HAZOP study in India | HAZOP consulting services India | Process safety design

HAZOP study in India | HAZOP consulting services India | Process safety design

A HAZOP study is used to verify the integrity of design or procedures with respect to safety and operability. HAZOP studies need extensive experience and highly skilled multi-disciplined teams.  Process Hazard Analysis is a systematic approach for identifying, evaluating, and controlling the hazards of processes.

Why HAZOP

HAZard and OPerability (HAZOP) is a well known and well documented study. HAZOP is used as part of a Quantitative Risk Assessment (QRA) or as a standalone analysis. The purpose of HAZOP is to investigate how the system or plant deviates from its original design intent and create risk for personnel and equipment and operability problems. The process hazard analysis methodology selected must be appropriate to the complexity of the process and must identify, evaluate, and control the hazards involved in the process.

HAZOP studies have been used with great success within chemical and the petroleum industry to obtain safer, more efficient and more reliable plants. HAZOP has become a standard method in the design of process system in India.

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What HAZOP companies do

HAZOP companies have a strong and experienced pool of experts within technical safety. These experts have extensive experience with HAZOP both as part of the design of process plant either as an independent risk analysis or a preliminary study and modification. This also includes procedural HAZOPs.

A typical HAZOP study will be conducted this way:

  • Familiarization with background documentation
  • Planning of the workshop meeting in a pre-meeting with the customer in order to identify HAZOP strategy, division of the subsystems/nodes (e.g. line, pump, vessel, compressor), choose relevant Piping and Instrument Diagrams (P&ID), and identifying guide words
  • Accomplishment of the HAZOP review
  • Documentation of observations into information and actions point, document findings on the P&IDs.
  • Draft report for client review.
  • Final HAZOP report.

The process hazard analysis shall address the following:

  • The hazards of the process
  • The identification of any previous incident that had a likely potential for catastrophic consequences
  • Engineering and administrative controls applicable to the hazards and their interrelationships
  • Consequences of failure of engineering and administrative controls
  • Stationary source siting
  • Human factors and
  • A qualitative evaluation of a range of the possible safety and health effects of failure of controls.

A Process Hazard Analysis (PHA) team includes process safety specialist, engineers, operators, supervisors and other workers who have knowledge of the standards, codes, specifications and regulations which apply to the process being studied.

 

Water audit in India

Water audit in India

Historically, the water auditing process has been quite inconsistent in India. This represents perhaps one of the greatest shortcomings in an otherwise highly reliable utility services sector.  Many utility managers compile at least a cursory water audit each year; however, without specific requirements, most of the water utilities conduct infrequent water audits, and therefore are likely suffering notable losses.

Thus, the industry has begun to address the longstanding need to better establish accountability in its operations.

A water audit is an accounting procedure. The purpose of a water auditis to accurately determine the amount of unaccounted-for water (UAW) in a water distribution system. UAW is calculated from verified supply and consumption records, factoring in various estimated usage figures.

Typical steps involved in a water audit include:

