Module 6 – Basic Troubleshooting & Common Operational Issues

Objective:
By the end of this module, a trainee will be able to:

1. Recognize common operational issues in a butadiene or petrochemical plant.

2. Apply structured troubleshooting methods safely and effectively.

3. Identify early signs of equipment or process problems.

4. Understand operator interventions vs. actions requiring supervision.

6.1 – Introduction to Troubleshooting

Definition:

• Troubleshooting = the systematic approach to identify, diagnose, and resolve operational abnormalities.

• Essential skill for operators to maintain safe and stable plant operation.

Key Principles:

1. Observe First: identify symptoms, trends, alarms, noises, or vibrations.

2. Analyze: compare with normal operating trends and reference checklists.

3. Act Safely: apply corrective action within operator scope, escalate when necessary.

4. Document: record observations, actions, and outcomes for traceability.

Analogy:

• Troubleshooting = “detective work”: gather clues, verify facts, take safe corrective action.

6.2 – Structured Troubleshooting Method (5-Step Approach)

1. Identify the Problem:

   • Check alarms, trends, field observations, and operator logbooks.

   • Example: high temperature in distillation column, unusual vibration in pump.

2. Gather Information:

   • Review process parameters: flow, temperature, pressure, levels.

   • Inspect field equipment visually and audibly.

   • Confirm instrument readings.

3. Analyze & Hypothesize:

   • Compare abnormal readings to normal operating ranges.

   • Consider potential causes: mechanical, instrumentation, or process upset.

4. Take Corrective Action (Within Operator Scope):

   • Adjust flow, temperature, or level according to SOP.

   • Switch pumps or compressors if needed.

   • Initiate safe shutdown if abnormality cannot be corrected.

5. Verify & Document:

   • Ensure corrective action resolves abnormal condition.

   • Record symptoms, actions, and results in logbook.

Operator Tip:

• Never bypass safety interlocks.

• Always escalate unusual or critical deviations.

6.3 – Common Operational Issues (Conceptual)

1. Pump & Compressor Issues:

• Symptoms: vibration, noise, reduced flow, cavitation, overheating.

• Possible Causes: suction blockage, pump misalignment, mechanical wear.

• Operator Actions: verify suction/discharge valves, check strainers, switch to standby pump.

2. Distillation Column or Reactor Issues:

• Symptoms: abnormal temperature, pressure, level fluctuations, poor separation.

• Possible Causes: feed composition changes, fouling, tray/pad issues, cooling failure.

• Operator Actions: monitor trends, adjust flow/temperature, notify supervisor if abnormal persists.

3. Heat Exchanger Fouling:

• Symptoms: higher pressure drop, reduced heat transfer, lower efficiency.

• Possible Causes: scale buildup, corrosion, flow restrictions.

• Operator Actions: monitor differential pressure, schedule cleaning per SOP.

4. Instrument & Control Issues:

• Symptoms: wrong readings, alarms, slow actuator response.

• Possible Causes: sensor drift, calibration issues, electrical fault.

• Operator Actions: verify reading plausibility, reset alarms, escalate for maintenance.

5. Utility Failures:

• Symptoms: loss of cooling, steam pressure drop, air supply failure.

• Possible Causes: pump trip, valve closure, supply disruption.

• Operator Actions: switch to backup, notify supervisor, follow SOP for shutdown if necessary.

6. Safety Alarms & Interlocks:

• Symptoms: ESD activation, fire/gas alarm, pressure relief.

• Operator Actions: follow emergency SOP, ensure safe evacuation, notify control room.

6.4 – Early Detection Signs (Operator Awareness)

Mechanical Equipment:

• Vibration, unusual noise, leakage, heating, discoloration.

Process Variables:

• Sudden deviation in flow, temperature, pressure, or level trends.

Utilities:

• Reduced cooling water flow, low nitrogen pressure, instrument air alarm.

Instrumentation:

• Erratic readings, failed alarms, unresponsive actuators.

Operator Tip:

• Regular field rounds and observation are more important than reacting to alarms alone.

6.5 – Troubleshooting Best Practices (Conceptual)

1. Stay Calm & Observant: avoid rushing into corrective action.

2. Follow SOPs: corrective action should always align with company procedures.

3. Prioritize Safety: isolate hazards before attempting intervention.

4. Communicate: inform supervisors, control room, and adjacent units.

5. Document & Learn: every troubleshooting incident is a learning opportunity.

Analogy:

• Operator = “mechanical detective”; each clue (noise, vibration, alarm) leads to safe resolution.

6.6 – Example Conceptual Scenarios

Scenario 1 – Pump Cavitation:

• Observation: unusual noise, vibration, lower discharge flow.

• Operator Action: check suction valve, verify strainer clean, switch to standby pump, report issue.

Scenario 2 – Column Pressure Spike:

• Observation: pressure rises above normal range.

• Operator Action: check feed flow, cooling system, valves, follow SOP for relief or shutdown.

Scenario 3 – Utility Failure:

• Observation: low cooling water pressure.

• Operator Action: switch to backup pump, notify maintenance, monitor temperature downstream units.

Scenario 4 – Instrument Drift:

• Observation: level gauge shows sudden spike while actual level stable.

• Operator Action: verify sensor, cross-check with manual measurement, log issue, escalate.

6.7 – Quiz / Knowledge Check

1. What are the five steps in structured troubleshooting?

2. Name three common mechanical issues an operator may encounter.

3. List two early detection signs for process abnormalities.

4. Why should alarms never be bypassed?

5. In a cooling water failure, what is the first operator action?

6. Explain why documentation is important in troubleshooting.

6.8 – Media Sites Integration

• Videos:

  • Conceptual pump troubleshooting demo

  • Distillation/reactor trend analysis walkthrough

  • Field observation & abnormality detection simulation

• Diagrams / Infographics:

  • Common operational issues chart

  • Troubleshooting flowchart

  • Early detection signs infographic

• PDF Downloads:

  • Operator troubleshooting checklist

  • Trend comparison guide

  • Conceptual scenario exercises

• Interactive:

  • Embedded quizzes and decision-tree exercises

6.9 – Summary & Key Takeaways

1. Troubleshooting is structured, observation-driven, and safety-first.

2. Early detection of abnormal conditions prevents equipment damage and unsafe situations.

3. Common issues include pumps, compressors, columns, heat exchangers, utilities, and instruments.

4. Operators must act within scope, communicate, follow SOPs, and document all interventions.

5. Each incident is an opportunity to learn and improve operational understanding.