Successful Trouble Shooting for Process Engineers: A Complete Course in Case Studies

636 Pages·2006·4.02 MB·English

by  Donald R. Woods

SuccessfulTroubleShooting
forProcessEngineers
D.R.Woods
SuccessfulTroubleShootingforProcessEngineers.DonWoods
Copyright(cid:1)2006WILEY-VCHVerlagGmbH&Co.KGaA,Weinheim
ISBN:3-527-31163-7
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Donald R. Woods
Successful Touble Shooting
for Process Engineers
A Complete Course in Case Studies
Author & AllbookspublishedbyWiley-VCHare
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(cid:1)2006WILEY-VCHVerlagGmbH&Co.KGaA,
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ISBN-13: 978-3-527-31163-7
ISBN-10: 3-527-31163-7
V
Contents
Preface XIII
1 WhatisTroubleShooting? 1
1.1 CharacteristicsofaTrouble-ShootingProblem 2
1.1.1 SimilaritiesamongTSProblems 2
1.1.2 DifferencesbetweenTSProblems 3
1.2 CharacteristicsoftheProcessUsedtoSolveTrouble-Shooting
Problems 3
1.2.1 HowtheTypeofProblemGuidestheTSProcessorStrategy 3
1.2.2 FiveKeyElementsCommontotheTSProcess 4
1.3 Self-TestandReflections 5
1.4 OverviewoftheBook 9
1.5 Summary 9
1.6 CasestoConsider 9
2 TheMentalProblem-SolvingProcessusedinTroubleShooting 17
2.1 ProblemSolving 19
2.2 TroubleShooting 23
2.2.1 ConsiderationswhenApplyingtheStrategytoSolveTrouble-Shooting
Problems 23
2.2.2 Problem-SolvingProcessesUsedbySkilledTroubleShooters 24
2.2.3 DataCollectionandAnalysis:ApproachesUsedtoTestHypotheses 25
2.3 OverallSummaryofMajorSkillsandaWorksheet 25
2.3.1 GettingOrganized:theUseofaTrouble-Shooter’sWorksheet 25
2.3.2 FeedbackaboutyourTroubleShooting 29
2.4 ExampleUseoftheTrouble-Shooter’sWorksheet 35
2.5 Summary 40
2.6 CasestoConsider 40
3 RulesofThumbforTroubleShooting 43
3.1 Overall 43
3.1.1 GeneralRulesofThumbandTypicalCauses 43
3.1.2 CorrosionasaCause 45
SuccessfulTroubleShootingforProcessEngineers.DonWoods
Copyright(cid:1)2006WILEY-VCHVerlagGmbH&Co.KGaA,Weinheim
ISBN:3-527-31163-7
VI Contents
3.1.3 Instruments,ValvesandControllers 46
3.1.4 RulesofThumbforPeople 47
3.1.5 Trouble-ShootingTeams 48
3.2 TransportationProblems 51
3.2.1 GasMoving:PressureService 52
3.2.2 GasMoving:VacuumService 53
3.2.3 Liquid 54
3.2.4 Solids 56
3.2.5 Steam 58
3.3 EnergyExchange 58
3.3.1 Drives 58
3.3.2 ThermalEnergy:Furnaces 60
3.3.3 ThermalEnergy:FluidHeatExchangers,CondensersandBoilers 61
3.3.4 ThermalEnergy:Refrigeration 65
3.3.5 ThermalEnergy:SteamGeneration 66
3.3.6 High-TemperatureHeat-TransferFluids 66
3.4 HomogeneousSeparation 67
3.4.1 Evaporation 67
3.4.2 Distillation 69
3.4.3 SolutionCrystallization 72
3.4.4 GasAbsorption 73
3.4.5 GasDesorption/Stripping 75
3.4.6 SolventExtraction,SX 76
3.4.7 Adsorption:Gas 77
3.4.8 Adsorption:Liquid 77
3.4.9 IonExchange 77
3.4.10 Membranes:ReverseOsmosis,RO 79
3.4.11 Membranes:Nanofiltration 79
3.4.12 Membranes:Ultrafiltration,UF,andMicrofiltration 79
3.5 HeterogeneousSeparations 79
3.5.1 Gas–Liquid 80
3.5.2 Gas–Solid 81
3.5.3 Liquid–Liquid 82
3.5.4 Gas–Liquid–LiquidSeparators 84
3.5.5 DryerforGSSeparation 85
