Process installation

Gas turbine fuels can contain natural surfactants if the cmde fraction is high in organic acids, eg, naphthenic (cycloparaffinic) acids of 200—400 mol wt. These acids readily form salts that are water-soluble and surface-active. Older treating processes for sulfur removal can leave sulfonate residues which are even more powerful surfactants. Refineries have installed processes for surfactant removal. Clay beds to adsorb these trace materials are widely used, and salt towers to reduce water levels also remove water-soluble surfactants. In the field, clay filters designed as cartridges mounted in vertical vessels are also used extensively to remove surfactants picked up in fuel pipelines, in contaminated tankers, or in barges. 

Nearly every manufacturing, shipping, and installation process is a potential source of a defect. Manufacturers, in recognition of this, mount major efforts to minimize or eliminate defects. Although an exhaustive list of defects is beyond the scope of this book, some common ones will be discussed. 

In addition to the fixed capital investment needed to purchase and install process equipment and auxiliaries, there is a continuous expenditure referred to as operating cost, which is needed to operate the process. The operating cost (or manufacturing cost or production cost) includes raw materials, mass-separating agents, utilities (fuel, electricity, steam, water, refrigerants, air, etc.), catalysts, additives, labor, and maintenance. The total annualized cost of a process is defined as follows ... 

A model installation process is illustrated in Figure 9.4 above. 

How do you ensure that installation processes which directly affect quality tified, planned, and carried out under controlled conditions are iden-... 

Interim reports document the installation process and provide a way to flag opportunities and problems to management s attention in a timely manner, which helps avoid surprises. At the same time, be careful that your interim reports are precisely that don t try to second-guess final reports, or extrapolate from local findings prematurely. 

For facility-specific installation, it may make sense to start the installation process everywhere at once, paying particular attention to priority facilities. However, if your company is a decentralized one with many sites, you may wish to subdivide the installation by, for example, product lines or t) es of operations. 

This experience will serve you well as you begin the installation process. Many of the activities and tasl will be very familiar, and rely on information you have already gathered. In particular, the pilot test will have yielded valuable tools for selling PSM if properly conducted and documented, the test will have generated a range of ideas and materials that cem serve as the core of your efforts. 

For these reasons, in addition to executive communications, you should consider the advantages of other internal communications methods to gain participants buy-in. The installation process presents a natural opportunity in fact, employee communications should be a priority as you begin the roll-out. 

As part of planning your company s PSM system roll-out (Chapter 7), you have established a number of benchmarks and parameters for the installation process. For example, pilot testing should yield realistic estimates for individual facilities schedule, staffing, and other resource requirements, as well as workable formats for reporting. The installation plan you developed should derive from these results, adapting them to the full range of your company s operations. 

For a plant that has not adopted PSM in the initial round of design, development, and installation, expansion requires repeating the installation process described in Chapter 7. In such a case, your systems are already designed and the effort required is a continuation of the roll-out a full pilot test should not be necessary. 

Quality documentation and records This requirement should be developed during the whole of the installation process. You need to document your system. However, you must carefully consider the timing of publication. In some projects it may be appropriate to issue documentation from day one and routinely update it. 

The most important objective of the pilot study is testing and improving the integration plan. Deficiencies may be uncovered in the design or installation process. Problems with the installation will usually be evident immediately, as will some design problems other design problems may not be evident for sometime. 

Some refineries also install processes to produce petrochemical feedstocks. However, from a volume viewpoint, it is not a large part of refmei y income. Even though profit margins can be high, most refineries restrict their capital investments to those... 

In today s world the decision is more complex. Markets are more sophisticated, skills can be in short supply, technological change can soon outdate newly installed processes, and there has been a phenomenal revolution in communications, both in terms of the physical movement of goods and people and of information around the world. As a consequence, companies often have to consider a wide number of options, and the eventual decision is based on optimizing the perceived net benefits. 

Most couplings require lubrication and care must be taken to ensure that the proper type and quantity is used during the installation process. Inadequate or improper lubrication reduces coupling reliability and reduces its useful life. In addition, improper lubrication can cause serious... 

