Successful Trouble Shooting for Process Engineers D R Woods Successful Trouble Shooting for Process Engineers Don Woods Copyright  2006 WILEY-VCH Verlag GmbH & Co KGaA, Weinheim ISBN: 3-527-31163-7 Further Titles of Interest: Büchel, K H., Moretto, H.-H., Woditsch, P Hattwig, M., Steen, H (Eds.) Industrial Inorganic Chemistry Handbook of Explosion Prevention Second, Completely Revised Edition 2000 ISBN 3-527-29849-5 Weissermel, K., Arpe, H.-J Industrial Organic Chemistry 2004 ISBN 3-527-30718-4 Oetjen, G.-W., Haseley, P Freeze-Drying Fourth, Completely Revised Edition Second, Completely Revised and Extended Edition 2003 ISBN 3-527-305789-5 2004 ISBN 3-537-30620-X Mollet, H., Grubenmann, A Hagen, J Formulation Technology Industrial Catalysis Emulsions, Suspensions, Solid Forms A Practical Approach 2001 ISBN 3-527-30201-8 1999 ISBN 3-527-29528-3 Sundmacher, K., Kienle, A (Eds.) Jakobi, R Reactive Distillation Marketing and Sales in the Chemical Industry Status and Future Directions 2003 ISBN 3-527-30579-3 Rauch, J (Ed.) Multipurpose Plants 2003 ISBN 3-527-29570-4 Elias, H G An Introduction to Plastics Second, Completely Revised Edition 2003 ISBN 3-527-29602-6 Second, Completely Revised Edition 2002 ISBN 3-527-30625-0 Bamfield, P Research and Development Management In the Chemical and Pharmaceutical Industry Second, Completely Revised and Extended Edition 2003 ISBN 3-527-30667-6 Donald R Woods Successful Touble Shooting for Process Engineers A Complete Course in Case Studies Author Prof Donald R Woods Chemical Engineering Department McMaster University Hamilton Ontario Canada, L8S 4L7 & All books published by Wiley-VCH are carefully produced Nevertheless, authors, editors, and publisher not warrant the information contained in these books, including this book, to be free of errors Readers are advised to keep in mind that statements, data, illustrations, procedural details or other items may inadvertently be inaccurate Library of Congress Card No.: applied for British Library Cataloguing-in-Publication Data A catalogue record for this book is available from the British Library Bibliographic information published by Die Deutsche Bibliothek Die Deutsche Bibliothek lists this publication in the Deutsche Nationalbibliografie; detailed bibliographic data is available in the Internet at  2006 WILEY-VCH Verlag GmbH & Co KGaA, Weinheim All rights reserved (including those of translation into other languages) No part of this book may be reproduced in any form – nor transmitted or translated into machine language without written permission from the publishers Registered names, trademarks, etc used in this book, even when not specifically marked as such, are not to be considered unprotected by law Printed in the Federal Republic of Germany Printed on acid-free paper Typesetting Kühn & Weyh, Satz und Medien, Freiburg Printing betz-druck GmbH, Darmstadt Bookbinding J Schäffer GmbH, Grünstadt ISBN-13: ISBN-10: 978-3-527-31163-7 3-527-31163-7 V Contents Preface 1.1 1.1.1 1.1.2 1.2 1.2.1 1.2.2 1.3 1.4 1.5 1.6 XIII What is Trouble Shooting? Characteristics of a Trouble-Shooting Problem Similarities among TS Problems Differences between TS Problems Characteristics of the Process Used to Solve Trouble-Shooting Problems How the Type of Problem Guides the TS Process or Strategy Five Key Elements Common to the TS Process Self-Test and Reflections Overview of the Book Summary Cases to Consider 2.2.2 2.2.3 2.3 2.3.1 2.3.2 2.4 2.5 2.6 The Mental Problem-Solving Process used in Trouble Shooting 17 Problem Solving 19 Trouble Shooting 23 Considerations when Applying the Strategy to Solve Trouble-Shooting Problems 23 Problem-Solving Processes Used by Skilled Trouble Shooters 24 Data Collection and Analysis: Approaches Used to Test Hypotheses 25 Overall Summary of Major Skills and a Worksheet 25 Getting Organized: the Use of a Trouble-Shooter’s Worksheet 25 Feedback about your Trouble Shooting 29 Example Use of the Trouble-Shooter’s Worksheet 35 Summary 40 Cases to Consider 40 3.1 3.1.1 3.1.2 Rules of Thumb for Trouble Shooting 43 Overall 43 General Rules of Thumb and Typical Causes Corrosion as a Cause 45 2.1 2.2 2.2.1 Successful Trouble Shooting for Process Engineers Don Woods Copyright  2006 WILEY-VCH Verlag GmbH & Co KGaA, Weinheim ISBN: 3-527-31163-7 43 VI Contents 3.1.3 3.1.4 3.1.5 3.2 3.2.1 3.2.2 3.2.3 3.2.4 3.2.5 3.3 3.3.1 3.3.2 3.3.3 3.3.4 3.3.5 3.3.6 3.4 3.4.1 3.4.2 3.4.3 3.4.4 3.4.5 3.4.6 3.4.7 3.4.8 3.4.9 3.4.10 3.4.11 3.4.12 3.5 3.5.1 3.5.2 3.5.3 3.5.4 3.5.5 3.5.6 3.5.7 3.5.8 3.5.9 3.5.10 3.5.11 3.5.12 3.5.13 3.6 3.6.1 Instruments, Valves and Controllers 46 Rules of Thumb for People 47 Trouble-Shooting Teams 48 Transportation Problems 51 Gas Moving: Pressure Service 52 Gas Moving: Vacuum Service 53 Liquid 54 Solids 56 Steam 58 Energy Exchange 58 Drives 58 Thermal Energy: Furnaces 60 Thermal Energy: Fluid Heat Exchangers, Condensers and Boilers Thermal Energy: Refrigeration 65 Thermal Energy: Steam Generation 66 High-Temperature Heat-Transfer Fluids 66 Homogeneous Separation 67 Evaporation 67 Distillation 69 Solution Crystallization 72 Gas Absorption 73 Gas Desorption/Stripping 75 Solvent Extraction, SX 76 Adsorption: Gas 77 Adsorption: Liquid 77 Ion Exchange 77 Membranes: Reverse Osmosis, RO 79 Membranes: Nanofiltration 79 Membranes: Ultrafiltration, UF, and Microfiltration 79 Heterogeneous Separations 79 Gas–Liquid 80 Gas–Solid 81 Liquid–Liquid 82 Gas–Liquid–Liquid Separators 84 Dryer for GS Separation 85 Screens for Liquid Solid Separation or Dewatering 85 Settlers for LS Separation 86 Hydrocyclones for LS Separation 86 Thickener for LS Separation 86 Sedimentation Centrifuges 87 Filtering Centrifuge 87 Filter for LS Separation 88 Screens for Solid–Solid Separation 88 Reactor Problems 88 PFTR: Multitube Fixed-Bed Catalyst, Nonadiabatic 89 61 Contents 3.6.2 3.6.3 3.6.4 3.6.5 3.6.6 3.6.7 3.6.8 3.6.9 3.6.10 3.6.11 3.6.12 3.7 3.7.1 3.7.2 3.7.3 3.8 3.8.1 3.8.2 3.8.3 3.9 3.9.1 3.9.2 3.9.3 3.9.4 3.9.5 3.9.6 3.9.7 3.10 3.11 3.12 3.12.1 3.12.2 PFTR: Fixed-Bed Catalyst in Vessel: Adiabatic 91 PFTR: Bubble Reactors, Tray Column Reactors 93 PFTR: Packed Reactors 94 PFTR: Trickle Bed 94 PFTR: Thin Film 96 STR: Batch (Backmix) 96 STR: Semibatch 98 CSTR: Mechanical Mixer (Backmix) 99 STR: Fluidized Bed (Backmix) 101 Mix of CSTR, PFTR with Recycle 106 Reactive Extrusion 106 Mixing Problems 107 Mechanical Agitation of Liquid 107 Mechanical Mixing of Liquid–Solid 108 Solids Blending 108 Size-Decrease Problems 109 Gas Breakup in Liquid: Bubble Columns 109 Gas Breakup in Liquid: Packed Columns 109 Gas Breakup in Liquid: Agitated Tanks: 110 Size Enlargement 110 Size Enlargement: Liquid–Gas: Demisters 110 Size Enlargement: Liquid–Liquid: Coalescers 110 Size Enlargement: Solid in Liquid: Coagulation/Flocculation 111 Size Enlargement: Solids: Tabletting 111 Size Enlargement: Solids: Pelleting 111 Solids: Modify Size and Shape: Injection Molding and Extruders 112 Coating 126 Vessels, Bins, Hoppers and Storage Tanks 126 “Systems” Thinking 127 Health, Fire and Stability 130 Individual Species 130 Combinations 131 4.1 4.2 4.3 4.4 4.5 4.6 Trouble Shooting in Action: Examples 133 Case ’3: The Case of the Cycling Column 133 Case ’4: Platformer Fires 138 Case ’5: The Sulfuric Acid Pump 141 Case ’6: The Case of the Utility Dryer 144 Case ’7: The Case of the Reluctant Crystallizer 157 Reflections about these Examples 162 5.1 5.1.1 5.1.2 Polishing Your Skills: Problem-Solving Process 165 Developing Awareness of the Problem-Solving Process 165 Some Target Skills 166 The TAPPS Roles: Talker and Listener 166 VII VIII Contents 5.1.3 5.1.4 5.2 5.2.1 5.2.2 5.2.3 5.2.4 5.3 5.3.1 5.3.2 5.4 5.4.1 5.4.2 5.4.3 5.4.4 5.5 5.5.1 5.5.2 5.5.3 5.6 6.1 6.1.1 6.1.2 6.1.3 6.1.4 6.2 6.2.1 6.2.2 6.2.3 6.2.4 6.2.5 6.2.6 6.3 6.3.1 6.3.2 6.4 6.4.1 Activity 5.1: (35 minutes) 168 Feedback, Self-Assessment 172 Strategies 173 Some Target Skills 174 The Extended TAPPS Roles: Talker+ and Listener+ 175 Activity 5.2: (time 35 minutes) 176 Feedback, Self-assessment 179 Exploring the “Context”: what is the Real Problem? 180 Example 180 Activity 5-3 181 Creativity 183 Some Target Skills 183 Example: Case ’10: To dry or not to dry! (based on Krishnaswamy and Parker, 1984) 186 Activity 5-4 190 Feedback, Self-Assessment 191 Self-Assessment 191 Some Target Skills 192 Activity for Growth in Self-Assessment 192 Feedback About Assessment 193 Summary and Self-Rating 194 Polishing Your Skills: Gathering Data and the Critical-Thinking Process 195 Thinking Skills: How to Select Valid Diagnostic Actions 196 How to Select a Diagnostic Action 196 Select from among a Range of Diagnostic Actions 196 More on Gathering and Interpreting Data 200 Summary 209 Thinking Skill: Consistency: Definitions, Cause–Effect and Fundamentals 209 Consistent Use of Definitions 210 Consistent with How Equipment Works: Cause fi Effects: Root Cause-Symptoms 212 Consistent with Fundamental Rules of Mathematics and English 217 Consistent with Fundamental Principles Of Science: Conservation of Mass, Energy, High to Low Pressure, Properties of Materials 218 Consistent with Experience 218 Summary 219 Thinking Skills: Classification 219 Classify the Starting Information 219 Classifying Ideas from Brainstorming 220 Thinking Skills: Recognizing Patterns 221 Patterns in the Symptoms 221 Contents 6.4.2 6.5 6.5.1 6.5.2 6.5.3 6.5.4 6.5.5 6.5.5a 6.5.5b 6.5.5c 6.5.5d 6.5.6 6.5.7 6.5.8 6.5.9 6.5.10 6.6 6.7 6.8 Patterns in the Evidence 223 Thinking Skill: Reasoning 223 Step 1: Classify the Information 224 Step 2: Write the Conclusion 225 Step 3: Identify the Context 225 Step 4: Clarify the Meaning of the Terminology 226 Step 5: Consider the Evidence 227 Identify the Evidence 227 Check for Consistency 227 Which Evidence is Pertinent? 228 Diagram the Argument 229 Step 6: Formulate the Assumptions 230 Step 7: Assess the Quality of the Reasoning 230 Step 8: Assess the Strengths of the Counterarguments 232 Step 9: Evaluate the Consequences and Implications 232 Activity 6-14 232 Feedback and Self-Assessment 233 Summary 233 Exercises 234 7.1 7.1.1 7.1.2 7.1.3 7.1.4 7.1.5 7.2 7.2.1 7.2.2 7.2.3 7.2.4 7.2.5 7.3 7.4 7.5 Polishing Your Skills: Interpersonal Skills and Factors Affecting Personal Performance 237 Interpersonal Skills 237 Communication 237 Listening 238 Fundamentals of Interaction 239 Trust 240 Building on Another’s Personal Uniqueness 243 Factors that Affect Personal Performance 244 Pride and Unwillingness to Admit Error 244 Stress: Low and High Stress Errors 245 Alienation and Lack of Motivation 249 “I Know Best!” Attitude 249 Tendency to Interpret 249 The Environment 253 Summary 253 Exercises and Activities 253 8.1 8.1.1 8.1.2 8.2 8.2.1 Prescription for Improvement: Put it all Together Approaches to Polish Your Skill 259 Triad Activity 259 Individual Activity 262 Cases to Help you Polish Your Skill 263 Guidelines for Selecting a Case 263 259 IX X Contents 8.2.2 8.3 9.1 9.2 9.3 9.3.1 9.3.2 9.4 9.5 The Cases and Understanding the Choice of Diagnostic Actions for each Case 263 Summary 396 What Next? 397 Summary of Highlights 397 Reflection and Self-Assessment are Vital for the Development of Confidence 401 Going Beyond this Book: Setting Goals for Improvement 402 Prepare Yourself for Success 402 Use Reflection and Self-Assessment Effectively 403 Going Beyond this Book: Updating your Rules of Thumb and Symptom ‹ Cause Data for Process Equipment 403 Beyond this Book: Sources of Other Cases 403 Literature References Index 405 I CD Contents Appendix A Feedback about Experience with Process Equipment Appendix B Improving “Systems Thinking” 411 415 Appendix C Feedback on the Cases in Chapters 1, and 423 Appendix D Coded Answers for the Questions Posed to Solve the Cases Appendix E Debrief for the Trouble-Shooting Cases 435 537 Appendix F Other Tasks for the Skill-Development Activities in Chapter Appendix G Selected Responses to the Activities in Chapters and Appendix H Data about “Causes” for Selected Process Equipment 569 573 565 I Index – diagnostic actions to help select 197 – example questions to ask 24 – example use, Case ’4 139 – Case ’5 141 – Case ’6 145 – how to apply 24 – use of fundamentals in 23 – when to use 4, 23 Bayes theorem, use 25 BDI, Bin density index – cited 56, 58 – defined 108 Bernoulli’s equation, use 51, 58, 419, 565 Bias, personal 25, 205 – in collecting evidence 205 – in reaching conclusions 205 – self test 206 – types: – anchoring 25, 205 – availability 205 – confirmation 25 – inadequate synthesis 206 – misinterpretation 206 – need to avoid 195, 205 – overinterpretation 25 – premature closure 25, 205 – pseudodiagnosticity 25, 205 – representative 25, 205 – test 206 – underinterpretation 206 Bins, symptoms-cause 126 – cases involving 182, 222, 347 Blenders, solid, symptoms-cause 108–109 – cases involving 333 Bloch, H.P 44, 403, 408 Blowers, symptoms-cause 52 Boiling film 63 – nucleate 63 198 267 Brainstorm, see Creativity Bubble formation, symptoms-cause 110 Bubble reactors symptoms-cause 98 Bucket elevators, symptoms-cause 56 – – – – – – – – c Carry out the plan see Do it Cases, overall list of, with ratings 268–271 – Case ’1 – answer – Case ’2 – answer – Case ’3 10 – answer 133–138 – critique 212 – – – – reasoning 224–232 – evidence 227, 228 – meaning 226 – diagram of cause-effect 228, 229 – classification 224 – conclusion 225 – context 225 – worksheet 423 Case ’4 10 – answer 138–140 – cited 180 – worksheet 