Problem Solving For Process Operators And Specialists

Problem Solving for Process Operators and Specialists

This book provides methods to train process operators to solve challenging problems. The book is split into two parts. The first part consists of two parts; first developing a daily monitoring system and second providing a structured 5 step problem solving approach that combines cause and effect problem solving thinking with the formulation of theoretically correct hypotheses. The 5 step approach emphasizes the classical problem solving approach (defining the sequence of events) with the addition of the steps of formulating a theoretically correct working hypothesis, providing a means to test the hypothesis, and providing a foolproof means to eliminate the problem. The initial part of the book focuses on defining the problem that must be solved and obtaining the location, time and quantity based specifications of the problem. This part of the book also presents techniques to find and define problems at an early point before they progress to the critical level. The second part of the book deals with the utilization of fundamental chemical engineering skills to develop a technically correct working hypothesis that is the key to successful problem solving. The primary emphasis is on simple pragmatic calculation techniques that are theoretically correct. It is believed that any operator can perform these calculations if he is provided the correct prototype. Throughout the book, the theory behind each pragmatic calculation technique is explained in understandable terms prior to presenting the author's approach. These techniques have been developed by the author in 50+ years of industrial experience. The book includes many sample problems and examples of real world problem solving. Using these techniques, theoretically correct working hypotheses can be developed in an expedient fashion.

Problem Solving Approaches for Maintaining Operational Excellence in Process Plants

Comprehensive reference providing methods for process operators to solve challenging process problems and develop working hypotheses for typical process equipment Problem Solving Approaches for Maintaining Operational Excellence in Process Plants provides a template for achieving an enhanced level of operating efficiency in chemical processing plants and refineries. With examples included throughout to demonstrate key concepts, this book includes methods for formulating working hypotheses for typical process equipment such as pumps, compressors, heat exchangers/furnaces, fractionating towers, and reactors, with additional information on defining and setting metrics and the application of the techniques in unusual situations, as well as the application of these techniques in view of commercially available computer simulation programs. This book covers topics including initial considerations in problem solving, basic steps in problem solving, and verification of process instrument data, with solved problems showing how techniques can be applied to prime movers, plate processes, kinetically limited processes, and unsteady state problems. This newly revised and updated Second Edition includes coverage of the latest research and developments in the field. Written by a team of highly qualified industry professionals, Problem Solving Approaches for Maintaining Operational Excellence in Process Plants includes discussion on: Lumped parameters as the ideal approach to determine values for key performance indicators (KPIs) Theoretical KPIs in comparison to actual operation as a method to find “hidden problems” Situations where experience-based solutions are unavailable due to lack of technically trained personnel Solutions to problems where a previous analysis has confirmed a need for new equipment or enhanced operating procedures Digital twins and their usefulness in predicting yields, executing plant operations, and training operating and technical personnel Problem Solving Approaches for Maintaining Operational Excellence in Process Plants is an essential reference on the subject for chemical engineers, industrial engineers, process operators, process shift supervisors, chemical engineers with minimal exposure to industrial calculations, and industrial managers who are looking for techniques to improve organization problem solving skills.

Management and Control of Production and Logistics 2004 (MCPL 2004)