sushil kumar mohapatra: Margaret, and
sushil kumar mohapatra: it used to be, but.
Shubham Chauhan: I grew up here.
Ketan Kevadiya: Studies. I think semantic.
Ketan Kevadiya: I didn't win.
Uttam: Good morning. All.
sushil kumar mohapatra: Morning, time.
Uttam: Is there any last minute change in this? Because I see only 3.
Uttam: Hope you are there.
Uttam: Dayton, Shubam and Sushil Kumar.
sushil kumar mohapatra: So this is the new clip
sushil kumar mohapatra: that has been shared on the group.
Uttam: Right? Right? Because I received
Uttam: from Uper University, New Link.
sushil kumar mohapatra: There's.
Uttam: Verse.
Uttam: but I think there may be some confusion because other people have not joined.
Uttam: Typically, we are.
sushil kumar mohapatra: The old one has been deleted, sir.
sushil kumar mohapatra: so nobody can learn that, only.
Uttam: Okay, okay?
Uttam: Or the timing. Wise 9 30 was converter. It was like initially 10 o'clock. Then.
sushil kumar mohapatra: No, sir, it was 9, 30.
Uttam: 9 30. Only.
Uttam: Okay.
Uttam: so what shall we do? I will check with once with
Uttam: university guys.
Uttam: Okay? So we then we'll start.
sushil kumar mohapatra: Lucas.
Uttam: Hello.
Uttam: so I just got update from
Uttam: Mithool that the lecture will be starting at 10 o'clock.
sushil kumar mohapatra: Okay, sir.
Uttam: So let us start at 10 o'clock.
sushil kumar mohapatra: Right? Okay, thank you.
Chetan Bhoyar: Money.
Chetan Bhoyar: Certainly. Go ahead.
Chetan Bhoyar: Is it more minimal
Chetan Bhoyar: pop.
Uttam: Good morning. We'll start at 10 o'clock.
Santosh Kumar Palo: Okay.
Santosh Kumar Palo: daughter.
Santosh Kumar Palo: yeah.
Santosh Kumar Palo: for people to move.
Santosh Kumar Palo: Hello, yes. Yes. Yes.
Santosh Kumar Palo: Good morning. All day. Okay, all day.
Santosh Kumar Palo: Kind of like another
Santosh Kumar Palo: single platforms, and another one, too.
Santosh Kumar Palo: I said, Paterno, this year
Santosh Kumar Palo: I'm a Purinauck. I appreciate what for? A good day,
Santosh Kumar Palo: hey? To go to Portugal tour there!
Santosh Kumar Palo: What is it
Santosh Kumar Palo: after husband? Or in.
Chetan Bhoyar: And hard work.
Dhanasekaran P: Hello!
Dhanasekaran P: So we're not actually
Dhanasekaran P: believe it.
Uttam: So we are good to start. Good morning, everybody.
udit jogidas: Or morning.
Chetan Bhoyar: But morning.
Uttam: Good morning. So this is the last pillar of the
Uttam: Rbps risk based process safety.
Uttam: And we are going to finish this today. This particular topic.
Uttam: Can you see my screen.
udit jogidas: Yes, sir.
Santosh Kumar Palo: Yes, sir.
Ravi Patel: Good yes, sir.
Uttam: So we have gone through
Uttam: 16 elements
Uttam: from the initial pillars, commit to process safety, understand hazards and risks manage risk.
Uttam: and then the final pillar is
Uttam: learn from experience, which has 4 elements.
Uttam: incident, investigation
Uttam: measurements and metrics, auditing
Uttam: management review and
Uttam: continuous improvement.
Uttam: So
Uttam: all these 20 elements are very important. And today we'll focus on the 4 elements from this particular pillar. Learn from experience.
Uttam: So
Uttam: incident investigation.
Uttam: Now, we have small incidents, big incidents, recordable incidents.
Uttam: non recordable incidents, and so on. We have some
Uttam: guideline, or if it is not there, we should have a guideline, and we will see in this particular
Uttam: these particular slides.
Uttam: Why it is so important to have a proper incident. Investigation
Uttam: assist. What is this? Is incident. Investigation is a systematic approach for determining the causes of an incident and developing recommendations that address the cause
Uttam: causes to help prevent or mitigate future incidents.
Uttam: So we don't want to repeat the incidents, otherwise
Uttam: it will be
Uttam: madness actually to if you get repeated incidents. And one day you can know very big process of incidents. So
Uttam: incident investigation is a process of reporting, tracking, and investigating incidents.
Uttam: So 1st thing is.
Uttam: all incidents should be reported
Uttam: and recorded.
Uttam: then tracking.
Uttam: unit-wise.
Uttam: shipped wise.
Uttam: and so on.
Uttam: How these incidents are happening in which particular processes or equipments
Uttam: the incidents are happening that is tracking
Uttam: and an investigating.
Uttam: This includes a formal process of investigating incidents, including stopping.
Uttam: So
Uttam: you have to have a
Uttam: In Incident Investigation
Uttam: Committee, small group
Uttam: who will.
Uttam: who will collect samples who will collect data
Uttam: and they will analyze
Uttam: the causes of the incident, and they will come up with recommendations. So this topping is very important, performing, documenting
Uttam: and tracking investigations of process safety incidents.
Uttam: Then you have to train the incidents
Uttam: and incident investigation data to identify recurring incidents. Whatever is happening repeatedly
Uttam: those kind of patients you can identify
Uttam: managing the resolution and documentation of recommendation generated by the investigations
Uttam: so resolutions. The recommendations
Uttam: should be implemented as soon as possible, or by the given timeline.
Uttam: and it should be documented as well.
Uttam: and we have to see similar processes within the company where this can be implemented. So if you have similar processes
Uttam: running at different sites
Uttam: at one side. You have an incident happening.
Uttam: and you have recommendations. Those recommendations should be implemented at all such manufacturing sites
Uttam: within the company.
Uttam: Now let us look at this case, study of ethylene oxide explosion.
Uttam: So this is
Uttam: from a medical
Uttam: industry.
Uttam: many medical devices industry.
Uttam: This happened in 2,004, and explosion inside
Uttam: occurred in an air pollution control device
Uttam: and the medical product sterilization chamber.
Uttam: So
Uttam: the materials are being initially
Uttam: whatever is used in the medical devices
Uttam: are sterilized before shipping
Uttam: to the hospitals and all doctors and all. So this sterilization
Uttam: is done using certain way, and in this case
Uttam: the incident injured 4 workers and severely damaged. The facility.
Uttam: Neighboring businesses were evacuated for several hours, and operation. At this particular facility with this
Uttam: disrupted for 9 months, you can see
Uttam: the level of description in this portal.
Uttam: Now you see
Uttam: the medical devices, maybe their machineries.
Uttam: There are loads
Uttam: injection wires, and so on.
Uttam: Syringes, catheters.
Uttam: whatever is used for the treatment of patient
Uttam: like this
Uttam: when it is manufactured. After that it is clean, and after that you have to stabilize this. So you have to remove all the pathogens, bacteria, or any microorganisms. You have to kill it before you can use it for treatment of the patient. So this is all related to
Uttam: machinery
Uttam: or stands.
Uttam: catheters, and so on.
Uttam: Now, what happened in this particular industry?
Uttam: They have done a process, hazard analysis, revalidation in 2,001. The written report of this evaluation of potential explosion scenarios fail to identify
Uttam: or address the recent history of sterilization industry with lean oxide
Uttam: explosions. Now, itlene oxide is used for stabilization of the medical devices.
Uttam: This is the most used. Gas!
Uttam: Recently, after this incident, people have proposed and come up with different solutions, like
Uttam: super critical Co, 2 carbon dioxide.
Uttam: nitrogen, dioxide
Uttam: hydrogen, peroxide vapors and combination of hydrogen, peroxide vapors and ozone. But
Uttam: for many devices.
Uttam: Italian oxide is the preferred gas for sterilization
Uttam: and explosion. So to control Italy oxide. You know that Italy oxide is very flammable gas.
Uttam: and it is also toxic and can cause cancer.
Uttam: So you have to remove thoroughly
Uttam: the traces of ethylene oxide from the
Uttam: medical devices after the staluration cycle is complete.
Uttam: and for that purpose
Uttam: they use. In this case.
Uttam: They removed by they recirculated the air and remove the traces of the ethanol oxide gas, and it was passed over hot
Uttam: metal wire frames.
Uttam: and it caused combustion of the
Uttam: traces. Traces of this itin oxide gas.
Uttam: so that patients are always safe. They don't have to go through the traces, and cancer can be avoided. Cancer like this one.
Uttam: So
Uttam: in 1997, an explosion
Uttam: was reported
Uttam: at a nearby facility that is Griffith Plant, that resulted in a specific recommendation for additional engineering controls.
Uttam: Now, this is no one.
Uttam: This particular site
Uttam: is doing the same business.
Uttam: and already one incident is reported, and the incident investigation resulted in a specific recommendation.
Uttam: So this was neglected.
Uttam: The company officials told Chemical Safety Board that these incidents were reviewed, but did not result in return action items.
Uttam: So
Uttam: you have to keep a track on. If you are in particular
Uttam: type of industry. You are manufacturing particular type of chemical, or you have a hazardous process, specific, hazardous process.
Uttam: You have many other companies industries who are doing the same.
Uttam: So in that case, any incident reported in such kind of industries, you have to track it, and you have to learn from those experiments. Otherwise the same incident can happen at your site also.
Uttam: So let us go through this
Uttam: case, study video
Uttam: and see what happened here
Uttam: on August 19, th 2,004, an explosion at the sterogenics. International facility in Ontario, California, injured 4 workers and caused extensive damage to the 66,000 square foot facility. The blast occurred when ethylene oxide gas used in the sterilization process ignited and exploded.
Uttam: The US. Chemical safety and Hazard Investigation Board investigated the accident.
Uttam: This was an incident involving a chemical that is both highly flammable and toxic to humans.
Uttam: It is fortunate that no one was in the immediate vicinity of the explosion, because it was likely there would have been more serious injuries and possibly fatalities.
Uttam: The Csb. Investigation reveals several factors that led to the explosion at sterogenics. This video digest is intended to graphically show what happened, and how such accidents may be prevented in the future.
Uttam: Sterogenics, international uses, ethylene oxide to sterilize medical products, such as syringes, catheters, and bandages, and then ships them to medical suppliers.
Uttam: Products arrive at the plant, pre-packaged and stacked on pallets ready to be sterilized in large steel chambers.
Uttam: The plant contains 8 sterilization chambers operated and monitored by personnel. Using a computer system in the control room.
Uttam: Packaged medical products are added to the chamber, and the doors are sealed.
Uttam: The chamber is then filled with ethylene oxide.
Uttam: which penetrates the packaging over a period of several hours.
Uttam: killing any germs and sterilizing the products inside.
Uttam: After the sterilization phase, ethylene oxide is removed from the chamber and the packaged products in several steps.
Uttam: 1st about half the gas is pumped from the chamber to a pollution control device called a scrubber, where it is removed by chemicals.
Uttam: Next, virtually all the remaining ethylene oxide is removed in a step called gas washing.
Uttam: This involves injecting air and nitrogen into the chamber where they mix with the ethylene oxide.
Uttam: This mixture is then pumped from the chamber to the scrubber.
Uttam: This process is critical to reducing the concentration of ethylene oxide to below explosive levels, and is repeated several times until there is only a trace amount of ethylene oxide remaining.
Uttam: This trace amount of gas is not explosive, but it is toxic
Uttam: and must be removed by ventilating the chamber before workers can enter.
Uttam: The front door is raised a few inches.
Uttam: which automatically opens a vent at the rear of the chamber.
Uttam: Air is drawn through the chamber
Uttam: to another pollution control device
Uttam: called a catalytic oxidizer.
Uttam: Once the air enters the catalytic oxidizer, it is heated as it passes over open flames.
Uttam: Any remaining traces of ethylene oxide are removed as the air passes over a metal catalyst.
Uttam: After the chamber has been ventilated for several minutes, operators can safely enter to remove the products
Uttam: during the sterilization process. Gas washes are key to removing ethylene oxide and preventing explosions.
Uttam: But on the day of the accident this critical step was bypassed.
Uttam: On August 19, th 2,004, the computer alerted operators to a possible error in the amount of ethylene oxide that had been injected into Chamber number 7
Uttam: operators in the control room instructed the computer to abort the.
Dhanasekaran P: Sterilization cycle and remove the gas.
Dhanasekaran P: The system automatically performed the normal series of gas washes which removed virtually all of the ethylene oxide.
Dhanasekaran P: Finally the Chamber was ventilated to the oxidizer
Dhanasekaran P: operators then remove the products from the chamber
Dhanasekaran P: maintenance. Technicians arrived and performed tests which did not reveal any problems.
Dhanasekaran P: They then ran a test cycle that injected 120 pounds of ethylene oxide into the empty chamber.
Dhanasekaran P: And again, they could not identify a problem
Dhanasekaran P: as the system performed the 1st step of pumping ethylene oxide to the scrubber.
Dhanasekaran P: The technicians ask the supervisor for permission to bypass the time-consuming gas washes.
Dhanasekaran P: The supervisor agreed.
Dhanasekaran P: All of them incorrectly believed that because there were no products in the Chamber to absorb ethylene oxide.
Dhanasekaran P: all the gas would be removed in the 1st step
Dhanasekaran P: making the gas washes unnecessary.
Dhanasekaran P: They did not realize that about half of the ethylene oxide, originally injected still remained in the chamber.
Dhanasekaran P: There was no monitoring system to alert them. To this explosive concentration of gas
Dhanasekaran P: the Supervisor provided a technician with his special computer password to manually advance the cycle bypassing the gas washes.
Dhanasekaran P: A short time later the front door was raised activating the Chamber ventilation system.
Dhanasekaran P: This drew a large amount of ethylene oxide from the chamber through the back vent to the open flames in the oxidizer.
Dhanasekaran P: The explosive gas ignited.
sushil kumar mohapatra: Flamefront traveled back through the ducting
sushil kumar mohapatra: into the sterilization chamber, igniting the remaining ethylene oxide and causing a powerful explosion.
sushil kumar mohapatra: It destroyed the sterilization chamber.
sushil kumar mohapatra: bulging the chamber walls outward.
sushil kumar mohapatra: blowing off both of the two-ton chamber doors, sending one of them 75 feet away. Knocking out this hole in the north wall.
sushil kumar mohapatra: The force of the blast caused widespread structural damage throughout the building.
sushil kumar mohapatra: The control room was showered with flying glass from the windows
sushil kumar mohapatra: debris, including the computers that control the process littered the inside of the room.
sushil kumar mohapatra: while the accident would seem to have been caused by a single event bypassing the gas washes. The Csb. Investigation actually revealed several causes for the explosion. The Supervisor, with the critical password, did not understand why the gas washes were essential, whether the Chamber was empty of products or not.
sushil kumar mohapatra: Next, the sterilization chamber was not equipped with a gas monitoring system to warn employees of explosive levels of ethylene oxide.
sushil kumar mohapatra: The Company's process. Hazard analysis program never thoroughly evaluated the hazard presented by the oxidizer.
sushil kumar mohapatra: Despite a history of oxidizer explosions in the sterilization industry.
sushil kumar mohapatra: the Csb investigation noted that the control room had glass windows that were not shatter resistant. The control room suffered significant damage in the explosion, and all the injuries occurred to workers inside the room.
sushil kumar mohapatra: If your control facility is located in an area where an explosion could occur, consider using reinforced window materials or replacing any windows with video cameras. Another lesson from this incident is the importance of regular training.
sushil kumar mohapatra: Maintenance. Technicians had last been trained about the need for the gas washes in 1997, 7 years before the incident, the Maintenance Supervisor, who was authorized to use a password to skip the gas washes, was hired after 1,997, and never received the training.
sushil kumar mohapatra: So a very important lesson is, be sure, personnel are fully trained on process hazards before authorizing them to override automatic systems. The Csb. Made several recommendations to the company government agencies and others.
sushil kumar mohapatra: Oxidizers are commonly used for reducing air pollution.
sushil kumar mohapatra: However, they have been the source of numerous explosions.
sushil kumar mohapatra: Our recommendations are aimed at reducing this hazard.
sushil kumar mohapatra: Inside an oxidizer. Fuel air and an ignition source are all present.
sushil kumar mohapatra: There is a serious risk. If the fuel air mixture is too concentrated.
sushil kumar mohapatra: facilities with oxidizers should use multiple layers of protection.
sushil kumar mohapatra: such as gas monitors, safety interlocks and alarms
sushil kumar mohapatra: to prevent a single mistake from leading to an explosion.
sushil kumar mohapatra: The Csb. Recommended that the National Fire Protection Association, which creates fire codes used around the country require additional safeguards to prevent explosions at ethylene oxide.
Mitul Parikh: Facility.
Mitul Parikh: Specifically they recommended. The codes require the use of gas concentration, monitoring equipment, alarms and explosion damage control devices.
Mitul Parikh: We also recommended that sterogenics install similar safety devices and improve its employee training and hazard analysis programs. Finally, we recommended that the National Institute for Occupational Safety and health or niosh work with the ethylene oxide industry to promote the use of gas monitoring and other safety measures.