427 Case ’5 11 – answer 141–144 – patterns 223 – worksheet 430 Case ’6 12 – answer 144–156 – worksheet 202, 217, 217–218 Case ’7 13 – answer 157–162 – cyclical 223 – Why? 180 Case ’8 35 – actions 271 – answer 36–39, 537 – destroyers activity 240 – listening activity 239 Case ’9 181 – actions 274 – answer 538 – brainstorm 190 – identify symptoms 220 Case ’10 186–87 – actions 278 – answer 538 – cyclical 223 – example approaches 204 – patterns 223 Case ’11 214 – actions 282 – answer 540 – hypotheses 216 – root cause 217 Case ’12 247 – actions 280 – answer 540 Case ’13 251 – actions 282 – answer 541 Case ’14 252 – actions 285 – answer 541 Index – Case ’15 – answer – Case ’16 – answer – Case ’17 – answer – Case ’18 – answer – Case ’19 – answer – Case ’20 – answer – Case ’21 – answer – Case ’22 – answer – Case ’23 – answer – Case ’24 – answer – Case ’25 – answer – Case ’26 – answer – Case ’27 – answer – Case ’28 – answer – Case ’29 – answer – Case ’30 – answer – Case ’31 – answer – Case ’32 – answer – Case ’33 – answer – Case ’34 – answer – Case ’35 – answer – Case ’36 – answer – Case ’37 – answer – Case ’38 – answer – Case ’39 – answer – Case ’40 – answer – Case ’41 255 33 256 433 256 433 257 434 286 543 289 543 291 544 294 544 297 544 299 545 304 546 308 546 312 547 314 548 317 548 321 548 323 549 327 549 330 550 333 550 335 550 339 551 342 551 345 552 347 552 350 553 354 – answer 555 – Case ’42 357 – answer 556 – Case ’43 362 – answer 556 – Case ’44 364 – answer 557 – Case ’45 367 – answer 558 – Case ’46 370 – answer 559 – Case ’47 374 – answer 559 – Case ’48 377 – answer 560 – Case ’49 380 – answer 561 – Case ’50 383 – answer 561 – Case ’51 387 – answer 562 – Case ’52 391 – answer 563 – Other cases 403 – Feedback about hypotheses in cases 267 – Rating of cases 262, 263, 537 – Selecting cases 263 Cause (of trouble) see also Hypothesis and related terms Cues and Symptoms – actual cause in case 264, 591 – relating cause to magnitude of the extent of symptoms 43 – relating to when: startup of new process, startup after shutdown, usual operations 44 Cause-effect information, see also specific equipment for details – activity to check consistency 213 – activity to improve skill 213 – consistency between 213 – use of 195 Cellular PE, extrusion 120 Centrifuges, filtering, symptoms-cause 87 – brainstorming 187 – cases involving 186 Centrifuges, sedimentation, symptomscause 87 – causes 576 Change strategy for TS: – contrast with basics strategy 23 – description 23 – example questions to ask 23 – when to use 4, 23, 197 I I Index Check, see Look back stage in generic strategy Check and double check, see Accuracy Chin, T.G 409, 534 CI, Chute index – cited 56, 57 – defined 108 Classifying information 219 related term Analysis – activities to improve skill 219–220 – as first step in reasoning 224 – example 224 – definition 219 – how to 219, 399 – need for 20, 21, 195, 219, 399 – of ideas from brainstorming 220 – of starting information 219 – of triggering events 220, 399 Coagulation, symptoms-cause 111 Coalescers, fundamentals 110 – symptoms-cause 110–111 Coating, symptoms-cause 126 Commissioning 266 – diagnostic actions 586 Communication: – activities to improve skill 237–238 – criteria for effective 237 – definition 237 – preference to interpret 249 – self test of skill Compressors: – cases involving 1, 291, 304, 317, 350, 391 – centrifugal, symptoms-cause 52 – frequency of faults 44 – MTBF 44 – reciprocating, symptoms-cause 52 Conclusion (inference, proof or disproof of hypothesis): – example 228 – reasoning process to test validity 223–232 – write down 224 Condensers, shell and tube, symptoms-cause 62 – cases involving 251, 252, 255–256, 312, 317, 321, 323, 370, 374 – causes 575 Consistency (among evidence): – activities to improve skill 209–228, 227, 399 – diagnostic actions to check 267–268, 588–589 – examples 199, 227 – how to check with evidence 227 – importance of, for reasoning 209 – need for 195, 209 – to assess reasoning 230 – types of – cause-effects 212, 399 – evidence 227, 399 – experience with equipment 228, 399 – rules of Mathematics and English 217, 399 – words/definitions 210–212, 399 Contamination (impurities) and crystallization 72 Context – definition 224 – example 224 – how to identify 225 – of reasoning 224 Control, process: – activities to improve skill 418, 421 – four elements of – self test about knowledge of – symptoms-cause 47 Control room: need to visit 198, 267, 589 Controller, process, causes 574 Conveying, solids, see also Pneumatic conveying, and feeders – cases involving 182, 186, 222, 333 – symptoms-cause 34 Corrosion: – general reasons why corrosion becomes a cause 45 – symptom-case data 45 – types of corrosion and their frequency 45 Costs, see also Financial penalty of diagnostic action 264 and 582 Covey, S., cited 22, 406 Cox chart, use 418 Cracking, catalytic, reactor, symptoms-cause 101 Creativity, and Brainstorming and Hypothesis generation: – activity to improve your skill 190 – and skill in classification of ideas 219 – case ’7 171 – checklist of triggers 183–186 – example Case ’10 187–190 – feedback form 191 – need for 20,183 – target skills 183 – to identify root cause, example on TS Worksheet for Case ’8 38 Criteria: – and goals 401, 193 – need for must and want 22 Index Critical thinking, see also Reasoning, and Diagnostic actions: – activities to improve skill in consistency 209, 399 – list of subskills 195 – need for 20 – reflections about 400 Crystallization, solution: fundamentals 67 – cases involving 13–15, 157ff, 186 – symptoms-cause 72 – vacuum and circulating system, symptomscause 72 Cues (for storing experience in Long Term memory) 20 Cues/evidence (for trouble) see also Diagnostic actions – how to critique of evidence 227, 231: – check for consistency 227 – diagram 228–229 – test pertinence of 228 – number of cues used per case 34 – suggestions for weighting 25 – suggestions to prevent overlooking 25 Cycling, related term Surging: – batch cycles 221, 222 – symptoms-cause 130, 63–65, 71, 101 Cyclone, GS, symptoms-cause 81–82 – cases involving 333 d Data handling, see also Diagnostic actions: – activities to improve skill 399 – and cycling 222 – elements of the TS process 33, 398 – errors in data 208 – interpreting data 208, 249–250 – list of detracting and enriching behaviors 30 – options for gathering data 196ff – personal bias in 204–208 – reflections about your approach 400 – self test of skill Decanters – cases involving 179 – symptoms-cause 82–84 Decision making: – elements of the TS process 22, 33 – list of detracting and enriching behaviors 32 – self test of skill Define: second stage in a generic problem solving process: – and skill in