Nine real diagnostic scenarios in a Symptoms → Diagnosis → Testing → Resolution format — column flooding, exchanger fouling, pump cavitation, PID tuning, reactor runaway risk, relief valve chattering, column foaming, a field P&ID discrepancy, and instrument fouling.
Guessing at a cause and swapping a part is a coin flip dressed up as a repair. This module works through nine real process problems — a distillation column flooding traced to excessive vapor rate, a heat exchanger underperforming from fouling, a pump cavitating from insufficient NPSH, a control loop oscillating from improper PID tuning versus valve stiction, a reactor runaway risk from inadequate cooling, a relief valve chattering, foaming mistaken for flooding in a separation column, a P&ID discrepancy found in the field, and a level transmitter giving a false reading from a plugged impulse line — each built around at least two plausible causes that present the same visible symptom.
Every scenario assumes the P&ID reading (Module 13), process safety (Module 14), HAZOP (Module 15), and plant operations (Module 16) content that came before it — a real fault in the field rarely announces on its own which discipline it actually belongs to.