Mitul Parikh: Csb. Recommendations are aimed at preventing accidents.
Mitul Parikh: If followed, we believe these recommendations will go a long way towards developing safer workplaces. To read the full report on the Csb's investigation.
Uttam: So in this case, process hazard analysis, revalidation narrowly address the potential for an explosion, but did not comprehensively
Uttam: evaluate the need for additional injuring controls, or apply lessons learned from past incidents in the sterilization industry
Uttam: and at its own facilities.
Uttam: Now, if I have to ask you what is the reason for this particular incident.
Uttam: Can anybody let me know what is the reason?
Uttam: What is the cause of the incident?
sushil kumar mohapatra: accident. Investigations were not in written document, and introductions has not been implemented.
Uttam: Right.
Uttam: That is one of the cause.
Uttam: Alright.
Uttam: So
Uttam: in this case, if you have to add additional injuring controls.
Uttam: what you will add
Uttam: if you have to recommend
Uttam: any additional safeguards.
Uttam: See! The gas
Uttam: was burnt, the traces of the gas was burnt
Uttam: on a hot oxidizer plate.
Uttam: and the when there was a
Uttam: more concentration of the gas ethylene oxide. The plane traveled back to the chamber
Uttam: so as a engineering control or some kind of a control, we can add
Uttam: in line playmaster, right?
sushil kumar mohapatra: Yes, josh.
Uttam: So that no, this the flame will not travel back to the chamber.
Uttam: Apart from that, of course. They are going to. After this incident and the report, they will be monitoring the clean oxide concentration, and so on. But you, even after that also, we have to have such kind of flame arrestors.
Uttam: so that in any case the plane should not travel back to the Chamber.
Uttam: Now there are 2 types of incident incident investigations, apparent cause analysis, Aca and root cause analysis. Rca.
Uttam: 1st of all, we should understand that incident. Investigation
Uttam: is not a process to assign blame. Typically, what happens if you see all the incident reports
Uttam: they will be
Uttam: blaming some kind of a human error
Uttam: employee error, and so on. Machine error.
Uttam: Write.
Uttam: Recently a big explosion happened in Dumbboli.
Uttam: 1st report is saying that
Uttam: boiler explosion. Second report is saying that a reactor explosion.
Uttam: But how it happened, what was the reaction
Uttam: is not published.
Uttam: not known.
Uttam: So
Uttam: that's why other industries will not learn from this. Although many people died in that Dombo incident, I think a week ago.
Uttam: no information is available.
Uttam: they decided to shift
Uttam: the entire industry industrial area to somewhere else from Domboli, because it is highly
Uttam: residential area. Now.
Uttam: root cause analysis is not done here.
Uttam: Write.
Uttam: so we have to keep in mind incident.
Uttam: Investigation is not a process to assign blame
Uttam: to
Uttam: people, to employees, to
Uttam: operators, to machines.
Uttam: and so on. Incident investigation is a way of learning from incidents that
Uttam: occur over the life of a facility, and communicating the lessons learned to both internal personnel and other stakeholders.
Uttam: Some companies
Uttam: do not investigate unsafe behaviors and operational discipline issues
Uttam: and near misses, and only trained such incidents
Uttam: only trends means
Uttam: they just keep the number. Some record that this incident happened.
Uttam: but there is no investigation.
Uttam: So what will be the outcome of this if you continue
Uttam: to just record the incidents.
Uttam: small fires, injuries, and all these near Miss
Uttam: ruptured. This failed, and so on.
Uttam: You are not understanding why this happens, and you are not overcoming the causes of this, so in future a big incident can take place.
Uttam: So this is.
Uttam: then there is a apparent cause analysis, a less formal investigation method that focuses on the immediate causes of a specific incident.
Uttam: So whatever case study we have seen.
Uttam: the immediate cause is what
Uttam: illuminated
Uttam: that the person.
Uttam: provided the password
Uttam: to overcome the interlock, so that the next process step can be taken. A. In this case they were supposed to have gas dilution several times by using air and nitrogen mixture.
Uttam: But they didn't perform this.
Uttam: So the
Uttam: this is the apparent cause.
Uttam: Write.
Uttam: then, root cause analysis, a formal investigation method that attempts
Uttam: to identify and address the management system failures that led to an incident.
Uttam: These root causes often are the causes or potential causes or other seemingly unrelated incidents identifies
Uttam: the underlying reasons. The event was allowed to occur, so that workable corrective actions can be implemented to help prevent recurrence of this of the event. So the in the case study
Uttam: of medical devices, sterilization.
Uttam: the root causes are
Uttam: training was not given. There was a person who hired after the training, and he never received the training
Uttam: right? This is one there was no
Uttam: itin oxide gas detector or gas concentration was not measured
Uttam: in the
Uttam: chamber.
Uttam: If they are saying that they have to.
Uttam: Bring down that
Uttam: concentration below certain level, there should be a device to measure it
Uttam: otherwise, how we can guarantee that
Uttam: now the
Uttam: concentration is below the required level, and then they can go ahead with the trace removal
Uttam: of this Italian oxide.
Uttam: So that was another issue
Uttam: right, there are not insufficient safeguards.
Uttam: So all these are the root causes.
Uttam: wrong practices of sharing
Uttam: password
Uttam: that is unauthorized
Uttam: and not
Uttam: following the procedure given procedure. These are all the root causes
Uttam: part of root for this.
Uttam: Now, you see, there are levels of analysis.
Uttam: You have a trained only, or you have parent cause analysis which is covering only human errors and equipment failures and task control issues.
Uttam: And then, if you extend this
Uttam: to the all the root causes.
Uttam: then you have
Uttam: root cause analysis. Rca, which look into process control issues, management system issues and organizational culture issues.
Uttam: So this is a time consuming. It takes more time, but it is worthwhile, because
Uttam: when you identify root causes, you can overcome those, and you, your process then becomes more safe
Uttam: by
Uttam: implementing the required safeguards
Uttam: and admin administrative controls.
Uttam: Now here is a incident investigation, Flowchart.
Uttam: So you have to have a incident investigation management system
Uttam: training up personnel involved in investigation element process. So you have to give training
Uttam: to the people who? who do the incident investigation. So that can be a committee of
Uttam: people from employees from process safety from Ehs department, from Plant Operations Department.
Uttam: your maintenance department, and so on.
Uttam: And they have to collect evidences.
Uttam: They have to take samples and analyze, and so on.
Uttam: They have to take photographs.
Uttam: do interviews, and so on, and then understand how
Uttam: the incident happened and what are the root causes? So this training is required.
Uttam: There are different methods
Uttam: of incident investigation. So people have to be trained in those methods.
Uttam: When incident occurs.
Uttam: incident data is entered into a database. So you have to maintain a database of all the incidents over the life cycle of the company
Uttam: and periodic. You should do a periodic analysis of database for clonic incidents, the incidents which are, you see, seemingly repeat, getting repeated. We are to do the analysis, maybe yearly.
Uttam: because incidents in a year. Reportable incidents, incidents.
Uttam: You will have different classes of incidents
Uttam: near Mrs.
Uttam: And your operational behavior issues will be more. Your misses will be less
Uttam: small. Fires will be further, less, and process September should be much more less
Uttam: so. Depending upon that, you can fix a period.
Uttam: and you have to evaluate periodically this.
Uttam: maybe once in a year, once in 6 months, and so on.
Uttam: Then.
Uttam: when an incident occurs
Uttam: as per the policy.
Uttam: apparent cause, analysis, root, cause, analysis, are trained only
Uttam: can be done. If it is only trained. Only
Uttam: then it stops there.
Uttam: If you are going to do apparent call analysis or
Uttam: root cause analysis team is activated.
Uttam: The team also
Uttam: reviews the earlier incident reports
Uttam: which help them
Uttam: for us identify or looking at similar incidents.
Uttam: The team gathers document and
Uttam: preserve the evidences.
Uttam: analyze
Uttam: evidence
Uttam: and identify root causes.
Uttam: develop recommendations and
Uttam: restart criteria. Restart criteria is now you have to again start the operations, because this is your continuous business.
Uttam: So the incident happens. Then you
Uttam: clean everything and you are facility. You keep ready. Some of the damage equipments are replaced, and now you are ready to restart the process manufacturing process. So what is the criteria for that? That is a restart criteria.
Uttam: Prepare incident, investigation, report
Uttam: implement recommendations, and ensure. Follow up.
Uttam: then share lessons learned within the facility to the management, to the affected employees
Uttam: who are going to restart the process
Uttam: critic and continuously improve the incident element. Again, you have to have metrics
Uttam: for this.
Uttam: Yeah, instead of investigation element.
Uttam: And you have to audit this management program as well.
Uttam: Now, what are the key principles of incident investigation maintain a dependable incident reporting, and
Uttam: in so investigation practice
Uttam: the issue with
Uttam: incident reporting is, nobody want to convey the bad news.
Uttam: Write.
Uttam: If it is the good news
Uttam: that you are improve, or you have manufactured
Uttam: the required amount in less
Uttam: time period
Uttam: it will be conveyed to everybody.
Uttam: But if the incident happens.
Uttam: there is a process delay
Uttam: that information is not willingly shared.
Uttam: So we have to have dependable incident reporting and investigation practice
Uttam: identify potential incidents for investigation
Uttam: use appropriate techniques to investigate incidents. We look into this
Uttam: further
Uttam: document, incident investigation results follow through and on results
Uttam: of investigation and train data to identify repeat incidents that warrant more investigation.
Uttam: So we have to implement the program consistently across the company.
Uttam: establish and implement written procedures to report on collect data related to investigate and
Uttam: learn from incidents.
Uttam: You have to have formal procedure format for reporting format for collecting data.
Uttam: procedures for collecting data.
Uttam: and so on
Uttam: provide a champion and coordinator for program to support investigation team.
Uttam: You have to have an internal champion.
Uttam: and of course you can invite external
Uttam: experts to investigate. But then
Uttam: it is good to have an internal champion and coordinator for the incident investigation element
Uttam: define an appropriate scope
Uttam: for the incident investigation element.
Uttam: So in this case
Uttam: defined technical scope
Uttam: by specifying the risk and consequence threshold that triggers different levels of investigation, such as detail, investigation, like root cause analysis, or a lower level investigation.
Uttam: like apparent cause analysis or trending.
Uttam: so based on
Uttam: the risk and consequence thresholds.
Uttam: So we have seen this earlier.
Uttam: The amount of
Uttam: loss
Uttam: based on that. You can have different thresholds.
Uttam: and based on that, you can decide whether it is trending
Uttam: you should do trending, or Aca or Rca.
Uttam: The thresholds are based on
Uttam: injuries, number of injuries and fatalities.
Uttam: In the other cases the plant damage, machinery, damage, environmental damage
Uttam: and business damage.
Uttam: communicate the technical scope of the incident element by providing facility specific examples.
Uttam: So in your guideline.
Uttam: you should explain how to
Uttam: define the technical scope.
Uttam: identify facility, specific examples of near miss incidents and train workers to appropriately report near misses
Uttam: involve component personnel. That is very much important, because the root cause analysis requires a greater level of expertise in the analysis techniques
Uttam: provide Rca and forensic training. Forensic training is
Uttam: again
Uttam: related to collecting the evidences
Uttam: to incident investigation leaders focusing on skills
Uttam: needed to lead investigation team and use of Rca techniques
Uttam: provide awareness, training and repressure training on incident element processes to all employees and contractors focusing on appropriate reporting of incidents, including near misses.
Uttam: Then monitor incident investigation practices for effectiveness.
Uttam: Establish a formal investigation review process for teams to use the
Uttam: con to use at the conclusion of each investigation.
Uttam: establish and collect incident, investigation, performance, metrics and performance management reviews of the incident investigation process.
Uttam: If anybody is doing it properly
Uttam: or need to improve all that will come under this
Uttam: monitor. All sources of potential incidents
Uttam: so perform active assessment of data, such as logs.
Uttam: data trends
Uttam: and emergency response actuations that could identify near misses and incident precursors.
Uttam: If you are
Uttam: reaction.
Uttam: or any process.
Uttam: you have a data over a period of years.
Uttam: you can identify that. And
Uttam: okay, at what conditions
Uttam: there will be deviation which can lead to runaway
Uttam: or an incident. So that is what Paula.
Uttam: data analysis using data trends
Uttam: ensure that all incidents are reported.
Uttam: So the barriers for reporting incidents is.
Uttam: people don't want to
Uttam: show to the management that there is a issue.
Uttam: And that's why
Uttam: that mindset
Uttam: people will not report the all the incidents. Only if it is sufficiently big enough they will report, otherwise they will not report.
Uttam: because that shows that
Uttam: where the incident happened, that particular unit, those particular employees operators
Uttam: where
Uttam: not following certain things.
Uttam: or they, they have made a mistake somewhere. That's why reporting is typically awarded. In this cases.
Uttam: Periodic surveys of personnel are performed to assess
Uttam: near miss reporting effectiveness.
Uttam: Trained graphs and statistics are developed showing the number and type of incidents reported
Uttam: fire, for example, gas release, toxic release.
Uttam: loss up.
Uttam: primary content.
Uttam: sleeps
Uttam: false, and so on. So these are
Uttam: types of incidents. Level one level 2, level 3. What we have seen earlier
Uttam: initiate investigation
Uttam: promptly.
Uttam: Why? It is important. Because
Uttam: if you want to do root cause analysis.
Uttam: you have to
Uttam: collect lot of information from the incident site.
Uttam: You have to collect samples. Yeah.
Uttam: the incident. What happened is, no, there will be eyewitnesses. So it is fresh in their mind what happened. You are to interview those people immediately.
Uttam: so that you get
Uttam: more reliable information about the incident.
Uttam: The time difference between the incident and the beginning of the investigation is formally tracked to identify potential investigation initiation causes.
Uttam: So if there is a long time gap
Uttam: some of these
Uttam: proofs of the incident. Why, why it happened?
Uttam: No, those will be vanished
Uttam: in the cleaning.
Uttam: firefighting, and so on.
Uttam: So that's why, immediately, as soon as possible. Investigation
Uttam: should be started, at least video
Uttam: shooting photographs
Uttam: and so on.
Uttam: so that critical information is not lost.
Uttam: kits containing the basic tools and equipment that the investigation team will need are assembled.
Uttam: establish time limits for notifying the appropriate personnel of the incidents.
Uttam: Now let us look at what data
Uttam: is required during the investigation.
Uttam: So you see.
Uttam: there is a book for guidelines for investigating chemical process incidents.
Uttam: and in that there is a checklist given.
Uttam: So
Uttam: data to be collected.
Uttam: Enter NRO. This is, enter the letter N. If needed.
Uttam: enter the letter O, if obtained
Uttam: like material separated data, sheets.
Uttam: material balance, corrogen data site maps, and so on. Interlock drawings, instrument loop diagrams, ladder logic drawings, control system management of change records.
Uttam: prior prior incident investigation reports, training manuals and records.
Uttam: meteorological records, dispersion calculations and so on.
Uttam: Then you out
Uttam: where I started. Okay, the initial data. Sorry.
Uttam: This one is.
Uttam: People data on shipped operators, offshit operators, maintenance personnel assigned to the area process engineers.
Uttam: operations, management, maintenance, management, chemistry and other laboratory personnel, warehouse personnel. So these are all related to people who are present at the site
Uttam: and from different departments.
Uttam: Then you have physical data tanks, walls.
Uttam: pressure, boundary equipment, such as gas case and flanges, samples from relevant vessels and piping raw material samples, quality control samples.
Uttam: residuals are wasted, generated
Uttam: new chemicals, present
Uttam: portable and temporary equipment, undamaged areas and the equipment
Uttam: relief system devices, including rupture, disc metallur, meta, logical samples and so on. Explosion fragments, data record sensors, process controls.
Uttam: electrical switch gear and so on. Then electrical data, volatile control instrument records
Uttam: distribute to you control system Dcs perform complete system backup of the data Plc, setpoints and security camera taps
Uttam: and then position data
Uttam: as pound position for every wall related to the event as pound position for controls and switches.
Uttam: position, approval, relief devices, tank levels.
Uttam: pointer needle positions from locally mounted temperatures, pressures and flow devices.
Uttam: location of flame and scorch marks.
Uttam: position and sequence of layers of materials and debris, and so on.
Uttam: So you see smoke traces.
Uttam: locations of witnesses.
Uttam: So all this
Uttam: paper data
Uttam: process, data records, operating procedures, checklist manual shift logs.
Uttam: repair records. And all these
Uttam: run histories.
Uttam: equipment drawings and specification sheets
Uttam: save operating limits.
Uttam: lot of data to be collected for the inside investigation.
Uttam: So this is what
Uttam: the in a investigation team should be well trained in collecting this kind of data.
Uttam: and this should be part of your
Uttam: guideline
Uttam: interface with emergency management element develop a formal interface between emergency element and the incident element to ensure protecting incident site evidences.
Uttam: So when emergency rescue or emergency procedures are being followed, firefighting, or whatever those
Uttam: the they should be also trained to collect evidences and they should
Uttam: trained to protect the incident site evidences.
