Batch Reactor Is Widely Used In The Chemical Mechanics Essay

Batch Reactor Is Widely employmentd In The Chemical Mechanics EssayA batch nuclear nuclear reactor is widely used in the chemical substance substance and treat industry to perform some(prenominal) operations such as providing an environment of chemical reactions, crystallization, harvest-tide mixing, dissolution of solids, polymerization, liquid to liquid line of descent as substantially as batch distillation. The equipment comprises of tank that has an integrated heating and cooling arrangement as well as an fomenter. The main advantages of using a batch whole is it ability to perform conglomerate function with come on the need to change or break containment. Toxic and highly potent compounds ass be processed in the batch unit. Part oneQuestion 1 a) Explain why you would project this batch chemical reactor as a whole shebang unit.According to the definition of a chemical kit and boodle, a jell is comprised of several units that be interconnected by shriek. Materials m ove in and out of these units. These materials or fresh materials are converted into different products. In this example, the batch reactor is a separate unit of the purposet which processes the cutting materials introduced before supplying them to the cartridge extractor administration. This batch reactor is in any case the principle chemical converter in this plant. b) Explain your reasons for concluding that this unit is critical for give outThis unit is critical for the takings in this process because It prepares and processes the raw materials by heating them to the prescribed temperature and similarly providing the aimd atmospheric pressure for the process.It hold backs broad utilization of the centrifuge unit this is because it produces more than the centrifuge can process. the batch unit produces 18 (te) of product The batch unit is the principle raw material processor in this process, it receives raw materials, process them to lie with products, thereafter, t hese materials are sorted out by the centrifuge. There is no other unit for processing materials in this plant unit. The batch unit temporary stores the materials before they are banquet to the centrifuge system. b) Extract all(prenominal) user requirements for this designated unit from the plant description. Are there any production windows?The main user cultivation is The vessel consist of a summited agitated glass lined vessel, heated to a certain temperature and pressure and consist of a thermocouple, a temperature alarm and has a synthetic rubber relief valve The equipment list is as well as provided to the plant engineer with information about the different components installed on the plant. The drawing of the batch unit also shows the plant engineer the layout of the different components in the reactor. Jacket safety valve, temperature pocket, temperature withstandler, steam trap, agitator and the pipe work. The batch reactor process is also described so that the user or the operator can clearly clear how the processes are carried out, for example the batch unit starts when 18 (te) of raw materials are introduced to the reactor, the content are heated through to a preset temperature/ cadence profile that takes 10 hours the products are then feed to the centrifuge system. This explanation helps the user or the plant operator understand its operation. d) Extract any embodied requirements for this unit from the plant descriptionSome of the corporate requirements for this unit obtained from the text are The equipment is shutd profess for 16 hours during the 40th week of apiece year. The production of the batch reactor is also indicated, that is the manufacturing unit makes 13,000 te of tidy sum pharmaceutical product within a given yearThe information provided for the batch reactor jacket is also vital to the corporate use. This information is the jacket is a registered steam receiver and also has a safety relief valve The attach to guidelines state that reactors should be maintained to archive 25 years and flip boxes should be maintained to give 15 years bearing. e) Extract any legislative requirements for this unit from the plant description.The legal requirements include The procedure for controlling guardianship activities moldiness conform to the environment standard ISO14000. The manufacturing process must be licensed by FDA and the British pharmaceutical product. The manufacturing activities must comply with GMP (good manufacturing practice) and the process must be to the quality standard ISO 9002. f) Table 1 shows the existing life plan for this unit. Comment on whether you think that some of the tasks designated for the scheduled shutdown could be bonkd during production windows or when the plant is on-line. Could any of the tasks designated for completion during production windows be completed on-line?From