In the 1970s, there was a concerted effort at the chemical company I worked for to provide extra process measurement connections throughout the plants for pressure and temperature measurement. These connections could be used as needed to help identify and solve unforeseen problems. The installation of a wired transmitter on a temporary basis was not [...]
At one time, I worked in a large continuous process plant that had alarms coming in constantly. The operators could hit the “Silence” button in their sleep. We had a case where a process flow was accidently diverted to the wrong tank, and it eventually filled and overflowed the tank. Even though the tank had [...]
When I am in an instrument and valve repair shop, I see many more control valves than instruments, particularly with the advances in sensor technology, transmitter intelligence, and asset management systems. Valves are mechanical devices and as such require more maintenance. Packings, seals, seats, and O-rings wear out. To ease maintenance, a control valve must [...]
This may seem like a crazy tip, but there is a lot more truth in this statement than you might realize. It’s directed to management, but a young engineer may have reason and opportunity to encourage management to do this. Concept: Simple things like strong coffee and a fast brewing pot seem minor, but during [...]
I became sensitized to the importance of measurement location when I found the easiest way to keep a pH electrode from fouling was to install it in a pipe with a flow velocity of 5 to 7 fps, preventing the usual 100X deterioration in the speed of response that resulted from just a few millimeters [...]
Over the years, I have learned a number of valuable tips, either the hard way or from my talented colleagues. Here are some points that will be extremely useful to any project manager. Concept: Successful project management requires a diverse skill set and covers a broad range of activities. Most project managers acquire that skill [...]
When we did process control improvements in the 1980s and 1990s, the major limitation was the lack of a reliable field analyzer. None of the plants had field analyzers on raw materials. The specialty chemicals production units had very few field analyzers and were flying blind. Plants for chemical intermediate products had field analyzers on [...]
As a project manager I am responsible for a myriad of activities, but if I consider them in aggregate I realize that they are just different manifestations of the same thing: my job as a project manager is to recognize risk and manage it. Concept: Successful project managers are masters at evaluating, mitigating, and avoiding [...]
The biggest mistakes I have seen in the process industry came from trying to cut costs by not using the best technology instrumentation and systems. We tend to forget that measurements are the only windows into the process and controllers and final control elements (e.g., control valves) are the only means of affecting the process. [...]
You’re studying the elephant in school. You look at the pictures, learn about the anatomy and physiology of the animal, research its habits, etc. With enough study you might write a paper or two, and in time you might even be considered an expert on the beast. Studying an elephant is one thing, but it [...]
