Chemical Engineering World November 2018

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NEWS Industry News

06

FEATURE CHALLENGES IN SETTING UP ETP FOR REFINERIES Satya Narayana Y V V, SFC Environmental, Technologies Pvt Ltd

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MAPPING THE WAY TO CONTROLLING NUISANCE NOISE Arne Berndt, Owner & Adviser at SoundPLAN, GmbH and SoundPLAN, International LLC

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MWH GLOBAL WATER RECYCLING PLANT DESIGN EASES WATER CONSUMPTION BY 60 PER CENT Aidan Mercer, Industry Marketing Director, Utilities and Government, Bentley Systems

34

INTEGRATED ENGINEERING, OPERATIONS AND ASSET MANAGEMENT ARE VITAL FOR CHEMICAL INDUSTRIES Valentijn de Leeuw, Vice President, ARC Advisory Group, Europe

40

EFFECTIVE RISK MITIGATION STRATEGIES FOR PROJECTS Shailesh Dhume, Principal Consultant, Infuse Consulting

46

HOW ENGINEERING SOFTWARE CAN HELP Philippe Marceau, Executive Vice President, Hexagon PPM EMIA

50

INTERFACE CHALLENGES…A CONTRACTOR’S PERSPECTIVE Arpan Shah, Mott MacDonald Industry Account Leader

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NEWS FEATURE Bridging the industrial sector’s skills gap with experiential learning

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Simon India Commissions WHR plant for Cement Plant

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4 • November 2018

MARKETING INITIATIVES

INTERVIEW THE ERA OF COLLECTIVE RESPONSIBILITY Mr Suneet Prakash, Head – Group Projects, Aditya Birla Management Corporation Pvt Ltd

72

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CEW Industry News India-Azerbaijan sign protocol on science and technology cooperation

the Ministry of Chemicals & Fertilizers has taken various steps to ensure availability of ‘Affordable, Quality Medicines for All’, the Minister added.

In this background, Mr Mandaviya informed that the Pharma sector has seen a positive growth after the implementation of GST. Before GST, Annual Turnover of the Pharma Sector as on May 31, 2017 was ` 1,14,231 crores while after GST, the Annual Turnover of Pharma sector May 31, 2018 touched ` 1,31,312 crores, which is 6 per cent higher than the Pre-GST regime. Exports from Pharma Sector during 2016-17 were ` 2,75,852 crores while post-GST, in the year 2017-18, they were recorded at ` 3,03,526 crores, which is 10 per cent higher than the PreGST Regime. The Minister added that as per estimates, the export figure for the current year is likely to be ` 3,27,700 crores, which will be almost 12 per cent higher than the export figure of Pre-GST regime for 2016-17.

The 5th meeting of India-Azerbaijan Inter-Governmental Commission on Trade and Economic, Science and Technology Cooperation (IA-IGC) was held on 11-12 October, 2018 in New Delhi. The meeting was cochaired by Union Minister of Commerce & Industry and Civil Aviation, Mr. Suresh Prabhu and Minister of Ecology and Natural Resources of the Government of Republic of Azerbaijan, Mr. Mukhtar Babayev. The two sides exchanged views on current economic situation and reviewed the current status of bilateral trade, investment and their cooperation in the fields of trade, economy, science and technology. They emphasised to further strengthen and expand their cooperation in trade and investment, transportation, energy and hydro-carbons, SMEs, agriculture, food safety and environmental protection, tourism, culture, health and pharmaceuticals, space technology, education and scientific research, chemicals and petrochemicals and mining.

Trade turnover between India and Azerbaijan in January-August 2018 was USD 657.9 million. Both sides felt that bilateral trade was far below the potential and there was a need to step up the cooperation to enlarge the trade basket and increase bilateral trade and investment. Both sides agreed to take measures to enhance trade relations and expand business relations between the two countries. It was decided to send trade delegations to raise awareness regarding economic developments and reforms in the two countries and have regular exchange of information about trade exhibitions, fairs, conferences and other business events.

Both sides agreed to convene the next meeting of the India-Azerbaijan Inter-Governmental Commission on Trade, Economic, Science and Technology co-operation in Baku. The dates for the meeting will be mutually agreed through diplomatic channels.

Impact of GST largely positive and constructive on Pharma Sector Impact of Goods and Services Tax (GST) on Pharma sector has largely been positive and constructive, informed Minister of State for Road Transport, Highways, Shipping and Chemicals & Fertilizers, Mr. Mansukh Mandaviya, in a statement here today. Following the vision of Prime Minister of India, Mr. Narendra Modi, to ensure health security for all citizens of India, 6 • November 2018

There has been a significant jump in number of Drug Approvals from 7,857 before GST July 1, 2016 to June 20, 2017 to 10,446 post-GST July 1, 2017 to June 30, 2018. Under the ‘One Nation, One Tax’ regime, the removal of complexity of multiple taxes has reduced their cascading effect on the final product. GST is expected to decrease the manufacturing cost in view of merging of different taxes levied earlier and promote ease of doing business. It will create one single market for all stakeholders with equal chance towards development. Moreover discontinuation of Central Sales Tax post-GST, will reduce transaction costs, as inter-state transaction between two dealers will become tax neutral. Now, the pharma companies can consolidate their warehouses at strategic locations, effecting a reduction in cost of distribution. As a result, it will benefit warehouse strategy and improve supply chain efficiency in pharma sector.

hte develops accelerated catalyst aging protocol for hydrotreatment application together with MOL G hte – the high throughput experimentation company has been commissioned by MOL Group to develop an accelerated catalyst aging protocol for a diesel hydrotreatment application. With the results, MOL will be able to better predict long-term performance when selecting refining catalysts.

Selecting the right catalyst in a refinery is crucial for optimizing economic profit and efficiency. When selecting a new diesel hydrotreatment catalyst it is important to consider the start of run activity and selectivity, but also to predict the lifetime, which can be several years. Evaluating longterm stability can be costly and time-consuming. Hence, hte has been commissioned by MOL to develop an accelerated catalyst aging protocol.

This protocol simulates catalyst deactivation under realistic process conditions but with a much reduced test duration. Aging catalysts under actual process conditions provides more reliable information about longterm stability than empirical laboratory aging protocols. The project was completed in the third quarter of 2018. With the results, MOL is able to predict the long-term activity of its pre-selected catalysts.

"Diesel hydrotreatment is an important refinery process. Being able to predict catalyst activity during the entire life span gives us more confidence in selecting the right catalyst for our refineries," says Thomas Raetzsch, Head of Downstream Research and Development at MOL Group. "We are pleased that MOL has chosen to work with hte again. We look forward to further strengthening our partnership with MOL and our role in the European refining market," says Wolfram Stichert, CEO at hte. He adds that this type of protocol is adaptable to other processes and will be included in hte’s R&D Solutions offering.

Chemical Engineering World

CEW Industry News SEZ Policy Report Submitted to Commerce Minister

The Baba Kalyani led committee constituted by the Ministry of Commerce& Industry to study the existing SEZ policy of India submitted its report to the Union Minister for Commerce & Industry and Civil Aviation, Mr. Suresh Prabhu. The objectives of the committee were to evaluate the SEZ policy and make it WTO compatible, suggest measures for maximizing utilisation of vacant land in SEZs, suggest changes in the SEZ policy based on international experience and merge the SEZ policy with other Government schemes like coastal economic zones, Delhi-Mumbai industrial corridor, national industrial manufacturing zones and food and textiles parks.

While submitting the report to the Commerce Minister, Mr. Baba Kalyani, Chairman, Bharat Forge Ltd., said that if India is going to become a USD 5 trillion economy by 2025 then the current environment of manufacturing competitiveness and services has to undergo a basic paradigm shift. The success seen by services sector like IT and ITES has to be promoted in other services sector like health care, financial services, legal, repair and design services.

The Government of India has set a target of creating 100 million jobs and achieving 25 per cent of GDP from the manufacturing sector by 2022, as part of its flagship ‘Make in India’ programme. Furthermore, the Government plans to increase manufacturing value to USD 1.2 trillion by 2025. While these are ambitious plans to propel India into a growth trajectory, it requires evaluation of existing policy frameworks to catalyse manufacturing sector growth. At the same time, policy needs to be compiled with the relevant WTO regulations. The Commerce Ministry will immediately begin formal consultations with the Finance Ministry and other Ministries so that implementation of the committee’s recommendations may be done without any delay.

Vision of a USD 5 Trillion Indian Economy The Working Group tasked to develop a roadmap towards achieving a 5 trillion dollar economy by 2025 has prepared its report and it is being circulated to the stakeholders for further suggestions. The Working Group was constituted by the Department of Industrial Policy and Promotion in the Ministry of Commerce and Industry with participation from government and industry. The Group held extensive and broad-based consultations with stakeholders to better understand the aspirations and the potential.

The sectoral sub-groups were also formed to take the task forward. India is one of the fastest growing major economies and is currently ranked as the world’s sixth largest economy. Projections of growth, over the medium term, remain encouraging and optimistic for India. The underlying strengths are indicative of the potential of India to achieve a USD 5 trillion economy by 2025. The current structure of the economy and the emerging dynamics provide us grounds to target achieving 1 trillion dollar from agriculture and allied activities, 1 trillion from manufacturing and 3 trillion from services.

8 • November 2018

The Government has several ongoing initiatives across sectors focused on growth. In agriculture the Government is aiming to reorient policy focus from being production-centric to becoming income-centric. The emphasis on incomes provides a broader scope towards achieving the needed expansion of the sector. The proposed Industrial Policy 2018 provides an overarching, sector-agnostic agenda for the enterprises of the future and envisions creating a globally competitive Indian industry that is modern, sustainable and inclusive. The Champion Services sector initiative is also under way to accelerate the expansion of select service sectors. The Working Group has accounted for these initiatives and encourages a fresh impetus to achieve the target of a five trillion economy.

Lanxess to Investment of around INR 1250 crores in the next five years in India

Specialty chemicals company Lanxess is strengthening its asset base in India. The company plans to invest up to INR 1250 crores till 2023. Focus areas of the investment will be the businesses for chemical intermediates, high-performance plastics and water treatment products. LANXESS had already invested a sizeable amount in India over the years, among others for Greenfield investments and acquisitions. The company currently operates production facilities for five business units at its sites in Jhagadia and Nagda. “The Indian economy is currently the world’s fastest rising major economy, with the chemical industry as one of the fastest growing sectors.

We aim to even better capitalize the huge potential of the Indian chemical market and are therefore now launching a major investment package,” said Hubert Fink, Member of the Board of Management of Lanxess AG. Since inception of company in India in the year 2004, Lanxess has steadily grown its business in terms of asset base and turnover. In the last ten years, sales in India have more than doubled from INR 1008 crores to INR 2608 crores.

The main growth driver for Lanxess in India is the changing population which is rapidly becoming larger, younger, more middle class and more urban. “The demographic trend in India is leading to an increased demand in the areas of mobility, urbanization, nutrition and clean water. Lanxess can cater these demands with its wide portfolio of specialty chemicals,” said Neelanjan Banerjee, Managing Director and Country Speaker of Lanxess in India. Among the products supplied by Lanxess are high-performance plastics for the automotive and electronics industries, flame retardants for application in the automotive and construction industries, chemical intermediates and active ingredients for the use in agriculture as well as ion exchange resins and reverse osmosis membranes for the processing and cleaning of water.

Chemical Engineering World

CEW Industry News ISPRL Signs MoU with ADNOC to Explore Storage of Crude Oil in Underground Facility

Board, Government of India to expand its city gas footprint in 13 new Geographical Areas (GAs) in the recently concluded 9th round of CGD bidding. In addition, the company has also won 9 GAs in its joint venture company with Indian Oil Corporation, i.e. Indian Oil - Adani Gas Ltd. (IOAGPL).

In a national event being held in the capital on 22nd November, the Hon’ble Prime Minister Shri Narendra Modi will lay the foundation stones of City Gas Distribution (CGD) projects in 65 GAs covering 129 districts recently allocated in the 9th CGD bidding. The ceremony will be broadcasted LIVE from all locations where dignitaries from the respective State Governments and PNGRB will grace the landmark event.

Indian Strategic Petroleum Reserves Ltd (ISPRL) has signed the Memorandum of Understanding (MoU) in Abu Dhabi with the Abu Dhabi National Oil Company (ADNOC) to explore the possibility of storing ADNOC crude oil at ISPRL’s underground oil storage facility at Padur in Karnataka, which has a 2.5 million tonne capacity. Under the MoU, ADNOC is expected to store crude in compartments at Padur. The MoU with ISPRL, an Indian government-owned company mandated to store crude oil for emergency needs, follows the arrival, on November 4, of the final shipment of the initial delivery of ADNOC crude to be stored in another ISPRL underground facility at Mangalore, also in Karnataka, which will store 5.86 million barrels of ADNOC crude oil.

The MoU was signed by Abdulla Salem Al Dhaheri, Director of Marketing, Sales and Trading at ADNOC and Mr. HPS Ahuja CEO & MD ISPRL on the sidelines of the Abu Dhabi International Petroleum Exhibition and Conference (ADIPEC). The signing was witnessed by H.E. Dr Sultan Ahmed Al Jaber, UAE Minister of State and ADNOC Group CEO, and Mr. Dharmendra Pradhan, Minister of Petroleum and Natural Gas & Skill Development and Entrepreneurship, Government of India.

On the occasion, H.E. Dr Al Jaber said “India is an important oil market and this agreement underscores the strategic energy partnership between the UAE and India that leverages the UAE and ADNOC’s expertise and oil resources. It is our firm hope that we will be able to convert this framework agreement into a new mutually beneficial partnership that will create opportunities for ADNOC to increase deliveries of high quality crude oil to India's expanding energy market and helping India meet its growing energy demand and safeguard its energy security.” The existing and newly announced strategic reserve facilities put together will provide around 21 days of emergency coverage for India’s crude oil requirements. ADNOC is the only foreign oil and gas company, so far, to invest by way of crude oil in India’s strategic petroleum reserves program.

Adani Gas expands pan-India CGD presence, bags 13 CGD projects Adani Gas Ltd. (AGL), the city gas distribution arm of the Adani Group, has bagged authorization from the Petroleum and Natural Gas Regulatory 10 • November 2018

Pranav Adani, Managing Director, Agro, Oil and Gas, Adani Group stated, “Government of India has set itself a target to increase the share of natural gas in India’s primary energy mix to 15% till 2022 from the 6.5% in 2015. Given the pressing need for energy security in the country, natural gas is set to play a critical role in India’s energy strategy. With authorization to develop gas infrastructure and distribute natural gas in 13 new geographic areas in AGL and 9 GAs in IOAGPL, we continue to be at the forefront of the Indian natural gas story.

We endeavor to utilize our decade-long experience and CGD expertise to expeditiously develop these new geographical areas to provide gas to consumers in an economic, reliable and safe manner using the stateof-the-art technology and automation tools.” This will mark as another major achievement by the Hon’ble Prime Minister, who is committed to the reduction of India’s carbon footprint achievable through timely adoption of natural gas. In his speech in Urja Sangam 2015 in New Delhi, he stated that “in the next four years, piped gas connections will increase from 28 lakh to 1 crore to reduce pollution in the cities.”

The development of CGD network in 65 Geographical Areas is also expected to generate significant employment opportunities.

Cabinet condoles the demise of Mr. Ananth Kumar Union Minister for Chemicals & Fertilizers and Parliamentary Affairs The Union Cabinet expressed profound sorrow at the sad demise of Mr. Ananthkumar, Union Minister for Chemicals & Fertilizers and Parliamentary Affairs who passed away on November 12, 2018 in Bengaluru. He earned his Bachelor's Degree in English literature from Karnataka University in Hubali and LLB Degree from JSS Law College, Karnataka University.

Mr. Ananth Kumar started his public activities as a student activist.

Subsequently, he became a member of the BJP and was the Organising Secretary of the Party's Karnataka Unit. In his long political career, he had earlier held the portfolios of Union Minister of Tourism; Culture, Youth Affairs and Sports; Urban Development and Poverty Alleviation; Rural Development. He had also been Chairman and member of several Parliamentary Committees.

Mr D.V. Sadananda Gowda assumes charge of the Ministry of Chemicals & Fertilizers Mr. D. V. Sadananda Gowda, has assumed charge of the Ministry of Chemicals & Fertilizers, in addition to his existing portfolio of Union Minister of Statistics & Programme Implementation.

Chemical Engineering World

CEW Industry News Unprecedented Power Station Asset Sale Announced

Global advisory and asset management specialist, Gordon Brothers has announced the exceptional sale of major power generation equipment from the UK power station, Seal Sands in Teesside, North East England.

This unique sale is unparalleled with in the industry due to the pristine, virtually unused condition of the equipment. The majority of assets are unused since installation and have received ongoing maintenance to ensure perfect working condition. All assets are available for immediate purchase; major assets can be obtained through private treaty sale direct with Gordon Brothers, whilst general plant equipment can be purchased via an online auction. The sale comes at a time when demand for sustainable, environmentally friendly power generation is increasing, making these assets a valuable and extremely cost-effective resource. A full catalogue of equipment for sale and a video of the power station can be found on the Gordon Brothers website.

India's plastics export jump to USD 4.59 bn as per PLEXCONCIL India’s plastics exports posted a growth of 31.6% at USD 4.59 billion during the period April-September 18 (H1 2018-19) as against USD 3.48 billion in same period during H1 2017-18, registering a faster pace of growth than the overall merchandise export growth from India as per The Plastics Export Promotion Council (PLEXCONCIL). During H1 2018-19, India reported merchandise exports worth USD 164.04 billion, up 12.5% from USD 145.75 billion in H1 2017-18.

According to PLEXCONCIL, plastics formed 2.80% of India’s overall merchandise exports in H1 2018-19. The growth in India’s plastics export has been primarily boosted by higher shipment of plastic raw materials, plastic sheet, film, plates, and packaging materials. During H1 2018-19, 23 out of the top 25 destination countries recorded year-on-year growth in plastics export from India.

Exports to China, Vietnam and Mexico witnessed high growth rates ranging between 70-140% during the H1 2018-19 period. Mr. Ravish B Kamath, Chairman, PLEXCONCIL, said, “China, United States and United Arab Emirates continue to be top-3 destinations for India’s plastics products.

