This differential represents lost revenue. In most cases, even the best crew can dramatically improve performance given the tools and training necessary. Do not have a good understanding of the fundamental principles of the unit operations within their control . A basic understanding of each unit operation provides the operator with knowledge that can be used to optimize performance, troubleshoot process problems, and when necessary, provide maintenance with the necessary information to minimize required downtime while problems are small, before they become major and cause significant outages. Do not have the knowledge of interlocks necessary to minimize downtime .
Process plants tend to be complex with respect to inputs necessary to satisfy motor control logic.
Lack of knowledge of the interlock logic can result in short shutdowns becoming extended outages. Do not take representative samples in accordance with a strict procedure . It is impossible to optimize a process unless highly accurate measurements are taken at appropriate points in the process. These measurements require good samples. Can damage equipment since in many cases standard procedures are not used for plant start-up and shutdown .