Production Management of Chemical Industries 1st Edition by Kiran Golwalkar 3319282514 9783319282510

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ISBN-10 :  3319282514 

ISBN-13 :  9783319282510

Author:  Kiran R. Golwalkar 

This book covers all major areas of operation, pollution control, safety, modernization, diversification, and resource management for cost control in the industrial production of chemicals. The author details the importance of obtaining the right type of raw materials and equipment for maximum plant efficiency and discusses revival of plants that have been idle for long periods. He also presents important issues concerning product quality, energy recovery, safety, pollution control and improving profitability by proper management of resources. The book is ideal  for shop floor engineers, middle level management, and owners of small- and medium-scale facilities in many countries as it serves as a guide for keeping the plant operations running in adverse situations, for reducing energy consumption; improving profitability, resource allocation, and workforce planning.  

Production Management of Chemical Industries 1st Table of contents:

1 Introduction
1.1 Typical Features of Chemical Industries
1.2 Modern Managements
1.2.1 Important Management Activities for the Chemical Industry
1.2.2 Estimation of Demand for the Products
1.3 Basic Engineering Documents
1.3.1 Rated Capacity
1.4 Detailed Market Survey
1.5 Finalising the Product Mix
1.5.1 Future Product Mix and Product Life Cycle: A Word of Caution
1.5.2 Overloading of Equipments
1.6 Selecting the Process and Technology
1.7 Detailed Engineering Document
1.8 Procurement of Plant Equipments and Machineries
1.9 Creating Infrastructure Facilities
1.10 Financial Arrangements (Cash Flow Planning)
1.11 Organisation of Structure for Industrial Administration
1.11.1 Manpower Planning for Various Departments
1.11.2 Statutory Rules and Regulations
1.11.3 Organisation Resource Planning and Allocation
1.11.3.1 Resource Allocation
1.11.4 Running on Contract
1.11.5 Logistics
1.11.6 Communications
1.12 Technical Matters
1.12.1 Procurement of Raw Materials and Other Items
1.13 Safety Management
1.14 Process Control Laboratory
1.14.1 Quality Control
1.15 Utilities
1.15.1 Energy Efficiency, Cogeneration, and Various Methods of Heating
1.16 Technical and Other Audits
1.17 Pollution Control and Disposal of Wastes
1.18 Water Budgeting
1.19 Electrical Installations
1.20 Maintenance Management
1.20.1 Some Quick-Fix Solutions
1.21 Management of Stores
1.22 Fire Fighting Systems
1.23 Innovation, and Research and Development
1.24 Revival of Old Plants
1.25 Project Division for Expansion and Diversification
1.26 Cost Reduction
2 Financial and Commercial Matters
2.1 Financial Costs
2.2 Cost of Procurement
2.3 Cash Flow Planning for Site Jobs
2.3.1 Testing of Static Equipments
2.3.2 Testing and Mechanical Trial Runs of Moving/Rotating Machineries
2.3.3 Statutory Inspections
2.3.4 Pollution Control Facilities and Waste Disposal Arrangements
2.4 Cash Flow Planning
2.4.1 Typical Start-up Expenses
2.4.2 Sale of Products
2.5 Investment of Own Funds by the Promoters
2.6 Hooking up with Running Plant
2.7 Depreciation
2.8 Government Assistance and Tax Concessions
2.9 Marketing of Products
2.9.1 Production for Export/Prestigious Clients
2.9.2 Selling the Product
2.9.3 Instruction Manuals
2.9.4 Confirmation of Product Quality
2.9.5 Internal Records (For Manufacturer)
2.9.6 Dispatch of Products and Storing at Client’s Site
2.9.6.1 Drop Tests and Stack Tests
