Plant operations, list

Chemical plant operation (listed as part of Operation 500,000 0.28... 

Figure 10-2 A typical process safety checklist. A list of this type is frequently used before a more complete analysis. Adapted from Henry E. Webb, What To Do When Disaster Strikes, in Safe and Efficient Plant Operation and Maintenance, Richard Greene, ed. (New York McGraw-Hill, 1980).

The Center for Chemical Process Safety (CCPS) of the American Institute of Chemical Engineers (AIChE) has identified twelve elements that must be part of any chemical process safety management program [5]. Application of these elements specifically to plant operations has also been defined [6]. Because of the critical importance of these twelve elements, they are listed here as follows for reference ... 

Plant operator training in HazMat Response is also required by PSM and RMP. The plant operators who respond to a fire or spill of any listed chemical must be trained on how to properly handle such incidents. This training element is absolutely critical in any emergency response incident. 

Not listed in Table 6.4 of possible unit modifications are improved unit controls. These can be applied in many ways to both the reactor/regenerator and gas plant. Operating closer to limits increases revenue by forcing the operation to several limits rather than one or two. A good FCC model is needed if all the benefits are to be realized. 

The results shown in Col. 2 of Table IV are rather discouraging In that, for most elements, the a value Is comparable to the mean value. Much of the variation may be due to variations of the compositions of the input coals. All but one plant operate In the United States, but some use eastern U.S. coals and other consume western U.S. coals, which usually have large differences in the concentrations of many elements (17, 45). One could perhaps remove this source of fluctuation by calculating the values with respect to the input coals rather than to the crust. Thus, in Col. 3, we list the coal values, defined as... 

General Safety Precautions. The preparation and handling of the items covered by this specification, and the subassemblies thereof, involve hazardous operations and therefore require explosives safety precautions. Use of this specification will not be construed as to relieve the contractor or manufacturer of responsibility for the safety of his operations. Listed below are certain minimum provisions which a contractor or manufacturer (who prepares the item covered) should observe in order to fulfill his responsibility for safety. At Bureau of Naval Weapons, Navy Department, and other government plants, these provisions are mandatory. Such other warnings and precautions, pertinent to the operational effectiveness or safety during preparation of the specified items, are included in detailed technical requirements of the specification... 

Schlachman(Ref 21) lists the US War Dept sponsored synthetic ammonia plants operating during WWII and Faith Keyes Clark (Ref 83) gives a list of cuirent US ammonia plants... 

The following items represent the more common operating costs, although the list should not be considered complete for any plant. Operating costs are usually calculated on an annual basis, and subsequently calculated per tonne of product (for example) when determining the profitability and selling price of the chemical. 

Analyses of coals which have been processed in the continuously operated pilot plants are listed in Table 1. Process liquid yields from the liquefaction step for these coals are shown in Figure 4 for different residence times in the liquefaction reactor. Longer residence time increases conversion of coal to liquids, but also increases hydrocracking of liquids to gas. 

A listing of critical alarms and safety interlocks essential to safe plant operations must be made. 

Table 23.9 lists the major hemihydrate plants operating in 2000. Many of the smaller facilities on the ninth edition list have been shut down. However, two major single-stage hemi plants have recently started operation. The Indo-Jordan facility has been particularly successful operating at full capacity from the initial startup, and up to 1000 tons per day P205 on two 80-m2 Eimco belt filters. 

The fusion is carried out in an autoclave, an apparatus of such great importance both for the laboratory and for plant operations that a separate chapter has been devoted to its use (page 350). The ingredients listed above are placed in the autoclave and held, with continuous stirring, at 178-180°C. for 8 hours. The pressure is about 7 atmospheres. 

Hazard and Risk Assessment Tools The hazard and risk assessment tools used vary with the stage of the project from the early design stage to plant operations. Many techniques are available, both quahtative and quantitative, some of which are listed in the following section. Reviews done early in projects often result in easier, more effective changes. 

Suppliers and potential suppliers are classified with respect to expected or known compliance with environmental and safety standards. In a first approach, this classification is performed according to their location in OECD countries or non-OECD countries, since the risk of noncompliance with environmental and safety standards is expected to be higher in non-OECD countries (Kranz and Sargasser, 2003). Products/producers assigned a C3 rating represent a potentially high risk and are therefore subjected to a particularly careful check. This means that BASF employees visit the supplier and carry out an EHS assessment to determine whether the supplier s plant operates according to Responsible Care standards. A company can only be included in our list of suppliers if its facilities meet our requirements. 

As the existing check-lists already provided a detailed and structured representation of the process, they were used to create a first version of the WOMS model. Subsequently, discussions with the operating personnel and the plant engineer addressed the shortcomings of the process as specified in the old check lists and the variants actually followed during plant operation. 

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