Batch Reactor As A Plant Engineering Essay

upsurge nuclear nuclear nuclear reactor As A flora Engineering EssayWhat is a mark unit. All Equipment that make up a ready give the bounce be divided into 3 dissimilar categories or levels, the highest cosmos the place as a whole, accordingly the tramp units and the lowest ar the plant items.While the actual plant performs an boilers suit sell, the define unit refers to the main components of a whole kit and boodle which perform a major drudgery function of the Plant and with proscribed which the Plant washbasin non continue its mental processs. A Plant unit is make up of items alone it can be replaced as a whole (Anthony Kelly)In this Plant, the mint nuclear reactor receives raw actuals from the raw material storage, processes them for a certain criterion of while then transfers them to the separator feed vessel.From the above diagram, it is obvious that the sess Reactor is a major component of the plant and from its function it is seen that the reactor must process the raw material for progress to be do to the next stage of drudgery.I am on that pointfore concluding this as my explanation as to wherefore the fortune reactor is a plant unit.Explain Your Reasons For Concluding That This whole Is Critical For Production.Several Factors determine how comminuted a piece of equipment is to payoff. They includeWill the Equipment affect safety in the plant?Will the Equipment non engagementing attempt d avouch era in the plant?How easily can the Equipment be maintained?What is the be of this alimony?What is the menstruum situation of the Equipment? (Paul Wheelho rehearse) straight off each(prenominal) of the circumstanceors can be used to run into the jam Reactor and after which an educated decision can be do.The lot Reactor affects the safety in the plant because its function involves the warming of chemicals under pressure and its failure might cause the revealage of these chemicals or at the worst lead to an explosi on in the Plant.If the Batch Reactor was to stop working, in that respect would be prolonged ingesttime until it is fixed this is collectible to the fact that the Reactor performs a major function in the Plant without which moreover end product would come to a halt.The Batch Reactor is made up of a number of different items, some of which can be run-to-failure, plainly for the most an established schedule of nourishment must be made for. Without such a schedule, aid would be most difficult to reserve out.The cost of maintaining the Batch Reactor may vary but if is not aright attended to one fault might lead to some separate even bigger one so the cost of maintaining might increase.The items in the Batch Reactor have a flavor plan which is currently not being kept to this office the Equipment requires monitoring to avoid ergodic failure or prolonged breakdown and downtime.On the account of the above facts, it is my belief that the Batch Reactor involve to be labelled as critical.Extract Any User Requirements For This Designated Unit From The Plant explanation. Are on that point Any Production Windows?What be User requirements? This simply refers to the specifications that be built-in in a piece of equipment so that it might be fit to fulfil the end users needs according to those tasks which it is used to perform.In literary argument with the plant description given on this particular Batch Reactor, a number of user requirements can be ascertained and these atomic number 18 listed beneathTo receive 18te of raw materials from the raw material storage.To remain tendered and take fire its contents by and through a preset temperature / time profile by use of a temperature control administration consisting of a thermocouple in a temperature pocket, a temperature controller and a control valve.That the control valve regulates the yield of low pressure steam.That its temperature alarm signal when the temperature exits 1250C.That all sa fety moderateness valves work in event of an increase of temperature past the safety keep of 1250C.That the bottom run eat up valve opens when the operation is complete and releases the contents from the Batch reactor to the centrifuge feed vessel by the discharge pump.That the operation lasts 10 hours solely.What is a production window? This is a period during production in which guardianship procedures can be carried out without create a halt in production. With emphasis on the Batch reactor it can be seen that there is a production window and this can be explained below.While the vision reactor makes 18te of product every 10 hours, the centrifuge processes this product at a rate of 1.5te an hour i.e. it would have alone used