For chemical processors industrial safety is a top concern. Industrial accidents can lead to lost production, injury and in some cases even death. This special report examines how organizations can reduce risk, prevent incidents and ensure safety and compliance in hazardous environments with improved processes. Topics covered include:
- How to Achieve Effective Process Safety Management (PSM) -- Senior managers play an important role in improving PSM. Their efforts should be visible and their leadership felt to ensure success.
- Getting To The Root Of Accidents -- Accident investigations usually focus on operator error or technical failures. However, applying systems thinking may provide greater insights on underlying causes and, in the long run, prevent more incidents.
- Optimizing Safety and Efficiency Through Modern Design-- This ignition protection method helps ensure accuracy, safety and compliance in hazardous environments
Optical Dissolved Oxygen Measurement in Power and Boiler Applications
Over the past decade a few trends have started to gain pace within the industry, driving a change in instrumentation requirements for operations managers and plant chemists:
- Maintenance and operations budget cuts have resulted in fewer plant personnel, forcing plant staff to optimize their workload even further
- As the cost of building new power and boiler systems increase, many operators now look to plant life extensions as a solution to bridge gaps in production capacity at a lower investment premium
These trends have changed the requirements in these applications. Starting from these trends, this article analyzes the options for oxygen measurements that are precise, reliable, stable, and above all require low to zero maintenance.04/27/2015
Process Safety Management (PSM), driven by the OSHA 1910.119 standard, aims to prevent the unwanted release of hazardous chemicals. This whitepaper presents an overview of PSM, explains the requirements of a Mechanical Integrity (MI) program, and illustrates how PSM and MI can be established within an asset management framework.04/21/2015
Eastman Chemicals, one of the world’s largest chemical companies, recently decided to strengthen their information security and reliability, as well as develop a path forward to lower software maintenance costs. This Case Study shows how Eastman achieved their goals by globally standardizing on Bentley's ProjectWise software in order to replace an aging, but critical, in-house records management system. The ProjectWise solution has enabled Eastman to significantly reduce their IT costs, and is helping them achieve greater security of their vital plant information while providing a modern data-centric environment to move beyond engineering records into asset performance improvement.04/14/2015
Determining what plastic tubing is best for an application can be a challenge. This report includes topics such as ingredients, temperatures, pressure and vacuum requirements, and flexibility to assist engineers and buyers with tubing and hose selection. Helps avoid costly purchasing errors.04/14/2015
While all manufacturers have standard operating procedures (SOPs) in place for quality operations, how do executives know if individuals across the company’s various business units and geographic regions are following procedure?
Global chemical manufacturers are turning to enterprise quality management systems (EQMS) to take control over quality operations. As a result, manufacturers can quickly identify and address deviations and complaints, uncover potential issues and implement global continuous quality improvements to cut up to 40% in quality management costs.
In this paper, we examine:
- The regulatory, operational and economic challenges facing chemical executives today as they work to deliver safer chemicals products in an increasingly regulated and competitive business environment
- How a disconnected approach to quality management increases risks and costs for global chemical manufacturers
- How an EQMS implemented as part of a company’s overall business strategy delivers operational and cost benefits that transform quality management from a cost center to a revenue driver
Pneumatic conveying is an effective form of moving dry materials. However, the long lengths of conveying pipe present a challenge when it comes to addressing cleanliness and sanitation.
While the closed nature of pneumatic conveying systems protects material from outside contamination, like debris, insects, etc., it is difficult to identify and protect against internal forms of contamination, such as buildup, microbial growth, etc. A plant HACCP or sanitation plan that does not address thousands of feet of pipe and dozens of elbows is incomplete and at risk for a recall.03/24/2015
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
The phrase “Vacuum Cleaning System” refers not only to cleaning by means of vacuum hose and tools, but also to a multitude of tasks which can be accomplished by the same basic system components: a vacuum producer and separators. In this paper, we cover the vacuum cleaning system as a tool for good housekeeping. Such a system is generally designed to pick up and convey dry and free-flowing material that can enter and pass through the vacuum cleaning tool and hose. Further, the system is designed to allow for a selected number of operators.02/24/2015
The safety performance of industrial piping material cannot be overstated—these environments have hundreds, often thousands, of lives at stake. Among the many piping choices, the superior strength, performance and safety of CPVC make it an ideal system for industrial process water applications.
