This document provides an overview of troubleshooting skills for process operations. It discusses the key elements of troubleshooting including defining the problem, investigating causes, planning solutions, implementing plans, evaluating results, and concluding. Common troubleshooting techniques are explained such as fishbone diagrams, fault tree analysis, 5 whys, and mind mapping. A case study example applies these techniques to troubleshoot a pump failure where the root cause was determined to be reverse motor rotation due to an operator error in verification. The presentation aims to improve troubleshooting skills for both experienced and new process engineers.

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2. Trouble Shooting Skills
Presented By: Nasir Hussain
Process Operation Engineer
DHDS Unit Pak Arab Oil Refinery
Date: 19.02.2018
Contact: nasir.mughal3010@gmail.com
Whatsapp:00923334647564

3. Contents
1. Introduction
2. Benefits/Advantages of TS skills
3. Types of troubles
4. Key elements for troubleshooting
5. Strategy of Troubleshooting
6. Troubleshooting Techniques
7. Case Study
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4. What is Troubleshooting?
 It is the technique to diagnose the fault
safely and efficiently, decide on
corrective action and prevent the fault
from reoccurring.
 To identify and correct the cause while
the process continues to operate under
current conditions.

5. Advantages
 Increased profitability of the Units
 Logical approach towards trouble
shooting and root cause analysis
 Learning of brainstorming techniques
 Improved skills of troubleshooting
 Use of modern skills for TS of process
problems.
 Equally important for experienced and
fresh people
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6. Types of Troubles
1. Known means, those troubles which
have established SOPS like power
failure, steam failure etc.
2. Unknown, which may arise any time but
with different symptoms & without any
established SOPS.
3. Problems during startups & shutdowns
4. Problems during commissioning
5. “Change” when significant changes and
maintenance carried out.

7. Key Skills for Trouble Shooting
1. Skill in problem solving
2. Knowledge about a range of process
and equipments
3. Knowledge about the properties, safety
and unique characteristics of the
specific chemicals and process
conditions.
4. People skills

8. Skills Explanation
1. Problem Solving Skills 1. Data handling, collecting, evaluating and find the
relevant data
2. Monitoring, checking, double checking while
being organize & explore the multiple causes
3. To view the problem logically and find the root
cause.
4. Decision making based on priority, avoiding bias.
2. Knowledge about the process
and equipments
1. Process understanding
2. P&ID, PFDS, SOPS, Operating manuals etc.
3. Common faults, typical symptoms, operating and
design conditions of the equipments like pumps,
exchangers, compressors etc.
4. Understands basic engineering skills (heat &
mass balance etc.)
5. System thinking
3. Knowledge about the
properties of process fluids
1. Must be known to handle safely emergencies.
2. Behavior of the fluids gases, Hydrocarbons,
steam, water etc.
3. Health, flammable limits etc.
4. People or Communication
skills
1. Good communication & listening skills
2. Team work
3. Building and maintaining trust 8

9. Strategy of Troubleshooting
1. Define the problem
2. Investigate the problem
3. Plan a solution
4. Implement the plan
5. Evaluate and check
6. Conclude

10. Steps Explanation
1. Define the problem • Initial assessment
• Obvious parameters
• Categorize the problem (Safety, power failure etc.)
• Ask questions What? When? Where? Who?
• List down the symptoms
• Don’t jump to the root cause
2. Investigate the
Problem
• Trends view , alarms history etc.
• Field verification
• Comparison with design data
• Discussion with plant staff
• P& ID reviews
• Brainstorming
• Use of Fishbone/ FTA or other technique
• Hypothesis development
• It needs half of the total time
• Use of simulation tools (if available)
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Steps Explanation
3. Plan a solution • Decision making based on hypothesis
• Manage resources
• Apply single action at a time
• How to implement the hypothesis findings
• Plan smaller changes for effective monitoring
4. Implement the plan • Implement the plan as per root cause or hypothesis.
• Sampling, modification etc.
• Small changes are usually tested , and data is gathered to
see how effective the change is?
• Systematic, carefulness and monitoring
5. Evaluate and Check • Compare the results with the expected/planned outcomes.
• Did it answer the problem?
6. Conclude • If the results are satisfy during check phase then continue
with this if doesn't then again go for problem exploration,
hypothesis development and then planning

