Conceptual Approach for Trouble Shooting of Chemical Process Industry. Proper design and trained operating manpower ensures trouble free plant operation.
2. klcenter@gmail.comKoncept Learning Center
Sharing Experiences
Trouble Shooting of CPI
What is Trouble?
Deviation from Normal Plant Operation
Normal Plant Operation Abnormal Plant Operation
1.) Product Specs
a.) Composition NaOH (33%w/w) NaOH (32%w/w)
b.) Color White Yellowish
c.) Smell Sweetish Pungent
3. klcenter@gmail.comKoncept Learning Center
Sharing Experiences
Trouble Shooting of CPI
What is Trouble?
Deviation from Normal Plant Operation
Normal Plant Operation Abnormal Plant Operation
2.) Process Parameters
a.) Pressure 2.5 kg/cm2 (g) 2.4 kg/cm2 (g)
(at Heat Exchanger Out)
b.) Temperature 105 oC 104 oC
(Distillation Column Bottom)
4. klcenter@gmail.comKoncept Learning Center
Sharing Experiences
Trouble Shooting of CPI
What is Trouble?
Deviation from Normal Plant Operation
Normal Plant Operation Abnormal Plant Operation
3.) Material Consumption
a.) Raw Material ‘A’ 1.2 tons 1.3 tons
(Per Ton of Product)
b.) Sulfuric Acid (98%w/w) 0.5 kgs 0.55 kgs
(Per Ton of Product)
5. klcenter@gmail.comKoncept Learning Center
Sharing Experiences
Trouble Shooting of CPI
What is Trouble?
Deviation from Normal Plant Operation
Normal Plant Operation Abnormal Plant Operation
4.) Utility Consumption
a.) Steam 2.5 tons 2.6 tons
(Per Ton of Product)
b.) Electricity 150 KWH 160 KWH
(Per Ton of Product)
6. klcenter@gmail.comKoncept Learning Center
Sharing Experiences
Trouble Shooting of CPI
What is Trouble?
Deviation from Normal Plant Operation
Normal Plant Operation Abnormal Plant Operation
5.) Hardware
a.) Centrifugal Pump No Sound Sound like Gravel or Marbles
b.) Distillation Column No Vibration Vibration in Valve Tray
c.) Pipe Line No Leakage Liquid leaking from valve
7. klcenter@gmail.comKoncept Learning Center
Sharing Experiences
Trouble Shooting of CPI
What is Trouble?
Deviation from Normal Plant Operation
Normal Plant Operation Abnormal Plant Operation
6.) Miscellaneous
a.) Scaling of Condenser In pre-define limits Very High
b.) Pump Bearing Failure No Frequent
c.) Emergency Shut Downs No Frequent
8. klcenter@gmail.comKoncept Learning Center
Sharing Experiences
Trouble Shooting of CPI
What is Trouble?
Deviation from Normal Plant Operation
Some troubles can be easily sensed by
human senses like eyes, ears, etc.
while other needs to be worked out
9. klcenter@gmail.comKoncept Learning Center
Sharing Experiences
Trouble Shooting of CPI
Typical Industrial Troubles
• Not getting production plant capacity
• Product quality is not acceptable
• Utility consumption is higher than committed
• Plant stoppages are frequent
• Frequent breakdown of plant hardware
• Plant require higher maintenance
10. klcenter@gmail.comKoncept Learning Center
Sharing Experiences
Trouble Shooting of CPI
Types of Troubles
• Sitting over the problem and not aware about it
• Knowingly sitting over the problem
• Very much away from the problem
• Keeping self away from the problem
• Painted Problem or Concealed Problem
• Artificially created problem
12. klcenter@gmail.comKoncept Learning Center
Sharing Experiences
Trouble Shooting of CPI
How to Identify Trouble?
oTop-Down Approach
• Identification by Top Management
• Losses in Balance Sheet
• Lower Production Rate from Annual Production Report
•Communicated up to Shop Floor Persons for Identification
of exact trouble place
13. klcenter@gmail.comKoncept Learning Center
Sharing Experiences
Trouble Shooting of CPI
How to Identify Trouble?
oBottom-Up Approach
• Sensed by Shop Floor Person
• Pipe Line Leakage
• Sound in Operating Pump
•Communicated to Higher Management Persons for working
out severity of trouble for prioritizing activities
14. klcenter@gmail.comKoncept Learning Center
Sharing Experiences
Trouble Shooting of CPI
How to Identify Trouble?
For Effective Trouble Identification,
maintain good communication channels
between Top to Bottom/ Bottom to Top.
15. klcenter@gmail.comKoncept Learning Center
Sharing Experiences
Trouble Shooting of CPI
Shooting or Solving the Trouble
What Shooting Requires?
