBLE SHOOTING 5OR8SHOP E@ERCISE =
'o )e a)le to sell your (rodu/ts, your (lant must o)tain *#- /erti!i/ation. 'his ensures that the
(lant has /onsistently en!or/ed uality /ontrol (ro/edures. 9our /ustomer seri/e enineerre(orts that one o! the /ustomers is dissatis!ied :ith the )utane (rodu/tM you don>t hae more
details. %s a result, you hae esta)lished a routine /om(osition analysis o! arious streams in the
de(ro(aniNer and de)utaniNer in the t:o?distillation (ro/ess that has )een o(eratin !or years.
'he /om(osition monitorin (roram has )een o(eratin !or one :ee;. 'he la)oratory analyses
indi/ate too mu/h aria)ility in the mole !ra/tion (ro(ane in the )ottoms o! the de(ro(aniNer, C?.
For the last day, the mole !ra/tion (ro(ane has )een a)out 0.04, :hile the taret is 0.015.
e!ore the ne: (ro/edures, :e neer ;ne: that :e :ere o(eratin the (lant (oorly, so no one
/aredO *! you /annot o)tain *#- /erti!i/ation, the /om(any :ill not )e a)le to sell (rodu/ts to the
;ey /ustomers.
eryone is mad at you !or !indin the (ro)lemO 9ou )etter sole this (ro)lem so that the (lant
/an /ontinue to o(erate and you are sa!e at :or;.
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TROUBLE SHOOTING 5OR8SHOP E@ERCISE ;
'he o(eration o! the u(stream (ro/ess, :hi/h (re(ares the !eed to the t:o?distillation to:er
(ro/ess, is )ein modi!ied to a//ommodate a ne: /atalyst and modi!ied ra: material/om(osition. 'he ne: u(stream (ro/ess has )een o(eratin !or nearly a shi!t, and the t:o
distillation to:ers seem to )e !un/tionin :ell. 9ou note that some o! the tray tem(eratures are
di!!erent !rom )e!ore the /hane, )ut the (rodu/t (urities, as measured )y s(e/ial la)oratory
analysis, are ery near their s(e/i!i/ations. 9ou are satis!ied that all is :ell. 9ou return to your
o!!i/e to eat that mu!!in that you (ur/hased on the :ay to :or; this mornin.
ust :hen you hae )re:ed the /o!!ee and heated the mu!!in in the mi/ro:ae, the (lanto(erator /alls you. 'he hih (ressure alarm in the de)utaniNer is on, and the o(erator is :orried
that the sa!ety ale :ill o(en. 9ou are neer sure that it :ill /lose /om(letely, so :e don=t
:ant it to o(en unless needed. He thin;s that the u(stream /hane is the /ause o! the (ro)lem
)ut doesn>t ie you a /lear reason :hy.
9ou hae not )een :or;in in this unit !or lon, so here is your /han/e to ma;e !riends :ith
the o(erator. 7et=s :or; :ith the o(erator to !i this (ro)lemO
TROUBLE SHOOTING 5OR8SHOP E@ERCISE
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TROUBLE SHOOTING 5OR8SHOP E@ERCISE <
'his t:o?distillation to:er (ro/ess :as su//ess!ully started u( in anuary, :hen a /are!ul /he/;
indi/ated that the o(eration :as ery /lose to the desin alues. 9ou are sure o! that )e/ause you
:or;ed 12 hours (er day to /he/; and dou)le /he/; eerythin.
*n %uust, you are assined the res(onsi)ility !or this (ro/ess. 9ou de/ide to ta;e a /are!ul loo; at
the /urrent o(eration. 7a)oratory analysis o! the de(ro(aniNer a(or (rodu/t indi/ates a hih loss o!
(ro(ane to the !uel system, 2.5 times the desin alue.
'his loss o! (rodu/t to !uel is /ostin lots o! moneyO 9ou :ant to !ind the /ause !ast P you :ould
li;e to (roide a solution as :ell as a (ro)lem to the (lant manaer. 'ime to a((ly your trou)leshootin s;illsO
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