There are simply a lot of problems in a processing or a production plant. I did mentioned a
broad or general ideas on the problems before this.
It will be very frustrating if a problem arises from an uncontrollable source. For example, today, there was a power surge which came from the local power supply. It happened so fast and we felt the power interruption in a split second. Immediately, I looked through the CCTV and checkout what was happening from inside my office. The plant operators were running here and there checking the valves, pumps and other equipments. Three units of boilers which are supposed to supply steam to the plants shut off. The boiler man worked very hard to start up the boiler step by step. My colleague, a charge man, swiftly checked the LV (Low Voltage) room to checked on any problem or tripping on our site. Fortunately, everything was in perfect order. It was the 1 second power surge that affected us and definitely resulted in a terrible downtime to our production.
How to avoid such downtime?
For our side, we cannot avoid this. It must be control from the local power supplier, in our case, Tenaga Nasional Berhad (TNB). They must ensure their local power station is performing well and delivering sufficient power to surrounding factories and plants. Well, that's one kind of downtime that is very costly and unavoidable. A problem that is beyond our control.