Comprehensive reference providing methods for process engineers and 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.

Table of Contents:
Preface xi 1 Focus of Book 1 1.1 Introduction 1 1.2 Metrics and KPIs 2 1.3 Finding Hidden Problems 3 1.4 Experience-Based Solutions 4 1.5 Achieving and Maintaining Operational Excellence 5 2 How to Achieve and Maintain Operational Excellence 7 2.1 What is Operational Excellence? 7 2.2 What is the Value of Operational Excellence? 8 2.3 What are the Limitations to Achieving and Maintaining Operational Excellence? 11 2.4 Achieving and Maintaining Operational Excellence 11 3 Initial Considerations 15 3.1 Introduction 15 3.2 An Electrical Problem 17 3.3 A Coffeemaker Problem 18 3.4 Applications of Concepts to Plant Problem Solving 21 3.5 Limitations to Problem Solving in Process Plants 24 4 Successful Plant Problem Solving 29 4.1 Introduction 29 4.2 Finding Problems with a Daily Monitoring System 29 4.3 Solving Problems with a Disciplined Learned Problem-Solving Approach 36 4.4 Determining the Optimum Technical Depth 42 4.5 Using the Directionally Correct Hypothesis Approach 47 5 Examples of Plant Problem Solving 49 5.1 Industrial Examples 49 5.2 Polymerization Reactor Example 49 5.3 Application of the Disciplined Problem-Solving Approach 51 5.4 Lessons Learned 55 5.5 Multiple Engineering Disciplines Example 56 5.6 Application of Disciplined Problem-Solving Approach 57 5.7 Lessons Learned 62 5.8 A Logical, Intuitive Approach Fails 63 5.9 Lessons Learned 65 Nomenclature 65 6 Development of Working Hypotheses 67 6.1 Introduction 67 6.2 Areas of Technology 67 6.3 Formulating Hypotheses Via Key Questions 68 6.4 Beauty of a Simplified Approach 71 6.5 Verification of Proposed Hypotheses 71 6.6 One Riot—One Ranger 73 7 Application to Prime Movers 75 7.1 Introduction 75 7.2 Kinetic Systems 75 7.3 Pump Calculations 78 7.4 Centrifugal Compressor Calculations 80 7.5 Displacement Systems 82 7.6 Displacement Pump Calculations 85 7.7 Calculations for Positive Displacement Compressors 87 7.8 Problem-Solving Considerations for Both Systems 89 7.8.1 Compressors 89 7.8.2 Pumps 91 7.9 Example Problem 7.1 92 7.10 Lessons Learned 98 7.11 Example Problem 7.2 99 7.12 Lessons Learned 103 7.13 Example Problem 7.3 104 7.14 Example Problem 7.4 104 7.15 Lessons Learned 109 7.16 Example Problem 7.5 109 7.17 Example Problem 7.6 111 7.18 Lessons Learned 118 7.19 Example Problem 7.7 118 7.20 Lessons Learned 124 7.21 Example Problem 7.8 125 7.22 Lessons Learned 131 Nomenclature 131 8 Application to Plate Processes 135 8.1 Introduction 135 8.2 Fractionation with Sieve Trays 135 8.3 Problem-Solving Considerations for Fractionating Towers 139 8.4 Development of Theoretically Sound Working Hypotheses 140 8.5 Problem-Solving Reboiler Circuits 142 8.6 Example Problem 8.1 145 8.7 Lessons Learned 154 Nomenclature 154 9 Application to Kinetically Limited Processes 155 9.1 Introduction 155 9.2 Kinetically Limited Models 155 9.3 Limitations to the Lumped Parameter Approach 158 9.4 Guidelines for Utilization of this Approach for Plant Problem Solving 159 9.5 Example Problem 9.1 160 9.6 Lessons Learned 167 9.7 Technique for Estimating Polymer–Volatile Equilibrium 168 9.8 Example Problem 9.2 169 9.9 Lessons Learned 174 9.10 Example Problem 9.3 175 9.11 Lessons Learned 183 Nomenclature 184 10 Application to Unsteady State 187 10.1 Introduction 187 10.2 Approach to Unsteady State Problem Solving 188 10.3 Example Problems 189 10.4 Problem 10.1 189 10.5 Lessons Learned 196 10.6 Example Problem 10.2 197 10.7 Lessons Learned 204 10.8 Final Words 205 Nomenclature 206 11 Application to Other Plant Improvements 209 11.1 Introduction 209 11.2 Debottlenecking Reactors 210 11.2.1 Kinetics 210 11.2.2 Heat Removal 211 11.2.3 Stepwise Procedure 211 11.2.4 Real Life Example 212 11.2.5 Macro Heat Removal 212 11.2.6 Micro Heat Removal 213 11.3 Real-World Hydraulic Debottleneck 216 11.3.1 Introduction 216 11.3.2 Always Account for Non-idealities 217 11.3.3 A Quick Guide for a Successful Hydraulic Test Run 218 11.3.4 A Recommended Workflow for an Effective Hydraulic Revamp 220 11.3.4.1 Utilize Equipment/Device’s Characteristics 220 11.3.4.2 Use a Calibrated Hydraulic Model 221 11.3.5 Maximize Diesel Production by Revamping the Draw-off System 222 11.3.6 A New Feed Preheater