the company bread and butter guidelines, it can be seen that the company stipulates a 16 hour shutdown for the batch reactor during it 40th week of operation each year. Various sort and aid activities are carried out to ensure that the batch reactor archives 25 years life and the gear boxes give a 15 year working life. In step-up to the alimentation activities, the industry should be kept clean and painted to ensure that it passes the pharmaceutical inspectors test and observe unnecessary shutdown. The maintenance activities should further be scheduled in such a manner that they dont step in or affect the operation of the plant thereby maximizing the profits obtained from the production line. This calls for the computer programming of smartness maintenance operation to be done when the plant is still operating. Based on this classification, three maintenance operation are carried out for this batch reactor these are On linethese are maintenance activities that run concurrent with the production line. The maintenance activities are performed when the machine is still in use. Proper scheduling must be done to ensure that these activities are well mean for. The online and offline maintenance windows should also non coincide. Offline maintenance These are maintenance activities that are performed when batch reactor is switched off or some prison-breaking has to occur the machine is shut off and a part in the system is removed or repaired. Back up systems are used.Maintenance windowthis is a user defined period of condemnation in which automatic maintenance activities are carried out. During the maintenance window, the need for maintenance use is first evaluated, and if the system does non meet the required parameters a maintenance use is carried out. If the required conditions are met the maintenance activity is not carried out (IBM, 2009). The activity for this batch reactor can be scheduled as follows employmentCommentsCV1, replacing trim Currently the machine is shutdown before this maintenance activity is performed, based on the time taken to perform this activity and the frequency, it is best that it is done during the production window. Agitator gear case instructing the anele Checking the petroleum seal offs for leaks ocular check These activities are performed when the reactor is running, due to their frequency and time required these activities they can be done when the machine is still running(online)Agitator coupling Can be done when the production is progressing (online) as the process takes a short time and is performed often.SV1, pressure test and inspection This is a soused activity and can only be performed when the reactor is shutoff. Agitator visual check Does not require to be performed during shut off, it can be done as the machine operates (online) and can also be scheduled during the production window. It can also be performed when the agitator coupling is being checked innate inspection contract test Should be done when the equipment is shutoff as it is a rigorous activity and takes a long time Pressure test and inspectionIt can be done during the production window. Visual checks for leaks Leak test shaking remindering of the push and pump bearing Should be done on daily basis. The pump force should also be checked as the leak tests are done. This pass on help supervise the pump. The checks are done by the plant operator. g) Analyze the recorded jobs from the computer maintenance circumspection system (CMMS) for this unit. (These jobs are shown in a Microsoft Excel spreadsheet called Worklist.xls.) Is there any evidence which confirms that the life plan is being carried out? Is there any evidence to say if the life plan is impressive or not?To check and analyze the data recorded on the computer maintenance management systems for this unit. The different maintenance activity was evaluated and the frequency of these activities, as well as the time taken to complete this activity was evaluated. The excel data was first sorted into the various groups of maintenance ac tivities. The obtained data was as follows For the agitator coupling the Visual check yearly ticket for weekly task were as follows 8/8/1996 4.335.2 intend8/8/19974.335.2 intend8/8/19984.335.2 plan8/8/19994.335.2 aforethought(ip)8/8/20004.335.2plotted8/8/20014.335.2Planned8/8/20024.335.2Planned8/8/20034.335.2PlannedFrom the table the maintenance activities were carried out as per the schedule and the activities took a longer time than was actually planned for. were as planned for. For the agitator visual check, the table is as shown in the trope below 3/3/1996 24Planned3/4/200224PlannedThe activity interval time was 6 years between subsequent maintenance activities and this was carried out as per the life plan specifications. They however took more time than was specified.For the oil seals, the maintenance information was as