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Hello!
We are excited to have you on our career tour. I am Rho, your guide through this wonderful journey.

Supervising involves monitoring plant operations, and analysing
and resolving any issues that may occur to ensure efficient
chemical production.

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Let's first understand the basics of supervising a chemical operation

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In this tour you will be working at a major fertiliser manufacturing plant.
Fertilisers are used by farmers to supply nutrients to crops which are essential for their growth.

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You will supervise a crystallizer in the plant, from control room using computers which receive real-time data from the plant. Control room operators constantly monitor this data and may alert you in case of an issue.

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Steps in supervising

Monitor

Monitor parameters (like product temperature, yield) to ensure an
operation is running smoothly

Troubleshoot (if any issue)

Diagnose

Deviation of a parameter from desired value will indicate an issue with the operation, identify cause of the issue

Resolve

Resolve the issue by coordinating with plant teams and changing
operation conditions from control room as required

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These are the major steps involved in supervising chemical operations

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Assignment

Data From Plant

Crystallizer Solution Temperature

Coolant Flowrate

Actual

25m3/hr

Setpoint

25m3/hr

Warning! None

In control room you will get actual value of crystallizer temperature
every 5 seconds while actual value of coolant flowrate will be updated
every second.

You need to ensure actual crystallizer temperature remains equal to
its ideal value while actual coolant flowrate remains equal to its
setpoint, throughout the operation for proper crystallization.

Note: crystallization is shown to take 100 seconds only for the
purpose of this assignment, actual operation takes much longer

Back Proceed
play button About crystallizer system
How to troubleshoot crystallizer issues?
view-instruction-icon Troubleshooting Guide
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Let’s get to work! Video and guide below will explain how to solve this assignment.
On proceeding you will be taken to your workspace to work on this.

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Start Working

You will now begin supervising the crystallization operation. This assignment has a duration of 100 seconds in which you need to monitor data and troubleshoot any issues that arise.

left-arrow Back
Start Working right-arrow

How to troubleshoot crystallizer issues?

Issue Cause Remedy
Actual coolant flowrate
is not equal to setpoint		 Issue in flowrate
control instruments		 Ask instrumentation team to
look into the issue
Actual crystallizer
solution temperature is
not equal to ideal from
the beginning of
crystallization operation		 Issue in the
operation prior to
crystallization

Change coolant flowrate
appropriately to get
solution temperature to
ideal

Allowed coolant flowrates:

21 m3/hr

25 m3/hr

29 m3/hr

Higher the coolant flowrate
greater will be the fall in
crystallizer solution
tempertature

*Note : If actual crystallizer solution temperature is equal to ideal keep coolant flowrate at 25 m3/hr

Got it!

Successful Troubleshooting

Unsuccessful Troubleshooting

Improper Troubleshooting

See assignment details
view-instruction-icon Troubleshooting Guide

Data From Plant

Crystallizer Solution Temperature

Coolant Flowrate

Actual

25m3/hr

29m3/hr

21m3/hr

Setpoint

25m3/hr

29m3/hr

21m3/hr

Warning! None

Warning!

Actual crystallizer solution temperature is not equal to ideal

Warning!

Actual coolant flowrate is not equal to setpoint

Coolant flowrate issue

Contact Instrumentation Team Contact Instrumentation Team Contact Instrumentation Team Contact Instrumentation Team

Change coolant flowrate setpoint


21 m3/hr


25 m3/hr


29 m3/hr

Final temperature of crystallizer is within 0.5 °C of ideal, so crystals have formed properly.

You saved the batch inspite of an error from previous operation. Good work!

Final temperature of crystallizer varies from ideal by more than 0.5 °C, so crystals have not formed properly.

The entire batch has been wasted. You should have done better troubleshooting to save the batch.

Final temperature of crystallizer is within 0.5 °C of ideal, so the crystals have formed.

But you changed the coolant flowrate too many times, causing undesirable fluctuations in crystallizer temperature. This has affected the crystal quality.

Final temperature of crystallizer is within 0.5 0C of ideal, so the crystals have formed.

But for some time the difference between ideal and actual causing temperature of crystallizer exceeded 3 0C. This has affected the crystal quality.

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duration-icon

Duration of this assignment is over

Proceed right-arrow

Change coolant flowrate

Are you sure you want to change the coolant flowrate setpoint?

Cancel

Yes

Change coolant flowrate

Are you sure you want to change the coolant flowrate setpoint?

Cancel

Yes

Change coolant flowrate

Are you sure you want to change the coolant flowrate setpoint?

Cancel

Yes

Send below message to the instrumentation team

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“Actual coolant flowrate is not equal to Setpoint.

Could you please check if there is any issue with the flowrate control elements like controller and valve?”

Cancel

Send Message right-arrow

Send below message to the instrumentation team

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“Actual coolant flowrate is not equal to Setpoint.

Could you please check if there is any issue with the flowrate control elements like controller and valve?”

Cancel

Send Message right-arrow

Reply from the instrumentation team

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“We found that the Actual coolant flowrate is same as Setpoint.

Please check your plant data again.”

Got It!

Reply from the instrumentation team

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“We found that there was an issue with the valve.

It has been solved and the Actual coolant flowrate will become equal to the Setpoint soon”

Got It!

In control room you will get actual value of crystallizer temperature every 5 seconds while actual value of coolant flowrate will be updated every second.

You need to ensure actual crystallizer temperature remains equal to its ideal value while actual coolant flowrate remains equal to its setpoint, throughout the operation for proper crystallization.

Note: crystallization is shown to take 100 seconds only for the purpose of this assignment, actual operation takes much longer

Got it!

Troubleshooting Guide

Issue Cause Remedy
Actual coolant flowrate
is not equal to setpoint		 Issue in flowrate
control instruments		 Ask instrumentation team to
look into the issue
Actual crystallizer
solution temperature is
not equal to ideal from
the beginning of
crystallization operation		 Issue in the
operation prior to
crystallization

Change coolant flowrate
appropriately to get
solution temperature to
ideal

Allowed coolant flowrates:

21 m3/hr

25 m3/hr

29 m3/hr

Higher the coolant flowrate
greater will be the fall in
crystallizer solution
tempertature

*Note : If actual crystallizer solution temperature is equal to ideal keep coolant flowrate at 25 m3/hr

Got it!

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You have reached the end of this tour. Thank you for joining us. We hope to see you again soon!

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