To Flush or Not to Flush: The Importance of Critical Thinking When Troubleshooting Process Deviations

In a chemical processing plant, slurry drums play a vital role in blending powders into a liquid mixture. Accurate density measurement of the slurry is crucial to maintaining product consistency and preventing equipment damage. A density gauge installed on the slurry drum monitors these levels. Recently, a plant faced recurrent issues with high-density readings, leading operators to flush the input leads as a default troubleshooting measure. However, despite their efforts, there was no noticeable improvement after the flushing.

Possible Root Causes of the High-Density Readings

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 does not involve any flushing for corrective action:

• Seal failure in the disk valve: If the disk valve located after the mechanical feeder lost its seal, it would result in an increased powder feed to the slurry drum. This additional powder would cause the density in the drum (process variable) to increase. The control system, in an attempt to maintain the desired density, would decrease the output to adjust the valve position. Despite these adjustments, the density could continue to increase, potentially causing the valve to close completely (0%). A downstream density meter would also read an increased density, confirming that the lost seal was allowing more powder than desired and that the controller response alone could not maintain the proper density.
• Faulty density sensor: If the high readings were due to the input leads beginning to plug, causing the sensor to read a false high, the density would still show an increase and the control system would respond in the same way. However, the downstream density meter would indicate a decreasing trend. Since the valve closes as a result of the faulty reading, insufficient powder would be supplied, leading to a lower density reading.

Operator Response to the Process Deviation
Rather than investigating the underlying issue, the automatic reaction was to flush the input leads, assuming that the elevated readings were due to material buildup. However, this approach led to production delays and wasted resources, with no real resolution to the root cause of the issue:

• Increased downtime: Flushing required production to be halted multiple times.
• Wasted resources: While the solvent and materials used in unnecessary flushes do not add significant cost, human resource time and energy are wasted.
• Prolonged problem: Since the true cause was not addressed, the issue persisted, increasing frustration among the staff and creating inefficiencies in production.

Only after flushing would operators consider other potential causes if the issue persisted. Becht introduced a more effective approach, 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.

Building Critical Thinking Skills to Solve the Real Problem

At Becht, we understand the importance of effective troubleshooting and the role critical thinking plays in resolving complex process issues. Our training program encourages operators to step back and view the entire system, encouraging a deeper understanding of cause and effect. This approach helps them move beyond simply following procedures or relying on outdated practices, empowering them to think critically and make more informed decisions. Just as we helped identify and address the institutionalized error of defaulting to flushing without proper investigation, we are committed to providing operators with the skills needed to tackle similar challenges proactively.

Becht offers a range of solutions to help:

• Tailored training programs: We offer specialized training designed to cultivate critical thinking and problem-solving skills. Our programs guide operators through systematic approaches to identify root causes, analyze data, and implement effective solutions.
• Hands-on workshops: Our hands-on workshops provide practical experience in troubleshooting real-world scenarios. By simulating various issues and guiding operators through the investigative process, we help them develop the confidence and expertise to address deviations effectively.
• Ongoing support and consultation: Becht provides continuous support and consultation to ensure that operators can apply learned skills in their daily operations. Our experts are available to assist with complex troubleshooting tasks and to refine problem-solving strategies.
• Best practices implementation: We help organizations establish and implement best practices for troubleshooting and decision-making. By integrating these practices into standard operating procedures, operators can consistently apply critical thinking and avoid common pitfalls.
• Performance evaluation: We offer tools and methodologies to evaluate and enhance operator performance, ensuring that critical thinking skills are effectively applied and continuously improved.

Partner with Becht to transform troubleshooting practices and empower your team with the critical thinking skills necessary for operational excellence. Together, we can ensure that your operators are equipped to handle challenges with confidence and precision.