The power industry is susceptible to a variety of cyber threats, which can wreak havoc on control systems. Management, engineering and IT must commit to a comprehensive approach that encompasses threat prevention, detection and elimination.03/27/2006
As companies and industries increasingly rely on technology, security risks become greater. With growing numbers of Windows machines and increased scarcity of skilled technical resources, a “perfect storm” of cyber threats in production facilities is looming.09/21/2012
Sponsored By: Parker
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
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
Reliability programs are now standard business practice in companies that rely heavily on machines, equipment and other physical assets. However, plants are continually challenged in identifying new and cost-effective ways to ensure their assets are performing and that they are managing to minimize operational risks. In this Chemical Processing Reliability eHandbook we take a look at proactive approaches for improving reliability and maintenance in today’s processing plant including:
- Rotating equipment - how to take advantage of improved internals and better seals
- Meeting process requirements and protecting equipment with strainers
- Insights from surface temperature measurements and the critical role IR thermography is to maintenance
Download your copy of this Chemical Processing Reliability eHandbook now.11/14/2014
One of the trickiest materials to process, solids are comprised of powders or particulates, a continuous gaseous phase (usually air) and, almost always, a liquid component. Processors that handle solids know only too well the types of throughput problems that come up on a recurring basis. Effective, economical and safe slurry management; flowability during processing, accurate inventory and volume level management are all very real challenges faced by processors of solids. In this Chemical Processing Powder eHandbook, we take a look at how to effectively handle solids including:
- Properly accounting for how bulk solids actually will flow in a vessel or overall process -- we take a look at some simple parameters that can often provide a good sense of flowability
- Strategies for avoiding slurry trouble
- Mitigating pipe segment force imbalances with Reactor Excursion and Leakage Analysis Program
- Acoustics-based level measurement for accurate powder measurement in bins, tanks and silos
- Explosion protection methods including suppression, isolation and venting
Learn more about how to effectively handle powders during processing. Download your copy of this ChemicalProcessing Powder eHandbook now.11/20/2012
As many chemical processors know, processing powders can be tricky. Powder properties can be affected if the materials are stored for long periods. Powders can be compressed, vibrated, aerated and exposed to moisture. And specific processes like granulation, blending, drying, milling, lubricating and compression put requirements on how powders can be handled. In this Chemical Processing Powder eHandbook, we take a look at how to effectively process powder including:
- Compression dryers – the case for choosing a solution that produces optimal air quality and low energy consumption
- GHS – understanding the requirements and what it means to chemicals processors
- Predicting powder flow behavior
- Vibratory screen cleaning methods
- Fine powder flushing - eliminating a common bin-afflicting problem caused by trapped air
- Tubular Drag Conveying Technology – an alternative to pneumatic conveying
- Addressing dust hazards – including explosions
Are you looking for proactive solutions to pollution issues? Pondering 2016 regulation challenges? Looking to improve safety, sustainability and cost savings? Considering how to select the right VOC abatement method?
This Chemical Processing eHandbook takes a look at how chemicals manufacturers can meet some of the challenges of Pollution Control issues before they start. Download this Chemical Processing eHandbook for insights and strategies including:
- 2016 Presents Regulation Challenges: Legislation will focus on unfinished business, work plan chemicals and green chemistry efforts?
- Plants Plug Away at Leaks: The quest for improved safety, sustainability and cost savings drives efforts to reduce fugitive emissions.
- Select the Right VOC Abatement Method: There’s no one-size-fits-all approach and use varies greatly by application.
- Increase Sustainability with Thermal Oxidation: The right emission control system can help meet compliance and reduce energy costs.
Is figuring out how to choose the proper pump, pick the proper flow meter or select the correct rupture discs keeping you awake at night? Do you want some guidance on how to make these decisions?
This Chemical Processing eHandbook takes a look at how chemicals manufacturers are making the right selections. Download this Chemical Processing eHandbook for insights and information on:
- Defeat A Double Whammy: Select the proper pump to handle low suctions head and cavitation.
- Pick the Proper Flow Meter: Consider a wide range of factors to determine the optimal choice.
- Choose Rupture Discs Wisely: Selecting the correct pressure relief method and configuration depends on a variety of factors.
For chemical processors, changing process conditions demand quick responses in order to keep processing effective and to keep processes running properly. For processes undergoing such changes, accurate and timely measurements, such as vibration monitoring, redundant tank level measurement and steam header temperature profiling can be difficult to collect. In well-established plants it’s both very expensive and time consuming to get measurement points online using conventional wired instrumentation. Many processors are now turning to wireless devices that can supply data from numerous points that never could have been justified otherwise. In this Chemical Processing Wireless eHandbook we take a look at wireless technology solution successes:
** How installing a wireless pH analyzer for crucial insights on seal integrity provided Fuji Film with a low-cost monitoring solution for protecting a pricey pump
** How one of the world’s largest producers of chlorine, caustic soda and vinyl chloride embraced wireless technology and achieved operating economies and more efficient control of its chemical processes
Treating and reusing process water is a multidimensional challenge for process plants. Compliance with regulatory requirements to prevent and mitigate industrial pollution can require significant capital investment as well as ongoing maintenance outlays. The increasing scarcity and cost of fresh water for production processes also compounds the problem. In this Chemical Processing Wastewater eHandbook we take a look at how to widen your perspective on wastewater including:
- Optimizing water cleanup with activated carbon - including a few pointers to make the most of absorption systems
- Improving plant performance with solids/turbidity monitoring - how continuous monitoring in the liquid processes stages of a wastewater treatment plant offers important benefits
- How to solve partially filled pipe flow measurement challenges
- How variable frequency drives can reduce installation and programming costs while providing a host of other benefits
Download your copy of this Chemical Processing Water Wastewater eHandbook now.06/25/2014
This Chemical Processing Water/WastewatereHandbook, Waylay Water Systems Woes, takes a look at how manufacturers are meeting some of today’s water system challenges. Are you faced with the challenge of properly applying plastic piping? Is PH troubleshooting concerning you? Would you like to learn more about treating condensate water with activated coconut based carbon?
