Process System Surveillance & Troubleshooting Workshop

Course Length:2 days(10 hours) OR 3 days(8 hours)

Course Purpose:

The workshop provides participants (operations personnel) a 3-step method for troubleshooting and determining root cause of a process upset. This method is based on the logic or predictability designed into the system. K&S ensures that students understand the function of the various processes and the associated factors that must be controlled to achieve the function of the equipment. Emphasis is also placed on the necessity of selecting appropriate (safe & economical) corrective action plans that return the process to normal without creating additional problems. Pro-active monitoring and control of the process is also stressed as a way to recognize abnormal early on and prevent losing control of the process. Operator confidence and workplace morale are positively impacted as a result of the training!

Course Objectives:

After course completion the student will be able to:

  • Solve complex problems (determine root cause) using a 3-step method with 100% accuracy.
  • Describe the functions of the 5 most common processes (Reaction, Absorption, Stripping, Decanting/Separation, & Distillation) in industry.
  • List the process control factors associated with each of the processes (Reaction, Absorption, Stripping, Decanting/Separation, & Distillation)
  • Use the process control factors to develop a punch list for troubleshooting that process.
  • Determine if a process upset is the result of a controller problem or a mechanical problem.
  • Generate a list of items that will reduce the cost of product manufacturing.
  • Recognize abnormal conditions in the process early on and prevent losing control of the system.
  • Develop and implement safe and economical corrective action plans that return the process back to normal.
  • Mass balance a column to prove flow meters, pumps, level controls, etc.
  • Take better control of the process to eliminate environmental upsets.
  • Improve communications with co-workers using a common language for problem solving.
  • Operate the process with increased confidence.
  • Increase up-time in their respective process.
  • Train others in a common method for troubleshooting process problems.

Who should attend?

This course is intended for anyone with day to day responsibilities for operating the plant or improving the process. This includes outside Operators, Console Operators, Supervisors, Engineers, Electrical and Instrument Technicians. Any level of experience will benefit.

Prerequisites:

Basic operating skills/knowledge helpful, but not required.

 Topical Outline:

  • Motivational
    1. Class goals / Objectives
  • Define the Process Person’s Job (K&S Model)
    1. Understand the type of specialized training needed
  • Challenge the participants base level process logic knowledge
    1. Introduce universal process
    2. Work 3 problems
    3. Start developing a logical method of thinking
  • Reaction process discussion
    1. Develop control factors
    2. Introduce the 3-step method
    3. Introduce the 3-step form
    4. Work reaction process problem
  • Separation / Decanting process discussion
    1. Develop control factors
    2. Discussion on proofreading data using process logic
  • Absorber process discussion
    1. Develop control factors
    2. General process optimization discussion
    3. Work absorber process problem
    4. Review 3-step method / form
    5. Re-emphasize the use of mass balance
  • Stripper process discussion
    1. Develop control factors
    2. Work absorber process problem
    3. Review 3-step method / form
    4. Re-emphasize indicator (LI, TI, PI, FI) Value
  • Distillation process discussion
    1. Develop control factors
    2. Discuss binary, azeotrope, extractive distillation methods
    3. Work distillation process problem
    4. Review 3-step method / form
    5. Re-emphasize the use of temperature profile
  • Full system problems
    1. Work full system problems
    2. Proofread, determine cause, and critique each problem
    3. Develop / Initiate corrective actions
  • Close program
    1. Review class goals / objectives

     

    This Workshop can be presented at your facility. Contact K&S Associates
    for more information