  1. The water use inventory
  • It is important that facility executives develop an understanding of exactly how and where their facility uses water. To do this, an inventory of all water use points in the facility with flow rates must be developed.
  • In addition to identifying all water use points and flow rates, the inventory should identify if the water being used is hot or cold, or if it undergoes special filtering or treatment. Reducing water use in applications that use hot or treated water will produce savings that go beyond solely the cost of the water.
  • When completing the inventory, pay attention to any unexplained water flow. As piping systems are modified over the years, it is easy to lose track of what piping serves what equipment. Don’t be surprised to find water flowing from equipment that is no longer used or even installed.
  1. Metering
  • Unfortunately, most facilities only have a single, master water meter. Readings from master meters will provide an indication of how a facility compares to other facilities, but it will not show where to look for areas where water use can be reduced, particularly if the facility is large or complex.
  • Narrowing use down to possible areas where use can be reduced requires submetering.
  • Again, the key to gaining useful information from submeters is to have the meters read on a regular basis, and as frequently as possible. Frequent readings help to quickly identify and locate leaks.
  1. Review maintenance practices
  • Preventive maintenance programs have long been recognized as effective tools for improving system performance while reducing overall operating costs. With water use historically being an ignored or low priority item, chances are few preventive maintenance steps have been put in place to specifically address water use.
  • Does anyone ever test once-through cooling systems to determine that they are operating at the proper flow rate?
  • How often are cooling towers and boilers checked to see that the make-up water systems are operating properly?
  • Do building occupants even know that they can and should report instances of excessive water use or waste?
  • How often are restrooms checked for faucets that don’t fully shut off or flush valves that leak or stick on?
  • What mechanism is in place to review water using items that are being purchased for use within the facility? For example, refrigeration systems that use once-through water cooling are less expensive and easier to install than closed loop systems. Closed loop systems however, have minimal water requirements.
  • Is there an established procedure that reviews equipment purchases that addresses the issue of water use?
  1. The water efficiency plan
  • Once information has been gathered on how water is being used in the facility, an action plan can be established for reducing water use.
  • The plan should identify who will take responsibility for implementation. It should make certain that individual has the authority and support needed to implement the plan.
  • The water audit should have identified a number of areas in which water savings can be achieved. The water efficiency plan should set the priorities for implementation based on costs, benefits and available manpower.

Benefits

  • Reducing water use in a facility is a win-win situation. Using less water means lower utility costs.
  • It also means reduced chemical treatment costs in systems such as boilers and cooling towers. Finding and eliminating long-standing leaks can create a better work environment for building occupants, as well as reduce damage to building components.
  • Reducing water use can also enhance the public image of a facility. Facility executives should publicize the program’s successes and give credit to those involved. Even something as simple as installing moisture sensors on an irrigation system can improve the facility’s image.

 

 

Energy Auditing for industrial facilities in india

Energy Auditing for Industrial Facilities in India

An energy audit is a four-step process that includes the phases of planning, investigating, implementing, and sustaining.  A successful energy audit with maximum ROI comes only with a strategic plan and perfect execution.

An energy audit is not just about taking measurements, measurements must be part of systematic processes to identify and implement the most cost effective energy management & energy conservation programs.

Energy audits involve gathering system information, measuring energy use, developing conservation strategies, choosing the most cost-effective plan, implementing changes, and verifying results. A proactive industrial facility continues improving energy efficiency by repeating the 4 step process at regular intervals.

To sum up, for performing an energy audit- several tasks are typically carried out depending on the type of the audit and the size and function of the building. Some of the tasks may have to be repeated, reduced in scope, or even eliminated based on the findings of other tasks. Therefore, the execution of an energy audit is often not a linear process and is rather iterative.

A generic framework procedure can be outlined for most facilities which is as shown below:

  1. Facility & Utility Data Analysis

    The main purpose of this step is to evaluate the characteristics of the energy systems and the patterns of energy use for the building. The building characteristics can be collected from the architectural/ mechanical/electrical drawings and/or from discussions with building operators. The energy use patterns can be obtained from a compilation of utility bills over several years. Analysis of the historical variation of the utility bills allows the energy auditor to determine any seasonal and weather effects on the building energy usage. Some of the tasks that can be performed in this step are presented below, with the key goals expected from each task noted in italics:

  • Collect at least 3 years of records of utility data [to identify a historical energy use pattern]
  • Identify the fuel types used (electricity, natural gas, oil, etc.) [to determine the fuel type that accounts for the largest energy use]
  • Determine the patterns of fuel use by fuel type [to identify the peak demand for energy use by fuel type]
  • Understand utility rate structure (energy and demand rates) [to evaluate if the building is penalized for peak demand and if cheaper fuel can be purchased]
  • Analyze the effect of weather on fuel consumption
  • Perform utility energy use analysis by building type and size (building signature can be determined including energy use per unit area [to compare against typical indices]
  1. Walk-through survey

