Chemical Engineering World

Labels: Chemical Plant, Equipments, Learning Curve, Problem, Processing., Pump, Quality

posted by Kipas Repair JB @ 12:32 AM, ,

300 , Design Project 2, 5S, NPSH, Pump - Rambling!!!
Sunday, November 04, 2007

I did not realize that the previous post about "Dipping Tape and Measuring Oil Tonnage" was my post number 300. That makes this current post that you're reading - number 301 in this Chemical Engineering World blog. Wow, it has been about 1 year and 3 months since I began blogging about my working experiences. I never expected , thought or dreamed this blog can be like what it is today. I never imagined to have more than 250 subscribers (at this moment and growing) for a technical chemical engineering blog. Thanks for your support.

This coming days will be a very hectic one for me. Tonnes of jobs and projects are waiting for me at work. We are going to have some minor 9 hours plant maintenance job. That job must be carefully coordinated in order to reach its objective - which is to improve the vacuum system in our plant process. I also have my plant monthly reports to complete and that is not easy as it need us to really focus and concentrate.

At the same time, the final year design project 2 file number 2 just arrived last Friday from a local university for me to read, digest, check, evaluate and give marks. I'm not sure when I can finish reading the design project report, but I was ordered to complete and email the marks by the end of this week... Well, I got to rush for that as well.

Oh yes... I almost forgot that I also need to conduct a 5S training for my plant operators. Maybe I'll arrange that on Tuesday afternoon.

Yesterday, on Saturday, I attended a very brilliant 3 hours training regarding pump. The training was conducted by one of our very experience and knowledgeable superior. From the training I discovered various types of pumps with various applications. We also did some real practice on how to calculate the Net Positive Suction Head (NPSH), based on our plant condition and situation. This was more advance from the basic NPSH that we learned in university. Furthermore, at university, we only know the theory, but this time, we experience and appreciate the NPSH knowledge... of course after we faced all the pump problems in the plant. We did learned other stuffs on why the pump trips, cavitate, air lock etc and it's relationship with the pump curve.

Lately, I also received few emails asking me some favours on various issues and also asked for some advice/assistance. I'm trying my best to entertain those request, but occasionally, lately, I'm too busy. I hope you can understand my situation. I'll try my very best to get back to some of you. I'm also struggling and fighting with time to keep this blog updated with fresh feed and content for you to read. That's why I really appreciate anybody who is willing to provide one or two post (or more... which is good) so that we can have this blog updated more frequently. If you have anything to share, it can be from your own experience or some new stuff that you learn or know, you're welcome to email it to me. If it suite this blog, why should I not post it in this blog for you?!!

I also have some post which I did mentioned to elaborate more. I'll continue them soon. Just bare with me for a while. Some of you have personally asked the continuation of those post. Sorry for the delay mate...

Labels: Chemical Engineer, Jobs, Pump, Study, Training

posted by Kipas Repair JB @ 11:26 PM, ,

Wilden Pump Seminar
Monday, July 16, 2007

Last week, I attended a half day Wilden Diaphragm Pump Seminar organized by Winston Engineering in Hyatt Hotel Johor Bahru. I like going to this type of seminar or training held in good 5 star hotels. Besides learning about the products and technologies, we were served with very nice yummy foods. It was a very informative and enriching seminar. Sometimes we can meet with colleagues from other companies and do some networking as well. OK, before I proceed, let me provide some basic information or definition of a diaphragm pump.

"Air operated pump that uses a flexible diaphragm to separate the pumping chambers. Handles high viscosity liquids or liquids with suspended solids" (definition from bascousa.com).

"A diaphragm pump is a positive displacement pump that uses a combination of the reciprocating action of a rubber or teflon diaphragm and suitable non-return check valves to pump a fluid. Sometimes this type of pump is also called membrane pump" (definition from en.wikipedia.org).

Diaphragms inside a diaphragm pump which are from various sizes and materials (rubber, plastic, Teflon® PTFE etc....)

