Automation In The Chemical Industry – Commissioning & Automation Services In India

Throughout the chemical industry, there is more global competition as well as more stringent environmental protection requirements. Throughout India, various chemical plants encounter an array of challenges – and automation can help to provide solutions.

Commissioning and automation services are capable of reducing the time to market, effectiveness and availability within the plant, as well as reducing plant costs. Every chemical plant across India needs to explore the various options that exist in terms of commissioning as well as taking advantage of automation services when and where possible.

Every plant wants to reach maximum performance – and automation can help to reduce risks and improve productivity. As such, both of these can translate to lower operational costs.

Entire processes can be automated, ranging from process control systems to weighing technology to batch requirements. Further, automation can be customized to the needs of an individual plant.

When commissioning takes place within the chemical industry, automation is often recommended in order to deal with technical problems that could or have arisen. It is easier to generate reports when there are organized control systems in place that are used to measure, weigh, and generally work with the chemicals that may be used throughout a plant, especially if they are toxic or hazardous in nature.

Many chemical plants throughout India have benefited from automation, and this is a trend that is sweeping around the globe. When modular system architecture is integrated into the plant, it is capable of optimizing processes and pre-defining an array of functions that take on engineering tasks.

Any plant that has worried about the commissioning process can explore automation as a way of passing the stringent environmental requirements. This is because there are various alarms that can be managed when issues arise and it eliminates a significant amount of human error that could otherwise take place.

No one wants to encounter problems, whether it has to do with system processes, costs, or productivity – and this is why automation is being integrated into an array of industries, and chemical plants are just one of the many.

While the cost to automate is not always within an operating budget, it is usually quick to show a profit and that is because of the costs that are saved throughout, due to enhanced productivity and a reduction in man-hours needed in order to complete the different functions throughout the chemical plant.

By taking advantage of commissioning and automation services in India, chemical plants are able to learn more about their options, even before they open their doors for the first time. Plants that have struggled in the past may also want to explore new ways to integrate automation for the commissioning process so that it is easier to pass requirements throughout the different regions of India.

Improved Energy Consumption Via Heat Integration & Pinch Analysis

A respected tool for achieving energy efficiency is process heat integration with pinch analysis. This article presents an overview on pinch analysis and its mode of employment in operation and process design to achieve energy efficiency gains in real-world. The Heat integration comprises of several techniques that assist engineers to properly evaluate entire sites and processes instead of focusing on individual operations.

This includes knowledge-based systems, hierarchical design methods, Pinch analysis, numerical and graphical techniques. Pinch methods dominate in the area of energy efficiency. The terms heat integration (PI) and pinch analysis are frequently used interchangeably.

Pinch analysis which is also known as process integration, energy integration, heat integration or pinch technology is employed in achieving minimal energy consumption by optimizing energy supply methods, process operation conditions and heat recovery systems. It is a methodology for minimizing the consumption of energy through chemical processes by targeting feasible energy targets thermodynamically.

As a systematic technique for analyzing the flow of heat through an industrial process, pinch analysis’ process data is represented as a set of streams or energy flows. Naturally, heat is required to flow from hot to cold objects in the Second Law of Thermodynamics. This is a major concept that represents the overall heat demand and heat release of a process as a function of temperature.

For the identifications of the Pinch and targets for cold and hot utilities, the Problem Table algorithm is the tool to use. It is a fundamental computational tool. The location where the heat recovery is the most constraint is designated by the Pinch which is characterized by ΔTmin (a minimum temperature difference between hot and cold streams).

As a result, the system can be divided into two separate subsystems that are located above and below the Pinch respectively. Hot utility is only required above the Pinch while cold utility is required below the Pinch. So far, the identified hot and cold utility consumption turns out to be Energy Requirements (MER). Once a heat transfer (cross-pinch) is present, no design can achieve MER.

Redundancy many be introduced by the separation of the original problem in the number of heat exchangers. In order to reduce the number of units, the removal of the Pinch constraint may be necessary especially when the capital cost is high. An optimized cost of operation against the reduction in capital costs will be cleared by extra energetic consumption.