for Energy Saving 224 11.3.7 Increase Wash Water Flow to Reduce the Corrosion Rate 227 11.3.8 Improve Diesel Recovery from a Crude Distillation Column 228 11.3.9 Other Considerations 230 11.4 Debottlenecking By Improving Operating Procedures 232 11.4.1 Improving Water Clarification 232 11.4.1.1 Introduction to Water Clarification 232 11.4.1.2 Sand Filtration Basics 233 11.4.1.3 Evaluate Backwash Performance 235 11.4.1.4 Operational Issues Related to Inefficient Backwash 236 11.4.1.5 Field Techniques for Backwash Tuning 238 11.4.1.6 A Real-World Example 241 11.4.1.7 Other Tips 242 11.5 Trust Creating a Disaster—Heat Exchanger Corrosion from Improper Cooling Water System Operation 243 11.5.1 Background 243 11.5.2 Penny Wise, Pound Foolish—Misconception of Cooling Water System Operation 245 11.5.3 Take Ownership 251 Nomenclature 251 12 Applications of Novel Process Engineering Fundamentals to Plant Problem Solving 255 12.1 Introduction 255 12.2 Novel Approaches to Plant Problems 255 12.3 Mostly used Engineering Fundamentals to Solve Plant Problems 256 12.4 Application of New Engineering Fundamentals to Plant Maintenance Problems (Example Problem 12.1) 257 12.5 Application of the Disciplined Problem-Solving Approach 258 12.6 Lessons Learned 260 12.7 Tank Roof Raising for Maintenance Example 260 12.8 Application of the Disciplined Problem-Solving Approach 261 12.9 Lessons Learned 263 Nomenclature 264 13 Verification of Process Instrumentation Data 265 13.1 Introduction 265 13.2 Data Verification Via Technical Resources 265 13.3 Flow Measurement 269 13.4 Temperature Measurement 272 13.5 Pressure Measurement 272 13.6 Level Measurement 273 13.7 Data Verification Via Human Resources 275 13.8 Example Problems 275 13.9 Example Problem 13.1 276 13.10 Lessons Learned 280 13.11 Example Problem 13.2 280 13.12 Lessons Learned 284 13.13 Example Problem 13.3 284 13.14 Example Problem 13.4 286 13.15 Lessons Learned 290 Nomenclature 290 14 Successful Plant Tests 291 14.1 Introduction 291 14.2 Ingredients for Successful Plant Tests 292 14.3 Pretest Instrument and Laboratory Procedure Evaluation 292 14.4 Statement of Anticipated Results 293 14.5 Potential Problem Analysis 295 14.6 Explanation to Operating Personnel 297 14.7 Formal Post-Test Evaluation and Documentation 298 14.8 Examples of Plant Tests 299 14.9 Example Plant Test 14.1 299 14.10 Lessons Learned 301 14.11 Example Plant Test 14.2 302 14.12 Lessons Learned 307 14.13 More Complicated Plant Tests 307 14.14 Other Uses for Plant Tests 308 14.15 Key Plant Tests Considerations 308 15 Utilization of Commercially Available Simulation Tools 309 15.1 Process Simulation and Modern Chemical Engineering 309 15.2 Breaking Down the Problem 311 15.3 Green Field Problem Example 313 15.3.1 Situation 313 15.3.2 Input Parameter 313 15.3.3 Output Parameter 313 15.3.4 Design Parameters 314 15.4 Brown Field Problem Example 315 15.4.1 Input Parameter 316 15.4.2 Output Parameter 316 15.4.3 Design Parameters 317 15.5 Do Not Gamble with Physical Properties for Simulations 317 15.6 Examples—Effects of Equation of State on the Required Compression Power and Cooling Duty 318 15.6.1 Input Parameter 318 15.6.2 Output Parameter 318 15.6.3 Design Parameters 318 15.7 Be Skeptical with your Initial Design Assumptions 319 15.8 Obtaining a High-Quality Plant Data for your Process Model 320 15.9 Verifying your Plant Data 323 15.10 Example—Heat Balance of Heavy Gas Oil Pumparound 324 15.11 Reconciling your Data 325 15.12 Example—Hydrocracking Catalyst Testing 326 15.13 Model Calibration 331 15.14 Process Simulation as a Training Tool 336 Nomenclature 336 16 Putting it Altogether 339 16.1 Introduction 339 16.2 Do Not Forget to Use Fundamentals 339 16.3 Example Problem 16.1: Do Fundamental Processes Developed in the United States Translate to Europe? 340 16.4 Lessons Learned 348 16.5 Example Problem 16.2: An Embarrassing Moment 349 16.6 Lessons Learned 355 16.7 Example Problem 16.3: Prime Mover Problems are not Always What They Appear To Be 356 16.8 Lessons Learned 364 16.9 Example Problem 16.4: The Value of a Potential Problem Analysis 365 16.10 Lessons Learned 371 16.11 Example Problem 16.5 371 16.12 Lessons Learned 377 Nomenclature 378 17 A Final Note 379 Appendix Conversion Factors from English Units to CGS Units 381 References 383 Index 385