Uttam: use effective data
Uttam: collection methods.
Uttam: interviewing techniques.
Uttam: formal test plans
Uttam: for physical data analysis.
Uttam: use consider methods to preserve data
Uttam: provide. So that is documentation and electronic saving of the data.
Uttam: provide data collection, guide guidance and methods for performing instant investigation, to facilitate rigorous analysis of the data collected.
Uttam: then investigate causes to an appropriate depth based on the earlier criteria
Uttam: from the guideline.
Uttam: Whether it is only A/C or we have to go to root cause analysis that should be decided, and that kind of a in depth analysis should be performed. A checklist is used to for each analysis to assess the investigation against the established
Uttam: depth of analysis criteria. So how you, somebody, will decide
Uttam: whether we we should do only Aca or we should go ahead with the Rcso. There should be checklist to arrive at that that particular decision.
Uttam: so that it is easy
Uttam: for the team to decide.
Uttam: demand technical rigor in the investigation process ensure that the investigation team approaches the investigation with an open mind and consider all evidences.
Uttam: All investigation reports are required to specifically document credible causes that
Uttam: we are not investigated
Uttam: and data that do not support or review the team's findings and conclusions.
Uttam: This is very important.
Uttam: So the investigation reports are required to specifically document
Uttam: credible causes that were not investigated because of certain reasons.
Uttam: proofs were not available.
Uttam: sufficient information was not available. So there are. There are other credible causes which can cause the incident, but
Uttam: that that, were those were not investigated, so that should be part of the report
Uttam: and data that do not support
Uttam: or review the team's findings and conclusion.
Uttam: So then there will be some logical conclusion
Uttam: and findings in the report.
Uttam: And there are data sets which do not support that findings and conclusion that also should be part of the report.
Uttam: provide investigation personnel with appropriate expertise and tools.
Uttam: so that turning should be given and
Uttam: then
Uttam: develop effective recommendations.
Uttam: Now let us look at the methods.
Uttam: So there are different methods.
Uttam: You may be aware, with all these.
Uttam: One of this is for you wise method. So you ask question, why? Why? Why? 5 times.
Uttam: and from this
Uttam: whoever proposed this.
Uttam: that asking for you times Y is
Uttam: sufficient to our to arrive at the root cause.
Uttam: So you start with the incident, ask why.
Uttam: get an answer.
Uttam: and you have to have countermeasure for that.
Uttam: Then again, to the answer, you ask why?
Uttam: And you repeat this, and let us see this
Uttam: example. So here is
Uttam: oil on the floor
Uttam: because of certain leak and all. So the question is, why is there oil on the floor? The answer is, oil leaks from the cylinder rod when activated
Uttam: counterimger is put absorbing clay on the spill and then remove.
Uttam: Now this particular answer, you have to again ask.
Uttam: why did oil leak?
Uttam: So? Answer is, the oring was cut.
Uttam: the counter imageries replace the oring find, and use better orings.
Uttam: Now, again, the question is, why oring
Uttam: got cut?
Uttam: Because the rod was flawed.
Uttam: Avoid dirt entry in the oil tank
Uttam: right then why was the rod plot dirt in the oil
Uttam: abrids the rod?
Uttam: So there was a cut developed on the
Uttam: rod cuts because of the dirt.
Uttam: and that's why
Uttam: the oil ring got the oil ring got cut.
Uttam: so cover the holes and gaps
Uttam: in the upper plate of the tank.
Uttam: Okay? Top dish.
Uttam: Then why dirt? Why did dirt get in the oil? There are holes
Uttam: and gaps
Uttam: on the upper plate of the tank
Uttam: check periodically the upper plate for holes and gaps and correct it. So this is what is a
Uttam: typical example to illustrate 5 y. Method.
Uttam: Then there is a bow tie method.
Uttam: the bow time method.
Uttam: It looks like a bow tie. So you have at the center
Uttam: the tie, and then the bow shape.
Uttam: At one side. We have hazards and initiating events
Uttam: and prevent you barriers
Uttam: on the other side of the bow tie. We have consequences, impacts, and mitigative barriers. So this is a typical shape of a bow tie.
Uttam: and in between we have a loss of contentment. The incident.
Uttam: So now you have this barriers
Uttam: which can fail.
Uttam: which can be missing
Uttam: unreliable, inadequate, and effective barriers. So let us see, a failed barrier is a correctly implemented at some point.
Uttam: and then, for whatever reason stops performing its function.
Uttam: so that safeguard
Uttam: was initially identified as a good safeguard.
Uttam: But after a certain time, because of, say, there is no maintenance or something, for whatever reason it stops performing its function.
Uttam: then missing barrier is a
Uttam: barrier which is missing it, if it is never been fully implemented.
Uttam: So on record. It is there, on, on paper, it is there, but in reality it is
Uttam: not implemented.
Uttam: Unreliable barrier barrier is the barrier functions as planned.
Uttam: and instead does not escalate further, and there is evidence that it might not function
Uttam: in the future without corrective action.
Uttam: So
Uttam: you have to monitor it. For example.
Uttam: if you are using a
Uttam: combination of shifted lip wall and rupture disc.
Uttam: Okay, if the rupture disk
Uttam: has developed a
Uttam: crack
Uttam: and it is not monitored.
Uttam: And this typically is used where you have corrosive environment, the corrosive gases, weapons will
Uttam: enter into the above area, and this can cause corrosion in the pressure leaf wall or the safety leaf wall, and then it may not
Uttam: per pump properly.
Uttam: So that is the unreliable barrier I'm just. I have just given one example.
Uttam: it will perform 1st as required, but then afterwards, for if the incent is repeated, it it will not perform. There is no guarantee.
Uttam: Inadequate barrier is a barrier that works according to its specification.
Uttam: but do not stop the incident from progressing
Uttam: and effective barrier is always works as per plan
Uttam: and incident does not escalate further, and there is a high confidence that it will continue to do so, even if the incident repeats.
Uttam: the effective barrier will protect it from going to loss of contentment.
Uttam: Now
Uttam: here is the example.
Uttam: So here what we are showing you accumulated performance over time for high level trip system performance across a plan. So you have
Uttam: tanks. You have solvent tanks, for example, storage tanks
Uttam: in different units, and you have high level trip.
Uttam: Maybe
Uttam: you have purchased these from different suppliers. Vendors, or maybe these are of different types, models makes.
Uttam: So here is a data showing that overall
Uttam: the
Uttam: overfill of storage tank. This particular
Uttam: overfill happened
Uttam: 13 times.
Uttam: There were 8 threads near misses, and
Uttam: for you events.
Uttam: Now, if you look at the barriers of different makes and suppliers
Uttam: and different types of BA models of barriers of high level drip system.
Uttam: there are 3 failed.
Uttam: one missing.
Uttam: 2 unreliable, one adequate, and if it effective.
Uttam: so based on this monitoring, you can replace all other
Uttam: by the effective ones which you have identified.
Uttam: Right?
Uttam: So this is what
Uttam: the incentive, you know, although you can keep on monitoring
Uttam: for a particular type of protection.
Uttam: The other method is a call tree analysis.
Uttam: So poultry analysis is a logical diagram, as you see here.
Uttam: and then it is connected with
Uttam: logical process.
Uttam: process like R, and and so you have calls. One cost 3 and Cos 4. One of this
Uttam: happens, then it will go to next causes.
Uttam: and then all of these are present. In this case it will go to incident.
Uttam: so falter is the logic diagram based on the principle of multi causal causality means there are multiple causes
Uttam: for an incident to happen
Uttam: which traces all branches of event that could contribute to an incident or failure. It uses sets of symbols, labels, and identifiers. In many cases there are multiple causes for an incident
Uttam: or accident, and or other loss, making events. Poultry analysis is one analytical technique for tracing the events which could contribute.
Uttam: So you identify all causes
Uttam: which can cause the incident.
Uttam: For example, if you have a
Uttam: fire incident. The simple, faulty analysis is that you have certain
Uttam: initial. No fuel related to fuel related to air or oxygen supply, and a related ignition source, different reasons.
Uttam: So which fuel types are available
Uttam: from where the air or oxygen will be provided, and from where the ignition source will be provided there are different ignition sources. Anyone is available, and then you have to have all these 3 present to have a fire.
Uttam: fuel, oxygen, and ignition.
Uttam: For example.
Uttam: here is a F for fire and explosion accident in oil tankers. So this 1st part is
Uttam: fuel, and this part is ignition.
Uttam: So you see that
Uttam: it starts from cargo, residue, cargo, leakage.
Uttam: combustible gas accumulation, combustible gas leakage.
Uttam: Any of these thing can come, and then you have combustible liquid material, combustible gas material.
Uttam: So actually, you have to go from top here so primable material source
Uttam: where it can come from either
Uttam: transported cargo or ship fuel.
Uttam: Write.
Uttam: The transported cargo
Uttam: actually is storing the
Uttam: combustible liquid and gases, and the ship fuel is used.
Uttam: Tour
Uttam: drive the ship from one location to other location. Right.
Uttam: So in the ship wheel you have use up
Uttam: inappropriate fuel or use of appropriate fuel from anywhere
Uttam: the ship will can, and the source can
Uttam: be used as a flammable material source in terms of
Uttam: transported cargo. Then you have combustible gas model or combustible liquid material. Now.
Uttam: if you look at the fire causing factors.
Uttam: Now here it is assumed that oxygen is available when the loss of contentment happens
Uttam: so.
Uttam: and fire causing factors, you have cargo factors.
Uttam: Your hard work
Uttam: which may be certain repair work which is which may be required
Uttam: during the shipment
Uttam: and use of
Uttam: inappropriate equipment now under cargo.
Uttam: This can be because of the tank cleaning, or because of the static electricity.
Uttam: And for inappropriate equipment, you can have actually inappropriate equipment, spark and fire coming from these activities. So this is what is a poultry analysis, part
Uttam: fire and explosion
Uttam: in oil tankers.
Uttam: So I hope the Fta is clear to
Uttam: all of you.
Uttam: Now, implementation of keep. So these are the incident, investigation techniques, fire, wise.
Uttam: ft, analysis, and so on.
Uttam: Now, implementation of key principles of investigation. So document instead, investigation results prepare in investigation report.
Uttam: provide specifications for the content of report, such as abstract
Uttam: background, narrative root causes, findings and recommendations and other information.
Uttam: So this is sample Reformal report outline.
Uttam: and we have to cover these topics
Uttam: in detail. You have to explain these
Uttam: so title page.
Uttam: table of content, introduction, executive summary background.
Uttam: sequence of events and description, incident.
Uttam: evidence and cause analysis, findings, recommendations, non contributory factors.
Uttam: attachments and appendices and references.
Uttam: The typical format
Uttam: provide clear linking between causes and recommendations.
Uttam: resolve recommendations, document and track recommendations, use a database to track status of investigation recommendations, review the status
Uttam: of each action item
Uttam: on a periodic basis.
Uttam: including review and approval of changes to the implementation. Plans and schedule
Uttam: ensure that
Uttam: the reason for delay in implementation, schedule, or changes to scope of actions are valid and documented
Uttam: communicate findings internally
Uttam: through via emails, newsletters posting within the facility. Interestingly, results are communicated during safety meetings within the facility
Uttam: communicate findings, externally.
Uttam: review incident investigation reports with all relevant facilities
Uttam: like what initially we discussed.
Uttam: If you have, similar processes are done at different facilities within the company, then it should be shared with the relevant facilities, share findings and lessons learned with industry, peer groups
Uttam: respecting business confidentiality.
Uttam: So even if
Uttam: you are
Uttam: same, product is being manufactured
Uttam: at other by other company. The peer group is that all?
Uttam: For example, petroleum industries, all pharma industries, all pigment diced up industries, all textile industries whatever.
Uttam: So that is the peer group. So you have to
Uttam: share
Uttam: the findings and lessons learned. So that
Uttam: and if everybody within that peer group starts doing that, you learn from each other, and your process becomes
Uttam: safer. If you start implementing those findings.
Uttam: maintain incident investigation. The records
Uttam: develop a document retention policy with regard to data, logs and summaries, investigation reports and investigation files, a central Archue.
Uttam: OP. Investigation reports and backup information is maintained.
Uttam: Log all reported incidents
Uttam: analyze incident trends.
Uttam: then
Uttam: assessing incident investigation, repeat calls.
Uttam: These indicate a weakness in the investigation process
Uttam: means
Uttam: that the investigation is not done properly, so that
Uttam: the recommendations are not good, so that the
Uttam: incident is repeated.
Uttam: So repeat causes means
Uttam: the incident. It indicates the weakness in the investigation process, and it means that either the recommendations that are being developed are ineffective, or the recommendations are not being implemented.
Uttam: That is also
Uttam: one reason for repeat causes, actual and potential losses from incident losses typically decrease over time.
Uttam: however, the number of reported incidents may actually increase as personnel become more aware of what the company wants reported.
Uttam: So now we are looking at
Uttam: useful leading metrics for incident investigation. So
Uttam: if you are looking at actual and potential losses, you are trending over a period of time.
Uttam: so losses typically decrease over time.
Uttam: because now you are implementing
Uttam: process. September management Rbps, and you are doing in-depth analysis, and
Uttam: you are having
Uttam: required safeguards. So number of incidents will go down, losses will go down as
Uttam: the processptic culture is improved.
Uttam: But then you have to see this data from 2 ways.
Uttam: The number of reported incent may actually increase as the personnel become more aware, so more
Uttam: behavioral problems or indiscipline behavior or
Uttam: near misses will be reported. So people are more aware what to report.
Uttam: So that is one reason.
Uttam: then.
Uttam: ratio of incident to near miss
Uttam: reports by shipped
Uttam: department or unit.
Uttam: So this
Uttam: ratio you can trend over time.
Uttam: So 1st shipped second shift, night shift
Uttam: department, which particular manufacturing operation or process.
Uttam: having more incidents
Uttam: unit an increase in this ratio may indicate an issue with the incident reporting process
Uttam: number of incidents reported per unit time. This is driven by 2 underlying factors, the number of accidents
Uttam: or near misses that actually occur and the number that are reported.
Uttam: So you have to when you are looking at the train, whether it is going up or down, or it is constant.
Uttam: You have to look at these and understand whether this is
Uttam: because of the actual number of near misses and accents, or the number that is
Uttam: reported.
Uttam: average time to initiate investigation. This metric will assist in the identification of barriers to start of an investigation.
Uttam: The barriers, maybe.
Uttam: like
Uttam: the team
Uttam: it is time is take time taken to identify the team members
Uttam: that the team members may not be available at the site
Uttam: are the team members. There are no enough sufficiently trained team members.
Uttam: and so on.
Uttam: Assessing incident, investigation.
Uttam: ratio of low, moderate, high level of effort investigation. This ratio can indicate that lower levels of analysis are being used when higher levels of efforts are
Uttam: appropriate. So
Uttam: this ratio, again, critically, you have to see that whether A/C and Rca
Uttam: are done appropriately, and there should not be a
Uttam: so
Uttam: plot that where Rc. Is required there only Sca is done.
Uttam: So that's why this
Uttam: train days or metric is reviewed. You need to review properly average effort expanded
Uttam: per investigation. This metric will help management calibrate investigation personnel to the expected level of report for each type of analysis
Uttam: like for Asia, maybe a week's time is required, maybe for Rca.
Uttam: One month time is required.
Uttam: So average a port when you trend over
Uttam: period for different incidents.
Uttam: You can categorize minimum. How much time is required
Uttam: if, say, one week, time is required for Aca, apparent cause analysis, and somebody is doing it, for within one day or 2 days, then
Uttam: the incident investigation may not be proper.
Uttam: Or if Rca is done typically in one month, if somebody is reporting that in one week.
Uttam: then you may assume that this particular root cause analysis is not done proper. It is done in a hurry.
Uttam: and you can relook at that
Uttam: average time up
Uttam: complete investigation reports, average time to complete investigation report delays in completing the reports can indicate that
Uttam: the investigation and reporting process are not given sufficient priority in the company.
Uttam: Now investigation is done, but then you have to document it.
Uttam: Soup.
Uttam: People who are doing this investigation report also have their own responsibilities within the company.
Uttam: because they are part of multi-dimensional multifunctional themes.
Uttam: Somebody is from maintenance. Somebody is from
Uttam: operations. Manufacturing. Somebody is from process safety
Uttam: and their regular duties are there. Apart from that, they are also part of the investigation committee.
Uttam: So in this case.
Uttam: if everybody gets busy after the investigation, and nobody documents that or the document report is delayed. So
Uttam: there is
Uttam: like
Uttam: reporting process are not given sufficient priority in the company. If that happens, then all your reports are waste, because then, once report is not report is ready, then only it can be circulated.
Uttam: and
Uttam: recommendations can be implemented
Uttam: average time to resolve recommendations. Leverage recommendations
Uttam: that address fundamental company processes generally tank
Uttam: take longer to implement and therefore can adversely impact this metric.
Uttam: So you have to say something which is like
Uttam: trainings.
Uttam: and you have to start from the training material itself.