As a result, heat recovery problem will become an optimization of both capital and energy costs which is restricted by a minimum approach in temperature when designing the heat exchangers. For effective heat integration, there is need for data extraction and stream selection in Pinch Analysis. Constant CP is the major computational assumption in Pinch Analysis.

Design Of Air Cooled Heat Exchangers – Utility Optimization Services In India

Air cooled heat exchangers, often abbreviated as ACHEs, and are commonly found throughout India. Refineries and chemical plants will often use these in place of water-cooled heat exchanges – and that is because it doesn’t involve any issues regarding water, where there is shortage of water as well as pollution.

The air cooled heat exchangers are commonly referred to as air coolers, which are different from devices that cool the air, referred to as air chillers.

The overall design of air cooled heat exchangers can vary, but it involves the tube bundle where there are multiple finned tubes that terminate into a header box. The fins are made of aluminum strips and spirally wound. The fins can take on various formations, being overlapped or single. Ultimately, they are designed to provide contact resistance, which can increase based upon the temperature due to differential expansion.

Throughout India, it is important to look at utility optimization services in order to offer cooling without having to depend upon water. The country is not known for having a large amount of water to begin with, and it cannot be used within cooling units because it could take away from drinking water. Additionally, the polluted waters are incapable of being used within the heat exchangers.

The design of these ACHEs are relatively straightforward. The core tubes can be made from stainless steel or various alloys. While carbon steel is used in some instances, it is not typically found in India simply because of cost.

Air moves over the tubes in a cross flow path using axial flow fans. The way in which the air moves can be arranged in order to create induced or forced draft. This depends on what the overall goal is. Forced to draft is most common and easier to maintain. Induced draft is used for even air distribution, but requires additional power because the fans are found within the hot air stream.

As such, in order to optimize the utilities throughout India, it is most common to see a forced draft arrangement on the air cooled heat exchangers. Further, the sound is not too loud, as the principal noise is found coming from the fans. Designs can be created to reduce the noise if necessary.

The average air cooled heat exchanger is a large piece of equipment in comparison to some of the other heat exchangers, though as long as there is sufficient space, it can provide free airflow and be used in a variety of different environments.

Ultimately, the choice of design is based upon the desired ambient temperature. When temperatures rise in India, many people are glad to have these exchangers – and since it requires no dependency on water, it’s that much more advantageous to incorporate these designs into refineries, chemical plants, and various other locations.

Fire pump design – A complete guide

When you embark on a fire pump design in India, one of the most important things to consider is your water supply. If you will use your city’s water supply as the main source for your pump, you’ll need to ensure that an accurate and thorough test of the city water is done. Some rules to follow include:

  • Make sure that your water test is no older than a year.
  • Make sure that the water test is done close to the tap as possible.
  • Ensure your test is done during the highest time of water usage in your area.

In cold climate areas like Jammu and Kashmir, Ultarakhand, Himachal Pradesh and Sikkim or anywhere around the Himalayan area, testing during summer will be most ideal as many residents and commercial properties will be watering their crops and using water to cool down. In addition, in high density areas, peak times for water usage in the morning are between 6 am and 9am, and this may be the most ideal time for testing.

Another point to consider with regard to your water test will be: Does the city supply sufficient water to meet 150% of your fire pump design? This ensures that the city supply will carry enough volume to meet system demand. If this however isn’t the case, request another test this time plotting a water supply curve or using hydrants.

If your water supply is from a private source such as a ground storage tank or lake, keep in mind that some jurisdictions don’t allow using suction lift with fire pumps. This then means, if your water supply is below the suction inlet to your fire pump, you’ll need to use a lone vertical turbine pump in preference to the different kinds of pumps available.

Your final job parameter to size your fire pump will be required water flow for the systems that the pump will serve (standpipes, sprinklers and or others). If you use standpipe systems, the flow will be related to size and type of structure the pump will be protecting. In whichever case, the system demand will dictate the flow and pressure required.

