Integrated Maintenance and Energy Management in the Chemical Industries (eBook)

Preface 6
Conflicting Priorities 6
Revenue Allocation 7
Assistance to Plant Management 8
Inventory Control 9
Acknowledgement 11
Contents 13
Chapter 1: Introduction to Some Important Chemical Industries 25
1.1 Introduction to Some Important Chemical Industries 25
1.2 Importance of Process Units and Machinery 25
1.3 Brief Description of Some Important Chemical Industries 26
1.3.1 Manufacture of Sulphuric Acid 26
1.3.2 Manufacture of 25%, 65% Oleum, Liquid SO3 Plants 27
1.3.3 Manufacture of Papermaker’s Alum 28
1.3.4 Manufacture of Alum 28
1.3.5 Manufacture of Single Super Phosphate 29
1.3.6 Manufacture of Caustic Soda and Chlorine by Electrolysis 30
1.3.7 Manufacture of Nitric Acid 31
1.3.8 Carbon Di-Sulphide (Electric Furnace Process) 32
1.3.9 Manufacture of Viscose Rayon (Staple Fiber) 32
1.3.10 Manufacture of Refractory Bricks 33
1.3.11 Petroleum Industries 34
1.3.12 Manufacture of Sugar 35
1.4 Some Important Equipments in Process Plants Described Above 35
1.4.1 Some Typical Process Units and Mechanical Equipments 35
1.4.2 Typical Essential Features of Equipments Used in Above Industries 36
1.4.3 Process and Operation which Have Considerable Energy Changes 37
Chapter 2: Managing the Organisation 38
2.1 Typical Features of Chemical Industries 38
2.2 Guidelines from Board of Directors for Integrated Management 39
2.3 Modern Management: Aims, Policies and Priorities 39
2.3.1 Typical Aims 40
2.4 Typical Policies 40
2.5 Typical Priorities 41
2.6 Integrated Management of Chemical Industries 42
2.7 Regular Interactions 43
2.8 Guidelines and Instructions 43
2.9 Revision of Policies 43
2.10 Departments in the Organisation 44
2.10.1 Marketing 44
2.10.2 Production Units 45
2.10.3 Safety Department 46
2.10.4 Environmental Pollution Control 47
2.10.5 Maintenance Department 48
2.10.5.1 Mechanical Maintenance 48
2.10.5.2 Electrical Maintenance 49
2.10.6 Instrumentation 50
2.10.7 Provision of Utilities 51
2.10.8 Purchase 51
2.10.9 Logistics 53
2.10.10 Human Resources (HR) 53
2.10.11 Innovation, Research & Development (R&
2.10.12 Stores and Inventory Control of Machinery Spares 56
2.10.13 Commercial Matters, Finance, Taxation, and General Administration 57
2.10.14 Project Planning, Future Expansion 58
Chapter 3: Integrated Maintenance: Aims, Responsibilities and Activities 59
3.1 General Guidelines 59
3.2 Internal Discussion among Production and Maintenance Engineers 60
3.3 Internal Study 60
3.3.1 Plant Capacity 60
3.3.2 Operational Safety 61
3.3.3 Design of Process Units and Machinery 62
3.3.4 Material Handling Equipment 63
3.3.5 Essential Matters to Be Written in Purchase Order PO for Project 63
3.3.6 Plant Layout for Safe Operation and Ease of Maintenance 65
3.3.7 Performance Guarantee Test 66
3.3.8 Annual Maintenance Contract 67
3.3.9 Quality Assurance Plan QAP 67
3.3.9.1 Cooperation by Purchaser 69
3.4 Responsibility of Maintenance Engineers 69
3.4.1 Useful Suggestions from Maintenance Engineer 70
3.4.1.1 Provide the Following 71
3.5 Increasing Life of Process Units and Machinery 72
3.5.1 Some Suggestions for Better Life of Process Units and Equipments 72
3.6 Spares for Process Units and Internals/Accessories 76
