Many companies have old DCS platforms. In computing terms, they’re ancient. Considering all that is connected and controlled by the DCS — thousands of field instruments, valves, operator interfaces and other devices working together to make the process run efficiently and reliably, having an ancient platform is flirting with disaster.
The risks are many:
- System failures
- Part availability issues
- Difficulty integrating new apps and systems
- Reduced support availability
- Operation inefficiency
While the headache of migration is sometimes too much to bear, fortunately, the DCS you install today may never have to be completely replaced because its modularity will allow it to be improved incrementally.
This white paper will detail the steps to make proper migration choices and manage the process to get more out of your DCS system.12/19/2018
Combustible dust fire and explosion hazards continue to challenge process safety practices throughout industries that store, handle or use combustible particulate solids.
To help realize sound ideas and solutions to eliminate fire and explosion threats from combustible dusts, Chemical Processing has put together an eHandbook. It includes insight on:
- Take Key Steps Against Combustible Dust Hazards -- Having a sound mechanical integrity program in place is crucial.
- Defuse Dust Dangers -- Carefully consider and then counter risks of fire and explosion.
- Prevent Dust Explosions With Pressurization Systems -- Technology provides safe, economical option for installing electrical equipment in a hazardous location.
The US DOE estimates that 25% of compressed air is lost to leaks— resulting in unnecessarily high operating costs. In many plants the leak losses are much higher. Kaeser’s white paper, “Compressed Air System Leaks: The Cost, Common Culprits, Detection, and Repair” explains how to determine the annual cost per compressed air leak, sheds light on where most leaks occur, and describes best practices for leak detection.12/05/2018
Have you looked around your site for condensate that could be put to good use? Do you know what happens when a partial pressure causes poor performance in ancillary equipment? Do you know if off-standard operations are costing you energy dollars? Unless you can confidently respond yes to all these questions, it’s in your best interest to learn more.
To help you with the answers, Chemical Processing has put together an eHandbook. It includes insight on:
- Energy Saver: Justify Condensate Recovery -- Consider some potential opportunities for achieving energy savings.
- Distillation: Do You Understand Partial Pressures? -- Non-azeotropic mixtures can cause problems in ancillary equipment.
- Energy Hog Restricts Plant Production Rates -- A seemingly minor change causes a major problem.
- Deftly Deal with Distillation Performance -- Several issues contribute to water hammer and leakage of condensate.
From moving materials to managing risks, so many things can go wrong where dust is concerned. Seemingly benign, dusts create an assortment of hazards that include flying particles that can lead to eye injury, slip hazards and ergonomic injuries. The most serious hazards of dust threaten lives and include respiratory ailments and explosion hazards.
To help you preempt powder problems, Chemical Processing has put together an eHandbook. It includes insight on:
- Take a Key Step Against Combustible Dust Hazards -- Having a sound mechanical integrity program in place is crucial.
- Make the Right Moves With Belt Conveyors -- Understand important factors in their selection, design and operation.
- Don’t Blow Your Safety Rating -- Industrial vacuum cleaners should be part of your dust control program.
Reliability improves safety, efficiency, balance sheets and competitiveness. It’s a breeze when things work as they should. It’s only when things go awry that we realize we need to focus on making things steadfast.
To help you with your reliability game, Chemical Processing has put together an eHandbook. It includes insight on:
- Proof Test Prudently -- Understand how to effectively evaluate low-demand safety instrumented functions
- Enhance Your Motors’ Efficiency -- Consider more than just using variable frequency drives
- Safely Use Mobile Devices -- Understanding ignition sources and levels of device protection are crucial to eliminating risk
Today’s manufacturing environments must heed to regulations set by OSHA’s Hazard Communication Standard (HCS) regarding combustible dusts - as part of OSHA’s Combustible Dust National Emphasis Program (NEP). Statistics show that over 1000 inspections that OSHA has completed, only 18 to 22 percent of the facilities followed OSHA requirements.
In response to OSHA’s NEP, many facility and safety managers have revamped their housekeeping practices and added industrial vacuum cleaners approved for use in Class II Div II areas to mitigate the possibility of secondary explosions caused by fugitive dust.
Learn how industrial vacuum cleaners – compressed-air driven portable, continuous duty, and central systems – are the best line of defense in mitigating combustible dust hazards.10/23/2018
For years, single seals were the go-to option for North American refineries and petrochemical companies, but now the industry preference is shifting toward dual seals. Learn about the trends driving dual pressurized seal adoption and how they are helping refineries and petrochemical plants lower emissions, increase safety, improve reliability and reduce costs.10/23/2018
A modern refinery is a highly complex but integrated system, separating as well transforming heavier hydrocarbons into saleable fuels and chemicals. Improving efficiency and avoiding problems is critical, as it directly relates to sending more products to the market.
To help you remain frustration free, Chemical Processing has put together an eHandbook. It includes insight on:
- Simulator Training Extends Its Role -- Chemical makers now seek enterprise-wide and lifecycle opportunities.
- Deftly Deal With Distillation Performance -- Several issues contribute to water hammer and leakage of condensate.
- Grasp The Nuances Of Level Measurement -- The differences in the way devices work can profoundly affect readings.
So many factors can impact flow. Piping issues and hose maintenance are just a few. Indeed, poorly designed suction piping can result in pump damage and even failure. And knowing the right time to replace
hoses in a chemical processing plant is a common concern among many plant managers and maintenance
To help you mitigate flow problems, Chemical Processing has put together an eHandbook. It includes insight on:
- Prevent Suction Piping Problems – Follow best practices when designing pump systems
- Create a Preventive Hose Maintenance Plan – Follow these five steps to determine the best replacement timeline
- Consider Portable Flow Instruments – Some circumstances warrant the use of such devices
Often, due to compression dynamics in multi-staged vacuum-pressure systems there is a mismatch of capacities between the vacuum and compressor pumps (with vacuum pumps having a much larger nominal pumping speed than the compressors).