These three countries accounted for 27.5% of India’s plastics product exports, by value, during H1 2018-19. And we added new destination countries for plastics export which includes French Guiana, Guam, Kiribati Republic, Lesotho, Marshall Island, Mayotte, Monaco, Nauru Republic and United States Virgin Islands.”

Mr. Sribash Dasmohapatra, Executive Director, PLEXCONCIL, added, “In the first half of 2018-19, the trend in plastic exports from India has been very positive with a strong year-on-year growth vis-a-vis 2017-18 with August 2018 topping USD 800 million and registering 38.1% y-o-y growth.

12 • November 2018

India’s plastics exports in H1 2018-19 were boosted by higher exports, especially to North-East Asia, Africa, European Union, ASEAN, South Asia, and North America.”

Mr. Kamath further said, “Having achieved a superior growth in H1 201819, we are confident of surpassing our export target of USD 10.6 billion in 2018-19 for products under the purview of our council. We laud the Hon’ble Prime Minister’s historic support and outreach initiative for the Micro, Small and Medium Enterprises (MSME) sector that was unveiled recently. Since MSMEs form the backbone of our economy, the above initiative in form of easier access to credit of upto ` 1 crore within 59 minutes, and increase in interest rebate from 3% to 5% for exporters, among others are steps in the right direction. We at the council shall continue to make concerted efforts towards supporting the above initiative. We remain committed to our ongoing efforts directed towards increasing the export of value-added plastic products from India.”

The country's plastics industry offers immense potential in terms of capacity, infrastructure and skilled manpower. India is currently ranked among the top five consumers of polymers in the world and has 30,000 plus plastic processing units employing over four million (40 lakh) people across the country. Plastics are among the fastest-growing industries in the country experiencing a double-digit growth rate on an average. The plastics industry in India is making significant contribution to the economic development and growth of various key sectors in the country which includes automotive, construction, electronics, healthcare, and FMCG. The plastic processing industry has the potential to contribute in bringing foreign investments and thus India's vision of becoming a manufacturing hub. The country is set to have 18 plastic parks with an investment of ` 400 crore from the Government to boost domestic production of plastics. The setting up of plastic parks is expected to further increase competitiveness and investments, achieve environmentally sustainable growth and adopt the cluster development approach to consolidate capacities in the plastics sector in addition to job creation. The Indian Plastics Industry offers huge growth opportunities due to lower per capita consumption as compared to world average coupled with low labour cost and availability of skilled manpower and training centers.

Air Liquide Engineering & Construction wins a contract with a new chemical customer in China Air Liquide Engineering & Construction has signed a contract to supply an air separation unit (ASU) to Shandong Runyin Bio-Chemical Industry Co. Ltd (Runyin), a subsidiary of Shandong Ruixing Group, a large chemical company and one of the key high-tech players in China. Under the terms of the contract, Air Liquide Engineering & Construction will design and build a large ASU with a production capacity of 2,950 tons of oxygen per day. The ASU will be an integral part of the customers’ key research and development project for chemical production. In support of this project, Air Liquide will provide its strong expertise and best-in-class oxygen production technologies which enable maximized energy efficiency and reduced environmental footprint. The first industrial production is expected in 2020. Domenico D’Elia , Senior Vice President, Sales and Technology, Air Liquide Engineering & Construction commented: “ Air Liquide demonstrates the commitment to contribute to the upgrading of China industries. This success with our new customer, Shandong Runyin Bio-Chemical, reaffirms our ability to provide competitive solutions that are safe, reliable and highly efficient . ” Chemical Engineering World

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CEW Industry News Siemens and Bentley Systems Announce Integrated Asset Performance Management (APM) Solution for Power Plants

AkzoNobel Specialty Chemicals is Now Nouryon The former AkzoNobel Specialty Chemicals has relaunched as Nouryon, a new company with a 400-year head start. The move follows the recent acquisition of the business by The Carlyle Group and marks the company’s transition to becoming an independent, global specialty chemicals leader.

The new Nouryon name builds on our heritage and is inspired by two of our company’s many pioneers, Jan Nourij and Gerrit van der Lande. Noury & Van der Lande was one of the first companies to realize the important role chemistry could play in everyday life.

The move follows the recent acquisition of the business by The Carlyle Group and marks the company’s transition to becoming an independent, global specialty chemicals leader. “Launching our new company is a significant milestone to add to our proud history and we are all looking forward to this exciting new chapter,” said new CEO Charles W. Shaver. “We are ready to leverage our experience, global presence, and strong company culture to unleash our full potential as an independent company,” he said.

Siemens and Bentley Systems have announced a joint technology and service solution, consisting of their complementary offerings, to speed up the digitalization of power plants and provide intelligent analytics with a range of innovative offerings and managed services solutions. The new service, to be hosted on Siemens’ cloud-based open IoT operating system, MindSphere, will combine Bentley’s advanced asset performance software capabilities with Siemens’ complementary technology and service expertise to empower power plant owners to take full advantage of digitalization, which helps improve maintenance operations and planning.

Siemens’ asset performance management (APM) solution, part of the company’s Omnivise digital solutions portfolio, covers the entire power plant, including the combustion and steam turbines as well as associated generators and pumps, motors, transformers, valves, switchgears, and other equipment that affects plant reliability and performance. Using intelligent models based on predictive analytics, the solution takes data from multiple sources, applies domain and analytical expertise, and then seamlessly integrates into a customer’s existing Computerized Maintenance Management System (CMMS)/Enterprise Asset Management (EAM) environment to improve maintenance planning, reduce outages, and increase workforce efficiency. APM service solutions are tailored to each organization’s unique needs, based on variable factors such as plant configuration, on-site resources, equipment expertise, and plant operations and maintenance strategy. The scope of options ranges from on-premises installation or cloud-based MindSphere hosting, to turnkey set-up of APM – complete with Siemens asset models – to APM as a service, with a fully integrated managed service solution set up and run remotely by Siemens power plant experts.

Laura Anderson, head of the said, “APM for Power Plants is evidence of the benefits this strategic alliance brings to our customers. By combining Siemens’ and Bentley’s complementary and proven areas of expertise, this innovative offering will help our customers manage costs, improve reliability, and increase the performance and availability of their thermal power infrastructure.”

Greg Bentley, CEO, Bentley, said, “We’re excited to be delivering, in this case for power plant owners, operational advantages made uniquely possible by our work with Siemens to leverage IoT and performance digital twins. In effect, we are together advancing APM towards asset performance modeling—where our engineering technologies (ET) compound the value of IT and operations technologies (OT).”

20 • November 2018

“We are starting from a great position,” Shaver added. “We have a great set of businesses, leadership positions across our portfolio, long-term customer partnerships, and a dedication to continuous improvement and innovation we can leverage for further success. As an independent company we can accelerate our progress on all fronts and take our rightful place alongside other industry leaders.” Nouryon has a history that stretches back nearly 400 years and its new name and brand identity reflect that heritage. Noury & Van der Lande was one of the first companies to realize the important role chemistry could play in everyday life; today, Nouryon is a world leader in essential chemistries used to manufacture everyday products. “When we started developing our new name and brand we asked our employees what mattered most to them,” explained Vivi Hollertt, Chief Communications Officer at Nouryon. “Our employees are especially proud of our heritage, as well our track record of growing through partnerships, innovation, sustainability, and contributing to society. We combined all of this to create a brand identity for Nouryon which is true to who we are and helps us stand out from our competitors.” Nouryon’s new company purpose - Your partner in essential chemistry for a sustainable future - reflects this pride as well as the focus going forward. The company’s success has been built on strong partnerships and it believes that collaboration is key to future success.

Nouryon will be working closely with customers and other partners to innovate, make strategic investments, and develop essential, sustainable solutions that meet customer needs and fuel shared growth.

ELGi launches oil-free air-compressor range ELGi Equipments, one of India’s leading air-compressor manufacturers, recently launched its range of oil-free air-compressors at the recently held “Compressed Air Best Practices Conference” in Chicago. The oil free range comprises of machines ranging from 60 horsepower and 100 horsepower with 7 and 8.8 Bar pressure options. The company has reiterated its commitment to enabling energy efficiency and meeting high purity air demands and the air cooled designed will ensure ease of installation at all customers, while the aluminium coolers will ensure efficient cooling. High efficiency NEMA motors power the machines with separate ducting for noise reduction. ELGi is one of five companies in the world with a proprietary oil free Airend design. The new models are supported

by ELGi’s class leading four year Airend warranty and a strong service network. The added models will ensure that ELGi is able to service all oil free air needs in the USA market. The global market demand for oil free air compressors is USD4 billion in 2017 with an estimated growth rate of 3 – 4 per cent by 2024.

Chemical Engineering World

CEW Features Technical Article

Challenges in Setting Up ETP For Refineries Petroleum refining is a complex operation and unit operations within refineries vary depending on the type of crude and the type of end products. Refining is a water intensive operation which generates large quantity of waste water that needs to be treated so as to avoid environmental degradation. A proper understanding of the unit operations as well as pollutant loads is necessary in order to set up a suitable Effluent Treatment Plant (ETP). This article discusses about various challenges that we have faced in the designing and operating of several Refinery ETPs in India.

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haracterisation Of Waste Water In order to design an ETP for an upcoming refinery, design parameters like the flow rate, Biological Oxygen Demand (BOD), Chemical Oxygen Demand (COD), Suspended Solids (SS), Oil & Grease (O&G), Sulfides, Phenols, Ammonia etc., have to be assumed.

The selection of the scheme and the estimation of unit sizes depend on the inlet characteristics and hence it is imperative that the assumed design parameters be as close to the actual parameters that will be encountered once the plant is commissioned. It is quite normal to assume higher values while designing the plants.

However, one should keep in mind that some processes do not perform efficiently when they are over designed.

separator followed by a Dissolved Air Flotation (DAF) or Induced Air Flotation (IAF) unit.

• Flow Equalisation: Flow of wastewater generated from refinery from various manufacturing process units is not uniform. The flow variation is equalised by providing an equalisation tank of sufficient capacity and constant flow is maintained in all downstream treatment units. This makes the process control much easier.

• Removal of Suspended Solids: This is achieved using a clarifier or it can be combined with O&G removal in a DAF unit

Typical Treatment Scheme The treatment philosophy adopted to treat refinery waste waters consists of a series of steps to sequentially remove the pollutants so that the treated wastewater meets the required regulatory norms. The typical treatment steps are:

• Removal of Sulphides: Lower sulphide concentration can be handled in biological treatment system. However, high concentrations of sulphides need to be taken care before wastewater enters into biological treatment system.

Oxidation of sulphides using Hydrogen Peroxide is most popular method of oxidising them.

• Removal of O&G: This is necessary as downstream operations are sensitive to the presence of high levels of O&G. In a refinery wastewater treatment system, two steps of oil removal are typically required to achieve the necessary removal of free oil from the collected wastewater prior to feeding it to a biological system. This oil removal is achieved by using an American Petroleum Institute (API) or Tilted Plate Interceptor (TPI) or equivalent oil water

Various • Biological Treatment: biological systems have been adopted including Activated Sludge Process, Bio-tower, Sequential Batch Reactor, Anaerobic reactors, Membrane Bioreactors etc. Every process has its own inherent advantages and disadvantages and a suitable system has to be selected by the designer based on factors such as organic load, treatment efficiency required, land area available etc.

22 • November 2018

• Polishing of Treated Waste Water This step includes units like Pressure Sand Filters (PSF), Dual Media Filters (DMF), Activated Carbon Filter (ACF) to remove the residual suspended solids as well organic pollutants that have passed through the earlier treatment steps.

• Reuse and Recycle : As the refinery consumes a large quantities of water, it is imperative one must try and reuse the treated waste waters back in the process. Additional treatment units like Microfiltration, Ultrafiltration or Reverse Osmosis may be adopted in order to meet the reuse water quality that is required Challenges and Solutions in Biological Treatment of Refinery Wastewater The key treatment step in the refinery ETP is the biological treatment as the bulk of the pollutants are removed in a cost effective manner in this step. Hence it is important to design this system in a robust manner so that it can operate efficiently. It is important to note that in the biological treatment step, the pollutants are degraded by microorganisms and it is imperative that a conducive environment is maintained such that the microorganisms can operate up to their maximum potential. A list of various factors that influence the design and operation of the biological system are given below: • Fluctuation of Wastewater Characteristics: One of the main challenges in refinery wastewater treatment is its variation in characteristics.

As mentioned earlier, when assuming the Chemical Engineering World

CEW Features in a biological system of a refinery is shown here (Figure 1).

Figure1: Foam in refinery

Figure2: Typical Refinery ETP

pollutant load for design of the ETP, it is normal to assume higher values so that the designs are ‘safe’. This causes problems during the operation of the ETP when the actual pollutant load is much lower.

Also, based on variations in quality of crude and refining process, wastewater quality also varies. The biological system should be selected to take care of these variations. The biological system should be able to vary process parameters such as air supply, Mixed Liquor Suspended Solids (MLSS), Food to Microorganism (F/M) ratio, etc., to suit variations in feed.

Modular design of biological process also helps in handling variations of wastewater quality. If provided with multiple process tanks, plant can be operated based on the actual pollution load by using all process tanks or part of them.

• Oil & Grease: The performance of the O&G removal equipment is sometimes upset due to a surge in the inlet O&G quantity due to dumping of oil within the refinery. This causes O&G to slip into the biological system affecting the microorganisms. This also causes foaming in the aeration tanks that affects the quality of the treated water. A figure showing the foaming 24 • November 2018

• Sulphides: Refinery wastewaters contain high levels of Sulphides that are toxic to microbes and hence have to be removed prior to the biological treatment.

In case sulphides slip into the biological system, it exerts demand on the aeration system since it consumes the oxygen that is meant for the respiration of the microorganisms. Hence it is normal to consider a safety margin in the design of the air blowers so that it can meet any contingency due to sudden air demand because of sulphides. Care should be taken that sulphide concentration in biological system are below toxic limits.

• Complex Organic Compounds and Heavy Metals: Complex organic compounds such as phenols, benzene products, etc. are also part of refinery wastewater. Their concentrations depend on the source and quality of crude oil. These compounds are not easily biodegradable and may be toxic to biological system at higher concentrations.

Hence, the ETP should be designed to handle these complex organics in case they are present in wastewater. Heavy metals also pose problem to biological treatment.

Both complex organics and heavy metals should be taken care in pretreatment if present in higher concentrations.

• Nutrients: The growth and performance of the microorganisms depend on the availability of critical nutrients like nitrogen and phosphorous in the waste water.

Ideally, a BOD:N:P ratio of 100:5:1 is required for best performance. Normally abundant nitrogen is present in the refinery wastewater. However, it is important to constantly analyse the wastewater and add nitrogen (typically as Urea) and phosphorous (as Phosphoric acid or Di Ammonium Phosphate) to make up for any deficit.

Many a times, total nitrogen levels in the wastewater are much more than required which necessitates treatment to reduce them. Hence, the biological system selected should be able to remove excess nitrogen along with organic pollutants.

• Energy efficiency: The oxygen required for the microorganisms are delivered through fine bubble diffusers that release small bubbles of air from the bottom of the aeration basins. Air blowers are installed to supply air into biological process. Air blowers constitute major portion of power consumption in the ETP. Any steps taken to optimise energy consumption shall result in energy efficiency of the plant.

Biological process should be provided with oxygen control system to supply air as per the organic pollution load coming into it. Dissolved Oxygen (DO) or Oxygen Uptake Rate (OUR) based blower control optimizes both energy consumption and process performance. Energy efficient blowers further improve the energy efficiency of the ETP. • Process Automation: Due to variations in wastewater characteristics, it is advisable to install process automation to control vital process parameters such as DO, OUR, MLSS, Sludge recirculation, Sludge wasting, etc. This helps in automatically keeping the process parameters at their optimum levels and generates consistent quality of treated wastewater.

Conclusion Refinery wastewater characterisation is very complex exercise that requires an understanding about the refining processes involved. The designing of the ETP is a challenging job as treatment units have to be robust enough to handle continuous variations in the concentration of pollutants.

The operation of the biological system governs the performance of the ETP, as it removes the bulk of the pollutants.

Ideal operating conditions have to be provided for the microorganisms in order to ensure effective treatment. The biological system should be selected to handle any variations in flow and characteristics of refinery wastewater.

Author’s Details Satya Narayana Y V V SFC Environmental Technologies Pvt Ltd satya@ctechsbr.com Chemical Engineering World

CEW Features Technical Article

Mapping the Way to Controlling Nuisance Noise Taking steps to reduce noise levels in the workplace can be expensive, but there are many benefits, both in terms of worker safety and cost reductions. However, for any mitigation activity to be appropriate and effective, an accurate assessment of noise sources is required, along with details of how noise travels around the site.

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n the wide-field of chemical engineering, nuisance noise can come from a variety of sources and have a range of impacts. For example, the heat and noise generated by the distilling processes in refineries and the seemingly endless racks of pipes transporting sound across the premises can seem both deafening and disorientating. Spray-on foam is one way to help dampen the noise and reduce heat loss, but how much should be used and where will it be most effective? What other measures could be implemented to make the biggest difference?

considered: type of noise; noise levels and temporal pattern frequency distribution; noise sources (location, power, directivity); noise propagation pathways, through air or through structure; room acoustics (reverberation). In addition, other factors have to be considered; for example, number of exposed workers, type of work, etc.”

Getting to the Source Noise emissions on occupational sites vary widely in sound power, frequency spectra, directivity and also in their

timings. Their regularity in different work situations also varies between irregularly distributed noise impulses and almost continuous noise.

The danger of hearing loss is a given if people are exposed to a noise level of more than 85 decibels (dB). The risk of hearing loss increases with the magnitude and exposure time and the frequency of the noise; with higher frequencies doing more damage. Hearing loss makes up between 30 per cent and 40 per cent of occupation-related illnesses.

Whether designing processes and equipment for large-scale manufacturing, test production methods and by-products treatment, or direct facility operations, chemical engineers need to be protected from excessive noise, and plan the protection of those who will work in the situations being designed.

In the arena of noise control the saying ‘scientia potentia est’ (‘knowledge is power’) is very apt. It is not hard to recognise nuisance noise, but identifying its exact source and field of propagation can be a very different matter. If you are going to reduce noise and mitigate its harmful effects, then you need to know as much about it as possible. To be truly effective, any attempts at noise control must be based on an accurate analysis rather than guesswork or reference to previously recorded levels.