3.6.1 Procurement of Spares 76
3.6.2 History Cards of Individual Process Unit 77
3.6.3 Safety Margin for Higher Stock Level 77
3.6.4 Considerations for Procurement and Storage of Various Items 78
3.6.5 Other Necessary Spares for Process Inputs, Equipments, and Auxiliary Items 79
3.6.6 Product Quality Control (Necessary Inputs for Maintaining Product Quality) 82
3.6.7 Auxiliary Facilities/Items for Process Plant 82
3.6.8 Electrical Spares 83
3.6.9 Refrigeration Units 84
3.6.10 Diesel Generator Sets 84
3.6.11 Instrumentation Spares 84
3.6.12 Cooling System Based on NaOH or LiBr 84
3.6.13 Heat Recovery Boiler and Economiser 85
3.6.14 Process Control and Material Testing Laboratory 85
3.6.15 Disposal of Hazardous Wastes (Please See Appendix (IV) Also) 85
3.7 Careful Production Planning and Operation 85
3.7.1 General 86
3.7.2 Maintenance Engineer Can Propose Some Changes in Operating Conditions in Consultation with Production Engineers 87
3.7.3 Operation–Dos and Don’ts (Advice Given by Original Equipment Manufacturer) 89
3.7.4 Some Preventive Steps for Longer Equipment Life 90
3.7.5 Installation of Special Equipments 90
3.7.6 Management Support for Innovation, Research and Development 90
3.7.7 General Guidelines for Maintenance 91
3.8 Main Activities of the Maintenance Department 91
3.9 Site Fabrication Facilities 93
3.10 Budgeting for Maintenance Jobs 93
3.10.1 Observations 93
3.10.2 Estimate Cost of Maintenance 94
3.10.3 Contingency 95
3.11 Some Typical Accidents and Their Prevention 95
3.12 Practical Matters/Issues to Be Looked into 96
Chapter 4: Monitoring the Process Plant 98
4.1 Condition Monitoring of Process Units 98
4.1.1 Some Typical Symptoms 98
4.1.1.1 General Visual Inspection: (of All Process Units and Machinery) 99
4.1.2 Examples from Some Chemical Industries 101
4.1.2.1 Sulphuric Acid Plant 101
4.1.2.2 Single Super Phosphate Plant 105
4.1.2.3 Alum Plant 106
4.1.2.4 Nitric Acid Plant 107
4.1.2.5 Carbon Di-Sulphide (CS2) Plant 108
4.1.2.6 A Typical Water Treatment Plant 109
4.1.2.7 Reverse Osmosis Unit and Ultra Filtration/Micro Filtration Units 109
4.1.2.8 Process Boilers 109
4.1.2.9 Air Pollution Control System 110
4.1.2.10 Effluent Treatment Plant 110
4.2 Likely Reasons for Unsatisfactory Output/Performance 110
4.2.1 Some Typical Causes for Unsatisfactory Performance 111
4.3 Typical Conditions Exceeding the Design Values or Recommendations from OEM 112
4.4 Technical Planning for Maintenance Work 113
4.4.1 Planning for Maintenance Work 113
4.5 Examples of some Typical Cleaning Jobs of Process Units 116
4.6 Record Keeping for Maintenance of Plant Units and Machinery 116
4.6.1 Typical Operating Conditions 118
4.6.2 Maintenance History 118
4.7 Considerations for Further Improvement 119
4.8 Cost of Maintenance 119
4.8.1 Direct Costs 119
4.8.2 Indirect Costs of Maintenance 120
Chapter 5: Planning for Maintenance Work 122
5.1 Coordination of Maintenance Activities 122
5.1.1 Typical Symptoms Which Indicate Chance of Breakdown 122
5.2 Check List for Planning of Major Maintenance 123
5.3 Advancing the Shutdown 124
5.4 Postponing the Plant Shutdown 125
5.5 Carrying out Maintenance Jobs In-House 125
5.5.1 By Own Technicians/Engineers 125
