This document outlines challenges in process industries like maximizing production while ensuring quality and safety. It discusses the importance of troubleshooting skills given increasing risks and responsibilities. While most training approaches are too generic or equipment-specific, the presented approach describes a 5-phase troubleshooting methodology including understanding the background, identifying event sequences, analyzing causes, making conclusions, and providing recommendations. The goal is to teach a systematic approach while prioritizing safety.

1. ““The Fundamentals of ProcessThe Fundamentals of Process
Troubleshooting”Troubleshooting”
“The real plant is no place for practice.”“The real plant is no place for practice.”

2. Process Industries ChallengesProcess Industries Challenges
Maximize Production Output While MaintainingMaximize Production Output While Maintaining
Product QualityProduct Quality
Higher Operating Rates/RisksHigher Operating Rates/Risks
Increased Operator Scope of ResponsibilityIncreased Operator Scope of Responsibility
Increased Safety AwarenessIncreased Safety Awareness
Increased Usage of Sophisticated Plant AutomationIncreased Usage of Sophisticated Plant Automation

3. Why Troubleshooting Matters toWhy Troubleshooting Matters to
Operations PersonnelOperations Personnel
Consequences of failure getting largerConsequences of failure getting larger
-->Cost, scale, EHS impact.-->Cost, scale, EHS impact.
Loss of experienced staff = loss ofLoss of experienced staff = loss of
troubleshooting expertstroubleshooting experts
Well running plants provide forWell running plants provide for
complacency, with few chances to keepcomplacency, with few chances to keep
troubleshooting skills sharpenedtroubleshooting skills sharpened

4. What Have We Learned fromWhat Have We Learned from
Good Troubleshooters?Good Troubleshooters?
Knowledge counts: Expertise in processKnowledge counts: Expertise in process
leads to troubleshooting expertiseleads to troubleshooting expertise
Experienced troubleshooters keep gettingExperienced troubleshooters keep getting
called to help --> And so they maintain andcalled to help --> And so they maintain and
improve their troubleshooting skillsimprove their troubleshooting skills
The best troubleshooters are systematic andThe best troubleshooters are systematic and
“system thinkers.”“system thinkers.”
Everybody wants them, but few have themEverybody wants them, but few have them

5. Successful TroubleshootingSuccessful Troubleshooting
requires:requires:
An understanding of basicAn understanding of basic
process parametersprocess parameters
The ability to think inThe ability to think in
systems termssystems terms
A systematic trouble-A systematic trouble-
shooting methodologyshooting methodology

6. Formal Training ApproachesFormal Training Approaches
Most formal approaches toMost formal approaches to
teaching troubleshootingteaching troubleshooting
skills fall into one of 2skills fall into one of 2
categories:categories:
Very genericVery generic
Equipment specificEquipment specific
These approaches have theirThese approaches have their
limitationslimitations

7. Generic Approach toGeneric Approach to
TroubleshootingTroubleshooting
As taught in a leading plant safety seminar:As taught in a leading plant safety seminar:
Define the problemDefine the problem
Gather relevant factsGather relevant facts
Identify the source of the problemIdentify the source of the problem
Develop possible solutionsDevelop possible solutions
Select the best solutionSelect the best solution

8. Generic ApproachGeneric Approach
While this is certainly a respectableWhile this is certainly a respectable
list of tasks, many people find itlist of tasks, many people find it
difficult to apply them across adifficult to apply them across a
broad range of problems.broad range of problems.
Some examples specific to theSome examples specific to the
trainee’s job would certainly help!trainee’s job would certainly help!
Often, though, the instructors forOften, though, the instructors for
this type of training have little plantthis type of training have little plant
operations or maintenanceoperations or maintenance
experience.experience.

9. Specific TroubleshootingSpecific Troubleshooting
ApproachApproach
While this approach is onWhile this approach is on
target for this particulartarget for this particular
problem, such as specificproblem, such as specific
equipment operations,equipment operations,
most people would havemost people would have
trouble generalizing thetrouble generalizing the
technique and applying ittechnique and applying it
to other - particularlyto other - particularly
dissimilar - problems.dissimilar - problems.

10. The Fundamentals of ProcessThe Fundamentals of Process
TroubleshootingTroubleshooting
Learning Objectives:Learning Objectives:
Describe the 5 Phases ofDescribe the 5 Phases of
effective trouble-shootingeffective trouble-shooting
Describe the specific StepsDescribe the specific Steps
within each troubleshootingwithin each troubleshooting
PhasePhase
Successfully apply the Phases/Successfully apply the Phases/
Steps to actual operationsSteps to actual operations
problemsproblems
Distinguish between “possible”Distinguish between “possible”
and “probable causes”and “probable causes”
Recognize the differenceRecognize the difference
between “trial and error” &between “trial and error” &
“designed testing”“designed testing”
Recognize the adverse effect ofRecognize the adverse effect of
each of the following phenomena:each of the following phenomena:
– Lock on/lock outLock on/lock out
– Task interferenceTask interference
– Organization hierarchyOrganization hierarchy
– Unintended consequencesUnintended consequences
Successfully counter the influenceSuccessfully counter the influence
each of the above has on effectiveeach of the above has on effective
troubleshootingtroubleshooting
Conduct the practice of trouble-Conduct the practice of trouble-
shooting fully recognizing thatshooting fully recognizing that
safety -- process and personnel -- issafety -- process and personnel -- is
always the first priorityalways the first priority

11. 05 Phases of Troubleshooting05 Phases of Troubleshooting
Back Ground: Understand the process and pin theBack Ground: Understand the process and pin the
problemproblem
Sequence Of Event: Identify components of theSequence Of Event: Identify components of the
incidentincident
Event Analysis: Discuss and list all possibleEvent Analysis: Discuss and list all possible
causescauses
Conclusion: Evaluate the causes and select causesConclusion: Evaluate the causes and select causes
Recommendations: Changes for improvement andRecommendations: Changes for improvement and
controlcontrol