The World Health Organisation, in its paper ‘Engineering Noise Control’ says: “To adequately define the noise problem and set a good basis for the control strategy, the following factors should be 28 • November 2018

Figure 1: SoundPLAN - External Noise

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CEW Features In noisy locations, when considering how to control the sound, the primary requirement is to locate and document the areas where the noise reaches 85 dB or above. This is known as the ‘noise contour line’. In areas where noise levels exceed 85 dB, workers should wear hearing protection. Failure to clearly mark the noise contour line could leave companies open to fines and litigation. There must always be signs showing employees and visitors where hearing protection is required and it is the supervisor’s responsibility to ensure it is always worn.

The contour line applies both inside the building and outside.

If a workplace has areas that may be close to or above 85 dB, then a noise study should be carried out to define all areas where hearing protection is required. Workers can also be provided with noise dosimeters to keep track of their daily dosage of noise. A well-studied and documented noise policy is better than paying for lawsuits from workers with hearing problems and paying for disability because of tinnitus and hearing loss.

Mapping the Noise Using the data from the study, and other relevant sources, with sound mapping software means that realistic noise simulations can be developed. These can show the sources of the loudest noise and the propagation across the site. Measurement alone shows only one noise level and it is not possible to assess how much noise came from any source.

However, computer-devised simulations mean you can now isolate and address problem areas.

Equipment (PPE) required. Removing, or reducing the need to wear PPE can also improve working conditions and communication between workers. This can help improve productivity levels and reduce accidents.

Figure 2: SoundPLAN - Noise in A Building

size, geography, objective, and most significantly, the available data which can be imported and used.

Noise Reduction Pays There are a number of benefits to controlling noise in industrial situations.

The protection of workers’ health should be a priority, but there are considerable financial incentives too.

Health and Safety: As well as the more obvious concerns around damage to hearing, there are a number of other potential health implications of longterm exposure to excessive noise.

These include sleep disturbance and cardiovascular disease as well as other physical disturbances. It can also affect workers’ psychological well-being, leading to communication issues, nervousness and reduced reactions.

Potential Cost Savings: Although there will be an initial outlay for noise audits, new quieter equipment and mitigation factors, properly managing noise should show a positive return on your balance sheets.

Noise mapping also means you can predict future levels of noise and take steps to control it, whereas measurements cannot occur until the entity making the noise is physically there. This means you can work with ‘what-if scenarios’ prior to building a facility and to also assess how effective new quieter equipment or noise mitigation techniques would be.

Not taking action can be expensive.

If excessive noise is left untreated, businesses can face legal action from workers whose health has been affected.

This in turn can increase insurance premiums. There is also the cost of lost man hours when workers take time off sick and the management time to deal with both sick leave and litigation. Those costs can soon mount up, so investing in noise control can quickly pay for itself.

No two noise maps will be the same as their make-up is dependent on the project

Further, direct cost savings can be seen with the reduction of Personal Protective

32 • November 2018

Legal Requirements Simply ignoring nuisance noise is not an option. Most industrial nations have specific noise rules that sit alongside health and safety regulations. These include the Noise Control Act (USA), Occupational Exposure Limits (Canada), the Environmental Noise Directive (EU) and Control of Noise at Work Regulations 2005 (UK) and the Noise Pollution (Regulation and Control) Rules, 2000 (India). This national legislation requires noise control measures to be implemented so that the lowest reasonable levels of noise emission and noise exposure can be achieved. All employers should make themselves aware of the rules affecting their employees, especially if they are working across international boundaries where legislation may not be consistent.

Hearing the Message Loud and Clear Once you’ve created a noise map and developed your noise policy you can introduce controls to start defending workers against the problem noise. By reducing the noise by just a few decibels the risk of hearing loss and other harmful effects is considerably lessened.

Using low-noise and well-maintained equipment or placing a barrier between the worker and noise source are relatively simple steps, but they can have a huge impact on people’s lives. Using noise mapping software gives you the knowledge to accurately identify the most appropriate changes and safeguard your workers and your business.

Author’s Details Arne Berndt Owner & Adviser at SoundPLAN GmbH and SoundPLAN International LLC E: arne@soundplan.com Chemical Engineering World

CEW Features Case Study

MWH Global Water Recycling Plant Design Eases Water Consumption by 60 Per Cent Severe water restrictions and the construction of expensive desalination plants in recent years have not adequately comforted the New South Wales region from the effects of a 10-year long drought. In a process to tackle the issue, GTPL amalgamated a water recycling plant into the Googong Greenfield Development project. Googong retained MWH Global to assist the plant design based on its expertise working on some of the world’s largest and most significant water and natural resource projects. The case study discusses in-depth about how the software facilitated MWH to work meticulously with constructors, providing valuable information comprising material takeoffs, tabulated 3D coordinates, and spool piece equipment lists to diminish construction costs. It also explores how Bentley software helped safeguard water efficiency by recycling up to 62 per cent of the township’s wastewater for non-potable use.

Creating a Water-efficient Culture Googong is a pristine site located in New South Wales, less than 20 kilometers southeast of Canberra, Australia’s national capital. Googong Township Proprietary Limited (GTPL), a newly formed partnership, is developing the area into a self-contained community comprising schools, parks, shops, businesses, and 6,200 homes for 18,000 residents. Given that severe water restrictions and the construction of expensive desalination plants in recent

34 • November 2018

years have not sufficiently relieved the New South Wales region from the effects of a 10year drought, GTPL incorporated a water recycling plant into the Googong Greenfield Development project. Googong retained MWH Global to facilitate the plant design based on its expertise working on some of the world’s largest and most significant water and natural resource projects.

GTPL wanted a design that used membrane bioreactor technology (MBR)

as the foundation for an integrated water cycle with a dedicated water recycling plant that would meet water demand and ensure sustainability by only using the equivalent water needed for 6,500 people. To begin the cycle MWH had to tap into the main supply line to Canberra for fresh potable water, and feed that water into assigned potable water storage tanks in Googong. That water then would be gravity fed from the tanks to Googong residences for drinking and

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Googong’s water recycling plant will meet the water demand of 18,000 residents and ensure sustainability by only using the equivalent water needed for 6,500 people.

showering. Wastewater, runoff water from the properties, and rainwater was also needed to be collected and pumped into the water recycling plant to be filtered and disinfected. This water was then sent to the water recycling storage tanks to be gravity fed back to the residences for irrigation, toilet flushing, and household washing. Facing complex challenges from difficult terrain and tight deadlines, the project team required precision engineering to deliver the project on time and on budget. To overcome these challenges, MWH utilized global resources and implemented an integrated and collaborative design approach using Bentley software.

Optimizing Information Mobility Harnessing resources from Sydney, Melbourne, Brisbane, and Pune, India, MWH required collaborative software to seamlessly integrate workflows among the multi-site design teams. “Being a multi-national company, we don’t always have the skills we need in our home office. Therefore, we do a lot of drafting in our Pune, India, office. We used ProjectWise® to control the models and drawings,” explained MWH head CAD designer Terry Sowden. Implementing an integrated design approach using Bentley Navigator allowed MWH to simultaneously deliver drawings and models with managed version control, and capitalize on the time difference between Australia and India to keep the project moving along the tight schedule.

36 • November 2018

MWH used 3D modeling from concept through detailed design, including earthwork, roads, structures, piping, and mechanical equipment. Information mobility kept design and construction on schedule. The team used automatic signoff to issue drawings and models, and i-models kept data integrity to the client on site. MWH used 3D models, via Navigator and i-models, in review meetings and twoday workshops involving all stakeholders early in the design process. This provided MWH with valuable insight on where to locate valves and pumps and how they would operate as part of the plant under various scenarios.

With this information, the design team could identify and address operational, maintenance, construction, and clash and dimensional issues at the 3D model review stage before beginning construction. This saved significant time that might otherwise be spent making costly changes later in the process.

Accurate Modeling Establishes Freshwater Connection With Googong’s fresh potable water being fed from a single water line to Canberra, MWH had just a six-day tie-in window to tap into the city’s water supply before the supply to Canberra was threatened.

Precise modeling was crucial to establishing the DN1800 pipe connection within this time constraint. The spool pieces for the pipe that were designed based on the plant model and they had

to be absolutely millimeter perfect, and had to fit within the inconsistent incline of the pipe. With four circumferential welds required to attach the spools, each taking six hours to complete, there was no room for error. MWH relied on Bentley software to create intelligent collaborative models enabling the team to streamline design and analysis and ensure accuracy to fit the spools and keep the project on schedule.

Within the six-day tie-in period, each day was predicated on the success of the prior day’s work, with the fifth day being the most crucial as the final spool was to be fitted. “There were a lot of nervous people monitoring the progress on site and through photos. On day five, the final spool slotted in perfectly, and there were a lot of relieved and happy faces,” stated Sowden.

Overcoming Terrain and Site Restrictions Another challenge facing MWH was managing the site constraints of the Googong area. Located on a sixmeter sloping terrain overlaying rock formations, the AUD 7 million water treatment project required optimum cutand-fill ratios to minimize costly rock excavation for the underground piping and services. MWH used PlantWise® to lay out the yard piping separated in three strata with services on top, process piping in the middle, and drainage on the bottom. Working with many gravityfed pipes that required a 300 millimeter Chemical Engineering World

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Project Summary

Fast Facts

Organization MHW Global

• MWH designed Australia’s first integrated water cycle to provide potable, recycled, and wastewater services to a new Greenfield community development.

• Bentley 3D modeling applications facilitated collaborative design and decision making enabling MWH to meet the developer’s tight delivery schedule and overcome challenging terrain.

• ProjectWise, PlantWise, and Navigator provided MWH with an integrated modeling solution by optimizing information mobility among a multi-site design team, allowing all stakeholders’ input during the model review stage.

Location New South Wales, Australia Project Objective • Deliver a water treatment plant using MBR technology with an integrated water cycle.

• Reduce potable water consumption for the new Greenfield community.

• Minimize wastewater discharge to the environment by substituting recycled water for household use and urban irrigation.

• Ensure timely delivery and operation to coincide with township development.

Products Used ProjectWise, AECOsim Building Designer, InRoads, Bentley Navigator, PlantWise, and LumenRT separation between each pipe and numerous pipe crossings, MWH needed to accurately define the location of the directional changes within the model and accommodate changes in real time from construction crews already onsite.

With the Export Coordinates function in Bentley PlantWise, MWH was able to input thousands of coordinates for each separate pipe and automatically export that information to an Excel spreadsheet.

Using this function accelerated information sharing allowing design and construction to occur simultaneously.

“While we were still designing, the construction people were on site actually constructing this. We were able to make the changes in the model and then have the Excel spreadsheet quickly updated,” explained Sowden.

In addition to sub-terrain piping, the above-ground facilities had a limited footprint imposed by the developers to allow more space to accommodate homes as well as to minimize noise to the residences. The above-ground pumps 38 • November 2018

ROI • The water plant design will reduce the community’s potable water consumption by 62 per cent.

• Identifying operational, maintenance, construction, and design issues using 3D modeling enabled MWH to meet an aggressive deadline and minimize risk.

water-efficient design during township consultations. The 3D visualizations helped instill Googong’s residents with a richer understanding of project intent, and revealed where the plant would situate in the Greenfield development.

Bentley’s collaborative software enabled MWH to work closely with constructors, providing valuable information including material takeoffs, tabulated 3D coordinates, and spool piece equipment lists to minimize construction costs.

Engaging operations, construction, maintenance, and design staff during the model reviews helped identify clashes, diminishes changes during construction, and reduce operational costs. The real payoff, however, is that wastewater from Googong homes is now treatable and the new integrated water cycle will reduce potable water consumption by 62 per cent.

needed to be shielded by the bioreactor wall from the homes for noise prevention and had to maintain an equivalent gap on all sides for maintenance purposes.

3D collaborative modeling was essential to meeting these requirements, and enhanced communication among the designers and constructors to ensure plant integrity.

Advancing Water Management With an integrated design approach using ProjectWise (collaboration and model control), Bentley plant design applications (piping design), AECOsim Building Designer (BIM), InRoads® (civil design), and Navigator (3D model reviews), MWH delivered its drawings on time and met the project deadline. The project delivery team brought life to the 3D plant models using LumenRT, Bentley’s immersive visualization software, integrating flythrough animations and presenting the

Author’s Details Aidan Mercer Industry Marketing Director, Utilities and Government, Bentley Systems Chemical Engineering World

CEW Features

Integrated Engineering, Operations and Asset Management are Vital for Chemical Industries This article discusses improving return on chemicals assets using integrated engineering, operations, maintenance and compliance management.

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hemical industries are diverse in terms of products and processes, and the nature and state of the assets. In the developed world, assets are on average older, intrinsically less reliable and efficient, but in these regions companies have the highest skilled personnel and most advanced methods in place to compensate for it. The regular economic cycles in petrochemicals and polymers have been replaced by irregular, more regional economic ups and downs, with high amplitude. The high growth in developing Asia is slowing down significantly. The oil and gas boom in North America has created growth in the chemical industry in the region in the recent years. The recent drop in oil price has created economic relief for chemical producers globally but demand may suffer because of the economic slowdown. The best strategy for the future is likely one of high flexibility and adaptability to react to global and regional market fluctuations, product innovations, feedstock costs and regulations.

Necessary Steps A first step is to reduce the cost of assets throughout their lifecycle. This includes effective engineering, leading to more flexibility and lower cost designs that can be operational more quickly. Engineering and design costs can be reduced by make information transparent across disciplines, regions, offices and sites and easier to reuse. Sharing and transparency must be extended across the enterprise borders to engineering, procurement and construction firms (EPC’s), subcontractors, to achieve tighter collaboration. Collaboration during design and construction has significantly increased during the past years, and as contractors provide more and more services for plants in operation too, it is expected that the importance of efficient cross-enterprise collaboration will further increase.

Compliance of processes and equipment

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can be efficiently handled when requirement engineering is electronically linked to qualification processes.

Information should also be reused across engineering, operations and maintenance within the corporation, and by their subcontractors.

As all stakeholders work on the same asset, they should all work off the same asset information to coordinate and optimize their plans and actions. This concept is referred to as integrated engineering or integrated operations.

In a second stage, these efficient processes can be applied to more productive and flexible process designs using intensification, modularization, and mobile processing units.

Accurate asset information requires a stateof the art application and data repository that must be complemented by processes for keeping asset information up-to-date.

People must be trained and motivated to use them. When these key success factors are in place, operations and maintenance can be optimized, to sustain a compliant and reliable asset at the lowest cost and with the lowest inventory of spare parts. This includes modern asset management strategies, such as predictive maintenance and condition monitoring, and the simultaneous optimization of asset capabilities and production requirements.

Companies that have pioneered these new practices, report increased engineering productivity, improved handover, accelerated operational readiness, reduction of regulatory compliance cost, reduced maintenance costs and improved reliability.

Asset Management Challenges The chemical industry is very diverse and, depending on the region, features various characteristics. We can broadly distinguish the following categories:

• Aging, commodity producing assets.

These are most likely to be found in advanced economies, and need to be operated and maintained at the lowest operating cost possible. At the same time, they need to operate reliably, safely and be compliant with regulations. Asset information is at risk of being dispersed on paper and in various systems.

• Recent assets for commodity products using classical, mostly continuous process technologies. These assets are mostly found in growing economies, for example in South-East Asia, but also in the USA. Asset information is more likely to be available in electronic format.

Reliability, safety and compliance are likely to be satisfactory, but need to be maintained.

• Assets for specialty chemicals, specialty polymers, agrochemicals, food and pharmaceutical ingredients, mostly using traditional batch processing. The products have a high innovative content, and plants are regularly adapted and reengineered, or have been recently constructed. In these cases, it is likely that electronic asset information is available. Regulatory compliance is an increasing cost factor.

• Assets using modular and/or intensified process technology for chemicals or polymers. Existing plants are built for research and process development purposes. The first commercial modular plants are coming on-stream. Asset information is available in electronic form.

• From an engineering and asset information management perspective, a number of challenges can be distinguished: • In plants under construction by engineering procurement and construction firms (EPC’s), owner-operators (OO’s) require a tighter collaboration than before. Being responsible for the plant’s performance and regulatory compliance at startup, they Chemical Engineering World

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n Management (AIM) and Information Handover CEW Features

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Asset Information Quality and Quantity During Handover

Context Management A their New Category of AIM as well as the tracking of construction before– starting actual work.

Further over the premises.

It is a realSolutions challenge to require design reviews in electronic form

the available or missing spare parts, etc.,

utilities and storage facilities are distributed

and commissioning progress against electronic documents. More and more qualification processes use electronic design and requirement documentation, with electronic sign-offs.

• In recently constructed plants, the asset information built up during engineering and construction is traditionally handed over on paper, and is often incomplete or outdated at the moment of transfer. NIST estimates that the cost of information losses during handover to be 1.8 percent of capital expenditure. There is a huge opportunity to improve the process by making it electronic, and make sure the information is reused.

• In existing plants, when engineering or maintenance troubleshoot an operational issue or need to start a modified project, they first spend time – sometimes weeks or months - to find out the actual status and performance of equipment and piping,

time is lost in ordering missing parts or equipment, increased time to repair, and multiplying travel times. In other cases wrong or excess parts are available, which increase working capital without benefit. Incomplete, inaccessible, and inaccurate asset information therefore leads to a longer project duration, longer “mean time to repair” (MTTR), higher operational and capital expenditure than necessary. Compliance costs increase, or compliance becomes impossible as accurate information cannot be produced at any point in time.

NIST estimates the cost of information losses in the operate-maintain phases of the asset to 2.4 percent of the capital expenditure cost, higher than the cost of losses during handover.

keep track of the asset state, as operations, maintenance and contractors work independently on the same assets.

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42 • November 2018

• Chemical plants are usually part of large industrial complexes, where plants, and

Whether asset information is built up during engineering and construction, or by Chemical Engineering World

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Features implementation of standardized processes across the extended enterprise, reducing the number of systems and interfaces, and organizing centralized maintenance and support and promoting company-wide knowledge management.

!

ARC’s AIM Solution Map

ARC’s Model for Asset Lifecycle Information Management,

In the case of maintenance and improvement projects related to automation and instrumentation, seamless, bi-directional integration with automation systems simplifies the changes to the automation systems significantly, by enabling the configuration of the control system directly from the design in the engineering tool. Vice versa, when a control system configuration is changed in the field, the control system would automatically update the application with the actual control system configuration.

