Module 22 – Troubleshooting & Problem Solving

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

1. Understand a systematic approach to troubleshooting in a petrochemical plant.

2. Identify common operational issues in process units.

3. Make safe, informed decisions as an operator during abnormal situations.

4. Apply basic problem-solving techniques to prevent escalation.

5. Document and communicate findings effectively.

22.1 – Introduction to Troubleshooting & Problem Solving

Definition:

• Troubleshooting = the process of identifying, diagnosing, and resolving problems in a system or process.

• Problem Solving = applying logical and structured methods to resolve abnormal conditions safely and efficiently.

Importance:

• Prevents process upsets, equipment damage, and safety hazards.

• Reduces downtime and production losses.

• Builds operator confidence and expertise.

Operator Role:

• Observe process trends and alarms.

• Diagnose the root cause using logic and SOPs.

• Take corrective action safely and document the process.

Analogy:

• Troubleshooting = “diagnosing why a car won’t start and fixing it step by step.”

22.2 – Systematic Troubleshooting Approach

Step 1: Observation & Data Collection

• Check alarms, trends, readings, and equipment status.

• Record abnormal values and recent changes.

• Note utility status and environmental factors.

Step 2: Identify Symptoms & Priority

• Determine which systems are affected.

• Prioritize safety, environmental, and production impact.

Step 3: Hypothesis & Analysis

• Consider possible causes based on symptoms.

• Use knowledge of process design and normal operation.

Step 4: Verify & Test

• Check instruments, valves, pumps, and other equipment.

• Compare observed data with expected normal values.

Step 5: Take Corrective Action

• Adjust setpoints, start/stop equipment, or isolate systems.

• Always follow SOPs and safety guidelines.

Step 6: Monitor & Confirm Resolution

• Observe return to normal operation.

• Check product quality, process stability, and utility status.

Step 7: Document & Communicate

• Record cause, action taken, and outcome in logbook.

• Notify control room, maintenance, and supervisor if needed.

Analogy:

• Troubleshooting flow = “detect → diagnose → fix → verify → document.”

22.3 – Common Process Issues & Operator Actions

• Temperature Abnormality

Reactor or column too hot/cold

Adjust heat input, check cooling/heating systems, monitor trend

• Pressure Drop/Increase

Pump, column, or pipeline

Check for blockage, valve position, pump performance, ESD interlocks

• Flow Issue

Low/high feed or product flow

Verify pump operation, strainer condition, valve position

• Level Issue

Tanks, reflux drum, or reboiler

Adjust level control, check instrumentation, verify feed/return lines

• Quality Deviation

Off-spec product

Check feed composition, temperature, pressure, and separation efficiency

• Utility Failure

Steam, cooling water, instrument air

Notify control room, follow SOP for safe operation, initiate backup systems

Operator Tips:

• Always check trending data for gradual issues.

• Verify SOP and normal operating limits before taking action.

• Collaborate with maintenance for recurring issues.

22.4 – Decision-Making Guidelines

1. Safety First: protect personnel and environment before production.

2. Assess Impact: prioritize based on severity and risk.

3. Check SOPs: follow standard procedures for known issues.

4. Collaborate: involve control room, maintenance, and supervisors.

5. Escalate When Needed: if situation is beyond operator capability.

Analogy:

• Operator decision-making = “chess player evaluating options and consequences before each move.”

22.5 – Preventive Troubleshooting Practices

• Regularly monitor key process variables and equipment condition.

• Perform daily rounds and inspection checklists.

• Document minor deviations to prevent major incidents.

• Attend training and refresher sessions on process systems.

• Participate in mock drills and scenario exercises.

Analogy:

• Preventive troubleshooting = “regular health checkups to prevent serious illness.”

22.6 – Quiz / Knowledge Check

1. What are the seven steps of a systematic troubleshooting approach?

2. How should an operator prioritize actions when multiple alarms occur?

3. Name three common process issues and operator actions.

4. Why is documentation important after troubleshooting?

5. Give an analogy for troubleshooting in a process plant.

6. What should an operator do if a problem is beyond their capability?

22.7 – Media Sites Integration

• Videos:

  • Step-by-step troubleshooting examples (temperature, pressure, flow)

  • Operator analyzing trends and taking corrective action

  • Scenario simulation of recurring process issue

• Diagrams / Infographics:

  • Troubleshooting flowchart

  • Decision-making tree

  • Process variable trend illustrations

• PDF Downloads:

  • Troubleshooting checklist template

  • Common issues and actions guide

  • Operator logbook template

• Interactive:

  • Embedded quizzes

  • Scenario exercises: detect and resolve abnormal trends

22.8 – Summary & Key Takeaways

1. Troubleshooting is systematic observation, diagnosis, and correction of process problems.

2. Operators must prioritize safety, process impact, and communication.

3. Common issues include temperature, pressure, flow, level, quality, and utility deviations.

4. Decision-making should follow SOPs, risk assessment, and escalation protocols.

5. Documentation and preventive practices improve plant reliability and operator expertise.