Various types and sizes of metal diaphragm pumps which are from stainless steel, aluminium and alloy. There are also two types of join: bolted (stronger, tougher and can withstand higher pressure) and clamp (easy maintenance)

This is the demonstration set for the Wilden Pro-Flo X which is their latest diaphragm pump. The pump is capable to deliver similar flow with lesser air consumption which means we can save on our utility cost - the air. The comparison is made with the older version of Wilden's diaphragm pump.

For more complete and comprehensive information about Wilden pump, please check Windenpump.com.

Oh yea...Wilden also have diaphragm pump made of plastic. I'm not sure this pump is suitable for what industry?

This is Wilden's latest patented pump which can run without pumping fluid. Normally, pump will be damaged if they run empty, but this pump is not like that. Can you see the ping pong ball floating on top of the discharge line of the pump?

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Labels: Equipments, Learning Curve, Pump, Seminar

posted by Kipas Repair JB @ 10:04 PM, ,

ISO and HACCP Audit
Thursday, April 19, 2007

My plant was audited today and we thoroughly prepared for this occasion since last week. It was an ISO and Hazard Analysis and Critical Control Points (HACCP) audit. We have to ensure all records and documents are well kept and organized. We must clean the plant and clear it from unwanted objects such as cotton rags, welding rod, plastic, food wrap, cigarette bud, water clogging, etc which were lying around (the lists of objects that you can find in the plant are too long but please don't assume we are not cleaning the plant. We clean the plant on a daily basis, but sometimes unwanted objects suddenly appears!!! It's a very big plant - 10 floors). Besides that the plate heat exchanger (PHE) and pump tray should be dry and clean (for your information, sometimes the PHE and pump leaks and oil is contained in the tray. This can be considered oil lost!!! Oil is money in the oil industry).

The Critical Control Point (CCP), [which is a point, step or procedure at which controls can be applied and a food safety hazard can be prevented, eliminated or reduced to acceptable (critical) levels] in my plant is the filter bags. The filter bag record and differential pressure was inspected randomly. This CCP is very important in food industry because it is the most critical step in ensuring the safety and cleanliness of a food product. I don't intend to describe more about this as it might be too technical (unless anybody wants to know more, you can ask me via email).

The glasses at the pressure gauge, temperature gauge and vessels were inspected as well. In addition, the pest control program was checked too. During the interview, we managed to answer and convince the auditor that the ISO and HACCP standards are well applied. I'm glad that we passed through this round of audit without any non-conformance (NC). Thanks to all the supervisors, shift leaders, plant operators and contract workers for their commitment, dedication and hard work for the audit preparation.

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Labels: Heat Exchanger, Oil and Fats, Pump, TQM

posted by Kipas Repair JB @ 11:16 PM, ,

Paint in Plant
Saturday, February 17, 2007

I use to think painting was simple and easy. But, when it comes to painting pumps, heat exchanger frame, walls, beam etc it opens a new chapter of knowledge inside me. Yesterday, we met with Nippon paint supplier. We learned something new about metal surface, epoxy, coating technology and others.

As I mentioned earlier in my previous post regarding 5S, we intend to improve the cleanliness and condition of our plant. We want the paint to last for about 2-3 years minimum. We don't want the paint to be nice for only a few months time before it faded and chipped of.

Initially, the supplier said that zinc chromate should be applied to prevent corrosion from progressing on the metal surface. It acts as a primer (which means the first layer to be appllied on the metal surface). Then, undercoat or finishing coat will be applied and this depends on how much cost we are willing to pay (either to have single coat or double coat). Having 2 layers of coating is better but the price is higher.

However, after considering the high temperature of pumps and heat exchanger frames and other tough environment factors in the plant, a primer layer of epoxy was suggested. Earlier, I heard that epoxy as a primer is the best to suit for tough environment, but technically I don't really know the chemistry detail behind it. A special coat (that will create stronger bond with the epoxy primer) will ensure that the quality of paint and its colour will last longer. Those combination will be slightly more expansive due to its quality.

We did get some advice on the correct painting technique and other relevant informations. Now, I'm waiting for the quotation of the primer and coating (paints).

Following is the correct painting technique from Nippon
Painting The Right Way

Now that you have chosen your ideal colours and type of finish, here are a few important tips to make your paint job came out with flying colours.