The NAMUR standard NE 150 enables doing this in a standardized manner.

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between internal or external engineering departments and maintenance . /2* #4#&9! 4#%5/F! ! 3 J+ ! , ) %&5%&! > 2%2: 5> 5%&! /) 4. &#) %/! =) , . /! 87#> 27#49! (and/or ) %! operations) may occur during > 2#%&2# %#%: ! #% =) 7> 2&#) %! Hof . 24 9F! ! 3 J+ tool, ! . /57!

5%1# 5%&!/) 4.disciplines &#) %/! =) ,these . /! projects or changes. It is of utmost operations and maintenance an#& existing common to7)all%> engineering importance that the stakeholders work off installation, the 1# end is # always involved front-end 87#> 27# 49!) %!#>in87) %: there !. /2* 4#&9!=)an7!$ #= =575%in&!/& 2' 56)and4$detail 57/Fengineering. !!3 J+ !/) To 4. &#)the %/!same, up-to-date asset and engineering installation in operation that undergoes increase engineering efficiency, he proposed data. This has important benefits for maintenance activities and engineering to implement modular engineering – using engineering and modernization projects by projects related for reasons of improvement, standardized, generic engineering modules simplifying the work, unloading personnel, troubleshooting or debottlenecking. comprising all functions built and maintained while guaranteeing accurate and up-to-date within the common tool. © ARC Advisory Group • ARCweb.com asset information. It creates even more As a result, two or more organizational entities benefits by saving engineering work when work on the same assets, using – ideally - Many plants apply a wide variety of control the same changes need to be applied to the same asset information: engineering systems. To further increase engineering several sites. Many standards are available to design changes and improvements; efficiency, control engineering should be for this complex domain. ISO 15926 is operations and maintenance for day-to-day done at a generic level, enabling reuse the most well-known, standardizing the activities and long term asset management. of designs. The designs can be used to equipment specification. .

To streamline the collaboration between configure systems, and compile the generic those entities, the concept of “integrated designs within different DCS brands. engineering” was created.

The next step is the transfer of the engineering information to operations and The “Integrated Engineering” Concept maintenance and keeping it up to date with In 2005, Dr. Thomas Tauchnitz published a the goal to transform “as- built” information vision for “integrated engineering” (Tauchnitz, into “as-maintained” information to ensure Author Details 2005), based on three basic principles: accuracy and save time. “[…] every information is generated and “integrated engineering” maintained at only one location, existing Therefore, knowledge is reused where possible, and incorporates different disciplines during the software tools stay interfaced while the design and build stages, and also integrates production plant is in operation.” He sketched engineering, operations, maintenance and Valentijn de Leeuw the workflow as starting with process design automation during operate and maintain Vice President followed by the transfer of the resulting stages of the installation life cycle. the vision includes the process information to an engineering software Finally, ARC Advisory Group, Europe

Engineering and Operations/Maintenance

44 • November 2018

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CEW Features

Effective Risk Mitigation Strategies for Projects The most common risks for projects are improper execution strategy, contractor selection, permitting, vendor selection and design changes. The article will address common risks encountered in projects and effective strategies to mitigate these risks. Examples will be provided for these common pitfalls

A

modern day project manager has to always juggle between the 4 key project objectives of safety, quality, cost and schedule. To manage these objectives one of the key tools is risk management.

Project risks are internal and external and as with any type of risks the key to their management is early identification and effective mitigation.

In this digital age, with so many tools available to the project management team to manage risks, it is seen that inspite of the best laid plans, projects go off track and fail in achieving one or more of their key objectives.

Below we shall examine some key pitfalls in projects where risks are missed out and could lead to possible project derailment.

Stakeholder Identification/Engagement One of the prime reasons for projects going off track is inadequate involvement of key stakeholders. A classic case is to bring in the Production Manager into the project close to commissioning. Very often production in charge has a very different outlook compared to the design team and can lead to last minute changes in the plant.

All the key stakeholders need to be identified right at the start of the project and their roles defined very clearly. Involve production engineers as well as Site HSE in early model reviews to avoid last minute changes.

Another pitfall is to give too much or the wrong category of information to stakeholders. A common example is to feed the project steering committee with too much technical details. The role of the Steering committee is to guide the 46 â&#x20AC;˘ November 2018

project team in key decisions on costs and schedule and not to provide technical solutions to issues. With too much technical information, the key project cost issues might get drowned in data or some member of the steering committee might start interfering in technical details for which they are not responsible for. Both situations can have damaging effect on the project Contracting Strategy Contracting strategies can make or break a project. A lot of companies go with a one strategy fit all approach. But unfortunately there is nothing like a perfect contracting strategy. Below are just broad guidelines on selection of a appropriate contracting strategy EPC Lumpsum: Go in for a lumpsum EPC contract only if the scope of the project is well defined and contractors are available who have experience in similar plants. Going in for a Lumpsum contract for a new Process or a plant which has a lot of specialised equipment can be a recipe for disaster.

EPC Reimbursable: This strategy can be very effective where the project owner has little or no regional experience where the project is being set up. The risks associated with less knowledge of local conditions can be mitigated to a large extent by passing them on to a good local contractor.

EPCM model: Probably the safest contracting strategy. But EPCM model can easily lead to large cost escalation as the EPCM contractor has very little stake in the project. Also this model can easily turn out to be a sparring game between the Engineering and Construction contractors.

It is essential that each project be assessed Z on specific requirements and

then the contracting strategy be finalised very early in the project.

Vendor Selection The general attitude towards vendors is that there is a prequalified approved vendor list so it is just a matter of following the approved list for the project, Since all the vendors are prequalified, no risk is foreseen for vendors. But this is far from reality. Even vendors with whom clients are working for decades can be the source of major risk to the project.

The first check required is whether the key vendors have adequate spare capacity at present to handle the load posed by the project. In absence of this it is possible that the vendor will supply the items required but with substantially longer delivery times.

For critical suppliers, it is worthwhile to do a financial due diligence especially if the client has not worked with the vendors for a substantial period of time. There are multiple cases globally where the vendor collapsed financially in the middle of the execution phase and disrupted the project as the order had to be diverted to alternate vendors. This risk is especially high for Single Source vendors.

Permitting Getting local permits brings in the uncertainty associated with dealing with a variety of Government authorities. Delays in obtaining permits can not only jeopardise the project schedule but sometimes even bring about design changes which would throw the project cost out of bounds.

Many times some of the requirements of local authorities are unwritten. So the best solution to handle this is to have an Engineering Contractor well versed with preparing and submitting statutory Chemical Engineering World

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CEW Features approval drawings. In addition, it is advisable to submit the approval drawings quite early in the project.

It is worthwhile to submit revised drawings when the final versions are available so that major modifications especially to the building layouts due to authority feedback is avoided.

Design Change Design changes in a project are inevitable and these are normally covered in the project estimates as design creep allowances. But the design changes if not properly managed can easily go beyond the creep allowance and bloat up the project cost.

A few simple steps can easily ensure that design changes are minimised.

Focus on getting major design reviews done pretty early in the project. These include HAZOP, SIL Assessment and Constructability reviews. These reviews can bring in maximum changes in the

design leading to cost increases. But for carrying out the reviews early, it has to be planned that all the deliverables required for these reviews be completed early.

Ideally these reviews (at least HAZOP and preliminary constructability review) should be completed before the sign off of the FEL3 (Front End Loading) package.

The rest is up to rigorous project control that every change after the design signoff is properly recorded and measured. While this does not minimise the changes but at least keeps track of the variations and genuine scope changes can be identified.

them. In such a case the entire project risk assessment exercise is futile.

It is one of the key responsibilities of the project management team to manage risks to the project and ensure minimum monthly reviews of the risk register are done.

Last but not the least remember that Risks are never eliminated, they are always mitigated. Manage risks effectively and meet the project goals of safety, quality, costs and schedule.

Author Details

Managing Risk Register Project risks are identified at the start of the project through a risk workshop and recorded in the project risk register.

But many a times the risk register is not updated on a regular basis and the risks though clearly identified at the start of the project actually start affecting the project just because no one bothered to monitor

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CEW Features

How Engineering Software Can Help It all started with steam and power, next came mass production with the help of electricity, followed by the digital revolution that transformed the way we work. And what is next? The Fourth Industrial Revolution, the latest upheaval in modern manufacturing that focuses on computerization. What are the benefits and challenges brought by this new paradigm? Philippe Marceau, Executive Vice President at Hexagon PPM EMIA discusses the way smarter factories will shape change for the chemical industry worldwide.

A

ccording to McKinsey(1), Industry 4.0 can be defined as the next phase in the digitization of the manufacturing sector, that is inspired by four modern changes in the industry: the recent rise in data volumes, computational power, and connectivity; the emergence of analytics and business-intelligence capabilities; new forms of human-machine interaction such as touch interfaces and augmented reality systems; and improvements in transferring digital instructions to the physical world, such as advanced robotics and 3D printing.

Similarly, according to the 2016 Global Industry 4.0 Survey by PwC(2), Industry 4.0 refers to a profound digital transformation that is underway for the leading industrial and manufacturing companies across the globe. The 2000+ companies that responded to the survey are expecting to dramatically increase their overall level of digitization.

While just 33% rate their company as advanced today, that number jumps to over 70% when looking ahead to 2020.

It is worth to mention that Industry 4.0 and Fourth Industrial Revolution are not necessary synonyms. The earlier refers strictly to the changes taking place in the manufacturing industry, whilst Fourth Industrial Revolution discusses in a wider scope a systemic transformation of the society. With this in mind, this article discusses Industry 4.0 in a more narrow scope, focusing on the effects on manufacturing.

Key innovations behind Industry 4.0 As stated in the Industry 4.0 briefing by the European Union(3), Industry 4.0 depends on a number of new and innovative technological developments: • The application of information and communication technology (ICT) to digitize information and integrate systems at all stages of product creation and use

50 • November 2018

•

•

•

•

•

(including logistics and supply), both inside companies and across company boundaries; Cyber-physical systems that use ICTs to monitor and control physical processes and systems. These may involve embedded sensors, intelligent robots that can configure themselves to suit the immediate product to be created, or additive manufacturing (3D printing) devices; Network communications including wireless and internet technologies that serve to link machines, work products, systems and people, both within the manufacturing plant, and with suppliers and distributors; Simulation, modelling and virtualization in the design of products and the establishment of manufacturing processes; Collection of vast quantities of data, and their analysis and exploitation, either immediately on the factory floor, or through big data analysis and cloud computing; Greater ICT-based support for human workers, including robots, augmented reality and intelligent tools.

Mass customization and enhanced safety There are several benefits that cyberphysical production systems bring: being able to work in a cloud-environment conveys completely new levels of scalability, flexibility and integrity. Having a real-time feedback loop enabled by sensor technology minimizes errors, provides overview of production line and enables proactive steps to be taken to fix any possible problems. Quickness of sharing data enables real-time and improved decision-making…and the list goes on.

Some of the key benefits for Industry 4.0 also include: • Mass customization. Smart factories enable increased flexibility in production.

Automation and transmission of data enables different products being produced in one facility.

• Safety enhancement in dangerous working environments. Safety risks at traditionally risk-prone environments such as offshore rigs and chemical facilities are lowered by providing augmented reality and simulation solutions.

• Improved quality. Sensor data can be used to determine errors during manufacturing phase to proactively identify mistakes.

• Enhanced productivity. Manufacturing industry can cut downtime up to 50% with smarter facility solutions, according to the Digital Transformation of European Industry and Enterprises report(4).

In addition, it is estimated that Industry 4.0 can bring estimated annual efficiency improvements between 6%-8%.

Towards Big Data Many chemical manufacturers are still focusing on the daily management of operational systems instead of directing their attention towards engineering data and information. However, the leap towards Big Data can only happen when actionable and accurate engineering data is made available.

This brings us to the question: how can a chemical owner operator start to move towards Industry 4.0 and a Big Data environment? The starting point is simple: moving away from a documentcentric approach to having a data-centric environment for engineering information.

This would include hosting all data and documentation in a centralized location and therefore having a complete representation of the physical asset in a virtual format.

Being able to add construction and welding documentation, as well as all the information contributed by suppliers to the database provides an excellent starting point for moving towards a Big Data approach. This enables the owner to answer questions such Chemical Engineering World

Features CEW process removes manual errors, improving both efficiency and productivity immensely.

Conclusion Access to accurate and up-to-date information and improved access to it enables many of the Big Data benefits, such as improved decision making and better forecasting – after all, the more information you have, the better business decisions you can make, which tends to reduce cost while increasing efficiency and productivity.

as: • Where throughout all my plants has a certain device (i e, a sensor or a pump) been deployed?

• How are the majority of these devices performing?

• Which ones are derailing from expected performance (corrosion, early failure, etc.) and what could be the root cause for this unexpected behaviour?

This approach enables chemical plant owners to gain an unparalleled overview of how their manufacturing facility is performing and take proactive action towards fixing any problems before they result in lowered efficiency, plant downtime or hindered product quality.

The role of engineering information The first steps towards a Big Data approach and benefiting from Industry 4.0 can be taken by leveraging the already existing data and information. Smarter engineering information management solutions, such as SmartPlant® Foundation and SmartPlant Fusion, enable facility owners to turn their scattered, unintelligent data into intelligent engineering information. This information can be checked for accuracy, quality and actuality no matter what the original format is – paper, PDF, network drives or legacy databases. After checking information quality, the actionable information can be made available for all users and applications throughout the company, enabling real-time decision making, improved efficiency and productivity.

This kind of data-centric environment is based on a single instance of an object, and intelligent, reactive relationships between Chemical Engineering World

them. These relationships allow owners to manage change and find what they are looking for based on what they know, without having to worry about duplicates or inconsistent data.

Once engineering information is more actionable, accurate and up-to-date, smarter software solutions bring yet another paramount benefit to manufacturers: the ability to access engineering information via a Zero Footprint application. This type of a browser-based application enables secure access to critical information at any time on almost any platform with a simple link, providing decision makers with the information they need in a timely and efficient manner.

When combined with augmented reality solutions, Zero Footprint applications provide owner operators an unprecedented access to real-time data of the manufacturing facilities.

Another good example of intelligent engineering information benefiting smarter facilities is the ability to enable machine-tomachine communications. With this, manual errors are diminished as the machines can automatically access information and communicate with each other. These type of production control systems already exist, one of them being Intergraph Smart Production. Here, engineering information is used for the partial production and production of weld assemblies, work planning and nesting of parts. Engineering data is also used automatically with the most important production techniques such as cutting, sawing and splitting. This automated

As the technology continues to advance, the line between the digital and the physical world will continue to blur.

Industry 4.0 will enable the chemical industry to take a leap to the next level of productivity, safety, and efficiency. These improvements will not come without a price, but with an innovative and trustworthy technology partner, the challenges related to digitization of manufacturing can be mitigated and engineering data can be turned into an intelligent information asset for the company.

References: 1. Manufacturing’s Next Act by Cornelius Baur and Dominik Wee ©McKinsey&Company 2. Industry 4.0: Building the Digital Enterprise ©PwC 3. Industry 4.0 Digitalisation for Productivity and Growth ©European Parliament 4. Digital Transformation of European Industry and Enterprises. A report of the Strategic Policy Forum on Digital Entrepreneurship. Strategic Policy Forum. ©European Parliament

Author Details Philippe Marceau, Executive Vice President Hexagon PPM EMIA November 2018 • 51

CEW Features

Interface Challenges…A Contractor’s Perspective A continuous happening and most worrisome part during entire life cycle of any project is maintaining a healthy, synchronous and harmonious relationships among all Interfaces. As speed mismatching of different gears of a giant machinery may lead to disastrous failure or catastrophic breakdown, similarly a badly managed project becomes like a best recipe turned into a bad meal though all ingredients exist. The article covers some of the practical views of Interface Challenges together with their causal factors and mitigation aspects are narrated.

1 PROJECT LIFE CYCLE 1.1 Major activities during project life cycle are as under: • During Initiation / Start-up • Kick of meeting (internal/external) to set up roles and responsibilities • Scope of each stake holder, defining Project Approach and Methodology and entire line of deliverables.

• Schedule Charting / Resource planning • Understanding of client expectations by all stake holders • Execution • High energy consuming period / utilization of most resources • Need for corrective and fast decisionmaking process • From all stake holders, delivery is expected of defined and properly structured qualitative efforts • Most often, struggle is observed to maintain schedule, costs, credit management and quality of deliverables • Monitoring and Control • Technical Progress • Need exists for efficient Document Control Index (DCI), Monthly Progress Review(MPR), S-Curve for control and monitoring • ○Identifying problems / potential risks and mitigation action plan • ○Strategy to achieve milestones and meet deadlines 52 • November 2018

• Immediate reporting of Significant deviation / Corrective action / Change control procedure • Physical Progress • Setting KPIs / fixation of base-line / indicating S-curve in report • Normal applied method of Earned Value Management (EVM) • Financial Progress • Monitoring Actual/Forecast costs budgeted vs budgeted / revised cost • Final winding up • When all deliverables / documents / ‘As Built’ are handed over to the Client - the final stake holder.

• Demobilising all site activities and releasing site staff.

• Settling final invoices • Client feedback 2 INTERFACE 2.1 Definition • It is transparent boundary layer or battery limits pertaining to each stake holder.

• Interfacing is an activity which helps to maintain the smooth flow of information among all interdependent and interrelated stake holders (disciplines or specific functional activity holders) at all levels in a project.

2.2 Responsibility • It becomes responsibility of project management team to manage successfully to avoid interface conflicts hence practically Project Manager becomes the Interface Manager at all times!

• The Project Manager is ultimately held responsible for the In-time, Within-budget and Within-scope completion of his project. It is therefore his responsibility to control and coordinate the work of all the functional groups to achieve the targets of project scope, cost and schedule.

2.3 Types of Interfaces 2.3.1 Internal Interface • Interfaces within the project (inter disciplines / HR-Admin / Finance / IT) • Normally they are sequential (when one delivers only, other can start) and reciprocated (give and take harder relationship to maintain) 2.3.2 External Interface • Interfaces with external agencies (client / sub-contractors, vendors, fabricators, package suppliers, consultants, statutory authorities) • Normally most of them are of sequential nature and very less reciprocated 3 INTERFACE MISMATCH 3.1 Main Causes • Improper Kick-off meeting – taken for granted approach for routine deliverables • Scope clarity confusion – no explanation about grey area • Less communication-meetings-information exchange Chemical Engineering World

Features CEW • Negligence towards maintaining Minutes of Meeting (MoM) during meeting with important stake-holders and distributing them afterwards for current updated status.