5.5.2 Through Contractors/Externals Parties 126
5.5.3 Site Fabrication Jobs (May Be Done Through External Agencies) 127
5.5.4 Award of Contract for Maintenance Work 127
5.5.5 Quality Assurance Plan for Contract Work 128
5.5.6 Conditions to Be Included in a Maintenance Contract 128
5.5.7 Controversies During Maintenance Work by Contractors/External Parties 128
5.5.8 Additional Work Given During Execution or End of Contract 130
Chapter 6: Maintenance of Process Units 131
6.1 Material Handling System 131
6.1.1 Pneumatic Conveyors 131
6.1.2 Electrical Overhead Travelling (EOT) Cranes 132
6.1.3 Hoists 133
6.1.4 Belt Conveyors 133
6.1.5 Bucket Elevators 134
6.1.6 Screw Conveyors 134
6.2 Crushers, Grinders, Pulverisers 135
6.2.1 Air Classifier 135
6.3 Units Operating at High Temperatures (Furnaces, Reactors, Oxidisers.) 136
6.4 Process Reactors (Fixed Unit with No Moving Parts) 136
6.4.1 Reactors with Heating/Cooling Arrangements 137
6.5 Absorption Towers 138
6.5.1 Observations During Operation 138
6.5.2 Fibre Bed Mist Eliminators (FBME) 140
6.5.3 Drying and Final Absorption Towers 142
6.6 Catalytic Converters (Fixed Beds of Catalyst) 143
6.6.1 Heat Exchange Surfaces 143
6.6.2 Converter Overhaul 146
6.6.3 Conversion System with Fluidised Bed 148
6.7 Filter Press FP 148
6.8 Pressure Leaf Filter- (Example: For Liquid Sulphur) 151
6.8.1 Observation During Running 151
6.8.2 Maintenance Work 152
6.9 Trombone Coolers 152
6.9.1 Observations for Trombone Cooler 153
6.9.2 Maintenance: (Check and Attend) 153
6.10 Shell and Tube Heat Exchangers 154
6.10.1 Allowable Pressure Drop 154
6.10.2 Materials of Construction–Typical 155
6.10.3 Maintenance: Check the Following Thoroughly 155
6.11 Plate Heat Exchangers 156
6.12 Condensers for Volatile Materials 157
6.12.1 Observation during Operation of Incoming Vapors/Gaseous Streams 157
6.12.2 General 157
6.12.3 Vertical Unit 158
6.12.4 Condenser (Horizontal Units) 158
6.13 Rotary Dryers 158
6.14 Tray Dryers 159
6.15 Hot Gas Filter 159
6.15.1 Observations to Be Made During Operation of the Plant 160
6.15.2 Maintenance 160
6.16 Multiple Effect Evaporators 160
6.16.1 Important Components of a Multiple Effect Evaporation System 161
6.16.2 Observations to Be Made During Operation 162
6.16.3 Maintenance Procedure 162
6.16.4 Items to Be Inspected and Attended 163
6.17 Water Treatment Plants 163
6.17.1 Main Components of a Typical Water Treatment Plant 164
6.17.2 Observations to Be Made During Operation 164
6.17.3 Maintenance 165
6.18 Sludge Settler 165
6.19 Air Pollution Control System 166
6.19.1 Observation on Individual APC Units 166
6.19.2 Cyclones 167
6.19.3 Impingement Separators 169
6.19.4 Bag Filters 169
6.19.5 Ventury scrubber 170
6.19.6 Packed Scrubbing Tower 170
6.20 Induced Draft Fans (Rubber Lined) 170
6.21 Electro Static Precipitators (ESP) – Dry/Wet Type 171
Chapter 7: Maintenance of Common Machinery, Process Units and Equipments 173
7.1 Stationary or Static Equipments 173
7.1.1 Chimney 173
7.1.2 Steel Structural Members: Regularly Inspect and Attend Any Weak Spots 174
7.1.3 Elevated Storage Reservoirs (ESR) 175
7.1.4 Vertical Storage Tanks 175
7.1.5 Horizontal Cylindrical Storage Tanks 177
7.1.6 Weigh Bridges 178
7.1.7 Ducts and Piping 178
