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
The nature of batch operations poses unique problems. Ensuring reagent chemicals are added at the optimal time so as not to cause a temperature change is crucial. Additionally, there are several questions you must ask in order to properly bridge your batch operations and continuous ones. Topping it all off, you must improve energy efficiency.
To help you do a whiz-bang job on your batch processing, Chemical Processing has put together an eHandbook. It includes insight on:
- Quickly Estimate Reagent Addition Time -- A simple equation suffices in many situations involving batch reactors.
- Bridge Batch And Continuous Operations Better -- Developing an accurate timeline can lead to important insights.
- Improve Energy Efficiency Of Batch Processes -- Such processes often offer substantial opportunities for savings.
The purpose of a reliability program is to ensure that a plant’s physical assets can meet production goals at the lowest possible unit cost while mitigating safety and environmental risks. Such a program requires ongoing assessment, testing and performance reporting. It should become embedded into the culture of the plant as just “part of the way work is done.”
To help make reliability attainable, Chemical Processing has put together an eHandbook. It includes insight on:
- Successfully Implement a Reliability Program -- Avoid eight common pitfalls that can lead to failure
- Make Your Improvement Program Endure -- Decline is inevitable unless you address plant culture issues
- Establish Equipment Wellness -- Achieve longevity and reduced costs with an asset management plan for fluid sealing systems
ISO 9001:2015 is a new version of ISO 9001, replacing the 2008 version. Organizations have a 3 year transition period to adopt the changes, with a deadline of September 2018. This white paper will be relevant for managers from any organization who follow ISO 9001 and use any type of weighing devices or processes in the course of their business.
This white paper aims to:
Explain the changes in the revised standard of ISO 9001:2015 and describe the timeline associated with transition to the new version.
Look at the effect of these changes on weighing devices and weighing processes, as weight measurements are a critical process step which can significantly affect quality.
Provide guidance and recommendations on how to consider weighing devices in order to meet the process requirements and risk-based thinking approach outlined in the revised version of ISO 9001.
Introduce the firmly established Good Weighing Practice™ strategy which fully supports the risk-based process approach and explain how this already complies with ISO 9001:2015 and can be easily implemented into a Quality Management System.09/11/2017
Reactor cleaning is an often-overlooked area to tap into efficiency. The advantages of water jetting are multiplied by automation, which makes cleaning completely hands-free.
This report sponsored by NLB takes a look at how these systems not only allow companies to maintain (and improve) high levels of productivity and safety — but help them keep up with changing market demands. Download this NLB Special Report for insights and strategies including:
- Assess Heat Exchanger Performance -- A proper evaluation can determine whether a shutdown is needed
- Clean Reactors With Water Jets -- Automated high-pressure water jet systems provide efficient, hands-free operation to help maintain and improve productivity and safety.
This Chemical Processing eHandbook examines some of today’s Refining challenges and solutions for chemical manufacturers.
Download this Chemical Processing eHandbook for insights and solutions including:
- Optimize Energy Costs in Petroleum Refineries: Improve refining margins with more energy efficient measures
- Understand the Changes in API RP 754: The second edition of this standard on process safety performance indicators contains some important revisions
- Head Off Hydrogen Hazards: Proper material selection and piping design are crucial
Refineries in the US alone spent a staggering 2.5 billion dollars on fuel consumption from natural gas in 2010. Fired heaters are the largest energy consumer in the manufacturing sector, and represent a tremendous opportunity for energy savings.
However, energy efficiency is not the only concern for fired heaters. Compliance and safety are continuous challenges.
In this eBook, Yokogawa explains how to improve fired heaters safety & efficiency by controlling combustion using TDLS technology. Download it now and learn:
- The 4 top industry challenges related to fired heaters
- How to efficiently and safely manage combustion
- How TDLS technology can improve operational excellence in fired heaters
The right handheld gives technicians more flexibility in both the field and the workshop, helping them to save time and feel more confident about the device repairs and configurations performed on a day-to-day basis. With Power the Loop technology in the AMS Trex communicator, technicians have more power than ever at their fingertips. Download the whitepaper to see how Power the Loop impacts three key areas of daily operation.03/21/2017
Industrial vessels of various types are used extensively in the processing of chemicals, petrochemicals, and pharmaceuticals. Applications commonly involve storage or process tanks, drums, blenders, reactors, kettles, mixers, fermenters or shipping containers. In addition, reusable totes and intermediate bulk containers (IBCs) provide for convenient and cost-effective storage and transport. The cleaning of this essential equipment, however, has long been a challenge.
In this Chemical Processing special report learn more about:
How modern impingement cleaning technologies improve safety and sustainability
How one chemical company profits from faster cleaning turnarounds and fully clean totes
Salt water, sour gas and other corrosives play havoc with metallic instruments and vessels. However, the use of correct materials can prevent failures and resulting damage. So where can you find guidance as to how to select the right metals? The National Association of Chemical Engineers (NACE International) sets standards "To protect people, assets and the environment from corrosion". Learn more about NACE and their processes by viewing this paper.05/24/2016
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