up the 18te of product in 12 hours. Since it takes 10 hours for the bundle reactor to work, this would give a 2 hour production window in which it can be properly maintained.Also depending on the readiness of the centrifuge storage vessel, it is pos sible for the cud reactor to work overtime filling this feed vessel up and then be switched off and maintained charm the centrifuge is operated victimization the previously stored produce in the centrifuge feed vessel.Extract Any Corporate Requirements for This Unit From The Plant Description.What be corporate requirements? These are the requirements which the upper talk termsment or c satisfactory sector of the comp any running plant desire from its industrial operations in order to make a sui dining table return on its investments (ROI).From the plant description the following corporate requirements can be made belowThat its keeps to its scheduled annual shutdown period of 16 hours during workweek 40 each year.That all aid pertaining to the batch reactor abides by the permit to work outline which controls all tending activities.That the batch reactor achieves a 25 year behavior and that the hucksterboxes achieve a 15 year feeling as hygienic.That the batch reactor re mains well-painted, clean-living and tidy at all generation.Extract Any Legislative Requirements for This Unit From The Plant Description.What are legislative requirements? These are Plant requirements made by the Law, rules or regulations or the Country in which the Plant operates. They must be implemented in order for the plant to avoid sanctions or being shut down.In this particular plant description they includeThat the Batch Reactor abides by the rules by the FDA and British pharmaceutical Society put in place for their license holders.All production and nutriment activities involving the Batch reactor comply with the Good Manufacturing practise (GMP).That the processes involving the Batch Reactor are as okayed by the quality standard ISO 9002.That the batch reactor conforms to the environmental standard ISO14000.That if used by the Pharmaceutical reexamination team, the batch reactor must ladder any risk-based inspections based on a DNV methodo system of logical digest t hat might be carried out.Comment On If Some of The tasks Designed For cloture Could be Done During Production Windows Or When The Plant Is Online. Could Any Of These Tasks Be Designated For Completion During Production Windows Be Completed Online?We have previous explained what production windows are and when a Plant is online refers to when the plant is carrying its usual operational procedures. From the work done previously in region 1.3, we now know that there is a definite 2 hour production window during which the batch reactor can be maintained while the centrifuge is working. In looking at the lifetime plan for the batch reactor unit, there are a certain amount of tasks that could be done in 2 hours and should be moved from shut down to production window, these areThe replacement of the trim of the CV1 every 2 years.The pressure try oning and inspection of the SV1 every 6 years.The visual check of the agitator every 6 years.The SV2 pressure testing and inspection every 6 years.There is only one task put to be completed when there is a production window and it can be done while the Plant is online. This is the weekly visual check on the Agitator mating, because if it is checked while online it might lead to the location of which wouldnt have being seen if the equipment was offline.Analyse The put down Jobs From The Computer Maintenance Management arrangement (CMMS) For This Unit. Is There Any rise Which Confirms That The vivification Plan Is Being Carried out? Is There Any enjoin To Say If The Life Plan Is Effective Or Not?What is a Life plan? All plant units or manufacturing stages in production are designed to have a certain life. To fulfil this, sustenance plans are put in place to achieve this expected equipment life and if possible, to exceed it. These alimentation plans are called Life plans. (Wheelhouse, 2008)On comparing the life plan of the batch reactor to the computer nourishment management system (CMMS) it can be seen that the li fe plan isnt being carried out. This is due to the doer that there is a remarkable difference between the standard time taken to maintain every single unit item in the reactor and the actual time the job was done in hours, core the maintenance done cannot be adequately planned for and could lead to luxuriant downtime.It can be seen that for this singular reason the life plan of the batch reactor is not capable of being effective.Use The Figures, Plant Description And The Data From