Avoid Problems

In your effort to avoid any troubles that may arise during your fire pump design and installation process, make sure you do some thorough research and consult with local authorities in your jurisdiction and insurance representatives before you embark.

Certain jurisdictions have different requirements for the design and installation of fire pumps. Regulations in Punjab Province may require suction control valves for all fire pumps to prevent falling below 20 psi within the main, and those in Delhi may be different. Insurance companies will also have their different requirements for installing fire pumps. Do your research, get the necessary paperwork to ensure a smooth process.

Deluge Suppression Systems

Deluge suppression systems are systems where all sprinklers that are connected to a water piping system remain open,i.e., the heat sensing element is removed or designed specifically that way. These systems are designed and used for special hazards where there’s a concern for rapid fire spread, as they offer a simultaneous water application over the entire hazard. At times they are installed in building openings or personnel egress paths to slow the travel of fire (e.g. openings in fire rated walls).

Water won’t be present in the piping till the system functions. Due to open sprinkler orifices, piping will be at atmospheric pressure. To stop supply pressure from forcing water into the piping, deluge suppression systems or deluge valve is then used in the supply connection.

Because of heat sensing elements in automatic sprinklers will have been removed, the deluge system should remain open as communicated by the fire alarm system. The kind of fire alarm instructing device is mostly selected based on the nature of the hazard like heat detectors, optical flame detectors or smoke detectors. The instructing device communicates with the fire alarm panel, which in turn instructs the deluge valve to open. Activation can be done manually as well, depending on the system objectives. Manual activation is normally done through a pneumatic or electric fire alarm pull station, which instructs the fire alarm panel, which in turn instructs the divulge valve to open therefore allowing water into the piping system. Water will simultaneously flow from all sprinklers.

Deluge fire sprinkler systems are different to standard fire sprinkler systems in that all nozzles being used in the system will be open and when water is allowed to enter the system, it flows from every discharge device. Because of this, such types of systems are mostly found in industrial type hazards across India as they require water application over a large hazard area. A deluge valve controls the water as it doesn’t allow water into the piping system until such a time when it is required.

A detection system incorporates the use of flame, heat or smoke detectors is used for opening the deluge valve in the event that fire or any of its combustion products are detected. Every system piping will be filled with water which will discharge from nozzles and sprinklers used in the system. To add to the application of water, certain deluge suppression systems incorporate foam concentrates to mix with water and create a form-like solution which then provides a protective foam blanket to control a fire.

Deluge suppression systems are widely used across different industrial sectors in India, but mostly by industries that specialize in chemicals, explosives, and petrochemicals and they are highly rated fire hazard zones.

Effluent Minimization Strategies for Waste Minimization and Cost Reduction

Waste minimization is essential for every industry that manufactures products and incurs cost. In India alone, there are a large number of manufacturers producing simple products such as plastic and this is often subject to the question of waste. It is known that the minimization of waste is the maximization of profit. The consumption of earth’s natural resources is seen as one of the major environmental problems we face in the world today and industrial waste and emissions can have drastic effects both financially and environmental. More so, issues such as global warming and ozone depletion are factors that emanate from local manufacturers. In India alone, the amount of emissions caused by manufacturers is alarming and businesses need to come up with new ways for waste minimization.

Waste minimization & Cost reduction strategies

Waste minimization has become one of the business regulations for businesses in India and thousands or manufacturers have been induced to employ waste reduction programs. However, very few people truly understand the cost that wastes can have on their own businesses or just how much it is costing the environment. It is therefore noted that waste reduction is a tool for creating a better world with more competitive industries.

When looking at waste minimization, there are three main proponents that can be drivers of this new world. These are: people, systems and technology.