This step should identify potential energy savings measures. The results of this step are important since they determine if the building warrants any further energy auditing work. Some of the tasks involved in this step are

 

  • Identify the customer’s concerns and needs
  • Check the current operating and maintenance procedures
  • Determine the existing operating conditions of major energy use equipment (lighting, HVAC systems, motors, etc.)
  • Estimate the occupancy, equipment, and lighting (energy use density and hours of operation)
  1. Baseline for Building Energy Use

The main purpose of this step is to develop a base-case model that represents the existing energy use and operating conditions for the building. This model will be used as a reference to estimate the energy savings due to appropriately selected energy conservation measures. The major tasks to be performed during this step are

  • Obtain and review architectural, mechanical, electrical, and control drawings
  • Inspect, test, and evaluate building equipment for efficiency, performance, and reliability
  • Obtain all occupancy and operating schedules for equipment (including lighting and HVAC systems)
  • Develop a baseline model for building energy use
  • Calibrate the baseline model using the utility data and/or metered data
  1. Evaluation of Energy-Saving Measures

 

In this step, a list of cost-effective energy conservation measures is determined using both energy savings and economic analysis. To achieve this goal, the following tasks are recommended:

 

  • Prepare a comprehensive list of energy conservation measures (using the information collected in the walk-through survey)

 

  • Determine the energy savings due to the various energy conservation measures pertinent to the building by using the baseline energy use simulation model developed in Step 3

 

  • Estimate the initial costs required to implement the energy conservation measures

 

  • Evaluate the cost-effectiveness of each energy conservation measure using an economical analysis method (simple payback or life-cycle cost analysis)

 

Sustainability in the modern world

Better understanding sustainability in the modern world

We as a society – a global society – are better understanding the impact that we have on the environment with all of the behavior and choices that we make, and are committed to rolling back our environmental footprint as much as humanly possible by building more sustainably.

LEED sustainability projects help companies and individuals dramatically lessen their environmental footprint while at the same time provide a blueprint for future projects to work off of.

Sustainable building practices, a repurpose thing of materials, and a drive to build structures and projects that are much more in tune with their natural surroundings than they might have been previously will help you and your operation move forward into the 21st century with confidence knowing that you’re part of the solution.

Sustainability is absolutely mission critical when constructing new projects today

It is absolutely impossible for us to imagine moving forward as a society with the same kind of traditional building practices and construction “rules and regulations” that dictated our decisions for the past hundred years or so.

With the population absolutely exploding, our individual carbon footprints expanding, and obvious signs of environmental impact all around us, sustainability is the name of the game – and we all need to make sure we are doing our part.

New technological advances in solar technology, water repurposing, geothermal energies, and innovative ways to capture the wind all help to improve sustainability dramatically, as do “green construction initiatives” that help to dramatically eliminate unnecessary waste.

If you’re thinking about undertaking a major construction initiative, you’re going to want to work with the best sustainability engineers around to get the job done the right way.

Finding the right sustainability engineers becomes a lot easier when you know what to look for

Of course, that means you’re going to have to find engineers that are going to be able to assist you with your sustainability project in the first place.

LEED certification is the first thing that you’re going to want to look for, but you’re also going to want to take a very close look at the kind of LEED projects these engineers have worked on in the past to make sure that they are going to be able to provide you with the answers you are looking for.

You want to be sure that you’re working with experts that have successfully completed LEED projects that have had at least hit the “Gold” level – though engineers that consistently produce “Platinum” level projects are amongst the very best in the business.

Remember though, that your LEED certification is going to be based entirely off of the amount of points that you’re able to secure with all of the green initiative and sustainability components that you put together.

You’re going to have to take a very holistic view with your sustainability engineers to make sure that you are tackling this project the right way, and that you are doing so to produce sustainable results and not just capture a certification that you’ll be able to flaunt on the next company report.

Role of Process engineering in Life sciences in India

Better understanding the role process engineering serves in our life

It’s absolutely amazing to think of the tremendous advances we’ve all been able to witness in just the last 100 years or so.

