K&S Associates Troubleshooting Inc.


Performance Solutions & Troubleshooting Methodologies for the Refining & Chemical Industry
Process Troubleshooting Workshop 

Process Systems Surveillance & Troubleshooting Workshop
As Originally Developed and Delivered by K&S Associates

Course Description

Course Length: 2 days (9 hours) 

Course Purpose:

This workshop is designed to teach students (operations personnel) a 3-step method for troubleshooting and determining root cause of a process upset.  This method is based on the logic or predictability designed into the system. K&S ensures that students understand the function of the various processes and the associated factors that must be controlled to achieve the function of the equipment.  Emphasis is also placed on the necessity of selecting appropriate (safe & economical) corrective action plans that return the process to normal without creating additional problems. Pro-active monitoring and control of the process is also stressed as a way to recognize abnormal early on and prevent loosing control of the process.  Operator confidence and workplace moral are positively impacted as a result of the training!

Course Objectives:

After course completion the student will be able to:

Solve complex process problems (determine root cause) using a 3-step method with 100% accuracy.

Describe the functions of the 5 most common processes (Reaction, Absorption, Stripping, Decanting/Separation, & Distillation) in     industry.

List the process control factors associated with each of the processes (Reaction, Absorption, Stripping, Decanting/Separation, &         Distillation).

Use the process control factors to develop a punch list for troubleshooting that process.

Determine if a process upset is the result of a controller problem or a mechanical problem.

Generate a list of items that will reduce the cost of product manufacturing.

Recognize abnormal conditions in the process early on and prevent loosing control of the process.

Develop and implement safe and economical corrective action plans that return the process back to normal.

Mass balance a column to prove flow meters, pumps, level controls, etc.

Take better control of the process to eliminate environmental upsets.

Improve communications with co-workers using a common language for problem solving.

Operate the process with increased confidence.

Increase Up-Time in their respective process.

Train others in a common method for troubleshooting process problems.

Day 1

Introductions & Objectives (Motivational)

1. Importance of the good troubleshooter

2. Team work

3. System logic

Production Person’s Job Model 

1. Data gathering

2. Monitoring

3. Specialized Training Needed to perform correctly

Introduction of the Universal Process Unit 

1. Logic of the Unit/Process

2. Logic of the Controllers

3. Work 3 simple problems

4. Begin Developing Logical Method of Thinking

Discuss in Detail each of the 5 processes that make up Universal Process Unit

1. Reaction (Function & Factors)

2. Introduce the 3-Step Method of determining Root Cause

Work Reaction Problem Using 3-Step Method

3. Decanter / Separation (Function & Factors)

      Discussion of Proofreading Data Using Process Logic

4. Discussion of Tower Internals (Packing/Trays)

       Discussion of DPI (differential pressure)

Day 1

Introductions & Objectives (Motivational)

1. Importance of the good troubleshooter

2. Team work

3. System logic

Production Person’s Job Model 

1. Data gathering

2. Monitoring

3. Specialized Training Needed to perform correctly

Introduction of the Universal Process Unit 

1. Logic of the Unit/Process

2. Logic of the Controllers

3. Work 3 simple problems

4. Begin Developing Logical Method of Thinking

Discuss in Detail each of the 5 processes that make up Universal Process Unit

1. Reaction (Function & Factors)

2. Introduce the 3-Step Method of determining Root Cause

Work Reaction Problem Using 3-Step Method

3. Decanter / Separation (Function & Factors)

      Discussion of Proofreading Data Using Process Logic

4. Discussion of Tower Internals (Packing/Trays)

       Discussion of DPI (differential pressure)



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