Method Troubleshooting

Troubleshooting methods—means of diagnosing process problems include educational, 

Troubleshooting models—tools used to teach troubleshooting techniques. Basic models include distillation, reaction, and absorption and stripping, or combinations of these three. 

Troubleshooting the operation of process equipment requires a good understanding of basic components and how the equipment operates. Equipment used in modern manufacturing is run 24 hours a day, 7 days a week, 52 weeks a year. Routine maintenance is performed on this equipment during scheduled maintenance times. 

Plants that build redundancy nlo their processes provide backup systems for critical equipment. For example, pumps and compressors typically have two or three backups. Process technicians should attempt to uncover as much information as possible about the equipment used in their units. Much of this information can be found in technical manuals or the operating manuals. Manufacturer information is typically included in the engineering specifications, drawings, and equipment descriptions. 

Data collection, organization, and analysis can be used to troubleshoot process problems. Check-sheets are used to collect large quantities of data. This quantitative data can be organized into graphics or plotted as trends to discover process variation or changes. Data analysis utilizes a variety of quality techniques to put all of the parts in place. 

With tool bag in hand, you now set off to troubleshoot the process problem. There are three alternative methods to consider  

To a large extent, experience does not help me solve very many problems. It isn t that I don t see the same problem repeatedly. I certainly do. It s just that a problem has so many different faces that I fail to recognize the true nature of the problem. Superficially, it looks unique. 

Relying on experience wastes time. Relying on experience as a guide drags me into the quagmire of trial and error. I have an inner weakness for trial-and-error solutions. It s inertia and laziness on my part. It s part of my propensity carried forward from childhood, for the quick fix without the commensurate effort. 

It s true many problems are solved by experience (someone has seen the same problem before). It s true most problems are solved by trial and error (alternatives are tried until something works). My difficulty is that process problems that can be solved by trial and error or by ordinary experience rarely reach me. They are handled by the shift operators or solved by the unit engineers. 

It s the intractable problems that are my domain. The ones caused by several malfunctions, all of which have to be corrected before any improvement is obtained. It s the problems that appear to be unrelated to any prior plant operating experience. 

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Kucera, J., "Troubleshooting Methods to Improve System Performance -Part 1," UltraPure Water, 24 (3), April, 2007. 

If a printer is not printing at all, then you should start with the DOS troubleshooting method. First, reboot the computer in Safe Mode DOS Prompt. (See the section Windows-Based Utilities for more information on Safe Mode.) Then copy a file or a directory listing to the printer port. If the file or directory listing doesn t print, the cause is most likely a hardware failure or loose cable. If it does print, then you can assume the printing problems are associated with the Windows printer drivers. 

As in any scientific document, one must provide a rationale for the parameters chosen and their effect on the overall success of the transfer. This includes an explanation for the system suitability parameters that have been established for the method. System suitability can be a powerful tool for troubleshooting method discrepancies in addition to being a test of the conformance of the system to a set of parameters before analysis. 

As part of the process of method transfer and troubleshooting methods, the production of some form of checklist or aide-memoire of historical issues should be... 

Most composites are produced by extmsion or injection molding, therefore troubleshooting methods should be related to the processing method and reviewed using information in respective sections below. 

Use of troubleshooting methods allows the user to systematically analyse a large number of compounding problems. There are many problems that can potentially occur during compounding which makes it difficult to develop a troubleshooting method that can be used for all compounding problems. 

Process Troubleshooting—instruction in the different types of troubleshooting techniques, methods, and models used to solve process problems. Topics include application of data collection and analysis, cause-effect relationships, and reasoning. Emphasizes application of troubleshooting methods to scale-up from laboratory bench to pilot unit. Describe unit operation concepts solve elementary chemical mass/energy balance problems interpret anal ical data and apply distillation and fluid flow principles. 

A number of troubleshooting methods can be used with these models. Methods vary depending on individual educational faculty, consultants, and industry. The basic approach to most methods includes the development of a good educational foundation. 

Respond to alarms and control systems that are outside operational guidelines. Compare troubleshooting methods and models. 

Compare and contrast troubleshooting methods with troubleshooting models. 

Troubleshooting methods—means of diagnosing process problems include educational, instrumental, experiential, and scientific. 

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