Power Failure in Our Industry!
Thursday, May 26, 2011
Once upon a time in the Chemical Reaction Engineering Research Laboratory
On a sweet Thursday afternoon (today) when I just started my experiment, a sudden power failure occurred without warning. I was actually in the toilet when the power cut off took place. My wife called and asked, "Do you have electricity there in the lab?". I answered, "We have power here in the lab and I just started my experiment". Then 2 lab assistants walk out from the polymer lab (which is next to the reaction engineering lab) and informed me that the power failure just happened. I was surprised.
Immediately I ran into the lab and discovered that the lab black out. Oh my God!!! This is not good. It's not really about my experiment. It's the Gas Chromatography (GC) which I'm more worried about. The GC is such an important equipment for me and the rest of the students as we use it to identify and quantify our products from the reactor. The GC is very sensitive and frequent power cut-off can jeopardize the equipment and interrupt our research activities. Repairing the GC cost huge amount of money and with limited research budget, we need to do everything to avoid the GC from malfunctioning.After about 15 to 20 minutes the electrical power resumed. Thank God. I switched it on. I then checked the GC and its PC hoping that nothing will go wrong. When the power failure occurred just now, the oven temperature (of the GC) was 250oC. The standard operating procedure to switch off the GC is when the oven temperature is below 40oC. Sudden GC shut down is not recommended at all. It is strictly a big NO. Luckily the GC works well and nothing seems to be wrong. I restarted my experiment and completed it 3 hours later.
Power Failure in the Plant
The incident reminded me on the power failure that once in a while also occurred in the physical refinery plant I worked in several years ago. Such unavoidable power cut-off from the Electricity Company will firstly trigger chaos within the control room and the entire plant. The supervisor, shift leader and plant operators have to act fast to close all main valves manually from various sections. The flow, temperature and pressure from numerous unit operation equipment such as Niagara filter (filter leaves), deodoriser, packed column, heat exchanger need to be controlled until power resumed. The huge 3000 tonnes per day plant can only be minimally controlled via the PLC which was temporarily powered with UPS (uninterupted power supply) - which provided a few minutes power back up.
Secondly, the power cut off will result in substantial lost and I have to assess and make report about it. Even a milisecond power failure will result in vacuum drop in the plant in result to oil rejection (due to quality off-spec). That also will cost massive lost to the company.What can we do?
As for my case, in the lab... nothing much can be done. I rest my faith to the God. It's good to install UPS for the GC. If UPS is the answer, then we must have 4 UPS unit in the lab as there are all together 3 GC's and 1 GCMS. However, having UPS alone will not entirely protect this expansive machines. For me, the power company (electricity supplier) must be responsible in providing smooth and reliable power for us (the customers). They should pay all the damage and losses that hit us. Maybe this does not sound like an engineer's solution...
Other option?
A more interesting option is to create and manage our own power system...but can we do it with our resources? I'm referring to solar, wind and frequency (Tesla) energy. I would love to develop one of this power sources AFTER I complete my study. I'll try and do it at my home first... :)
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Labels: Chemical Engineer, Chemical Engineering, Chemical Plant, Control System, Energy, Equipments, green, Learning Curve, Plant Shutdown, Problem, Process Parameters, Processing.
posted by Kipas Repair JB @ 7:54 PM,
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Some Problems We Find in A Processing & Production Plant
Saturday, April 05, 2008
As a process engineer or production executive, we shall always hope and wish that the plant will be smooth. A processing or production plant will always have a problem whether we like it or not. What will the problem be? Are they thought in the university? Can you get them in the text books? I bet you would not get those valuable informations anywhere there?
So, how can you get them? You'll actually get them when you work and experience those problems yourself. Another way of getting those precious information is by asking and learning it from experience executives and engineers.
I've been working for almost three years in my current work place and I observed all these problems. I think it might be useful if I share all those plant problems with you guys. There are a lot of problems and I shall post it in this blog from time to time. The problems varies and comes from various angles and areas such as (without any particular arrangement):
1. Utilities problems :
power, natural gas, steam, water, chemicals, LFO, diesel, processing aid, air etc. Processing cost can increase the overall production cost.
2. Maintenance & Equipment problems :
Pump, piping, instrumentation, pressure transmitter, level transmitter, temperature indicator, NPSH, cavitation, control valve, steam trap, leakage, insulation.
