Plant Operations

Introduction to Pinch Analysis

AIChE Webinar
Apr 27, 2011
This webinar introduces the basic principles and tools of pinch analysis and shows how they can be applied in real-world applications.

Process Troubleshooting

AIChE Webinar
Oct 6, 2010
Professor Woods acts as a coach, guiding you through a process that matches your unique style. His goal is to help you recognize and polish your...

Piping and Instrumentation Drawings

AIChE Webinar
Jul 22, 2009
Piping & Instrumentation Drawings (P&IDs) are important communication tools for engineers. To be effective in the workplace, you must be able...

Process Flow Diagrams

AIChE Webinar
Jul 15, 2009
The webinar will benefit those inside and outside the process engineering community who need familiarity with PFDs as communication tools.

Apply Six Sigma for Process Improvement and Problem-Solving

March
2011
Back To Basics
George Liebermann
Many manufacturing processes are not run as efficiently as they could be. The Six Sigma methodology provides a foundation for continuous improvement and for solving quality, operational, and other problems.

Deflagration and Detonation Flame Arresters

May, 2002
Designed for chemical engineers and other technical personnel involved in the design, operation, and maintenance of facilities and equipment where deflagration and detonation flame arresters (DDFAs) may be required, this book fosters effective application and operation of DDFAs through treatment of...

Avoiding Static Ignition Hazards in Chemical Operations

September, 1999
Written by Laurence Britton, who has over 20 years' experience in the fields of static ignition and process fire and explosion hazards research, this resource addresses an area not extensively covered in process safety standards or literature: understanding and reducing potential hazards associated...

Prevent Pulsation Problems in Piping Systems

March
2006
Fluids and Solids Handling
Mark Corbo
Eliminate unnecessary damage in piping systems by following these guidelines to avoid pulsations from pumps and compressors.

Cost Management in Heat-Transfer-Fluid Systems

July
2006
Heat Transfer
Conrad E. Gamble, P.E.
By taking ownership of fluid-related decisions for the entire life of the project, from design through dismantling, users can secure the best and lowest-cost approach in process heating and cooling.

Easy Ways to Improve Energy Efficiency

December
2012
Operations & Maintenance
Alan Rossiter, Veerasamy Venkatesan
Managing the energy consumption of a process does not need to be complicated. This article presents some examples of less-complicated strategies.

Optimal Automated Process Fault Analysis

January, 2013
With this book as their guide, readers have a powerful new tool for ensuring the safety and reliability of any chemical processing system. It details a tested and proven strategy to develop optimal automated process fault analyzers.

Distillation Troubleshooting

March, 2006
The last half-century of research on distillation has tremendously improved our understanding and design of industrial distillation equipment and systems. High-speed computers have taken over the design, control, and operation of towers. Invention and innovation in tower internals have greatly...

Pipe Flow: A Practical and Comprehensive Guide

May, 2012
Pipe Flow provides the information required to design and analyze the piping systems needed to support a broad range of industrial operations, distribution systems, and power plants.

Troubleshoot and Solve Pneumatic Conveying Problems

June
2010
Fluids and Solids Handling
Eric Maynard, Eric Maynard
Use this scientific approach instead of a costly trial-and-error method to diagnose problems and implement solutions for conveying systems.

Succeed at Process Integration

January
2004
Career Catalyst
Alan Rossiter
In the application of pinch analysis for energy efficiency improvement and process optimization, technical excellence is necessary and human interactions are important for project success.

Make Your Plant More Energy-Efficient

December
2005
Heat Transfer
Alan Rossiter
Improve energy management by optimizing current equipment and operations, implementing economic investments, and engaging in sustaining activities.

Exploring Instrumentation Alternatives

September
2008
Instrumentation
Robert Baker
Salvaged, remanufactured, refurbished or new-surplus equipment may be a cost-effective option. Here's how to recognize when such devices may no longer meet safety or regulatory requirements.

Evaluating Chiller Performance

May
2003
Heat Transfer
Charles Churchman
Use these simple temperature and flow measurement techniques to evaluate chilled-utility performance and identify the most cost-effective upgrades.

Specifying Laser Scanning Services

May
2005
Plant Design
Eric Hoffman
Increasingly, project managers are called upon to employ laser scanning technology. However, little information available to aid with its specification. This article discusses the basics of laser scanning and the parameters that should be included...

