18 14 Maximum Capacity Test Run and Debottlenecking Study 14.1 Introduction 14.2 Understanding Different Safety Margins in Process Equipment 14.3 Strategies to Exploit the Safety Margin 14.4 Capacity Expansion versus Efficiency Reduction 14.5 Maximum Capacity Test Run: What is it All About? 14.6 Objective of a Maximum Capacity Test Run 14.7 Bottlenecks of Different Process Equipment 14.8 Key Steps to Carry Out a Maximum Capacity Test Run in a Commercial Running Plant 14.9 Scope and Phases of a Detailed Improvement Study 14.10 Scope and Limitations of MCTR
19 15 Loss Assessment 15.1 Different Losses from the System 15.2 Strategy to Reduce the Losses and Wastages 15.3 Money Loss Audit 15.4 Product or Utility Losses
20 16 Advance Process Control 16.1 What is Advance Process Control? 16.2 Why is APC Necessary to Improve Profit? 16.3 Why APC is Preferred over Normal PID Regulatory Control (Lahiri, 2017c) 16.4 Position of APC in the Control Hierarchy (Lahiri, 2017c) 16.5 Which are the Plants where Implementations of APC were Proven Very Profitable? 16.6 How do Implementations of APC Increase Profit? 16.7 How does APC Extract Benefits? 16.8 Application of APC in Oil Refinery, Petrochemical, Fertilizer and Chemical Plants and Related Benefits 16.9 Steps to Execute an APC Project (Lahiri, 2017d) 16.10 How Can an Effective Functional Design Be Done? References
21 17 150 Ways and Best Practices to Improve Profit in Running Chemical Plant 17.1 Best Practices Followed in Leading Process Industries Around the World 17.2 Best Practices Followed in a Steam and Condensate System 17.3 Best Practices Followed in Furnaces and Boilers 17.4 Best Practices Followed in Pumps, Fans, and Compressor 17.5 Best Practices Followed in Illumination Optimization 17.6 Best Practices in Operational Improvement 17.7 Best Practices Followed in Air and Nitrogen Header 17.8 Best Practices Followed in Cooling Tower and Cooling Water 17.9 Best Practices Followed in Water Conservation 17.10 Best Practices Followed in Distillation Column and Heat Exchanger 17.11 Best Practices in Process Improvement 17.12 Best Practices in Flare Gas Reduction 17.13 Best Practices in Product or Energy Loss Reduction 17.14 Best Practices to Monitor Process Control System Performance 17.15 Best Practices to Enhance Plant Reliability 17.16 Best Practices to Enhance Human Resource 17.17 Best Practices to Enhance Safety, Health, and the Environment 17.18 Best Practices to Use New Generation Digital Technology 17.19 Best Practices to Focus a Detailed Study and R&D Effort
22 Index
List of Tables
1 Chapter 2Table 2.1 Comparisons between smart and conventional chemical industries
2 Chapter 4Table 4.1 Representing the whole plant as a black box with consumption and co...Table 4.2 Summary of profit margin and cost intensity
3 Chapter 6Table 6.1 Table to calculate production cost, cost intensity, profit, and pro...Table 6.2 Table to relate production cost, cost intensity, with key parameter...Table 6.3 Plant reliability assessmentTable 6.4 Typical performance of control loops in industry
4 Chapter 7Table 7.1 Input and output variables for the ANN model
5 Chapter 8Table 8.1 Initial Population of x 1 and x 2 and Their FitnessTable 8.2 Mutation and CrossoverTable 8.3 New Generation PopulationsTable 8.4 Optimum Value