7.1.8 Metering Tanks 178
7.1.8.1 Advantages 179
7.2 Electrical Items 179
7.2.1 Erection and Commissioning Activities (Including Site Fabrication) 180
7.2.2 Power Required for Operation 180
7.2.3 Equipments and Facilities to Be Installed 180
7.2.3.1 Metering Panel 181
7.2.3.2 Step Down Transformer(s) 181
7.2.3.3 Transformers and Rectifiers 181
7.2.3.4 Other Facilities 183
7.2.3.5 Heating Furnaces 183
7.2.3.6 Electrical Motors 183
7.2.4 Maintenance of Other facilities 184
7.2.5 Diesel Generators 185
7.2.6 Captive Power Generation 185
7.2.7 Uninterrupted Power Supply UPS 186
7.3 Rotary Equipments 186
7.3.1 Typical Rotary Equipments 186
7.3.2 Features Required 187
7.3.4 Types of Relief Mechanisms 188
7.3.5 Installation in Plant 188
7.3.6 Fans, Blowers, Compressors, Exhausters 188
7.3.6.1 Maintenance Checks and Activities 190
7.3.7 Reciprocating Compressor 191
7.4 Some Auxiliary Equipments 193
7.4.1 Typical Effluent Treatment Plant 193
7.4.1.1 Main Equipments 193
7.4.1.2 Maintenance of Following Items Is Required 194
7.4.2 Dissolvers 195
7.4.3 Melters, Ball Mills, Ribbon Blenders 196
7.4.3.1 Melter 197
7.4.3.2 Ball Mill 197
7.4.3.3 Ribbon Blenders 198
7.4.4 Oil Firing System 198
7.4.4.1 Observations During Operation 198
7.4.4.2 Check the Following During Maintenance Jobs 199
7.4.5 Rotary Screen 199
7.4.6 Pumps for Process Liquids 200
7.5 Pressure Vessels 201
7.5.1 Classification of Pressure Vessels: Fired and Unfired 201
7.5.2 Some Examples of Pressure Vessels 202
7.5.3 Considerations for Procurement of Pressure Vessels 203
7.5.4 Further Considerations for Design and Fabrication 204
7.5.5 Materials of Construction (MOC) 205
7.5.6 Heads for pressure vessels 206
7.5.7 Checking Fabrication Activities 206
7.5.8 Documents to Be Available to Plant Engineers 207
7.5.9 Quality Assurance Plan 208
7.5.10 Statutory Documents: To Be Made Available to Purchaser by Vendor 209
7.5.11 Safety Valves 209
7.5.12 Pre-commissioning Checks 210
7.5.13 Operation of Pressure Vessels 211
7.5.14 Additional precautions 211
7.5.15 Maintenance of Pressure Vessels 212
7.6 Civil Works and Their Maintenance 214
7.6.1 Preventive Steps for Civil Structures and Foundations 214
7.6.2 Safe Load Bearing Capacity of Soil 214
7.6.3 Alternative Plant Layouts 214
7.6.4 Civil Structures and Foundations 215
7.6.5 Other Civil Works 215
7.6.6 Observations and Maintenance 216
Chapter 8: Tools and Facilities for In-House Maintenance 217
8.1 Arranging Facilities for In-House Maintenance 217
8.1.1 Maintenance Tools and Facilities 217
8.1.2 Dynamic Balancing Machine 218
8.1.3 Maintenance Tools and Facilities for Process Units 219
8.1.4 Refractory, Rubber, and Other Linings 220
8.1.5 Equipments for Fabrication 220
8.2 Instrumentation Control 220
8.2.1 Introduction 220
8.2.2 Parameters Generally to Be Measured and Controlled 221
8.2.3 Procurement of Instruments 222
8.2.4 Some Special Instruments 222
8.2.5 Typical Working Principle of Some Instruments 223
8.2.6 Procure Necessary Accessories 223
8.2.7 Controlling Instruments 223
8.2.8 Precautions to Be Taken During Installation of Instruments 224
8.2.9 Auxiliary Facilities and Equipments to Be Kept Ready 224
8.2.10 Some Common Reasons for Wrong Indications/Malfunctioning of Instruments 225