Uttam: So it will take time.
Uttam: So in that case, you have to identify this, and you have to understand certain things.
Uttam: If you are tracking average time to resolve recommendation, there will be some outliers to this.
Uttam: Okay, that is what is meant here.
Uttam: Number of times recommendations, completion.
Uttam: dates are revised. This metric indicates how committed the company is to implementing recommendations as originally planned.
Uttam: So suppose
Uttam: there is a resizing of the process up to all is required.
Uttam: You have to give sample outside
Uttam: if it is not available in in house testing
Uttam: sample will be done
Uttam: for that. You have to give the work order.
Uttam: Work, order should be authorized.
Uttam: then one corridor will be released, then sample will be sent
Uttam: the person. The testing company will
Uttam: complete the sample analysis. They will provide the data
Uttam: and then you have to order
Uttam: again a new pressure lift device for proper size.
Uttam: and this can take time, and then there is a recommendation. But the completion dates are revised because
Uttam: you may feel it is important.
Uttam: but the supply chain management person may stuck in
Uttam: negotiations.
Uttam: So it is whose fault?
Uttam: So you have to explain to all the
Uttam: team members the urgency of your requirement
Uttam: and in safety related matters.
Uttam: If you waste time like that, another incident may happen.
Uttam: Number of investigations triggered by trend analysis. This metric can indicate how often trending
Uttam: analysis are per pumped.
Uttam: So you have all these useful leading metrics. You you have to
Uttam: collect lot of data and then trend over a period of time. So that was
Uttam: incident. Investigation. Next is measurement and metrics.
Uttam: Shall we? What
Uttam: 5 min break here.
sushil kumar mohapatra: Sure, sir.
Uttam: So we will start at 1120,
Uttam: and then we will continue till we finish this.
Uttam: so we should be able to finish by one o'clock.
Uttam: So before we move on to next element, measurement and metrics.
Uttam: I just want to know
Uttam: how many of you are being part of any incident investigation team.
Uttam: or how it is done.
Uttam: at your facility.
Sanjay Joshi: Yes, sir.
Uttam: Anybody of your part of
Uttam: insulting investigation team.
Bakshi.Manish: Yeah. Part of the maintenance.
Uttam: Right? Right? So which technique typically you use.
Bakshi.Manish: The different organization. We use a different techniques like the the one
Bakshi.Manish: they are using support. Technically.
Bakshi.Manish: the software built by the Us agency.
Uttam: Right, right.
Bakshi.Manish: In that we are doing the insert investigation.
Bakshi.Manish: And
Bakshi.Manish: right now in Dalmia, we are doing the Acmi analysis
Bakshi.Manish: and all all 6 steps we are following. As discussed. As you said.
Bakshi.Manish: all these steps we are following
Bakshi.Manish: 1st reporting or training.
Bakshi.Manish: We 1st we have a procedure how to report it based on that. We provide the training.
Bakshi.Manish: and then, whenever in send happen, they have to report within 8 h
Bakshi.Manish: and based on the risk. Cisco, we form the incident
Bakshi.Manish: investigation team. Otherwise, then, I only trained to follow
Bakshi.Manish: right. Suppose the risk is for based on the one to 25 is criteria is given.
Bakshi.Manish: So 16 to 25 there is no investigation is required. It's a tribal divisibility
Bakshi.Manish: remaining incent will be required for the complete process.
Bakshi.Manish: Taking investigation team collecting the facts, interview the key persons
Bakshi.Manish: and document review everything.
Bakshi.Manish: And then we do the analysis of that. What are the facts we gather? We do the analysis and make the root cause we do the root cause analysis. There's no tree.
Uttam: Right? Right? Thank you, manish, for sharing
Uttam: this, because
Uttam: I I think many of our team this particular class may not have done
Uttam: in certain investigation themselves.
Uttam: So your experience is very valuable
Uttam: for this class.
Uttam: Thank you for sharing.
Bakshi.Manish: Thank you.
Uttam: So next is the measurement and metrics. Now we have seen for last 17 elements
Uttam: that at each element you can
Uttam: track how this is being implemented
Uttam: in the facility.
Uttam: So
Uttam: then, this particular metric is about all that, and then
Uttam: how you implement this measurement and metrics, and then critically evaluate
Uttam: the performance of measurement and metrics.
Uttam: So metrics, element establishes performance and efficiency indicators to monitor
Uttam: the near real time effectiveness of the Rbps management system
Uttam: and its constituent elements and work activities.
Uttam: This element addresses which indicators to consider how often to collect data
Uttam: and what to do with the information to help ensure responsive, effective Rbps management system operations. So whether to collect
Uttam: weekly, monthly.
Uttam: quarterly, half yearly yearly all that
Uttam: which data to be collected which metrics are important for
Uttam: your but facility for a particular process, and so on.
Uttam: A combination of leading and lagging indicators is often the best way to provide a complete picture of
Uttam: process, safety, effectiveness
Uttam: we have seen leading and lagging indicators earlier.
Uttam: however, lagging indicators, such as incidents are too infrequent because the process of t incidents happens once in
Uttam: 10 years, maybe once in 5 years. So
Uttam: within the facility.
Uttam: so we may not get sufficient
Uttam: information
Uttam: over a period of time
Uttam: from lagging indicators.
Uttam: and hence use of leading indicators, so indicators, such as near misses and unsafe behaviors, is very important.
Uttam: Now we have seen this process safety pyramid.
Uttam: You have lagging indicators
Uttam: which are coming from process, safety incidents
Uttam: and other loss of containment incidents.
Uttam: And then you have leading indicators which are near misses
Uttam: and unsafe behaviors are insufficient operating discipline.
Uttam: processivity, incident involve a confluence of root causes
Uttam: such as degraded effectiveness of management, system, or, worse, the complete failure of the management system activities
Uttam: facilities should monitor the real time performance of management system activities
Uttam: rather than wait for incident to happen, or for infrequent audits to identify latent management system pillars. So you have audit process that
Uttam: we'll see later.
Uttam: And audit process can find the issues with the process. September management
Uttam: element
Uttam: failures.
Uttam: R,
Uttam: you can get it from the incident. But then why to wait here for the incident? So if you proactively monitor using the metrics measurement and metrics, you can understand the gaps and loopholes.
Uttam: A systematic purpose of monitoring using measurements and metrics allows
Uttam: safety related problems to be identified and corrective actions to be taken before a serious process. Incident occurs.
Uttam: Now let us look at
Uttam: this incident, which happened in a deep water horizon of shared drilling, rig, explosion, and fire. This happened
Uttam: 2010,
Uttam: 11 fatalities, 17 injuries and serious environmental damage. There is a report available
Uttam: also.
Uttam: Let us look at this case. Video.
Uttam: April 22,01011 workers died, and 17 were seriously injured by an explosion on the Deepwater horizon. An offshore drilling rig located approximately 50 miles off the coast of Louisiana.
Uttam: The rig burned for 2 days, eventually sinking and triggering the largest oil spill in Us. History. As oil and gas spewed up from the seafloor.
Uttam: the deepwater horizon had been drilling an oil well in 5,000 feet of water in an area of the Gulf of Mexico known as the Mccondo Prospect.
Uttam: In 2,010 the Csb. Launched an investigation to examine the technical, organizational, and regulatory factors that contributed to the accident.
Uttam: During the investigation. The Csb. Made new findings about why a key piece of safety equipment.
Uttam: the Deepwater horizon's blowout preventer failed to seal the well during the emergency.
Uttam: These new findings help explain why the accident was so devastating.
Uttam: and the Csb. Cautioned.
Uttam: Other blowout preventors currently in use could fail in similar ways.
Uttam: Drilling an offshore well involves creating a pathway between the drilling rig and oil and gas reservoirs trapped beneath the seafloor.
Uttam: A deep hole or well bore is drilled through layers of sub-sea rock and sediment
Uttam: these rocky layers can contain trapped water, crude oil, and natural gas under pressure.
Uttam: An unplanned flow of these well fluids into the well bore known in the industry as a kick can be dangerous
Uttam: without careful management. A kick can lead to a blowout the uncontrolled release of flammable oil and gas from the well.
Uttam: A blowout can be catastrophic, since oil and gas, reaching the drilling rig can quickly find an ignition source.
Uttam: Fire or explosion
Uttam: endangering the lives of the drilling crew
Uttam: to prevent kicks, drillers pump a dense slurry called drilling mud into the well, creating a barrier between the undersea oil and gas and the piping that leads to the rig.
Uttam: If this mud barrier fails or is somehow removed, the safety of the drilling crew depends on a critical piece of equipment located on the seafloor called the blowout preventer or vop.
Uttam: The vop is a complex, electrically and hydraulically powered device that is essential for controlling the well and in an emergency situation preventing a disaster. On the platform high above, on the sea surface
Uttam: the vop is connected to the rig by a large diameter pipe called a riser. If a kick occurs, the blowout preventer is designed to prevent flammable oil and gas from traveling up the riser to the drilling rig.
Uttam: This is done by sealing the area around the drill pipe known as the annular space.
Uttam: To do this the crew can manually close pipe rams
Uttam: and doughnut shaped rubber devices known as annular preventers.
Uttam: If those devices should fail to work. The last resort is a pair of sharp metal blades which form a blind shear RAM designed to cut the drill pipe and seal the well.
Uttam: The blind shear RAM can be activated manually or by automated emergency systems
Uttam: at approximately 8 45 PM. On April 20, th 2010, a kick occurred in the Mccondo. Well.
Uttam: oil and gas entered the well, bore undetected, eventually passing above the blowout preventer and travelling quickly up the riser toward the Deepwater horizon, and the 126 people on board. Just after 9 40 Pm. Drilling mud forced upwards by the rising oil and gas suddenly blew out onto the rig
Uttam: crew. Members responded by closing the upper annular preventer in the vop. However, this did not seal the well as intended, and flammable oil and gas continued to flow into the riser toward the raid.
Uttam: Next the crew closed a pipe RAM.
Uttam: This successfully closed the annular space and sealed the well.
Uttam: but tragically. This proved to be only a temporary fix.
Uttam: Oil and gas that were already above the pipe RAM continued to flow inexorably toward the deepwater horizon.
Uttam: As the oil and gas escaped the riser onto the rig, the pressure dropped in the annular space above the pipe RAM,
Uttam: but at the same time the pressure in the drill pipe climbed substantially.
Uttam: The drill pipe was closed at the top.
Uttam: but oil and gas continued to flow in from the reservoir below.
Uttam: After extensive analysis the Csb. Concluded that this large difference in pressure
Uttam: likely caused the drill pipe to buckle. Essentially bending the pipe off center. Inside the blowout preventer.
Uttam: The buckling pushed sections of the drill pipe outside of the reach of the blind shear RAM blades.
Uttam: This would eventually prove to be catastrophic.
Uttam: At approximately 9 49 PM.
Uttam: The flammable hydrocarbons found in ignition source.
Uttam: 1st explosions shook
Uttam: horizon
Uttam: with the drill pipe buckled
Uttam: the explosion and subsequent loss of electrical and hydraulic power from the raid
Uttam: likely activated an automated system on the blowout preventer known as the Amf Deadman.
Uttam: which closes the blind shear RAM and cuts the drill pipe.
Uttam: This emergency system is designed to activate when electric power, hydraulic pressure and communications from the rig have been lost. The Amf. Deadman system was operated by 2 redundant control systems on the vop known as the Yellow Pod and the Blue Pod. The redundancy is supposed to increase the reliability of the system in an emergency situation.
Uttam: The yellow and blue pods worked independently of each other
Uttam: and were comprised of identical enclosed computer systems and sets of solenoid valves.
Uttam: When activated, the solenoid valves controlled important vop functions, such as closing the blind shear RAM.
Uttam: If electrical power from the rig was lost, as happened on April 20, th 2010.
Uttam: Both the yellow and blue control pods contained backup, 27 volt. And 9 volt. Batteries to power emergency functions. The 9 Volt batteries, powered computers that would activate the solenoid valves
Uttam: which were powered by the 27 volt. Batteries.
Uttam: However, evidence indicates the blue pod had been miswired at some time before the vop was lowered onto the seafloor. This caused the pod's 27 volt. Battery to drain, and made it impossible to operate the solenoid valve for the blind shear RAM on the night of the accident.
Uttam: and within the redundant yellow pod, the solenoid for the blind shear RAM had been miswired.
Uttam: The solenoid valves were controlled by 2 coils of electrical wire.
Uttam: These 2 coils were designed to work in concert, generating a magnetic field strong enough to operate the valve.
Uttam: but within the miswired solenoid valve the 2 coils actually opposed each other, leaving the valve paralyzed.
Uttam: Only a 3rd unplanned failure allowed the yellow pod to operate on the night of the accident. One of the 9 Volt batteries that powered the solenoid valve's computer had failed. As a result. The affected computer system could not initiate the command to energize the miswired coil.
Uttam: Had both coils of the miswired solenoid valve been energized.
Uttam: the 2 coils would have generated opposing forces on the valve.
Uttam: the solenoid valve would have remained closed, and the blind shear RAM would never have been closed.
Uttam: However, the failed battery rendered one coil inoperable, and most likely allowed the other coil to open the solenoid valve by itself.
Uttam: This in turn initiated closure of the blind shear RAM.
Uttam: This should have cut the drill pipe and sealed the well, greatly reducing the impact of the accident, but because the drill pipe was buckled and off center. Inside the blowout preventer. It was trapped and only partially cut. With the failure of this last ditch measure there was nothing left to stop the massive oil spill
Uttam: and the destruction of the rig.
Uttam: During its investigation the Csb. Identified a mechanism that likely caused the drill pipe to be buckled around the time of the explosion.
Uttam: This mechanism is called effective compression.
Uttam: Although effective compression had previously been noted as a hazard in other drilling operations, it had never been identified as a problem affecting drill pipe during well operations.
Uttam: effective compression occurs because, although pipe may appear to be perfectly straight, in fact, it has minute bends and irregularity invisible to the naked eye.
Uttam: Along these bends the side of the pipe that is curved outward is slightly longer.
Uttam: and has more surface area than the other side.
Uttam: when there is a large difference in pressure between the inside and outside of the pipe, as happened on April 20, th 2010,
Uttam: the longer side of the pipe experiences a larger bending force.
Uttam: Eventually this force can become great enough to buckle even heavy pipe.
Uttam: This is an important finding, Csb investigator said.
Uttam: because the same conditions of differential pressure could occur at other drilling rigs. Even if a crew successfully shuts in a well.
Uttam: the Csb. Warned, this could make existing blowout preventer designs less effective in emergency situations.
Uttam: In the case of the deepwater horizon accident.
Uttam: the buckled drill pipe prevented the blind shear RAM from sealing the well.
Uttam: Oil and gas from the well flowed out of the buckle, drill pipe and into the Gulf of Mexico. For 87 days
Uttam: a reported 5 million barrels of oil eventually spilled.
Uttam: causing one of the worst environmental disasters in United States history.
Uttam: So
Uttam: what happened here? Why, it is important
Uttam: to learn from or to to look at the metrics.
Uttam: This particular company transportation noted 1, 21 well
Uttam: control events in 2,009 that spanned 32 different operators
Uttam: from various geographical locations
Uttam: of those 1 21 mail events, 71, where categories as kicks.
Uttam: kicks it uncontrolled.
Uttam: blow up oil and gas
Uttam: to the top.
Uttam: The transportation data demonstrate that well, kicks are not an isolated problem only for Bp or the Gulf of Mexico region.
Uttam: but that kicks occur for many operators worldwide. So this is.
sushil kumar mohapatra: Day.
Uttam: Data which is available.
Uttam: A review of several previous transition incident investigation, demonstrate restricted transmissions
Uttam: off
Uttam: lessons learned globally, both inter company and intra company to raise awareness of needed industry, wide information, sharing improvements.
Uttam: while Vp. And transotion had corporate policies for risk management and risk. Reductions, neither assume effective responsibility for ensuring their
Uttam: implementation at this particular site Macondo
Uttam: transition identified rather unloading events, such as the 2 that occurred on transition rigs
Uttam: in the 2 years before Macando as the biggest concern when identifying areas for will control improvement.
Uttam: Transition did not enforce its own policy to use return standing instruction to the driller, which a previous transaction. Incident.
Uttam: Investigation noted that
Uttam: should raise awareness
Uttam: and highlight under balance condition in a well
Uttam: when a single barrier is present, single barrier, VOP.
Uttam: Transition noted gaps between corporated policies, corporate policies, and actual practition to previous riser unloading events on its international rigs. But it did not address
Uttam: them. Corporate wide company, wide
Uttam: influenced by its decentralized organization structure. It's a very big company, but it is having a decentralized organization structure. So learning from one
Uttam: or 2 incidents.
Uttam: or even the worldwide incidents.
Uttam: has not resulted in a corporate policy.
Uttam: So this is why
Uttam: measurement and metrics should be trended, and
Uttam: this particular example shows us that why it is important.
Uttam: and then
Uttam: the
Uttam: learning should be
Uttam: practice
Uttam: within all the sites
Uttam: having similar processes.
Uttam: Now, the implementation of measurement, and matrix depends on act.