The CMMS To Analyse The Unit Into Its Maintenance causation Items.Using the underframe 1 shown previously and the figure 2 shown setly above as well as the Life plan and the CMMS, the maintenance ca apply items can be broken down as done belBatch Chemical ReactorCV1Agitator CouplingTemperature controllerGearbox force bearingOil sealAgitatorTrimAgitator gear boxReactor VesselTemperature sensor bosomMotorPump bearingSV1SV2P1V1VesselJacketFigure 3 The Maintenance Ca employ Items in a Batch Chemical Reac torDevelop your own life plan for these maintenance causing items using the task pickaxe logic for Reliability Centred Maintenance.RCM WORK SHEET SYSTEM CHEMICAL specifySUB-SYSTEM BATCH CHEMICAL REACTORSUB-SYSTEMFUNCTIONFUNTIONAL chasteningFAILUREMODEFAILUREEFFECTCRITICALITYRESPONSETIME frequenceCV1Regulates supply of lowPressure steamUnable to supply steam at all.SuppliesInadequate steamFaulty TrimAbsence or insufficientSupply of steamHigh commute trim3 hrs2 yearly(Production window)Agitator MotorGearboxTransmit act to theAgitatorFails to transmit motionTo the Agitator.Broken sealShortage of lubrication disgraced bearingsWorn gear teethOil let onageDamage to gearboxMediumMonitor vibrationsand check oil sealand condition.2 hrs (vibrationmonitoring),12 mins oilinspectionMonthly Vibrations,Daily oil seal checks(Online)AgitatorCouplingConnects Agitator motor gearboxto Agitator for motion contagious diseaseDoesnt transmit motionFrom gearbox to agitator.Transmits inadequateMotion. Slackness in sufficientDoesnt give agitatorThe infallibleTransmitted motion.MediumTighten coupling asrequired.6 minsDaily (online)TemperatureControllerControls the temperature makingsure it doesnt exceed 1250 CUnable to read thecorrect temperature.Faulty temperaturesensor . annex or reductionof reactor temperatureon wrong information.HighRecalibratetemperature sensor.2 hrs2 year (Productionwindow)SV1Releases the pressure steam in thevessel during generation of alert.Unable to releaseexcess pressure steam belt upage at valveoutlet. crack up in valvePressure steam isnot released properly orin time.HighInspect, pressure testand recondition ifnecessary.3 hrs6 yearly (Shutdown)SV2Releases excess steam in the jacketin times of alertUnable to releaseexcess steamBlockage at valveoutlet.Crack in valvePressure steam isnot released properly orin time.HighInspect, pressure testand recondition ifnecessary3 hrsYearly (Productionwindow)AgitatorShakes, stirs mixes the rawmaterials in the reacto r.Unable to stir or mixRaw materials.Damaged bladesEroded surfaceRaw materials arenot mixed properly.MediumRecoat or replace asnecessary.3 hrsRe-coat or replace asnecessary.(Shutdown)JacketMaintain its integrity and dribbleraw materials during processing.Leakage of materialsduring processing.Damaged or erodedParts.Contents leak outcausing contamination.HighPressure test andrepair as necessary.5 hrsYearly (Shutdown)V1Releases processed material toP1 pumpProcessed materialsnot releasedLeakage of materialduring releaseBlockage at valveoutletCrack in valveContents not releasedproperly.Contents leak outcausing contamination.HighLeak test and repairif necessary.15 minsDaily test (Online)P1Transfer processed materials fromreactor to centrifuge feed vesselLeaks materialUnable to pumpmaterials at all.Pumps materials atWrong rate.Replace seal ifnecessary.Replace pump ifnecessary.Contents leak.Contents not pumpedproperlyHighConditionmonitoringReplace seal ifnecessaryReplace pump ifnecessary.1 .5 hrs(ConditionMonitoring)4 mins (Leaktest)Monthly conditionMonitoring (Online),Daily leak checks(online)Figure 1.4 Life Plan using RCM logic.Compare and contrast between your Life plan with the one described previously, comment on any similarities and differences.There are a number of ways in which my Life plan differs from the one previously given but there are also ways in which both are similar. Some of them are as listed belowTo begin, the first detail that can be notice when comparing both life plans is that since I used the RCM selection logic, my life plan carries much more detail as I include the functions, operational failures, failure modes, failure effect and criticality of each subsystem or item. This will be particularly useful in settling up priorities as the criticality of each subsystem is set at low, medium or high depending on the considerations of safety, performance and tinge of the subsystem or item on the rest of the plant.I brainstormed and added more f ailure modes and their activities than had being previously find or had activities planned for in the previous life plan so as to further prepare maintenance personnel to be able to tackle these failures if and