8.2.11 Corrective Actions 225
8.2.12 Maintenance of Instrumentation on Regular Basis 226
8.2.13 Some Typical Thermocouples 227
8.2.14 Selection of the Thermocouple 227
Chapter 9: Trial Runs and Restarts of Equipment After Maintenance Work 228
9.1 Analysis and Planning for Maintenance 228
9.2 Mechanical Trials 229
9.3 Pumps Used in the Plant 229
9.3.1 Vertical Submerged Pumps 229
9.3.2 Horizontal Pumps Installed Outside 230
9.4 Steam Jacketed/Heating Jacketed Pumps, Pipelines and Valves 230
9.4.1 Reciprocating Pumps 230
9.5 Metering Pumps 231
9.5.1 Check Points 231
9.6 Corrosion and Erosion of Pumps in Chemical Plant 231
9.7 Filter Press 232
9.8 PHE (Plate Heat Exchanger) 233
9.8.1 Checking Before Trial Run 233
9.9 Air Pollution Control System (Venturi and Packed Tower) 234
9.10 Wet Electro Static Precipitator WESP 234
9.10.1 Checking Before Trial Run 234
9.10.2 Maintenance Check 234
9.10.3 Wet ESP 235
9.11 Oil Firing System 235
9.11.1 Check During Maintenance and Trials Thereafter 235
9.12 Rotary Screens (for Separation) 236
9.12.1 Trial Run of Rotary Screens 236
9.13 Condensers (Check After Maintenance) 237
9.14 Converter (Check After Maintenance) 237
9.15 Ball Mill (Maintenance and Subsequent Check) 237
9.16 ID Fans (Check During Maintenance and Trials Thereafter) 238
9.17 Melter/Dissolver (Steam Heated with Agitator) During Maintenance and Trials Thereafter 238
9.18 Heat Exchanger (Check After Maintenance) 238
9.19 Hoists and Electrically Operated Travelling EOT Crane (Check After Maintenance) 238
9.20 Belt Conveyor, Bucket Elevator (Check After Maintenance) 239
9.21 Screw Conveyor (Check After Maintenance) 239
9.22 Disposal of Waste from Various Units 239
Chapter 10: Management Approach to Increasing Energy Efficiency 241
10.1 Erection 241
10.1.1 Mechanical Trials 241
10.1.2 Trials of More Machines/Sub-Sections of the Plant 242
10.1.3 Dry Run of the Plant (Without Feeding Raw Materials) 242
10.1.4 Restart of the Plant After Major Stoppage/Annual Shut Down 243
10.2 Better Technology 244
10.2.1 Better Technology for Oleum 244
10.2.2 Continuous Process for 65% Oleum 244
10.2.3 Better Process for Liquid SO2 246
10.3 Better Plant Layouts: Some Examples 246
10.3.1 Layout for Sulphuric Acid Plant 246
10.3.2 Guidelines for Improving Plant Layout 247
10.3.3 Layout for a Typical Viscose Rayon Plant 248
10.4 Packaged Boilers 248
10.5 Heating Systems 250
10.5.1 Electrical Heating 250
10.5.2 Heating by Steam 252
10.5.3 Oil Fired Heating System 253
10.5.4 Coal Fired Heating 256
10.5.5 Fuel Gas Fired Heating (Natural Gas, LPG, Propane) 257
10.5.6 Heating by Hot Process Gases 258
10.5.7 Heating by Heat Transfer Oils (Hot Thermic Fluids) 259
10.5.8 Format 260
10.6 Selection of Better Design of Process and Equipments 262
10.7 Exploring More Sources for Heat Recovery for Further Improvement 264
10.8 Selection Criteria for Energy Saving/Energy Recovery Equipment 265
10.8.1 Design of the System 265
10.8.2 Define Required/Expected Performance from the Proposed Equipment 266
10.8.3 Calculate Requirement of Energy 266
10.8.4 Materials of Construction 267
10.8.5 Convenience During Operation and Maintenance 267
10.8.6 Introducing New Units in the Plant 268
