Being armed with the knowledge on how to best care for your equipment can produce a myriad of desirable results –improved reliability of that equipment, improved quality of your production and safety for your workforce to name a few. For chemical processors and all manufacturers the benefits for proactively caring for your equipment can translate in to gains in financial performance as a result of decreasing unexpected breakdowns, downtime and maintenance costs. In this Chemical Processing Special Report we take an in-depth look at how to successfully implement an operator care program focused on caring for your plant’s equipment. We also delve deeply into rotary impingement technology and the benefits it brings to manufacturers tasked with tank cleaning to ensure reliable, uncontaminated, quality batches during production.08/25/2015
High-pressure water jetting is powerful and versatile, helping contractors and industrial companies do hundreds of challenging jobs.
While many jobs are still done manually, new semi-automated systems can maximize three elements crucial to any company’s success: productivity, safety and environmental responsibility.05/12/2015
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
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
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
More than 25% of maintenance done today is unnecessary and can introduce additional failure risks. Developing and implementing predictive maintenance strategies and practices can lead to improved safety and reduced operating costs. In this Chemical Processing eHandbook, we take a look at strategies and solutions for overcoming predictive maintenance challenges including:
- Asset management software - identifying the most relevant and accurate data on which to build maintenance and repair strategies
- The importance of maintenance on smaller component - using gauges as early warning devices can improve uptime, safety and profits
- Uncovering important insights from your data and the use of statistics such as regression analysis for emulating pump curves or control valves
Download your copy of this Chemical Processing Predictive Maintenance eHandbook now.09/26/2014
Corrosion and premature piping failure are two problems that plague chemical piping applications everywhere. Metallic systems are necessarily limited in their life spans by corrosion concerns, and operations managers must always face the question of when their pipes will eventually need repair or replacement. Polymer piping systems have made great strides across multiple industries in the past few decades, and investigating the benefits that can be realized by making the switch from metallic systems can help to bring unexpected value to many applications.
This paper will specifically evaluate the benefits of polymer piping systems in three industries: power generation, chemical processing, and mineral processing.09/22/2014
During industrial manufacturing, many companies use a wide variety of chemicals from methanol, acetone and benzene to foodstuffs like wine and edible oils stored in large tanks at different points in the manufacturing process. In a technique called “chemical tank blanketing,” or “padding” nitrogen is commonly applied to protect chemicals stored in tanks against contamination, degradation or chemical change as well as to prevent fire or explosions. This white paper first discusses blanketing basics and benefits. It reviews considerations for tank blanketing systems and discusses a newer approach, which is typically more cost effective for most applications, is that of generating nitrogen on-demand in the plant itself.09/12/2014
Corrosion, leak detection and mitigation, flow pressure and volume are all factors that maintenance managers and other decision makers need to contend with as they manage flow at their chemical processing plants. In this Chemical Processing Flow eHandbook, we delve in to solutions and strategies for managing these challenges including:
- Leak management - treat them as calls for action against the underlying problem
- VFDs for centrifugal pumps - such drives may provide energy savings and avoid operating problems
- Dealing with corrosion - piping made of high-performance plastic provides unmatched performance and longevity
- Ceramic in electromagnetic flow meters - material used for measuring tubes offers high performance, longevity and a host of other benefits
Learn more about these best flow practices. Download your copy of this Chemical Processing Flow eHandbook now.04/16/2014
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
Medium voltage variable frequency drives (VFDs) are often the best choice to capitalize on opportunities to significantly reduce the operating and maintenance costs associated with relatively large rotating equipment. Even a seemingly modest energy savings of a few percent of the operating load can translate into significant energy savings. In this special report we take a look at how to make the most of VFDs: how optimum performance depends upon proper installation and control; how controlling the speed of VFDs can help eliminate waste and promote efficiency, reliability and quality and; considerations for changing drive speed over pumps. Download now.03/25/2014
Tank cleaning has always been viewed as a necessary evil for manufacturers. During the cleaning process, a significant amount of resources (time, chemicals, water, electric and labor) is required between batches to ensure a reliable, uncontaminated, quality batch is produced. Although these repeating expenditures have a significant effect on the bottom line, many chemical manufacturers continue to rely on outdated processing for cleaning, not realizing the potential opportunity for substantial cost reductions and revenue recovery through CIP optimization.This whitepaper includes specific case studies on the benefits of rotary impingement and CIP optimization vs. the standard tank cleaning processes. These benefits include drastic savings in time and water usage as well as employee safety.11/19/2013
This concise, compelling overview of best practices in purchasing and maintaining ethylene valve packages is an essential read for industry professionals. The white paper will tell you how to: 1) Select the right seats and seals; 2) Select the right coating materials; 3) Know the quality of the valves you're buying; 4) Find a trusted single resource for your valve package purchases; 5) Keep up with required maintenance.10/15/2013
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 accessible09/19/2013
Perhaps the most critical challenge facing the automation industry is that of aging control systems at or near the end of their product lifecycles. A legacy control system can suffer from technical, functional or supply obsolescence. With a well-planned and executed control system migration, however, plants can improve availability and reliability, while increasing production flexibility. In this Chemical Processing Special Report: Making the Most of Migration, we take a look at: Obsolescence planning – addressing concerns and planning for a successful evolution strategy; Restoration Possibilities – how new tools and innovative methods support and breath new life into aging distributed control systems; DCS Migration; More! Download your copy of this Chemical Processing Special Report: Making the Most of Migration now!08/27/2013
This expert whitepaper, sponsored by Infor, discusses market “verticalization” and its importance when selecting an Enterprise Asset Management / Computerized Maintenance Management System.08/12/2013
Automated water jetting removes hardened deposits from tanks and reactors quickly and thoroughly, saving hours of downtime and getting tanks back into service sooner. A new white paper explains high-pressure water jetting, introduces typical equipment, and compares the process with other methods.04/15/2013
White paper provides descriptions and the cleaning efficiency levels of the most commonly used tank cleaning practices, including specific case studies on the cost-saving benefits of rotary impingement tank cleaning and CIP optimization vs. standard tank cleaning processes.08/27/2012
By understanding the key functions and architecture of a process-oriented, formula based ERP application, you will have a better foundation for choosing a solution that best suits your company and type of manufacturing.
This practical guide and checklist ties the unique operations of chemical manufacturers to specific ERP functionality and architecture. Topics include:
- Formula Specifications
- Variability and Quality
- Product Accountability and Costing
- IT Maintenance
Don't settle for a "one size fits all" ERP solution. With the "right fit" ERP solution, you will be able to streamline operations, reduce costs and scale production, while complying with federal regulations -- all with minimum customization.