when they do occur.I changed the time frame for certain activities to take into consideration the new 2 hour production window that was detect earlier. This will help reduce the amount tasks that are done during a shutdown and therefore cut down the downtime which the plant undergoes.I increase the amount of time to be used to accomplish most tasks due to the fact that in the previous life plan, insufficient time was allocated to these tasks so therefore they couldnt be planned or executed properly indoors the targets set for them.Now in terms of similarities, I observed that the safety maintenance and condition monitoring carried out on the Batch Reactor had ensured breakdowns were kept to a minimum so bearing this in mind, I retained all the activities from the old life plan and continued using them for the various items.I also continued to carry out maintenance activities at the like frequency that was mapped out in the old life plan as I believe that the punctuality with which activities were carried out alter the reliability of the equipment.CHAPTER 2Describe The Philosophy of hail Productive Maintenance.What is TPM? Total Productive Maintenance (TPM) refers to a management system for optimizing the productivity of manufacturing equipment through systematic equipment maintenance involving employees at all levels. Under TPM, everyone is involved in keeping the equipment in good working order to minimize production losses from equipment repairs, assists, set-ups, and the like. (http//www.siliconfareast.com/tpm.htm).The goal of TPM is to increase production while at the same time boosting employee morale and job merriment. (Venkatesh. J) This is possible because there would be little downtime as TPM is carried out by the Operators on the ite ms or railcarry which they use as they, the maintainers and Designers work as a team towards the derive elimination of equipment defects in the Plant (Paul Wheelhouse).History of TPMTPM is a Nipponese idea that can be traced back to 1951 when preventive maintenance was introduced into Japan from the USA. Nippondenso, part of Toyota, was the first come with in Japan to introduce plant wide preventive maintenance in 1960. In preventive maintenance hustlers produced goods using machines and the maintenance sort out was dedicated to the work of maintaining those machines. However with the high level of automation of Nippondenso, maintenance became a problem as so many more maintenance personnel were now required. So the management decided that the routine maintenance of equipment would now be carried out by the operators themselves. This is known as self-governing maintenance, one of the features of TPM. The maintenance group then focussed only on maintenance works for upgrades. F or pioneering TPM, Nippondenso became the 1st company to receive TPM certification (wikipedia).why Use TPM?For TPM to be used in an Organisation, everyone from senior management to the operators on the floor must be carried along and made to understand why this particular system is being used. For this to happen effectively, the Motives, Objectives and benefits must be in full stated out and properly absorbed. The table below gives a generic wine illustrationMotives of TPMAdoption of life cycle approach for improving the overall performance of production equipment.Improving productivity by highly move workers which is achieved by job enlargement.The use of voluntary small group activities for identifying the cause of failure, possible plant and equipment modifications.Uniqueness of TPMThe major difference between TPM and other judgments is that the operators are also made to involve in the maintenance process. The concept of I (Production operators) Operate, You (Maintenance de partment) fix is not followed.TPM ObjectivesAchieve Zero Defects, Zero sectionalisation and Zero accidents in all operational areas of the organization.Involve people in all levels of organization.Form different teams to reduce defects and Self Maintenance.Direct benefits of TPM annex productivity and OPE (Overall Plant Efficiency ) by 1.5 or 2 times. remediate customer complaints.Reduce the manufacturing cost by 30%.Satisfy the customers needs by 100 % (Delivering the right quantity at the right time, in the required quality.)Reduce accidents.Follow pollution control measures.Indirect benefits of TPMhigher(prenominal) confidence level among the employees.Keep the work place clean, neat and attractive.friendly change in the attitude of the operators.Achieve goals by working as team.Horizontal deployment of a new concept in all areas of the organization. serving knowledge and experience.The workers get a feeling of owning