  • People: Changing a notion or culture can only be implemented if it is first targeted at people. People influence systems and systems influence technology. People should be educated on waste minimization and cost reduction. They should be enlightened on the fact that the littlest raw material saved in production processes can have multiple uses and benefits and should therefore not be wasted. If the whole of India starts to see waste minimization differently, it may just have a greater effect globally.
  • Systems: Also, a systematic approach should be geared towards measurement and controlling problems that occur with eyes set on maintaining efficiency levels. Apart from the obvious benefits of waste minimization, there are also cost implications. Businesses should therefore put new systems in place to ensure that people are producing efficiently.
  • Technology: Lastly, technology could be a major driver of this new world system. Capital investment should be introduced to improve manufacturing productivity and reduce waste creation. Technology has a major deciding role on the world we live in today. Therefore, technology should be motivating waste minimization and helping reduce cost.

A number of companies have also developed strategies to ensure that there are reduced amounts of waste in manufacturing processes. This is because there is a greater enlightenment on the fact that raw materials can be used for several production processes with even by-products having relevance in the production of commodities. Companies are advised to perform studies of the true cost of waste and should create new strategies for the management of this problem.

Waste minimization and cost reduction should be at the forefront of thoughts for people and businesses in India. It would provide a greater and more efficient world we live in and also reduce the costs of doing business.

Pharmaceutical Industry Services In India

Today, the Indian Pharmaceutical Industry is on the verge of experiencing dramatic changes in its epidemiological, economic and demographical levels. However, these changes go beyond the scope of the industry but affect the production of world-class Indian medicines by influencing its manufacturing practices with regular updates and meeting up with regular standards.

While it is expected of every pharmaceutical manufacturer to accept new methods and best practices, they are required to adhere to these regulations right from the techniques involved with drugs discovery, then with manufacturing and packaging, and finally to the distribution of drugs to consumers.

As the pharmaceutical industry continues to expand, the Indian pharmaceutical industry has significantly undergone impressive changes in the last decade, like any other industry. By tradition, the Indian pharmaceutical industry is mainly focused on the sales of pharmaceutical products.

In terms of volume, the Indian pharmaceutical sector contributes to 10% of the global pharmaceutical industry while it accounts for about 1.4% in terms of value. Consolidation of the overall Indian Pharm market has always been the key industry feature. In the last decade, the market has been affected with a string of mergers and acquisitions of pharmaceutical industries thereby making it largely fragmented.

India continues to acquire great importance as the pharmaceutical industry expands globally. Although India is currently achieving giant strides in the pharmaceutical industry worldwide, as the world’s leading producer of generic drugs, it however, has a small market in terms of per capita consumption and western standards. It has got one of the world’s lowest per capita consumption of pharmaceuticals which currently stands at about $4.50 per person.

India’s domestic market is currently undergoing real transformation which reflects changes in India’s demographic profile and rising disposable incomes in urban areas. More emphasis is been put in place by leading drug companies aimed at meeting the incessant demand for high-value volume. The Indian pharmaceutical industry accounts for 12% of lifestyle drugs for wealthy urban customers. Drugs for lifestyle or chronic diseases make up this highly lucrative market segment.

The overwhelming increase in ailments like high cholesterol and hypertension has placed India on a high profile for its role in supplying acute drugs. India has often been referred to as the world’s diabetes capital due to its immense contribution to the fast growing demand to the global pharmaceutical market with drugs for lifestyle and chronic disease.

As India continue to blossom as a growing market for contract research and development, contract manufacturing and clinical trials, there is a growing reliance on exports from India by the largest pharmaceutical products. The current growth of the India’s pharmaceutical industry is fueled by the lifestyle segment which includes anti-depressants, cardiovascular, anti-ulcer, hypertension drugs, osteoarthritis, Alzheimer’s disease and cancer.

Automatic Sprinkler System Design Factors

Irrigation and water systems for a residence can prove to be an essential mechanical aspect of any garden or lawn. Designing a proper automatic sprinkler system for your home is something that should be done with great care and technical know-how. In India, there a number of companies that provide this service for homeowners or companies with areas that require watering.