classification 219 – – – – context, how to identify 225 critique use of 163 description 20, 21, 28 example use in TS Worksheet for Case ’8 36 – for Case ’5 141 – for Case ’6 145 – prompts for use in the TS Worksheet 26, 40 Dehydration, glycol system, symptoms-cause 73, 74, 75, 76, 129 Dehydrogenation, safety 96, 98, 99 Demisters – fundamentals 110 – symptoms-cause 110 Depropanizer: – Case ’8 description 35 – cases involving 35, 213, 327, 345, 362, 367, 377 – P&ID, 34 – TS Worksheet for 35 Design fault, occurrence 44 Design data fault, occurrence 44 Desorption, gas, fundamentals 67 – cases involving 181, 383, 387 – symptoms-cause 75 Diagnostic actions – activity to improve skill 201, 202 – and cycling 222 – chart relating to hypotheses and evidence on TS Worksheet, see Hypothesis, chart – consistency tests 267–268, 588 – costs incurred 264, 582 – criteria for selecting 196, 264 – equipment to help 203–204 – errors in evidence 208 – examples for TS Case ’8 39, 201 – how to select 24, 196, 264, 587 – interpreting data 208 – options 196: – recent events 197, 265, 583 – safety 196, 264, 583 – to correct 200, 264, 268 – to help select TS strategy 197 – to understand what’s going on 198, 267, 585, 587 – to test hypotheses 198, 267, 587 – personal style in selecting 204 – reflection about 400 – relating to hypotheses 24 – site visit 589 – time required for selected 204 – trends and patterns 590 I I Index – using senses 589 Differences in concentration for mass transfer 67 – exchange equilibrium for separations 67 – molecular geometry for separations 67 – partition coefficient for separations 67 – pressure for fluid flow 51 – solubility for separations 67 – temperature for heat transfer 58 – vapor pressure for separations 67 Distillation column – activities to improve skill 418 – cases involving 170, 10, 35, 211, 222, 247, 251, 252, 256, 299, 321, 327, 345, 354, 362, 367, 372, 377, 383, 387 – causes 576 – frequency of failures of 44, 201 – good practice 69 – self test of knowledge about – symptoms-cause 69–72 Do it, fifth stage in a generic problem solving process, – description 20, 21, 28 – example on TS Worksheet for Case ’8 39 Doig, L 403, 408 Drives, see Engines, Motors and Turbines – for extruders 120, 121 Dryers, symptoms-cause 85 – cases involving 186, 347 Dudzic, Mike, cited 286, 543 Dutta, S., cited 101 e Edgar, M.D Ejectors, steam: – cases involving 13, 181, 335 – symptoms-cause 53–54 Elaboration, as part of the Look back stage 20 – importance of in problem solving 17 Electrical failure, occurrence 44 Elonka, S.M 403, 408 Elstein A.S 24, 405 Emulsion, formation of stable, cause 129 Energy, conservation of 58 Energy, mechanical, fundamentals 58 Energy, thermal, see Heat exchangers, and furnaces Energy exchange, fundamentals 58 Engage, first stage in a generic problem solving process – critique use of 163 – description 20, 21, 28 – example use in the TS Worksheet for – Case ’5 141 – Case ’6 145 – Case ’8 35 – prompts for use in the TS Worksheet 26, 40 Engines, symptoms-cause 58 Entrainment (GL), symptoms-cause 74, 84 Entrainment (LL), symptoms-cause 74, 85 Environment in which you TS: – impact on your approach 253 – self test 254–255 Environmental impact of process: self test about knowledge of Equilibrium, phase, use of 67 Esso Chemicals, cited 251, 321, 541, 548 Esterification, safety 96, 98, 99 Ethylene 247, 299 Evacuation 196, 265 – as diagnostic action 265 Evaporators, general, fundamentals 67 – cases involving 257, 335 – forced circulation, symptoms-cause 68 – multiple effect, symptoms-cause 68–69 – symptoms-cause 67 – vapor recompression, symptoms-cause 68 – vertical falling film, symptoms-cause 65, 68 Evidence, see Cues Exercise solving: – contrast with problem solving 17 – definition 17 – diagram of 19 – example use, Case ’7 157 – frequency of, for experienced trouble shooters 17 Experience, past, and use in problem solving, trouble shooting 17 Experience with process equipment, see specific equipment for details – and consistency 218 – keeping up-to-date 402–403 – need for and importance of 4, 397, 402 – reflections about your data base 398 – self test of 6, 411 – stuff left in lines 433, 584 Explore, the third stage in a generic problem solving process, – and skill in classification of information 219 – critique use of 163 – description 20, 21, 28 – example for Case ’4 139 Index – example use in TS Worksheet for Case ’8 36 – example use of Why? Why? Why? 180 – prompts for use in the TS Worksheet 26, 41 Extruder, symptoms-caus see also Reactive extrusion 120–125 – blown film, symptoms-cause 121, 122, 124 – cast, symptoms-cause 122 – coating, symptoms-cause 122 – coating wire and cable, good practice 120 – filament, symptoms-cause 122, 124 – pipe, symptoms-cause 122 – sheet, symptoms-cause 122 – single screw, good practice 120 – symptoms-cause 123 – twin screw, good practice 120 – vented twin screw, good practice 120 f Fabrication fault, occurrence 44 Facts, related to Opinions and Opinionated facts: – activities to improve skill 211, 250–253 – definition 210 – examples 211 – facts versus opinions 208 – opinionated facts – definition 210 – examples 211 – opinions – definition 210 – examples 211 – preference to interpret 249 Fans, symptoms-cause 52 – cases involving 308, 312, 321 Farrell, R J., cited 256 Faults, see Causes FCCU, fluid catalytic cracking unit, see Cracking, catalytic FDI, Feed density index – cited 56, 57, 58 – defined 108 Feedback: – self tests: – experience with process equipment 411 – of critical thinking skills 233 – of PS skill 194 – of trust 242 – personal style, confirmation bias 206 – personal style in TS 206 – skill in five elements of TS 5–8 – forms: – brainstorming 191 – criteria identification 193 – example data 177 – goal setting 193 – listener 180 – PS strategy 178 – reflections about critical thinking skills 233 – reflections about PS skills 194 – reflections for TAPPS 172 – self assessment 193 – talker-listener in TAPPS 173 – teamwork 50–51 – trust 242 – TS environment 254–255 Feeder, belt, symptoms-cause 57 – cases involving 186, 347 – from bottom of hopper, symptoms-cause 57 – screw conveyor, symptoms-cause 57 – solids volumetric, symptoms-cause 57 Filter (LS), symptoms-cause 88 – cases involving 286, 342 Financial penalties 1, 4, 266 – cases involving 321 Fisher, K., cited 48, 406 Flash drum, three phase separator (GLL), symptoms-cause 84–85 Flexibility, need for 22 – as part of the synthesis elements of TS 21, 22 Flocculation, symptoms-cause 111 – case involving 289 Fluid dynamics: – faults, occurrence 44 – fundamentals 51 – types of faults 51–52 Fluoroplastics, extrusion 120 Foaming, symptoms-cause 62, 67, 69, 71, 74, 80, 93–98, 110, 128 – reboiler selection 