3.5.6 ScreensforLiquidSolidSeparationorDewatering 85
3.5.7 SettlersforLSSeparation 86
3.5.8 HydrocyclonesforLSSeparation 86
3.5.9 ThickenerforLSSeparation 86
3.5.10 SedimentationCentrifuges 87
3.5.11 FilteringCentrifuge 87
3.5.12 FilterforLSSeparation 88
3.5.13 ScreensforSolid–SolidSeparation 88
3.6 ReactorProblems 88
3.6.1 PFTR:MultitubeFixed-BedCatalyst,Nonadiabatic 89
Contents VII
3.6.2 PFTR:Fixed-BedCatalystinVessel:Adiabatic 91
3.6.3 PFTR:BubbleReactors,TrayColumnReactors 93
3.6.4 PFTR:PackedReactors 94
3.6.5 PFTR:TrickleBed 94
3.6.6 PFTR:ThinFilm 96
3.6.7 STR:Batch(Backmix) 96
3.6.8 STR:Semibatch 98
3.6.9 CSTR:MechanicalMixer(Backmix) 99
3.6.10 STR:FluidizedBed(Backmix) 101
3.6.11 MixofCSTR,PFTRwithRecycle 106
3.6.12 ReactiveExtrusion 106
3.7 MixingProblems 107
3.7.1 MechanicalAgitationofLiquid 107
3.7.2 MechanicalMixingofLiquid–Solid 108
3.7.3 SolidsBlending 108
3.8 Size-DecreaseProblems 109
3.8.1 GasBreakupinLiquid:BubbleColumns 109
3.8.2 GasBreakupinLiquid:PackedColumns 109
3.8.3 GasBreakupinLiquid:AgitatedTanks: 110
3.9 SizeEnlargement 110
3.9.1 SizeEnlargement:Liquid–Gas:Demisters 110
3.9.2 SizeEnlargement:Liquid–Liquid:Coalescers 110
3.9.3 SizeEnlargement:SolidinLiquid:Coagulation/Flocculation 111
3.9.4 SizeEnlargement:Solids:Tabletting 111
3.9.5 SizeEnlargement:Solids:Pelleting 111
3.9.6 Solids:ModifySizeandShape:InjectionMoldingandExtruders 112
3.9.7 Coating 126
3.10 Vessels,Bins,HoppersandStorageTanks 126
3.11 “Systems”Thinking 127
3.12 Health,FireandStability 130
3.12.1 IndividualSpecies 130
3.12.2 Combinations 131
4 TroubleShootinginAction:Examples 133
4.1 Case’3:TheCaseoftheCyclingColumn 133
4.2 Case’4:PlatformerFires 138
4.3 Case’5:TheSulfuricAcidPump 141
4.4 Case’6:TheCaseoftheUtilityDryer 144
4.5 Case’7:TheCaseoftheReluctantCrystallizer 157
4.6 ReflectionsabouttheseExamples 162
5 PolishingYourSkills:Problem-SolvingProcess 165
5.1 DevelopingAwarenessoftheProblem-SolvingProcess 165
5.1.1 SomeTargetSkills 166
5.1.2 TheTAPPSRoles:TalkerandListener 166
VIII Contents
5.1.3 Activity5.1:(35minutes) 168
5.1.4 Feedback,Self-Assessment 172
5.2 Strategies 173
5.2.1 SomeTargetSkills 174
5.2.2 TheExtendedTAPPSRoles:Talker+andListener+ 175
5.2.3 Activity5.2:(time35minutes) 176
5.2.4 Feedback,Self-assessment 179
5.3 Exploringthe“Context”:whatistheRealProblem? 180
5.3.1 Example 180
5.3.2 Activity5-3 181
5.4 Creativity 183
5.4.1 SomeTargetSkills 183
5.4.2 Example:Case’10:Todryornottodry!(basedonKrishnaswamy
andParker,1984) 186
5.4.3 Activity5-4 190
5.4.4 Feedback,Self-Assessment 191
5.5 Self-Assessment 191
5.5.1 SomeTargetSkills 192
5.5.2 ActivityforGrowthinSelf-Assessment 192
5.5.3 FeedbackAboutAssessment 193
5.6 SummaryandSelf-Rating 194
6 PolishingYourSkills:GatheringDataand
theCritical-ThinkingProcess 195
6.1 ThinkingSkills:HowtoSelectValidDiagnosticActions 196
6.1.1 HowtoSelectaDiagnosticAction 196
6.1.2 SelectfromamongaRangeofDiagnosticActions 196
6.1.3 MoreonGatheringandInterpretingData 200
6.1.4 Summary 209
6.2 ThinkingSkill:Consistency:Definitions,Cause–Effectand
