Batch Reactor Is Widely Used In The Chemical Mechanics Essay

Batch Reactor Is Widely Used In The Chemical Mechanics EssayA jam nuclear nuclear reactor is widely used in the chemical and influence industry to perform several operations such as providing an environment of chemical reactions, crystallization, product mixing, dissolution of solids, polymerization, liquid to liquid line of descent as well as batch distillation. The equipment comprises of tank that has an integrated heating and cooling schema as well as an agitator. The main advantages of using a batch unit is it ability to perform various function with stunned the need to change or break containment. Toxic and highly potent compounds can be processed in the batch unit. Part oneQuestion 1 a) Explain why you would regard this batch chemical reactor as a ground unit.According to the definition of a chemical dress, a dress is comprised of several units that atomic number 18 interconnected by piping. Materials move in and out of these units. These materials or raw materials a r converted into different products. In this example, the batch reactor is a separate unit of the set which processes the raw materials introduced in the first place chip ining them to the spin frame. This batch reactor is similarly the principle chemical converter in this plant. b) Explain your reasons for concluding that this unit is critical for mathematical productThis unit is critical for the return in this process because It prep ars and processes the raw materials by heating them to the prescribed temperature and also providing the required pressure for the process.It ensures full utilization of the extractor unit this is because it produces more than the centrifugate 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 pad products, thereafter, these materials are sorted out by the centrifuge. There is no other unit for processing materials in thi s plant unit. The batch unit temporary stores the materials before they are make to the centrifuge system. b) Extract some(prenominal) exploiter requirements for this designated unit from the plant description. Are there every production windowpanes?The main user reading is The vessel consist of a jacketed agitated glass lined vessel, heated to a certain temperature and pressure and consist of a thermocouple, a temperature alarm and has a sanctuary relief valve The equipment list is also 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 controller, steam ensnare, agitator and the pipe work. The batch reactor process is also described so that the user or the operator can clearly understand how the processes are carried out, for example the batch unit starts whe n 18 (te) of raw materials are introduced to the reactor, the content are heated through to a preset temperature/ term 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 corporate requirements for this unit from the plant descriptionSome of the corporate requirements for this unit obtained from the text are The equipment is shutd consume for 16 hours during the 40th week of each year. The production of the batch reactor is also indicated, that is the manufacturing unit makes 13,000 te of bulk pharmaceutical product within a apt(p) 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 company guidelines state that reactors should be maintained to archive 25 days and gear boxes should be maintained to give 15 years live liness. e) Extract any legislative requirements for this unit from the plant description.The legal requirements include The procedure for controlling care activities must 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 completed 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 caution 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 test and maintenance activities are carried out to ensure tha t the batch reactor archives 25 years life and the gear boxes give a 15 year working life. In addition to the maintenance activities, the industry should be kept decipherable and painted to ensure that it passes the pharmaceutical inspectors test and prevent unnecessary shutdown. The maintenance activities should however be scheduled in such a manner that they dont throw in or affect the operation of the plant thereby maximizing the profits obtained from the production line. This calls for the scheduling of light maintenance operation to be through with(p) 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 be after for. The online and offline maintenance window s should also not coincide. Offline maintenance These are maintenance activities that are performed when batch reactor is switched off or some recess 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 prison term in which automatic maintenance activities are carried out. During the maintenance window, the need for maintenance act is first evaluated, and if the system does not meet the required parameters a maintenance activity 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 ActivityCommentsCV1, 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 box Checking the petrol eum color Checking the anoint molds for leaks opthalmic 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 watchfulness This is a rigorous 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 go over Internal inspection Pressure 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 Vibration manageing deviceing of the take and pump bearing Should be done on daily basis. The pump force back should also be checked as the leak tests are done. This will help supervise the pump. The checks are done by the plant operator. g) Analyze the recorded jobs from the computer maintenance centering 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 effective 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 activities. The obtained data was as follows For the agitator coupling the Visual check annual ticket for periodical task were as follows 8/8/1996 4.335.2 plan8/8/19974.335.2 mean8/8/19984.335.2Planned8/8/19994.335.2Planned8/8/20004.335.2Planned8/8/20014.335.2Planned8/8/20024.335.2Planned8/8/20034.335.2PlannedFrom 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 figure 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 box and checking of the motor bearing, the data for year 1996 and 2002 is as shown in the table below Vibration monitor gearbox motor bearings 2/10/199612PlannedVibration monitor gearbox motor bearings3/10/199612PlannedVibration monitor gearbox motor bearings4/10/199612PlannedVibration monitor gearbox motor bearings5/10/199612PlannedVibration monitor gearbox motor bearings6/10/199612PlannedVibration monitor gearbox motor 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 bearings11/10/200212PlannedVibration 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 determine if reconditioning was required, the maintenance was as scheduled and took place 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 maintenance activities, there were some reactive maintenance activities these resulted from detection of anomalies in the system. Some o f these activities are shown in the table below.Component Item Activity Date Standard time Actual time Type of job ReactorP1Replace leaking mechanical seal7/2/199644ReactiveCentrifugeP2Replace mechanical seal1/18/199723ReactiveReactorT1Re-calibrate temperature sensor9/1/199823ReactiveRaw Material storageP3Replace seal11/16/199855ReactiveCentrifugeP2Replace mechanical seal3/29/199924ReactiveCentrifugeP2Replace mechanical seal5/18/199922ReactiveRaw Material StorageP3Repair base 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 scheduled. 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 causation itemsFrom the diagrams 1 and 2, the main areas that are in all probability to last 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 Globe 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 capture 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 reactor unit, the reactor safety valve SV2, the safety valve discharge pipe work is also likely to cause plant failure and should be che cked 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 leakage should also be done. Checks should be done regularly. (vii)Checking the pump for proper workability Pump delivering materials to the centrif ugal unit should be checked. Some checks include the driving 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 specialized tests using thermometers and thermocouple sensors to detect if the heat exit in the steam trap is sufficient enough.Checking the raw materials storage The warehouse used to store the raw materials should be regularly inspected to ensure that the materials are not contaminated. Presence of excess water, hum idity, temperature and pests whitethorn 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 corrode or the paint has not been scourged. These tests are obligatory 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 Centered MaintenanceFor the implementation of RCM the following main tasks are carried out excerption of the equipment to perform analysis Identification 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 system 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 Time 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