Uttam: check, act, plan, and do
Uttam: check, act.
Uttam: plan, and do CAPD.
Uttam: Metrics can address performance issues, efficiency issues, or both, in all operating pages. One or more metrics can establish for each Rbps element.
Uttam: or a few can be created for the entire system.
Uttam: High-risk situations usually detect a greater need for formally
Uttam: formality
Uttam: and thoroughness in scope and level of details. For example, a large number of sensitive metrics
Uttam: facilities whose operations are very dynamic may result in
Uttam: safety management system, elements, metrics that change frequently
Uttam: resulting in a need to gather and report metric data more frequently.
Uttam: So you are.
Uttam: Operations are changing over a period of time. So there's a dynamic operations
Uttam: frequently change.
Uttam: So in that case you have to be very
Uttam: vigilant
Uttam: and collect more data
Uttam: facilities with sound processeptic culture can generally rely on taking snapshots of metrics at less frequent intervals.
Uttam: If you are dedicated manufacturing unit.
Uttam: our processes are running without any change for many years, such as
Uttam: you know.
Uttam: petroleum industries, traction Asian
Uttam: ammonia, some ammonia manufacture certain examples I'm giving where the process is not change, the equipment is not changed.
Uttam: and then you have to collect less frequently.
Uttam: If your process dynamics is such that your processes are being changed at a site. Multi functional?
Uttam: Utilities. Reactors are there
Uttam: or multi use
Uttam: equipments? Are there. So your process keep on changing. Then you have to collect the data
Uttam: more frequently.
Uttam: facilities with an evolving or undermine
Uttam: undetermined process. Septic culture may require more
Uttam: numerous metrics and greater command and control management system features to ensure good performance.
Uttam: So if your process. Septic culture is well developed.
Uttam: then
Uttam: people, you have no or less issues with the undisciplined behavior. Or
Uttam: you are.
sushil kumar mohapatra: Thank you. Joe.
Uttam: Data is recorded. You are near. Misses
Uttam: are recorded properly in investigations are done properly, so in that case you require less frequent, but
Uttam: your processptic culture is not evolved. So you are just started processing management implementation of process management at your facility.
Uttam: In that case, command and control management and more
Uttam: data collection from for metrics is required.
Uttam: The key principles of measurement and metrics elements are
Uttam: establish consistent implementation.
Uttam: So you have to identify the key metrics for E, at least one or 2 for each element.
Uttam: and you have to collect the data.
Uttam: So that is, that should be in your guideline.
Uttam: Assign an owner, owners of
Uttam: the metric system to monitor programs. Effectiveness on a routine basis.
Uttam: determine triggers for metrics, collection and reporting.
Uttam: So triggers can be.
Uttam: There is a Moc. There is a
Uttam: adog basis.
Uttam: regular schedule, or for a cause, incident, management of change, or whatever
Uttam: process change
Uttam: ensure that the scope of the metrics is appropriate, determine the facility areas. Individual metrics, element should be applied.
Uttam: determine the Rbps element elements for which metics would be useful. Determine whether performance indicators, efficiency indicators are. Both are
Uttam: desired.
Uttam: involve competent personnel, define the metric roles and responses for various groups of personnel, provide training on the metric system.
Uttam: To those who are assigned specific roles within the metric system. So
Uttam: how to collect data that training should be provided
Uttam: to the people.
Uttam: keep matrix practice effective, maintain the records of metric system data and make it ex accessible to all affected personnel.
Uttam: establish and collect metrics. Data on the metrics element regularly provide input to internal audits
Uttam: optometric practices.
Uttam: implement appropriate element metrics
Uttam: develop appropriate metrics, such as for each selected Rbps element ensure that an appropriate means exist for collecting data
Uttam: on selected rbps elements, collect and refresh metrics, collect and repress metrics, data at appropriate intervals.
Uttam: summarize and communicate metrics in useful format
Uttam: spreadsheets.
Uttam: scorecard, dashboard, etc.
Uttam: Here is the example
Uttam: of tire, 3.
Uttam: Other
Uttam: loss up
Uttam: primary content, small fires and all.
Uttam: and you have plant locations. Plant one, plant 2, plant 3, plant 4,
Uttam: and you have
Uttam: a particular metrics that you are looking at. Lopc, so other Lopcs plant 154 are reported in a given period. Plant 2 42 are reported plan 3,
Uttam: 11 are reported, planned. 4,
Uttam: only 4 are reported.
Uttam: So this is what
Uttam: now you know, where you should put more effort
Uttam: in terms of implementation of process safety management.
Uttam: Rbps elements
Uttam: summarize and communicate metrics in a useful format.
Uttam: communicate metrics, data as per the policy to queue management, personal or widely within the facility depending upon the guideline.
Uttam: No other thing is use the matrix element to improve Rbps element.
Uttam: So here we are looking at trend. Every month
Uttam: we have number of occurrences, occurrences of particular metrics.
Uttam: and you see that
Uttam: for a period of time it is going up, down, up, down, at certain point. It is touching the
Uttam: number, which is 9 year, which is
Uttam: something going beyond the threshold.
Uttam: Now.
Uttam: if it is going to the above threshold.
Uttam: action may be required
Uttam: at this particular case. So up to
Uttam: 8 there is no issue. When it touches 9, the upper threshold value
Uttam: action may be required, and you have to look into this, why it is so frequent here.
Uttam: So you have to reduce this frequency of the incident here.
Uttam: and you have to look into those details. What is going wrong with the process of management elements.
Uttam: the useful leading metrics for measurements and metrics, number of Rvps elements for which metrics are maintained. So you have 20 rvps elements.
Uttam: and in that how many numbers?
Uttam: Of elements.
Uttam: you are
Uttam: tracking
Uttam: number of audit findings dealing with the metrics, element, results of audits
Uttam: or measurement reviews indicating that metrics are in consistent use.
Uttam: number of metrics for which data are collected.
Uttam: the refresh rate of metrics.
Uttam: the frequency of communicating metrics to the management are the concerned people.
Uttam: percentage of management personnel that use metrics for decision making
Uttam: percentage of employees who have seen metrics.
Uttam: So if you are providing a link, how many people have
Uttam: click the link that can be monitored.
Uttam: Frequency of metrics used in management review meetings.
Uttam: number of problems avoided, discovered through the use of metrics.
Uttam: So these are the typical useful leading metrics for measurement and metrics.
Uttam: Now, for
Uttam: previously we have seen the useful leading metrics for all
Uttam: 17 process, safety management elements, Rbps element, that
Uttam: how to monitor the effective implementation of each of this element. Now.
Uttam: this particular is a additional element, which is, we are looking at measurement and metric, and that also we should see
Uttam: whether it is appropriately we are doing this or not.
Uttam: So that's why this
Uttam: metrics you can use
Uttam: the
Uttam: penalty. Second, last element is auditing.
Uttam: Now, auditing is done
Uttam: by internal team or by external team or by clients, and so on.
Uttam: So auditing is a systematic, independent review. To verify conformance with the prescribed standards of care.
Uttam: it employs a well defined review process to ensure consistency, and to allow the auditor to reach
Uttam: dependable conclusions.
Uttam: Now you have quality related audits. You have.
Uttam: Similarly, you have process, safety management, related audits.
Uttam: The audits. Element is intended to evaluate whether management systems are performing as intended
Uttam: in terms of documentation. If, when you start implementing process up to management, the documentation is as good as your
Uttam: your department.
Uttam: So both these are very essential
Uttam: and similar audits or no, which are done by Qa. Department, the the
Uttam: Hs. Department, or the process of T
Uttam: management department
Uttam: can do the similar documentation.
Uttam: It complements other Rbps control and monitoring activities in elements such as management review
Uttam: metrics and inspection work activities that are part of the asset integrity
Uttam: and conduct of operation elements. So
Uttam: where you can use this data
Uttam: from audits
Uttam: for management, review metrics
Uttam: and inspection work activities
Uttam: which are required for asset integrity and conduct of operations.
Uttam: elements.
Uttam: The audit element comprises a system for scheduling.
Uttam: so you have to have a calendar for audit
Uttam: stopping who will do the audit
Uttam: will be part of the auditing team, effectively performing and documenting periodic evaluations of all Rbps elements
Uttam: as well as providing systems for managing the resolution of findings and corrective action generated by the audits.
Uttam: The purpose of audit is to find gaps in process, September management system and correct those to ensure
Uttam: protection of
Uttam: employees.
Uttam: So all processing management implementation is, first, st is protection of employees, because those employees are very close to the
Uttam: risk
Uttam: business clients because
Uttam: we have to have business continuity.
Uttam: So if
Uttam: you are providing certain you are manufacturing materials and providing to certain businesses.
Uttam: So if you have a incident there.
Uttam: the supply will be interrupted.
Uttam: So business clients!
Uttam: You have to protect interest of those
Uttam: critical assets of plants.
Uttam: machineries, reactors, columns.
Uttam: vessels
Uttam: all that plant
Uttam: community which is
Uttam: close to your facility.
Uttam: The some of the employees may be living near to the your facility, or there may be
Uttam: other residents
Uttam: who are living near to your facility
Uttam: environment.
Uttam: So you see, the purpose of auditing is to protect all these employees, business clients.
Uttam: plant machinery.
Uttam: community and environment.
Uttam: Now here is the importance of auditing.
Uttam: The example is toscore refinery fire incident.
Uttam: So this happened in 1999.
Uttam: And you see there is a photograph from this, and
Uttam: there are multiple
Uttam: flanges here. There are certain pipings and a wall here.
Uttam: There are few walls here.
Uttam: What happened here
Uttam: on February 2399,
Uttam: a fire occurred in the crude unit of Tesco corporations. Avon oil refinery in California.
Uttam: Workers were attempting to replace piping attached
Uttam: to a 1 50 foot tall fractionator tower. So this is a fractionator tower
Uttam: while the process unit was in operation. So you see.
Uttam: they have not stopped the process.
Uttam: It is under operation and in under operation.
Uttam: The workers are attempting to replace a piping.
Uttam: So how it is done.
Uttam: so you have to
Uttam: how blinds
Uttam: remove the content from the pipe which need to be replaced.
Uttam: and then you can
Uttam: remove the portion of the piping.
Uttam: During remote of the piping Nafta was released onto the hot fractionator and ignited the flames engulfed 5 workers located at different heights of the tower on the tower. 4 men were killed and one sustained serious injuries.
Uttam: There is a report
Uttam: in the 3 years prior to the incident. Neither Toscos, Corporate Safety Group nor I want facility management conducted documented audits of the repine that is, line breaking
Uttam: lockout, tagout, or blending procedures and practices.
Uttam: So there is no audit. For last 3 years
Uttam: Tasco's safety management oversights
Uttam: system did not detect or correct serious deficiencies in the execution of maintenance
Uttam: and review or process changes at its I want the refinery.
Uttam: Tasco's auditing program
Uttam: did not record or remedy the pattern of serious deviations from the same performance of maintenance work
Uttam: and proper review of operational changes in process units. So these deviations include opening of pipe containing flammable liquid prior to draining
Uttam: transport of flammable liquids to open containers, proximate.
Uttam: 2 sources of ignition.
Uttam: inconsistent use of blind list
Uttam: lack of supervisory oversight of hazardous work activities and inconsistent use of management, of change.
Uttam: control reviews for process changes.
Uttam: So
Uttam: you see.
Uttam: such kind of incident happens if your audit process is not correct.
Uttam: and the frequency of audit is not sufficient.
Uttam: so that is the importance of auditing.
Uttam: Now, key principles of auditing are
Uttam: maintain. Dependable practice ensure consistent implementation, develop an audit program that addresses issues such as the scope of application.
Uttam: scheduling
Uttam: team, stopping recommendation, resolution, and documentation of audits, establish an audit element owner and audit team. So who will do the audit for a particular process.
Uttam: and who will be part of that team, define roles and responses for the audit element
Uttam: who will overlook
Uttam: the audit element implementation, so that person will be responsible for all the audits
Uttam: or the facility or the facility
Uttam: develop audit protocols to address facility or company. Specific requirements
Uttam: involve competent personnel. So definitely, skills are required.
Uttam: Person team members
Uttam: have should have a familiarity with regulatory requirements.
Uttam: interviewing techniques, sampling schemes and written and oral communication
Uttam: identify skill sets for various roles such as lead auditor, corporate audit expert
Uttam: facility coordinator team member
Uttam: provide the required training to the audit team members
Uttam: identify when audits are required.
Uttam: establish a baseline schedule for audits and identify triggers for additional audits.
Uttam: So audits, maybe you can have a frequency 6 months, quarterly, 6 months a year. But then, if any other things are happening like a Moc management of change, control.
Uttam: or a incident or a procedure, change or material change, or p and id change.
Uttam: These are the triggers for additional audits.
Uttam: Conduct, element, work, activity, determine the audit scope and schedule.
Uttam: Then you have to assemble the team, assign responsibilities, gather evidence, information. Okay.
Uttam: plan on site activities.
Uttam: conduct the audit.
Uttam: It's it. Always start with a kickoff meeting, gather audit data
Uttam: records through record sampling reviews, observations, interview assess Rbps, implementation strengths, weaknesses and gaps related to establish
Uttam: requirements.
Uttam: report preliminary audit observations and findings in periodic meetings during the audit.
Uttam: So all the 20 elements.
Uttam: When you are doing the audit, you have to do for all 20 elements, and you have to see strengths, weaknesses, and gaps.
Uttam: conduct an audit close out meeting for each of the element. You have to do this
Uttam: share detail findings and high level preliminary conclusions with the facility.
Uttam: representatives.
Uttam: document and audit document. The audit prepare a draft report and forward it to the appropriate facility personnel for review.
Uttam: issue. The final report and forward it to appropriate facility personnel.
Uttam: So once the review is there, there may be some corrections. Then you
Uttam: issue the final report.
Uttam: address, audit findings and recommendations develop an action plan to address report findings.
Uttam: Suppose you have. You are
Uttam: auditing process, septiculture
Uttam: pillar. In that we have 5 elements.
Uttam: prose, receptive culture.
Uttam: Yeah, stakeholder.
Uttam: you have
Uttam: other elements.
Uttam: And then you understand, Hazaras, and risk in that you have 2 elements. Manager is you have other so for each element
Uttam: you have to have a what is the gap? And what is the action plan to improve that
Uttam: implementation of that particular
Uttam: Rbps elements
Uttam: respond, assign the responders and establish the deadlines for the improvement.
Uttam: follow up to resolve and document resolution of
Uttam: and audit recommendations. So there may be training required. There may be manpower requirement. Additional manpower is required for auditing
Uttam: or to implementation of the Psm. And so on.
Uttam: maintain required documentation of the audit, including resolution of recommendations.
Uttam: Monitor Rbps maturation over time for each facility.
Uttam: So initially you are starting. You don't have
Uttam: implementation of rbps. Then you start implementing. You start with
Uttam: set up elements, then you add other elements
Uttam: slowly, and
Uttam: the people get habitated
Uttam: to follow these
Uttam: guidelines and elements.
Uttam: so that maturation
Uttam: you have to see
Uttam: over a period of time.
Uttam: share best practices, identify Rbps management system, strength, disseminate information on Rbps management system
Uttam: best practices to other facilities.
Uttam: So if one of the unit is doing best in one particular or few elements, so those should be
Uttam: shared with other facilities who are who need to improve.
Uttam: assign matrix element number of.
Uttam: So
Uttam: these are the useful leading metrics for auditing
Uttam: assign matrix element, number of near miss
Uttam: and incident investigation identifying Rbps management system, weaknesses
Uttam: that
Uttam: were not detected by prior audits.
Uttam: So if the risks are not identified, the hazards are not identified properly
Uttam: so by the previous audit.
Uttam: and then incident happened. So we have seen lot of these case studies
Uttam: in some of the case studies the risk are not identified. In the other case, studies. There is a training issue. Training is not given.
Uttam: In other there is a Moc was not implemented properly
Uttam: are
Uttam: the.
Uttam: There are so many things relating to these cases. So
Uttam: the number of near miss an incident investigation which you can assign to a specific element
Uttam: weakness.
Uttam: So these are that you have to report
Uttam: percentage of audits completed according to schedule.
Uttam: average and maximum number of days overdue for open recommendations.
Uttam: So as a result of audit, you will have recommendations, and you have to close in time.
Uttam: So you have to look at the number and maximum average and maximum number of days overdue for open recommendations.
Uttam: number or percentage of unresolved audit recommendations.
Uttam: Interval between completion of onset work and completion of the audit report.
Uttam: There should not be much delay actually, between this.
Uttam: if there is a delay.
Uttam: then
Uttam: some of the
Uttam: information may be lost.
Uttam: and that will not be part of the recommendation.
Uttam: so people tend to forget it. So documentation is important. At the same time, completion of audit report is also should be done as soon as possible.
Uttam: Percentage of audit findings that are repeat findings.
Uttam: This also shows that
Uttam: audit finding into the last audit was done, and there was some gap, was pound, but and some recommendations were given, but because those recommendations are not implemented.
Uttam: so the same observation is again repeated.