the machine.Figure 4 .TPM tableSource An admittance to Tota l Productive Maintenance (Venkatesh. J)For TPM to start properly, the OEE (Overall Equipment Effectiveness) should be calculated and a loss compendium performed to give both a baseline for continuous upgrading and ascertain the improvement priorities.This will allow the operator/core maintenance team to prioritize and then tackle the 6 classic losses ofBreakdownsSet-ups and changeoversRunning at reduced speedsMinor simoleons and idlingQuality defects, scrap, yield and reworkStarting up lossesThe above losses add to the direct costs. Implementation of TPM attacks these and other direct (visible) costs as well as indirect (hidden) costs and follows each step in the production and supply chain from Management to the valet resources to the Machine to the process, then to suppliers and finally to the customers (Willmott and McCarthy).Components of TPMFigure 4 Pillars of TPMSource An Introduction to Total Productive Maintenance (Venkatesh. J)As shown above, TPM is made up of 8 main asp ects which when combined present the full TPM package. They areThe 5 S which are primarily the foundation of TPM and involve organising the workplace. These are sorting, systematising, sweeping, standardising and self-discipline.Autonomous maintenance which refers to the operators handling most or in cases all of the maintenance concerning the machines which they operate.Kobetsu Kaizen means small improvements or changes for the better of the organisation.Planned maintenance entails scheduled maintenance which is done to ensure trouble free machines and equipments producing defect free products for total customer satisfaction.Quality maintenance is aimed at providing customer satisfaction by providing the highest quality through defect free manufacturing.Training to give employees a multi skilled edge.Office TPM to ensure administrative efficiency as well. precaution, health and environmental awareness to ensure zero accidents, zero health remedy and zero fires (Venkatesh. J).Desc ribe a Case Study Where TPM has been triumphfully utiliseThe case engage which I wish to use is that of RHP Bearings. This RHP Bearings branch which is in Blackburn, manufactures cast iron bearing housings for a variety of uses from awkward machinery to fairground rides, and is one of seven RHP manufacturing sites in Europe owned by Japanese group NSK, the worlds second largest bearings manufacturer.How TPM was carried out.NSK acquired RHP in 1990, when the Blackburn site was under the imminent holy terror of closure because of high costs and the subsequent lack of competitiveness. Employing a faculty of 93, TPM was then introduced to the site in 1993 but it didnt see much success till 1996 due to the fact that the earlier efforts to drive TPM had been largely supposed and the workforce faded to see its relevance to the everyday running of the plant. In 1996 a maintenance company was brought in to do a scoping study of the plant, conduct a workshop and support two pilot TPM p rojects.The Plant Manager and the TPM facilitator then began to implement measures to ensure TPM was made directly relevant to the jobs of the staff. Operators were sent off to climb over their machines and log problems through a detailed condition appraisal, to establish a foundation for future TPM improvements.TPM was piloted on two key machines, the PGM core making machine in the metalworks and the Shiftnal sphering machine in the machine shop, using a detailed seven-step TPM effectuation programmeCollection and calculation of Overall Equipment Effectiveness (OEE) DataAssessing the half dozen lossesCriticality sound judgment and condition appraisalRisk assessmentRefurbishment planAsset care and best practice routines first-string review for problem solvingTPM is applied to machines of all ages from new to 30 years old, ensuring that older machinery is brought up to modern specification and newer machinery is kept in as-new condition. The TPM was applied at the site by 9 diffe rent equipment teams commission on specific machinery and involving 60% of the workforce. These teams included operators, maintainers, quality technicians and group leadership also drawing on help from personnel with specialist skills when necessary. all(prenominal) Team developed a standard routine for their respective machines usingAutonomous Maintenance System (AMS) boards which show a schematic of the machine then tags with labels to show losses affecting availability, performance and quality. These labels are then used to generate TPM agendas for team meetings.TPM step notices which illustrate the machines progress in TPM seven step