Practical Guidelines for the Chemical Industry: Operation, Processes, and Sustainability in Modern Facilities

Preface
Who Can Benefit from This Book?
Sources of Our Information
Acknowledgements
Contents
About the Authors
Chapter 1: Management Functions
1.1 Introduction
1.2 Successful Managements
1.3 Arranging Funds for Various Activities (While Minimising Capital Requirement)
1.4 Market Survey
1.5 Process Selection
1.6 Selection of a Proven Technology
1.7 Procurement of Plant Units, Machinery, and Their Installation
1.8 Manpower Planning
1.9 Arranging Site Infrastructure
1.10 Erection and Commissioning
1.11 Utilities Planning
1.12 Water Budgeting
1.13 During Regular Operations of the Process Plant
1.14 Maintenance of Process Units and Machinery
1.15 Aims for Research and Development
References/for Further Reading
Chapter 2: Hazid, Hazop, and Ensuring Safety
2.1 Introduction
2.2 Hazard Analysis: HAZAN
2.3 Check Points for HAZAN Study
2.4 Classification of Hazards
2.5 HAZID: Hazards Identification
2.6 Identification of Hazards by Critical Examination of
2.7 Check List for Prevention of Dangerous Situations
2.8 Ensuring Safety in Plant
2.9 HAZOP (Hazard and Operability) Study
2.9.1 When Should HAZOP Study Be Carried Out?
2.9.2 After Starting Operations (and Running the Plant for a Few Days/Weeks)
2.9.3 Steps for Carrying Out HAZOP Study
2.9.4 Suggested Procedure
References/for Further Reading
Chapter 3: Materials of Construction
3.1 Introduction
3.2 Basis for Selection of Material of Construction in Process Industries
3.3 Common Materials of Construction Used in Process Industries
3.3.1 Ferrous Metals
3.3.1.1 Properties of Steel Are Improved by Alloying with Elements Such As
3.3.1.2 Composition, Properties, and Application of Ferrous Materials
3.3.2 Stainless Steels
3.3.3 Non-ferrous Metals
3.3.4 Non-metals
3.4 Materials of Construction for Extreme Services
3.4.1 Materials of Construction for High Temperature Service
3.4.2 Materials of Construction for Low Temperature Service
3.5 Corrosion
3.5.1 Harmful Effects of Corrosion
3.5.2 Types of Corrosion
3.5.3 Methods for Corrosion Control
3.5.3.1 Cathodic Protection (CP)
3.5.3.2 Anodic Protection
3.5.3.3 Corrosion Inhibitors
3.5.3.4 Protective Linings for Equipment Shells
3.5.3.5 Cladding
3.5.3.6 Hot-Dip Galvanization
3.5.3.7 Corrosion-Resistant Coatings
3.5.3.8 Corrosion-Resistant Paints
3.6 External Insulation Material
3.6.1 Design of the Thermal Insulation
3.6.2 Factors for the Selection of Insulation Material
3.6.3 Various Insulation Materials
References/for Further Reading
Chapter 4: Pressure Vessels
4.1 Introduction
4.2 Classification of Pressure Vessels
4.3 Important Considerations for Design and Selection of Pressure Vessels
4.4 Design of Pressure Vessels
4.4.1 Pressure Vessel Codes and Standards
4.4.1.1 ASME Boiler and Pressure Vessel Code (BPVC)
4.4.2 Significance of Internal Pressure, External Pressure, and Design Pressure
4.4.3 Significance of Design Temperature
4.4.4 Heads of Vessels
4.5 Selection of Material of Construction
4.6 Corrosion Allowance
4.7 Inspection Guidelines
4.7.1 Inspections during Visit to Fabrication Shop
4.7.2 Visual Test (VT)
4.7.3 Radiographic Test
4.7.4 Pressure Tests
4.7.4.1 Hydrostatic Tests
4.7.4.2 Pneumatic Tests
4.8 Stress Relieving by Post Weld Heat Treatment (PWHT)
4.9 Documentation
4.10 Pre-commissioning Checks
4.11 Operation of Pressure Vessels
4.12 Precautions
4.13 Maintenance of Pressure Vessels
4.14 Special Equipment
4.14.1 Spherical Storages
4.14.2 Gas Cylinders
4.15 Protective Devices
4.15.1 Pressure Relief Valves and Safety Devices
4.15.2 Other Pressure Release Systems
4.15.3 Safety Valves Provided by Vendor of Pressure Vessel
4.15.4 Additional Precautions
References/for Further Reading
Chapter 5: Piping Design and Pumping Systems
5.1 Introduction
5.2 Factors to Be Considered for Piping Design
5.3 Codes for Piping
5.4 Pipe Size
5.5 Pipe Fittings
5.6 Valves
5.6.1 Mode of Operation
5.6.2 Functions of Valve
5.6.3 Classification of Valves
5.6.4 Types of Valves and Their Applications