2.9.6.2 Seaworthy Containers
2.9.6.3 Storage Precautions
2.9.7 Delivery Schedules
2.9.8 A Word of Caution
2.10 Agreements for Technical Consultancy
2.10.1 General Conditions
2.11 Running the Plant on Contract Basis
2.11.1 Typical Options for External Assistance
2.11.2 Agreement Between the Purchaser and External Party
2.11.3 Important Jobs to Be Done by Purchaser
2.12 Organisational Resource Planning
2.12.1 Fulfilling of All Orders Accepted by the Sales Department
2.12.2 Tracking All Purchase Orders Issued
2.12.3 Manufacturing/Production Operations
2.12.4 Safety Issues
2.12.5 Effluent Treatment
2.12.6 Maintenance
2.12.7 Effect of Weather Conditions
2.12.8 Manpower
2.13 Resource Allocations for Increasing Revenue
2.13.1 Cost of Idle Resources to the Organisation
2.13.2 Some Typical Reasons for Resources Becoming Idle
2.13.3 Remedial Actions
2.13.4 Allocation of Resources
2.13.5 Spare Capacity Available
2.14 Cost Reduction
2.14.1 Factors Contributing to Variable Cost of Production
2.14.2 Some Tips for Reducing Variable Cost
2.15 Total Quality Management (TQM)
2.15.1 Quality and Other Goals
2.15.2 The Key Elements for Successful Implementation of TQM
2.15.3 Suggestion Schemes
3 Procurement of Equipments
3.1 Introduction
3.2 Planning for Procurement
3.2.1 Common Equipments and Machineries
3.3 General Guidelines
3.3.1 Purchaser’s Obligations
3.4 Process Units/Machineries (Present Requirements)
3.5 Units Required in Future
3.6 Selection of Equipments
3.7 Some Miscellaneous Items for Making a Choice
3.7.1 Vertical Submerged Pumps
3.7.2 Refractory Bricks
3.7.3 Caesium-Promoted Catalyst
3.7.4 Heat Exchangers
3.7.5 Pressurised Cooling Water Flow Arrangement
3.7.6 Tangential Spray Scrubbing Towers
3.7.7 Teflon Gaskets
3.7.8 Graphite Electrodes
3.7.9 Shaft Sealing Arrangements
3.7.10 Centrifugal Blower
3.7.11 Water-Tube and Smoke-Tube Boilers
3.7.12 Partition Rings
3.7.13 Demisters
3.7.14 Lower Portion of Towers as Circulation Tanks
3.7.15 Protective Linings for Equipments
3.7.16 Rubber/Fibreglass Reinforced Linings
3.7.17 Poly Tetra Flouro Ethylene (PTFE) Lining
3.7.18 Glass Lining for Equipments
3.7.19 Lead Lining and Lead Bonding
3.7.20 Valves, Flanges, Gaskets, Expansion Bellows, Bolts, and Nuts
4 Erection and Commissioning
4.1 New Process Plant
4.1.1 Future Expansion and Diversification
4.2 Prerequisites for Erection
4.2.1 Site Office Management: Important Activities
4.2.2 Parallel Activities
4.2.3 Site Fabrication of Large Vessels (Storage Tanks, Absorption Towers, Converters)
4.3 Erection
4.4 Precommissioning Checks of Infrastructure
4.5 Items to Be Examined Before Commissioning of Equipments
4.5.1 General Checkpoints Common for All Equipments (Prior to Their Commissioning)
4.5.2 Pumps
4.5.3 Blowers
4.5.4 Electrical Items
4.5.5 Heat Exchangers
4.5.6 Boilers
4.5.6.1 Steam-Heated Units
4.6 Pressure Vessels
4.7 Distillation Units
4.7.1 Condensers
4.8 Refrigeration Systems
4.8.1 Cooling Towers
4.9 Reactor with Agitators
4.10 Water Treatment Plant
4.11 Effluent Treatment Plants
4.11.1 Aeration System
4.12 Melters for Solids
4.13 Calciners
4.14 Pipelines for Liquids and Ducts for Gases
4.15 Dry Compressed Air for Instrumentation
4.16 Precommissioning Checklist for Items: Case Study of a Sulphuric Acid Plant
4.17 Preliminary Checking of Infrastructure: Case Study of a Sulphuric Acid Plant
5 Procurement of Raw Materials and Other Items
5.1 Selection Criteria
5.2 Rate of Consumptions and Inventory
5.3 Acceptance of Items Which Do Not Meet Specifications
5.4 Storage of Raw Materials at Production Unit
5.5 Types of Packing for Procurement