Automatic Sprinkler System Design

Planning an efficient automatic sprinkler system for your property requires you to note a number of essential things. One needs to correctly understand the design capacity of the sprinkler system and just how much water is actually available for the sprinkler system to utilize. Often times, irrigation systems in India are done using the public water supply. A number of things should therefore be checked, these include:

  • Check the water pressure (PSI). Attaching a pressure gauge to the external faucet nearest to the water meter can do this. You should ensure that no other water in flowing within the house. Turn on the water supply and take a record of the number indicated.
  • Determine the water volume available for the sprinkler system
  • Also, using an appropriate system design capacity chart, locate your own sprinkler system design capacity and static pressure.

After checking these basic things, then you can proceed to installing your sprinkler system.

  • Do an appropriate plot plan by indicating and sketching the location of your house, taking note of all trees, lawns and fences around the house.
  • After determining the water pressure and volumes necessary, the next step is to select the sprinkler head. There are three main types and these include; rotors for large areas, rotating steam spray sprinklers and small area sprinklers.
  • After understanding the reach and capacity from choosing your sprinkler heads, you can design where you want to locate your sprinkler heads around your lawn. Sprinkler heads usually come with specifications on their reach so be sure not to place sprinklers far apart so that everywhere on your lawn can be watered. Sprinklers can also be divided into zones if the yard is quite large.
  • Properly ensure all points of connection are in proper correspondence with each of the specifications needed, including pipes and valves. Most professionals would recommend PVC pipes because of the constant water pressure from the backflow preventer to the zone control valves.
  • Run a proper system installation ensuring the wires for the main control are all connected.

Automatic sprinkler systems are quite technical to install and you should contact the help of an experienced professionals. Most homes in India have small watering areas so the workload may not be so much of an undertaking. For larger areas such as fields and parks, a proper technical team should be employed to properly take care of all the technicalities that may arise on the job. It may also not be a one-day job so patience is required in order to sort out all the small aspects to ensure your automatic sprinkler system is working perfectly.

Custom Simulations in India : Filtration and Separation Systems in India

Specially designed custom filtration and separation analysis provide critical support for improving engineering standards. The simulated field tests can establish insights into performance of filtration and separation processes thereby reducing physical testing and prototyping costs. Actual physical field test are often unreliable and cost prohibitive.

Virtual simulation has the advantage of enhancing the capabilities of the entire engineering project, from the critical dynamics for developers, engineers and operators. Optimization of these treatment systems is the goal of any custom filtration and separation simulation. There is diverse application in simulation capabilities in areas of filtration, separation and distillation.

Industrial solutions to evaluate the performance standards of filtration and separation devices allows your operator’s, developers and engineers to collaborate in the development of improved system dynamics. Our custom analysis allows for cost effective innovation on a large scale. Simulating real world conditions that impact the entire endeavor is vital to the success of the entire program. Our aim is to enhance your devices dependability through our in-depth and thorough studies.

This promotes a fluid flow of interaction form all design work to field specific working condition simulations. Physical tests are time consuming and expensive and often do not yield usable analysis. Spending thousands of hours and funds on testing that yields no usable data can be detrimental to the entire project. Modeling and simulation of the filtration process allows departments to see the flow of functional steps from a unique perspective.

The ability to find the effective filtration solution is critical for the development of reliable products and industry specific tools. It is hard to find a place or dynamic within the industries of our day that do not require that filtration play a basic role. The quality of drinking water, the efficiency of engines, the treatment of wastes and the quality of the air that we breathe all require and depend on filtration systems.

The business of filtration and separation is expanding across global industry driving fierce competition to develop reliable systems. We can carry out comprehensive mathematical studies to provide engineers with the proper tools to develop their ideas. Filtration and separation systems are intrinsically Multiscale, Multiphasic and Multiphysics processes.

Expanding the analysis process will provide the missing link for maximum productivity and portability. We can help your team tap into the virtual flow of your filtration and separation design needs. We will help align all process and systems for high levels of quality.

Approaches for the microscale or pore scale and macro scale or filter scale requires detailed investigation. Our simulation programs are scalable and customizable to suite your industry specific needs. We have developed Software tools over the last decade that will support your programs specific details. Finally, we are already helping multiple suppliers, developers, engineers and industries illustrate the potential for industry specific mathematics and analysis to solve practical particle flow problems.