Equipment troubleshooting

In 1983, I started teaching a three day process equipment troubleshooting seminar, to chemical engineers and experienced plant operators in the petroleum refining and chemical process industry. Since the inception of the seminar, in excess of 5000 men and women have attended the classes. The seminar is largely based on my 30 years experience in field troubleshooting, and process unit revamp design. 

Primary equipment Mold design Process controls Auxiliary equipment Troubleshooting Testing... 

A follow-up quantitative GC-MS analysis did not disclose excessive levels of TCPP in the unstained polyurethane foam, as compared with samples taken from other, problem-free enclosures. However, significant variability in the flame retardant amounts at different foam locations was detected. Therefore, based upon a follow-up review of the manufacturing process, it was hypothesized that the flame retardant had separated from the polyol prepolymer (since specific gravity of TCPP is close to 1.3 g/cc). It was not clear whether this separation was due to inadequate stirring, pauses in production of malfunction in the polyol / isocyanate mixhead. However, in the final analysis it was clear that the flame retardant on the ABS surface acted as a stress crack agent, and it was occasionally being delivered with the foam to the ABS surface in excess amounts. Polyurethane delivery equipment troubleshooting was subsequently undertaken by the enclosiu e manufacturer. 

Gans, M., Systematize Troubleshooting Techniques, Chemical Engineeiing Piogiess, April 1991, 25-29. (Equipment malfunction examples)... 

The purpose of the plant-performance analysis is to operate on the set of measurements obtained, subject to the equipment constraints to troubleshoot to develop models or to estimate values for model parameters. 

Impressed Current Equipment and Transformer-Rectifiers 239 Table 8-2 Troubleshooting at cathodic protection stations... 

Too few people eonsider the equipment with the seal seleetion. In most eases, poor equipment will give poor seal performanee, regardless of the seal or arrangement ehosen. Also, beware that different pumps with the same shaft diameter and TDH may present different sealing problems. (Note These same eonsiderations may be used for troubleshooting.)... 

Design and operations are separated in this book for clarity, and so troubleshooting for all types of equipment is included in this section. 

Troyan, J. E., series Hints for Plant Startup, Chemical Enginnering, Part I—Troubleshooting New Processes, November 14, 1960, p. 223 Part II—Troubleshooting New Equipment, March 20, 1961, p. 147 Part III—Pumps, Compressors, and Agitators, May 1, 1961, p. 91. 

Design or troubleshooting During design, an on-site experiment with the actual equipment is usually not possible. Numerical prediction may then be easier. However, to investigate comfort complaints, field measurements are quicker, perhaps in combination with simulations. 

These two volumes are thorough, practical references for specifying, designing, operating, and troubleshooting surface production equipment. 

Troubleshooting deals with identifying and solving problems. Problems can be immediate or long term and can be associated with off-spec products, poor efficiency, process improvements, capacity increases, or potential shutdown items. Problems can be related to management, operation, hardware and equipment, or process issues. Solutions can include improved operating procedures and training, preventative maintenance, or installation of new equipment or controls. 

Studies have determined that probably 60% of defects result from the machine/ equipment, 20% mold/die, 10% material, and 10% operator. Available are software programs already installed on the machines processor controller or available as a software package that can provide some troubleshooting help. 

To aid the manufacturing plants, remote troubleshooting has been available from different equipment manufacturers and service facilities. Users of certain microprocessor equipment need not be concerned about their plant s personnel s ability to service and maintain the equipment. Via a communication link from your computer controller to the... 

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