5.5.1 Purchasing by Tankers
5.5.2 Solids/Powders of Special Materials
5.6 Catalysts
5.6.1 Considerations for Purchase of Catalysts from Manufacturer
5.6.2 Fluidised Bed of Catalyst
5.6.3 Process Conditions Leading to Loss of Activity
5.6.4 Initial Cost and Royalty
5.6.5 Handling and Storage
5.6.6 Performance Guarantees
6 Safety Management
6.1 Introduction
6.2 Preliminary Analysis
6.3 Revised Detailed Engineering Document
6.3.1 Process Details
6.3.2 Properties
6.3.3 Procurement
6.3.4 Use of Guide Words
6.4 Equipment Design and Construction
6.5 Process Vessels and Machineries
6.6 Structural Stability of the Chemical Plant
6.7 Design of Plant Layout
6.7.1 Receiving of Raw Materials
6.8 Other Precautions
6.9 Piping and Instrumentation Diagrams
6.10 HAZOP Study
6.10.1 Further Analysis
6.11 Safe Erection and Mechanical Trials
6.11.1 Dispatch from Fabricator’s Works
6.11.2 Unloading at Site
6.11.3 Site Erection
6.11.4 Mechanical Trials
6.12 Safe Commissioning
6.13 Standard Operating Procedures for Safe Working
6.14 Personal Safety Items
6.15 Ensuring Safety After Expansion of Capacity
6.15.1 Plant Expansion
6.15.2 Diversification to New Products
6.16 Safe Maintenance Practices for the Plant
6.16.1 Instructions for Safe Maintenance
6.16.2 Important Safety Precautions to Be Taken Before Working Inside a Closed Vessel
6.17 Some Examples from Industries
6.17.1 Process Vessels with Heating Jackets or Coils
6.17.2 In Case of Vessels with Cooling Jacket
6.17.3 Multiple Safety Devices
6.18 CASE Studies (Please See the Illustrations)
6.18.1 Ammonia-Based Chilled Water Plant
6.18.2 Safety Interconnections for Oil Firing System
6.18.3 Falling Film SO3 Condenser
6.18.4 Typical Unsafe Layout and Design
6.18.5 Improved (Safer) Fittings for a Process Reactor
6.18.5.1 It Is Difficult and Dangerous to Remove the Accumulated Pasty Sludge
6.18.5.2 The Wide Angle Observation Nozzle
6.18.6 Pressurised Cooling System for Shell and Tube Cooler
6.18.7 Cooling System Under Siphon
6.18.8 Precautions for Operation of Boiler
6.19 Safety Valves
6.19.1 Markings on Safety Valves
6.19.2 Malfunctioning of Safety Valves
6.20 Preparing for Some Likely Emergency Situations
6.20.1 Points for Discussions
6.21 Safety Organisation
6.21.1 Members (To Be Decided by Management)
6.21.2 Safety Policies
6.21.3 Design a Work Permit System
6.21.4 Investigations and Corrections
6.21.5 Follow-Up
7 Pollution Control
7.1 Reducing the Generation of Effluents
7.2 Economic Benefits of Pollution Control
7.3 Pre-operational Pollution
7.4 Some Typical Reasons for Environmental Pollution
7.4.1 Incorrect Design of Process Units
7.4.1.1 Fugitive Emissions
7.4.2 Incorrect Operation and Improper Maintenance
7.5 Preventive Actions for Pollution Control
7.5.1 Modify the Process
7.5.2 Use of Better Catalyst
7.5.3 Use Better Equipment
7.5.4 Equipment Design with Adequate Margin for Overload Operation
7.6 Standard Operating Procedures (SOPs)
7.6.1 Confirm the Following Before Starting a Process Plant
7.7 Condition Monitoring and Preventive Maintenance of Key Equipment
7.8 Contribution by Other Departments to Reduce Pollution
7.8.1 Better Selection of Process Equipment
7.8.2 Stage Inspections During Procurement
7.8.3 Procurement of Materials
7.8.3.1 Some More Precautions During Procurement and Storing
7.9 Manpower Planning for Proper Plant Operation
7.10 Electrical Power
7.11 Transportation of Materials
7.11.1 Solids
7.11.2 Liquids
7.11.3 Gases
7.12 Design of Plant Layout
7.13 Communications
7.14 Errors in Sampling Leading to Errors in Process Control
7.15 Standard Input and Output Norms (SIONs)