• Clear View of Target (Trouble)
• Ability to Hit the Target (Solving the Trouble)
16. klcenter@gmail.comKoncept Learning Center
Sharing Experiences
Trouble Shooting of CPI
Shooting or Solving the Trouble
What Shooting Requires?
• Clear View of Target (Trouble)
Far & Beyond
• Target from Far Distance
•Unable to see target
•e.g. Pump vibration from outside of plant campus
• Target beyond Self Experience
•Unable to differentiate between Normal & Abnormal
•e.g. Pump cavitation sound not experienced earlier
Experience to get more clarity of Trouble (Trouble is an Opportunity for Growth)
17. klcenter@gmail.comKoncept Learning Center
Sharing Experiences
Trouble Shooting of CPI
Shooting or Solving the Trouble
What Shooting Requires?
• Clear View of Target (Trouble)
Vision Power
• Higher Knowledge Level
•Despite far distance, trouble can be viewed well.
•Distant symptoms are enough to view the trouble clearly
by higher level knowledge
Far & Beyond
18. klcenter@gmail.comKoncept Learning Center
Sharing Experiences
Trouble Shooting of CPI
Shooting or Solving the Trouble
What Shooting Requires?
• Ability to Hit the Target (Solving the Trouble)
Skill Development by Routine Practice
• Fixed Target (Static Trouble)
•Relatively easy to solve as trouble is well defined.
•e.g. flow from Tank-1 to Tank-2 is not possible due to
insufficient elevation difference (Correct Elevation)
• Moving Target (Dynamic Trouble)
•Set of Causes
19. klcenter@gmail.comKoncept Learning Center
Sharing Experiences
Trouble Shooting of CPI
Steps of Trouble Shooting
1. Identify the Trouble
2. Take Preventive Action
3. Determine the Cause
4. Correct the Trouble
5. Return to Service
20. klcenter@gmail.comKoncept Learning Center
Sharing Experiences
Trouble Shooting of CPI
Steps of Trouble Shooting
1. Identify the Trouble
Engineering Approach for Trouble Identification
Troubled Area
Block Diagram
21. klcenter@gmail.comKoncept Learning Center
Sharing Experiences
Trouble Shooting of CPI
Steps of Trouble Shooting
1. Identify the Trouble
Engineering Approach for Trouble Identification
Troubled Area
Process Flow Diagram
22. klcenter@gmail.comKoncept Learning Center
Sharing Experiences
Trouble Shooting of CPI
Steps of Trouble Shooting
1. Identify the Trouble
Engineering Approach for Trouble Identification
Troubled Area
P & I Diagram
23. klcenter@gmail.comKoncept Learning Center
Sharing Experiences
Trouble Shooting of CPI
Steps of Trouble Shooting
1. Identify the Trouble
Engineering Approach for Trouble Identification
Troubled Area
Incorrect Type of ReducerIsometrics
24. klcenter@gmail.comKoncept Learning Center
Sharing Experiences
Trouble Shooting of CPI
Steps of Trouble Shooting
1. Identify the Trouble
2. Take Preventive Action
If required, Stop the complete plant
Off Spec Product Produced
Distillation Column Tray Vibrations
Or Stop a Section of the Plant
Recovery Section only
Or Stop a Unit of the Section
Stop Running Pump while operating with Standby Pump
25. klcenter@gmail.comKoncept Learning Center
Sharing Experiences
Trouble Shooting of CPI
Steps of Trouble Shooting
1. Identify the Trouble
2. Take Preventive Action
3. Determine the Cause
• Causes of Trouble Due to
• Material – Impure Input Materials
• Machine – Inadequate Preventive Maintenance
• Manpower – Untrained Operator
26. klcenter@gmail.comKoncept Learning Center
Sharing Experiences
Trouble Shooting of CPI
Steps of Trouble Shooting
1. Identify the Trouble
2. Take Preventive Action
3. Determine the Cause
• Causes of Trouble Entered During Stage of
• Plant Design – Wrong consideration of design parameters
• Equipment Selection – Low Pump Head
• Plant Erection – Wrong motor placement
• Plant Operation – Valve is not fully open
• Plant Maintenance – Placed Damaged Gasket
27. klcenter@gmail.comKoncept Learning Center
Sharing Experiences
Trouble Shooting of CPI
Steps of Trouble Shooting
1. Identify the Trouble
2. Take Preventive Action
3. Determine the Cause
4. Correct the Trouble
28. klcenter@gmail.comKoncept Learning Center
Sharing Experiences
Trouble Shooting of CPI
Steps of Trouble Shooting
1. Identify the Trouble
2. Take Preventive Action
3. Determine the Cause
4. Correct the Trouble
5. Return to Service