• Hastened Squad checks for urgent delivery and missed-out clash checking meetings.

• Quality System failure • Missing or pending updation of (Document Control index) DCI by Individual stake-holder • Progress status of executed work not exchanged within inter-disciplinary circles or among other stake-holders 3.2 Effects • Friction, Stress and lethargy generation among project team • Poor co-ordination and lack of collaboration among all stake-holders • Generation of design errors and lowquality deliverables.

• Mismatch among all inter-dependent stake-holder’s deliverables • Construction conflicts at site creating execution delays • Leading to ultimate system performance degradation 4 ANALYSIS AND MITIGATION PLAN Challenges 4.1 During Design Phase (Internal Interface) • Causes • Delay in submitting design output on which further work of other discipline depends • Change in design • Change in Business Plan • High TAT (Turn Around Time) by client to approve documents • Change in scope (capacity enhancement or augmentation) after halfway through design •

Mitigation Points • Frequent meeting by PM to review the progress and status of deliverables of all concerned stake holders responsible for particular phase

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• PM needs to remain in close contact with client and demand a mutually agreed signed-off change order with revised scope details in case of change in plant-process design.

• PM needs to percolate down all details to the affected stake-holders.

He has to submit the cost of Change Order to client for confirmation and Go-ahead signal.

• For each change PM has to take care for its Impact on Cost as well as Time Schedule and keep each stakeholder aware of changes.

• Early engagement of external competent agency to outsource certain design activities to meet the schedule.

4.2 During Procurement Phase – Delay factor (External + Internal interface) • Causes inputs from Design • Delayed discipline • Delay in Procurement Cycle • Delay in Long lead item • Delay and/or insufficient inputs from Vendor for review and comments • Delay in final GAD from Vendors for detailing / design further.

• Sometimes for early start, site execution is started on assumption / vendor approved drawings of similar equipment and ultimately causing reworking due to mismatch afterwards upon actual delivery of package or FEG items.

• When the vendor/supplier does not follow design drawings to the point leading to clashes on site during execution.

• Mitigation points • Action plan for long lead items shall be chalked out at earlier phase.

• Accordingly, information-data gathering and up to preparation of final Purchase Order Specifications should be in first line of preference.

• Maintain “Delay Analysis” log and alert all concerned on regular interval

communication with • Regular responsible person of Package supplier / Vendor / Fabricator with physical progress review visit at works shall be more helpful.

• Critical parameters for designing must be adhered to by Package / FEG vendor to avoid reworking because of site clashes 4.3 External Interface Factor – Subcontractors / Vendors • Causes • Delay in deliverables / supply items • Mismatch between GAD / supply item specification from input feed data • ○Mismatch in Fabrication drawings and changes in Nozzle schedule and orientation • Changes in final scheme other than intended specifications.

• Rejection as not meeting QA / QC requirements during inspection by TPI or self.

•

Mitigation Points • Demand for stagewise document delivery for review and for updated schedule.

• Regular communication with responsible person of Package supplier / Vendor / Fabricator with physical progress review visit at works shall be more helpful.

• Reputed TPI intervention shall be more helpful at such times.

4.4 Project Site Management Activity

by Site Executor / Contractor • Causes • Insufficient resources • Insufficient cash flow • Execution clashes among other stake-holders • Last moment drawing / design change / revisions • Execution mismatching the design / drawings • Decision making delay on critical / general points by design discipline / procurement / client responsible authority • ○Delay in supply of free issue or bought out items from client.

November 2018 • 53

CEW Features • Unplanned execution in haphazard fashion not in sequential order • Lack of constructability •

Mitigation Points • Site visit by PM team at regular interval and meetings with all stakeholders to resolve all clashes, hindering factors and accumulated issues is the key factor to smoothen out problems.

• Strong site supervision, monitoring and giving detailed feedback to project management team is most essential.

• Sometimes the deputed site supervisor becomes unofficial employee of contractor and becomes sympathiser who inadvertently hides inefficiency of contractor.PM should be always on lookout for such tendency development in site staff.

• For cash flow issues and supply of free issue material from client, candid and honest discussions with client will build confidence and rapport. Incidentally, client and all major stakeholder shall provide proactive support with ‘in the interest of project’ attitude.

4.5 Major Key Factor – Project Management Efficacy • Causes • Not following schedule - crisis management approach • Ad-hoc approach in decision making process • Wavering decisions • Finance crunch • Cash flow problems • Not sound procurement strategyfavouritism-dishonest decisions • Unrealistic time line, milestones and approach • Delay in Procurement • ○Choice of spurious quality of Vendors / contractors • ○ Unprofessional approach • ○ Stop and Go in business plan 54 • November 2018

•

Mitigation Points • ○ Project management team should ensure that they have clearly defined scope, displayed correct manhour budget and realistic time schedule which are some of the major driving factors. Mile stone targets and time lines should be achievable with resources allocated for the delivery of project. Here the role of Project planner becomes vital for visualizing and minimizing the risks.

• ○ Project management team should be strong, experienced and having a proactive approach in changing situations and scenarios • ○Information gathering and redistribution among all relevant stake holders is the prime requisite of Project management team.

• ○A continuous Project Schedule updation with carrying out Gap Analysis / Critical Path Analysis and monitoring by project team will help.

• ○Daily updation of main DCI and deliverable submission records is one of major key factors.

• All stake holders should work on a common shared platform to avoid ambiguity and mismatches / clashes.

Document control is also utmost important. Right revision drawing shall be used for execution.

• ○ Cash flow should be continuous and WIP should be minimum. Extra efforts should be immediately claimed to maintain profitability on positive side.

•○ Suggestion / Selection of contractors and vendor - fabricators should be based on past records and good certifications to avoid problems in maintaining procurement schedule and quality aspects to avoid delay in overall project schedule.

• ○ Major factor is maintaining smooth flow internal interface which is mostly of reciprocated and sequential nature. Personal egos, temperaments and attitudes cause frictional environment. This hinders flow of client deliverables and

lowers qualitystandards of designdocuments as inter-discipline squad checks; clash check group meetings lose their value-added importance.

• For bigger project (say >INR 25 Mn), engage one Project Engineering Manager (PEM) may be appointed to take care of inter-discipline coordination and quality engineering delivery.

Author Details

Arpan Shah Mott MacDonald Industry Account Leader Marketing.India@mottmac.com Chemical Engineering World

News Features CEW

Bridging the industrial sector’s skills gap with experiential learning

T

he growing skills gap which can lower business profitability and staff productivity is one of the most pressing issues amongst employers in the industrial world today.. They are facing the most acute talent shortage in 12 years. According to a survey conducted by Manpower Group, India is among the top 10 most-affected markets with 56 per cent of employers facing difficulty in filling vacant positions here due to growing skills gap. The rapid pace of technological advancement and automation has exacerbated this situation.

According to a McKinsey Global Institute report, by 2020, the world will face a shortage of approximately 40 million highskilled workers and 45 million mediumskilled workers. However, at the same time there will be a surplus of 95 million workers whose skill set may not match the demands of the industrial market.

For businesses, training new hires on systems and processes — which can range from six months to a year in technical roles — can potentially lead to substantial waste of time and effort. Additionally, businesses also have to endure the loss of knowledge and skills when highly trained workers retire or leave the organization.

So far, most businesses have followed the traditional method of an official handover – where the outgoing employee records his or her knowledge in different forms of documentation to prevent the leakage of knowledge. These knowledge repositories are generally used later to train the new hires. However, such passive methods of learning have proven less effective to train millennial employees. There is an urgent need for businesses to cast away the traditional methods of training and invest in a more immersive competency. Immersive competency is a type of workforce training that involves immersing an employee in the environment in which they will work, through simulation such as virtual and augmented reality. Augmented reality is being adopted in the digital space by today’s

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millennials and in a country like India where smartphone devices are proliferating, there is a huge scope for AR and VR adoption.

Tailor-made for millennials Research shows that millennial respond better to experiential learning techniques, rather than passive learning methods such as listening (e.g. lectures) or visualizing (e g, presentations).

Active learning methods such as immersive competency result in retention of 70 to 80 per cent of the knowledge even after three months compared to only 30 per cent retention through passive learning methods.

Immersive competency also reduces the time required to train an employee to just a couple of months whereas passive learning methods take half a year. Active learning methods blur the boundary between learning and working to make the two processes seamless, which leads to the creation of an informed and capable workforce in a short span.

As part of its Connected Plant initiative, Honeywell has developed Honeywell Connected Plant Skills and Safety, a suite of solutions for end-to-end management of worker competency, productivity and safety. This is an ecosystem which delivers information, insight and collaboration to help manufacturers address the skill gap challenge.

Training made simple and easy Honeywell’s advanced training solution is a cloud-based solution, which uses a combination of augmented reality and virtual reality. It equips, both the experienced workers and new hires, with mixed reality headsets that simulate various plant situations. Users can record and save their work to the cloud, so anyone can access that information whenever they need it.

Immersive competency becomes digitally accessible to everyone, no matter where they are, whenever they need to learn more about a specific procedure or situation. The result is a continuous cycle of learning by

doing, and working while learning.

The training solution is built, using knowledge passed down from experienced workers, to simulate every area of operational practice. This means developing scenarios which cover various job activities such as installation, configuration, inspection, maintenance, troubleshooting, replacement of working parts, etc.

The Honeywell solution improves skill retention versus traditional training methods by up to 100 per cent and reduces the length of technical training by up to 60 per cent. Additionally, the employees’ training progress is tracked as part of a formal competency management system.

The bespoke solution also allows to link industrial staff competency to plant performance by measuring the training’s effectiveness based on real outcomes.

Transforming the workspace Honeywell has empowered customers to reduce operational costs by up to 50 per cent in some areas. For example, a procedure which formerly involved flying in three workers by helicopter to carry out maintenance — at a cost of around $10,000 — now requires only one.

Evolving technology and process automations will create demand for new skills while making others obsolete.

Businesses will need to train employees with new skill requirements to bridge the skills gap and remain ahead of competition.

Adopting technology-based immersive competencies is the most effective and efficient way to bridge the employee skill gaps.

Author Details Rahul Khare, Regional Business Leader (India & South Asia) Honeywell November 2018 • 55

CEW News Features

Simon India Commissions WHR plant for Cement Plant

S

imon Carves India, a world class EPC Company of Adventz group was incepted in the year 1995 as joint venture between Simon Carves and the Zuari group. Subsequently, the company became 100 per cent equity company of Adventz group and renamed as Simon India Ltd and has been actively serving the Oil & Gas, Chemical, Petrochemical, Fertilizer, Cement and Power industries across the globe through operations in India and Saudi Arabia.

The group has successfully executed projects from concept to commissioning and is currently pursuing major projects in fertilizer industry and has recently been awarded the project of Mundra LPG terminal for Adani Group.

This year, Simon India Ltd has successfully commissioned the Waste Heat Recovery (WHR) project for OCL India Ltd, the flagship company of Dalmia Group the cement plant. The WHR system is installed in Rajganapur line – 2 cement plant.

This system is having two boilers (AQC and PH), one ACC (eight cells), TG and associate system like instrument air, DM water, air-conditioning and pressurization,

DCS and control. The system was commissioned in two phases and the first 5

MW plant started operating on 1 st February 2018 taking steam from the AQC boiler along with ACC and TG. The PH The package parameters include: boiler was connected with the system on 16 th May 2018 and Package Quantity Parameter Present Operating Parameter max generation achieved 11 MW AQC Boiler 1 Flue Gas Temp – 500oC Flue Gas Temp – 510oC Flue Gas Flow Rate – 78330 N cu m/hr Flue Gas Flow Rate – 78330 N against 9.2 MW of contractual commitment. Now the WHR Heating Surface Area (HP) – 13,989 sq m cu m/hr Heating Surface Area (LP) – 4,918 sq m system is running continuously at 9.8 MW PH Boiler 1 Flue Gas Temp – 330oC Flue Gas Temp – 351oC Flue Gas Flow Rate – 293750 N cu m/hr Flue Gas Flow Rate – 293750 N Achievements: Heating Surface Area (HP) – 13,235 sq m cu m/hr 1. Installed WHR system is Heating Surface Area (LP) – 6,953 sq m capable to generate about Air Cooled 1 Cells – 8 Cells – 8 10 per cent more than the Condenser Steam Flow – 56 TPH Steam Flow – 56 TPH contractual commitment.

(ACC) Back Pressure – 0.116 ata Back Pressure – 0.10 ata 2. PH boiler having height of Steam Temp – 48.38oC Steam Temp – 48.38oC 100 m erected within two and TG 1 Power Generation Capacity – 9.2 MW Average Generation Achieved – a half months which is lesser Generator Capacity – 10 MW 9.8 MW than the than estimated time HP Steam Pressure – 14 kg/sq cm Generator Capacity – 10 MW of four months.

HP Steam Temp – 445oC HP Steam Pressure – 14.5 kg/ Steam Flow – 35.2 T/hr sq cm HP Steam Temp – 440oC Steam Flow – 41.75 T/hr 56 • November 2018

Chemical Engineering World

CEW

Marketing Initiatives

Industrial Water System Assessment

I

n chemical process industries water is used for different applications.

For e g, process, utilities, cleaning, flushing, gardening and for domestic purpose. In this way water is a key material used in chemical process

industries.

The

main

sources

of

water for companies are industrial development corporations, in house bore well and from nearby river in case of sugar and paper industries. The total mass of water on earth undergoes through water cycle i.e. evaporation and condensation. This condensation in the form of rain varies geographically.

Hence we see some regions are under acute water scarcity and some are abundant. Due to high population and industrial growth water demand is ever increasing and availability is limited.

So, it becomes a responsibility of an individual and industries to make use of water more efficient.

In industries water efficiency is measured as specific water consumption. It is the ratio of water consumed per unit of production. The first step to improve this indicator is to conduct water audit exercise in the plant. Water audit is a performance oriented technical activity.

Like any other audits water audit is also a systematic study of water usage, consumption, and losses. The basic objective of this study is to identify opportunities of water conservation. In most industrial places water is cheaply available and hence water efficiency is overlooked. Water audit is very useful tool to identify inefficiencies and opportunities to improve specific water consumption ratio.

Chemical Engineering World

There are 5 elements of water audit namely, verification of existing meters, quantification of losses, establish water balance, identification of water saving opportunities and preparation of audit report. In verification of existing meters main incoming line meter and all other meters installed in various consumption areas are verified by comparing flow rate with calibrated ultrasonic flow meter. This ensures the correctness of daily readings taken and noted.

For quantification of losses auditor actually measures the losses such as evaporation in cooling tower, leakages from various points in the plant equipment and unmetered use if any in the plant. By establishing water balance we come to know about the incoming and outgoing water flow quantities.

This also identifies the major and minor areas of consumption. Identification of water saving opportunities is based on 3R principle, R- Reduce water usage, R - Reuse water and R - Recycle of water.

Preparation of user friendly report with necessary evidences, calculations and practical recommendations is very important.

For audit purpose auditor gathers information from facility such as sources of water, cost of water, water quality test reports and total number of manpower working in the factory.

Water audit involves key measurement parameters such as flow rate, time of usage, water temperature, and water surface area. Human behavioural habit plays important role in water consumption in industries. From the above exercise the performance ratio, the specific water consumption is

calculated to encourage plant managers to set water consumption target for their team.

For successful water audit project it is important to address audit findings immediately and implement recommendations on priority.

Author Details

Prashant Gongle

Proprietor EnPro Consultant, Pune Email: enproconsultant@gmail.com November 2018 â&#x20AC;˘ 57

CEW Products SUNSCAN

Twinlobe Blowers/Vacuum Booster SUNSCAN is available in various models suitable for RTD, T/C, mA and mV types of input. The scanner scans all input channels against alarm and trip settings and generates output. Scanner supports operator mode where display selections alarm acknowledgement and dwell time adjustments can be made. It also supports supervisory level controlled through password to adjust alarm and trip settings, group configuration, output response adjustment, addition/ detection of channels, etc; SUNSCAN also supports individual LEDs to indicate

status.

For details contact: SUN Indl Automation & Solutions Plot No: 95, Developed Electronic Indl Estate Perungudi, Chennai 600 096 Tel: 044-30788900 E-mail: sias@vsnl.com or Circle Readers’ Service Card 01

Twinlobe blowers/vacuum booster is of modular design for max flexibility, always allows meeting customer’s requirements, and has positive displacement, high operating speed due to dynamically balanced rotors. It is entirely mechanical and light in weight with relatively low power consumption.

It finds application in cement, effluent treatment, pollution control plant, fertiliser, textile, glass/tube industries, pharma and chemical.

For details contact: Indovac Pumps & Engg Co 21 Anand Raj Indl Estate Sonapur Lane, B/h Asian Paints, Off LBS Marg Bhandup (W), Mumbai 400 078 Tel: 022-25664917 Telefax: 91-022-25664917 E-mail: indovac@yahoo.co.in or Circle Readers’ Service Card 02

Oil-free Air-compressors ELGi Equipments offers range of oil-free air-compressors and reiterate its commitment to enabling energy-efficiency and meeting high purity air demands.

ELGi’s oil-free range comprises of machines ranging from 60 and 100 HP with 7 and 8.8 bar pressure options. The air-cooled designed will ensure ease of installation at all customers, while the aluminium coolers will ensure efficient cooling. High-efficiency NEMA motors power the machines with separate ducting for noise reduction. ELGi is one of five companies in the world with a proprietary oil-free Airend design. The new models are supported by ELGi’s class leading four year Airend warranty and a strong service network. The added models will ensure that ELGi is able to service all oil-free air needs in the market.

These compressors are used across a variety of manufacturing applications, witnessing strong demand from the food and beverage sector, owing to mandatory health and safety requirements. An industry focus on economical manufacturing methods, lower installation and maintenance costs are also contributing to the growth.