5.6.5 Material of Construction of Valves
5.6.6 End Connections for Valves
5.6.7 Basis for Selection of Valves
5.6.8 Valve Characteristics
5.7 Pipe Joints
5.8 Colour Coding for Piping
5.9 Important Terminology to Be Provided with Piping and Instrumentation Diagram
5.10 Piping Stresses
5.11 Underground Piping
5.12 Piping Layout
5.13 Pressure Drop in Pipelines
5.14 Material of Construction for Pipes
5.15 Pumping System
5.15.1 Classification of Pumps
5.15.2 Pump Selection
5.15.2.1 Positive Displacement Pumps
5.15.2.2 Rotodynamic Pump
5.15.3 Different Types of Heads in Pumping Calculations
5.16 Fans and Blowers
5.16.1 Guidelines for Installation/Erection and Commissioning
5.16.2 Positive Displacement Type Blowers
5.16.3 Reciprocating Compressor
5.16.4 Screw Compressor
References/for Further Reading
Chapter 6: Cooling and Heating Systems
6.1 Introduction
6.2 Practical Considerations for Cooling Systems
6.3 Spray Ponds for Cooling Water
6.4 Cooling Towers
6.4.1 Observations During Operation
6.4.2 Maintenance of Cooling Towers
6.4.3 Fill Material and Supporting Wooden Flats
6.5 Conventional Refrigeration Plants
6.5.1 Some Typical Components Are
6.5.2 Observations to Be Made for Safe and Smooth Working
6.5.3 Safety Valves
6.5.4 Safety Trips/Interconnection
6.5.5 Some Typical Precautions for Maintenance Work
6.5.6 Additional Safety Precautions
6.6 Vapour Absorption Chiller (Fig. 6.1)
6.6.1 Check Points for Proper Working
6.7 Heating Systems
6.7.1 Considerations for Heating Duty
6.7.2 Physical and Chemical Properties of the Heating Medium/Fuels
6.7.3 System Design Criteria
6.7.4 Practical Guidelines for Heating Systems
6.7.5 Air Pollution Control Equipment
6.7.6 Storage and Handling Arrangements
6.7.7 Manpower Required
References/for Further Reading
Chapter 7: Cogeneration of Steam and Power, Steam Traps, and Heat Exchangers
7.1 Introduction
7.2 Generation of Steam
7.3 Precautions During Steam Generation
7.4 Simultaneous Generation of Power and Steam for Heating
7.4.1 Steam Super-Heater
7.5 Steam Traps
7.5.1 Inverted Bucket Type
7.5.2 Float Type
7.5.3 Trap Selection for Operation with Superheated Steam
7.5.4 Thermostatic Traps
7.5.5 Thermodynamic Traps
7.5.6 Steam Trap Selection for Heating Duties
7.5.6.1 For Steam Distribution Piping
7.5.6.2 For Steam-Heated Equipment
7.5.6.3 For Steam-Driven Equipment
7.5.7 Testing of Steam Traps
7.5.8 Generation of Condensate Loads
7.5.9 Some Typical Reasons for Steam Traps Not Working
7.6 Heat Exchangers
7.6.1 Types of Heat Exchangers
7.6.2 Design Considerations
7.6.3 Safety and Convenience
References/for Further Reading
Chapter 8: Process Control and Instrumentation
8.1 Introduction
8.2 Objectives That Can Be Achieved by Instrumentation and Control Are
8.3 Advantages of Process Control
8.4 Some Typical Hardware Required
8.5 Design of Sampling Systems
8.6 Typical Problems with Hardware
8.7 Preventive Measures for Process Control
8.8 Limitations of Control Systems
8.8.1 Hovering of Values of Process Parameter
8.8.2 Typical Examples
8.8.2.1 Examples of Feedback Control
8.8.2.2 Examples of Feed Forward Control
8.8.3 Practical Guidelines for Instruments
References/for Further Reading
Chapter 9: Practical Considerations and Guidelines for Project Managers, Plant Managers and Plant Engineers
9.1 Statutory Permissions and Compliances
9.1.1 Statutory Permissions Needed for Pressure Vessels
9.1.2 Statutory Permissions for Storages and Electrical Units
9.1.3 Compliances with Statutory Requirements
9.1.4 Additional Requirements
9.2 Purchase Orders for a New Process Plant
9.2.1 Introduction
9.2.2 Purchase Order (PO)
9.2.3 Typical Terms and Conditions of Performance Guarantee Test
9.2.4 Scope of Supply by Vendor Should Include
9.2.5 Commercial Terms
9.2.6 Purchasing a New (Major) Equipment
9.2.7 Relocating a Plant
9.2.8 Typical Criteria for Such Decision
9.2.9 Preliminary Assessment
9.2.10 Check Points
9.2.11 Estimate Expenses Required for
9.3 Expansion of Capacity of Existing Plant
9.3.1 Practical Guidelines for Capacity Expansion
9.3.2 Augment Existing Process Units and Machinery for Plant Expansion