Download this Chemical ProcessingeHandbook nowfor insights and strategies including:
- Properly Applying Plastic Piping: Use of such piping requires careful consideration of a number of issues.
- Succeed at PH Troubleshooting: Heed some pointers to properly diagnose the cause of a problem.
- Treat Condensate Water with Activated Carbon: High-purity coconut based carbons reduce silica leach, rinsing requirements
The Carbon Disclosure Project (CDP), London, has released its Global Water Report 2014. Water challenges, especially in the chemicals industry have not diminished and in fact, are becoming an increasingly larger concern for processors. As stated by Paul Simpson, CEO of the CDP , “Leading companies increasingly recognize that business-as-usual approaches to water management are no longer sufficient.” Download this Chemical Processing eHandbook for:
- Additional findings from the latest CDP report – with a focus on the chemicals industry
- An overview on simple monitoring actions and how adopting best practices may lead to significant savings
- How water conservation efforts can pay off
- How to handle more flow – success often depends upon lowering head losses or raising pump pressure
Effective energy management can help achieve more efficient use of energy without reducing production levels, product quality or employee morale, and without compromising safety and environmental standards. It should not only address higher efficiency generation, energy conversion, distribution and utilization, but also explore lower-cost energy alternatives. Simply put, energy management is optimizing the energy cost per unit of product output. In this Chemical Processing Energy Efficiency eHandbook, we take a look at how to achieve effective energy management including: • Energy management programs – the roles and responsibilities needed to create an effective energy management program • Internal and external resources needed for an effective energy management program including what to expect from top management • Energy management basics – the five key activities to help reduce energy use • Compression dryers – a review of three alternatives: heat, desiccant and refrigerant. Understanding whether the purchase “cost” outweighs the “value” in terms of energy consumption and production levels.09/26/2012
Chemical makers increasingly are focusing on water-related issues. In particular, concern over availability is spurring leading operating companies to implement a host of novel strategies and technologies to optimize water use. Chemical makers are implementing strategies and solutions to scale back on their overall usage of water, reuse water and put clean water back in to circulation. In this ChemicalProcessing Water Optimization eHandbook we take a look at how chemical companies are dealing with water challenges
Download your copy of this Chemical Processing Water Optimization eHandbook now.06/13/2013
Reliability programs are now standard business practice in companies that rely heavily on machines, equipment and other physical assets. But, in today’s lean economy, companies have fewer resources than ever to manage and maintain these assets. Plants face challenges in identifying new and cost-effective ways to ensure their assets are performing and that they are managing to minimize operational risks. In this Chemical Processing Reliability/Asset Management eHandbook we take a look at proactive approaches for improving reliability and maintenance in today’s processing plant including:
• Equipment rotation: identify damaged and worn components before they cause problems
• Backflush strategies: flow reversal can remove fiber buildup in heat exchangers
• Advanced Reliability Management: key steps for leveraging limited resources and critical assets
• Predictive Maintenance: detailed analysis of maintenance records can further improve equipment reliability
Chemical facilities are under mounting pressure to process ever larger quantities of wastewater to increasingly higher standards while staying within a variety of cost constraints. Plant operators face the dilemma of how to maintain treatment throughput at reasonable cost even when the plant reaches design capacity. Potential changes to production mixes can compound the challenge. Fortunately, adopting the latest wastewater-treatment technology can inject new life into a plant, extending useful asset life without heavy upfront capital investment. In this Chemical Processing Wastewater eHandbook we take a look at how to boost wastewater improvement efforts including:
- An exploration of an innovative system that enables wastewater capacity expansion
- Why chemical makers are increasingly focusing on water-related risks and opportunities
Download your copy of this Chemical Processing Wastewater eHandbook now.12/19/2013
For chemical processors, the use of water in their processing can correlate to significant costs. Cost, coupled with an increasing focus on the environmental impact of both water usage and wastewater creation, are challenging processors to take a closer look at both their consumption of water and production of wastewater. Wide-ranging water optimization efforts, from fixing pipe leaks to minimizing cooling tower blowdown, are providing significant savings to chemical makers, but there’s more. In this ChemicalProcessing Water/Wastewate eHandbook we take a look at how to deal with water challenges including:
• Reducing water consumption and increase recycling – including examples of achievement and strategies from BASF, Air Products, Eli Lilly & Co, and Pfizer
• RO Membranes: proactive steps can maximize life and performance for water purification
Water is a critical utility at process plants, often serving both as a heating and a cooling medium. Many process plants rely on this water for processing and other applications. Providing the water, usually by heating via steam coils or direct steam injection nozzles, takes significant energy. In this Chemical Processing Water eHandbook we take a look at water best practices including:
- How to cut energy consumption in water systems in both hot and cold water applications
- Polymer piping - we identify benefits over metallic systems
- TOC analysis challenges - techniques that address barriers to standard online TOC measurement methods