The last step in the installation process is verifying coupling and shaft alignment. With the exception of special application couplings such as spindles and jackshafts, all couplings must be aligned within relatively close tolerances (i.e., 0.001-0.002 inch). 

Another important aspect from a practical point of view is the entire installation process. During an installation many different working groups come together and have contact via more or less specified interfaces. In Germany, the installation activities are usually divided into three sectors ... 

Traditionally, processes have used a single destruction technique, and this has historically been the case also for HYDECAT . Thus, nearly all installed processes treat the waste hypochlorite at the concentration it exits the scrubbing system down to concentrations suitable for discharge (Fig. 26.2). The key aspect in the re-evaluation described herein is to question the practices of firstly single technology and secondly end-of-pipe treatment the destruction of the hypochlorite exclusively in the blowdown stream from the scrubber. That is, it is questioned whether installation of a single treatment technique solely to process the effluent at its natural concentration from the scrubber loop is necessarily the best process option. This chapter will consider the two parts of the question paraphrased above sequentially. 

The throw-away processes with aqueous slurries of lime or limestone as the scrubbing media are the most extensively installed processes. These processes create a waste sludge containing calcium sulfite, calcium sulfate, fly ash, unreacted alkali, and other minor dissolved species in the free water contained in the sludge. Since flue gas contains oxygen, some of the dissolved sulfur dioxide is oxidized, and calcium sulfate is formed. 

Table 5.6 displays some examples of inserts, the targeted goals and installation processes, without claiming to be exhaustive. 

The final task of the pre-installation process should be a preinstallation qualification. This is a site-readiness evaluation indicating whether the location into which the HPLC system is to be installed is actually ready to accommodate this system. This should include the following utility/spatial/environmental and safety considerations ... 

Following successful completion of the pre-installation process, it is time for the system to be installed and to implement the core of the validation protocol—the IQ/OQ/PQ. Based on the overall timeline, these procedures have been grouped into two task groups upon installation and pre-installation. Focusing on the upon installation tasks, these include both the IQ and OQ protocol, implemented in respective order. They can be generally defined as follows ... 

The IQ protocol for a system is often partly, if not totally, developed by the vendor of that system. This is understandable, considering that, typically, the vendor has the best understanding of how to properly install the system and would also know how best to validate the installation process. 

In 2000 two major petrochemical companies installed process NMR systems on the feed streams to steam crackers in their production complexes where they provided feed forward stream characterization to the Spyro reactor models used to optimize the production processes. The analysis was comprised of PLS prediction of n-paraffins, /xo-paraffins, naphthenes, and aromatics calibrated to GC analysis (PINA) with speciation of C4-C10 for each of the hydrocarbon groups. Figure 10.22 shows typical NMR spectral variability for naphtha streams. Table 10.2 shows the PLS calibration performance obtained with cross validation for... 

The project plan should encompass all aspects of a fire protection system, such as the underground fire water distribution system, fire pumps, aboveground water header, valving and standpipes, structural support, and detection and alarm systems. All work on the fire protection system must be coordinated with other work activities at the site or in the operating unit. The recommended installation practices for the different types of fire protection systems are covered in consensus standards, such as NFPA. The installation process is illustrated in Figure 9-1. 

It is a common mistake to underestimate the effort and time required for site preparation. The users should carefully study the site preparation guide to ensure that the necessary preparations to house the new instrument in the laboratory are completed prior to installation. Inadequate site preparation can cause major inconveniences and long delays in the installation process. It is a waste of time and resources to have the service engineer show up in the laboratory but not able to do anything due to incomplete site preparation. 

As their conditions of use demand freedom from odor it has been imperative to install processes for handling the relatively high mercaptan contents. 

Coupon corrosion results are also influenced by the mounting and installation process within a bypass unit. Coupons must be mounted with plastic, or other suitable nonconducting, holders to ensure insulation from stray currents and electrolytic effects. The plane of the coupon should be parallel to the direction of flow and it should not touch the wall of the pipe. 

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