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CPO 253 Process Troubleshooting

This course will provide an overview of different troubleshooting techniques, procedures, and methods used to solve chemical process problems. Topics include application of data collection and analysis, cause/effect relationships, and reasoning. Laboratory instruction involves troubleshooting problems initiated by the instructor in operating pilot plants and computer simulators.

Credits

4

Prerequisite

Prerequisite: CPO 151 and ELC 101.

See Course Syllabus

Course Number and Title:

CPO 253 Process Troubleshooting

Campus Location

  • Stanton

Prerequisites

Prerequisite: CPO 151 and ELC 101.

Course Credits and Hours

4 credit(s)

3 lecture hours/week

2 lab hours/week

Course Description

This course will provide an overview of different troubleshooting techniques, procedures, and methods used to solve chemical process problems. Topics include application of data collection and analysis, cause/effect relationships, and reasoning. Laboratory instruction involves troubleshooting problems initiated by the instructor in operating pilot plants and computer simulators.

Additional Materials

None

Required Text(s)

Obtain current textbook information by viewing the campus bookstore - https://www.dtcc.edu/bookstores online or visit a campus bookstore. Check your course schedule for the course number and section.

Disclaimer

None

Core Course Performance Objectives (CCPOs)

  1. Apply knowledge of process variables, indicators and controllers, troubleshooting tools, and steps to solve problems in simple chemical process systems. (CCC 1, 2, 5, 6; PGC 3, 4)
  2. Solve problems in a decanter process by applying troubleshooting steps and tools. (CCC 2, 5, 6; PGC 3, 4)
  3. Apply troubleshooting steps and tools to solve problems in a reaction process. (CCC 2, 5, 6; PGC 3, 4)
  4. Solve problems in a steam generation process by applying troubleshooting steps and tools. (CCC 2 5, 6; PGC 3, 4)
  5. Apply troubleshooting steps and tools to solve problems in a distillation process. (CCC 2, 5, 6; PGC 3, 4)
  6. Solve problems in an absorption and stripping process by applying troubleshooting steps and tools. (CCC 2, 5, 6; PGC 3, 4)
  7. In a pilot plant and/or using a computer simulation, start up, operate, troubleshoot, and shut down absorption, distillation, and pH control units. (CCC 1, 2, 6; PGC 1, 3, 4, 6, 7)

See Core Curriculum Competencies and Program Graduate Competencies at the end of the syllabus. CCPOs are linked to every competency they develop.

Measurable Performance Objectives (MPOs)

Upon completion of this course, the student will:

  1. Apply knowledge of process variables, indicators and controllers, troubleshooting tools, and steps to solve problems in simple chemical process systems.
    1. Identify the five major variables in a simple process.
    2. Name the metric base units and International System of Units (SI) units for mass, length, volume, time and temperature, and their abbreviations.
    3. Convert physical quantities from one unit to another using conversion factors.
    4. Discuss the role of indicators and controllers in troubleshooting a chemical process problem.
    5. Describe each of the seven troubleshooting tools.
    6. Relate each troubleshooting tool to the five major process variables.
    7. List and explain the six steps in the troubleshooting method.
    8. Identify relevant process data, and verify the data using the troubleshooting tools.
    9. Use multiple data points and the troubleshooting tools to arrive at valid conclusion regarding the cause or causes of the process problem.
    10. Use the factor-label method in problem analysis and estimation techniques in solving problems.
  2. Solve problems in a decanter process by applying troubleshooting steps and tools.
    1. Define decanter process.
    2. List and explain the three factors that affect the decanter process.
    3. Given one factor that affects the decanter process, discuss the possibility of interrelationship between it and other factors.
    4. Describe the decanter process control theory.
    5. List the equipment associated with the decanter process system.
    6. Identify the control instrumentation for the decanter process.
    7. Explain the normal decanter process variables.
    8. Given a change in decanter factors, describe possible process outcomes.
    9. Apply the troubleshooting steps and tools to abnormal conditions in a decanter process.
  3. Apply troubleshooting steps and tools to solve problems in a reaction process.
    1. Define reaction process.
    2. Describe an effective reaction vessel.
    3. List and explain the seven factors that affect a chemical reaction.
    4. Given one factor that affects a reaction, discuss the possibility of interrelationship between it and other factors.
    5. Describe the reaction process control theory.
    6. List the equipment associated with a typical batch reaction process.
    7. Identify the control instrumentation for a typical batch reaction process.
    8. Explain normal reaction process variables.
    9. Given a change in reaction factors, describe possible process outcomes.
    10. Apply the troubleshooting steps and tools to abnormal conditions in a reaction. 
  4. Solve problems in a steam generation process by applying troubleshooting steps and tools.
    1. Define steam generation process.
    2. List and explain the five factors that affect steam generation.
    3. Given one factor that affects steam generation, discuss the possibility of interrelationship between it and other variables.
    4. Describe the steam generation control theory.
    5. List equipment associated with a steam generation system.
    6. Identify the control instrumentation for a steam generation process.
    7. Discuss normal steam generation process variables.
    8. Given a change in steam generation factors, describe possible process outcomes.
    9. Apply the troubleshooting steps and tools to abnormal conditions in a steam generation process.
  5. Apply troubleshooting steps and tools to solve problems in a distillation process.
    1. Define distillation process.
    2. List and explain the three factors that affect distillation.
    3. Given one factor that affects distillation, discuss the possibility of interrelationship between it and other factors.
    4. Describe the distillation control theory.
    5. List the equipment associated a typical distillation process system.
    6. Identify the control instrumentation for a distillation process.
    7. Explain normal distillation process variables.
    8. Given a change in distillation factors, describe possible process outcomes.
    9. Apply the troubleshooting steps and tools to abnormal conditions in a distillation process.
  6. Solve problems in an absorption and stripping process by applying troubleshooting steps and tools.
    1. Define absorption and stripping process.
    2. List and explain the three factors that affect absorption and stripping.
    3. Given one factor that affects absorption and stripping, discuss the possibility of interrelationship between it and other factors.
    4. Describe the absorption and stripping process control theory.
    5. List the equipment associated with an absorption and stripping process.
    6. Identify the control instrumentation for an absorption and stripping process.
    7. Explain normal absorption and stripping variables.
    8. Given a change in absorption and stripping factors, describe possible process outcomes.
    9. Apply the troubleshooting steps and tools to abnormal conditions in an absorption and stripping process.
  7. In a pilot plant and/or using a computer simulation, start up, operate, troubleshoot, and shut down absorption, distillation, and pH control units.
    1. Prepare laboratory reports to document operation of the following units in the unit operations laboratory: batch distillation, gas absorption, and pH control units.
    2. Prepare laboratory reports for the following computer process simulation modules: SPM 1200-Natural Draft Fired Heater, SPM 1500-Superheated Steam Boiler, SPM 1800-pH Control, SPM 1900-Instrumentation V-3-Element BFW Control, and SPM 2100-Continuous Stirred Tank Reactor.

