Process check list

Steam service, 426 Type, 400 Valves, parts, 412 Pressure-vacuum relief, 466 Calculations, 469 Emergency venting, 476-479 Equipment (valves), 468, 478, 480 Fire exposure, 479 Free air, 469, 474 Specification work sheet, 481 Thermal oulbreathing, 468, 469 Vacuum inbreathing, 468, 469, 475 Process check list, 35 Process design organization, 1, 2 Calculations, 37-39 Costs, 43 Manhours, 40-43 Scope, 2... 

What-ll/Checklist combines the creative, brainstorming features of a What-lf with the systematic features of a Checklist. The What-lf analysis considers accidents beyond the checklist the check list lends a systematic structure to the What-lf analysis. A What-lf7Checklist examines the potential consequences of accident scenarios at a more general level than some of the more detailed I l liA methods. It can be used for any type of process at any life cycle stage. 

From a construction viewpoint these summaries are a necessary check list to aid in keeping the construction program organized. Individuals who have no real knowledge of the scope of the Job, and in particular the process, can properly tie the project together in the field by use of these schedules. 

Layout and Process Development Engineering Check-List... 

Total head, centrifugal pumps, 180, 183 Discharge, 205 Head curve, 198 Suction head, 184, 186 Suction lift, 184, 186 Type, 184 Tubing, 63, 64 Two-phase flow, 124 Calculations, 125-127 Flow patterns, chart, 124 System pressure drop, 125 Types of flow, 124, 125 Utilities check list, process design, 34 Vacuum,... 

Check lists are useful aids to memory. A check list that has been drawn up by experienced engineers can be a useful guide for the less experienced. However, too great a reliance should never be put on the use of check lists, to the exclusion of all other considerations and techniques. No check list can be completely comprehensive, covering all the factors to be considered for any particular process or operation. 

A short safety check list, covering the main items which should be considered in process design, is given below. 

Balemans, A. W. M. (1974) Check-lists guide lines for safe design of process plants. Loss Prevention and Safety Promotion in the Process Industries, C. H. Bushmann (ed.) (Elsevier). 

Wragg [6] has provided the following basic environmental check-list for textile wet processing ... 

If the size of the production unit requires higher radiant power than can be provided, for technical reasons, by one lamp, clusters of light sources may be installed, which, consequently will alter the diameter or the height of the inner core of, for example, an annular photochemical reactor. However, following the check list of concepts (vide supra), optimal reaction conditions will in most cases limit the size of the photochemical reactor, and the planned rate of production may require several reactor units installed in a parallel mode (batch process) or in series (continuous process). 

Before a chemical process design can be properly embarked on, a certain body of information must be agreed upon by all concerned persons, in addition to the obvious what is to be made and what it is to be made from. Distinctions may be drawn between plant expansions and wholly independent ones, so-called grassroots types. The needed data can be classified into specific design data and basic design data, for which separate check lists will be described. Specific design data include ... 

Safety check lists can provide a uselul guide for the main items to be considered during the process design stage. It must be remembered that no list is ever complete and other considerations and techniques should also be applied. Safety check lists can be found in Coulson and Richardson, Volume 6 (1983 pp. 301-303) IChemE Flowsheeting for Safety (1976) Wells (1980) and Balemans (1974). 

The check list method is based on past experience. The process description, the operating mode, is screened using a list of possible failures or deviations from this particular operating mode. Thus, it is obvious that the quality and comprehensiveness of the check list directly govern its efficiency. Indeed, the experience of the authors confirms that the check list is essential. This method is well adapted to discontinuous processes as practised in the fine chemicals and pharmaceutical industries, where processes are often performed in multi-purpose plants. The basic document for the hazard identification is the process description, also called operating mode. Each step of the process is analysed with the check list. 

Cause and effect diagrams, which are produced after group discussions on the problem, or its effect, involve the production of detailed check lists and a structured brainstorming (see Section C, 1.8.3). Following this process the diagram will become very complex and has the appearance of the skeleton of a fish hence they are often called fishbone diagrams. 

The data of three consecutive injections of the check mixture are processed by AMDIS and evaluated by the operator. The results of testing are recorded in a check list and if they fulfill the acceptance criteria given in Annex 3 each system component is labelled separately OK when in waiting status in the OPCW Laboratory or Accepted for on-site use when tested for exit control (see Figure 3). The waiting status evaluation... 

In all calculations only as much detail was developed as was needed to generate insight. The process was broken down into subsections to identify the sources of loss. Subsequent breakdowns continued only until a clear picture of the sources on inefficiency was developed. A check on accuracy was maintained by insuring that the work balance, i.e., W ost = Wactuaj - W deal was reasonably close. As indicated above, the various segments of the process were listed in priority order based on the potential for improvement. Idea generation was then carried out based on the thermodynamic data. 

Preformulation testing of the specific API of interest and key excipients to be used in the product design stage, alone and in combinations with the API, should be included as a preliminary first step in the product and process development sequence. A simple check list of items worth consideration in preformulation studies with APIs and important or critical excipients is provided as follows ... 

Before we started the project, the start-up process was specified by means of several check lists, each of them providing detailed instructions for subprocesses like preparation or inertization. These check lists were represented in a simple textual form. A first version of the check lists had been created after the construction of the plant, and occasionally they had been modified to take into account the experiences made by the operators during their daily work. However, complete revisions of the check lists had never been done, such that no explicit record of the valuable know-how of the operators existed. Furthermore, the effects of some modifications of the control system of the plant had never been incorporated in the lists, which therefore contained some out-dated information. In consequence, not all instructions given in the check lists were followed by the different operators, who rather performed individual start-up procedures, resulting in a considerable variance of the start-up time and the quality of the chemical product. 

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. 

Definition of an improved up-to-date specification of the start-up process. Several deficiencies of the original process could be remedied. For instance, in some cases the location of equipment, hand valves, etc. hat not been considered when the original check lists had been created. Thus, a staff member strictly following these sequences would have to cover a considerable distance within the plant during a start-up. By rearranging some of the sequences, such distances could be reduced. 

Implementation of the improved start-up process. As the plant will further on be operated manually, the implementation of the improved start-up process had to ensure that the operating personnel will follow the procedures defined there. To this end, the relevant information must be passed to the staff. As the representation of the start-up process by means of check lists is widely established, it has been decided to transform the final WOMS model into a set of check lists. 

Release for Sale should require the examination and certification by Quality Assurance of consolidated records of processing, packaging and quality control, to ensure compliance with the Master Formula, compliance with all procedures, acceptable yields and reconciliations and compliance with product specifications. A check list system should be used forthe collected documents to verify that all are present The release should include the dated signature of the person authorised to approve the distribution of the batch (see also Contract Manufacture). 

During the packaging process the packaging line should be continually monitored to ensure that the integrity of the finished product is not in any way compromised. Written procedures and tabulated check lists should be signed at regular intervals by competent and suitably trained people. 

API Standard 665, Fired Heater Data Sheet, was developed to minimize problems of incomplete specifications. Its five pages provide a complete check list. Information which must be defined by he purchaser is marked with an asterisk and includes such data as complete process requirements, fuel characteristics, structural design data, coil design conditions, types of headers and terminals required and site conditions. 

---