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August 1, 2014
No re-measurement is required with this shaft-alignment tool Elos Fixturlaser The EVO (photo) is an all-digital shaft-alignment tool with an adaptive user interface, which shows how a misaligned machine must be moved vertically or horizontally by adding or removing shims at the machine’s feet. The EVO requires no re-measurements in between horizontal and vertical adjustments during the alignment...
http://www.chemengonline.com/processing_and_handling/operations_and_maintenance/Focus-on-Maintenance-Equipment_12009.html
July 1, 2014
New safety and environmental regulations, longer plant uptime and changes in maintenance practices have created new requirements across the chemical process industries (CPI). Among the plant equipment affected by these changes are control valves, since they are used in numerous applications in a variety of process conditions. Figures 1 and 2 show typical control valves installed in CPI plants. The primary...
http://www.chemengonline.com/processing_and_handling/operations_and_maintenance/Control-Valve-Selection-True-Cost-Savings-Are-Available_11915.html
April 1, 2014
Pressure variations resulting from the oscillatory flow patterns found in positive-displacement machinery, especially reciprocating compressors, are referred to as “pulsations.” Found in both liquid- and gas-handling systems, pulsations are a common phenomenon in the chemical processing industries (CPI). Operational problems associated with pulsations include resonance conditions, high...
http://www.chemengonline.com/processing_and_handling/operations_and_maintenance/Protecting-Against-Compressor-Pulsations_11629.html
January 1, 2014
Rising temperatures and rapid or excessive heat buildup are useful markers for determining the operational health of many types of machinery and components that are used in a wide array of industrial and manufacturing settings. The types of mechanical and electrical systems for which temperature increases often signal problems include (but are not limited to): rotating machinery, such as motors, turbines...
http://www.chemengonline.com/processing_and_handling/operations_and_maintenance/Remote-Thermal-Sensing_11336.html
January 1, 2013
Virtually every process-plant manager pursues the commendable goals of safely extending equipment life and maximizing both the availability and reliability of plant assets. Achieving these objectives usually requires upfront effort and money — both of which can be scarce resources. But even the realistic manager who knows that reliability comes at an ufront price may not want to authorize these...
http://www.chemengonline.com/processing_and_handling/operations_and_maintenance/Use-Simplified-Lifecycle-Cost-Computations-to-Justify-Upgrades_10087.html
August 1, 2012
There is a temptation that steam design engineers find difficult to resist — to put condensate from high-pressure (HP) steam mains directly into the low-pressure (LP), pumped condensate-return (CR) mains. After all, the CR main is so convenient — it is generally laid right next to the outgoing steam main in the same tunnel, trench or racks as the CR main returning to the steam plant. And, the...
http://www.chemengonline.com/processing_and_handling/operations_and_maintenance/Waterhammer-In-Condensate-Return-Lines_9551.html
January 1, 2012
      Lubricants in rotating machines reduce friction and wear, dissipate heat, protect surfaces, keep out foreign contaminants and remove wear particles. Commonly used liquid lubricants fall into two main categories: mineral (petroleum-based) oils and synthetic oils. Mineral oils are produced by refining crude petroleum. They usually contain trace amounts of some unwanted substances. By...
http://www.chemengonline.com/processing_and_handling/operations_and_maintenance/Lubricating-Rotating-Machinery_8840.html
November 1, 2011
For decades, plant-wide oil-mist systems have been used to lubricate rolling-element bearings in high-speed applications throughout the petrochemicals, textiles, pharmaceuticals, mining and other chemical process industries (CPI). Applications range from small motors to large rotating cylinders and a variety of fluid movers. Plant-wide oil-mist systems provide a centralized way to supply lubricating oil to...
http://www.chemengonline.com/processing_and_handling/operations_and_maintenance/Selecting-Oil-Mist-Systems_8615.html
July 1, 2011
Distillation columns are often workhorses in the chemical process industries (CPI), and at times, it is necessary to physically inspect the interior of a column. This article demonstrates what an inspection can reveal, by sharing the experience of actual fractionation-tower inspections in a petroleum refinery. The points mentioned are intended to provide guidance to future tower inspectors, so that they...
http://www.chemengonline.com/processing_and_handling/operations_and_maintenance/Inspecting-Fractionation-Towers_8214.html
April 1, 2011
Good troubleshooting skills are invaluable in chemical engineering practice. While their value is clearly gleaned from the impact they have on plant performance, it is also a reflection of the intangible process of learning them. Last month, at the AIChE Spring meeting in Chicago, Ruth Sands, former CE author and mass transfer consultant at DuPont Engineering Research & Technology, presented attendees...