For details contact: Elgi Equipment Ltd Trichy Road, Singanallur Coimbatore, Tamil Nadu 641 005 Tel: 0422-2589555 Fax: 91-0422-2573697, 2589401 E-mail: enquiry@elgi.com or Circle Readers’ Service Card 03 24

58 • November 2018

Chemical Engineering World

Products CEW AODD Pumps Shanbhag & Associates is the authorised national distributor for the entire range of Dellmeco Products with an all India sales and service network. The range of Dellmeco pumps includes solid block AODD pumps in PE, PTFE in conductive and non-conductive housings from 1/4” to 3”; SS, CI, PTFE, coated and aluminium housing AODD pumps from 3/4” to 3”; hygienic, zero hold-up sanitary SS-316L AODD pumps from 1/2” to 2.5”; jacketed and highpressure AODD pumps for applications such as filter press; AODD pumps for powder transfer. The pumps internals are available in EPDM or with chemically bonded TFM diaphragms and ball valves. Dellmeco AODD pumps are absolutely lube-free; non-stalling in operation and corrosion-free.

Air valve body is available in corrosion-free engineered plastics. There are fewer moving parts and commonly used spares across models and sizes.

Dellmeco pumps find application in industries such as pharma, paint, chemical, clay and ceramics, electroplating/surface treatment, food, dairy and beverages, automotive, glass and fibreglass, oil and gas, marine/shipbuilding, metal and steel treatment, effluent-treatment, aircraft, etc.

For details contact: Shanbhag & Associates B-50 Nandbhuvan Indl Estate Mahakali Caves Road, Andheri (E) Mumbai 400 093 Tel: 022-40365711, Fax: 91-022-40365712 E-mail: info@shanbhags.com or Circle Readers’ Service Card 04

Motorised Double Diaphragm Pumps The DELLMECO DME Series is an electro-mechanical double diaphragm pump which is highly energy-efficient. Instead of running the double diaphragm pumps on compressed air or Ni gas which is the most expensive plant utility, DELLMECO offers energy-efficient electric geared motor as the driver for the double diaphragm pumps.

The pump technology is especially designed for universal applications which require low pressure - up to 6 bar. It is compact, special design does not require hydraulic fluid and where preventive maintenance is easy to carry out.

The DELLMECO DME unique design concept and low energy consumption enable us to combine high-tech with proven reliability and quality for the most demanding of customers. DME Series pumps housing is machined from PE and PTFE conductive blocks and also in aluminium, cast iron, AISI 316 industrial and AISI 316 L hygienic combinations; temperatures are up to 120°C; capability to run dry, low shear and to handle fluid; smooth product transfer; low operating costs through highly efficient electric drive; withstands corrosive chemicals against constant flow rate against variable pressure and viscosity; fully enclosed long life diaphragms; abrasion resistance with robust design; capacity up to 650 l/min without variable frequency drive (VFD) flow control; optional VFD flow control for process performance (from 35 to 70 Hz); availability of wide range of optional accessories; and compact design means less space required compared to ecc screw and peristaltic pumps.

For details contact: Shanbhag & Associates B-50 Nandbhuvan Indl Estate Mahakali Caves Road, Andheri (E) Mumbai 400 093 Tel: 022-40365711, Fax: 91-022-40365712 E-mail: info@shanbhags.com or Circle Readers’ Service Card 05 24

Chemical Engineering World

November 2018 • 59

CEW Products Miniature Float Switch

Planetary Gearboxes

Miniature float switch is suitable for single level sensing. It consists of a reed switch housed inside the SS housing and a permanent magnet inside the float assembly. The float moving with the liquid level makes (NC) and breaks (NO) the reed switch contact. It is used for sensing low, high or point level in tank.

The counting is through a M10 male thread.

It finds application in hydraulic oil, water boilers, chemical and pharma industries.

For details contact: Filpro Sensors Pvt Ltd No: 130, 10th Cross, Petechennappa Indl Estate Kamakshipalya, Magadi Main Road Bengaluru, Karnataka 560 079 Tel: 080-23286463 E-mail: sales@filprosensors.com or Circle Readers’ Service Card 06

The planetary gearbox PE completes the whole range of their automation gearbox series consisting of highend planetary gearboxes, right angle gearboxes, hypoid gearboxes, cycloid gearboxes, as well as various combinations thereof. The right angle gearbox PEB rounds off this Series with its prestage bevel gearbox. Smooth running is achieved through the use of Gleason Type spiral bevel gears in the pre-stage of the gearbox.

For details contact: EGT Eppinger Getriebe Technologie GmbH Breitwiesenweg 2-8 73770 Denkendorf Germany Tel: +49 711 934934-626 Fax: +49 711 934934-627 E-mail: info-egt@eppinger-gears.com or Circle Readers’ Service Card 07

M Pumps Shanbhag and Associates is the sole, authorised, national distributor for M Pumps an Italian manufacturer of seal-less, magnetic driven pumps. M Pumps is a unit of the Mischiatti Group and has been manufacturing magnetic driven pumps in API & non API standards for over 25 years.

The seal-less, magnetic driven pumps are offered in centrifugal, peripheral, sliding vane, selfpriming, centre-line mounted, inline and vertical pump versions. M Pumps manufactures these pumps in metallic, non-metallic and lined constructions.

It finds application in oil and gas, chemical, pharmaceutical, industrial refrigeration, offshore platform, electronic and galvanising and nuclear plant areas amongst others.

M Pumps is an ISO 9001 and ISO 14001 Certified company manufacturing to API 610 and 685 as well as non-API pump Standards. To safeguard the pumps Shanbhag also offer dry-running protection, temperature monitors on rear casing and ATEX Certification as options for many models as optional features.

Contact Shanbhag with fluid details and your pump requirements. Their national sales and service network will application engineer your pump requirements. With M Pumps, Shanbhag can offer high quality pumps at a competitive prices for your difficult applications.

For details contact: Shanbhag & Associates B-50 Nandbhuvan Mahakali Caves Road Andheri (E), Mumbai 400 093 Tel: 022-40365700, 40365711 Fax: 91-022-40365712 E-mail: info@shanbhags.com or Circle Readers’ Service Card 08

60 • November 2018

Chemical Engineering World

Products CEW Mineral Analysers & Identifiers

Self-cleaning Filters

The TerraSpec line of mineral analysers provides portable, rapid and non-destructive analysis of minerals in the lab or the field.

Mineral geologists appreciate the TerraSpec mineral analyser’s portability and ability to rapidly identify key minerals. When used as ore analyser; results are presented in seconds to speed ones processing decisions.

For details contact: Aimil Ltd Naimex House A-8 Mohan Co-op Indl Estate, Mathura Road New Delhi 110 044 Tel: 011-30810200, Fax: 91-011-26950011 E-mail: info@aimil.com

The Russell Eco Filters safeguards the quality of your liquids by eliminating oversized contamination.

The strainer achieves consistently high flow rates with the unique SpiroKlene System, which continuously cleans a reusable strainer element.

It improves product quality by eliminating contamination; increases productivity with easy clean and tool-free maintenance; and safeguards operators’ health and the environment.

For details contact: Russell Finex Pvt Ltd A-1201 Rustomjee Adarsh Regal Adarsh Vihar Complex, Off Marve Road Malad (W), Mumbai 400 064

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Heavy Duty Screw and Vane Pumps Within the SPX FLOW business, the breadth and depth of pumping knowledge is based on decades of pump development and experience. From its Plenty brand, comes a wide range of vane and screw pumps which are widely used for the pumping of heavy viscous fluids across industries such as oil and gas, power generation and naval, and are ideal for forced lubrication of rotating machinery and fuel transfer processes.

Plenty Triro triple screw pumps provide reliable, quiet, pulse and vibration-free operation. The clever design of these compact pumps with just three moving parts, increases pump reliability, reduces noise pollution and minimizes impact on other downstream equipment. They deliver a stable flow of fuel and oil and offer better efficiency than equivalent centrifugal pump models.

Well proven within the oil and petrochemical industries, the Plenty Twinro two screw pumps offer an ideal solution for heavy duty fuel transfer in accordance with API specifications. The pumps can handle most bulk liquid transfer duties, and are used extensively in bulk loading and unloading applications. Each rotor is a precisely machined piece; the accurate screw profile ensures volumetric efficiency, accuracy, low running costs and reduced deflection even at high pressure discharge.

The unique SPX FLOW Plenty vane pump offers advantages over conventional vane pump technology with gentle, low shear pumping action; low rate of wear; lower running costs, and variable flow without the need for variable speed drive systems. The pump incorporates a rotor between the vane tips and the stationary body core with two sets of parallel flats machined on the inside surface against which the vanes run. The ends of the vanes are angled to give a component of force to drive the rotor around and creating the same action as traditional vane pump designs, the shaft and rotor centrelines are eccentric and form expanding and contracting cavities as the shaft rotates. Precision engineering, heavy blades and high quality manufacturing ensure the Vane pumps offer long life and exceptional performance.

SPX FLOW’s experience with refinery and oil and gas specifications means that customers are assured of compliant solutions with all necessary documentation. The understanding of international specifications is supported by innate industry expertise and the ability to customize and package a pump to meet the most exacting of requirements.

For details contact: SPX International Ltd Lodge Park House Kettering Parkway Kettering Venture Park Kettering NN15 6XU, U.K. Tel: +44 (0)1604 889921 E-mail: Maryanne.Johnson@spxflow.com or Circle Readers’ Service Card 11 00 24

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November 2018 • 61

CEW Products High-concentration Spray Particle Size

Automatic Powder Filling Machine This sturdy compact clean, elegant and easy to operate machine is suitable for powder, talcum and spices. Capable of filling 3 bottles at a time – auto, no bottle no filling arrangement with suck back facility. The machine provides easy changeover and is flexible for powders of different nature. Semi-automatic single, double, triple head powder filling.

Measurements The Spraytec delivers rapid, real-time, high-concentration spray particle size measurements over an extremely wide dynamic range. It delivers the knowledge required to fully understand how atomization is achieved, providing the ability to resolve and understand the source of any variability in the performance of spray systems.

For details contact: Aimil Ltd Naimex House A-8 Mohan Co-op Indl Estate Mathura Road, New Delhi 110 044 Tel: 011-30810200 Fax: 91-011-26950011 E-mail: info@aimil.com

For details contact: Pharma Chem Machineries 311/2484 Motilal Nagar No: 2, M G Road Goregaon (W), Mumbai 400 090 Telefax: 91-022-28735321 E-mail: pharmach@gmail.com pharmachem79@gmail.com or Circle Readers’ Service Card 12

Multi-point Gas Detection System Used for continuous area surveillance, multi-point gas detection monitors either toxic or flammable gases in work places or closed areas.

It is a smart technology with diagnosis features consisting of main control panel for 8/16/30 detection points. All detection points are addressable.It has LED indication in control panel for fault, alarm and function, RS 232 printer output, common external hooter output with industrial hooter and light flasher.

Modbus addressable gas sensor module can be non-FLP/FLP for toxic gas/combustible gases with relay signal output and LED indications.

Cable from controller to gas sensor is in single loop hence saves enormous cost of cables compared to conventional system.

For details contact: Prima Equipment Pvt Ltd 21 Lohana Bldg, 3rd Floor Raopura, Vadodara Gujarat Tel: 0265-2416938, 2438655 E-mail: info@primaequipment.com or Circle Readers’ Service Card 14

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Precision Turbine Flowmeter Precision turbine flowmeter is available in different housing material such as brass, aluminium, SS, PVDF, etc.

Meter sizes is available in ½” to 2”; accuracy ranging from ±0.75 to ±1.5% of reading; flow ranges from 3.8 to 760 LPM (1 GPM to 200 GPM); pressure ratings from 7 to 200 bar and temperature -40 to 121oC. Meter is designed for thin fluids <100 cp.

Modular design allows for use with output modules, sensors and remote transmitters. Internal parts are simple to replace for easy maintenance. Lithium battery life is 5 years.

For details contact: MTS Engineers Pvt Ltd B-408, Wall Street-II Opp: Orient Club Nr Gujarat College Ellisbridge, Ahmedabad Gujarat 380 006 Tel: 079-26400063, 30160063 Fax: 91-079-40047430 E-mail: sales@mtsengrs.com or Circle Readers’ Service Card 15

Chemical Engineering World

Products CEW Silicone Solid/Sponge Gaskets

Butterfly Valves

It easily withstands temperature range of -80oC to 260oC. These gaskets are available in square, rectangular, circular, oval or any section as desired by the customer.

Cipriani Harrison;s butterfly valves are made from forged SS-304L and SS-316L, are highly polished and come standard with FDA silicone seat and a two-position squeeze handle. The dense polished valve disc has a slim design, which allows for a high CV and the PTFE stem bushing ensures an extra smooth disc rotation. Available in ½” through 9” with sanitary clamp, Butt-weld and I-line end connections as standard. A variety of handle options as well as horizontal and vertical pneumatic actuators provides flexibility in design and application.

For details contact: Shree Gaurav Rubber Products 112-B Marudhar Indl Estate Opp: Old Syndicate Bank, Goddev Road Bhayandar (E), Dist: Thane Maharashtra 401 105 Telefax: 91-022-28197355 E-mail: gaurav_rubber@rediffmail.com

For details contact: Cipriani Harrison Valves Pvt Ltd Sub Plot No: 2, B/s Margin Impex Ltd Nr Phase IV, GIDC Estate V U Nager, Anand, Gujarat 388 121 Tel: 02692-235082, 235182 Fax: 91-02692-236385 E-mail: info@harrisonengineers.com

Shree Gaurav’s silicone gaskets are available in various sizes, sections, colours as per the requirements.

They are autoclavable and food grade, hardness of solid silicone gasket is 35 Shore A to 80 Shore A.

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Network Analysers

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High-end Planetary Gearboxes MPR-4 Series panel type network analysers are compact solutions with their 96 x 96 x 45 mm dimensions designed for detailed measurement and analysis of electrical parameters. It has a wide operating voltage range of 45-300 V AC/DC.

Devices with internal memory up to 16 MB offer a wide range of I/O solutions with their replaceable modular structure depending on requirements and areas of use. Therefore they provide flexible detection and control of devices in the field.

The servo gearboxes PT complete the whole range of their servo gearboxes that consist of high-end planetary gearboxes, right angle gearboxes, hypoid gearboxes, cycloid gearboxes as well as various combinations thereof.

All common servo motors can be easily installed with all sizes of their gearboxes.

Real-time monitoring is possible via large graphic screen. Thanks to the communication feature of MPR-4 Series, energy measurements can be monitored easily from a single monitoring centre.

Their PT servo planetary gearboxes guarantee high stiffness and reliable transmission through their unique design. All ring gears, planet gears and sun pinions are case-hardened and ground. This provides for an outstanding transmission quality and allows for precise positioning tasks.

For details contact: Entes Dudullu OSB 1 Cadde, No: 23 34776 Umraniye – Istanbul Turkey Tel: +90 216 313 01 10 Fax: +90 216 314 16 15 E-mail: impex@entes.com.tr

For details contact: Eppinger Tooling Asia Pvt Ltd SF No: 345/2A-2B, Kondampatti Kinathukadavu Taluk Coimbatore Tamil Nadu 641 202 Tel: 04259-3040 E-mail: marketing@eta-tools.com

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Chemical Engineering World

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November 2018 • 63

CEW Products Single Quadrupole GC-MS

Horizontal Float Switch

The Thermo Scientific ISQ GC-MS system offers rugged and reliable performance and non-stop productivity. The ISQ GCMS features a new source design ideal for continuous high-throughput operation.

The vacuum interlock enables source removal without venting the system for non-stop productivity.

For details contact: Thermo Fisher Scientific India Pvt Ltd 102, 104, Delphi “C” Wing Hiranandani Business Park Powai, Mumbai 400 076 Tel: 022-67429494, Fax: 91-022-67429495 E-mail: sagar.chavan@thermofisher.com

The float lever carries a permanent magnet which is repelled by similar magnet mounted in the switch housing. The magnet having the same pole directed towards each other are separated by a nonmagnetic diaphragm. The glandless construction offer excellent sealing.

For details contact: Filpro Sensors Pvt Ltd No: 130, 10th Cross, Petechennappa Indl Estate Kamakshipalya, Magadi Main Road Bengaluru, Karnataka 560 079 Tel: 080-23286463 E-mail: sales@filprosensors.com

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ARM Multicore-based Visualisation Systems The fanless HMI family HMI40 is based on the ARM Cortex A9 (i.MX6 DualLite) 1 GHz multicore processor.

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Compressors

HMI40 systems have an isolated 24 V DC power supply input.

Sauer Compressors offers a wide range of compressors. The solutions meet all compressed air requirements on ships, ranging from starting and working air to SCR-systems for exhaust gas purification.

A new state-of-the-art compressor control and various accessories round out the manufacturer’s impressive line-up. As Sauer Compressors’ latest machine exclusively developed for commercial shipping, the Levante Series has quickly established itself as a go-to for the maritime industry. In its latest incarnation, the 3-stage air-cooled compressor Levante WP460L Marine comes with a fill-up capacity of up to 460 m3³/h at a pressure of 30 bar © Sauer Compressors. Due to its robust and compact construction, the low-maintenance compressor can fit into any engine room without taking up much valuable space. To improve inter-cooling efficiency, the air flow has been optimised by installing a newly developed cube-cooler between the motor and the compressor – enabling the recooling temperatures to be reduced by a third. For max usability and comfort, the Levante comes with an integrated gauge panel and an operator-friendly HMI.

For details contact: Maestrotek Innovations Pvt Ltd B-406, Teerth Techospace IT Park Sr No: 103, Off NH-4, Baner Pune, Maharashtra 411 045 E-mail: sales@maestro-control,com

For details contact: J P Sauer & Sohn Maschinenbau GmbH Brauner Berg 15 24159 Kiel, Germany Tel: +49 431 3940-0 E-mail: William.koester@sauercompressors.de

They are supplied with Windows Embedded Compact 7 Pro operating system and integrates the numerous and advanced functionalities of Premium HMI visualisation software (Basic or Advanced version) and ASEM UBIQUITY remote assistance software. They also include ASEM System Manager, a software utility suite for the management of the panel. The HMI40 family is available with 16 million colour LED Backlight TFT LCDs from 7” to 15.6”, in 4:3 and wide aspect ratio, with aluminium or aluminium TrueFlat front panels with 4 or 5 wires resistive touchscreen. All versions with wide LCD are also available with aluminium and glass TrueFlat Multi-touch front panel with projected capacitive touchscreen.

