Optimizing Troubleshooting in Slurry Drum Operations
Saving Time and Resources by Optimizing Troubleshooting in Slurry Drum Operations
Challenge: A chemical processing plant encountered recurrent high-density readings in a slurry drum. Operators consistently responded by flushing solvent though the input leads, assuming material buildup was causing inaccurate readings. However, despite their efforts, there was no noticeable improvement after the flushing.
Objective: Identify the root cause of the high-density readings in the slurry drum and implement effective corrective actions.
Becht Approach: Upon further investigation following Becht’s Troubleshooting Methodology, it was discovered that the root cause of the high-density readings could be traced to two possible issues, one of which would not involve any flushing for corrective action:
- Seal failure in the disk valve: The disk valve located after the mechanical feeder lost its seal, causing the density to increase and the valve to fully close
- Faulty density sensor: The input leads were beginning to plug, causing the sensor to read a false high and fully closing the valve
Solution: Even though the control logic responds the same way for both issues, a downstream density meter provides additional information to be considered before making a final decision on corrective action. If the disk valve has lost its seal, the downstream density meter would increase, indicating a leaking disc valve. In this case, flushing the leads would not solve the problem. However, if there was a false high reading, the density meter would decrease, which is consistent with a closed valve that is not leaking. Therefore, the issue was determined to be the plugged leads.
Client Value: Becht introduced a more effective approach based on our troubleshooting methodology, training operators to take a closer look at all the key variables and diagnose issues comprehensively, rather than relying on the old practice of “do this if you see that.” This made it clear that they were taking unnecessary actions and causing avoidable delays.
For more details and to better understand how proper training can help your operators achieve similar success, read the full article.
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