10.8.7 Estimated Cost for the Energy/Heat Recovery Proposal 268
10.8.8 Time Required for Implementation 268
10.8.9 General Considerations 268
10.8.10 Examples of Some Heat Recovery Systems 269
10.8.10.1 Hot Side.....Gas and Cold Side.....Gas 269
10.8.10.2 Hot Side.....Gas and Cold Side.....Liquid. 269
10.8.10.3 Hot Side.....Gas and Cold Side.....Solid... 269
10.8.10.4 Hot Side.....Solid and Cold Side.....Solid 270
10.8.10.5 Hot Side.....Solid and Cold Side.....Gas 270
10.8.10.6 Hot Side.....Liquid and Cold Side Also.....Liquid 270
10.9 Optimise Production Cycles 270
10.9.1 Optimise Batch Size 271
10.9.2 Avoid Frequently Starting and Stopping the Plant 271
10.10 Saving Electrical Energy in Chemical Plants 271
10.10.1 Variable Frequency Drives (VFD) for Speed Control 273
10.10.2 Electrolysis Process Plants 273
10.10.2.1 Power Required at the Electrolysis Plant 273
10.10.2.2 Factors for Optimising Cell design and Their Accessories 273
10.10.2.3 Power Supply Required for Cells (as per Production Rate Desired) 274
10.10.2.4 Some More Tips to Save Power in Chemical Process Plants 275
10.10.2.5 Energy Saving Cooling Systems 275
10.10.2.6 Tri-generation 276
10.10.2.7 A Modified System 276
Chapter 11: Examples of Modified Methods for Reducing Energy Consumption 277
11.1 Examples of Process Intensification 277
11.2 Cooling Systems and Refrigeration 281
11.3 Spray Ponds for Cooling Water 282
11.4 Cooling Towers 282
11.4.1 Observations during Operation 282
11.4.2 Maintenance 283
11.5 Conventional Refrigeration Plants 284
11.5.1 Main Components and Machinery 284
11.5.2 Observations to Be Made for Safe and Smooth Working 285
11.5.3 Safety Valves 285
11.5.4 Some Precautions for Maintenance Work 286
11.5.5 Additional Safety Precautions 286
11.6 Unconventional Chilled Water Systems 287
11.6.1 Caustic Soda Based System 287
11.6.2 Libr Based System 287
11.6.3 For Safety of Personnel 288
11.7 Other Cooling Arrangements 288
11.8 Steam Jet Cooling 288
Chapter 12: Methods for Minimising Consumption of Energy 289
12.1 Project Planning 289
12.2 Reduce Consumption by Process Units by Better Design and Construction 289
12.3 Considerations for Reducing Energy Consumption 290
12.4 Energy Saving by Improved layout for Safe Convenient Movements 291
12.5 Controlled/Modified Operations for Reducing Energy Consumption 291
12.6 Monitor Losses from Equipments and Ducts (Use Thermography Camera) 292
12.7 Check Losses During Plant Operation: (Some Typical Cases) 292
12.8 Examine Potential for Energy Recovery: (Please See Sect. 10.7 Also) 293
12.9 Energy Audit 293
12.10 Comparison with Ideal Conditions 294
12.11 Examine the Loss of Energy During Maintenance Work 296
12.12 Minimise Energy Consumption by Procuring Better Raw Materials 296
12.13 Situations to be Addressed 297
12.14 Examples of Saving Energy and Heat Recovery 298
12.15 Process Boilers 299
12.16 Optimising Power Consumption for Agitated Vessel 301
12.17 Dual Drive System 301
Chapter 13: Retaining Thermal Energy While Simultaneously Protecting Equipment 303
13.1 Refractory Materials and Their Properties 303
13.2 Installation of Refractory 307
13.3 Typical Curing Procedure 307
13.4 Observations during Running of the Process Units 308
13.5 Maintenance of Refractory Lining 309
