Chemical Processing Distilled

Upsets are going to happen, so why not plan for it? Learn how. In this episode of Distilled, we discuss managing upsets and distinguishing between shutdown-related and non-shutdown upsets. Dave points out a lot has changed over the years. Indeed, the preference is shutting down during upsets and advancements like safety instrumented systems aid in automatic shutdowns. However, concerns about overr...

In today’s episode, Traci Purdum will be reading a column from contributing editor Dirk Willard. This column “Properly Vet Contractors” was published to chemicalprocessing.com October 19, 2021. Engineers once flew around the country to check out contractors’ facilities before signing deals. Nowadays, many bosses instead heavily rely on the Internet. Unfortunately, a nifty-looking web site can make...

A sobering look at the economy, PFAS regulations continue, blue-ringed octopus key to sustainable energy, and black-mass recycling. All news found here: https://www.chemicalprocessing.com/industrynews Read by Executive Editor Jonathan Katz. 

The discussion revolves around operator training efficiency in the industry. Despite decades of training, companies often lack feedback on its effectiveness. New technologies like simulators and virtual reality offer objective ways to measure and improve training. Identifying and addressing deficiencies is crucial, similar to the aviation industry's approach. Differentiating between console and fi...

Welcome to the In Case You Missed It edition of Chemical Processing’s Distilled Podcast -- This podcast and its transcript can be found at chemicalprocessing.com. I’m Traci Purdum, EIC of Chemical Processing. In Case You Missed It brings the written word to life. In today’s episode, I will be reading a column from contributing editor Dirk Willard. This column “Career Advice: Master Cold Calls” app...

Predicaments can crop up at all stages of a chemical engineering career. Properly dealing with them without serious consequences often isn’t easy or sometimes even possible. You may face ethical as well as technical and political challenges. So, let’s look at a variety of these and how to deal with them. This edition of In Case You Missed It is based on the original column by contributing editor D...

In this episode we focus on alarm rationalization mistakes, emphasizing the importance of addressing underlying problems rather than just managing the steady-state alarm rate. The discussion highlights the need for a clear operator action for each alarm, uniqueness in alarms, and the impact of alarm floods on human factors. The conversation explores challenges, such as changes in processing equipm...

In this episode of Chemical Processing's Distilled Podcast, host Traci Purdum and guest Dave Strobhar, founder of Beville Engineering, discuss the importance of font size in operator training. They highlight concerns related to small font sizes on computer monitors used in control rooms, particularly with the increasing resolution of displays. Strobhar mentions the military's Mill Standard 1472, s...

In the chemical industry, understanding the health of rotating equipment is crucial for safety and productivity. Regular inspections, compliance with regulations and proactive maintenance are vital for equipment reliability. Ares Panagoulias, the director of condition monitoring and test lab at Hydro Inc., emphasizes the importance of data in assessing equipment health. He advises using remote mon...

In this episode, Traci and Dave discuss the importance of reducing emergency procedures in chemical processing for better operator training and performance. They explore the benefits of streamlining procedures, emphasizing that about 90% of emergency steps are common across various situations. Dave advocates for simplified, condition-based procedures to enhance operator response during high-stress...

Helping operators learn from past incidents and use pattern recognition to make better decisions faster will improve safety and efficiency.

SICK AG's David Inward on Chemical Industry Emissions Monitoring 

In this podcast episode, Dave Strobhar discusses an innovative approach to calculating operator needs and the impact of automation on staffing in the process industry. He emphasizes the importance of assessing the consequences of tasks not being performed rather than just counting tasks. Special conditions and cross-training are also explored as factors influencing operator requirements.

Chemical Processing Notebook is a new column and associated podcast presenting talking points from various industry experts on a wide range of topics. This first CP Notebook column focuses on the impact PFAS regulations are having on the supply chain, from the upstream chemical producers to the downstream manufacturers using per- and polyfluoroalkyl substances (PFAS) in their products.

In this episode, we're tackling the misconceptions around alarm targets and operator workload. Dave Strobhar debunks the myth that hitting a specific alarm target means operators are maxed out. He emphasizes that these targets are tools to assess alarm systems, not workload indicators.

In the evolving world of chemical processing, companies face a formidable challenge as they strive to keep pace with ever-evolving industry demands, develop novel formulations and deliver innovative products to market. Meeting customer needs often requires adjustments to production processes, including new plants, facility expansions and equipment upgrades. The successful execution of such project...

The physical properties of hydrogen differ highly from other gases. Plant operators are therefore faced with major challenges due to the necessary adaptations that need to be made. To help us understand the challenges and options available, Chemical Processing spoke with Frank Flow, head of analyzer products and chemical industry at Flexim Americas Corporation.

In this podcast episode, Traci and Dave discuss a study that shows advanced process control (APC) can lead to a degradation of operator skills. The study found that after just a week of using APC, there was a 10% loss in skill level, and after two weeks, there was a 50% loss. The data suggests that operators should periodically run the plant without APC to maintain their skills. The Center for Ope...

Analytical equipment needs to be robust, reliable and responsive in order to detect change and enable corrective action. It also should be easy to use and provide high uptime. When considering process organics monitoring, there’s a lot to unpack. To help make sense of all the capabilities, Chemical Processing spoke with Amanda Tyndall, senior product manager at Veolia Water Technologies and Soluti...

Keeping workers safe in hazardous environments requires constant communication. Add to the equation that many locations are also harsh industrial settings means ensuring the right communication equipment is appropriately rated while providing the needed functionality is paramount. To better understand how to select the right equipment, Chemical Processing spoke with Ryan Brownlee, product manager...

In this final episode of our three-part cybersecurity series with Matt Malone, ICS/OT cybersecurity consultant at Yokogawa, we talk about team strategy and old notions.  

Malware programs or endpoint protection programs are great tools. But in the same way that if you're a king sending an army out to battle, you're not going to have your soldiers storming the battlefield in a helmet and their underwear.

Part one of a three-part series aimed at helping you develop a sound cybersecurity plan focuses on assessments and training.

In this episode, we're going to try and get our arms around understanding and addressing risks and how proper equipment and training are key for safe operation in hazardous areas. Joining me to share his expertise is Ryan Brownlee, Global Compliance and Technology Consultant with Pepperl+Fuchs. In that role, he provides guidance in regard to current and new technology and product compliance trends...

In this episode of Solution Spotlight Traci Purdum, executive editor of Chemical Processing, speaks with Floyd Baker, vice president of Antea, a global software and services company specializing in asset integrity management software with digital twin.  Floyd has been working in the asset integrity management industry for his entire career of over 40 years, with half of that time spent on the owne...