Think about this – it really wasn’t all that long ago that the overwhelming majority of people on this planet were commuting by horse, had never even heard of an airplane, and were used to getting news and updates by radio.

Today, things have changed dramatically.

And though most of us are familiar with the major technological advances on the consumer electronics side of things, major leaps forward in the life sciences industry have been just as pronounced.

The application of engineering principles and practices to biology, nanotechnology, and the sciences of living organisms and how they operate have led to tremendous leaps forward in medical technology, in the health and wellness industries, and in helping us to lead happier and healthier lives than we would have been able to previously.

Process engineering plays a large role in these big breakthroughs.

Process engineering as it applies to the life sciences industry

Process engineers have always focused on distilling down the most complex parts of our lives to their bare essentials, stripping away every single step in the process to understand its role, its impact, and how things may be improved.

But when it comes to the life sciences, process engineers aren’t focused on breaking down the “engineering system” as they would in a more traditional engineering environment – but are instead focused on breaking down all of the complex systems inside the body or inside another living organism.

Looking at the body as an engineering project, process engineers get the chance to see how the body consumes fuel and raw materials, understand the thermogenic properties of the body, how each of the major and minor bodily systems dovetail into one another, and how information is exchanged throughout the body.

Obviously, that’s just the tip of the iceberg, but when you apply engineering processes and systems to the human body, you get the opportunity to look at things in a brand-new way. You get the chance to break down the body into its simpler and barest essentials, you get the opportunity to find ways to innovate and improve an already impressive system, and you come up with answers that may have seemed counterintuitive or nonobvious initially.

The future of process engineering in the life sciences industry

A big push in the life sciences industry by process engineers revolve around research into nanotechnology.

Process engineers (as well as researchers and engineers from all over the science spectrum) are looking for ways to create “mechanical cells” that do not have the shortcomings of traditional biological cells.

These nanomachines would be able to be programmed to deliver very specific results, and would essentially operate as digital or mechanical stem cells – performing a variety of mission-critical tasks throughout the body that may help eradicate disease and allow all of us to lead much happier, much healthier, and much longer lives without the baggage of “old age”.

 

Maximize your CIP/SIP results

Tips and tricks for getting the most out of Clean in Place/Sterilization in Place results

Regardless of whether or not you are runninga manufacturing facility, a laboratory, or any other kind of operation that takes advantage of closed systems, you’re going to want to be certain that your operation is perfectly clean and completely sterilized on a regular basis.

This is especially true of those in the beverage, food, or pharmaceutical industry, where taking advantage of the best Clean in Place/Sterilization in Place services are absolutely mission critical to providing consistent and reliable results that pass industry specifications and requirements.

In an effort to help you better choose the right CIP/SIP professionals to deliver you the kind of results you’re counting on, here are just a handful of things you’ll want to think about before you contract any services at all.

Make certain that you’re always working with qualified professionals

The very first thing that you need to make sure you are doing when you are working with these kinds of professionals is that they are exactly that – professionals.

There are quite a few generalized cleaning operations out there that possess some of the tools and technology necessary to provide CIP/SIP results but not the experience, the specialized knowledge, or the wisdom to deploy these solutions appropriately in all circumstances.

No, instead, you’re only going to want to work with those that have the necessary qualifications, the necessary certifications, and the kind of experience – usually years of experience – that give you the confidence to know that the jobs going to get done the right way the first time around.

This is especially important when you are in an industry where contamination in a closed system can have dramatic and drastic consequences.

Only take advantage of services designed for your setup and your technology

Secondly, you’re going to want to be 100% certain that the CIP /SIP you have decided to work with are experienced in delivering the kind of clean in place and sterilization in place results you’re looking for with your particular technology setup.

Though almost every industrial setup is going to be unique in itself, the truth is most solutions have some kind of aseptic production technology, technology that needs to be cleaned without any exposure to outside contaminants whatsoever.

If you’re producing sterile products that must be packaged in sterile containers, CIP/SIP services are an absolute must!