13.6 External Thermal Insulations 309
13.6.1 Ducts Carrying High Temperature Gases 310
Chapter 14: Equipments for Energy Recovery 311
14.1 Selection of Waste Heat Recovery Boilers (WHRB) 311
14.1.1 Scope of Supply (Shall Be as per Battery Limits Agreed Between Vendor and Purchaser) 312
14.1.2 Performance Guarantees (as agreed mutually) 312
14.1.2.1 Commercial Terms 312
14.2 Selection of Economiser 313
14.2.1 Considerations and Scope of Supply 313
14.2.2 Performance Guarantees (as agreed mutually) 313
14.2.2.1 Commercial Terms 313
14.3 Problems for WHR Systems 314
14.4 Precautions for Operation of Boiler 314
14.5 Co-Generation 315
14.5.1 Condensing Type Turbine 315
14.5.2 Back Pressure Turbine 316
14.5.3 Extraction Type 316
14.5.4 Estimation of Power and Steam Requirement 316
14.5.5 Numerical Example 316
14.5.6 Some Important Considerations for Selecting Steam Turbines 317
14.5.7 Steam Turbine Driven Generators 318
14.5.8 Check List Before Commissioning of Steam Turbine 318
14.6 Commissioning 319
14.6.1 Maintenance of Steam Turbine 320
14.7 Options to Be Looked in to for the Chemical Plant 321
14.8 Gas Turbine Generators 322
14.8.1 These Can Be Considered in Following Typical Situations 322
14.8.2 Gas Turbo Generator: System Components 323
14.8.3 Combustion System of Gas Turbine 323
14.8.3.1 Observations During Operation 324
14.8.4 Turbine 324
14.9 Type of Generators 324
14.10 Cleaning of Boilers 325
14.11 Boiler Maintenance 328
14.12 Cleaning of Economiser 329
14.13 Economiser Maintenance 329
Chapter 15: Safety Precautions During Maintenance and Energy Recovery 330
15.1 Safety Precautions During Maintenance: General 330
15.2 Typical Guidelines for Safety Precautions 331
15.3 Checks by Safety Officer 331
15.4 Maintenance of Equipment Handling Dangerous Items/Work Inside a Closed Vessel 333
15.5 Personal Protective Equipments 333
15.6 Alarms, Safety Devices and Interconnections (for Electrical Tripping) 334
15.7 Safe Commissioning of Energy Recovery Units 335
15.7.1 HAZOP Study 336
15.7.2 Checks Before Erection 336
15.7.3 Checks Before Commissioning 337
15.7.4 Observation During Operation 338
15.8 Safety Organisation 338
15.8.1 Safe Expansion of Capacity 339
15.8.2 Important Inputs from Safety Officer 339
15.8.3 Assistance by Safety Organisation 340
15.8.4 Emergency Response Training to Personnel 341
15.8.5 Safety Organisation to Arrange the Following 341
15.8.6 Coordination with External Parties 341
15.9 Guidelines for Storage of Petroleum Products and Fuels 341
Chapter 16: Examples of Waste Heat Recovery in Chemical Industries 343
16.1 Sulphuric Acid 343
16.2 Nitric Acid 344
16.3 Hazardous Waste Destruction Plant 345
16.4 Distillery Spent Wash Incineration (Fig. 16.4) 345
16.5 Sugar Industry 346
16.6 Production of SO3 by Boiling Oleum 346
16.7 Rotary Dryer Unit of Rice Husk Ash Pelletisation Plant 346
16.8 Heat Recovery (as Hot Air) From Hot Bricks 348
Appendix I: Lubrication 349
Appendix II: Vibration 352
Appendix III: Some Typical Non-destructive Tests 358
Appendix IV: Disposal of Hazardous Waste 360
Appendix V: Hydraulic Motors and Systems 363
Appendix VI: Protective Lining for Process Units 365
Appendix VII: Some Welding Processes 368
Index 370