Improving Reverse Osmosis Performance

September
2010
Reactions and Separations
Loraine Huchler
Follow these guidelines for monitoring, evaluating, and troubleshooting RO units to ensure reliable and efficient system operation.

Spray Dryers: A Guide to Performance Evaluation, 2nd Edition

August, 2004
Spray Dryers: A Guide to Performance Evaluation, Second Edition discusses the reasons for spray drying. These reasons are usually to produce a product with certain desired properties or with better efficiency than other methods. The book discusses how to plan in light of these objectives and gives...

AIChE Equipment Testing Procedure - Particle Size Classifiers, 2nd Edition

June, 1993
This procedure offers complete methodologies for sampling and measuring particle streams and summarizes methods of particle size analysis. It also lists operating variables to be considered and measured. Although the procedure is intended specifically for particle classification equipment, many of...

The Chemical Industry Phoenix

June
2012
Process Automation Corner
Terry McMahon
Seven years ago, I wrote a column for another publica­ tion entitled “The U.S. Chemical Industry: R.I.P.” This pillar of American economic strength, which a few years earlier was the leading exporter among U.S. manufac­turing sectors (with net exports of $15–20 billion annually), was shriveling due in large part to policy blunders and regula­tory mistakes.

Reduce Dust Explosions the Inherently Safer Way

October
2003
Fluids and Solids Handling
A. G. Dastidar, Faisal I. Khan, P. R. Amyotte
This article is aimed at the development of a framework for dust explosion prevention and mitigation that explicitly incorporates the principles of inherent safety. As distinguished from engineered and procedural safety features, inherent safety...

What’s the Price of Steam?

July
2005
Heat Transfer
Petar Varbanov , Robin Smith
Realistic steam prices are necessary for the efficient operation of a chemical production site, both to allocate realistic costs to the different businesses on the site and to provide a true economic incentive for energy conservation.

Reduce Your Compressed Air Costs

October
2011
Fluids and Solids Handling
Bill Scales, Ron Marshall
Annual operating expenses for compressed air systems can exceed the equipment’s purchase price. Follow these seven steps to implement efficiency measures that yield cost reductions.

Evaluating Cooling Tower Upgrades

May
2008
Heat Transfer
Tom Dendy
When considering improvements to cooling towers, it's important to perform an economic analysis of the options.

Improve Flange Joint Reliability

January
2011
Back To Basics
John Ludman, Mike Emery, Thomas Sandbrook
Proper design, installation, and maintenance of flanged connection systems can prevent loss of containment and process interruptions. Follow this seven-step approach to ensure reliability of this critical process equipment.

Estimate the Capacity of Simple Batch Processes

August
2002
Reactions and Separations
James L. Manganaro
Finding the throughput of a multiple-unit, multiple-step operation, even when it is relatively uncomplicated, is not always an easy matter. Several equations and graphical aids are provided to help determine yearly capacity.

Evaluating and Documenting Tower Performance

February
2010
Reactions and Separations
Daniel R. Summers
A good performance evaluation can lead to a significant improvement in column performance and establish a basis for future tower evaluations. <br>

Air Heater Cleaning Simplified

October
2001
Heat Transfer
Brad Buecker
This high-pressure water washing technique can be used to clean Ljungstrom-type air heaters.

Choose the Right Electric Motors for Hazardous Locations

November
2011
Back To Basics
Uriah Van Amerom
Risks associated with operating an electric motor in hazardous areas range from production downtime to injury and death. Learn how to assess the operating environment and select the appropriate motor.

Propel Your Pneumatic Conveying System to Higher Efficiency

April
2001
Fluids and Solids Handling
Francisco  Cabrejos, Herman  Purutyan, Thomas G. Troxel
For new and existing installations, there are many system and component choices available. Here’s how to narrow down the options to make the appropriate selection for optimal performance.

Steam Trap Troubles?

February
2005
Heat Transfer
Trinath Sahoo
First, prevent problems by selecting the appropriate trap and installing it properly. If problems arise, follow these guidelines for diagnosing and correcting them.

Understanding Steam Traps

February
2011
Back To Basics
James R. Risko
Steam trap failure can affect process operations and reduce profits. Choosing the right steam traps can improve reliability and reduce cost.

Evaluating Dryers for New Services

December
2003
Heat Transfer
Charles G. Moyers
Continuous dryers are accurately and easily evaluated using laboratory-scale simulators combined with the specific drying rate approach.