63 Fouling, symptoms-causes 63, 64, 67, 68, 69, 128 Fox, Don F., cited 342,-551 Francis, D., cited 48, 406 Freon, foaming 129 FRI, Flow ratio index – cited 56 – defined 108 Fundamentals: – and consistency 218 – energy exchange 58 I I Index – example in Case ’4 139 – fluid flow 51 – separations of homogeneous phases 67 – use of, for the basics strategy for TS 23 Furnaces: – cases involving 171, 256–257, 304, 308, 374 – fundamentals 58 – symptoms-cause 60 g Gans, M., cited 43, 133, 405–408 Gates, John, cited 247, 299, 540, 545 Garbage left in process, see Experience with process equipment Gas breakup, symptoms-cause 110 Gauly, R., cited 91, 101 Geitner, F K., cited 403, 408 Goals, express as results 22 – need for 401 – setting goals for improvement 42, 402 Goyal, O.P., cited 411 Grit chamber, symptoms-cause 86 h Halpern, D., cited 229, 407 Handbook data 266 Hazard see Health and safety HAZOP, use of HDPE, high density polyethylene, extrusion 120 Health and safety: – and Case ’4 140 – combinations of chemicals 131–132 – dust explosions, example data 131 – flammability, example data 131 – health, example data 130 – impact on diagnostic action 3, 196, 264 – importance in TS – need for knowledge about – reactions 131 – self test about knowledge of 6–7 – shutdown to avoid hazard 3, 264 – stability, example data 131 – symptom-cause 130–132 – symptoms of hazard in STR reactors 96 Heat exchangers: – cases involving 10, 12, 171, 247, 299, 304, 308, 314, 335, 339, 350, 357, 364, 391 – frequency of faults 44, 201 – fundamentals 58 – types: – air cooled, symptoms-cause 55 – trim coolers 65 – causes 575 – plate, symptoms-cause 65 – shell and tube: – causes 575 – fundamentals 58 – good practice 61 – self test experience – symptoms-cause 61 – spiral plate, symptoms-cause 65 Heat of reaction, and hazards 131 Heat transfer fluids, high temperature, symptoms-cause 66–67 – cases involving 252 HI, Hopper index – cited 56, 57 – defined 108 Holmes-Rahe scale for stress 22, 406 Hoppers, see Bins Hydrocyclone, LL, symptoms-cause 84 Hydrocyclone, LS, symptoms-cause 86 – cases involving 186 Hydrolysis, safety 96, 98 Hydrotreating, reactors, symptoms-cause 95 Hypothesis, – and cues 25 – and reasoning process to validate 223 – and skill in classification 219 – chart relating to evidence and diagnostic actions 24 – Case ’3 426 – Case ’4 429 – Case ’5 430 – Case ’6 148, 202–203 – Case ’7 158, 159, 171 – Case ’10 171 – Case ’11 216 – example for TS Case ’8 39 – example on TS Worksheet 42 – check with colleagues 587 – feedback for all cases 537ff – feedback for some cases 267 – generate early 24 – generating multiple, as part of the synthesis element of the TS process 21, 22 – need to generate 195 – number of active 24 – self rate of skill i “I want to and I can”, use of 20 – Case ’5 141 Index – example use in TS worksheet for Case ’8 36 Ice formation: in steam ejectors 53 “If then ” logical statements, characteristics of 214 Impact sensitivity 131 Indicator, see Instruments Inference, see Conclusion Injection molding, symptoms-cause 112–119 – cases involving 347, 380 Instruments, sensors, indicators, recorders – causes 574 – frequency of failure 201 – simple consistency tests 267–268, 588 – symptom-cause data 46 Insurance, and data 266, 586 – case involving 321 Interpersonal skills, see People skills Ion exchange IX: – cases involving 256 – fundamentals 67 – symptoms-cause 77–78 IS and IS NOT: – as diagnostic action 265, 584 – example use in TS worksheet – Case ’3 135, 136 – Case ’4 139 – Case ’5 141 – Case ’6 145 – Case ’7 158 – Case ’8 36 – use in strategy 23, 197 j Johanson, J R – cited 56, 108 – description 20, 21, 29 Johnson, D A., cited 135 Johnson, D W., cited 210 Johnson, D W., and Johnson, F P., cited 243 Johnson-Laird, P N., cited 206, 405 Jungian typology, (MBTI) and style 204, 234, 243, 399 k Kepner-Tregoe 23, 406 King, C J., cited 12,323 Kirton, M J., cited 243, 406 Kister, H., cited 135, 403, 405, 406, 408 Kletz, T., cited 245, 253, 407–409 Knock out pots, symptoms-cause 80 – cases involving 247, 291, 299, 350 Knowledge about process equipment, see Experience with process equipment Koros, R M., cited 95 Krishnaswamy, R., cited 173, 407, 538 l Lapp, S A., cited 245, 407, 409 Latex crumb, flocculation, symptoms-cause 111 Lieberman, N P., cited 101, 133, 403, 405–409 Limitations, personal, need to learn and identify 22 Listening skills: activities to improve skill 239, 250–252 – characteristics of 238 – feedback via TAPPS 173 – need for skill 249 – self rate – self rate the environment 255 – the SIER model 238 – three skills 238 – activities to improve skill 239 – attending, characteristics of 238 – how to 239 – reflecting, characteristics of 239 – tracking, characteristics of 238 LLDPE, extrusion 120 LM ID, log mean temperature difference 58, 61 Look back description 20, 21, 29 Luckenbach, E C., cited 101 Lynn, Scott, cited 294, 330, 370, 544, 559, 550 m Maintenance, as diagnostic action 265, 584, 585 Marangoni effects, causes 76, 83 Marlin, T E., cited 35, 327, 309, 345, 350, 354, 357, 362, 367, 377, 537, 546, 549,552, 553, 555, 556, 558, 560 Mass balance 266 Material failure fault, occurrence 44 MBTI, see Jungian typology McNally Institute, cited 403 Mean time between failure, MTBF, use of data 44 Mechanical failure, occurrence 44 Membranes – fundamentals 67 – symptoms-cause 79 I I 10 Index Mental representation of the problem: – as part of the Explore stage 21 – importance in problem solving 17 Methyl ethyl ketone, and foaming 129 Microfiltration, see Membranes Mixers: mechanical agitators, L Mixing, solids, see Blending – cases involving 181, 297 – frequency of faults 44 – symptoms-cause 107–108 MM, molar mass 103, 124 Monitoring: – example application in TS Worksheet for – Case ’5 141, 142 – Case ’6 145 – Case ’8 36 – example data of 177 – importance of in problem solving 20, 260 Motors, electric: – MTBF 44 – symptoms-cause 59 MPI, main plant items MSDS, rating 130, 263, 264, 583 MTBF see Mean Time between failures n Nano filtration, see Membranes Neutralization, safety 96, 98, 99 NFPA, National Fire Protection Agency, rating 130, 264, 583 NIPR, net inlet pressure required 54 Nitration, safety 96, 98, 99 Nominal group 49 NPSH, net positive suction head 54, 64, 201 – activities to improve skill 420 – and Case ’5 141 – definition 420 o On-going process, typical causes for 44 Operators see also People – example interaction with, – by Ahmed 239 – by David 143 – by Frank 158 – by Jose 238 – importance of talking to 198, 591, 587 – on other plants 268, 588 Opinionated facts, see Facts Opinions, see Facts Oxidation, safety 96, 98, 99 p P&ID (process and instrumentation diagram): – as diagnostic action 268, 589 – for