1. Prepare the Surface

• The most important stage. Ensure all surfaces are clean, dry and grease-free.
• Wash with water & liquid detergent.
• For heavy and stubborn stains, use turpentine and wash thoroughly.
• Fungus & mould: remove as above, followed by fungicidal wash or bleach.

2. Apply the Sealer or Primer

3. Apply the Undercoat

4. Apply the Finishing Coat

5. Be responsible to the environment

• Do not dispose of unwanted paint down drains.
• Allow paint to dry out in the container before dropping them into the rubbish bins.

Get some painting tips from Nippon
Learn more from http://www.nipponpaint.com.my/

Labels: Chemical Engineering, Heat Exchanger, Pump, TQM

posted by Kipas Repair JB @ 10:54 PM, ,

Plant 5S
Monday, February 12, 2007

I have my own plans and targets for my plant. I want to make the plant a better place to work. I want to improve the system and way of work. I want to beautify the 9 storey physical refining plant. I want all the pumps, heat exchangers, insulation, vessels, cable tray, etc to look nice and well maintained. I want the paint on walls to be fresh and free from dirt. I want the plant to be totally clean and shining. I want the forklift to be in excellent tip top condition with new paint. I want to see the cooling towers, bleaching earth store and spent earth area to be in superb condition. I'm working on all of that with the help of all the plant supervisors and operators. These are what we call 5S. See below for the definition and description of 5S (A Japanese Concept of Total Productive Maintenance). I hope to achieve them within the second quarter this year.

5S is a reference to five Japanese words that describe standardized cleanup:

• Seiri (整理): tidiness, organization. Refers to the practice of sorting through all the tools, materials, etc., in the work area and keeping only essential items. Everything else is stored or discarded. This leads to fewer hazards and less clutter to interfere with productive work.
• Seiton (整頓): orderliness. Focuses on the need for an orderly workplace. Tools, equipment, and materials must be systematically arranged for the easiest and most efficient access. There must be a place for everything, and everything must be in its place.
• Seiso (清掃): cleanliness. Indicates the need to keep the workplace clean as well as neat. Cleaning in Japanese companies is a daily activity. At the end of each shift, the work area is cleaned up and everything is restored to its place.
• Seiketsu (清潔): standards. Allows for control and consistency. Basic housekeeping standards apply everywhere in the facility. Everyone knows exactly what his or her responsibilities are. House keeping duties are part of regular work routines.
• Shitsuke (躾): sustaining discipline. Refers to maintaining standards and keeping the facility in safe and efficient order day after day, year after year.

Labels: Chemical Engineering, Cooling Tower, Jobs, Pump

posted by Kipas Repair JB @ 10:43 PM, ,

Checking the Valves
Thursday, February 08, 2007

Before facing the shutdown in 11 days time, I toured my plant another round, just to check all the valves and other parts that need to be replaced. I went from one pump to another pump. There are a lot of pumps. They don't look good. Ugly black dirty oils covered them. I checked the suction and discharge ball valves. Some of the suction valve are 6" and 8" valve and the discharge valve are 4". Well, the sizes of big valves are easier to detect or decide. There's no big problem for me identifying them now. However, that was not the case when I joint the company earlier. It took me some time to get familiar with all types of valves and their brand.

Then I went from one heat exchanger to another heat exchanger. I checked out the drain valves. It's harder for me to estimate the sizes of those drain valves and deciding the brand. There are commonly small varying from 1/2" to 2". In between those sizes, there are also 1.75" 1", 1.5" and others. Deciding the correct size and brand is vital to order and purchase the repair kits/seats. Ordering the wrong spare parts will just be a total waste of money and time and the chance to replace the valve seats which can only be done during plant shutdown.

The darkish, oil layer covering the valves at the pumps and heat exchangers are something that must be improved. It should not be left dirty and uncomfortable for eyes. It should be cleaned and well maintained. I want the valves to be clean and shining like a new piece of metal. Well, We are working on that as well. I'm developing a 5S system (a Japanese Concept of Total Productive Maintenance (TPM)) for maintaining the plant to be a clean healty place and pleasant working environment.

Labels: Heat Exchanger, Plant Shutdown, Problem, Pump, Quality, Valve

posted by Kipas Repair JB @ 11:17 PM, ,

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!