This book provides methods to train process operators to solve challenging problems. The book is split into two parts. The first part consists of two parts; first developing a daily monitoring system and second providing a structured 5 step problem solving approach that combines cause and effect problem solving thinking with the formulation of theoretically correct hypotheses. The 5 step approach emphasizes the classical problem solving approach (defining the sequence of events) with the addition of the steps of formulating a theoretically correct working hypothesis, providing a means to test the hypothesis, and providing a foolproof means to eliminate the problem. The initial part of the book focuses on defining the problem that must be solved and obtaining the location, time and quantity based specifications of the problem. This part of the book also presents techniques to find and define problems at an early point before they progress to the critical level. The second part of the book deals with the utilization of fundamental chemical engineering skills to develop a technically correct working hypothesis that is the key to successful problem solving. The primary emphasis is on simple pragmatic calculation techniques that are theoretically correct. It is believed that any operator can perform these calculations if he is provided the correct prototype. Throughout the book, the theory behind each pragmatic calculation technique is explained in understandable terms prior to presenting the author's approach. These techniques have been developed by the author in 50+ years of industrial experience. The book includes many sample problems and examples of real world problem solving. Using these techniques, theoretically correct working hypotheses can be developed in an expedient fashion.

This book provides methods to train process operators to solve challenging problems. The book is split into two parts. The first part consists of two parts; first developing a daily monitoring system and second providing a structured 5 step problem solving approach that combines cause and effect problem solving thinking with the formulation of theoretically correct hypotheses. The 5 step approach emphasizes the classical problem solving approach (defining the sequence of events) with the addition of the steps of formulating a theoretically correct working hypothesis, providing a means to test the hypothesis, and providing a foolproof means to eliminate the problem. The initial part of the book focuses on defining the problem that must be solved and obtaining the location, time and quantity based specifications of the problem. This part of the book also presents techniques to find and define problems at an early point before they progress to the critical level. The second part of the book deals with the utilization of fundamental chemical engineering skills to develop a technically correct working hypothesis that is the key to successful problem solving. The primary emphasis is on simple pragmatic calculation techniques that are theoretically correct. It is believed that any operator can perform these calculations if he is provided the correct prototype. Throughout the book, the theory behind each pragmatic calculation technique is explained in understandable terms prior to presenting the author's approach. These techniques have been developed by the author in 50+ years of industrial experience. The book includes many sample problems and examples of real world problem solving. Using these techniques, theoretically correct working hypotheses can be developed in an expedient fashion.

An accessible guide to the main reasons pumps fail and what can be done about it Workhorses in many different industries, including the oil industry, water industry, chemical industry, food industry, and pharmaceutical industry to name a few, pumps are a vital contributor to maintaining and increasing the flow of production. In fact, the pump industry itself is a multi-billion dollar global business. Taking the unique approach of addressing both pump operators and pump designers, Pump Wisdom explains the causes of failure in centrifugal pump function whether it's pump selection, overlooked installation criteria, or the accumulation of small deviations and maps out remedies with well defined methods that target specific issues, rather than focusing on technical generalities and theory. Clearly written and concise, Pump Wisdom relies on proven tactics for reducing pump vulnerabilities and correcting imbalances between hydraulic assembly and mechanical assembly. In addition, it supplies sound tips for detecting and rectifying risky shortcuts taken by pump designers and manufacturers. Pump Wisdom also: Provides a concise explanation of how pumps function Details the specifications to be considered when purchasing a pump Provides tips on the installation of centrifugal pumps in process plants Written in concise language that avoids excessive mathematical treatment Explains pump hydraulics in easy to understand terms Emphasizes the mechanical aspects of pumps with coverage on bearings, seals, impeller trimming, lubricant application, lubricant types, and more Pump Wisdom sheds light on the techniques for stabilizing pump performance and maximizing pump efficiency. Its concise format allows readers to strike directly at the heart of the problem and helps them devise strategies to prevent costly failures before they occur.

Avoid wasting time and money on recurring plant process problems by applying the practical, five-step solution in Process Engineering Problem Solving: Avoiding "The Problem Went Away, but it Came Back" Syndrome. Combine cause and effect problem solving with the formulation of theoretically correct working hypotheses and find a structural and pragmatic way to solve real-world issues that tend to be chronic or that require an engineering analysis. Utilize the fundamentals of chemical engineering to develop technically correct working hypotheses that are key to successful problem solving.

"PUMP WISDOM was compiled to explain elusive failure causes. Some have to do with pump selection, others have to do with overlooked installation criteria or are simply the result of small deviations that add up. In other words, while a certain assembly dimension may be allowed to reach a defined upper limit, allowing another, and yet another deviation to reach its upper limit on the remaining pump components will lead to operation in a vulnerable region where frequent failures occur. This book sheds light on the issue and, quite unlike any other condensed text, shows exactly what to do so centrifugal process pumps don't fail again"--Provided by publisher.