Evaluation Criteria/Policies

The grade will be determined using the Delaware Tech grading system:

90-100 = A
80-89 = B
70-79 = C
0-69 = F
Students should refer to the Catalog/Student Handbook for information on the Academic Standing Policy, the Academic Integrity Policy, Student Rights and Responsibilities, and other policies relevant to their academic progress.

Final Course Grade

Calculated using the following weighted average

Evaluation Measure

Percentage of final grade

Summative: Test #1

10%

Summative: Test #2

10%

Summative: Test #3

10%

Summative: Test #4

10%

Summative: Final Exam

15%

Summative: Capstone Class Project

20%

Formative: Laboratory Work

25%

TOTAL

100%

Program Graduate Competencies (PGCs are the competencies every graduate will develop specific to his or her major)

  1. Maintain safety, health, and environmental standards during simulation exercises or in a chemical plant.
  2. Handle, store, and transport chemical materials according to all applicable federal, state, and local regulations.           
  3. Apply chemical process and quality systems in a simulated chemical process environment or a chemical plant.
  4. Operate, monitor, control, and troubleshoot batch and continuous chemical processes.
  5. Analyze samples of raw materials, intermediates, and finished products in a simulated chemical process environment or a chemical plant.   
  6. Perform routine, predictive, and preventive maintenance and service to process equipment and instrumentation.   
  7. Use computers and computerized equipment for communications and chemical process control. 

Core Curriculum Competencies (CCCs are the competencies every graduate will develop)

  1. Apply clear and effective communication skills.
  2. Use critical thinking to solve problems.
  3. Collaborate to achieve a common goal.
  4. Demonstrate professional and ethical conduct.
  5. Use information literacy for effective vocational and/or academic research.
  6. Apply quantitative reasoning and/or scientific inquiry to solve practical problems.

Students in Need of Accommodations Due to a Disability

We value all individuals and provide an inclusive environment that fosters equity and student success. The College is committed to providing reasonable accommodations for students with disabilities. Students are encouraged to schedule an appointment with the campus Disabilities Support Counselor to request an accommodation needed due to a disability. The College's policy on accommodations for persons with disabilities can be found in the College's Guide to Requesting Academic Accommodations and/or Auxiliary Aids Students may also access the Guide and contact information for Disabilities Support Counselors through the Student Resources web page under Disabilities Support Services, or visit the campus Advising Center.

Minimum Technology Requirements

Minimum technology requirements for online, hybrid, video conferencing and web conferencing courses.

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Cell phone/Electronic Device

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Tuition Adjustment Policy

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