Process technology plant operations

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Title:

Personal Author:

Speegle, Michael

Publication Information:

Clifton Park, NY : Thomson/Delmar Learning, 2007.

Physical Description:

xi, 368 p. : ill. ; 28 cm.

ISBN:

9781418028633

Subject Term:

Chemical process control -- Technological innovations

Chemical plants -- Technological innovations

Chemical plants -- Safety measures

Available:*

Library	Item Barcode	Call Number	Material Type	Item Category 1	Status
Searching... PSZ JB	30000010148626	TP155.75 S63 2007	Open Access Book	Book	Searching... Unknown
Searching... SPACE Kota Bharu Library	30000010087765	TP155.75 S63 2007	Open Access Book	Book	Searching... Unknown
Searching... SPACE Pulau Pinang Library	30000010087766	TP155.75 S63 2007	Open Access Book	Book	Searching... Unknown

Addressing modern-day process plant operations in an easy-to-understand format, this book reveals the important role technicians play in the function of a business unit. Operator responsibilities and functions are thoroughly examined, from recognizing opportunities that will improve process operations to detecting and removing threats to steady-state operation. Business fundamentals and the importance of quality are systematically explored, as well as the chemistry and physics of process operations. Maintenance duties, material handling, and process troubleshooting techniques round out the comprehensive coverage.

