Systems are becoming more complex. This complexity is changing the nature of the accidents and losses we are experiencing. Process design and process safety are critical considerations in chemical production and processing. With design and safety paramount at the outset of any new development or equipment retrofit, firms can minimize risk exposure, maximize productivity and position themselves to remain compliant and competitive. Advanced automation technologies continue to drive productivity improvements. In this Chemical Processing Improve Plant Safety eHandbook, we provide tips for safer processing including:
The role of senior management including six important steps senior management should take to insure safer processing
Optimizing process safety and efficiency through modern weighing design
The fundamentals of blast-resistant building
Download your copy of this Chemical Processing Improve Plant Safety eHandbook now.
Chemical plants vary widely in size and complexity yet share common goals for maximizing efficiency safely and cost effectively. This Chemical Processing Special Report tackles two areas in chemical processing - compressed air systems and powder handling - where gains can be achieved for improving efficiency. We also address the concerns of safety as it relates to drying compressed air in hazardous atmospheres.
Whether compressed air systems are centrifugal, rotary screw, reciprocating compressors or a combination, this Special Report provides and understanding of what’s involved in getting a suitable supply of compressed air.
Efficient powder handling can be achieved through optimized humidity management.
Safe drying practices in hazardous air locations
Chemical Processing’s Flow eHandbook: Master Flow Challenges
Issues related to physical properties, process parameters, electronic features and interconnections can all affect the flow of liquids and gases. Often working around the clock to process, transfer, and store sometimes hazardous and corrosive chemicals, processors must tackle issues related to physical properties and process parameters. In this Chemical Processing Flow eHandbook, we take a look at what it takes for chemical processors to master flow challenges for several types of materials with vastly different physical properties including:
How to increase process availability - coriolis mass flow meters provide reliable indication of gas entrainment
Overcoming the challenges of changing gas composition - new technology addresses need for more accurate and efficient biogas measuring
How to ensure proper control of parallel flow paths demands care
Case Study: Speed Pipe Installation - pipe-joining system eliminates need to weld or thread connections
Find out how to master flow challenges. Download your copy of this Chemical Processing Flow eHandbook now.
Chemical Processing’s Process Safety eHandbook: Tips for Safer Processing
Major accidents with multiple fatalities continue to occur worldwide in theprocess industries, causing distress to those involved and massive costs to companies. Almost daily, facilities in the process industries face a number of specific major accident hazard scenarios depending upon the nature of the substances they handle and their processing activities. These are caused by known initiating events such as failure of hardware or control systems, or errors by operating or maintenance staff. In this Chemical Processing Process Safety eHandbook, we provide tips for safer processing including:
>> The role of senior management including six important steps senior management should take to insure safer processing
>> Process safety documentation – strategies for ensuring that your documentation is up-to-date and readily accessible
Mixing Solutions and Slurries -- Effectively, Economically and Safely
Effectively mixing liquids and solids to create an optimal slurry is one of the perpetual challenges in the chemical industry. This case study demonstrates how an eductor-based mixing system can effectively handle a wide range of materials, utilizing the least amount of floor space, energy and human resources to achieve an optimized process. In addition, the eductor mixing system offers increased efficiencies over a conventional system of mixing by allowing solutions and slurries to be made on demand – as opposed to pre-mixed in large holding tanks. Another important benefit is the system limits exposure to operators, and mitigates issues of delivering solid material in a large vapor space. The design flexibility of an educator-based mixing system offers a high level of customization.
White Paper: Understanding the Risks Associated with FIBCs and Electrostatic Hazards
Flexible Intermediate Bulk Containers (FIBCs) have found their niche in the worldwide transportation of powdered, flaked and granulated products. FIBCs are typically made of woven plastic with some type of liner insert and are often referred to as super sacks, big bags or bulk bags in industry. During filling and emptying of FIBCs there is a steady accumulation of static charge that can result in electrostatic discharges from the FIBC. This may in turn provide sufficient energy for ignition of combustible particulate solids or flammable vapors, not to mention unsettling shocks to nearby personnel. In this white paper we review the NFPA 654 Standard for the Prevention of Fire and Dust Explosions from Combustible Particulate Solids and the importance of why identifying the Minimum Ignition Energy (MIE) of your combustible dust or flammable vapor is a necessary component for selecting the correct FIBC Type for your application. Download now.
CP Special Report: Hardware Safety
The U.S. Occupational Safety and Health Administration’s Process Safety Management (PSM) Standard [29 CFR 1910.119(j)] require plant management to identify and address hazards. Further challenging plant management, the mechanical integrity (MI) element of the PSM has been difficult for many facilities to implement. In fact, PSM audits by OSHA have consistently demonstrated that MI accounts for a large number of citations at most facilities. In this Chemical Processing Special Report, we take a look at how to effectively implement strategies to comply with PSM standards including:
Common piping, hoses and valves hazards – what PHA (Process Handling Analysis) teams should look for to improve the quality of the hazard evaluation
MI element of PSM – an in-depth look at the stated MI requirements, the perceived interpretation of these requirements and further considerations for identifying your plant’s compliance strategy
MI implications – the impact MI has on plant’s written procedures, training, inspection & testing, and how equipment deficiencies and quality assurance programs are managed
Continental Disc Corp.