Comprehensive reference providing methods for process operators to solve challenging process problems and develop working hypotheses for typical process equipment Problem Solving Approaches for Maintaining Operational Excellence in Process Plants provides a template for achieving an enhanced level of operating efficiency in chemical processing plants and refineries. With examples included throughout to demonstrate key concepts, this book includes methods for formulating working hypotheses for typical process equipment such as pumps, compressors, heat exchangers/furnaces, fractionating towers, and reactors, with additional information on defining and setting metrics and the application of the techniques in unusual situations, as well as the application of these techniques in view of commercially available computer simulation programs. This book covers topics including initial considerations in problem solving, basic steps in problem solving, and verification of process instrument data, with solved problems showing how techniques can be applied to prime movers, plate processes, kinetically limited processes, and unsteady state problems. This newly revised and updated Second Edition includes coverage of the latest research and developments in the field. Written by a team of highly qualified industry professionals, Problem Solving Approaches for Maintaining Operational Excellence in Process Plants includes discussion on: Lumped parameters as the ideal approach to determine values for key performance indicators (KPIs) Theoretical KPIs in comparison to actual operation as a method to find “hidden problems” Situations where experience-based solutions are unavailable due to lack of technically trained personnel Solutions to problems where a previous analysis has confirmed a need for new equipment or enhanced operating procedures Digital twins and their usefulness in predicting yields, executing plant operations, and training operating and technical personnel Problem Solving Approaches for Maintaining Operational Excellence in Process Plants is an essential reference on the subject for chemical engineers, industrial engineers, process operators, process shift supervisors, chemical engineers with minimal exposure to industrial calculations, and industrial managers who are looking for techniques to improve organization problem solving skills.

Simulating workplace conditions that process operators can be expected to troubleshoot, this book offers simple process incidents with a sense of urgency to solve. It emphasizes workplace organization, communications, teamwork, a workable problem-solving process, and problem prevention. Chapter topics include the troubleshooting team, communications for troubleshooters, detection and management of problems, climates for problem development, problem solving as a process, troubleshooting in the team environment, prevention of process upsets, and troubleshooting exercises. For novice process operators in training.

The National Science Foundation funded a synthesis study on the status, contributions, and future direction of discipline-based education research (DBER) in physics, biological sciences, geosciences, and chemistry. DBER combines knowledge of teaching and learning with deep knowledge of discipline-specific science content. It describes the discipline-specific difficulties learners face and the specialized intellectual and instructional resources that can facilitate student understanding. Discipline-Based Education Research is based on a 30-month study built on two workshops held in 2008 to explore evidence on promising practices in undergraduate science, technology, engineering, and mathematics (STEM) education. This book asks questions that are essential to advancing DBER and broadening its impact on undergraduate science teaching and learning. The book provides empirical research on undergraduate teaching and learning in the sciences, explores the extent to which this research currently influences undergraduate instruction, and identifies the intellectual and material resources required to further develop DBER. Discipline-Based Education Research provides guidance for future DBER research. In addition, the findings and recommendations of this report may invite, if not assist, post-secondary institutions to increase interest and research activity in DBER and improve its quality and usefulness across all natural science disciples, as well as guide instruction and assessment across natural science courses to improve student learning. The book brings greater focus to issues of student attrition in the natural sciences that are related to the quality of instruction. Discipline-Based Education Research will be of interest to educators, policy makers, researchers, scholars, decision makers in universities, government agencies, curriculum developers, research sponsors, and education advocacy groups.

To be a successful manufacturing operation, employees must eliminate equipment and production related losses. However, most shopfloor workers don't have the necessary skills to perform the problem-solving tasks that accomplish this goal. They must be trained in the proper methods for logically and systematically discovering the root causes of a situation. Based on the firsthand experiences of author Bob Sproull, Process Problem Solving: A Guide for Maintenance and Operations Teams presents a precise methodology for understanding problems in a manufacturing environment. The book begins by introducing various problem-solving tools, including fish diagrams, tree diagrams, cause-and-effect diagrams, and flow diagrams. Using real-world examples, Sproull takes readers systematically through each tool and discusses them in depth. The central tool in Process Problem Solving is the Problem Analysis Flow (PAF) chart. Containing ten major sections, it combines many of the tools discussed at the beginning of the book. According to the author, the PAF chart is the most thorough and comprehensive problem-solving tool. It creates a systematic method for understanding and solving the root causes of problems. To teach the necessary problem-solving skills, Sproull uses powerful learning techniques that guide the reader through the process. Each chapter begins with a section entitled "What You Should Learn in this Chapter," which specifically emphasizes the main points presented. In addition, each chapter is sprinkled with "keyword" boxes that advise the reader of important terms. Process Problem Solving is filled with Sproull's "Problem Solving Truths." These are key ideas the author wants to highlight, so the reader retains important pieces of information. Finally, Process Problem Solving follows a "learn and do" approach. The end of each chapter asks the reader to talk about what they have learned. This interactive approach helps readers retain and understand the material. With this informative book, shopfloor workers get the training they need to understand the root causes of manufacturing problems. It contains: Forms for problem-solving tools Real-world examples A step-by-step program Diagrams, graphs, and essential charts Questions at the end of each chapter that encourage interactive learning Appendices that contain actual case studies 40 problem-solving truths