shown in the table below Check oil seals and for leaks annual ticket for weekly task 7/7/19968.6710.4PlannedCheck oil seals and for leaks annual ticket for weekly task7/7/19978.6710.4PlannedCheck oil seals and for leaks annual ticket for weekly task7/7/19988.6710.4PlannedCheck oil seals and for leaks annual ticket for weekly task7/7/19998.6710.4PlannedCheck oil seals and for leaks annual ticket for weekly task7/7/20008.6710.4PlannedCheck oil seals and for leaks annual ticket for weekly task7/7/20018.6710.4PlannedCheck oil seals and for leaks annual ticket for weekly task7/7/20028.6710.4PlannedAgain the time taken was longer, however the maintenance was according to the life plan. For the vibration monitor gear case and checking of the get bearing, the data for year 1996 and 2002 is as shown in the table below shiver monitor gearbox push bearings 2/10/199612PlannedVibration monitor gearbox repel bearings3/10/199612PlannedVibration monitor gearbox motor bearings4/10/199612PlannedVibration monitor gearbox motor bearings5/10/199612PlannedVibration monitor gearbox motor bearings6/10/199612PlannedVibration monitor gearbox mot or bearings7/10/199612PlannedVibration monitor gearbox motor bearings8/10/199612PlannedVibration monitor gearbox motor bearings9/10/199612PlannedVibration monitor gearbox motor bearings10/10/199612PlannedVibration monitor gearbox motor bearings11/10/199612PlannedVibration monitor gearbox motor bearings12/10/199612PlannedFor the 2002 data Vibration monitor gearbox motor bearings 1/10/200212PlannedVibration monitor gearbox motor bearings2/10/200212PlannedVibration monitor gearbox motor bearings3/10/200212PlannedVibration monitor gearbox motor bearings4/10/200212PlannedVibration monitor gearbox motor bearings5/10/200212PlannedVibration monitor gearbox motor bearings6/10/200212PlannedVibration monitor gearbox motor bearings7/10/200212PlannedVibration monitor gearbox motor bearings8/10/200212PlannedVibration monitor gearbox motor bearings9/10/200212PlannedVibration monitor gearbox motor bearings10/10/200212PlannedVibration monitor gearbox motor bearings11/10/200212Planned Vibration monitor gearbox motor bearings12/10/200212PlannedAgain the life plan was strictly followed and all maintenance activities planned were carried out every month. For the pressure test (SV2), again the maintenance activities followed the life plan Pressure test and inspect 9/6/199623PlannedPressure test and inspect9/6/199723PlannedPressure test and inspect9/6/199823PlannedPressure test and inspect9/6/199923PlannedPressure test and inspect9/6/200023PlannedPressure test and inspect9/6/200123PlannedPressure test and inspect9/6/200223PlannedFor the pressure test and inspection to ensure if reconditioning was required, the maintenance was as scheduled and took invest after 6 years as shown in the table below however the time for the activity was longer than it was expected.Pressure test and inspect 3/3/199623PlannedPressure test and inspect3/4/200223PlannedFor the steam jacket, the life plan was followed but again the allocated time was short. Despite the carefully planned main tenance activities, there were some antiphonal maintenance activities these resulted from detection of anomalies in the system. Some of these activities are shown in the table below.Component Item body process Date Standard time Actual time Type of job ReactorP1Replace leaking automatonlike seal7/2/199644 excited extractorP2Replace mechanical seal1/18/199723ReactiveReactorT1Re-calibrate temperature sensor9/1/199823ReactiveRaw Material StorageP3Replace seal11/16/199855ReactiveCentrifugeP2Replace mechanical seal3/29/199924ReactiveCentrifugeP2Replace mechanical seal5/18/199922ReactiveRaw Material StorageP3Repair plinth impact damage10/1/199944ReactiveRaw Material StorageP3Repair seized pump10/3/20001212ReactiveReactorT1Re-calibrate temperature sensor4/17/200122ReactiveCentrifugeT3Replace temperature sensor6/25/200222ReactiveFrom this analysis it can be seen that maintenance operations were done as scheduled and planned. However, most of the activities took a longer time than was sc heduled. The planned maintenance operations were not wholly effective as reactive maintenance operation were performed. h) Use your experience in conjunction with Figures 1 2, the plant description and the data from the CMMS to analyze the unit into its maintenance make itemsFrom the diagrams 1 and 2, the main areas that are promising to fail include The major maintenance causing units are (i)The steam unit The unit comprises of the safety valves, the steam jacket, the steam jacket safety valve, the earth control valve etc. these units are bound to fail and cause critical damage to the equipment as well as the manpower manning the plant. Their maintenance is critical. (ii)The agitator unit Comprises of the agitator, the agitator motor, the motor gearbox and coupling. The gearbox and