Guidelines for Effective Troubleshooting

A successful troubleshooting assignment will require someone to  

Management, engineering, and operations departments perceive problems differently. Frequently, there is someone familiar with the operation who most likely knows the symptoms and possibly can offer a solution to the problem, but for various reasons, people who are in a position to implement the solution may not have thought to ask him or her. Typically, those closest to the problem are the unit operator and maintenance foreman and they will offer the most valuable input. All four operating shifts should be consulted. Do not draw any conclusions before gathering all applicable facts. 

Begin by listing all potential causes or combinations of causes, using a brainstorming approach. Then, systematically rule out each cause. Do not eliminate uncommon causes too quickly—if it were an easy problem it would have already been taken care of it. Additionally, ensure that limits outlined by process and equipment documentation are consistent with the actual operation of the unit. 

Most FCC problems are due to changes in the feedstock, catalyst, operating variables, and/or mechanical equipment. As previously stated. 

Catalyst circulation is like blood circulation to the human body. Without proper catalyst circulation, the unit is dead. Troubleshooting circulation problems requires a good understanding of the pressure balance around the reactor-regenerator circuit and the factors affecting catalyst fluidization. The fundamentals of fluidization and catalyst circulation are discussed in Chapter 5. 

---