Modern chemical, biochemical, and pharmaceutical manufacturing operates in complex processing environments where unexpected operational problems, safety risks, and performance deviations must be identified and resolved efficiently. Graduates entering these industries must therefore be able to diagnose process behaviour, interpret incomplete or ambiguous data, and make informed technical decisions in collaboration with multidisciplinary teams. This module develops the knowledge and structured analytical thinking required to troubleshoot industrial processes while reinforcing the connection between process understanding, modelling, and safe operation. By integrating problem-solving methodologies with contemporary approaches to process safety and analysis, the module prepares graduates to address real operational challenges and supports the transition from theoretical study to professional engineering and scientific practice.

The module will inform students on a wide range of topics pertinent to the identification, troubleshooting and solution of process issues, process simulation techniques, and process safety. Indicative examples are as follows: - Characteristics of trouble shooting problems and the methodologies used to solve them. - Approaches to the analysis and formulation of solutions to process issues. - Data gathering and critical thinking techniques. - The use of interpersonal communication skills in handling management issues associated with industrial process problems. - Practical methodologies: recognising patterns, cause-effect, reasoning, and selection of valid diagnostic actions; process trouble shooting rules of thumb; formulation of realistic solutions to process problems. - Selected process trouble shooting case studies in the chemical and biochemical industries. - Process modelling for trouble shooting. - Introduction to computational fluid dynamics (CFD) for process engineering applications. - Overview and application of the Bow-Tie technique to process hazard analysis. - Principles of inherently safer design. - Process safety management model. - Hazard & operability (HAZOP) study, including a HAZOP workshop on a continuous process.

On successful completion of this module students should be able to: • Analyse industrial process data and operational scenarios to identify the underlying causes of process performance deviations and failures. • Apply structured troubleshooting methodologies and process modelling techniques to investigate and resolve chemical and biochemical process problems. • Evaluate process hazards and operational risks using established process safety frameworks and analysis tools. • Diagnose complex process incidents and historical industrial accidents by integrating technical evidence, modelling results, and safety analysis.

On successful completion of this module students should be able to: • Value the importance of structured, evidence-based approaches to troubleshooting and decision-making in complex industrial processing environments. • Demonstrate professional responsibility and effective collaboration when analysing industrial process problems and communicating safety-critical findings.

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This module is delivered through a student-centred approach that combines lectures with interactive, challenge-driven learning activities including case studies, group analysis, modelling exercises, and hazard analysis workshops. Lectures provide the theoretical foundation in structured troubleshooting methodologies, process modelling, computational fluid dynamics (CFD), and contemporary approaches to process safety and inherently safer design. Tutorials, modelling assignments, and safety workshops use authentic industrial scenarios and accident investigations to enable students to apply theoretical knowledge to realistic operational challenges. Through group-based troubleshooting exercises and accident analysis presentations, students develop the ability to clearly communicate technical findings and collaborate effectively (Articulate). Engagement with open-ended industrial case studies and modelling tasks encourages independent inquiry and evidence-based reasoning (Curious). Simulation assignments and problem-based activities require students to adapt methods to complex, evolving scenarios (Agile). Hazard analysis exercises such as Bow-Tie and HAZOP emphasise professional responsibility in identifying and managing industrial risks (Responsible). Recent developments and research findings are incorporated through updated industrial case studies, modern process safety frameworks, and contemporary modelling and safety analysis tools used in current engineering practice.