Engineering Maintenance Improving Plant Safety- Volume 2


SKU: CE150 Category:


For operators and facility managers in the chemical process industries (CPI), proper maintenance goes hand in hand with plant and process safety.

This Chemical Engineering Guidebook includes a collection of tutorial-style engineering articles. They provide tips, recommendations and best practices to help CPI facilities undertake maintenance-related activities, with a special eye toward improving plant safety for workers and the surrounding community.

Topics focus on reducing corrosion and managing specific equipment components properly to reduce leakage and emissions. This is also concentration on maintenance strategies for burners and other equipment systems that have potential risk of temperature excursions, fire and explosion.

Provided is explicitly on strategies for reducing the risk of dust explosions during the handling of powders and other bulk solids, proper maintenance of pipelines carrying gases and gas-detection systems, and reducing the risk of leakage.

Delivered in a PDF, 160 pages. Articles include:

Preventing Flow Stoppages in Powder Handling Processes

  • Predicting powder flow behavior is important to successful solids-handling processes. Provided here is a review of shearcell testing and how the technique can be used to predict arching, ratholing and other behaviors

Corrosion Complications

A Checklist for Safer Chemical Batch Reaction

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

Integrity of Aging Assets: Using Corrosion Data to Stave Off Extinction

  • Petroleum refineries built in the 1960s and 1970s have trouble dealing with the corrosive effects of modern feedstocks.

Continuous monitoring of corrosion can prevent process equipment failures

Particle Impact Problems in Pneumatic Conveying

  • Pneumatically conveyed solid materials inevitably impact pipe walls and other particles, which can create processing and equipment problems. Provided here is an outline of potential problems related to particle impacts and the physics behind them

Gas Detection

Achieving Excellence in Energy Efficiency

  • Effective energy-management programs provide motivation for behavioral, technical and business changes that improve efficiency

Disaster Preparedness at Manufacturing Facilities

  • Development of robust preparation and response procedures can help chemical plants to weather disaster events and return to normal operations in a safe and efficient manner

Energy Recovery in Compressed Air Systems

  • Users of compressed air can take advantage of heat recovery to enhance their sustainability, improve energy efficiency and reduce system lifecycle costs

Recommended Fluid Velocities in Pipelines

  • The recommended velocities for fluids’ transportation must be updated periodically to obtain the optimum value of the pipe diameter in the current economic conditions

Single-Use Gloves: Problems and Solutions

  • When wearing single-use protective gloves, sweat can create health and safety issues. Presented here is a look at the causes of the problems and possible solutions

Remote Thermal Sensing

  • By making it easy to detect heat anomalies, thermal cameras and infrared thermometers support preventive and predictive maintenance

Process Hazards Analysis Methods

Pressure Measurement for Real Gases

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

Avoid Safety Pitfalls During Plant Expansion and Modification

  • Follow this guidance to minimize risk when adding or modifying plant equipment

Alarm Management

Implementing a Corrosion-Under-Insulation Program

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

Industrial Combustion Products

Pressure-Relief System Design: Developments and Deficiencies

  • Areas of recent activity for pressure-relief systems include new calculation methods and updates to existing codes and standards. Included here is an overview of recent developments and a look at the results from a recent study of pressure-relief system deficiencies and solutions

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

Burner Inspection and Maintenance

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

Dust Management in Bulk-Material-Handling Operations

  • Dust management can be divided into three main categories: prevention, containment and suppression. Understanding the key considerations for each can help bulk solids handlers arrive at an optimal dust control solution

Resistance Temperature Detectors

Wireless Monitoring for Pressure Relief Systems

  • New diagnostic devices can identify when pressure incidents happen, while keeping an eye on the condition of pressure relief valves and rupture disks

How to Troubleshoot and Maintain Pressure Regulators

  • Following a five-step process enables better outcomes for fluid system control

Combustible Dust Fires and Explosions: Recent Data and Lessons Learned

  • A review of recent data from the Combustible Dust Incident. Database provides insights into dust-related process safety

Minimizing Leakage on Heat- Exchanger Girth Flanges

  • Thermal distortion in heat-exchanger internal components can lead to leakage, but several design measures can be taken to mitigate these concerns

Cybersecurity: Building Resilience from the Inside Out

  • Cybersecurity is no longer a far-fetched concept relegated to science fiction or conspiracy theories. It is a major and growing global risk across all industry sectors

Improve Energy Management to Reduce Your Facility’s Carbon Footprint

  • This article describes an approach that uses data analytics for finding and addressing root causes of process deviations that reduce energy efficiency in key plant utility systems, and shares three case examples

Reduce Risk and Cost with a Lifecycle Approach to Process Safety

  • Better upfront planning and management can lead to safer, more productive processes throughout every phase of operation

Microbial Control in Cooling Water

  • Three chlorine-based strategies for controlling microbial load in industrial cooling water are evaluated here

Gas Detection as a Risk Mitigation Technique

  • There are many differences between gas detection systems used for process monitoring and those used for protecting the safety of personnel

An Overview of Gas Flow Measurement

  • Many applications require accurate flowrate measurement for air or other gases. Installation requirements, calibration and maintenance are among the factors that must be considered when selecting a flow-measurement technology

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 enduser involvement