1. Terry A. Ring Chemical Engineering University of Utah
Trouble Shooting
Terry A. Ring
Chemical Engineering
University of Utah
1) The steam trap is blocked causing liquid condensate to back up in the heat exchanger so the steam does not contact the pipes in the exchanger.
2) The entering water is sub-cooled.
3) The steam pressure and temperature have dropped.
4) The heat exchanger has become fouled.
5) The steam is dirty, i.e., contains non condensable gases.

2. What is Trouble Shooting
Problem solving process to find the root cause of a problem.
Trouble Shooting is not an exact science.
Requires Paying attention to detail, good listening, understanding symptoms, viewing problem first hand

3. Try to Solve this problem
QUESTION FROM TROUBLE ANSWER FROM EXPERTS COST TO ANSWER SHOOTERS
Steam Pressure at PlOO? Higher Than Design. 5 min.
Steam Temperature at TIOO? Design Value. 5 min.
Amount of Condensate Drainable from Tubes Via the Bypass Valve? About 0.5 Pints of Condensate. 30 min.
Feedwater Exit Temperature After 10 min. of Bleeding? 68 Degrees Celsius. 40 min (120 min. if Drain Valve Already Opened)
Feedwater Exit Temperature After Bleeding Pipes? 3 Hours 45 Degrees Celsius. 3 Hours.
Bleed Gas Analysis Results. 20% Air. 2% Carbon Dioxide, Traces of Oil. 8 Hours.
Action Cost
Read meter 2 min.
Check History 5 min
Make Manual Measurement 30 min
Adjust Operating Conditions 30 min
Disassemble Equipment 4 hr
Install new Equipment 5 day

4. Costs for Analysis Action Cost Read meter 2 min. Check History 5 min
Make Manual Measurement 30 min
Adjust Operating Conditions 30 min
Disassemble Equipment 4 hr
Install new Equipment 5 day

5. Guidelines

6. Critical Thinking and Trouble Shooting
Kepner-Tregoe (K-T) Strategy
Clearly determine what is the problem
Classification of problem into
Do we need to determine the cause of the problem
Do we need to make a decision on the problem
Do we need to plan to avoid future problems
Develop multiple approaches simultaneously
Establish probability for success (and cost) of each approach before proceeding
Know what a potential response to a question will be under various problem scenarios.

7. Socratic Questioning

8. Kepner-Tregoe (K-T) Strategy

9. When asking question or asking for analysis
What will I learn if I ask this question?
How will I use this information to find the fault?
Keep 4 or 5 working hypotheses at any one time.

10. K-T Analysis

11. K-T Potential Problem Analysis
Possible Cause
Preventive Action
Contingency Plan A. 1. 2. B.

12. Try to Solve this problem
QUESTION FROM TROUBLE ANSWER FROM EXPERTS COST TO ANSWER SHOOTERS
Steam Pressure at PlOO? Higher Than Design. 5 min.
Steam Temperature at TIOO? Design Value. 5 min.
Amount of Condensate Drainable from Tubes Via the Bypass Valve? About 0.5 Pints of Condensate. 30 min.
Feedwater Exit Temperature After 10 min. of Bleeding? 68 Degrees Celsius. 40 min (120 min. if Drain Valve Already Opened)
Feedwater Exit Temperature After Bleeding Pipes? 3 Hours 45 Degrees Celsius. 3 Hours.
Bleed Gas Analysis Results. 20% Air. 2% Carbon Dioxide, Traces of Oil. 8 Hours.
Action Cost
Read meter 2 min.
Check History 5 min
Make Manual Measurement 30 min
Adjust Operating Conditions 30 min
Disassemble Equipment 4 hr
Install new Equipment 5 day

13. K-T Analysis

14. Possible Faults with Similar Behavior
1) The steam trap is blocked causing liquid condensate to back up in the heat exchanger so the steam does not contact the pipes in the exchanger.
2) The entering water is sub-cooled.
3) The steam pressure and temperature have dropped.
4) The heat exchanger has become fouled.
5) The steam is dirty, i.e., contains non condensable gases.