A power facility suffered recurring instrument air failures that resulted in revenue losses of $95,000 USD in Q3 2021, and full plant shutdown.
To solve the issue, I conducted a comprehensive Root Cause Analysis (RCA). I conducted data analysis, DCS reviews, and cross-functional interviews to identify issues. There were electrical faults and compressor control inefficiencies that needed a detailed cause map.
The comprehensive RCA led to the implementation of revised control sequences, enhanced PM scopes, and automation strategies. This effectively mitigated risks and resolved failures, protecting $95,000 USD in revenue.