http://www.chemengonline.com/processing_and_handling/operations_and_maintenance/Ten-troubleshooting-tips_7742.html
January 1, 2011
With productivity, growth and reliability as constant drivers, the proactive evaluation of all machinery is critically important. In order to gain useful insight, the maintenance team must capture comprehensive data related to machinery operation and carry out a logical interpretation of the data. The conventional language of equipment components — vibration — transmits relevant information...
http://www.chemengonline.com/processing_and_handling/operations_and_maintenance/Get-the-Most-out-of-Vibration-Analysis_6294.html
February 1, 2010
The massive buildup of new petrochemical capacity in the Middle East and Asia has been well documented, and its effect on future supply-demand much discussed. But a look at the average ages of plants in different regions in the years that follow this capacity buildup, prompts new conclusions on just how profound the effects of this new capacity will be. Ed Gartner, Director of SRI Consulting’s World...
http://www.chemengonline.com/processing_and_handling/operations_and_maintenance/Comparing-petrochemical-plant-aging_5447.html
December 1, 2009
Most chemical engineers involved with operating large chemical process facilities have encountered the following challenge: Several large engineering contractors built the facility in multiple phases, using different computer-software models. Retrieving drawings or data in both digital and non-digital form in such a situation only adds complexity to operations, maintenance and revamp activities and often...
http://www.chemengonline.com/processing_and_handling/operations_and_maintenance/Smooth-Your-Retrieval-of-Plant-Design-Data_5326.html
August 1, 2009
Cooling water systems that rely on cooling towers are a critical component at chemical process industries (CPI) facilities. However, during operation, these open recirculating systems concentrate the contaminants in the makeup...
http://www.chemengonline.com/processing_and_handling/operations_and_maintenance/Keeping-Cooling-Water-Clean_5005.html
July 1, 2009
The heat transfer sufaces of coal-fired process heaters and boilers often undergo severe fouling. If left intact, such deposits, consisting of slag from mineral matter contained in the coal, can reduce heat-transfer-surface availability, reduce thermal efficiency and cause corrosion. If the deposits are adherent and cannot be removed by conventional steam soot-blowers, shutdown and more rigorous cleaning...
http://www.chemengonline.com/processing_and_handling/operations_and_maintenance/The-Shotgun-Approach-Removal-of-Fouling-Deposits-on-Heat-Transfer-Surfaces-in-Coal-Fired-Process-Heaters-and-Boilers_4925.html
December 1, 2008
Organic-based thermal fluids provide relatively trouble-free service for significant periods of time. However, there comes a time when any fluid (either aromatic- or aliphatic-based) needs to be replaced. Since aromatic-based fluids generally cost more and are complicated to dispose of, they receive far more attention than aliphatic-based fluids when the time comes for replacement. Aliphatic-based fluids...
http://www.chemengonline.com/processing_and_handling/operations_and_maintenance/Cover-Story-Part-2-Heat-Transfer-Fluids-Maintaining-the-System_4385.html
November 1, 2008
Management is a process of managing risk; maintenance management is a process of managing risk for operational reliability. Since it is hard to manage what cannot be measured, effective maintenance management demands good data on machine health — a comprehensive condition monitoring program, carried out by skilled and determined personnel, using appropriate tools and technology. Condition-based...
http://www.chemengonline.com/processing_and_handling/operations_and_maintenance/Condition-Based-Maintenance-Management-Enhances-Reliability_4320.html
November 1, 2008
A very common heat exchanger in the chemical process industries (CPI) is the vertical thermosiphon reboiler (VTR; Figure 1). Due to size and fluid-flow restrictions, however, its heat transfer rate is often quite low. The subcooled region formed at the thermosiphon’s tube-bundle base usually causes reduction in the tubes’ average heat-transfer coefficient. Improvements in performance can be...
http://www.chemengonline.com/processing_and_handling/operations_and_maintenance/Engineering-Practice-Get-More-From-Vertical-Thermosiphon-Reboilers_4321.html
August 15, 2008
As fuel prices continue to rise, energy management is everyone’s business Market trends suggest that the demand for energy resources will rise dramatically over the next 25 years with the global demand for all energy sources forecast to grow by 57% and the U.S. demand for all types of energy expected to increase by 31% (see Figure 1). By 2030, it is expected that 56% of the world’s energy use...
http://www.chemengonline.com/processing_and_handling/operations_and_maintenance/Cover-Story-Making-Energy-Efficiency-Pay_4090.html
August 15, 2008
Corrosion is a cannibalistic force that usually attacks chemical process equipment from the inside out. That must be why it is often referred to as a hidden cost, because the economic impact of corrosion is becoming impossible to overlook. As Russell D. Kane, director of corrosion services for Honeywell Process Solutions (Phoenix, Ariz.; www.honeywell.com) points out, the price of corrosion reveal itself...
http://www.chemengonline.com/processing_and_handling/operations_and_maintenance/Editors-Page-Cutting-Corrosion-Costs_4100.html
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