Uttam: trained in number or significance of findings over a series of audits
Uttam: of the same facility.
Uttam: So if you are doing
Uttam: what is for last 5 years. You can
Uttam: look at the number of, or significance of findings
Uttam: for last 5 years, audits.
Uttam: percentage of recommendation that are rejected by the facility management.
Uttam: and that shows that either the audit is not done
Uttam: properly. So. Management don't think our management. There is a competitive person who thinks that
Uttam: these are very feldeased observations not required, or
Uttam: the team has done excellent work and has come up with the recommendations. But management is not concerned about the safety, so they don't want to give budget for that. So both ways we are to see.
Uttam: Now, this is the last element of the Rbps
Uttam: element, 20 management review
Uttam: and continuous improvement.
Uttam: So here top management is involved
Uttam: operation, said Site Head.
Uttam: and so on.
Uttam: Management review is the routine evaluation of whether management systems are performing as intended, and producing the desired result as effect efficiently as possible.
Uttam: It is the ongoing due diligence review by management that fills the gap between day to day work activities and periodic.
Uttam: horrible orders. Now.
Uttam: why? This is important, because management team, who are at the top.
Uttam: They are the people responsible for alloting the budgets.
Uttam: They are the people who understand the importance of business continuity.
Uttam: and that
Uttam: the next continuity will come from safe operations.
Uttam: So if you don't have safe operations, there can be processes, receptive incident, and you have seen that
Uttam: no, once you have processed incident, the site may be
Uttam: closed, or it may not be operating, operating for number of days or months.
Uttam: So there is a production loss
Uttam: and business gets discontinued.
Uttam: So that's why
Uttam: the top management
Uttam: to review the process of team management or Rbps implementation of Rbps.
Uttam: and
Uttam: then they will give the support
Uttam: whatever support is required.
Uttam: It is a system of scheduling, stopping, and effectively evaluating all our Rbps element, and for implementing any resulting plans for improvement or corrective action, or
Uttam: verifying their effectiveness.
Uttam: So it is related to all things.
Uttam: No, there may be.
Uttam: thank you.
Uttam: Requirement of upgradation of certain
Uttam: facilities.
Uttam: software, upgradation, a hardware upgradation
Uttam: required skill, man power, requirement.
Uttam: additional stopping required
Uttam: for implementation of process, safety
Uttam: management.
Uttam: and so on.
Uttam: External
Uttam: expert
Uttam: services are required.
Uttam: All those thing will come out of the auditing process and measurement and metrics, and
Uttam: then it should be presented to the top management.
Uttam: And when the management reviews all these things, the continuous improvement is possible, and it will be supported by the management.
Uttam: No, let us look at this case. Study.
Uttam: which is coming from hot work. Incident.
Uttam: It happened in 2,001 an explosion and fire occurred at the Motiva
Uttam: Enterprises
Uttam: refinery in Delaware.
Uttam: One contract employee died and 8 workers were injured. When a spent culprit, Cassid
Uttam: storage tank failed and released its content, which ignited
Uttam: so sulphuric acid
Uttam: storage tank
Uttam: we just spent when you say spent, it is
Uttam: having other impurities present which are primable.
Uttam: otherwise sulfuric acid is having very high, it is already oxidized.
Uttam: so it has very high boiling point. And all this so it will not ignite that easily, but
Uttam: when it is spent means it has. It is coming from a process.
Uttam: and it has various other impurities which are flammable.
Uttam: and it can also have
Uttam: impurities which can
Uttam: decompose over a period and form
Uttam: gaseous products which are flammable
Uttam: approximately 1.1 million gallons of spent cell previously was released.
Uttam: 99,000 gallons reached to Delaware River.
Uttam: So dispatch it is close to the river, and 99,000 gallons of culprit acid reach to the river that means water is contaminated.
Uttam: The
Uttam: aqua culture is having problem and all that
Uttam: issues related to environment.
Uttam: So let us look at this
Uttam: video.
sushil kumar mohapatra: If you are about 30 and not making one core, then there is something really, really wrong.
sushil kumar mohapatra: Ethan.
sushil kumar mohapatra: In 1979,
sushil kumar mohapatra: 20 year old John Capano was a contract worker performing maintenance at a New Jersey refinery.
sushil kumar mohapatra: We actually had pulled out of the refinery and were called back in to do one last job.
sushil kumar mohapatra: which was demolished an old tuffing station.
sushil kumar mohapatra: We were told that it was a water pumping station. It was not a water line, it was a crew.
Uttam: He is a survivor.
Uttam: and you can see how much
Uttam: Burns
Uttam: he had received an injuries and he had to go.
Uttam: Under multiple surgeries.
Uttam: crude oil line. In fact.
Uttam: we tried to just nail the pump, starting with removing the bolts from the flanges, and they were so corroded
Uttam: that we couldn't get them loose by conventional means. So
Uttam: we elected to use an acetylene torch at that point. As soon as the flange separated, it exploded with darn over 90% of my body
Uttam: 30 years and over 75 surgeries later. Mr. Capana now assists other burned survivors as they recover from their wounds, often suffered on the job.
Uttam: Don't think that something this tragic couldn't happen to you or somebody you love. This could happen to anybody.
Uttam: John Koppana's life was changed forever by a hot work, accident.
Uttam: welding, cutting, grinding, seemingly a routine operation, until suddenly flammable vapors are ignited by sparks or heat.
Uttam: We typically hear about hot work accidents weekly.
Uttam: It's become one of the most significant
Uttam: types of incidents a Csb. Investigates in terms of deaths in terms of frequency. The Chemical Safety Board found that since 1990, welding, cutting, and other
Uttam: on or near flammable storage tanks, caused fires and explosions
Uttam: that led to over 60 deaths.
Uttam: In February 2,010, the Csb. Issued a safety bulletin outlining 7 key lessons to prevent hot work accidents.
Uttam: The Bulletin followed a tragic explosion that killed 3 paper mill workers in Wisconsin. In July 2,008,
Uttam: together with 10 other serious hot work accidents investigated or reviewed by the CSB.
Uttam: The main message of the Csb. Safety Bulletin
Uttam: to conduct an effective hazard evaluation and perform gas monitoring before conducting hot wars.
Uttam: Proper use of combustible gas detectors would prevent many of these accidents and save lives.
Uttam: June 5, 2,006.
Uttam: A rural oil production site in Central Mississippi.
Uttam: operated by a company called Partridge Raleigh.
Uttam: All the workers are contractors employed by stringers, oilfield services hired to install tanks and piping at the site.
Uttam: they plan to connect a pipe between 2 of the site's 4 tanks.
Uttam: They empty a large storage tank.
Uttam: then check it for flammable hydrocarbons by a dangerous and unreliable technique, inserting a lit welding torch into the tank.
Uttam: Seeing no flash, the workers believe it is safe to weld on the tank.
Uttam: However, crude oil has remained inside one of the other production tanks, warming under the morning sun.
Uttam: Vapor from this oil flows into an adjacent tank
Uttam: and escapes through an uncapped pipe
Uttam: just 4 feet from where workers plan to weld
Uttam: sparks shower down from the welding process, igniting the flammable vapor.
Uttam: flames flash back into the storage tank.
Uttam: causing an explosion which blows off the tank lid and the ladder where 3 of the workers were standing.
Uttam: Flames shoot through a pipe into the
Uttam: causing an even more violent explosion.
Uttam: 3 workers were killed.
Uttam: and the 4th was severely injured.
Uttam: Csb. Investigators noted that combustible gas detectors were not used at any time prior to or during hot work.
Uttam: Partridge Raleigh had not established safety requirements for its contractors.
Uttam: and the contractor provided no hot work, safety training for its employees.
Uttam: Hot work accidents affect workers not only in the oil and gas industry.
Uttam: but also across other sectors, such as food production, paper and wastewater treatment.
Uttam: He was feeding you there. He was giving you a bottle, and then you were looking at him like, What are you doing?
Uttam: Clive and I were married about almost 2 years together. About 7 we we share a child. Her name is Leah Jones, and she is now gonna be 8. And she was 3 when he passed away.
Uttam: He was an all around maintenance man at the Bethune water treatment plans in the city of Dayton Beach. I just assumed that he had a normal every day, you know. 7 to 3, 30 Monday through Friday job, safe as my job, and I would have never dreamed. In a million years he would have been killed in a
Uttam: an explosion.
Uttam: January 11, 2,006. Clyde Jones is operating a crane at the wastewater treatment plant.
Uttam: while 2 other workers in a man lift basket are removing a steel roof that covers 2 chemical storage tanks.
Uttam: one empty, the other containing about 3,000 gallons of highly flammable methanol.
Uttam: but no combustible gas testing is required, or perform.
Uttam: The workers, use an oxyacetylene torch.
Shubham Chauhan: But the roof into sections.
Shubham Chauhan: Several contractors are repairing a catwalk in a sulfuric acid. Tank farm
Shubham Chauhan: task involves cutting near stores.
Uttam: Delaware.
Uttam: Ineffective monitoring techniques can be just as dangerous as no monitoring at all.
Uttam: July 17, 2,001.
Uttam: The Motiva enterprises, refinery, Delaware City, Delaware.
Uttam: Several contractors are repairing a catwalk in a sulfuric acid. Tank farm
Uttam: task involves cutting near storage tank 393,
Uttam: which contains waste sulfuric acid
Uttam: and flammable hydrocarbons.
Uttam: but the tank is severely corroded
Uttam: and has holes in its roof and shell
Uttam: at about 7 45 am.
Uttam: Motiva operators use a combustible gas detector to test the atmosphere around Tank 393.
Uttam: No flammable vapor is detected.
Uttam: They never test the atmosphere after that.
Uttam: but as the day goes on the temperature rises
Uttam: by 14 degrees.
Uttam: warming the contents of the tank
Uttam: and producing vapor that escapes through the holes.
Uttam: But workers are unaware of the growing danger.
Uttam: Around 1 30 PMA. Spark from an electric arc cutting system ignites the vapor, causing a powerful
Uttam: collapses.
Uttam: releasing 264,000 gallons.
Uttam: highly corrosive sulfuric acid.
Uttam: The sulfuric acid overwhelms the containment. Dyke and wastewater systems.
Uttam: Almost 100,000 gallons reached the Delaware river.
Uttam: killing fish and other aquatic life.
Uttam: A contract employee who had been working on the catwalk died in the accident.
Uttam: His body never found.
Uttam: 8 others were injured
Uttam: combustible gas detectors should be routinely used to identify and monitor for flammable atmospheres before and during hot work.
Uttam: More recent accidents illustrate the same key lesson
Uttam: gas monitoring was performed at Conagra, foods in Boardman, Oregon, on February 16, 2,009, but not in the immediate area where welding was planned. Sparks ignited flammable gas from decaying matter beneath a water clarifier tank, causing an explosion that killed one worker
Uttam: and 3 contract workers were killed at a Tepco fuel terminal, while they used a torch to cut into the roof of a gasoline storage. Tank
Uttam: gas testing occurred at 7 A. M.
Uttam: To.
Uttam: In this case.
Uttam: let us look at the report. Findings
Uttam: building work.
Uttam: One moment. Let me take the pointer
Uttam: building work to repair tank leaks, ignited hydrocarbon vapors
Uttam: in the vapor space of the tank. The one contact maintenance worker was killed and 8 others were injured. The incident resulted from a confluence of several factors.
Uttam: The corrosivity and primability hazards associated with
Uttam: changing the tank from fresh asset service to spent asset service where not identified and controlled.
Uttam: So that means
Uttam: initially, they were using fresh acid.
Uttam: and over a period they found that they can use spent acid.
Uttam: So they are going to make monetary savings
Uttam: because they can reuse the spent acid. And these
Uttam: change control was
Uttam: that the Hazar, associated with this change control were not identified and controlled.
Uttam: Repeated request
Uttam: or tank inspections and repairs were deferred or ignored.
Uttam: So there was a correlation, and this was ignored. The hardware permit failed to specify atmospheric monitoring despite
Uttam: previous permit denials because of toxic
Uttam: and playable gas concentrations.
Uttam: So for this particular work permit was tried several times, and previously the permit
Uttam: was not given because of the presence of toxic and flammable gas concentration.
Uttam: So this is a typical situation where
Uttam: this particular incident happen.
Uttam: where the gas was detected in the cold atmosphere initially, maybe in the night, early early morning, where? No, in the winter season, some of something like that, and there was no atmos primable atmosphere was pound.
Uttam: and then the actual work was started in the afternoon, where the temperature was high enough, and it generated the
Uttam: primable and toxic gas.
Uttam: So each of these contributing factors was the result of a management system breakdown that could have been identified and corrected by timely management review.
Uttam: So that is where management review helps.
Uttam: where the decision makers can look at the previous findings.
Uttam: the previous
Uttam: denials, and all these in this particular case.
Uttam: and they could have
Uttam: come up with a bit better practice for the gas detection and the hard work in this particular case, and this can be
Uttam: implemented for all the
Uttam: such kind of
Uttam: hazardous, risky operations.
Uttam: Now, the key principles of management review and continuous improvement element are.
Uttam: we are to define the roles and responsibilities.
Uttam: develop a written policy for managing the
Uttam: management review element itself
Uttam: include specific roles and responses in the management system governing the management review element. So who are going to present the data
Uttam: 1 min or 1 min, and it there is a background sound here.
Uttam: One mate.
Uttam: Sorry. So
Uttam: people who are going to present the data
Uttam: the findings, the trends
Uttam: to the management review team and the management review team who are going to be part of the management review team.
Uttam: So these are the roles
Uttam: and responsibilities.
Uttam: Establish standards for performance, develop management review protocols which addresses regulatory requirements and best practices. Now
Uttam: for India. We don't have much regulatory requirements for process safety management.
Uttam: but
Uttam: we know that it is very important. That's why we have.
Uttam: No, many of the Indian companies are taking it seriously.
Uttam: So
Uttam: even though there are no regulatory requirements, we have to have protocols per
Uttam: best practices
Uttam: based on the best practices, establish baseline schedule for reviews
Uttam: at least once in a year.
Uttam: The management review should happen.
Uttam: and this can.
Uttam: depending upon the site, number of sites, and the number of equipments, and all number of processes being performed.
Uttam: you can schedule it because at one go it may not be possible to review entire
Uttam: plans or the number of sites. So that's why it can be
Uttam: unit specific. It can be planned specific.
Uttam: Take depending on the size of the plant.
Uttam: Now
Uttam: you are. Ha! You have to review all the 20 elements of our Vp based system.
Uttam: and you have to say monthly
Uttam: in January you will reuse it, for example, conduct of operations in February you will review knowledge.
Uttam: management of change
Uttam: in March, maybe a set integrity like that.
Uttam: So you have to have a calendar, and in each
Uttam: a month you may review one or 2 elements.
Uttam: a process, safety
Uttam: management.
Uttam: validate program, effectiveness, identify majors by which the effectiveness of management reviews will be judged based on audit findings.
Uttam: so the trends
Uttam: will be presented to the management. The audit findings will be presented to the management for each of this
Uttam: process Rbps element.
Uttam: and then the management will
Uttam: come up with
Uttam: how to
Uttam: improve the system, how to improve the Psm system.
Uttam: determine the review scope, establish the scope of the review to regulatory requirements known as known system failures, etc.
Uttam: No regular requirements in our case may not be there. So we have to see known system failures.
Uttam: Prepare for review schedule, the review, gather information, prepare a presentation that is, of course, and you have to also share this to the management before the actual management review. So the team members who are going to review it
Uttam: able to share all this information
Uttam: at least a week before
Uttam: they will go through that, and then they will ask pertinent questions
Uttam: to identify gaps.
Uttam: conduct up review Ssrbps, implementations, strength, weaknesses, and gaps related to established requirements.
Uttam: document the review
Uttam: and appropriate review and forward it to appropriate facility, personal issue, a detail memorandum
Uttam: addressing observations, and the basis for conclusions as well as recommendations and assessments for corrective action.
Uttam: address, review findings and recommendation, develop an action plan to address review findings, assign responsibilities, establish deadlines.
Uttam: follow up to resolve, review recommendations and documentation resolution. So
Uttam: when you go back to this
Uttam: calendar.
Uttam: so January, you have conducted
Uttam: review of conduct of operation, element.
Uttam: February, you will start knowledge
Uttam: and management of change. These elements review.
Uttam: So
Uttam: before you start.
Uttam: if you have open recommendations here, or you have action plans for conduct operations.
Uttam: You may discuss those the status of those, and then start the new review.
Uttam: or you may have additional one meeting just
Uttam: to look at
Uttam: the current condition of the recommendations and implementation
Uttam: you should. So that is what
Uttam: follow up to resolve review recommendations and document resolution.
Uttam: strive for continuous
Uttam: improvement identify relevant metrics for each Rbps element. So we we have discussed number of metrics which can be used
Uttam: to monitor effective implementation of each of the element.
Uttam: So then, specific to your
Uttam: business, you can identify one or 2, maybe at the most 4,
Uttam: because it requires lot of
Uttam: efforts to collect data and ma man skill manpower also. So you have to see which import.
Sushil Kumar Mohapatra: Hope it.