The best CIP /SIP professionals are going to use isolators that make sure no air or oxygen makes it into a closed system, removing all potential for contamination almost entirely. Steam, hydrogen peroxide, and a handful of other specialized solutions may be deployed depending upon the kind of cleaning that you’re looking for and the manufacturing technology you’re using in your closed system.

Review the CIP/SIP experts you’ve worked with

Lastly, you’ll want to make sure that you can find at least a handful of appropriate outlets that give you the chance to review the CIP /SIP that you have chosen to work with.

This “inside information” straight from the mouths of people that have actually worked with CIP /SIP contractors and services will help business owners, management, and leadership choose the right experts going forward, and you’ll be contributing immensely to your industry and every other that needs to leverage these services later down the line.

Be honest and straightforward in your reviews so that people know exactly who to choose to work with moving forward.

 

MEP engineering in India – MEP consulting in India

MEP engineering in India | MEP consulting in India

Critical details to focus on when choosing MEP engineers

Regardless of whether or not you own a business or operation than needs to take advantage of MEP engineers or are an executive or manager that’s in the position to find and hire the right MEP consultants, you’re going to need to make sure that you know EXACTLY what you’re getting into before you jump right in.

Believe it or not, not all MEP engineering or MEP consulting experts are going to be able to deliver you the same kinds of results, and some are going to be a lot easier to work with than others.

There are a handful of different things that you’re going to need to make sure that you are aware of before you start this process, and we are going to break down some of the most important ones below.

Shall we get right to it?

The value of hiring MEP engineering or MEP consulting experts

There is a tremendous amount of expertise, specialized knowledge, and experience that you are going to be able to take advantage of when you hire in the right MEP engineering or MEP consulting experts.

People in the MEP (Mechanical/Electrical/Plumbing) engineering world have spent years and years going to school to learn about all of these crucial technologies and systems, and the best MEP consulting experts in the world have spent even longer in the “real world” creating custom-designed mechanical/electrical/plumbing solutions specifically tailored to the demands of their clients.

This isn’t the kind of expertise, knowledge, or experience that you’re going to be able to hire right off the street, and it certainly isn’t the kind of expertise, knowledge, or experience that you’re going to be able to hire out of a graduating class.

If you’re working on larger projects and want to make sure that your engineering is up to snuff, you’re going to want to be certain that you are moving forward step-by-step with the help of only the very best MEP engineering or MEP consulting experts available.

Track record is absolutely everything

To help make the hiring process easier, you’re going to want to look specifically at the track record for successful solutions and projects that a particular MEP engineering or MEP consulting expert already has under their belt.

Obviously, it’s going to be almost impossible to know whether or not you’ve made the right decision hiring a firm without taking a look at the kinds of work they’ve been able to deliver in the past – even if those projects don’t necessarily dovetail perfectly with the kind of project you’re trying to move forward with now.

This is the kind of insider information that you need to have on hand, the kind of insider information that almost all professional MEP engineering and MEP consulting experts are going to be happy to share with you during the interviewing process.

Any MEP firm that avoids sharing this information with you should probably be looked at and scrutinized more, or avoided altogether.

You need to be confident in your choice, and that confidence is only going to happen after you had the chance to look at the kinds of results they have delivered in the past.

Everything you need to know about process engineering in India

Everything you need to know about process engineering in India

It is absolutely impossible for any business in today’s ultra-competitive environment to survive very long without the help of process engineering professionals.

These professionals are the kinds of experts that are going to be able to effortlessly diagnose any and all inefficiencies, find and remove bottlenecks, and come up with new and innovative ways that allow businesses to compete without having to cut their prices – building in extra pockets of profit along the way.

Process engineering experts are also going to be able to take a look at the overall “foundation” of any particular business and help management better understand where things are being done efficiently and where things need a little bit of work.

The kind of process engineering experts we retain at Panorama Consulting have a varied background and expertise in a multitude of different areas, giving them – giving us – the unique opportunity to really help you better understand and diagnose your business without any headache or hassle along the way.