7.15.1 Disposal of Effluents
7.15.2 Disposal by CETP/CHWTSTD
7.15.3 Disposal of Solid Waste
7.16 Incineration of Solid Wastes
7.16.1 Waste Preparation and Feeding
7.16.2 Considerations for Installing/Procuring an Incineration Plant
7.16.3 General Guidelines for the Construction of Incinerators Stationary Kiln/Rotary
7.16.4 Air Pollution Control System
7.17 Disposal of Liquid Effluents/Wastewaters
7.18 Details to be Submitted by Vendor for the Approval of Plant Engineers
7.18.1 Removal of Sludge
7.19 Lamella Clarifier (an Important Unit in the Effluent Treatment Plant)
7.20 Tube Settler
7.21 Dissolved Air Flotation
7.21.1 Consider for Selection After Examining the Important Components
7.21.2 Disposal of Skimmed Out Wet Solid Material
7.22 Sequential Batch Reactor
7.22.1 Aeration Equipment and Air blowers
7.22.2 Effluent Removal Systems
7.23 Air Pollution Control
7.23.1 Pollution Control System for Gaseous Effluents
7.23.2 Inquiry for Gas Treatment/Scrubbing Systems
7.23.3 Efficiency of Treatment Desired
7.23.4 Cyclone Separators
7.23.5 Bag Filters
7.23.6 Venturi Scrubber
7.23.7 Packed Towers
7.23.8 Jet Scrubber/Ejector Scrubber
7.23.8.1 Spray Tower
7.23.8.2 Tangential Scrubbing Tower
7.23.9 Tower Packing Items
7.23.10 Spray Nozzles
7.23.11 Entrainment Separators and Candle Demisters
7.23.12 General
7.23.13 Electrostatic Precipitators (ESPs)
7.23.13.1 Tubular Precipitators
7.23.13.2 Dry Electrostatic Precipitators ESP
7.23.13.3 Wet Electrostatic Precipitators WESP
7.24 Chimney for Final Discharge
8 Maintenance
8.1 Condition Monitoring of Units and Machines
8.2 Preventive Breakdown Maintenance Programme
8.3 Facilities to Be Available in the Plant
8.4 Inventory of Mechanical/Electrical/Instrument Spares
8.5 Standardisation of Spares
8.6 Advancing the Plant Shutdown
8.7 Postponing the Plant Shutdown
8.8 Cost of Shutdown
8.9 Restarting the Plant After Annual Shutdown
8.10 Case Study: An Annual Shutdown of a Sulphuric Acid–Oleum Plant
9 Utilities
9.1 Waste Heat Recovery Boilers (WHRBs)
9.1.1 Water-Tube Boiler
9.1.2 Smoke-Tube Boiler
9.2 Steaming Economisers
9.2.1 Selection Criteria
9.3 Cogeneration of Power
9.3.1 Planning for Cogeneration
9.3.2 Options Which Shall Be Considered for Buying a Steam Turbine
9.3.2.1 Examples for Cogeneration
9.3.3 Points to Be Included in the enquiries for Steam Turbines
9.4 Steam Superheaters
9.5 Steam De-Superheaters
9.6 Electrical Equipments and Installations
9.6.1 Electrical Power Needed in Initial Phases—Before Start of Plant
9.6.2 Electrical Power Need
9.6.2.1 Running Load
9.6.2.2 Installed Load
9.6.3 Sanctioned Maximum Demand
9.6.4 Emergency Loads
9.6.4.1 Power Required for Other Equipments
9.6.4.2 Maintenance Facilities
9.6.5 In-House Power Generation
9.6.5.1 Excess Power Generated
9.6.5.2 Power Generation Is Less Than the Requirement
9.6.5.3 Gas Engines
9.6.6 Uninterrupted Power Supply for Critical Loads
9.6.7 Compliance with Statutory Rules and Instructions
9.6.8 Electrical Transformers
9.6.9 Electrical Power Distribution in Plant
9.6.10 Electrical Motors
9.6.11 Diesel Generator Set
9.7 Refrigeration Systems
9.7.1 Essential Components
9.7.2 Criteria for Selection/Procurement
9.8 Cooling Towers
9.8.1 Selection Criteria
9.9 Air Drying Plant
9.9.1 Considerations for Procurement
9.10 Nitrogen Plants
9.10.1 Pressure Swing Adsorption PSA Plant
9.10.2 Membrane Process for N2 Gas
9.11 Water Budgeting and Management
9.11.1 Quality of Water Required
9.11.2 Sources of Water
9.11.3 Storage Facilities for Water
9.11.4 Elevated Storage Reservoirs (ESR)
