Process Safety Management, 29 CFR OSHA 1910.119/OSHA 1910.106, required Pressure Relief Devices (PRDs) on equipment in operating units to have adequate calculations. Many devices did not have complete or current calculations. Safety reviewed and calculated pressure relief requirements, complying with OSHA regulations, for 13 different process units. This accounted for approximately 600 devices on reactors, reactor jackets, heat exchangers and storage tanks. All process operating units were in full compliance with OSHA regulations following corrective actions
Completed information summaries and files for 867 Pressure Relief Devices. This work required field review, identification of installation issues with sketch. Completed PRD Calculations and Summaries on critical devices.
Explosion at plant required quick and accurate response to minimize potential for future explosions. Used CHEMCAD process simulations to design $1.5 million reactor and dust collection system modifications to minimize risk. No additional explosions have occurred. Performed audit on dust handling system. Identified combustible dust issues. Wrote detailed report defining remediation defined by NFPA ad manufacturing practices.
Designed a flash/condensate/recovery process and preliminary design on a Thermal Oxidizer for a Hazardous Air Pollutant emitted from both process units ($4-5 million). Reviewed and updated the pressure relief device files and calculations in process unit. Provided process design for cryogenic condensation of emissions. Designed segmented and balanced vent system for the tank farm
Production unit required operators to lift 75# bales of Diene Rubber. OSHA limits were potentially being exceeded and back injury was a serious concern. Designed Bale Unloading System to eliminate manual unloading of bales. Design included prototype robotic arm and control system to handle 4 different stacking arrangements. Potential back injuries were eliminated and one operator could provide coverage saving $150,000 per year.
Client desired to process a sticky polymer on existing equipment with minimum cost. Designed modifications to existing facilities to process the sticky polymer through blending, conveying, extruding, palletizing, and packaging. $250K project cost produced 10 million lbs./yr of product at $2 million profit.