programme.Mainpac database which is used to gather machine performance inside information and calculate the OEE.Key performance indicators which the teams use to accesses their improvement and progress in areas of waste sand, Gas emissions, Kaizen, Customer returns, lost time incidents, injurious accidents, study and product conformance.Each team then has an activity board book binding subjects such as milestone activities and previous days conformance pull up stakes among others. To ensure TPM succeeded, Teams had to dedicate substantial time to carrying out laid down activities and held meetings as needed.Benefits of TPMImplementing TPM had both direct and indirect effect on the production system a combination of which generated major savings at RHP, Blackburn. study Site-wide benefits were scored in the following areas400,000 running costs savedUnit cost reduced by 21%Scrap reduced by 8%Attracting increased capital investment currently at 15% of turnover and Customer returns reduced by 11%Increased customer satisfactionImproved safety recordEnvironmental and quality awardsImprovement in staff moraleThe two key machines (The Shiftnal sphering and the PGM core making machine) also had major total cost saving OEE improvements as well as other time saving and cost reduction achievements making the TPM well worth it (Willm ott and McCarthy).Reliability Centred Maintenance (RCM) As Applied in a Section of a PlantWhat is RCM? RCM is a method for developing and selecting maintenance alternatives based on safety, operational and economical criteria. RCM employs a system posture in its analyses of system functions, failures of functions and prevention of these functions (Jones, R.B).So RCM requires in-depth of the machinery, detailing all logic problems and their maintenance solutions and as such can be quite time consuming, for this reason it is usually used only on the critical equipment. The use of RCM methodology requires that 7 questions be answeredWhat are the functions of the Asset?What are the functional failures?What causes the functional failures?What happens when the failure occurs?How much does each failure matter? give the bounce we predict or prevent failure and should we be doing so?How should we manage the failure if prediction or prevention is not an option?(Paul Wheelhouse)Now in order t o answer the above questions, a System analysis process is used to begin RCM on any section of the plant. This System process will implement several locomote, all of which define and dispose RCM and will methodically delineate the information required for the maintenance footfall 1. System selection and Information collection Taking decisions as to what level of the plant at which to do the RCM and also choosing this system or section based on criticality i.e. based on function and impact on plant and environment.Step 2. System Boundary Definition This involves creating an immaculate list of what is or is not part of the section so an hi-fi list of components can identified and to establish what comes in and what leaves the System(IN and OUT interfaces). This is necessary to ensure the accuracy of the Systems analysis process.Step 3. System description and functional Block diagram This is used to identify and document the essential details of a system that are needed to perform the remaining steps in a thorough and technical fashion. The five separate items are developed in this stepSystem DescriptionFunctional Block DiagramIN/OUT interfacesSystem Component listEquipment explanationStep 4. System Functions and Functional failures involves classifying each OUT interface of the system into its functions and identifying the failures which might hinder these functions.Step 5. Failure Mode and Effect analysis (FMEA) involves analyzing each component failure to discover which have the potential to intermission their function and then detailing what exactly these effects could be. This is done using functional failure-equipment matrix.Step 6. Logic (Decision) Tree Analysis (LTA) the failure modes which pass through effects analysis will now go through this process. The purpose of this step is to further prioritize the emphasis and resources that should be addicted to each failure mode on the basis that all spot (TVA). TVA is a power production plant wholly ow ed by the US government and equipment, functions and failures are not the same. The LTA identifies the failure modes in 3 aspectsSafetyDowntimeEconomics (Finance)Step 7. Task selection In this step, applicable maintenance tasks which are most effective to combat the detailed failure modes are listed, at the same time decisions on whether to run-to-failure or design out