The all in one motherboard provides two Ethernet 10/100/1000 Mbps ports, two USB 2.0 ports, a serial RS 232/422/485 interface with rear access, 1 GB DDR3 RAM, 4 GB Pseudo-SLC eMMC memory and a slot for a removable MicroSD. Optionally, an additional RS 485 Serial port with rear access is available.

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Chemical Engineering World

Products CEW Facility Monitoring System

AHU Pre-filter Cleaning & Drying Machine

Their facility monitoring software has been in use in pharma installations and has been updated to meet the rigorous demands of 21 CFR Part 11 with regard to electronic records. The software runs under MS Windows based around a real time database of results gathered from the datascan and particle counter instruments.

Each module has been subject to a full qualification procedure offering unrivalled reliability.

For details contact: Shreedhar Instruments 16 Shreeji Krupa Society Opp: MGVCL Circle Office Next to GMERS Medical College Gotri Road, Vadodara Gujarat 390 023 E-mail: sales@shreedhargroup.com

Ultramax Hydrojet Pvt Ltd offers automatic washing and complete drying of AHU pre-filters in SS as per cGMP norms. It can accommodate filter size from 150 x 150 x 50 to 610 x 610 x 355 mm. Customised machine manufactured according to customized requirement. Filter range is from 3 to 20 u. It finds application in formulation, vaccine, bulk drug and intermediates, hospitals and electronic and space application.

For details contact: Ultramax Hydrojet Pvt Ltd AC-31/4A, 6th Main Road SIDCO Indl Estate Thirumudivakkam Chennai 600 044 Telefax: 91-044-42852262, 42852264 E-mail: marketing@hydrojet.co.in

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Castfil PTFE Putty/Brushable

Compressors

Rollon Bearing offers Castfil PTFE putty/ brushable. It is a twopart epoxy-based cold-weld metal repair compound suitable for max temperatures up to 120oC. Castfil is a self-lubricating compound possessing high mechanical strength. It bonds strongly to most metals/plastics and offers long life protection against wear, abrasion and corrosion.

Sauer Compressors offers a wide range of compressors.

The solutions meet all compressed air requirements on ships, ranging from starting and working air to SCRsystems for exhaust gas purification. A new state-of-the-art compressor control and various accessories round out the manufacturer’s impressive line-up.

Castfil PTFE putty/brushable finds extensive usage in prevention of leakage in gas/liquid pipelines or valves; repair of blowholes, porosities, discontinuities, etc, in castings; repair of damages caused by abrasion or corrosion; rebuilding of critical machined parts; repair of oversized bearing bores, worn out shafts, scored guideways, etc.

For details contact: Rollon Bearings Pvt Ltd Shah Sultan Complex Cuinningham Road Bengaluru, Karnataka 560 052 Tel: 080-22266928, 22250287 Fax: 91-080-22250319 E-mail: rollon@rollonbearings.com

For details contact: J P Sauer & Sohn Maschinenbau GmbH Brauner Berg 15 24159 Kiel, Germany Tel: +49 431 3940-0 E-mail: William.koester@sauercompressors.de or Circle Readers’ Service Card 26

Chemical Engineering World

Same as the Levante Series, the 3-stage air-cooled Passat range is known for its exceptional durability in even the most demanding operating conditions. With filling capacities of up to 270 m3³/h, the Passat is situated slightly below the Levante.

Dividing the compression process into three stages notably decreases operating temperatures. This results in significantly lower maintenance costs and improved reliability.

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November 2018 • 65

CEW Products Portable Benchtop Analyser for Measuring O2 and CO2 The only truly portable battery powered gas analyser with MCERTS Certification, the MiniMP is a portable analyser designed to offer single or dual measurement of O2 and CO2 by utilising servomex’s advanced paramagnetic and infra-red sensing technologies. Features EN15267-3 (MCERTS V3.3, Annex F) makes the MiniMP for source testers that require reference O2 analyses for CEMS verification. Non-depleting sensor design ensures long service with minimal calibration.

For details contact: Spectris Technologies Pvt Ltd Plot No: A-168 MIDC Thane-Belapur Road, Khairane Navi Mumbai 400 710 Tel: 022-39342700 E-mail: MEI_Sales@servomex.com or Circle Readers’ Service Card 28

Intrinsically Safe Portable Analyser Designed for the measurement of toxic and flammable gas samples, the intrinsically safe Micro i.s is a unique analyser certified to Zone 0 and Zone 1 and suitable for measuring per cent levels of O2, CO and CO2.

Features intrinsically safe design to ATEX and IEC Standards ensures safety operation in hazardous environments. It is available in non-pumped or pumped version with optional sample conditioning kit.

For details contact: Spectris Technologies Pvt Ltd Plot No: A-168 MIDC Thane-Belapur Road Khairane Navi Mumbai 400 710 Tel: 022-39342700 E-mail: MEI_Sales@servomex.com or Circle Readers’ Service Card 29

Decentralised Drive Technology NORD DRIVESYSTEMS offers decentralised drives, with which even demanding applications, such as synchronised movement and flying saw, can be implemented easily. An integrated PLC and position control within the frequency inverters enables the synchronisation of several drives in master/slave operation. As a result, functions such as synchronised movement and flying saw can be implemented decentrally. This is especially useful in applications that require synchronous interaction of different drive axes.

The flying saw function enables coupling and parallel movement of a processing unit on to a moving work piece. As the transport of material travels on the master axis, the slave axis is synchronised and processing is executed as soon as synchronised movement is attained. The slave axis then returns to its initial position and the process is repeated. This way, the processing of a work piece is possible during transportation. Application examples include the cutting of materials or foodstuffs and the transfer of liquids. Due to the internal PLC and the POSICON position control within the NORDAC LINK and NORDAC FLEX frequency inverters several NORD drives can be synchronised in master/slave operation. The integrated POSICON functionality ensures that the inverters are able to determine the current position of the drive. As a result, functions such as synchronised movement and flying saw can be executed quickly and precisely. Up to three slave inverters can be controlled by one master inverter without requiring a higher level control. In addition, the inverters are freely configurable and easy to install and maintain due to their comprehensive plug-in capability. The networked drives are equipped with multiple interfaces and are ideal for Industry 4.0 applications. A PLC integrated into the inverters is able to reduce the higher level control and enables a modular automation concept. It is freely programmable and able to process data from connected sensors and actuators and, if necessary, it directly initiates a sequence control. The drives communicate their status data via the control system or into a secure cloud. NORD drives can be used for continuous Condition Monitoring and Predictive Maintenance. NORD launched the Predictive Maintenance applications as pilot projects within the scope of the Industry 4.0 environment.

For details contact: Getriebebau NORD GmbH & Co KG Getriebebau-Nord-Straße 1 22941 Bargteheide/Hamburg, Germany Tel: +49 45 32 / 2 89 -0 Fax: +49 45 32 / 2 89 -22 53 E-mail: pl.muthusekkar@nord.com / Joerg.Niermann@nord.com or Circle Readers’ Service Card 30

66 • November 2018

Chemical Engineering World

Products CEW Cable Float Switch

U-PVC Manual Valves

The cable float level switch is structured from chemical resistant polypropylene. Electrical switching circuit comprises of micro switch and iron ball to control the contact.

The switches are operated through an iron ball which enables On or Off contact signal when the floating angle is larger than a certain degree where the state of the iron ball and micro switch will be changed for actuation. It finds application in hydraulic oil, water boilers, chemical and pharma.

The U-PVC r a n g e includes ball valves, butterfly v a l v e s , diaphragm valves as well as check valves, sediment strainers, air release, foot valves, angle seat valves to be used in the construction of process and service lines to convey industrial fluids at max operating temperatures of 60oC. The entire range is produced using U-PVC resins complying with the Standards EN ISO 1452 and in observance to the requirements of DIN 8063 and EN ISO 15493 for the use of plastic pipes in industrial processes.

For details contact: Filpro Sensors Pvt Ltd No: 130, 10th Cross, Petechennappa Indl Estate Kamakshipalya, Magadi Main Road Bengaluru, Karnataka 560 079 Tel: 080-23286463 E-mail: sales@filprosensors.com

For details contact: Aliaxis Utilities and Industry Pvt Ltd Plot No: L-148 & 149, Verna Indl Estate Verna, Goa 403 722 Tel: 0832-6691500, 6691515

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Surface Treatment The nsd tupH surface treatment offered by NORD DRIVESYSTEMS is an outstanding anticorrosion treatment for gear units, smooth motors, frequency inverters and motor starters in washdown-optimised cast aluminium housings. Applying a special method, the surface is made corrosion-resistant and harder; in this way, aluminium behaves like stainless steel with regard to corrosion protection. This is not a coating, but the surface treatment creates a protective layer which is permanently bonded to the substrate material. In contrast to painting or coating, nothing can detach or flake off. Damages remain locally restricted and do not propagate. The surface is easy to clean and largely resistant to acids and alkalis.

It is even possible to use high pressure cleaners or a great variety of aggressive media.

For nsd tupH aluminium drive units, all DIN and standard components, including drive shafts, are made from stainless steel. The fanless smooth motors do not spread germs and run very quietly. They are available as synchronous and asynchronous motors and comply with efficiency classes IE2 and IE3 (asynchronous motors) and IE4 (synchronous motors).NORD drives with nsd tupH comply with FDA Title 21 CFR 175.300 and for this reason are suitable for food application. They have been successfully tested according to ASTM D714 (blistering), ASTM D610-08 (corrosion), ASTM D1654-08 according to DIN EN ISO 2409 (scratching), ASTM B117-09 according to DIN EN ISO 9227 (salt spray test) and ASTM D3170 (Gravelometer). In addition, their resistance to common cleaning agents which are used in the food industry has been confirmed in tests.

The nsd tupH surface treatment is advantageous for all drives used under extreme environmental conditions and for hygienically critical applications.

This also includes the beverage and food industry, water treatment and sewage plants as well as offshore and onshore applications.

For details contact: Getriebebau NORD GmbH & Co KG Getriebebau-Nord-Straße 1 22941 Bargteheide/Hamburg Germany Tel: +49 45 32 / 2 89 -0 Fax: +49 45 32 / 2 89 -22 53 E-mail: pl.muthusekkar@nord.com / Joerg.Niermann@nord.com or Circle Readers’ Service Card 33 24

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November 2018 • 67

CEW Book Shelf The Planning Guide to Piping Design Authors: Richard Beale and Paul Bowers Price: $133.82 No of pages: 288 pages (Paperback) Publisher: Gulf Professional Publishing (2nd Edition) About the book: This book covers the entire process of managing and executing project piping designs, from conceptual to mechanical completion, also explaining what roles and responsibilities are required of the piping lead during the process. The book explains proven piping design methods in step-by-step processes that cover the increasing use of new technologies and software. Extended coverage is provided for the piping lead to manage piping design activities, which include supervising, planning, scheduling, evaluating manpower, monitoring progress and communicating the piping design.

With newly revised chapters and the addition of a chapter on CAD software, the book provides the mentorship for piping leads, engineers and designers to grasp the requirements of piping supervision in the modern age.

Understanding and Negotiating EPC Contracts, Vol 2 Author: Howard M Steinberg Price: $267.41 No of pages: 376 pages (Hardcover) Publisher: Routledge (1st Edition) About the book: Any project which involves an EPC contract is also likely to involve a number of other complicated contracts. The challenge of the parties to an EPC contract is not to try to eliminate risk but rather put into place a narrative structure that enables the parties to predict the contractual result that would obtain if a risk materializes. If the EPC contract does not allow the parties to determine the consequences of an unanticipated situation, they will have to look to an expert, mediator, tribunal or court to impart guidance or pass judgment.

The sample forms of contract contained in Volume 2 are intended to serve as a guide to demonstrate how risks and responsibilities can be allocated among project sponsors, EPC contractors and the various other parties that may be involved in a project.

Collectively the sample forms in this volume offer an extraordinary resource that provides the benefit of lessons learned and priceless insight into any project being undertaken which can help assure the resilience of any EPC project.

Handbook of Liquefied Natural Gas Authors: Saeid Mokhatab, John Y Mak, Jaleel V Valappil and David A. Wood Price: $99.95 No of pages: 624 pages (Paperback) Publisher: Gulf Professional Publishing About the book: Liquefied natural gas (LNG) is a commercially attractive phase of the commodity that facilitates the efficient handling and transportation of natural gas around the world.

The LNG industry, using technologies proven over decades of development, continues to expand its markets, diversify its supply chains and increase its share of the global natural gas trade. This is a timely book as the industry is currently developing new large sources of supply and the technologies have evolved in recent years to enable offshore infrastructure to develop and handle resources in more remote and harsher environments. It is the only book of its kind, covering the many aspects of the LNG supply chain from liquefaction to regasification by addressing the LNG industriesâ&#x20AC;&#x2122; fundamentals and markets, as well as detailed engineering and design principles. A unique, well-documented, and forward-thinking work, this reference book provides an ideal platform for scientists, engineers, and other professionals involved in the LNG industry to gain a better understanding of the key basic and advanced topics relevant to LNG projects in operation and/or in planning and development.

68 â&#x20AC;˘ November 2018

Planning and Integration of Refinery and Petrochemical Operations Authors: Khalid Y Al-Qahtani and Ali Elkamel Price: $69.46 No of pages: 206 pages (Hardcover) Publisher: Wiley-VCH (1st Edition) About the book: An oil refinery is an industrial process plant where crude oil is processed and refined into more useful petroleum products, such as petrol / gasoline, diesel fuel, lubricant oils, asphalt, heating oil and kerosene.

Oil refineries are typically large sprawling industrial complexes with extensive piping running throughout, carrying streams of fluids between large chemical processing units.

Clearly divided into three main sections, this practical book familiarizes readers with the area of planning in petroleum refining and petrochemical industry, while introducing several planning and modelling strategies encompassing single site refinery plants, multiple refinery networks, petrochemical networks, and refinery and petrochemical planning systems.

It equally provides an insight into possible research directions and recommendations for the area of refinery and petrochemical planning.

Furthermore, several appendices are included to explain the general background necessary, including stochastic programming, chance constraint programming, and robust optimization.

For engineers and managers working in the petroleum industry as well as academic researchers in production, logistics, and supply chain management.

Chemical Engineering World

Project Update CEW New Contracts/Expansions/Revamps The following list is a brief insight into the latest new projects by various companies in India.

CHEMICALS Shalimar Paints lays down the foundation of its Nashik manufacturing plant with a planned monthly capacity of 2,180 kilolitres. Set to commence operations by April 2019 with a planned production capacity of 2,180 kilolitres per month, Shalimar's state-of-the-art Nashik facility will increase the brand's overall production capacity by 65 per cent. It is also expected to stimulate the local economy by creating around 200+ employment opportunities for prospective jobseekers in the region. The newest Shalimar plant hints at the brand's aggressive push to capitalise on the growing market demand for its high-quality, high-performance paint and coating products, as well as to further consolidate its position as one of the fastest growing paints companies in the country. Shalimar has also pledged further investment into its Nashik plant and aims to establish it as a key component within its regional distribution network, as well as its pan-India supply chain. The paint industry has been growing at a rapid rate in India and measures between 1.5 to 2 times GDP growths. Rapid urbanization, better transparency and consumer evolvement has been leading the growth of the industry.

Songwon Industrial Co Ltd a specialty chemicals company of South Korea has launched its new pilot plant in Panoli (Gujarat), thereby strengthening the organisation’s overall specialty chemicals development capability. Built on Songwon’s Indian site with all the necessary main unit operations, the new plant is equipped with the most up-to-date technologies and materials for producing a wide range of chemicals for a broad spectrum of applications - from one kilo up to several hundred kilo samples. To reinforce the organisation’s position in existing areas of business and enhance its ability to enter new areas, the new pilot plant will be supported by the Songwon’s strong local R&D team in Panoli, as well as its central technology innovation center located in Maeam, Korea.

Insecticides (India) Ltd has announced a ` 200-crore expansion plan to increase its capacity in the next three years. In the first two years, it would spend about ` 100-crore, followed by an investment of ` 100-crore in 2020. The firm is planning to set up an Export Oriented Unit in Gujarat with an eye on increasing export component of the business. Exports contributed about ` 35-crore in the total turnover of ` 1,109-crore in 2017-18. The firm has a share of about 5 per cent in the ` 18,000-crore crop protection market in the country.

MINING NTPC Ltd hopes its captive coal production will reach 100 million tonne as soon as its five coal blocks commence operations, aided by faster regulatory clearances and the part-privatization model of Mine Development and Operator (MDO). The success of the plan would determine fuel security of the operations of India's largest power producer.

Coal India aims to raise output from its troubled Rajmahal mine in Jharkhand to 60,000 tonnes a day by March 2019, having resolved land-acquisition related problems which had crimped production to 20,000 tonnes per day. Coal from the Rajmahal mine helps NTPC run close to 4,200 MW of power generation plants in eastern India, which supply power to Bihar, Jharkhand and West Bengal, and also to northern India including Delhi and Uttar Pradesh. NTPC’s generation capacities were faced with depleting coal stocks and lower power generation as supplies from Rajmahal dwindled. Reserves at Rajmahal within the land Chemical Engineering World

acquired by Coal India were almost exhausted and required expansion to keep production levels intact. However, land acquisition at two villages - Bansbiha and Taljhari - spanning 160 hectares, adjacent to the existing project turned out to be a lengthy process, as sorting out ownership issues resulted in inordinate delay. It led to drastic fall in supplies and stocks at the coalfield, as well as at two critical power plants in the region - at Farakka and Kahalgaon. At present, Coal India is using 15 goods trains to transport coal from the Rajmahal mine to power stations in the region.

One goods train can load up to 3,500 tonnes of coal. Coal India is also sending five loaded goods trains from West Bengal’s Ranigunj coalfields to augment supplies at power stations. At present, the entire production from Rajmahal is getting delivered to power plants and there has been no stock buildup yet.

CIL, ONGC to produce coal-bed methane from 10 new mines: support SAIL in one more. The Coal Ministry has identified 11 mines to produce coal bed methane (CBM). Of these, 10 will be worked on jointly by ONGC and Coal India Ltd (CIL). The two entities will also work on one mine with SAIL. Initially, ONGC will harness the gas and then CIL will extract coal from them …the first agreement for harnessing CBM through this route is expected to be signed soon. In addition to the mines with CIL, the two (ONGC and CIL) will also help develop Steel Authority of India Ltd’s Parbatpur coal block (Jharkhand). Here, too, ONGC will first harness the CBM. SAIL had surrendered the Sitanala and Parbatpur coal mines this year. In its representations while surrendering the Parbatpur mine, SAIL had said there was a reduction in the area available for coal mining due to overlapping of mining area. SAIL had engaged MECON to prepare a techno commercial viability report, which declared the project unviable.