Let’s break down a little bit more about process engineering and how these professionals help to add to your bottom line.

What exactly is process engineering, in the first place?

Before we really dive into the nuts and bolts of process engineering, it’s important that you understand exactly what this subject is – and what it is not.

To put it simply, process engineering is essentially a discipline of engineering that focuses on creating and optimizing already existing or brand-new manufacturing processes, operations, controls, and workflows.

When you leverage the services of top-tier process engineers, you’re going to be able to create a much more efficient and a much more effective operation. This will lead to lower costs, extra profits, and less headache or hiccups along the way.

The overall process engineering process

The very first thing that process engineers are going to want to do upon having their services retained is get a look at your business operations as they exist today.

This early “discovery” part of the process is absolutely essential. These experts are going to take the time to appropriately diagnose existing systems not only so that they can find any hidden inefficiencies to be resolved, but also so that they can create solutions that are as non-disruptive as possible.

Once this discovery process has concluded, the engineers are going to look closer at day-to-day operations, controls, and any support tools or departments that may (in any way whatsoever) impact overall efficiency.

This is where a lot of the innovative solutions are going to come from, and where a tremendous amount of improved efficiency comes into play.

Finally, your process engineers are going to provide you with a set of actionable plans that you’ll be able to put into action across all departments of your operation with the sole goal of eliminating bottlenecks, wiping away in efficiency, and improving operations dramatically. You’ll be able to go back-and-forth about the specifics of how to implement these details, but you’ll also be able to come away from this overall experience with a better understanding of your operation, any shortcomings, and the advantages you enjoy over your competitors.

Improving production efficiency

Improving production efficiency, implementing new technologies and revamping old technologies to make continuous improvements in processes and infrastructure

Here’s how the mighty fall

There is no such thing as a “born leader” what it comes to the world of business.

Look at all of the most successful businesses throughout human history and you’ll find that the pieces very rarely just kind of fell together on their own. Instead, these businesses and these organizations understood themselves, understood their mission, understood their objectives, and took advantage of opportunities as they became available – continuously improving their processes and their infrastructure to position them for great success.

At the same time, many of these businesses have fallen by the wayside because the leadership that helped to grow them to the giants of commerce that they’ve become are no longer around and the company culture has changed considerably.

Some of these once great businesses stop innovating, stop implementing new technology, and stop looking for ways to improve their systems and infrastructure and instead elect to coast on their reputation.

That used to buy businesses quite a bit of time in the past – maybe even 15 or 20 years – but nothing could be further from the truth today. Today we live in the most competitive business environment in human history, and any slowdown whatsoever (or missing even a single opportunity at just the right time) may be the first and final nail in the coffin.

Here’s how to avoid that fate!

Establish teams that focus ENTIRELY on internal projects

There are a lot of big businesses out there that focus entirely on creating the “next big thing” that they are going to bring to market without paying any attention whatsoever to their own internal projects, their own internal processes, or their own the infrastructure.

This is usually what seals their fate.

What you’ll want to do instead is create entire teams that focus entirely and only on internal projects, processes, and infrastructure. These teams will help keep you moving forward while making sure that you will always gain competitive advantages when they become available.

Step away and gain altitude regularly

It’s impossible to know exactly how your business is doing and what you need to do to grow if you are always working on day to day operations.

You need to gain some perspective, pull out and gain some altitude, and step away from the actual mechanics of working IN your business to better understand how you should be working ON your business.

This is the kind of approach that should be taken once a year at the very least. Pull out your senior management, bring in outside consultants for a new perspective, and come up with new ways to create innovative solutions, improve efficiency, and boost results across the board.

It isn’t going to be effortless by any stretch of the imagination, but it is going to be able to provide you and your employees with a better sense of direction about how to move forward. These continuous improvements will continue to build a reservoir of leverage you’ll be able to pull from, and you’ll be able to dominate in the midst of the most competitive business environment humans have ever known.

It’s the only way to succeed today.