depropanizer 34 – for ethylene 300 – information from 266 – symbols on 415 Pareto’s principle, use of 22 Parker, N H., cited 186, 407, 538 Pattern recognition: – look for as diagnostic action 590 – need for skill in 195 – types of patterns: – in cues/evidence 223 – in symptoms 221 Pearson, Doug, cited 584 Pelleting, strand type, symptoms-cause 111–112 – water ring, symptoms-cause 112 Penalties 266, 586 – cases involving 321 People: – activities to improve skill 240 – destroyers (four) of relationships 240 – fundamental interpersonal RIGHTS 239 – definition 239–240 – list of nine skills needed 47 – performance: – factors affecting 244–252 – impact of alienation 249 – impact of “I know best” 249 – impact of listening skills, see Listening – impact of motivation 249 – impact of personal style, see Personal style – impact of pride 244–245 – impact of stress on 22, 221, 245–246 – activities to improve skill 246–247 – self rate environment 254 – impact of the environment on 253–255 – self rate 254–255 – impact of unwillingness to admit error 244–245 – self rate environment 254 – impact of willingness to risk, self rate environment 254 – types of errors made 244 People problems, see Problems involving people performance review/assessment 249, see also Self assessment problem involving – five elements of – reflections about 400 – self rate Index – skill with, need for – trust, see Trust Personal style: – bias 25, 205–206 – effect on selecting actions 200, 204–208 – identify via Jungian typology (MBT1) 204–205, 243 – Saadia’s dominant P 156 – Frank’s dominant J 161 – example data 243 – impact on selection of diagnostic actions 204–208 – via Johnson and Johnson inventory 243 – via Kirton inventory 243 – need to identify 22 – preference to infer 249ff – self rate – self tests about bias 206 – skill in listening 238 – tendency to interpret 249–250 – activities to improve skill 250–252 – feedback 253 – self rate environment 255 PET, extrusion 120 pH, acidity, as cause of corrosion 45, 46 – as cause of stability 69, 71, 72, 74, 76, 78, 79, 82, 83, 87, 88 p-H, pressure enthalpy diagram, use for TS refrigeration 65 Pinch analysis, use of 61 Pipes, causes 574 Pistorius, J T., cited 95 Plan, fourth stage in a generic problem solving process – description 20, 21, 28 – example on the TS Worksheet for Case ’8 39 Platforming, reactors, symptoms-cause 91, 93 – cases involving 10 Pneumatic conveying, symptoms-cause 56–57 – cases involving 182 Polymerization: – cases involving 178, 297, 370 – reactors, STR, symptoms-cause 98 – safety 96, 98, 99 Powers, G., cited 245, 409 Pressure profile: – activities to improve skill 419 – self rate skill – use of 266 Problems involving people, impact of rules and regulations 22 Problems, example “problem” in TS Worksheet – Case ’3 137 – Case ’4 139 – Case ’5 141 – Case ’6 145 – Case ’8 36 – need to define the real problem 20, 21, 181 – versus exercises 17 Problems, TS see also Cases – as related to different types of equipment 44 – four common characteristics of – high temperature 44 – types: change versus on-going process 23 – for on-going process 3, 4, 44 – posing safety and health hazards 3, 264 – when startup after maintenance shutdown 4, 44, 265 – usual causes 4, 265 – when startup new process 3, 44, 265 – usual causes Problem solving, generic See also Trouble Shooting, mental process; See also subset skills of Analysis, Awareness, Creativity, Critical thinking, Strategies for problem solving – activities to improve skill 399 – and type of TS problem: – as related to different types of equipment 44 – high temperature 44 – on-going process 44 – startup after shutdown 44 – startup of new process 44 – contrast with exercise solving 17 – definition and description of mental process 17 – diagram of process 18 – list of characteristics 19, 20 – list of detracting and enriching behaviors 29 – reflections about your skill 399 – self test 194 – stages in a strategy 20, 21 – strategy for general problem solving 20, 21 Process and Instrumentation diagram, see P&ID Process control, see Control, process I 11 I 12 Index Process equipment, knowledge about, see Experience with process equipment Pumps, centrifugal: – activities to improve skill 420 – cases involving 11, 35, 186, 214, 251, 255–256, 286, 289, 294, 304, 308, 321, 330, 336, 342, 350, 357, 370, 383, 387 – causes 573–574 – fundamentals 51, 420 – frequency of faults 44, 201 – MTBF 44 – self rate experience – symptoms-cause 54, 579 Pumps, dry vacuum, symptoms-cause 53 – gear, symptoms-cause 55 – liquid piston vacuum, symptoms-cause 53 – mono, symptoms-cause 56 – reciprocating, symptoms-cause 54 – rotary, symptoms-cause 54 – rotary screw, symptoms-cause 56 PVC, polyvinyl chloride, extrusion 120 q Questions to ask, see Diagnostic actions r Rag at interface for SX or decanters – causes of 76 RAS, Rough wall angle slide – cited 56, 57 – defined 108 Reactors – cases involving 1, 10, 171, 178, 182, 297, 304, 308, 317, 330, 339, 357, 374, 391 – frequency of faults, 44, 201 – introduction 88–89 – safety, 96–99 – types – CSTR, mechanical mixer, symptomscause 99–100 – CSTR-PFTR with recycle, symptomscause 106 – PFTR, bubble reactors, tray columns, symptoms-cause 94 – PFTR, fixed bed, adiabatic, symptomscause 91–93 – PFTR, thin film, symptoms-cause 96 – PFTR, trickle bed, symptoms-cause 94–96 – PFTR multitube fixed bed, non adiabatic, symptoms-cause 89–91 – Reactive extrusion, symptoms-cause 106–107, 123, 125 – STR, batch, symptoms-cause 96–98 – STR, fluidized bed, symptoms-cause 101–106 – STR, semibatch, agitated bubble, symptoms-cause 98 – STR, semibatch, bioreactor, symptomscause 98 – STR, semibatch, symptoms-cause 98 – processes: – alkylation 83, 99 – platforming 91, 93 – polymerization 178 – symptom cause 98 Reasoning related term Critical thinking – activities to improve skill 223–232 – common biases in 205 – nine-step process 223–232, 299 Reboilers, general, fundamentals 63 – cases involving 10, 35, 323, 370 – causes 575 – symptoms-cause 63 – types: forced circulation, symptoms-cause 64 – kettle: – fundamentals 63 – symptoms-cause 63–64 – thermosyphon: – fundamentals 63 – symptoms-cause 64 – when used 64 Reflections – activity 5, 172, 194, 233, 251, 262 – need for 401, 403 Reforming, symptoms-cause 89, 91 – cases involving 171, 339 Refrigeration – symptoms-cause 65–66 – cases involving 202, 247, 299, 323, 350 Reverse osmosis, RO, see Membranes RI, Ratholing index – cited 56, 57 – defined 108 Riance, X P., cited 403, 409 Rights, personal: – list of 47, 239–240 – self rate Risk, willingness to 21, 22 Rogers, R., cited 297, 407, 544 Root cause, see Symptom Rotating equipment, frequency of faults 44 – MTBF 44 Index RTD, residence time distribution 