Download the whitepaper now.02/24/2015
Since its introduction to the market in 1959 by The Lubrizol Corporation, chlorinated polyvinyl chloride (better known as CPVC) has proven to be an attractive alternative to traditional industrial metallic piping systems in a wide variety of chemical process environment by offering a more reliable, long-term performance than many other materials.02/04/2015
Half the battle with flow is choosing the proper equipment. Indeed, flow meter selection and specification is crucial. With the wrong choice you’ll be floundering or worse. In addition, process engineers identify “oversizing” as the number one control valve problem. In this Chemical Processing Flow eHandbook, we identify tips to improve flow including:
- How to match the flow meter to the service
- How to handle more flow
- How to properly size control valves
- How to tackle biogas flow measurement challenges
Learn more about these best flow practices. Download your copy of this Chemical Processing Flow eHandbook now.01/28/2015
For chemical processors, assuring safe operations is always top of mind. In this Chemical Processing Special Report we take a look at three distinct areas of operations and steps to insure best safety practices in each.
- HIPS for Reactive Processes – how this safety-instrumented systems offer advantages over pressure relief valves
- HART DIAGNOSTICS - in safety instrumented system (SIS) field devices have been used for many years by several different SIS vendors. HART diagnostics provide much more information on the health of a field device than can be determined from a standard 4–20 mA signal.
- Proof testing - how this modern method improves efficiency, reduces errors, and meets compliance requirements
Precious metals are often present in hydrocarbon, petrochemical, and chemical catalysts. Techniques for recovering precious metals have been around for many years; yet many catalyst owners have misconceptions about how their refining organizations work. In "The Five Myths of Refining Precious Metals", critical information is shared about the chemical processing industry:
- Crucial aspects of weighing
- Sampling and analysis of catalysts
- Methods of catalyst recovery
- What to look for in a proposal from a precious metals refiner
- Understanding the cost of quality
- How to ensure maximum precious metals return value
- Environmental, ethical, and regulatory compliance issues
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
Economic growth, industrialization and population growth are driving the increasing demand for water, while factors such as climate change, pollution and regulation are affecting the supply and costs related to water.” The chemical industry, being highly water intensive, certainly is exposed to water-related risks. Any efforts to manage these risks and capitalize on opportunities begin with the measurement and appreciation of how water may impact business, followed by the development of strategies to protect the business both now and in the future. In this Chemical Processing Special Report we take a look at water challenges and potential solutions for chemical processors including:
- Water-related risks and opportunities
- How chemical makers strive to cut water consumption and improve treatment
- The Importance of visible TOC levels
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. In this Chemical Processing Special Report we take a look at what it takes for chemical companies to identify and implement water conservation strategies and practices including:
- Operating companies step up conservation and re-use efforts - real world example
- Tank cleaning - how a more-effective method can offer significant water conservation benefits
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
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. Whether retrofit or new, chemical processing is continually challenged by combustible dust. Combustible dust can pose a hidden hazard when accumulation occurs in unseen locations such as in mechanical spaces, above false ceiling, ventilation systems and dust collection systems. In this Chemical Processing Powder eHandbook, we take a look at strategies and solutions for mitigating combustible dust hazards including:
- Identifying hidden hazards - a case study outlining how a facility finds danger from accumulated dust and effectively addresses it
- Powder flowability - how new measurement methods now make it easier to evaluate flow
- Process safety - properly designed weigh model can optimize safety and improve efficiency
- A multivariate approach to powder processing - an overview of several methods that can help determine which powder properties have the greatest influence on performance
Learn how to preclude powder problems. Download your copy of this Chemical Processing Powder eHandbook now.11/11/2014
Increasingly precise process control strategies, often linked to computer control, have accelerated the use of sophisticated on-line chemical composition analyzers in plant applications. Instruments such as gas and liquid chromatographs, ion chromatographs, laser optic instruments, atomic absorption instruments and specific ion analyzers, which were rarities in laboratories ten years ago, are now found routinely in plant settings.
While continuing miniaturization and “rugged-ization” of the electronics are making the instrumentation circuitry more tolerant of the plant environment, the level of contamination in plant samples compared to laboratory samples continues to plague the process. This white paper reviews the factors in plant operation that may affect the deliverability of acceptable samples and provides guidelines for addressing these factors.11/04/2014