Fundamentals 209
6.2.1 ConsistentUseofDefinitions 210
6.2.2 ConsistentwithHowEquipmentWorks:CausefiEffects:
RootCause-Symptoms 212
6.2.3 ConsistentwithFundamentalRulesofMathematicsandEnglish 217
6.2.4 ConsistentwithFundamentalPrinciplesOfScience:
ConservationofMass,Energy,HightoLowPressure,
PropertiesofMaterials 218
6.2.5 ConsistentwithExperience 218
6.2.6 Summary 219
6.3 ThinkingSkills:Classification 219
6.3.1 ClassifytheStartingInformation 219
6.3.2 ClassifyingIdeasfromBrainstorming 220
6.4 ThinkingSkills:RecognizingPatterns 221
6.4.1 PatternsintheSymptoms 221
Contents IX
6.4.2 PatternsintheEvidence 223
6.5 ThinkingSkill:Reasoning 223
6.5.1 Step1:ClassifytheInformation 224
6.5.2 Step2:WritetheConclusion 225
6.5.3 Step3:IdentifytheContext 225
6.5.4 Step4:ClarifytheMeaningoftheTerminology 226
6.5.5 Step5:ConsidertheEvidence 227
6.5.5a IdentifytheEvidence 227
6.5.5b CheckforConsistency 227
6.5.5c WhichEvidenceisPertinent? 228
6.5.5d DiagramtheArgument 229
6.5.6 Step6:FormulatetheAssumptions 230
6.5.7 Step7:AssesstheQualityoftheReasoning 230
6.5.8 Step8:AssesstheStrengthsoftheCounterarguments 232
6.5.9 Step9:EvaluatetheConsequencesandImplications 232
6.5.10 Activity6-14 232
6.6 FeedbackandSelf-Assessment 233
6.7 Summary 233
6.8 Exercises 234
7 PolishingYourSkills:InterpersonalSkillsandFactors
AffectingPersonalPerformance 237
7.1 InterpersonalSkills 237
7.1.1 Communication 237
7.1.2 Listening 238
7.1.3 FundamentalsofInteraction 239
7.1.4 Trust 240
7.1.5 BuildingonAnother’sPersonalUniqueness 243
7.2 FactorsthatAffectPersonalPerformance 244
7.2.1 PrideandUnwillingnesstoAdmitError 244
7.2.2 Stress:LowandHighStressErrors 245
7.2.3 AlienationandLackofMotivation 249
7.2.4 “IKnowBest!”Attitude 249
7.2.5 TendencytoInterpret 249
7.3 TheEnvironment 253
7.4 Summary 253
7.5 ExercisesandActivities 253
8 PrescriptionforImprovement:PutitallTogether 259
8.1 ApproachestoPolishYourSkill 259
8.1.1 TriadActivity 259
8.1.2 IndividualActivity 262
8.2 CasestoHelpyouPolishYourSkill 263
8.2.1 GuidelinesforSelectingaCase 263
X Contents
8.2.2 TheCasesandUnderstandingtheChoiceofDiagnosticActionsforeach
Case 263
8.3 Summary 396
9 WhatNext? 397
9.1 SummaryofHighlights 397
9.2 ReflectionandSelf-AssessmentareVitalfortheDevelopmentof
Confidence 401
9.3 GoingBeyondthisBook:SettingGoalsforImprovement 402
9.3.1 PrepareYourselfforSuccess 402
9.3.2 UseReflectionandSelf-AssessmentEffectively 403
9.4 GoingBeyondthisBook:UpdatingyourRulesofThumband
Symptom‹CauseDataforProcessEquipment 403
9.5 BeyondthisBook:SourcesofOtherCases 403
LiteratureReferences 405
Index I 1
CDContents
AppendixA
FeedbackaboutExperiencewithProcessEquipment 411
AppendixB
Improving“SystemsThinking” 415
AppendixC
FeedbackontheCasesinChapters1,2and7 423
AppendixD
CodedAnswersfortheQuestionsPosedtoSolvetheCases 435
AppendixE
DebrieffortheTrouble-ShootingCases 537
AppendixF
OtherTasksfortheSkill-DevelopmentActivitiesinChapter5 565
AppendixG
SelectedResponsestotheActivitiesinChapters6and7 569
AppendixH
Dataabout“Causes”forSelectedProcessEquipment 573