Deck 16: Process Troubleshooting

Question 1

Primary operational problems are best described as:

A) Problems created or responded to during a process upset.
B) Catastrophic shutdown events.
C) A term used to describe the first problem that created a process upset.
D) Those conditions linked to hard wire interlocks.

Answer 1

A term used to describe the first problem that created a process upset.

Question 2

Identify the most important instrumentation used to troubleshoot process problems. Circle all that apply!

A) Control loops- pressure, temperature, level, flow, analytical
B) Analyzers and alarms
C) Video trends and chart recorders
D) Gauges & indicators

Answer 2

Control loops- pressure, temperature, level, flow, analytical
Analyzers and alarms
Video trends and chart recorders
Gauges & indicators

Question 3

Redundancy is a process that:

A) Shuts down the unit in an emergency.
B) Bypasses problem areas.
C) Stores spare parts in warehouse.
D) Uses backup systems for critical equipment.

Answer 3

Uses backup systems for critical equipment.

Question 4

Check sheets are used to:

A) Qualification document for new technicians
B) Collect large quantities of data.
C) Approve purchase of equipment
D) Management document used in HR for OSHA employee checks.

Question 5

Process control instrumentation is used to:

A) Guide process production and quality.
B) Control each variable in the system.
C) Monitor each variable in the system.
D) B & C

Question 6

Troubleshooting the operation of process equipment requires: Circle all that apply!

A) Good understanding of basic equipment components
B) Good understanding of how the equipment operates
C) A technical degree
D) Five years experience with operating systems

Question 7

In the following graphic, what would happen if P-104 failed and could not be restarted?

a. Steam flow will. . .
- increase
- decrease
- stay the same
b. Bottoms flow rate will. . .
- increase
- decrease
- stay the same
c. Bottoms temperature will. . .
- increase
- decrease
- stay the same
d. The bottoms level will. . .
- increase
- decrease
- stay the same

Question 8

In the following graphic, what would happen if the reflux control valve failed closed?

a. Column pressure will. . .
- increase
- decrease
- stay the same
b. Reflux flow rate will. . .
- increase
- decrease
- stay the same
c. Column top temperature will. . .
- increase
- decrease
- stay the same
d. The level in D-100 will. . .
- increase
- decrease
- stay the same

Question 9

In the following graphic, what would happen if the hot oil system failed?

a. Reactor pressure will. . .
- increase
- decrease
- stay the same
b. Vapor production will. . .
- increase
- decrease
- stay the same
c. Agitation and catalyst flow will. . .
- increase
- decrease
- stay the same
d. The level in the reactor will. . .
- increase
- decrease
- stay the same

Question 10

In the following graphic, what would happen if the hot oil system in the reactor failed?

a. Absorber column pressure will. . .
- increase
- decrease
- stay the same
b. Vapor recovery flow rate will. . .
- increase
- decrease
- stay the same
c. Vapor catalyst flow to separator will.
- increase
- decrease
- stay the same
d. The level in the columns will. . .
- increase
- decrease
- stay the same

Question 11

In this graphic, what would happen if CV-15 failed open?

a. Tray 8 temperature will. . .
- increase
- decrease
- stay the same
b. Reflux flow rate will. . .
- increase
- decrease
- stay the same
c. P-104 flow rate will. . .
- increase
- decrease
- stay the same
d. P-103 flow rate will. . .
- increase
- decrease
- stay the same

Question 12

List the four troubleshooting methods described in this chapter.

Question 13

List the five elements of a control loop.

Question 14

Draw a flow control loop.