Sushil Kumar Mohapatra: We.
Bakshi.Manish: You are not horrible.
Ketan Kevadiya: Hello!
Ravi Patel: So your audio is not available.
Ravi Patel: Hello!
Ketan Kevadiya: Thank you.
Ravi Patel: Teddy, are you as unreadable
Ravi Patel: jumps out.
Bakshi.Manish: I think we are not also audible to win.
Ravi Patel: Yes. Yes. Yes.
Ravi Patel: Same problem. Here.
Bakshi.Manish: It is animals.
Bakshi.Manish: Little, are you there?
Bakshi.Manish: It's only him.
Ravi Patel: I think we contacted Metro, Alexa.
Bakshi.Manish: Hello, Medusa!
Bakshi.Manish: Last man.
Bakshi.Manish: Unka voicemia, or Hammarawa, wise and pony jar for continue a class
Bakshi.Manish: a little bit.
Ravi Patel: I think we soon left already. Thank you. Slide is lost.
Ravi Patel: Hello! I am a developer.
Mitul Parikh: I know.
Bakshi.Manish: Wasn't that a
Bakshi.Manish: better target? The better target, the salviating a Polish name, American Gargan, as the gun I was
Bakshi.Manish: ever had. Innovation.
Bakshi.Manish: Okay, have a good day, my apologies. I'm good.
Bakshi.Manish: Aye for the team management. Thank you for the.
Ravindra: Hello!
Ravindra: Am I audible?
Ravindra: Yes.
Ravindra: okay. Thank you. Yeah.
Ravindra: How many, how many participants are there.
Ravi Patel: I don't run any participant.
Chetan Bhoyar: But in the morning session I think there were 14 to 15 candidates joined.
Ravindra: Okay. So
Ravindra: I think we, we will wait for 5 more minutes, and then we'll start.
Chetan Bhoyar: Yeah. Reference.
Ravi Patel: Organizer.
Ketan Kevadiya: Bye.
Ketan Kevadiya: I don't want these other ones now. But come on
Ketan Kevadiya: another part of my
Ketan Kevadiya: hi yourself.
Ketan Kevadiya: Yeah.
Ravindra: Okay, I I guess
Ravindra: no more participants will be there, because this is the post launch session.
Ravindra: I hope.
Ravindra: Okay, so we'll we'll we'll start ahead. So before going ahead.
Ravindra: let me know first, st how many chemical engineer are there?
Ravindra: Okay, Wandrajo, chemical engineer?
Ravindra: And how many nonchemical engineer? Are there?
Ravindra: Okay, aeronautical engineer, normally.
Ravindra: why? I'm asking this question because based on this, I need to
Ravindra: define the depth of my course. Okay.
Ravindra: for chemical engineer I can go ahead with with certain complex problem. But for non chemical engineer I'm
Ravindra: I cannot go with. The complex one.
Ravindra: So that's why I'm I'm asking you this question. Okay, is there anybody who is not? Who is graduate from science?
Ravindra: Maybe. Msc, bsc.
Ravindra: okay.
Ravindra: So okay, we'll. So we'll start with very basic concept. Maybe chemical engineer knows that.
Ravindra: The subject that I'm going to teach you is a stichometry.
Ravindra: I know
Ravindra: many of you knows stymmometry. A chem, of course. Chemical engineer.
Ravindra: No, in during your
Ravindra: graduation time you might have faced certain difficulties in understanding this subject.
Ravindra: Okay, so we'll try to keep this subject as simple as your
Ravindra: daily subject daily routine.
Ravindra: We'll I'll try to make it very simple. Okay.
Ravindra: okay. Do you know what is geometry?
Ravindra: Hello!
Ravindra: So if you want to say something.
Ravindra: and that's what.
Sudeep Wadia: Thank you. Jeff. Thank you. Guys. Nice new room.
Ravindra: So they publish.
Sudeep Wadia: But those are.
Ravindra: So they mute yourself.
Ravindra: So they.
Sudeep Wadia: Should be.
Sudeep Wadia: I don't know. Little
Sudeep Wadia: formula.
Ravindra: Okay, so we'll we'll go with very basic basic concept of this subject. We'll start with the scratch and then we'll move ahead with certain depth. Okay, so let us
Ravindra: let us start with the simple presentation. First, st
Ravindra: let me share my screen with you.
Ravindra: I hope my screen is visible to you all
Ravindra: years.
Ketan Kevadiya: Yes.
Ravindra: Okay. You know, the chemical engineering, if we start with the history of chemical engineering is the oldest branch
Ravindra: engineering. Okay, not oldest. There are few who started before chemical engineering. But man
Ravindra: knows the
Ravindra: the usage of metal from prehistoric time. Okay, so we we know that, okay.
Ravindra: so what is chemical engineering. So we.
Ravindra: a chemical engineer process raw material and convert it into final finished product, using number of steps.
Ravindra: that step that steps may be either unit operations or unit process.
Ravindra: So you might have seen many. Manufacturing process. So manufacturing process starts with unit operation.
Ravindra: Okay, so 1st unit operation is to convert raw material into into most suitable form for reaction. Okay, then, second, is unit process, where the raw material is chemically converted
Ravindra: into some useful into some useful product. And then again, at the last of the process, there are always unit operations, that unit operation, that physical changes is to convert raw product into final finish product. So
Ravindra: so chemical process, this chemical transformation consists of unit operation and unit process. So what is unit operation, unit operation is operation where physical changes takes place
Ravindra: and unit process where chemical transformation take place.
Ravindra: So you know what is physical changes like? In distillation column.
Ravindra: So this in distillation column, we use it as a for a separation technique. So it is unit operation where no chemical reaction take place. We operate low volatile material.
Ravindra: low boiling point,
Ravindra: component and separate it from the mixture
Ravindra: using
Ravindra: using boiling point difference. So driving forces, boiling point difference. So unit process is chemical transformation, all reaction like oxidation, reduction, nitration, hydrogenation.
Ravindra: and so on.
Ravindra: This come into unit processes part
Ravindra: so chemical engineer versus chemist. So how you can distinguish between a chemical engineer and chemist. Many consider that they both discipline are identical, but they are not identical.
Ravindra: Their role is different. So the chemical engineer
Ravindra: is more interested into converting the
Ravindra: research into reality
Ravindra: so that they they can earn profit.
Ravindra: And chemist is interested into development of new molecule.
Ravindra: Okay? So the role is different.
Ravindra: One is interested in development of molecule and other. One is converting that molecule into a commercial product so that they can earn
Ravindra: so that they can earn profit.
Ravindra: Okay.
Ravindra: so unit operations, fluid flow operation, heat transfer marks, transfer, drying distillation, crystallization, extraction, adaption, gas absorption, size, reduction, sedimentation, filtration, mixing u operation, sublimation, centrifugation, material handling iron. These are the unit operations.
Ravindra: unit processes, oxidation, reaction. All all reactions are unit of processes.
Ravindra: So basic chemical calculations. So you know, each element has certain weight, and we call it as atomic weight, so atomic weight
Ravindra: is, is belong to the element, like carbon.
Ravindra: oxygen.
Ravindra: chlorine. These individual element has a certain weight, and so we call it as a atomic weight, and the atomic weight is given based on the carbon. Has the
Ravindra: mass exactly 12. So, based on this mass, the other element has given a weight certain wave molecular weight, atomic weight.
Ravindra: Okay, so molecule. When these atom combine, they form molecule, and its weight is called molecular weight. Okay.
Ravindra: Equivalent weight is a ratio of molecular weight to Valence, and so valanced is is the number of hydroxyl, ion, or hydrogen. Ion
Ravindra: accepted for
Ravindra: for each atomic weight, or each molecular weight, that that number is balanced.
Ravindra: and its ratio is equivalent to it.
Ravindra: So you know, in in St. Geometry we used to calculate the substance in terms of moles, and so mole is
Ravindra: is the ratio of weight upon molecular weight.
Ravindra: If if we take weight in gram per molecular weight, then it gives us a gram moles of that particular component.
Ravindra: Okay, if our weight is in kilogram and the divided by molecular weight. Then it is kilogram. More of that particular component.
Ravindra: Okay.
Ravindra: I'll show how molecular weight is calculated for the for the student. They don't know how to calculate molecular weight. Maybe a non-chemical engineer
Ravindra: just a minute.
Ravindra: okay. Say, for example,
Ravindra: So we have
Ravindra: edge 2
Ravindra: and so forth, sulfuric acid.
Ravindra: And we want to calculate molecular weight of sulfuric acid. So we know atomic weight of hydrogen is one into so the in molecule of sulfuric acid, 2 hydrogens
Ravindra: ions are present, so one into 2
Ravindra: plus self. First, st
Ravindra: atomic weight is 32 plus
Ravindra: 16 is atomic weight of oxygen multiplied by
Ravindra: 4. So 4 ions present is, that's why multiplied by 4. So this is equal to 98. So this is how
Ravindra: molecular weight is calculated for for any, any element. But the condition is, you must know, the
Ravindra: atomic weight of that particular element element present into that.
Ravindra: that
Ravindra: molecule.
Ravindra: Okay. So you know, when we are dealing with chemical engineering, we need to
Ravindra: express concentration. So whenever we form
Ravindra: any, any new product, we we have to write assay of that particular
Ravindra: particular component. So how much purity is there that we need to write, and so purity is always expressed in terms of concentration. So concentration is nothing but most of that particular component present per unit volume of that particular component! It is expressed like this. So concentration. There are ways, number of ways to express concentration. And one
Ravindra: most popular way is normality.
Ravindra: So using normality, we can express concentration. So it is defined as number of gram equivalent of solute dissolved in one liter of solution.
Ravindra: So gram equivalent to volume of solution in liter. So this is how
Ravindra: normality expressed, and it is denoted by symbol. N.
Ravindra: So gram equivalent of solute. It is massing gram of predict. That substance divided by equivalent to it
Ravindra: and equivalent rates, is
Ravindra: molecular weight upon Valence.
Ravindra: Okay, second way is of expressing molarity is, is molarity. So molarity is number of Brahm moles of that particular solute dissolve in one litre of solution.
Ravindra: Okay, Graham, mole of solute dissolin
Ravindra: in a litter of solution.
Ravindra: Okay, molality is gram moles of solute dissolved in in 1 kg of solvent.
Ravindra: a mass obsolve one.
Ravindra: Okay, this is Molly.
Ravindra: We used to express composition based on weight percent based on volume percent and based on mole percent.
Ravindra: mole fraction is a ratio of individual moles upon total mole of system.
Ravindra: Okay, we know general gas. Equation. Pv, equal to Nrt, where P is pressure, absolute pressure. V is volume N is number of moles. R is universal gas constant. And T is temperature. Okay, so using this equation.
Ravindra: we can express concentration. Okay, so we know, PV. Equal to.
Ravindra: and RT. And concentration is
Ravindra: number of mole
Ravindra: moles
Ravindra: obsolete.
Ravindra: present
Ravindra: in
Ravindra: it's the same.
Ravindra: so
Ravindra: I can say, concentration is N. By V
Ravindra: number of more per unit volumes.
Ravindra: So.
Ravindra: so p upon RT.
Ravindra: So this is how we can express concentration using ideal gas flow.
Ravindra: So here R is universal gas constant, and R's unit is
Ravindra: Kilo Pascal, meter, cube.
Ravindra: kilo Mole, Kelvin. So it is very difficult to remember so best way. Pv. Are equal to Pv. Upon Nt.
Ravindra: So P. Is expressing Kilo Pascal.
Ravindra: Volume in meter cube.
Ravindra: number of mole in Kilo Mole
Ravindra: and T.
Ravindra: In Kelvin.
Ravindra: not degree in Kelvin. So this is how the unit is derived. And at this unit value of R is 8.3 1 4.
Ravindra: Why? And we use this value for calculation. Purpose.
Ravindra: I hope. You are getting this.
Ravindra: if we if we want to calculate the the
Ravindra: pressure, or we can apply the ideal gas law for 2 different state. So for 2 different
Ravindra: state stages, 2 different conditions. So ideal gas law is
Ravindra: is like this, p. One.
Ravindra: v. One upon t, one p. 2, v. 2
Ravindra: into, divided by t. 2.
Ravindra: As the constant r from both side get cancel. So this final equation we get, and this is this is at Ntp, so you know, Ntp is a normal temperature pressure condition. And we used to
Ravindra: who use this at various condition in industry, industrial applications. So you people know
Ravindra: much better than me, maybe. Okay, so normal temperature, normal temperature and pressure at this condition temperature is
Ravindra: and pressure is
Ravindra: how much temperature is there at normal temperature and pressure condition.
Ravindra: There are 2 2 conditions. One is NTP. And other one is stp.
Ravindra: Ntp is normal temperature and pressure and stp, standard temperature and pressure.
Ravindra: So normal temperature or standard, we take temperature as a 0 degree centigrade and pressure one atmosphere.
Ravindra: Okay?
Ravindra: So you know, when we are dealing with mixers. Generally in industry we use air for many applications. Pneumatic air is the instrument. Is air. Is there compressed air? Is there. So
Ravindra: so many time. We need to calculate the average molecular weight of gas mixture. So how we can calculate average molecular weight of gas mixture simply by
Ravindra: by
Ravindra: M. Average, is nothing but average molecular weight, and it is suppression of
Ravindra: MI. Into XI.
Ravindra: M is molecular weight of total component present in that gas mixture, and X is mole fraction of
Ravindra: of that particular component. Say, for example, so we have air
Ravindra: as a gas mixture.
Ravindra: so air is mixture of many gases.
Ravindra: Okay, but majority, 79% volume basis is nitrogen.
Ravindra: 20
Ravindra: percent, 20.5% oxygen
Ravindra: point 4%
Ravindra: CO, 2 and and rest.
Ravindra: Actually, this is 78.
Ravindra: This is 20 point something, and 1% is other agassis.
Ravindra: which include CO, 2,
Ravindra: plus
Ravindra: the rare guesses.
Ravindra: that is ergon and and so on that that inner devices. Okay. But for our calculation purpose, what we assume here.
Ravindra: 79% nitrogen
Ravindra: and 21% oxygen.
Ravindra: Okay, so both is equal to
Ravindra: 100%.
Ravindra: So we are, we are eliminating the other guesses.
Ravindra: Okay, so if we want to calculate average molecular weight of this nitrogen air. So we can use this formula. So M. Average
Ravindra: is equal to
Ravindra: molecular weight of nitrogen is 28
Ravindra: into
Ravindra: point 79
Ravindra: plus point
Ravindra: 21
Ravindra: into 32.
Ravindra: So this is how we can calculate m average or average molecular weight of particular gas.
Ravindra: Okay? And same way, we can use this equation to calculate density. Okay, you know.
Ravindra: Ideal gas law.
Ravindra: of course. Where are you going to use ideal gas law? So we know. Pv. Equal to
Ravindra: entity is our ideal gas law.
Ravindra: Okay.
Ravindra: so N is nothing but number of mole and number of mole is how number of mole is calculated.
Ravindra: Waiting
Ravindra: grams
Ravindra: upon
Ravindra: molecular weight
Ravindra: into RT.
Ravindra: Into pv.
Ravindra: so B
Ravindra: into
Ravindra: sorry molecular weight.
Ravindra: I'm I'm shifting this
Ravindra: this side P into molecular weight is equal to
Ravindra: waiting room
Ravindra: upon volume
Ravindra: into Rt.
Ravindra: So weight Ingram upon volume, weight
Ravindra: per unit volume is nothing but density, so density into R into T is equal to P upon molecular weight.
Ravindra: So so density we can calculate from here p into
Ravindra: molecular weight
Ravindra: r into t, using this. But when we talk about the gas mixture. This molecular weight is replaced by
Ravindra: average molecular weight. So I'm writing this side. So density of mixture is equal to
Ravindra: pressure
Ravindra: into average mole M average upon
Ravindra: rt, so using this equation, we can calculate density of mixture. So same thing is represented here for density of mixture. Okay, we can calculate density using this equation any any doubt? So far
Ravindra: your doubts are welcome. If you want to ask doubt, you can ask
Ravindra: at any time between between my discussion. No problem.
Ravindra: Okay? Let me let me explain this with with example. Okay.
Ravindra: just a minute.
Ravindra: Aye.
Ravindra: I was disconnected.
Ravindra: Hello!
Bakshi.Manish: Yeah. Everyone.
Chetan Bhoyar: Yes. Sorry. Well.
Ravindra: Audible.
Bakshi.Manish: Yep.
Chetan Bhoyar: Yes.
Ravindra: Okay. So what last you heard from my side I don't know. When I was disconnected I was. I was talking.
Bakshi.Manish: Erica.
Bakshi.Manish: Density of Guest Pictures.
Ravindra: Have you seen that problem that I have solved.
Bakshi.Manish: Problem. Yeah.
Bakshi.Manish: that is molecular weight of gas mixture. How we are calculated.
Ravindra: Okay, my screen is visible or not.
Bakshi.Manish: Get it.
Bakshi.Manish: loser!
Ravindra: Now.
Chetan Bhoyar: Yes.
Bakshi.Manish: Yes.