In this first case study, find out how Busch was able to identify an operational solution utilizing different control instrumentation, as well as design considerations including recycle lines and safety features to enable simple vacuum and pressure operation seamlessly. In the second case study, find out how dry vacuum technology improves operational reliability and eliminates oil costs in phenolic resin production.10/10/2018
The importance of selecting the right process automation technology can far outweigh the cost of an automation investment itself. Selecting the right technology and the right supplier can help your company respond quickly to changing market conditions, ensure long term maintainability, and minimize the Total Cost of Ownership (TCO) over the life of your plant.
The convergence of process automation technologies such as PLC, DCS and SCADA systems have created a situation where it is more challenging than ever for process manufacturers to select the best technology for their application.
Download this white paper and learn:
- DCS vs. PLC vs. Hybrid - 5 Factors to consider
- Who to Include in the Decision Process
- Vendor Selection Criteria- 6 Key Considerations
Not every water optimization program suits every wastewater. Indeed, there are several new technologies to consider as well as strategies to upgrade what’s already in place. Not only will sound programs and technologies improve efficiency, they will aid in sustainability, too.
To help achieve water efficiency, Chemical Processing has put together an eHandbook. It includes insight on:
- Plants Zero in on Wastewater Discharges -- Efforts increase to drastically reduce or even eradicate releases
- Drive Retrofit Improves Water Treatment Plant’s Efficiency -- Compact stand-alone matrix drives replace aging 18-pulse drive
- Oil Recycling Company Presses On -- Pipe press helps speed installation and reduce costs at new oil recycling facility
The need for process safety in the chemical industry is paramount. Technical knowledge and understanding of hazards and risks associated with operations in addition to the implementation of that knowledge into practice are the keys to keeping workers and the environment safe.
To help optimize process safety, Chemical Processing has put together an eHandbook. It includes insight on:
- Successfully Reduce Process Safety Events – Other companies can emulate the approach proven effective for Dow.
- Tackle Combustible Dust Safety Challenges – Indoor collection systems and proper venting help extinguish flames and contain extra-fine particulates.
- Use Asset Management Software To Improve EH&S Programs – Ability to capture events and link documents improves environmental, health and safety efforts.
Some companies think that their problems relate to mixing. In most cases, the difficulties result from not paying enough attention to the process and, sometimes, just from inadequate attention to the details. The results can be disastrous.
To help avoid mishaps, Chemical Processing has put together an eHandbook. It includes insight on:
- Stop Inconsistent Mixing – A range of factors can contribute to erratic performance.
- Get Educated On The Basics Of Particle Size Reduction – Proper methodology depends on solid materials and their properties.
- Consider Agitated Photo Reactors For Industrial Synthesis – Technology can help lower reaction temperatures and reduce byproducts.
- Prepare For Industry 4.0 – Integrated, holistic, smart operations help manufacturers gain a competitive edge.
The demands of sophisticated automated processing systems, the need for ever-tighter process control, and an increasingly stringent regulatory environment drive process engineers to seek more precise and reliable level measurement systems. Improved level measurement accuracy makes it possible to reduce chemical-process variability, resulting in higher product quality, reduced cost, and less waste. Regulations, especially those governing electronic records, set stringent requirements for accuracy, reliability and electronic reporting. The newer level measurement technologies help meet these requirements.08/21/2018
Drying problems, level sensing and explosions – no worries.
Have a drying problem? Consult a drying curve. Need to manage bulk solids? Laser technology brings a number of unique advantages to the table. Worried about dust explosions? Although pneumatic conveying processes are highly effective in transporting chemical products, if an explosion were to occur, the system could be extremely dangerous and pose a threat to personnel and equipment. Learn to mitigate this threat.
To help your powder game, Chemical Processing has put together an eHandbook. It includes insight on:
• Develop Drying Curves -- They can provide insights for solving many problems.
• Consider Laser Level Measurement Technology -- Its characteristics make it ideal for level measurement of bulk solids and liquids in silos, bins and beyond.
• Stop Explosions in Pneumatic Conveying Systems -- Mechanical isolation systems help mitigate explosions and protect equipment from potential damage.08/15/2018
People have been using various devices to measure level since about 3000 BC. The first historical references to a measuring device were dipsticks or staff gauges used to indicate the amount of water stored in reservoirs for farming. Next came crude float-type devices to indicate the height of drinking water reserves in underground cisterns or storage caverns.
Modern instrumentation uses more than 20 different technologies to satisfy the ever-growing requirements for level measurement in a wide variety of applications. Some instruments measure level directly, while others measure some other variable that is related to level.
To help you do your level best, Chemical Processing has put together an eHandbook. It includes insight on:
- Get To The Bottom Of Level Limitations – Positioning the lowest tap for a measurement demands care
- Consider FMCW Radar For Level Measurement – Technology helps plant continuously monitor inventory in dust-prone environment.
- 3D Level Sensors Help Address Storage Challenges – Technology and software advances provide greater visibility into a vessel’s inventory.
Sometimes using a radar sensor for liquid level measurement is child’s play. Sometimes. But not always. This paper covers a few challenging applications that prove through-air radar can reliably measure some of the toughest media and vessels to benefit the user.07/17/2018
Through the years many different vacuum technologies have been used to provide vacuum for chemical and pharmaceutical processes, including steam jet ejector, liquid ring, and rotary vane. Each of these technologies continue to have a place in chemical and pharmaceutical applications, but dry screw technology has become the technology of choice for most applications.07/17/2018