The SAIL board had then decided to return the Parbatpur mine to the Coal Ministry.

OIL & GAS Indian Oil Corporation, with the final clearance from the National Green Tribunal (NGT), is all set to re-start construction activities at its ` 2,200-crore LPG import terminal-cum-pipeline project at Puthuvypeen near Kochi. Necessary orders in this regard have been issued by the Kerala government and the work is expected to commence in January.

The NGT judgment has made it amply clear that there is no environmental pollution in the Puthuvypeen project. IOCL has adopted global standards on safety measures and one-third of the cost is being spent on safety.

The risk analysis study conducted by Projects & Development India Ltd has estimated the risk factor in a million chances per year. The Kochi terminal, with the pipelines connecting the bottling plant, will eliminate the movement of bulk LPG by road, citing the removal of LPG tanker lorry movement from Mangaluru to Tamil Nadu after the commissioning of Ennore terminal. The Kochi project consists of an import terminal, multi-user liquid terminal (MULT) jetty, Kochi-Salem pipeline and the bulk LPG terminal at Palakkad with a total investment of ` 2,200-crore. Of this, the ` 225-crore jetty is ready and the company has invested another ` 160-crore for construction activities. The physical progress of the work is only 40 per cent complete, which includes ground improvement, land development, etc.Early completion of the project will ensure LPG availability to the households across the counter. Kerala presently has an average waiting period of 15 days to receive a LPG refill. This could go up if the infrastructure expansion does not happen. Referring to LPG consumption in the State, it was 8.4 lakh tonnes in 2016-17, which would touch 13.2 November 2018 • 69

CEW Project Update lakh tonnes by 2022 and 22.7 lakh tonnes by 2028. India imports 50 per cent of its LPG requirements. With the boom in LPG requirement, imports are expected to go up. To meet the huge growth in volumes, infrastructure must be improved. LPG is imported through the major ports on the coast and there are 13 import terminals. Kochi is next on the list. The design of the terminal has been approved by regulatory agencies, who will inspect during the construction stage and prior to commissioning.

CPC Corp of Taiwan is planning to invest $ 6.6 bn in petrochemical project in Paradip, Odisha. In this regard, delegation led by CPC president ShunChin Lee met the Indian Minister for Petroleum & Natural Gas to discuss the proposal. With an annual production capacity of 15 million tonnes, the Indian Oil Corpn’s (IOC), Paradip Refinery was selected to host the new project, which will utilise the refinery’s feedstock. It will have many downstream units for the production of a wide range of end-products and petrochemical intermediates.

The National Institute of Technology - Tiruchi (NITT) and Bhabha Atomic Research Centre (BARC) have jointly established a biogas plant with a capacity to process one metric tonne of kitchen waste from the hostel. The biogas plant called NISARGRUNA will process vegetable and food wastes and waste water generated from the hostel mess. The project was executed by the DTDDF (Department of Atomic Energy Technologies Display and Dissemination Facility) Centre that BARC had established in the NIT-T premises following a MoU signed with the institution last year. The BARC experts who briefed the NIT-T authorities about the operation principle said NISARGRUNA Biogas Plant will produce biogas containing 70-80 per cent of methane and only 30-20 per cent of carbon dioxide. Processing of one metric tonne of biodegradable waste creates will lead to production of 25-30 kg Methane gas and 50-90 kg manure per day. In comparison, conventional Gobar gas plants have a single digester and produce biogas containing 55-65 per cent of methane and 45-35 per cent of carbon dioxide. The gas generated from the NISARGRUNA Biogas Plant will be used as fuel in the messes for cooking. The weed-free manure has high nitrogen contents and acts as an excellent soil conditioner. It offers ‘Zero garbage and Zero effluent’, and this technology will be more helpful for the kitchen and solid waste management at NIT-T. The NIT-T has identified five villages for pursuing UNNAT Bharat Mission. The DTDDF centre will implement the BARC technologies in the villages.

Vedanta Ltd plans to expand its alumina refinery at Lanjigarh in Odisha to 6 million TPA by 2021 using alternate bauxite resources as it looks beyond. The firm believes there are enough alternate resources of bauxite available to feed the expansion and has moved beyond the previously pursued high-quality bauxite beneath the pristine Niyamgiri hills. The Lanjigarh plant produced around 1.2 million tonnes of alumina last fiscal and has a current capacity of 2 million tonnes. Refusing to give cost estimates, while the plant currently imports 2.5-3 million tonnes of bauxite and sources almost an equal volume from domestic mines, the expansion project would need a total of 18 million tonnes of bauxite annually.

Vedanta had intended to supply the refinery with bauxite extracted from the Niyamgiri hills by a mining company owned by the state government, which backed the project. But protests from local villagers led to the union government and the Supreme Court blocking the move in 2013. Odisha has 700 million tonnes of known bauxite reserves, of which Niyamgiri holds an estimated 88 million tonnes. Odisha has 70 per cent of India's total bauxite reserves, the world's fifth-largest. Currently, costly bauxite is imported from as far as Brazil and Guinea at a port in neighbouring Andhra Pradesh before being moved by trains 275 km to Lanjigarh. Vedanta has 70 • November 2018

environmental and other clearances in place for the expansion and does not need any new land.

Oil India Ltd has signed an agreement with five PSU JV Partners in Guwahati.This agreement is in connection with construction of North-East Gas Grid Pipeline project. The gas grid project will connect eight NorthEastern States, viz, Assam, Arunachal Pradesh, Meghalaya, Manipur, Mizoram, Nagaland, Tripura and Sikkim. The proposed JV Company will have equal equity contribution from all the five PSU JV Partners.

Indian Oil Corpn (IOC) plans to invest ` 20,000-crore in city gas distribution (CGD) projects in the next five to eight years. IOC, which owns a third of India’s oil refining capacity identifies compressed natural gas (CNG) replacing some of the petrol and diesel consumed in vehicles today and LPG replaced by piped cooking gas in households. The company plans to invest at least ` 20,000-crore for the CGD business in those projects won during the ninth round of bids. The investment will mainly include setting up of CNG dispensing stations as well as laying pipelines in cities to transport gas to households for cooking purposes and industries for commercial use. According to oil ministry figures, India needs to invest an estimated $100 billion in natural gas infrastructure by 2022, including setting up a gas grid across 228 cities, Indraprastha Gas, India's biggest city gas retailer plans to add a record 60 CNG dispensing stations and give piped cooking gas connections to at least 2 lakh households this fiscal as it steps up efforts to achieve the government's target of a gas-based economy. IGL the company, which retails CNG to automobiles and piped cooking gas to household kitchens in Delhi and its suburbs, has adopted a dealer-franchise model in the push for rapidly expanding the network. The company, with 452 CNG stations in Delhi, Noida, Greater Noida, Ghaziabad and Rewari, has started to give the franchise to dealers who own land.The company, which currently has over 9.6 lakh piped cooking gas customers, has a target to add 3 lakh this fiscal. The government is aggressively pushing for use of CNG as a transportation fuel to cut on use of polluting liquid fuels like diesel. It also wants PNG to replace costlier LPG in kitchens with a view to cut oil import dependence and push up the share of natural gas in the country's energy basket to 15 per cent from current 6.2 per cent. India currently imports 81 per cent of its oil needs. In its push towards a gasbased economy, the government is targeting 1 crore PNG connections by 2020. The country, currently, has 45.26 lakh household kitchens using natural gas as cooking fuel. Gujarat has the highest number of PNG users at 19.07 lakh, followed by Maharashtra at 12.73 lakh. Delhi ranks third. Both, Gujarat and Maharashtra have multiple companies retailing CNG and PNG. In 2018-19, the government is targeting 20 lakh PNG connections all over the country, up from 12 lakh of 2017-18. In 2019-20, the target is 40 lakh.

ENERGY Juwi group has completed a 135-MW solar PV plant for Energon Soleq Ravi India Power Resources in the southern Indian State of Karnataka.

The plant covers an area of 243 hectares and is situated near the village of Guttigoli, Belgaum district. It is expected to generate more than 226 million kWh of electricity each year. Operation and maintenance of the solar power plant will be performed by juwi India, which provides maintenance, monitoring and reporting services. With this project, juwi India’s current total O&M portfolio has reached 347-MW and is expected to cross 500MW by this year’s end. juwi has also finalised the contracts for building a portfolio of 250-MW in South Africa after being selected as preferred EPC contractor for three utility-scale PV projects in bidding round 4.

Chemical Engineering World

NATIONAL

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Specialty & Custom Chemicals America

Dates: 16-19 December 2018 Venue: Race Course Ground, Rajkot, Gujarat Event: PlastShow covers west side of Indian plastic processor industries and manufacturers mainly Rajkot, Saurashtra and Vapi in South Gujarat. Also introducing this time is PlastMould Expo under the concurrent show to get maximum benefit from mould manufacturers in plastics.

Dates: 11-14 February 2019 Venue: Omni Fort Worth Hotel, Fort Worth, U.S.A. Event: This event focus is on specialty, custom, fine and industrial chemical markets, focus on suppliers with a North American base, renew the value proposition for attending trade shows, and renew fundamental business values.

For details contact: American Chemical Marketing 809 North Fairway Road Glenside, PA19038, U.S.A

For details contact: Sunline Infotech 212 Lotus Arcade, Opp: Automotive Gondal Rd Rajkot, Gujarat 360 001

Chemtech World Expo 2019 ENGIEXPO

Dates: 05-07 January 2019 Venue: AES University Ground, Ahmedabad, Gujarat Event: ENGIEXPO has emerged as prestigious brand in the field of exhibitions and trade-fair. The organizers believe in creating brand value, support product market and enhance sustainability even in worldwide worst economic scenario for exhibitors and participants by unlocking the unmatched potentials and opportunities for the industries.

For details contact: ENGIEXPO 10 Mehta Apartment, 2nd Floor Above Union Bank Beside Radha Vallabh Template Jaihind Cross Road, Maninagar, Ahmedabad Gujarat 380 008 E-mail: engiexpo@gmail.com ambalal@engiexpo.com

Event : CHEMTECH World Expo 2019 will create a common platform to bring the entire ecosystem of the chemicals manufacturing and the allied services providing sectors for 27th time in India. The event is for equipment, services or developing processes for the Chemical and Process industries. The evolution and the growth of Indian chemical and related industries has been both reflected and catalyzed by CHEMTECH. The interactive Exhibition and Trade Fair pioneered by Chemtech has become the event that the chemical industry comes together.

Concurrent events include EPC World Expo, Industry Automation & Control World Expo, Bio Pharma, Pumps Valves & Fittings World Expo; and international conferences on Refining & Petrochemicals and Specialty Chemicals.

IMTEX Dates: 24-30 January 2019 Venue: BIEC Bengaluru International Exhibition Centre, Bengaluru Event: Metal cutting machine tool exhibition with international participation. IMTEX 2019 is a 7 day metal cutting exhibition being held from 24th January to 30th January 2019 at the BIEC Bengaluru International Exhibition Centre in Bengaluru, India. An initiative of IMTMA, IMTEX is a flagship event for the Indian metal cutting industry. It is South East Asia’s apex exhibition showcasing the latest trends as well as technological refinements from India and other global players. The mega event attracts visitors from a wide spectrum of manufacturing and ancillary industries including key decision and policy makers as well as industry captains who are keen to source latest technologies and manufacturing solutions for their product lines.

For details contact: Indian Machine Tool Manufacturers’ Association 10th Mile, Tumkur Rd Madavara Post Bengaluru, Karnataka 562 123 Tel: 080-66246600, 66246661 E-mail: imtma@imtma.in Chemical Engineering World

Date : February 20th - 23rd, 2019 Venue : Bombay Convention & Exhibition Centre, Goregaon (East), Mumbai, India

For details contact: Vaishali Pednekar Senior Executive – Conference Tel: +91-22-4037 3619 Email: vaishali_pednekar@jasubhai.com

European Coatings Show Dates: 19-21 March 2019 Venue: NurnbergMesse GmbH, Nuremberg, Germany Event: This event showcases products that include coating raw materials, binders, solvents, pigments, fillers, additives, printing ink raw materials, adhesive raw materials, polymer dispersions, intermediates for construction chemicals, raw materials, additives and admixtures, laboratory and production equipment, testing and measuring equipment, plant and machinery, spray systems, drying and curing plant, environmental protection and safety at work, etc, in the chemicals and dyes industry.

For details contact: NurnbergMesse GmbH Messezentrum 90471 Nurnberg Nuremberg, Germany November 2018 • 71

INTERVIEW CEW Interview

The Era of Collective Responsibility

EPC companies are a major stakeholder for any project and over the past years many major projects are being built on One-Team concept where the major contractors and consultants engaged in a project are an integral part of the team led by project owners.

Mr Suneet Prakash, Head â&#x20AC;&#x201C; Group Projects, Aditya Birla Management Corporation Pvt Ltd shares his views on effective project implementation, empowering project managers and implementation of digital models.

What are some of key trends industry is project owners look at while setting up new projects or planning brownfield expansions?

Project owners work on a short-term and long-term business strategies and any capacity expansion whether it is brownfield or greenfield has to be aligned with the same. Having obtained this critical alignment, the other parameters that are considered are the financial returns that includes determining IRR and NPV, market positioning, funding of 72 â&#x20AC;˘ November 2018

project, statutory approvals and of-course the technical feasibility and timelines.

How has the relationship between project owners and EPC companies changed in the last couple of years?

Tell us about the project execution strengths of Aditya Birla Corporation and what is the criteria for selection of EPC consultants?

EPC companies are a very important stakeholder in any project. Over the past years many major projects are being built on One-Team concept where the major

contractors and consultants engaged in a project are an integral part of the team led by project owners. This is unlike in the past where owners were often on one side of table and the EPC contractors on the other. We have thus moved to an era of collective responsibility.

Aditya Birla group undertakes several greenfield and brownfield expansion projects to enhance its manufacturing capacities across the world. We have strong project teams in most of our businesses that can deliver projects to Chemical Engineering World

Interview CEW global standards. Some of our recent projects have set new global benchmarks in their execution time.

Our selection criteria for EPC contractors is quantitative in nature. Some of the major aspects that are considered include their track record, quality, efficiency, operating costs, safety record, resource availability, financial soundness and price competitiveness amongst others.

As the projects become more complex and larger in size, how have the challenges changed for the project owners and as a group how do you address these?

The average size of a typical project has grown manifold with time. This adds to the complexities in both design and construction. For large projects we generally use several contracting strategies like lump sum, EPcm, unit rate for execution of work. We prefer to work with multiple construction contractors for large projects. The project metrics for success are tracked with rigor and necessary interventions applied to keep projects on track.

How does the group follow HSE practices across all the projects in Aditya Birla Corporation?

Aditya Birla group follows stringent HSE standards in all its projects. This is done in a variety of ways including having a group policy for implementation benchmarked with global standards, training of workmen, selection of contractors known for their safety record, third party and internal audit and incentivizing. Deviations, if any, are dealt with sternly.

Since there is much pressure on cost and schedule of projects, how can project implementation be made more effective and efficient right through the concept to commissioning?

This is the ultimate goal of every project owner, but one where lot needs to be done still. Some of the key factors that can enhance project delivery include stage gate process of project implementation, completion of FEED before progressing to detailed engineering, maturing of Chemical Engineering World

engineering before commencement of construction, appropriate contracting strategy, executing and reporting to baseline and proper project closure.

Communication between stakeholders is of paramount importance.

One of the topics that comes up time and again in project management is that of empowering the Project Managers.

What are your views on empowering the project managers & how can this go a long way in improving efficiencies in project implementation?

The empowerment of the Project Manager is extremely important for him or her to perform effectively. According to me this is not a choice anymore. It starts with a proper definition of the role and responsibilities and then finding the right resource. The project sponsor should stay away from the duties of a Project Manager. In our Group all businesses have a well-established manual on ‘Delegation of Authority’ by which authority is vested in various personnel in any project. This helps in avoiding any ambiguity and ensures that no time is wasted in unnecessary approvals. If we have an appropriate resource as Project Manager then there is no downside to empowerment. Only positives.

How is Aditya Birla Group going about adopting digitalization across all the facilities? Have you developed an integrated model that will connect all the processes to a common integrated platform? What are the challenges in the foreseeable future and how does the group plan to address them?

We are working at an accelerated pace in adopting digitalization in all our operations including projects. Whereas different businesses have different models the process of connecting all processes is work under progress.

Having said that, project processes like contracting, procurement, logistics are mapped into the same model.

One challenge that exists is to seamlessly migrate from the project model to the operations model. Whereas a lot of effort

has gone into creating digital models for procurement, manufacturing including supply chain logistics the same is yet to be done on that scale for projects. We do plan to address this by developing smart digital platforms that can be assimilated by our ERP upon completion of projects.

EPC players are looking at Digitalisation as a solution provider to overcome the challenges in delays in project implementation. What are the major concerns for a project owner that the EPC companies need to address across each of the areas, viz, project planning, use of smart equipment compliant with industry 4.0, project schedule recovery, cost benchmarking studies, risk management and project cost reduction?

In India the biggest pitfall in a majority projects is the construction phase. The construction industry has been slow to adopt digitalization. The productivity of craft has hardly improved over past several years. Availability of good construction resources itself is a big challenge for most projects. EPC companies must leverage digitalization to enhance productivity, improve safety adherence and quality at construction sites. In project controls there is a massive opportunity in deploying digital means for creation and continuous tracking of project metrics, cloud computing and dynamic planning. Again, in engineering the use of Smartplant Tools will help avoid rework at sites and enable faster construction. EPC contractors who exhibit tangible benefits in project delivery by leveraging digital technology will have a clear edge. That’s what the project owners look at.

Tell us about the ongoing and future projects across various business verticals of the Group.

Aditya Birla group has several Greenfield and Brownfield projects in different phases of execution across businesses including Chemicals, Fibre, Aluminium and Carbon Black. Many more are in pipeline both in India and overseas. It is premature to discuss them at this stage.

November 2018 • 73

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