107, 124, 125 Rules of thumb: – importance of 218 – listing of by process equipment name, Chapter 3, 43ff s Safe park, use of 1, 3, 134, 141, 195, 197, 265 Safety, see Health and safety Safety interlock shutdown, SIS 265 Saletan, D., cited 403, 405, 408 Samples, collecting 200 SBI, Spring back index – cited 56, 57 – defined 108 SCAMPER, trigger for creativity 184 Screens, dewatering – cases involving 186, 286 – for Liquid Solid separation, symptomscause 85–86 – for Solid Solid separation, symptomscause 88 Scriven, M., cited 209, 229, 407 Self assessment, related topics Feedback – activity to develop skill 192 – feedback form 193 – how to develop skill in 192, 401 – need for 403 – of bias 206 – of creativity 191 – of critical thinking skills 233 – of experience with process equipment 411 – of five component skills in TS 5–8 – of personal style 206 – of personal style, confirmation bias 206 – of PS skills 194 – of TAPPS 172 – of trust 242 – target skills 192 – using to improve 401 Sensors, see Instruments Separation of species in heterogeneous phases, introduction to 79 – process equipment, symptoms-cause 80ff Separation of species in homogeneous phase, fundamentals 67 – process equipment, symptoms-cause 67ff Separator, gas-liquid, cases involving 304, 317, 321, 326, 350, 370, 391 Shaw, I D., cited 570 Short term Memory, STM 25 Shut down (the process), and safety, see also Health and safety – troubles after, for maintenance 4, 44, 265 Silveston, P L., cited 314 SIS, safety interlock shutdown 3, 265 Size enlargement, fundamentals 110 – process equipment for 110ff SMARTS: example use in TS Worksheet for – Case ’3 136, 423 – Case ’4 428 – Case ’5 141, 431 – Case ’8 37 Solids conveying, see Conveying, solids Solvent extraction, SX, fundamentals 67 – and coalescers, symptoms-cause 110 – SX, column extractors, symptoms-cause 76 – SX, centrifugal, symptoms-cause 77 – symptoms-cause 76 Sonic velocity, and compressors 52 Sour water scrubbers, SWS, causes of corrosion of 46 – symptoms-cause 75, 76 So What?, use 232 Startup, of new process: – as diagnostic actions 265 – typical causes of trouble 44, 265 – use of basic strategy for 23 Startup after shutdown: – as diagnostic actions 265 – typical causes of trouble 44, 265 – use of change strategy for 23 Steam, usage 198 Steam systems, causes of corrosion in 36 – cases involving steam generation 339 – good practice 58 – symptoms-cause 66 Steam traps, symptoms-cause 80 – causes 575 Stiction 47 STM, see Short Term Memory Strategies for problem solving, – activities to improve skill 173 – description 20, 21 Strategies for TS, related entries Basics and Change – selecting basics versus change 197 Stress: – activities to improve skill 246–247 – effect of high distress on propensity to make mistakes 22, 221, 245–246 – need for some stress 22 – need to manage 20, 22 I 13 I 14 Index – self rate environment 254 – suggestions on how to manage 22 Stripping, see Desorption, gas Style, preferred, see Personal style Subproblems, identify 20 Sulfinol 383, 387 Sulfolane, and foaming 129 Sulfonation, safety 96, 98, 99 Sulfuric acid systems, causes of corrosion in 46 Surfactants (causing foaming), examples 74 – causing emulsion stability, examples 84 Surface phenomena, importance 67 Surface tension: – and absorption 73 – and coalescers 111 – and wetting 94 – critical, use in absorption 73 – impact 69, 71, 73, 83, 110, 129 – in packed columns 109 – in reactors 94 – negative, definition 69 – positive, definition 69 Symptoms, (one type of cue): – characteristics of – definition 212 – how to identify symptom 220 – root cause versus symptom 24, 43, 195 – activities to improve skill in identifying root cause 217, 225 – examples, Case ’8 38, 216 Symptom-cause data, see specific pieces of equipment – diagraming 228, 229 – symptom-cause data for – Case ’3 228–229 – Case ’8 38 – symptom-hypotheses-diagnostic action chart, see Hypothesis, chart symptoms, list of for – Case ’6 147 – Case ’8 39 Synthesis – element in the TS process 21, 22, 33 – list of detracting and enriching behaviors 31 – self rate skill Systems thinking: – activities to improve skill 418 – definition 5, 7, 127 – elements in – need for – self rate skill t Tabletting, symptoms-cause 111 TAPPS (talk aloud pairs problem solving) – use of, to improve awareness 165–168 – use of, to improve the application of strategies 174–177 Tanks, frequency of faults 44 Taylor, W., cited 13, 214, 255, 317, 339, 357, 383, 387, 391, 540 Teamwork: – feedback form for meetings 50–51 – symptoms-cause 48–49 Temperature, high, fiult in systems operating at 44 Tests, selecting and designing, see Diagnostic actions Thermodynamics 267 Thickener, symptoms-cause 86–87 – cases involving 286, 342 Three phase separators, GLL, symptomscause 84 Time management: – how to 22 – need for good 22 Transmitters, symptom-cause data 47 Trends in evidence, see Patterns Trim coolers, use of 61 Trouble shooting, mental process: – activities to improve skill, triad 259–262 – as a problem solving process 17ff – assessment of skill 33, 262 – classification of components: – data and analysis elements 19, 398 – Case ’4 140 – Case ’5 144 – Case ’6 156 – Case ’7 161–162 – example rating form 33 – example critique for Case ’3 138 – list of detracting and enriching behaviors 30 – decision making elements 19, 22, 398 – Case ’4 140 – Case ’5 144 – Case ’6 156 – Case ’7 161–162 – example rating form 33 – example critique for Case ’3 138 – list of detracting and enriching behaviors 32 – problem solving elements 19, 20, 21, 398 – Case ’4 140 Index Case ’5 144 Case ’6 156 Case ’7 161–162 example rating form 33 example critique for Case ’3 137 list of detracting and enriching behaviors 29 – synthesis elements 19, 22, 398 – Case ’4 140 – Case ’5 144 – Case ’6 156 – Case ’7 161–162 – example rating form 33 – example critique for Case ’3 138 – list of detracting and enriching behaviors 31 – definition 1, – five key skills: – experience with process equipment 4, 398 – self test – people skills 5, 397, 400 – self test – problem solving 4, 397, 398 – self test – process safety and properties of materials 5, 397 – self test – systems thinking 5, 397 – self test – individual 262 – possible immediate corrective options – reflection about activities 401 – reflection about skill 398 – self rate five strengths 402 – strategies, see Basics strategy for TS and Change strategy for TS – worksheet, description 27–29, 587 – succinct version 26–27 – detailed version 40–42 – examples – Case ’3 423 – Case ’4 427 – Case ’5 141, 430 – Case ’6 145 – Case ’8 35–39 Trouble shooting problems, see Problems, TS Trust, building and developing: – activities to improve skill 241, 242 – components of 240 – definition 242 – need for 47, 240 – self rate skill 9, 242 – – – – – – Turbine, MTBF 44, 201 – cases involving 35, 171, 255, 339, 350 – steam, symptoms-cause 59 Turnaround, as diagnostic action 265, 584, 585 – trouble after 4, 44 Turner, J., cited 80 Tyler, Ted, cited 222 Types of trouble shooting problems, see Problems, TS u Ultrafiltration, see Membranes Uniqueness, see Personal style v Vacuum, equipment to produce, symptomscause 53–54 – and crystallizers, symptoms-cause 72 – and evaporators, symptoms-cause 68 – cases involving 13, 181, 252, 255–256, 335, 374, 383, 387 Valid conclusions, how to reach, see Reasoning Valves, causes 574 – block, symptom-cause data 47 – check, symptom-cause data 47 – control, symptom-cause data 47 – rotary star, symptoms-cause 56 Varadi, T., cited 94 Vendors, vendor files, use of 197, 266 – call 268 Vessels, pressure, frequency of faults 44 w Wasan, W.C., cited 405 Water, makeup contains corrosion, products, causes 46 Water treatment, flocculation, symptomscause 111 Weather, importance of 197, 584 – as diagnostic action 265, 584 – example impact 221 Wetting – and absorbers, symptoms-cause 73 – and decanters, symptoms-cause 83 – and demisters 110 – and packed columns 109 – and reactors 94 – and SX, symptoms-cause 76 What if? – example use in TS Worksheet for – Case ’4 429 I 15 I 16 Index – Case ’5 142, 432 – Case ’8 37 – to create counterarguments 232 – trigger for brainstorming 185 – when to use 198 Why? Why? Why? – activity to improve skill 181 – as diagnostic action 265 – example use on TS Worksheet – Case ’4 139 – Case ’7 180 – Case ’8 36 – prompt to use on TS Worksheet 26, 41 – use of during the explore stage of problem solving 20 Winter, D R., cited 347, 380, 552, 561 Woods, D R., cited 130 Worksheet, see Trouble shooting, worksheet y Yip, Jonathan, cited 256, 289, 543 Yokell, S., cited 546, 409 Young, D., cited 48, 406 z zpc, zero point of charge (isoelectric point), and stability 69, 71, 74, 76, 78–80, 83, 93, 111 [...]... additional research evidence into the process of solving troubleshooting problems is given In Section 2.3 is given a worksheet or template for solving trouble- shooting problems Also given is an assessment form to provide feedback about one’s performance as a trouble shooter An example use of the Worksheet is given in Section 2.4 for Case ’8 Successful Trouble Shooting for Process Engineers Don Woods Copyright... Appendix G Skill ’2: knowledge of process equipment Chapter 3 provides a convenient summary of the practical aspects about equipment needed for trouble shooters of over 50 different types of process equipment For most types of process equipment the following information is given: overall fundamentals, guidelines for good operation, and trouble shooting For trouble shooting, typical symptoms are given... illustrate different components in the trouble- shooting process However, no specific educaSuccessful Trouble Shooting for Process Engineers Don Woods Copyright  2006 WILEY-VCH Verlag GmbH & Co KGaA, Weinheim ISBN: 3-527-31163-7 XIV Preface tional plan is apparent No activities, with feedback, are provided for skill development Branan’s “Rules of Thumb for Chemical Engineers is mainly an excellent collection... to Consider Figure 1-5 The vacuum crystallizer for Case ’7 Feedback for these cases is provided in Chapter 4 15 17 2 The Mental Problem-Solving Process used in Trouble Shooting A trouble- shooting problem occurs As the trouble shooter processes the evidence, he/she mentally scans past experience to see if he/she has successfully solved anything like it before If that past experience is limited; if there... become an outstanding trouble shooter A number of excellent books have been published about trouble shooting Liberman ( Trouble- shooting process Operations”) describes a wide range of problems that he encountered, the fault that he discovered and the corrective action His personal approach to trouble shooting is illustrated Saletan (“Creative Trouble Shooting in the Chemical Process Industries”) provides... draw on the extensive research about the trouble- shooting process A skill development program should give you a chance to solve a wide range of trouble- shooting problems, to think about how you solved them and to set goals for improvement The central core of this book is 52 trouble- shooting cases that are presented in a unique format that allows you to select the process you will use to solve the problem... GmbH & Co KGaA, Weinheim ISBN: 3-527-31163-7 2 1 What is Trouble Shooting? Trouble shooting is the process used to diagnose the fault safely and efficiently, decide on corrective action and prevent the fault from reoccurring In this chapter we summarize the characteristics of a trouble- shooting problem, give an overview of the trouble- shooting process and “systems” thinking used to correct the fault... efforts trouble can occur – such as in Example Case ’2 The TS strategy is to recognize unsafe conditions and initiate emergency measures or, where possible, to return the operation to “safe-park” conditions where operation is safe until the trouble is solved Handling trouble during the startup of a new process When we start up a process or new approach for the first time, we may encounter trouble- shooting. .. pressure profile for about five piping configurations 10 = can estimate pressure profiles for a P&ID with interconnecting piping with 50 MPI 7 8 1 What is Trouble Shooting? – Process control: rate: _ 0 = Unable to identify and rationalize a process control system 5 = For a P&ID with 10 MPI, can identify good and bad process control; can identify the presence and absence of four levels of process control... mine Waterdown, September 2005 Don Woods 1 1 What is Trouble Shooting? Process plants operate about 28 days of the month to cover costs The remaining days in the month they operate to make a profit If the process is down for five days, then the company cannot cover costs and no profit has been made Engineers must quickly and successfully solve any troublesome problems that occur Sometimes the problems ... do?” Successful Trouble Shooting for Process Engineers Don Woods Copyright  2006 WILEY-VCH Verlag GmbH & Co KGaA, Weinheim ISBN: 3-527-31163-7 What is Trouble Shooting? Trouble shooting is the process. .. crystallizer for Case ’7 Feedback for these cases is provided in Chapter 15 17 The Mental Problem-Solving Process used in Trouble Shooting A trouble- shooting problem occurs As the trouble shooter processes... Problem-Solving Process used in Trouble Shooting 17 Problem Solving 19 Trouble Shooting 23 Considerations when Applying the Strategy to Solve Trouble- Shooting Problems 23 Problem-Solving Processes