Test Runs for the Process

Trade Secrets When a toll involves proprietary information, a system must exist to ensure that employees have the process safety related knowledge needed to meet the intent of the process safety management system. 

Some toll processes lend themselves to test runs in the pre-startup phase. Actual materials for the toll may be used in the test or substitute materials, typically with low hazard potential, are often used to simulate the charging, reaction, and physical changes to be accomplished in the toll. Flow control, temperature control, pressure control, mixing and transferring efficiency can be measured. Mechanical integrity can be verified in regard to pumps, seals, vessels, heat exchangers, and safety devices. 

Test run steps can frequently be incorporated into process startup procedures. Two examples would be pulling a vacuum on vessels and verifying it holds, or distilling a solvent and checking for the presence of water to verify the mechanical integrity of the heating and cooling equipment. 

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In addition, many of the variables that were up to now modeled as input variables should instead be modeled as dependent output variables. To do so, the interdependencies between the parameters must be quantified based on further literature analysis and on surveys of experts. An assistance program for the creation of simulation models will be conceptualized and implemented to support project managers in modeling new concepts of design processes. This contains both the conversion of the C3 model in an executable simulation model as well as the partial automation of test runs for the optimization of workflow management. 

Proof Testing A run through the process substituting nonhazardous materials (e.g., water) to check for the adequacy of the equipment e.g., heating/cool-ing load, and to verify procedural steps. 

In either type of test run, an opportunity exists to ensure the utilities for the process are capable of performing their function. 

It is probable that a full load cannot be obtained during the final test, for reasons of low ambient or lack of completion of other equipment for the process. In such circumstances, the commissioning engineer must establish the load which prevailed at the time and make an estimate of the system performance, on the basis of time run, or otherwise interpret the figures obtained. In such cases it may be advisable to agree to a tentative acceptance of the plant and carry out a full-load test at a later date. 

The agitation studies for PET depolymerization were performed in the Atlas Launder-ometer. The Launder-ometer is a device for rotating closed containers in a thermostatically controlled water bath. The procedure used in these experiments was adapted from an American Association of Textile Chemists and Colorists (AATCC) standard test method. The 5% sodium hydroxide solution (250 mL) was preheated to 80°C in a 1-pint stainless steel jar. The catalysts were added in the following amounts in separate experiments TOMAC (0.04 g, 0.0001 mol) TOMAB (0.045 g, 0.0001 mol) and HTMAB (0.045 g, 0.0001 mol). The PET fiber specimens (1.98 g, 0.01 mol) were placed in the containers along with ten -in. stainless steel balls to aid in the agitation process. The jars were sealed in the Launder-ometer, whose bath was at the desired temperature (80°C). The machine was allowed to run for the allowed treatment times (i.e., 30, 60, 90, 150, and 240 min) at 42 rpm. Upon decanting, any residual fibers... 

In a series of test runs, 15 rolls of wrap are made under carefully controlled conditions and the tear resistance of each roll is measured. The results are used as the basis of a quality assurance specification (see Problem 2.19). If X for a subsequently produced roll fails more than two standard deviations away from the test period average, the process is declared out of specification and production is suspended for routine maintenance. 

After the run has been completed, the product should be subjected to thorough analyses purity, impurity levels, residual solvents, and other appropriate tests. The product may also be examined for suitable conversion to the next intermediate. Yield, product purity, and the amount of product in various streams (e.g., aqueous extracts, mother liquors, and washes) can be used to calculate the mass balance for the processing. Monitoring the mass balance is an excellent way to determine how well a process is understood A low mass balance may be due to the formation of an impurity that could decrease product yield if not controlled in subsequent runs. 

In our follow-up testing we also run other special types of tests to further examine possible hazards identified in our initial screen or to clarify the significance of Sikarex test results for our process. Some of these special tests are listed in Table III. 

Before phase III and process finalization, process robustness is evaluated via several scaled-down runs to quantify process variability [14]. These studies form the basis for the process validation program if they are well documented, use operational range extremes, and test different resin/raw material lots. Based on the resulting data, additional optimization to improve robustness is conducted. Fully developed analytical assays are employed during these pre-phase III scale-down runs to ensure the process meets the quality acceptance criteria. Then during phase III, any remaining assays are validated [14]. 

The software of the Simultaneous Thermal Analyzer, STA 780 (STA 1000) also allows the ASTM E 698-79 method to be used. Unfortunately there is no computer program to process data from simultaneous TGA/DTA (TGA/DSC) test runs. For computation according to ASTM E 698-79 only separately sampled DTA (DSC) data can be used, so the advantage of a simultaneous measuring instrumentation cannot be fully realized. The conversion levels at peak maximum temperatures are also unknown, and the total conversion can only be ascertained after termination of the test run. The installed software version C 4.20 offers plots similar to those of the DSCASTMKin vl.OO ... 

Turn-Key Contract- The contract is concluded after the technology has been selected. This is a firm price contract (with a possible price escalation formula) for all deliveries and services including civil works, startup, and guaranteed test runs of the complete fertilizer plant. The contract preparation requires a large volume of work and time to define the scope and specifics of deDveries and services. The investor has little involvement in the construction process primarily the investor concentrates on training the labor and staff for plant operation and maintenance. 

From each set of test run data, the volumetric rates of each process stream can be calculated as necessary, plus other pertinent figures such as torque/ volume for dry solids work, polymer dose kg/ton db for flocculant work, g-volumes. 

Probably one of the more typical planning problems will be that the state of progress of the rest of the plant will not permit a smooth run for the safety system. For example the installation of instruments on a plant is often delayed by mechanical completion work, hence there is pressure to complete the testing of safety control loops quickly so that the process commissioning can begin. 

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