Preventing Maldistribution in Multi-Pass Trays

April
2010
Reactions and Separations
Henry Z. Kister, Matthew R. Olsson, Richard Dionne, Walter J. Stupin
This method, based on hydraulic equations in the open literature, calculates vapor/liquid distribution in four-pass trays to correctly predict flooding and efficiency.

Follow These Best Practices in Steam System Management

December
2001
Heat Transfer
David  Jaber, Fred L. Hart, Gilbert A. McCoy
These tips on how to improve steam generation, distribution and recovery can help a plant to increase its steam system efficiency by as much as 20-30%.

Rotating Equipment

October
2005
Fluids and Solids Handling
Kazim Akhtar
Protect compressors and turbines by using piping strainers and following the line procedures outlined in this article.

Nitrogen: A Security Blanket for the Chemical Industry

November
2011
Fluids and Solids Handling
Bill Carlson, Joe Dumoit, Paul Yanisko, Shiying Zheng
The benefits of nitrogen blanketing include improved process safety, better product quality, and longer equipment life. Here's how to achieve the desired safety or quality results while minimizing costs.

Properly Clean Out Your Organic Heat-Transfer Fluid System

May
2001
Heat Transfer
Ander  Beain, Jay  Heidari,  Conrad  Gamble
Follow these guidelines for applying side-stream filtration to on-line cleaning, and chemical or mechanical cleaning to equipment that has been drained of fluid.

Beware of Pitfalls of Carbon Dioxide Freezing Prediction

March
2005
Heat Transfer
Steve Chafin , Tim Eggeman
Carbon dioxide freezing in a cryogenic system can result in plugging and other operational problems. This article offers insights into the carbon dioxide freezing phenomenon.

Minimize Mechanical Integrity Budget Battles

February
2011
Safety
Daniel A. Long, P.E., Jack McCavit
Chemical processing and manufacturing plants must ensure the mechanical integrity of their equipment. These strategies and tactics can make doing so easier when budget issues arise.

Hydrogen: Liability or Asset?

September
2002
Reactions and Separations
Dennis Vauk, Ian Moore, Nick  Hallale
In a petroleum refinery, viewing hydrogen as an asset rather than a liability can lead to increased profits. The key is in the mindset. A typical investor uses money to make money. This article shows you how to use hydrogen to make money.

Improving the Reliability of Mechanical Seals

November
2005
Operations And Maintenance
Michael Huebner
With a better understanding of seals, their selection, material considerations, and operation requirements, users can greatly improve equipment reliability and reduce operating costs.

Learn to Effectively Operate and Maintain Pumps

December
2011
Back To Basics
Daniel Kernan
Centrifugal pumps play a central role in chemical processing. Proper pump operation and maintenance can improve a facility's productivity, reduce downtime, and trim costs.

Handling Flammable Liquids

July
2003
Fluids and Solids Handling
James C. Mulligan
Identify electrostatic hazards associated with liquid processing and understand the precautions available to control them.

Rx for Pharma

March
2009
Critical Issues
Girish Malhotra, P.E.
Chemical engineers could hold the key that helps pharmaceutical companies — facing pressure to control rising drug prices and competition from generics — reduce their manufacturing costs.

Improve and Maintain Cooling Tower Efficiency

April
2005
Heat Transfer
James L. Willa
Changing maintenance and/or operating procedures can significantly increase cooling tower performance without major capital expenditures. Here are some tips for ensuring proper design and operation of major tower components.

Don't Get Burned Picking Dry-Type Flame Arresters

October
2002
Fluids and Solids Handling
Stanley G. Grossel
These commonly used devices rely on an internal medium to extinguish flame fronts and take the punch out of shock waves, protecting piping, equipment and personnel. Selecting such equipment involves considering the probable type of combustion,...

Avoid Problems in Process Water Systems

October
2007
Heat Transfer
Marilyn W. Blaschke, Roger D. Metzler
Prevent corrosion, emulsification and fouling by implementing these operational and chemical measures.

Use Oxygen to Improve Combustion and Oxidation

July
2010
Reactions and Separations
Nancy C. Easterbrook, Reed J. Hendershot, Timothy D. Lebrecht
Substituting oxygen for air is often a low-cost, easy-to-implement option that can reduce capital costs, lower emissions, and improve process flexibility and reliability.
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