Chemical Process Plants — Proactive Maintenance Practices


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Throughout the chemical process industries, proper maintenance is essential to ensure the safe and reliable operation of the facilities, and increasingly, engineers are recognizing the direct impact that proper, proactive maintenance can have on budgets and bottom-line profitability.

This Chemical Engineering PDF guidebook provides a diverse collection of articles and a wealth of engineering information and recommendations. It helps CPI facilities plan for, and manage, their maintenance activities in the most proactive, organized and cost-effective way. 

Focus is on managing overall maintenance programs, using computerized maintenance-management programs, and optimizing maintenance efforts during planned shutdowns and turnarounds. It also provides practical engineering recommendations related to such maintenance-intensive operations as water and wastewater treatment, steam production and boiler operation, management of heat exchangers and heat transfer fluids, burners, rotating equipment, and more.

Delivered in a PDF, 138 pages.

Table of Contents

A Checklist for Safer Chemical Batch Reactions

A good understanding of the reaction chemistry is needed for a safe process design

Avoiding Project Failures

Recognize these key project-failure modes, so that corrective action can be taken

Facts at Your Fingertips: Non-chemical Water Treatment

Facts at Your Fingertips: Heat Transfer Fluids: System Filtration

Facts at Your Fingertips : Heat transfer system cleaning

Facts at Your Fingertips : Controlling Membrane Fouling

Heat Transfer Fluids: Maintaining the System

Use cost-effective techniques to find a solution for coke, sludge, high viscosity and deposits in your thermal fluid process

Maximizing Heat-Transfer Fluid Longevity

Proper selection, monitoring and maintenance can protect fluids and components from damage due to thermal degradation, oxidation damage and contamination

Troubleshooting Heat-Transfer Fluid Systems

Real examples demonstrate how to analyze problems in heat transfer systems. The culprit is oftentimes not the thermal fluid

Preventing Tank Corrosion

Why a tank’s coating-application process makes all the difference

Managing Pressure while Pigging an Oil Pipeline

Pressure control valves can manage pressure in oil pipelines, but pigging the line presents a challenge

Gear Units in CPI Plants

Follow this guidance to improve the selection and operation of gear units in CPI plants

Plant Revamps and Turnarounds: Some Lessons Learned

Although time is always precious, taking shortcuts and skipping standard procedures can be costly 

Wireless Diagnostics for Steam Traps

How harnessing new technology in steam trap monitoring can curb energy costs, reduce labor and make your operation safer

CPI Water and Steam Chemistry

Careful control of water and steam chemistry at CPI facilities can pay off handsomely in reliable operation

Tank Coatings: Covering the Basics of Selection and Specification

Good quality coatings can make all the difference where corrosion and chemical compatibility are concerned

Improve Rotary Equipment Reliability with Checklists

Design selection and commissioning of rotary equipment can benefit by following a structured, checklist-based method and by promoting end-user involvement

Computerized Maintenance Management Systems for Effective Plant Performance

Corralling gigabytes of predictive maintenance data isn’t easy, but it’s essential for streamlining your process

Seven Tools for Project Success

Having the right tools is essential for success. These tools are of use to both novice and experienced project managers

Maintenance and Repair of Glass-Lined Equipment

A customized inspection and maintenance program will minimize operational and performance problems

Internal Corrosion Sampling

Proper sampling and handling procedures are critical for supporting corrosion-management decision making

Dust Control in the Chemical Processing Industries

The prevention of dust hazards in the CPI is integral to process-safety management — wide reaching mitigation schemes must be implemented

A New Approach to Corrosion Monitoring

The impact of corrosion on assets and processes is great. Advances in technology allow engineers to assess corrosion in a whole new way, with real-time monitoring and the ability to link deterioration with process conditions

Implementing a Corrosion- Under-Insulation Program

CPI facilities need to put in place a systematic program for preventing and mitigating corrosion under insulation

Condition Monitoring for Rotating Machinery

This valuable insight into the performance of pumps and compressors will help improve operation

Five Steps to Replacing Aged Heat-Transfer Fluid

Follow these guidelines to help ensure efficient operation of heat transfer systems, and proper exchange and disposal of aged fluids

Beware of Flow- Accelerated Corrosion

Operators of steam-generating systems should understand flow-accelerated corrosion and the potential problems it can cause

Corrosion in Flexible Burner Hoses

Special care must be taken to avoid corrosion in flexible hoses for burners. This failure analysis illustrates the mechanism and provides recommendations

Don’t Overlook Composite FRP Pipe

Satisfying hydraulic and fluid flow issues are key considerations in the efficient design of FRP piping systems

A Method for Quantifying Pipe Vibrations

A technique to quantify vibration forces can help prevent pipe failures due to vibration-induced fatigue

Piping-System Leak Detection and Monitoring for the CPI

Eliminating the potential for leaks is an integral part of the design process that takes place at the very onset of facility design

Steam Management: Don’t Send Money Down the Drain Part 2

Driving energy savings through key solutions to condensate management

The Importance of Intensive Steam Trap Management

Payback is rapid, energy and maintenance savings are attractive, and the uptime assurance is incalculable in value

Condition-Based Maintenance Management Enhances Reliability

Understand reliability, condition monitoring and maintenance management to keep rotating equipment in top form

Dust Explosions: Prevention & Protection

Understand what causes these disasters and then put these practical measures in place

Burner Inspection and Maintenance

Burners and their components can be quite complex. Establishing maintenance and inspection best practices encourages long-term operational reliability

Critical Connections Demand Certainty

Understanding bolts’ behavior during routine tightening procedures helps to ensure leak-free, reliable operations

Tolerable Risk

While determined risk is generally well understood, tolerable risk can be the missing link to complete risk assessments

Strategies for Controlling Membrane Fouling

In water treatment, the bulk solution, concentration polarization, permeate flux and membrane properties are some of the parameters that can be influenced

Condition Monitoring Methods for Pumps

Applying condition monitoring tests to pumps can save costs by optimizing overhaul scheduling

Steam Balances Save Money

Developing – or digging out – the needed data is one key to a good steam balance. Another is holding lots of conversations with the plant’s engineers and operators