CHAPTER 7
INTRODUCTION TO PROCESS TROUBLESHOOTING
OBJECTIVES
• Describe the various troubleshooting models
• Describe how different variables affect each other.
• Explain how problems with process equipment affect other systems.
• Analyze process problems and provide solutions.
• Troubleshoot specific operational scenarios.
• Describe various instrumentation used to troubleshoot process problems.
• Distinguish between primary and secondary problems.
• Collect, organize, and analyze data.
• Respond to alarms and control systems that are outside operational guidelines.
• Compare troubleshooting methods and models.
REVIEW QUESTIONS
1. List the various types of troubleshooting models.
• Pump and tank model
• Compressor model
• Heat exchanger model
• Cooling tower model
• Boiler model
2. Compare and contrast troubleshooting methods with models.
Troubleshooting Methods
There are a number of troubleshooting methods that can be used with these models.
Methods vary depending on individual educational faculty, consultants, and industry.
The basic approach to most methods includes the development of a good educational
foundation.
Method One: Educational
• Basic knowledge of the equipment and technology
• Understanding of the math, physics and chemistry associated with the equipment
• Study equipment arrangements in systems
Troubleshooting is a process that requires a wide array of skills and techniques.
Modern control instrumentation includes; indicators, alarms, transmitters, controllers,
control valves, transducers, analyzers, interlocks, etc. The primary goal is to control
variables like temperature, pressure, flow, level, or analytical variables. It is possible to
control large, complex processes from a single room. In these types of systems,
Method Two: Instrumental
Method Three: Experiential
• Experience operating specific equipment and system
• Familiarity with past problems and solutions
Method Four: Scientific
• Grounded in principles of mathematics, physics, and chemistry
• Theory-based operations
• Good understanding of equipment design and operation
Each of thee methods can be used on the ten different models used in this chapter or
on any process unit.
3. Describe how control loops are used in process troubleshooting.
Many college process technology instrumentation programs are written
around the concept of the control loop. On process units that are fully
automated the control loop gives a technician the ability o control a much larger
4. Compare and contrast primary and secondary problems on an operating system.
6. List the various types of instruments used to troubleshoot. Answer: Control
NAME:____________________________ TEST A
DATE:____________________________
CHAPTER SEVEN
TEST INTRODUCTION TO PROCESS TROUBLESHOOTING
1. List the four troubleshooting models discussed in this chapter.
a.
b.
c.
d.
2. List the ten troubleshooting models discussed in this chapter.
1 .
2
3
4
5
6
7
8
9
10
3. Primary operational problems are described as:
a. a term used to describe equipment that has broken, ruptured, or is no
longer responding to its design specifications.
b. a term used to describe the first problem that created a process upset.
c. instruments used to detect process variables provide clues that can be
used to complete the big picture.
d. are created or respond to a primary operational problem that has created
a process upset and a trickle down effect.
4. Secondary operational problems are described as:
a. a term used to describe equipment that has broken, ruptured, or is no
longer responding to its design specifications.
b. a term used to describe the first problem that created a process upset.
c. instruments used to detect process variables provide clues that can be
used to complete the big picture.
d. are created or respond to a primary operational problem that has created
a process upset and a trickle down effect.
5. Describe Process Troubleshooting Method One
6. Describe Process Troubleshooting Method Two
7. Describe Process Troubleshooting Method Three
8. Describe Process Troubleshooting Method Four