9.11.5 Water Treatment Plants
9.11.5.1 Reverse Osmosis
9.11.6 Specifications of Treated Water
10 Instrumentation
10.1 Introduction
10.2 Main Objectives
10.2.1 For Operating Units
10.2.2 For Safety of Personnel and Plant Equipments
10.2.3 For Pollution Control
10.2.4 For Energy Efficiency
10.2.5 For Ensuring Quality of Products
10.2.6 For Efficiency of Operations
10.3 Types of Instruments for Process Monitoring
10.4 Selection Criteria for Plant Control Instruments
10.5 Installation and Commissioning
10.6 Some Practical Suggestions
10.6.1 Float-Type Level Indicator
10.6.2 Suggestions
10.6.3 Non-functioning of High-Level Alarms
10.7 Ultrasonic Instruments for Level Indication
10.8 Pressure Gauges
10.9 Thermocouple/Dial Thermometer
10.9.1 Watching Carefully
10.10 Rotameters
10.11 Turbine Metres
10.12 Vortex Metre
10.13 Some More Suggestions
10.14 For Feeding Liquids to Small Process Units
10.15 Gas Flowmeter Reading Incorrect
10.15.1 Precaution—Use a Roots-Type Blower with Variable Frequency-Driven Motor
10.16 Some Practical Tips if Thermocouples are Showing Incorrect Temperature Readings
10.17 Gas Leak Detection
10.17.1 A Word of Caution
10.18 Incorrect Readings by Weigh Bridge
10.19 Strength Indicator for Sulphuric Acid (Indicating Low Strength But Actual Strength May Be High
10.20 Stack Gas Analyser for Sulphuric Acid Plant
10.21 Stack Gas Analyser for Absorbed Exit for HCI Gas
10.22 General
10.22.1 Checking Purity of Filtered Liquids
10.23 Feed Control by Centrifugal Pump
10.24 Calibration Test Benches
11 Energy Efficiency
11.1 Thermal Energy
11.1.1 Modifications for Reducing Energy Consumption
11.1.2 Better Heat Exchanger Designs
11.2 Changes in Plant Layout
11.3 General Energy Saving Methods in the Plant Systems
11.4 Reduce Energy Consumption for Material Transfer
11.5 Saving Electrical Energy
11.5.1 Variable-Frequency Drives for Speed Control
11.5.2 Consider for Use
11.5.3 Electrolytic Processes (Examples-Manufacture of NaOH, Aluminium, Electrical Grade Copper, Gol
11.6 Heat Recovery and Cogeneration
11.6.1 Cogeneration of Power Through Waste Heat Recovery Boilers and Economisers
11.6.2 Heat Recovery from Gases
11.6.3 Heat Recovery from Hot Acid
11.7 Efficient Use of Steam
11.7.1 Use for Power Generation
11.7.2 Use as Heating Medium
11.7.3 Selection of Steam Traps
11.7.4 Steam Traps
11.7.5 For Considerations by the Plant Engineers
11.7.6 Some Typical Steam Traps
12 Methods for Heating
12.1 Introduction
12.2 Heating Load and Temperatures Required
12.3 Broad Selection of the Heating Method
12.4 Factors to Be Considered for Selection of Heating Method
12.4.1 Types of Equipment
12.4.2 Types of Processes
12.4.3 Space Availability
12.4.4 Operating Temperatures
12.4.5 Temperature Control Required
12.4.6 Purity of Material to Be Maintained
12.4.7 Availability of the Heating Medium at Site
12.5 Construction of the Equipment
12.6 Minimising the Loss of Heat from Process Units
12.7 Methods for Conservation of Heat/Reducing Requirement of Heat
12.8 Various Methods for Heating
12.8.1 Process Heating by Steam
12.8.2 Considerations for Buying a Coal-Fired Boiler
12.8.3 Electrical Heating
12.8.4 Heating Directly by Flue Gases
12.8.5 Heating by Hot Process Gases
12.9 Factors to Be Considered for Selection of Fuel
12.10 Accessories/Site Facilities Required for Using Various Fuels
12.10.1 Gaseous Fuels
12.10.1.1 Features of Gaseous Fuels
12.10.1.2 Accessories Required When Gaseous Fuels Are Used
12.10.1.3 Necessary Safety Precautions
12.10.2 Liquid Fuels
12.10.2.1 Features of Liquid Fuels
12.10.2.2 Arrangements and Accessories Required for Liquid Fuels