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13. TS/Root Cause Analysis Techniques
1. Fishbone Diagram
2. Fault Tree Analysis
3. Mind mapping
4. 5 Whys
5. What if Analysis
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14. Fishbone Diagram
 Also called Ishikawa or cause and effect
diagram developed in 1968
 It is used to find root cause, defect or
deficiency in the system, problem
solving and quality defects identification.
 Being used in manufacturing, service,
engineering, marketing etc. industries.
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16. Fault Tree Analysis
 It was originally developed in 1962 at
Bell Laboratories by H.A Watson in US
Air force.
 Mainly used in safety engineering,
reliability engineering, aero space,
nuclear power, chemical and process
etc.
 It is used for find cause of failure, root
cause, defects in the system .
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17. Advantages of FBD & FTA
 Display relationships clearly and
logically
 Show all causes simultaneously
 Facilitate brainstorming
 Stimulate problem solving
 Easy to draw
 Create visual record of a system
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18. A product pump of was taken in service after
complete overhauling but the pump was not
delivering the required flow. Develop the FSB &
FTA to find the root cause of the problem.
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Case Study:

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22. Fault Tree Analysis
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23. 5 Whys
Why questions Answers (Because)
Why did the pump fail to deliver
flow?
• The pump cavitates
• The controllers, instruments are not working
OK.
• Machine health is not OK.
Why did the pump cavitate? • Low NPSH
•Low liquid level
•Non condensable in the liquid
• Low Sp. Gravity of the liquid
Why machine is not OK. • Prime mover problem
• Suction strainer/line clogged
•Impeller size/condition is not OK.
Why the controllers are not working
OK?
•Spill back valve malfunctions
•Discharge controllers malfunctions

24. What if
What if questions Answers
What if the pump fail to deliver
flow?
• The pump cavitates
• The controllers, instruments are not working
OK.
• Machine health is not OK.
What if the pump cavitate? • Low NPSH
•Low liquid level
•Non condensable in the liquid
• Low Sp. Gravity of the liquid
What if machine is not OK. • Prime mover problem
• Suction strainer/line clogged
•Impeller size/condition is not OK.
What if controllers are not working
OK?
•Spill back valve malfunctions
•Discharge controllers malfunctions

25. Mind Mapping
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26. Process Trouble Shooting Sheet
Area/Section Date
Problem: P-8 Pump fails to deliver flow
Problem Symptoms
1 Discharge flow below 10 M3/hr and fluctuation at FT………..
2 Level of the product tank rising………..LT
3 Pump ampers low than the normal
4 Discharge pressure below 3-5 Kg/cm2 and fluctuation at FT………..
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Investigate the Problem by Asking Questions or FTA/FBD
Ask Questions Answers
Why did P-8 Pump fail to deliver flow ? 1. The pump cavitates
2. The controllers, instruments working is not OK.
3. Machine health is not OK.
Why did the pump cavitate? 1. Low NPSH
2. Low liquid level
3. Non condensable in the liquid
4. Low Sp. Gravity of the liquid
Why the machine is not OK? 1. Prime mover problem(Revrese rotation)
2. Suction strainer/line clogged
3. Impeller size/condition is not OK
Why the controllers ,Instruments working is not
OK?
1. Spill back valve malfunctions
3. Discharge controllers malfunctions
3. LT/FT/PT malfunction
Cause of problem
1.Prime mover reverse rotation
2. Operator failed to verify the rotation
Solution plan
1.Change the rotation of motor from Substation
2. Training of staff
Monitoring Required
1.Varify the rotation
2.After taking service observe Flow, amperes and Pressure
Conclusion
Pump failed to deliver desired flow because of the reverse rotation of the motor. Area operator initially failed to verify the
rotation.

27. Process Trouble Shooting Sheet
Area/Section Date
Problem: P-8 Pump fails to deliver flow
Problem Symptoms:
1 Discharge flow below 10 M3/hr and fluctuation at FT………..
2 Level of the product tank rising………..LT
3 Pump ampers low than the normal
4 Discharge pressure below 3-5 Kg/cm2 and fluctuation at FT………..
5
Investigate the Problem by Asking Questions or FTA/FBD
Ask Questions Answers
Why Symptom 1? 1. Pump cavitates
2.FT problem
3.Controllers malfunction
4.Prime mover problem
Why Symptom 2? 1.Pump fails to deliver
2.LT malfunction
Why Symptom 3?
1.Ampere meter problem
2.Pump cavitates or fails to deliver required flow..
Why Symptom 4? 1. Cavitation
2.Reverse rotation
3.PT nmalfunction
Why pump cavitates ? 1. Low level of vessel
2. Blanketing gas low pressure
3. Change in sp. Gravity of the liquid
4. Non condensable in the fluid
5. Suction strainer or line chocked
Cause of problem
1.Prime mover reverse rotation
2. Operator failed to verify the rotation
Solution plan
1.Change the rotation of motor from Substation
2. Training of staff
Monitoring Required
1.Varify the rotation
2.After taking service obverse Flow, amperes and Pressure
Conclusion Pump failed to deliver desired flow because of the reverse rotation of the motor. Area operator initially failed to verify the rotation.

28. References
1. www.wikpedia.com
2. Successful trouble Shooting for Process
Engineers by Prof. Donald R. Woods
3. Process Engineering Problem Solving by
Joe M. Bonen
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29. The End
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