3. Human resource problems :
Disciplinary, Late coming, absent, failure to obey instruction, negligence, psychology.
4. Report & Documentation problems :
Daily report, monthly report, quarterly report, yearly report, ISO & GMP related documents.
5. Communication problems :
Miscommunication, instruction, network, PC, server, bad relationship with up line, down line and colleagues.
6. Quality problems :
Laboratory, lab checking, quality control, testing error, solution/chemical contamination.
7. Supplier problems :
Raw material - product - goods out of spec, cheating.
8. Supporting equipment problems :
Deterioration of cooling tower performance, heat exchanger performance.
9. Planning problems :
Administration interruption, supply demand, market, margin.
10. Control system problems :
Supervisor Control and Data Acquisition (SCADA), Human machine interface (HMI) and PC, IT, network, softwares.
11. Stock, raw material, storage tank problems :
Network, false information, over flow, insufficient storage tank, contamination.
12. Stress, Pressure & Health Problems :
Meeting deadline, lack of time, inadequate knowledge, 24 hours alert and standby, meetings, reports, various crisis, inability to manage pressure from top management.
OK. That would be some very general and surface introduction on what problems we can expect from running a plant. I'll try to update and add more on those details from time to time. I welcome anybody who want to share problems that they faced in their plant. We can discuss it here and share it with the rest of the readers.
Labels: Chemical Plant, Control System, Cooling Tower, Energy, Environmental, Heat Exchanger, Learning Curve, Process Parameters, Study, Training
posted by Kipas Repair JB @ 9:23 PM,
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2 Major Exhibitions and Conferences in 2 Countries
Friday, November 23, 2007
There will be two major events (Exhibition and Conference) coming on this coming week from 27 - 30th November 2007. One will be held in Malaysia while the other one will be organized in Singapore. Check it out:
BioMalaysia 2007 - Venue: Putra World Trade Centre (PWTC), Kuala Lumpur.
BioMalaysia 2007, Malaysia’s premier international biotechnology event, brings together biotechnology and life science professionals, executives, entrepreneurs, investors and policymakers from all over the world to connect, network, learn and exchange ideas.
BioMalaysia 2007 is targeted at local and international biotechnology and life sciences attendees from all areas of the industry specifically in Agriculture, Healthcare and Industrial sectors.
This year’s theme focuses on innovation, the driving force of biotechnology. Get new perspectives and insights on how the biotechnology and life sciences industry plays a crucial role in innovation economy, and what the unique opportunities and challenges are in bringing innovative discoveries to commercialisation in the global markets. Hear what the roadmap for an Innovation Economy in Malaysia will be.
Featuring
- Latest research findings
- State-of-the-art technologies
- New product launches and demonstrations
- Networking opportunities with local and international attendees
- Business and collaborative opportunities
- Production and research capabilities
- Media publicity opportunities
Agriculture, Healthcare and Industrial Biotechnology
CIA 2007 - Venue: Suntec Singapore, Level 4.
ControlsAsia2007 - The 15th International Plant Process Engineering Exhibition and Conference
InstrumentAsia2007 - The 13th International Instrumentation, Measurement and Testing Exhibition and Conference
AnaLabAsia2007 - The 11th International Laboratory and Analytical Technology Exhibition and Conference
CIA2007 provides an ideal platform for the sharing of ideas and building of new contacts among the industry leaders and professionals in controls & automation, instrument, testing, analysis and process engineering. Preregister Online at: www.cia-asia.com
Personally, I have attended the CIA2006 held in KLCC last year. I gained a lot of informations, ideas, knowledges and goodies. It will be great to attend the CIA2007 in Singapore. Unfortunately, I could not make it to either the BioMalaysia2007 or the CIA2007 due to job constraint. Hopefully I can visit such exhibition later in the future. I hope anybody attending the exhibition or seminar can share their experiences with us.
Discuss your problems at Chemical Engineering Forum
Labels: Biology, Biotechnology, Control System, Equipments, Exhibition, Learning Curve, News, Quality, Seminar, Training
posted by Kipas Repair JB @ 11:16 PM,
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Inside McDonalds Meat Processing Plant
Tuesday, November 13, 2007
Everybody enjoys having a happy hour meal at the most famous franchise fast food restaurant - "Mcdonalds" and that includes me. In fact, I just had a nice dinner with my family 2 days ago in Mcdonalds Jaya Jusco Johor Bahru. As I googled about processing plant, I found this very interesting short video on how the meat for their famous burgers are processed. It is amazing to learn about their hourly quality control (QC) to ensure that the meat is tasty and juicy before packing it. The cleanliness factor is also strictly taken into consideration. After neatly, safely and cleanly wrapping the boxes (which contains the meat), they're distributed throughout the States.