Preface	p. ix
1 Process Technology Today	p. 1
Core Values and Competencies of Today's Workers	p. 2
Technicians and the Environment	p. 3
Roles of Today's Process Technicians	p. 3
Rethinking Process Plant Roles and Responsibilities	p. 8
The Process Technician as a Shift Worker	p. 8
2 Safety I: Process Hazards	p. 13
Hazards of Pressure	p. 14
Hazards of Steam	p. 17
Hazards of Air	p. 18
Hazards of Light Ends	p. 18
Hazards of Water	p. 20
Hazards of Electrical Shock	p. 20
3 Safety II: The Permit System	p. 27
Hot Work Permit (29 CFR 1910.119)	p. 28
Control of Hazardous Energy (Lockout/Tagout) 29 CFR 1910.147	p. 30
Confined Space Standard (29 CFR 1910.146)	p. 32
Confined Space Entry Program	p. 34
4 Quality as a Competitive Tool	p. 41
What Is Quality?	p. 42
Quality Systems	p. 42
Continuous Improvement	p. 43
Important Quality Concepts	p. 43
Strive to Increase Understanding	p. 46
Get Involved in Quality	p. 47
Control Charts for Quality	p. 47
Quality Is a Function of the Process	p. 49
5 Process Economics	p. 51
The Productive Process Technician	p. 52
Fuel Conservation	p. 53
Steam Isn't Cheap	p. 59
Avoid Heat Loss	p. 61
Relief Valve Leaks	p. 62
Avoid Waste of Utilities	p. 62
6 Communication	p. 65
The Elements of Good Communication	p. 66
Communication Methods for the Process Technician	p. 67
Important Process Unit Documents	p. 70
Management of Change	p. 73
Writing Operating Procedures	p. 73
Procedure Validation	p. 78
7 Process Physics	p. 85
Heat Measurement and British Thermal Units	p. 86
Vapor Pressure	p. 87
Steam and Heat Energy	p. 89
Specific Heat	p. 90
Thermal Properties of Substances	p. 92
Linear Expansion	p. 93
Volume Expansion	p. 94
8 Process Samples	p. 99
Unit Samples	p. 100
Sample Schedules	p. 102
Sample Collection and Technician Health	p. 103
Types of Samples	p. 105
Sample Containers	p. 105
Sampling Methods	p. 106
Sample Identification	p. 108
Sampling with Gas Detectors	p. 108
9 The Significance of Common Analytical Tests	p. 113
The Usefulness of Analytical Tests	p. 114
The Importance of Valid Samples	p. 115
Test Results for Process Control	p. 116
Testing for Physical Properties	p. 116
Testing for Impurities	p. 124
Appearance Tests	p. 125
Gas Chromatography	p. 127
Automated OnLine Analyzers	p. 127
10 Routine Unit Duties	p. 131
The Process Unit and Its Crew	p. 132
Duties of the Outside Technician (Field Technician)	p. 132
Duties of the Inside Technician (Board Person)	p. 139
Health, Safety, and Environmental Issues	p. 143
Duties of the Lead Technician	p. 143
11 Maintenance Duties: I	p. 147
Equipment Reliability	p. 148
Lubrication	p. 151
Moisture-A Destructive Lubricant Contaminant	p. 156
Lubricating Systems	p. 158
12 Maintenance Duties: II	p. 165
Pumps and Pump Maintenance	p. 166
Electric Motors	p. 168
Steam Traps	p. 170
Packing Gland Adjustment	p. 175
Unplugging Process Lines	p. 176
Piping Vibration	p. 180
13 Material Handling I: Bulk Liquids	p. 185
Small Bulk Liquid Material Handling	p. 186
Large Bulk Material Carriers	p. 188
Material Handling Techniques for Bulk Liquids	p. 193
Overview of Loading a Tank Truck	p. 196
Overview of Unloading a Tank Truck Using Pressurized Nitrogen	p. 197
Overview of Loading a Railcar	p. 198
Pre-Transfer and Post-Transfer Inspections	p. 201
Loading and Unloading Tank Trucks and Railcars	p. 202
14 Material Handling II: Bulk Solids	p. 209
Portable Containers	p. 210
Material Handling of Bulk Solids	p. 214
Material Handling Equipment	p. 215
Mechanical Conveying	p. 219
Hydraulic Conveying	p. 222
Pneumatic Conveying	p. 222
Technician Checks for Conveying Systems	p. 225
Weighing and Metering Bulk Solids	p. 225
Bagging Operations	p. 226
15 Material Handling III: Oil Movement and Storage	p. 231
Tankage	p. 232
Tank Gauging	p. 235
Tank Farm Technician Responsibilities	p. 239
16 Process Unit Shutdown	p. 251
Hazards of Unit Shutdown	p. 253
Normal Shutdown Process Planning	p. 254
General Outline for Unit Shutdown	p. 256
De-Inventory and Equipment Shutdown	p. 257
Unit Clear Up	p. 257
Clearing Process Equipment by Purging	p. 258
Blinding, Opening and Gas Testing for Entry	p. 264
17 Process Unit Turnaround	p. 269
Process Unit Turnarounds	p. 270
Goals and Objectives	p. 272
Turnaround Justification	p. 272
Turnaround Planning	p. 275
Activities During Turnaround	p. 277
Safety Concerns During the Turnaround	p. 279
Piping and Equipment Inspection	p. 282
Quality of Repair Work	p. 282
Pre-Startup Activities	p. 283
Evaluation of the Turnaround	p. 283
18 Process Unit Startup	p. 287
Pre-startup Evaluation of Newly Constructed or Modified Process Units	p. 289
Process Unit Startup	p. 289
Turnover and Inspection of Equipment	p. 291
Commissioning Auxiliary and Utility Equipment and Services	p. 292
Elimination of Air and Water in Vessels and Piping	p. 297
Inspection of Piping and Equipment Supports	p. 299
Blind Removal	p. 300
Safe Fluid Dynamic Testing of Equipment	p. 300
Pressure Tightness Test	p. 301
Turnaround Waste Disposal	p. 301
Introducing Feedstock to the Unit	p. 302
Introducing Process Materials	p. 302
Bringing the Unit Online	p. 304
Post-startup Review	p. 304
19 Abnormal Situations	p. 307
Control Systems and Abnormal Situations	p. 308
Types of Abnormal Situations	p. 309
Keep Running or Shut Down?	p. 310
Responding to Emergencies	p. 311
Responding to Specific Abnormal Situations	p. 312
Weather-Related Abnormal Situations	p. 318
20 Process Troubleshooting	p. 321
Troubleshooting and Interpersonal Skills	p. 323
Troubleshooting in the Process Industry	p. 323
Computerized Process Control	p. 324
Basic Troubleshooting Tools	p. 326
The Five Phases of Troubleshooting	p. 327
A Systematic Approach to Problem Solving	p. 327
Glossary	p. 335
Bibliography	p. 357
Index	p. 359

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Table of Contents