9.3.3 Revival of an Old/Idle Plant at Present Location
9.3.3.1 Decontaminate
9.3.3.2 Servicing and Repairs
9.3.3.3 General
9.4 Modernisation of an Existing Plant
9.4.1 Situations Which Indicate Need for Modernisation
9.4.2 Situations Which Indicate Need for Revamping
9.4.3 Study of the Past Plant Performance
9.4.4 Cost of Controlling Environmental Pollution
9.4.5 Study of Undesirable Incidents
9.4.6 Comparisons of Plant Performance
9.4.7 Important Aims of the Organisation
9.4.8 Differences in Assessments
9.4.9 General
9.4.10 Modification of the Production Plant and Infrastructure
9.4.11 Introducing Changes
9.4.12 Implementation and Monitoring
9.4.13 A Typical Practical Situation: Modernisation of the Existing Chemical Plant
9.4.14 Minimising the Investment: By Examination of Facilities in the Following Order
9.4.15 Diversification to New Products
9.4.16 General Considerations
9.5 Safe and Pollution-Free Start-Ups
9.5.1 Safe Start-Ups
9.5.2 Preventive Measures
9.5.3 Pollution-Free Start-Up
9.6 Managing Human Resources
9.6.1 Activities and Jobs
9.6.2 Matters to Be Looked into While Hiring Persons
9.6.2.1 Qualifications and Experience
9.6.2.2 Physical Fitness for Working
9.6.2.3 Alertness While Working in the Plant
9.6.2.4 Working Conditions for Efficient Operation
9.6.2.5 Remuneration and Other Facilities
9.6.2.6 Safety and Training, Refresher Courses
9.6.2.7 Incentives Can Be Given for Efficient Working
9.6.2.8 Quality Circles
9.6.2.9 Disciplinary Action
9.6.3 Provision of Protective Equipment
9.6.4 Span of Control
9.7 Engagement of Contractual Services
9.7.1 Examples
9.7.2 Special Requirements
9.7.3 Differences Arising During Contractual Work
9.8 Guidelines for the Project Engineers, Plant Engineers, and Maintenance Engineers
9.8.1 Guidelines for Project Manager
9.8.2 Examples
9.8.3 Other Guidelines
9.8.4 Guidelines for Plant Manager
9.8.5 Guidelines for Plant Engineers on the Shop Floor
9.8.5.1 Some Typical Examples of Process Systems
9.8.6 Standard Operating Procedures for Process Workers
9.8.7 Guidelines for Maintenance Engineers
9.8.7.1 Standard Safety Procedures for Maintenance Workers
9.8.7.2 Important Activities by Maintenance Engineers
9.8.7.3 Situations When the Annual Shutdown May Be Postponed
9.8.7.4 Guidelines for Advancing the Shutdown Before the Due Date
9.8.7.5 Safety Steps for Maintenance Work on a Process Unit or Plant Equipment
9.9 Suggestions for Reducing Breakdowns
9.9.1 At Design Stage
9.9.2 During Procurement
9.9.3 During Erection
9.9.4 During Testing of Process Units and Mechanical Trials of Machinery
9.9.5 Before and During Commissioning Runs
9.9.6 Check and Confirm
9.10 Reducing Cost of Production
9.10.1 Procurement of Raw Materials
9.10.2 Optimum Design, Operation, and Maintenance of Process Units and Machinery
9.10.3 Production Planning
9.10.4 Reducing Maintenance Costs
9.10.5 Reducing Cost of Inventory of Process Spares
9.10.6 Cost of Sudden Shutdown
9.11 Environmental Pollution Control
9.11.1 Solid Waste
9.11.2 Effluent Treatment Plant ETP
9.11.2.1 Wastewater Treatment
9.11.2.2 Operation of a Typical Effluent Treatment Plant
9.11.2.3 Monitoring Other System Components
9.11.3 Air Pollution Control System
9.12 Disposal of Dangerous CRIT Wastes
9.12.1 CRIT (Corrosive, Reactive, Inflammable, Toxic) Wastes
9.12.2 Disposal Pathway
9.13 Water Treatment Plant
9.13.1 Following Shall Be Checked Every Shift
9.13.2 General
9.14 Electrical Installations and Equipment
9.14.1 Details of Facilities Which Will Need Power
9.14.2 Electrical Load Details
References/for Further Reading
Appendix A: Material of Construction
Physical Properties of Various Materials of Construction
Appendix B: Pressure Vessels (Table B.1)
Appendix C: Piping and Pumping Systems (Tables C.1, C.2, and C.3)
Piping Sample Calculations
Sample Problem 1
Python Code for Sample Problem 1
Sample Problem 2
Python Code for Sample Problem 2
Appendix D: Cooling and Heating Systems (Figs. D.1and D.2, Tables D.1, D.2, and D.3)
Properties of Fuels
Solid Fuels
Liquid Fuels
Gaseous Fuels 
Conclusion
Index