Labels: Control System, Equipments, Learning Curve, News, Process Parameters, Processing.
posted by Kipas Repair JB @ 11:16 PM,
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My PLC (Programmable Logic Controller) Experience
Monday, October 29, 2007
At work there are still a lot of things to be done. The latest, hottest and interesting job in my list is the PLC (programmable logic controller) upgrading in my plant and control room. For me, this is a very enriching project and an excellent learning experience for me. All these while, I've been monitoring the temperature, flow rate, pressure, utilities, processes, costing, equipments, instrumentations, reports etc., but now I'm going to get myself a little bit familiar with the plant control system. Previously, at university, I don't really fancy process control; and advance control subjects, but now, I'm beginning to be develop some interest in them. However, if I'm not mistaken, the subjects don't really touched a lot of PLC stuffs.
OK, back to the present moment. Every process plant must have their own PLC to run the process or production plant. If not, the plant operators have to switch the pump, flow meter or other instruments manually and that's impossible at this era. It will be very difficult for them to control and monitor a running plant.
Lets see some definitions of PLC. According to Wikipedia: "A PLC is a digital computer used for automation of industrial processes, such as control of machinery on factory assembly lines. Unlike general-purpose computers, the PLC is designed for multiple inputs and output arrangements, extended temperature ranges, immunity to electrical noise, and resistance to vibration and impact. A PLC is an example of a real time system since output results must be produced in response to input conditions within a bounded time, otherwise unintended operation will result."
A non-technical term to describe a PLC: A PLC is the type of computer that controls machines. The PLC is used to control and troubleshoot machine. The PLC is the brain of the machine. Without it, the machine is dead.
For the past few days, I've been studying the input/output (I/O) arrangements at the control panel. These connect the PLC to sensors and actuators. PLCs read limit switches, analog process variables (such as temperature and pressure), and the positions of complex positioning systems. On the actuator side, PLCs operate electric motors, pneumatic or hydraulic cylinders, magnetic relays or solenoids, or analog outputs. The input/output arrangements have external I/O modules attached to a computer network that plugs into the PLC. The I/O points consists of digital input, digital output, analog input and analog output. I checked them and counted how many spare I/O points are available to be used for additional pressure transmitter, RTD, inverter and pump that we're going to install (which is part of some slice of plant upgrading projects).
Hmmm....I guessed, that's enough for some brief introduction on the PLC. I may continue about my PLC adventure in future.
Labels: Chemical Engineering, Chemical Plant, Control System, Learning Curve, Study
posted by Kipas Repair JB @ 11:06 PM,
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CITECT Control System Seminar
Friday, May 18, 2007
Citect has been providing global business solutions, engineering services and software to the automation market for over 30 years. Specializing in the delivery of innovative, reliable and cost effective solutions, Citect connects people in business and industry to real-time information in ways that improve business strategies and decisions. My plant is using Citect control system.
The email I received from events-asia@citect.com:
Citect Asia will hold a series of complimentary Tech Update seminars across SE Asia in late June, early July.
We will also be launching the Citect Asia Users Group at the Tech Update. The Citect Asia Users group will provide an important environment for users of Citect products to exchange ideas, obtain assistance on technical and management issues, and keep abreast of new product developments.
As seats will be limited at all locations, I am attaching preliminary details of dates and locations. Reservations can be made by emailing your name and the preferred seminar date to:
Please take advantage of this advanced notice to reserve your place now and avoid disappointment.
Yours SincerelyMichael Preston
Business Development Director, South East Asia
Citect Pte Ltd
Singapore
Tel +65 6482 2212
Fax +65 6482 2252
www.citect.com
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Labels: Chemical Engineering, Control System
posted by Kipas Repair JB @ 12:32 AM,
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The Author
I’m Zaki. I used to be a project, process and chemical engineer. Few years ago I successfully became a Chartered Engineer (IChemE) and Professional Engineer (BEM). I'm now employed as a chemical engineering educator/researcher/consultant. Hope you like reading my blog. I welcome any feedback from you. My email: zaki.yz[alias]gmail.com. TQ!
