Process Technology Plant Operations

by Speegle, Michael

• ISBN13: 9781418028633
• ISBN10: 1418028630
• Format: Paperback
• Copyright: 2006-06-08
• Publisher: Delmar Cengage Learning

Summary

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.

Table of Contents

Preface	ix
Process Technology Today	1	(12)
Core Values and Competencies of Today's Workers	2	(1)
Technicians and the Environment	3	(1)
Roles of Today's Process Technicians	3	(5)
Rethinking Process Plant Roles and Responsibilities	8	(1)
The Process Technician as a Shift Worker	8	(5)
Safety I: Process Hazards	13	(14)
Hazards of Pressure	14	(3)
Hazards of Steam	17	(1)
Hazards of Air	18	(1)
Hazards of Light Ends	18	(2)
Hazards of Water	20	(1)
Hazards of Electrical Shock	20	(7)
Safety II: The Permit System	27	(14)
Hot Work Permit (29 CFR 1910.119)	28	(2)
Control of Hazardous Energy (Lockout/Tagout) 29 CFR 1910.147	30	(2)
Confined Space Standard (29 CFR 1910.146)	32	(2)
Confined Space Entry Program	34	(7)
Quality as a Competitive Tool	41	(10)
What Is Quality?	42	(1)
Quality Systems	42	(1)
Continuous Improvement	43	(1)
Important Quality Concepts	43	(3)
Strive to Increase Understanding	46	(1)
Get Involved in Quality	47	(1)
Control Charts for Quality	47	(2)
Quality Is a Function of the Process	49	(2)
Process Economics	51	(14)
The Productive Process Technician	52	(1)
Fuel Conservation	53	(6)
Steam Isn't Cheap	59	(2)
Avoid Heat Loss	61	(1)
Relief Valve Leaks	62	(1)
Avoid Waste of Utilities	62	(3)
Communication	65	(20)
The Elements of Good Communication	66	(1)
Communication Methods for the Process Technician	67	(3)
Important Process Unit Documents	70	(3)
Management of Change	73	(1)
Writing Operating Procedures	73	(5)
Procedure Validation	78	(7)
Process Physics	85	(14)
Heat Measurement and British Thermal Units	86	(1)
Vapor Pressure	87	(2)
Steam and Heat Energy	89	(1)
Specific Heat	90	(2)
Thermal Properties of Substances	92	(1)
Linear Expansion	93	(1)
Volume Expansion	94	(5)
Process Samples	99	(14)
Unit Samples	100	(2)
Sample Schedules	102	(1)
Sample Collection and Technician Health	103	(2)
Types of Samples	105	(1)
Sample Containers	105	(1)
Sampling Methods	106	(2)
Sample Identification	108	(1)
Sampling with Gas Detectors	108	(5)
The Significance of Common Analytical Tests	113	(18)
The Usefulness of Analytical Tests	114	(1)
The Importance of Valid Samples	115	(1)
Test Results for Process Control	116	(1)
Testing for Physical Properties	116	(8)
Testing for Impurities	124	(1)
Appearance Tests	125	(2)
Gas Chromatography	127	(1)
Automated OnLine Analyzers	127	(4)
Routine Unit Duties	131	(16)
The Process Unit and Its Crew	132	(1)
Duties of the Outside Technician (Field Technician)	132	(7)
Duties of the Inside Technician (Board Person)	139	(4)
Health, Safety, and Environmental Issues	143	(1)
Duties of the Lead Technician	143	(4)
Maintenance Duties: I	147	(18)
Equipment Reliability	148	(3)
Lubrication	151	(5)
Moisture---A Destructive Lubricant Contaminant	156	(2)
Lubricating Systems	158	(7)
Maintenance Duties: II	165	(20)
Pumps and Pump Maintenance	166	(2)
Electric Motors	168	(2)
Steam Traps	170	(5)
Packing Gland Adjustment	175	(1)
Unplugging Process Lines	176	(4)
Piping Vibration	180	(5)
Material Handling I: Bulk Liquids	185	(24)
Small Bulk Liquid Material Handling	186	(2)
Large Bulk Material Carriers	188	(5)
Material Handling Techniques for Bulk Liquids	193	(3)
Overview of Loading a Tank Truck	196	(1)
Overview of Unloading a Tank Truck Using Pressurized Nitrogen	197	(1)
Overview of Loading a Railcar	198	(3)
Pre-Transfer and Post-Transfer Inspections	201	(1)
Loading and Unloading Tank Trucks and Railcars	202	(7)
Material Handling II: Bulk Solids	209	(22)
Portable Containers	210	(4)
Material Handling of Bulk Solids	214	(1)
Material Handling Equipment	215	(4)
Mechanical Conveying	219	(3)
Hydraulic Conveying	222	(1)
Pneumatic Conveying	222	(3)
Technician Checks for Conveying Systems	225	(1)
Weighing and Metering Bulk Solids	225	(1)
Bagging Operations	226	(5)
Material Handling III: Oil Movement and Storage	231	(20)
Tankage	232	(3)
Tank Gauging	235	(4)
Tank Farm Technician Responsibilities	239	(12)
Process Unit Shutdown	251	(18)
Hazards of Unit Shutdown	253	(1)
Normal Shutdown Process Planning	254	(2)
General Outline for Unit Shutdown	256	(1)
De-Inventory and Equipment Shutdown	257	(1)
Unit Clear Up	257	(1)
Clearing Process Equipment by Purging	258	(6)
Blinding, Opening and Gas Testing for Entry	264	(5)
Process Unit Turnaround	269	(18)
Process Unit Turnarounds	270	(2)
Goals and Objectives	272	(1)
Turnaround Justification	272	(3)
Turnaround Planning	275	(2)
Activities During Turnaround	277	(2)
Safety Concerns During the Turnaround	279	(3)
Piping and Equipment Inspection	282	(1)
Quality of Repair Work	282	(1)
Pre-Startup Activities	283	(1)
Evaluation of the Turnaround	283	(4)
Process Unit Startup	287	(20)
Pre-startup Evaluation of Newly Constructed or Modified Process Units	289	(1)
Process Unit Startup	289	(2)
Turnover and Inspection of Equipment	291	(1)
Commissioning Auxiliary and Utility Equipment and Services	292	(5)
Elimination of Air and Water in Vessels and Piping	297	(2)
Inspection of Piping and Equipment Supports	299	(1)
Blind Removal	300	(1)
Safe Fluid Dynamic Testing of Equipment	300	(1)
Pressure Tightness Test	301	(1)
Turnaround Waste Disposal	301	(1)
Introducing Feedstock to the Unit	302	(1)
Introducing Process Materials	302	(2)
Bringing the Unit Online	304	(1)
Post-startup Review	304	(3)
Abnormal Situations	307	(14)
Control Systems and Abnormal Situations	308	(1)
Types of Abnormal Situations	309	(1)
Keep Running or Shut Down?	310	(1)
Responding to Emergencies	311	(1)
Responding to Specific Abnormal Situations	312	(6)
Weather-Related Abnormal Situations	318	(3)
Process Troubleshooting	321	(14)
Troubleshooting and Interpersonal Skills	323	(1)
Troubleshooting in the Process Industry	323	(1)
Computerized Process Control	324	(2)
Basic Troubleshooting Tools	326	(1)
The Five Phases of Troubleshooting	327	(1)
A Systematic Approach to Problem Solving	327	(8)
Glossary	335	(22)
Bibliography	357	(2)
Index	359