the subscribe mechanism are bound to fail due continuous use as well as the forces acting on the agitator. Bearing wear are also likely to cause vibration on the shaft. (iii)The reactor unit The rea ctor unit, the reactor safety valve SV2, the safety valve drop down pipe work is also likely to cause plant unsuccessful person and should be checked regularly. (iv)The centrifuge The centrifuge system is also critical in the operation of this plant and is likely to cause major maintenance problems. Some of the maintenance checks include testing the motor bearing, checking the vibration on the machine, checking the wear on the seals of the centrifuge, physical check of the centrifuge as well as checking its drive motor and the valves leading to the pump and out of the pump. The minor units likely to cause maintenance problems are (v)Temperature sensor calibration The failure of the temperature alarm to detect increase in temperature beyond 125 degrees. This is due to a faulty temperature sensor. This calls for regular temperature sensor control, calibration and testing if the system works according to the set parameters. (vi)Checking the pipes Checking of the pipe work for any lea kage should also be done. Checks should be done regularly. (vii)Checking the pump for proper workability Pump delivering materials to the centrifugal unit should be checked. Some checks include the operate motor vibration tests, the motor starter tests as well as the functioning of the motor tests. Tests should be performed every month through physical checking of the motor. The agitator motor should also be checked to determine if its working at its rated torque and speed. (viii)Checking the steam trap The steam trap and the heat exchanger should also be regularly checked, this is because it cools the steam efficiently. The condenser should be checked for any leakages, blockages, wear, temperature and heat dissipation as well as its performance and efficiency. Tests involve both the physical checks as well as narrow tests using thermometers and thermocouple sensors to detect if the heat loss in the steam trap is sufficient enough.Checking the raw materials storage The warehouse u sed to store the raw materials should be regularly inspected to ensure that the materials are not contaminated. Presence of excess water, humidity, temperature and pests may damage the raw materials resulting to inferior products.Checking the raw materials feed mechanism The raw material feed mechanism should be checked to ensure delivery of materials to the batch reactor with ease. The motor used to run the feedstock should be checked, the physical leakages should also be checked and other component of the feed mechanism. The test should be done every month. Checking the paint coating Involves the Physical inspection of the plant to ensure that all the parts are not rusted or the paint has not been scourged. These tests are indispensable to ensure conformity with the pharmaceutical inspectors rules and regulation. The inspection can be done every year. i) Develop your own life plan for these maintenance causing items using the task selection logic for Reliability touch on Mainten anceFor the implementation of RCM the following main tasks are carried out infusion of the equipment to perform analysis designation of potential failures Identification and evaluation of the effects of the started failuresIdentification of the causes of failure Selecting the maintenance tasksMaintenance packaging1) Selection of equipment to perform analysis on The main equipments to perform analysis on are The batch reactor The centrifuge The steam jacket The centrifuge motor The raw materials handling equipment The identification of potential failures and the causes of failure The potential problems that are likely to occur areBATCH REACTOR The agitator The agitator motor failure The agitator gearbox failure The agitator coupling failure The centrifuge Centrifuge discharge pipe failure The centrifuge pump may fail The pump motor failure The piping system may fail The steam jacket Failure of the reactor safety valve Failure of the safety valve The temperature alarm s ystem failure The failure of the pressurized steam pipe network. Sensors and alarms Failure of the temperature controller The globe control valve failure The steam trap Raw materials feed system Failure of the inlet pipe work Failure of the motors conveying the raw materials The table below shows the maintenance strategy developed after conducting a RCM analysis. Table 1 RCM analysis Item Causes of failure Maintenance activity Frequency of maintenance judgment of conviction for maintenance The agitator The motor (1)Brush wear(2)Winding may overheat (3)The motor starters may fail Checking the motor 3 months 2 hours The gearbox (oil gearbox )(1)The viscosity of oil may reduce lubricity Testing the oil viscosity 3 months