12.10.3 Use of Solid Fuels
12.10.3.1 Features of Solid Fuels
12.10.3.2 Site Infrastructure Required
12.10.4 Industrial Waste
12.11 Combustion Air for Firing Systems
12.12 Safety Devices to Be Regularly Checked by Senior Engineers
12.13 Heat Transfer Oils (Thermic Fluids)
13 Inventory Control
13.1 Introduction
13.2 Record of Past Consumptions
13.3 Use of Guide Words
13.3.1 Simplify
13.3.2 Substitute
13.3.3 Strengthen
13.3.4 Safety Features
13.3.5 Standardise
13.4 Stocks for Emergency Use/Repairs
13.5 Suggestions
13.5.1 Minimum Stock Level to be Maintained
13.5.2 Reorder Point
13.5.3 Minimise the Time Required for Procurement
13.6 General Considerations
13.7 Supply Chain Management
13.7.1 Coordination
13.7.2 Example
13.8 Planning and Management of Supply
13.8.1 The Purchase Department
13.8.2 Production Department
13.8.3 Logistics
13.8.4 Make or Buy
13.8.4.1 Making In-house
13.8.4.2 Buying from Outside
13.8.5 Outsourcing
13.9 Performance Measurement
13.10 Warehousing Management
13.11 Just-In-Time (JIT)
13.12 Reverse Supply Chain
13.13 Some Suggestions Which May Be Useful
13.14 Improve the Equipment Designs/Operating Methods
13.15 FIFO—First In First Out
13.16 LIFO—Last In First Out
13.17 LILO—Last In Last Out
14 General Administration
14.1 Communications
14.1.1 Internal
14.1.2 External
14.1.3 From Superiors (Seniors) to Subordinates (Juniors)
14.1.4 From Subordinates (Juniors) to Superiors (Seniors)
14.1.5 InterDepartment (Sideways Communication)
14.2 General
14.3 Advantages of Good Communication Practice
14.3.1 To Take Care
14.3.2 To Avoid
14.4 Example of a Standard Operating Practice
14.5 Fire Fighting
14.6 Logistics
14.7 Compliance with Statutory Matters
14.7.1 Technical
14.7.1.1 Plant Layout and Structural Stability
14.7.1.2 Electrical Items Generally Covered Under Laws and Subject to Inspection
14.7.1.3 Pressure Vessels
14.7.1.4 Boilers, Economiser, and Steam SuperHeaters
14.7.1.5 Pollution Control
14.7.2 Inspection of Transport Vehicles
14.7.3 Legal and Commercial Matters
14.7.4 Operating Licences and Labour Laws
15 Process Control, Product Quality, and Research and Development
15.1 Laboratory Facilities
15.1.1 Investment in Laboratory Apparatus/Equipments
15.2 Product Quality
15.2.1 Visits to Clients’ Work
15.2.2 Factors for Ensuring Proper Quality
15.2.2.1 Process and Equipment Designs
15.2.2.2 Materials of Construction
15.2.2.3 Design of Plant Layout
15.2.2.4 Raw Material Quality
15.2.2.5 Additives
15.3 Process Control
15.3.1 Some General Checks
15.3.2 Supervision of Plant Operations
15.3.3 Selection of Sample Size for Examination of Produced Items
15.3.4 Shelf Life of Items
15.3.5 Confidence Level Required
15.3.6 Sampling Errors
15.4 Material of Construction of Vessels and Containers
15.5 Innovation, Research and Development
15.5.1 Aims of the Activities for Research and Development
16 Smooth Running of the Production Plants
16.1 Process for Manufacture of Sulphuric Acid
16.2 Batch Process for Manufacture of Papermaker’s Alum (Iron Free)
16.3 Process for Manufacture of Alum from Bauxite
16.4 Process for Manufacture of Single Superphosphate
16.5 Process for Manufacture of Caustic Soda and Chlorine
16.6 Process for Manufacture of Nitric Acid by Oxidation of Ammonia
16.7 Steam Generation by Coal-Fired Boiler
16.8 Some Useful Formats for the Production Managers
16.8.1 Production Record of a Plant
16.8.2 Record of Consumption of Raw Materials
16.8.3 Record of Expenses Incurred on Maintenance of the Plant
16.8.4 Record of Raw Material Stock Position
16.8.5 Record of Sale of Products
