Module 13 – Process Troubleshooting & Problem Solving

Objective:
By the end of this module, a trainee will be able to:

1. Understand the purpose of troubleshooting in a chemical plant.

2. Recognize common operational issues in butadiene/petrochemical plants.

3. Use a systematic approach to identify root causes.

4. Apply safe corrective actions.

5. Document and communicate problems effectively.

13.1 – Introduction to Troubleshooting

Definition:

• Troubleshooting = systematic investigation to identify and resolve abnormal conditions in plant operation.

Importance:

• Prevents process upsets, safety incidents, and production losses.

• Enhances operator decision-making and plant reliability.

Operator Role:

• Observe process trends and alarms.

• Apply logical problem-solving methods.

• Escalate issues when necessary.

Analogy:

• Troubleshooting = “diagnosing why a car won’t start: check battery, fuel, ignition, and sensors step by step.”

13.2 – Common Operational Issues

1. Flow Issues:

• Low or no flow through pump, line, or heat exchanger.

• Causes: strainer blockage, pump failure, valve misalignment.

2. Temperature Deviations:

• Too high or too low in reactor, column, or exchanger.

• Causes: heater malfunction, cooling water issue, feed imbalance.

3. Pressure Abnormalities:

• High pressure → safety relief activation

• Low pressure → feed/venting issue

• Causes: valve malfunction, compressor/pump issue, blockage.

4. Level Fluctuations:

• Tank, separator, or column level abnormal

• Causes: faulty level transmitters, improper feed, drain/overflow issue

5. Product Quality Off-Spec:

• Composition deviates from specification

• Causes: feedstock variation, temperature/pressure deviation, separation inefficiency

Operator Tips:

• Note trends and alarms before taking corrective action.

• Avoid hasty adjustments without understanding root cause.

13.3 – Systematic Troubleshooting Approach

Step 1 – Observe & Identify:

• Examine alarms, trends, and field indicators.

• Record abnormal parameters and affected units.

Step 2 – Isolate the Problem:

• Determine which system or equipment is causing the deviation.

• Use SOPs and logic diagrams to identify potential sources.

Step 3 – Analyze Causes:

• Consider feedstock, utilities, equipment, and instrumentation.

• Cross-check with normal operating ranges.

Step 4 – Take Corrective Action (Safe & Controlled):

• Adjust valves, flow, or temperature gradually.

• Switch to standby equipment if available.

• Notify control room or supervisor before major adjustments.

Step 5 – Verify & Monitor:

• Confirm process returns to normal range.

• Continue trend observation to ensure stability.

Step 6 – Document & Communicate:

• Record root cause, actions taken, and follow-up required.

• Share information during shift handover.

Analogy:

• Troubleshooting = “detecting which wire, fuse, or circuit is causing lights to flicker in a house”

13.4 – Operator Tips for Troubleshooting

1. Always follow SOPs and safety protocols.

2. Do not bypass interlocks or alarms without authorization.

3. Use trend data to detect slow-developing issues.

4. Collaborate with maintenance, control room, and lab for verification.

5. Stay calm and systematic, avoid random adjustments.

Analogy:

• Operator = “detective solving a puzzle step by step, using evidence (data) rather than guesswork.”

13.5 – Examples of Conceptual Troubleshooting Scenarios

• Pump vibration

High vibration observed

Bearing wear, cavitation, suction blockage

Check suction, strainer, standby pump, report to maintenance

• Reactor temp high

Temperature rising above setpoint

Heater malfunction, insufficient cooling

Reduce feed, adjust cooling, notify supervisor

• Column pressure drop

Pressure lower than normal

Leak, valve stuck open

Check valves, feed, and purge; notify control room

• Low product purity

Butadiene below spec

Feedstock impurity, temperature deviation

Check feed quality, reactor temp, separation unit; alert lab

• Cooling water high temp

Outlet temp exceeds limit

Pump low flow, fouled heat exchanger

Increase flow, clean exchanger, notify maintenance

Operator Tips:

• Document all steps for learning and handover.

• Use conceptual reasoning: always ask “what changed?”

13.6 – Quiz / Knowledge Check

1. What is the first step in systematic troubleshooting?

2. Name three common operational issues in a petrochemical plant.

3. Why should operators not bypass interlocks during troubleshooting?

4. Give an example of using trend data for troubleshooting.

5. What are the key steps after identifying the root cause?

6. Give an analogy for troubleshooting in everyday life.

13.7 – Media Sites Integration

• Videos:

  • Conceptual troubleshooting animation for common issues

  • Trend observation and operator response walkthrough

  • Panel and field check demonstration (conceptual)

• Diagrams / Infographics:

  • Troubleshooting flowchart

  • Table of common issues, causes, and actions

  • Conceptual scenario resolution diagrams

• PDF Downloads:

  • Troubleshooting checklist template

  • Scenario exercises guide

  • Operator observation log template

• Interactive:

  • Embedded quizzes

  • Scenario exercises: detect abnormal conditions and suggest corrective actions

13.8 – Summary & Key Takeaways

1. Troubleshooting = systematic problem-solving to restore safe, normal operation.

2. Common issues include flow, temperature, pressure, level, and product quality deviations.

3. Operators use observation, analysis, controlled action, verification, and documentation.

4. Trend data, SOPs, and collaboration with maintenance/lab are essential.

5. Safe and systematic troubleshooting prevents accidents, equipment damage, and process upsets.