Fired Up: Combustible Dust Raises Explosive Issues
Combustible dust fires happen in plants everyday. This white paper helps manufacturers learn more about combustible dust hazards and ways to handle combustible dust in your manufacturing plant in order to comply with OSHA's NEP. Learn more about choosing the right cleaning tools for your facility.
Nilfisk Industrial Vacuums
Drying Compressed Air in Hazardous Atmospheres
Hazardous locations have or could potentially have high concentrations of flammable gases, vapors, combustible dusts, etc. A small spark can lead to a horrific explosion dangerous to equipment and workers in the area. Equipment located in hazardous areas must be specifically designed to prevent ignition and explosion.
Improve Plant Safety - A Chemical Processing Special Report
In chemicals processing, significant hazards exist -- such as those from fire, explosions or toxic release. The processes themselves, the chemicals being processed and the procedures followed, or lack thereof, can all contribute to the risk exposure of these hazards. What can processors do to mitigate these risks? For chemicals processors, it's crucial to implement processes and solutions to detect and prevent these hazards from occurring in the first place.
Chemical Processing has taken an in-depth look at plant safety -- how to identify the hazards and implement processes and procedures to ensure a safer working environment. This comprehensive Chemical Processing Special Report titled: Improve Plant Safety is now available to download for free.
Gas And Dust Explosions -- Relief Sizing Formula
A large number of analytical and highly empirical correlations including monograms reflecting changing standards have been or are being proposed separately for gas and dust explosion relief venting. This white paper provides a generalized formula that is applicable to both gas and dust deflagrations including subsonic and sonic pressure relief conditions and is consistent with available experimental data and industry experience. Application of the model is illustrated for dust explosions. Download now.
Fauske & Associates
OSHA & NFPA Compliant: Keeping Your Plant Safe
In March 2008, OSHA reissued its Combustible Dust National Emphasis Program (NEP) notifying approximately 30,000 companies nationwide that they will be targeted for inspections over the next few years. Mettler Toledo recognizes that many manufacturers are not up-to-date on the latest hazardous area compliance regulations or may not know that their industry is subject to those regulations. Don't wait until your facility receives a surprise visit from OSHA or worse yet, for a catastrophic incident to occur. Take the proactive approach to addressing the "hazardous area advisory level" in your facility.
The Green Solution
The ever present emphasis on technological efficiency is just one of several forces behind the pressure on companies to "go green" despite a trying economy. The ultimate criterion that determines whether a motor is truly green is energy efficiency. Technology, long the key to efficiency, can help resolve this issue.
Process Safety Symposium Making Safety Second Nature
This 10-page document discusses how the reference from the Center for Chemical Process Safety -- "Inherently Safer Chemical Processes, A Life Cycle Approach," 1st Edition, 1996 -- was updated in 2007.
Inherent Safety has been well received by industry, but there has been significant advancement in the concept of inherently safer design over the last 10 years. This overview highlights lessons learned and best practices in inherent safety.
Unwelcome oxygen Tank blanketing is the process of filling the headspace in storage vessels and reactors with an inert gas to prevent its contents from exploding, degrading or polymerizing and to protect equipment from corrosion. A blanketing system is normally designed such that it operates under higher than atmospheric pressures, therefore preventing outside air from entering the vessel. As oxygen and moisture in the air can be undesired in numerous processes and applications, blanketing is done in a wide range of industries, varying from (petro)chemical to food and beverage, pharmaceutical to pure water.
Choosing the Right Emissions Control Option
Determining the most economical option to control airborne emissions during chemical process operations presents several unique challenges. As with any add-on control system, the goal is to minimize the annualized total costs while maintaining proper operation. In this white paper, learn the different options that are available and which ones fit your process the best.
Durr Systems Inc.
Spray Gas Quench Design Considerations
The use of spray nozzles to rapidly cool or quench gas streams is an essential application in many industrial processes, such as chemical reaction vessels, incineration, and power plant absorber gas inlet. An optimized spray quench design requires engineering analysis of the operating environment, spray nozzle performance and process reliability.
This technical paper describes the design considerations for spray gas quench systems such as nozzle selection, process control, system configuration and reliability. Application of this knowledge can result in a gas quench system that operates efficiently and reliably with reduced vessel size, reduced atomization energy consumption, and minimized downtime, to achieve capital and operational cost savings for your process.
Closed System Technology Drives the Trend Toward Safer, More Cost-Efficient Chemical Dispensing
In dozens of industries and in millions of applications around the world, dangerous chemicals are transferred from their original shipping containers into smaller jugs or buckets or applied to other end-use processes. Historically, the predominant dispensing method in many of these applications has been through an open system where the liquid is poured out of the container. With a poured system, the container is often flipped on its side and the liquid is poured into a secondary container.
The user then just carries the bucket to wherever it needs to go. A mental image of this technique quickly reveals its potential dangers and inefficiencies.