16.8.6 Rejected and Returned Products
16.8.7 Record of Stores Inventory
17 Identifications of Hazards: Some Practical Examples
17.1 Identification of Potential Sources of Hazards
17.2 Case Study: Manufacture of Sulphuric Acid
17.2.1 Identification of Some Hazards in Sulphuric Acid Manufacturing Plan
17.3 Illustration: Manufacture of Nitric Acid
17.3.1 Identification of Some Hazards in Nitric Acid Manufacturing Plant
17.3.2 Steam Supply to Ammonia Evaporators
17.3.3 Application of Some Typical Guide Words
17.4 Manufacture of Caustic Soda (Membrane Process)
17.4.1 Identification of Some Hazards in Caustic Soda Manufacturing Plant
17.4.2 Application of Some Typical Guide Words
18 General Technical Matters
18.1 Batch and Continuous Production
18.1.1 Salient Features of Batch Production
18.1.2 Cycle Time
18.1.3 Idle Time
18.1.4 Maintenance of the Process Units
18.1.5 Salient Features of Continuous Production
18.2 Pressure Vessels
18.2.1 Duty Conditions to Be Considered
18.2.2 General Arrangement Drawing
18.2.3 Finalise Detailed Arrangement
18.2.4 Mechanical Design
18.2.4.1 Proceed to Prepare Fabrication Drawings
18.2.4.2 Submit Fabrication Drawings for Statutory Approval
18.2.4.3 Placing Order for Fabrication
18.2.4.4 Quality Assurance Plan
18.2.4.5 Non-destructive Tests
Radiographic Testing
18.2.4.6 Statutory Documents
18.2.4.7 Post-weld Heat Treatment
18.2.4.8 Hydrostatic Test
18.2.4.9 Safety Valves
Some Practical Tips
18.3 Plant Operation at Different Pressures
18.3.1 Plant Operation Below Atmospheric Pressure
18.3.2 Plant Operation Above Atmospheric Pressure
18.3.3 Plant Operation at Above and Below Atmospheric Pressures
18.4 Typical Checklist for Smooth Production Run
18.4.1 Coordination with Marketing (Sales) and Logistics Department
18.4.2 Availability of Items for Process and Maintenance
18.4.3 Daily Checks of All Important Equipment
18.4.4 Mechanical, Electrical, and Instrumentation Spares
18.4.5 Preventing Interruptions Due to Adverse Situations
18.5 Some Quick Fix Solutions for Plant Operation
18.5.1 Items to Be Readily Available
18.5.2 A Word of Caution
18.6 Equipment Modification for Adding Cooling/Heating Capacity
18.7 Selecting the Process and Technology
19 Technocommercial Matters
19.1 Revival of Plants
19.1.1 Setting Up a New Industry
19.1.2 Revival of a Plant
19.1.3 Site Visit and Inspection
19.1.3.1 Other Matters to Be Observed/Checked
19.1.3.2 Detailed Inspection of Old Equipments
19.1.3.3 History Cards of Equipments and Machineries in Idle Plants
19.1.4 Further Planning
19.1.4.1 Basic and Detailed Engineering Documents
19.1.5 Requirement of Funds
19.1.6 Revival with Same Products: Process and Equipment Modifications Only
19.1.7 Raw Materials
19.1.8 Cost-Cutting Without Compromising on Safety
19.1.9 Revival with Expansion of Capacity
19.1.9.1 Certain Equipments Shall Need Upgradation
19.1.9.2 Providing New Equipments for Revival/Increasing Production Capacity
19.1.9.3 Time Required
19.1.9.4 Diversification to More Value-Added Products
19.2 Technical and Commercial Audits
19.2.1 Planning, Design, and Fabrication Activities
19.2.2 Procurement and Purchase Activities—Legal and Commercial
19.2.3 Regarding Implementation of the Project
19.2.4 Impact of the Project on the Organisation
19.2.5 Appointment of the Technical Auditor
19.2.6 Safety Audits
19.2.7 Performance Audits
19.2.8 Energy Audit
19.2.8.1 Important Stages of Energy Audit
19.2.8.2 Regular Examination by Thermographic Cameras

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Tags: Production Management, Chemical Industries, Kiran Golwalkar