Ravindra: Okay, we, I have solved this problem. Have you seen this problem?
Bakshi.Manish: No, no.
Ravindra: Okay.
Ravindra: okay, let me let me restart this one so that
Ravindra: you'll get clear idea how to solve these kind of sums.
Ravindra: Okay, so our aim is to calculate.
Ravindra: Our aim is to calculate density of mixture. So we want to calculate
Ravindra: fair. So we need to calculate density of
Ravindra: air.
Ravindra: Okay, so how we can calculate density of here. So we can use 2 formulas that we know. That is
Ravindra: M average and density of mixture.
Ravindra: So we know that air is
Ravindra: a mixture of
Ravindra: nitrogen and oxygen. Okay, we are eliminating this. The small
Ravindra: components. Okay, so nitrogen is 79% and oxygen is 21%
Ravindra: based on volume and volume percent equal to more person, so that we can directly take.
Sanjay Joshi: Morning!
Sanjay Joshi: Oh.
Ravindra: Yeah. Yeah. It's
Ravindra: Hello.
Bakshi.Manish: Please carry out!
Ravindra: Okay?
Ravindra: so we know that air is a mixture of 2 components, nitrogen and oxygen. So let us start with calculating the first, st we need average molecular weight. So average molecular weight of air is
Ravindra: molecular weight of nitrogen
Ravindra: into
Ravindra: more fraction of nitrogen, plus
Ravindra: molecular weight of oxygen
Ravindra: to more fraction of oxygen. So molecular weight of nitrogen is 28, multiplied by point 79
Ravindra: plus molecular weight of oxygen is 32 into
Ravindra: oxygen is 21. So this calculate this if you wish, point 84 4
Ravindra: air. So now we need to calculate density of mixture at
Ravindra: Ntp.
Ravindra: so this is equal to
Ravindra: B
Ravindra: into M average
Ravindra: upon
Ravindra: are
Ravindra: into T
Ravindra: to be. It's
Ravindra: atmospheric pressure, 1 0 1.3 2 5
Ravindra: and
Ravindra: 28.8 4,
Ravindra: divided by
Ravindra: universal deaths. Constant 8.3 1 4,
Ravindra: multiplied by
Ravindra: 2 73.
Ravindra: So this is 1.2. Please calculate this. This is not exactly 1.2. This is 1.1 2 point something
Ravindra: KG. Per
Ravindra: mentor queue.
Ravindra: So this is how we can calculate the density of
Ravindra: a mixture.
Ravindra: You can take any example of any mixture of gas, and using this relations, you can calculate
Ravindra: the density as well as average molecular weight of that particular mixture, so any any doubt. So far.
Ravindra: I think this is clear.
Bakshi.Manish: 1.2 6 right.
Ravindra: If you have doubt you please ask.
Ravindra: no doubt.
Bakshi.Manish: With.
Ravindra: Okay.
Bakshi.Manish: It is clear zone.
Ravindra: Okay, this is clear for.
Bakshi.Manish: Yes, sir.
Ravindra: Maybe. What about non chemical engineers.
Bakshi.Manish: It is clear, sir.
Ravindra: Okay. So so we have seen the very basic concept here in this session. That is
Ravindra: just a minute.
Ravindra: That is the concept of
Ravindra: atomic weight.
Ravindra: atomic weight, then
Ravindra: moles.
Ravindra: then
Ravindra: general gas equation.
Ravindra: you know, general gas equation is also called as equation of state.
Ravindra: Can can somebody tell me why, why it is called a general gas equation, or Id.
Ravindra: or equation of state.
Ravindra: What? What is equation of state?
Ravindra: Then? We have seen the
Ravindra: molarity.
Ravindra: normality
Ravindra: and molality.
Ravindra: Okay, then.
Ravindra: well.
Ravindra: ways of expressing
Ravindra: ways of expressing mixture.
Ravindra: that is
Ravindra: weight percent.
Ravindra: more percent
Ravindra: and volume percent.
Ravindra: Okay.
Ravindra: you know.
Ravindra: more percent
Ravindra: is always equal to volume percent
Ravindra: is always equal to pressure percent.
Ravindra: Okay.
Ravindra: please remember, many time, we directly take more percent equal to volume percent. And we start solving problem.
Ravindra: So
Ravindra: we are taking because more percent and volume percent are equal.
Ravindra: Okay? And then we have seen, the concept of average molecular weight and density of mixture.
Ravindra: So.
Ravindra: hey?
Ravindra: Any further clarification required on any any of our listed topic.
Bakshi.Manish: More verses, is.
Chetan Bhoyar: Is there any criteria when to consider mole person equals to volume percent? Or is it like.
Ravindra: Hang on!
Chetan Bhoyar: Ways we can consider.
Ravindra: It is, it is always equal by by there is one derivation. So if we
Ravindra: quiet, I can show you by by using ideal. Yes, flow, we can prove that more percent is always equal to volume percent, and it is always equal to pressure. A percent.
Chetan Bhoyar: Okay.
Ravindra: So there is no any criteria, so it is always equal.
Ravindra: you know. Molarity, normality, and molality. These are the ways of expressing concentration. We, we used to say, concentration concentration. But if we want a specific, we express in terms of molarity. Okay, if you see any research paper, the concentration is always expressed, based on molarity.
Ravindra: normality and mollality is quite rare, but molarity is very popular.
Ravindra: The research scholar use molarity quite oftenly
Ravindra: to express the express the strength of their solution.
Ravindra: A percent basis is common as well. So if we are using caustic, we used to say 10% caustic, 20% caustic. So like this.
Ravindra: okay, I, I hope you understood this very well.
Chetan Bhoyar: Yes.
Ravindra: So can we move ahead.
Chetan Bhoyar: Yes.
Ravindra: Okay, thank you.
Ravindra: Now we'll start.
Ravindra: the unit operation and unit processes.
Ravindra: Okay, let me share
Ravindra: slide with you.
Ravindra: I hope.
Ravindra: my slides are visible to you.
Chetan Bhoyar: Yes, basically.
Ravindra: Okay, you know, by material balance why we need to do balance material balance. And this
Ravindra: in industry, we used to calculate.
Ravindra: we use. We are interested in money.
Ravindra: and of course, obviously in money
Ravindra: and quantity. So whatever we are putting in and what we are getting out, that is our our interest. And so Montreal balance. Okay, so what we are putting in and what we are getting out.
Ravindra: So so that is material balance. So what material we are putting and what material we are getting
Ravindra: at the end. So for our simplicity purpose, here we are assuming steady state condition.
Ravindra: If you are interested, I'll I'll show how unsteady State balances are there in unstady state balance. We are considering accumulation as well as disappearance by any reaction. If if if any disappearance is there. So for this session, we are assuming here as a steady state condition.
Ravindra: So what steady State condition says
Ravindra: input
Ravindra: is always equal to output.
Ravindra: Of course this is our our assumption
Ravindra: when we are doing actual material balance.
Ravindra: So this case is not valid
Ravindra: for understanding purpose. We are assuming this.
Ravindra: Okay, so material balance.
Ravindra: just a minute.
Ravindra: Okay.
Ravindra: material balance. We need to calculate on various unit operations and unit processes. So we'll start with unit operation. So unit operation are the operation where only physical changes takes place. Okay? So we'll take one. One by one example of each unit operation, and we'll take how material balance is done on on that particular unit operation. So
Ravindra: 1st of all, I'll I'll take
Ravindra: distillation because distillation is not present here.
Ravindra: so I'll show how.
Ravindra: Vater. Balance on distillation column is
Ravindra: is done.
Ravindra: Okay.
Ravindra: so can anybody tell me why distillation is used in industry? What is application of distillation, or what is purpose of distillation?
Ravindra: Separation
Ravindra: for separation? We use distillation, column
Ravindra: and its driving forces.
Bakshi.Manish: Morning, plan.
Ravindra: Boiling point difference.
Ravindra: Okay?
Ravindra: So we we know that when we feed
Ravindra: any input to distillation column, we get multiple outputs
Ravindra: for simplicity. We are considering simple distillation where we are getting
Ravindra: 2 outcomes only.
Ravindra: This is our feed.
Ravindra: This is our
Ravindra: our top product that is distillate.
Ravindra: This is residue or West product.
Ravindra: W.
Ravindra: So in distillation. The mixture of
Ravindra: liquid mixture, miscible liquid mixture is separated using boiling point difference. So so we are getting 2 streams
Ravindra: when it's
Ravindra: hi volatile.
Ravindra: component, and one is low, volatile, component. So we are getting the low calling point.
Ravindra: Sorry component at as a top product
Ravindra: and bottom. One is high volume, high
Ravindra: boiling point component. Okay.
Ravindra: more volatile at top, less volatile at bottom.
Ravindra: Okay.
Ravindra: if we want to consider
Ravindra: if we want to do material balance. So we know we are considering input equal to output.
Ravindra: So in distillation column, we have one input and multiple outputs. So F
Ravindra: is equal to d plus w.
Ravindra: If we consider overall matter
Ravindra: trailer overall material balance, we have alarms on
Ravindra: component A so F
Ravindra: into excel equal to
Ravindra: XA into d
Ravindra: plus
Ravindra: exa into
Ravindra: W,
Ravindra: this is how we can calculate the component balance for component a say, say, for example, we have
Ravindra: alcohol
Ravindra: water mixture.
Ravindra: Okay? So alcohol is 20%.
Ravindra: If. And we, if we put this mixture into distillation column, we get alcohol at the top because it is
Ravindra: high volatile, component.
Ravindra: say at top, say 50%. Alcohol is there.
Ravindra: and at at bottom, say 2% alcohol. Is there.
Bakshi.Manish: Well.
Ravindra: So if we take balance out of
Ravindra: total feet, 20% is alcohol. And out of total distillate 50% is alcohol.
Ravindra: Okay? So based on this, we can calculate material balance. So material balance feed equal to D plus W and your d plus w will be your total feed.
Ravindra: and the total alcohol will be divided into 2 parts. One is, one will go at distillate, another one will remain at in a in a mixture itself in a in a waste quantity.
Ravindra: This is how you can calculate.
Bakshi.Manish: Tuna.
Ravindra: Montreal.
Ravindra: The drain balance.
Bakshi.Manish: On district.
Ravindra: Golem.
Bakshi.Manish: Music, to.
Ravindra: Yeah. Somebody want to ask something.
Ravindra: Somebody want to ask something.
Ravindra: You have a doubt. Please ask.
Ravindra: This is for distillation.
Ravindra: Next is for for your operation.
Ravindra: Let me let me show you for
Ravindra: you. Operator.
Ravindra: Okay, in industry. Your operator is used for
Ravindra: used for
Ravindra: 2 purposes.
Ravindra: Your operator is used for 2 main application.
Ravindra: One is for making for increasing concentration.
Ravindra: And second one.
Ravindra: your operation is one way of achieving crystallization.
Ravindra: Okay, so we can use you operator
Ravindra: for 2 purposes.
Ravindra: for increasing concentration
Ravindra: and for
Ravindra: forgetting.
Ravindra: The crystal at the end.
Ravindra: Okay.
Ravindra: so let us start the U operator.
Ravindra: Second unit operation is
Ravindra: your operation.
Ravindra: So your operation is unit operation. Use to increase the concentration of
Ravindra: we click on.
Ravindra: We used to call the weak solution as a weak liquor. So your operation is used to consume, make to increase the concentration.
Ravindra: Okay.
Ravindra: and how concentration is increased by your operating part of solvent. Say.
Ravindra: consider, this box is as your U operator.
Ravindra: and what we are feeding here, low, concentrated solution, we called it as a weak solution
Ravindra: is
Ravindra: weak solution or weak liquor.
Ravindra: Okay? And we are converting this V clicker into thick clicker
Ravindra: or thick solution.
Ravindra: Okay, how? By you operating
Ravindra: part of solvent and solvent is water water you operated.
Ravindra: But sometime.
Ravindra: sometime we get crystal
Ravindra: product
Ravindra: here.
Ravindra: if applicable.
Ravindra: Okay.
Ravindra: oops.
Ravindra: Goodness.
Ravindra: So your operator is used to increase the concentration.
Ravindra: Okay.
Ravindra: how concentration is increased by you operating part of solv world.
Ravindra: So material balance or your operator is
Ravindra: all material balance. If you consider
Ravindra: we clicker
Ravindra: is equal to
Ravindra: water evaporated
Ravindra: plus
Ravindra: take clicker obtain
Ravindra: plus
Ravindra: Bristol
Ravindra: product of thing
Ravindra: if applicable.
Ravindra: Okay, if it is not there, our our balance will stick to
Ravindra: this portion. Only.
Ravindra: Okay.
Ravindra: okay, let me tell you one more interesting fact here. When you face such a problem.
Ravindra: you can focus on
Ravindra: on unchanging component.
Ravindra: It gives you a very
Ravindra: it gives you the calculation part
Ravindra: very easy. It makes you calculation very easy if you focus on unchanging component. Okay? So in weak solution, what is present solute.
Ravindra: and how you are increasing concentration by you operating solvent
Ravindra: by you cooperating so on. So your solid part remain as such.
Ravindra: So if you have solute, say, X solute here that X remain here
Ravindra: seemed
Ravindra: so based on this unchanging component, you can. You can,
Ravindra: make your material balance very easy
Ravindra: using unchanging component. Or we sometime we called it as a tie component.
Ravindra: Okay.
Ravindra: okay, so next unit operation is absorption.
Ravindra: So absorption is
Ravindra: absorption is unit operation, which is used to separate a component of gas mixture using certain or suitable solvent.
Ravindra: If we want to use separate ammonia
Ravindra: from some gas mixture. We use water as a solvent, so that ammonia will
Ravindra: dissolve in water, and we can separate it out like this if we want to separate Co. 2. From mixture. We use any caustic solution to separate Co 2 from the mixture. So these solvents are selective in nature.
Ravindra: and how Montreal balance takes place.
Ravindra: So this operation is used in chemical in
Ravindra: for recovery, removal of solute gas component from mixture with other component gases called as inert gases with respect to absorption, so inert in with respect to absorption. So they they are not showing any solubility towards into your solvent. That's why we called it as inner gases, with the help of the help of suitable liquid solvent in which the solute gas is absorbed.
Ravindra: Mechanically agitated vessel pack column are generally used for for this absorption purpose.
Ravindra: And how we take material balance here.
Ravindra: Okay, so how many inputs are there? There are 2 inputs.
Ravindra: Europe.
Ravindra: There are 2 inputs. One is
Ravindra: feed. Yes.
Ravindra: this is, make sure
Ravindra: of gases.
Ravindra: plus.
Ravindra: and your outlet is
Ravindra: lingus
Ravindra: plus
Ravindra: solute
Ravindra: plus zone one.
Ravindra: The feed guess is also called at rich gas
Ravindra: solute rich gas. Okay? And when the absorption is complete you get lean gas, which is
Ravindra: free from
Ravindra: solute.
Ravindra: Say, for example.
Ravindra: let us take example of few guests.
Ravindra: So your flue gas contains
Ravindra: CO, 2
Ravindra: nitrogen
Ravindra: oxygen
Ravindra: ideally, these 2
Ravindra: in in and have water vapor. H. 2.
Ravindra: Okay. If we feed this gas into absorber. And we want to separate C 2
Ravindra: from few gas. So what we'll we'll do
Ravindra: will put
Ravindra: 10%. Anyways here, acoustic solution.
Ravindra: The caustic solution is basic, and it will absorb all acidic gases. That is Co. 2.
Ravindra: So this link gas consists of nitrogen.
Ravindra: oxygen.
Ravindra: H. 2 0. And with
Ravindra: ostracis of
Ravindra: Co. 2, and this Amma at the end, you will get
Ravindra: 10%, any of which.
Ravindra: plus solute
Ravindra: heath.
Ravindra: Using this technique, you can separate Co. 2 from flu glasses.
Ravindra: Any any doubt so far
Ravindra: here the key key factor is, you need to select solvent. Very wisely, that solar must have the higher solubility for your your component gas.
Ravindra: then you need to select
Ravindra: the solubility is important. And let me tell you one more fact that
Ravindra: you know. We are talking about solid, solid ladies. That's why I'm telling
Ravindra: solubility.
Ravindra: Okay? Solubility of gases
Ravindra: is always higher at lower temperature.
Ravindra: It's
Ravindra: solely
Ravindra: ability of gases
Ravindra: is higher.
Ravindra: it
Ravindra: low temperature
Ravindra: and wise for suffer.
Ravindra: Solid solutes! That is salt.
Ravindra: If we dissolve salt in water as we increase temperature, solubility goes on increasing
Ravindra: with temperature.
Ravindra: and for gases it, it behaved vice versa.
Ravindra: It behave vice versa. So solidity of gas
Ravindra: at low temperature is higher, and if you increase temperature, the solubility can decrease.
Ravindra: Okay, remember this. Okay, if if you are.
Ravindra: ask something, you can
Ravindra: any doubt.
Ravindra: Okay, so material balance, we we preferred innard gas here and based on inert gas, we can take material balance
Ravindra: while while so
Ravindra: problem, this will be very clear to you.
Ravindra: Now, extraction. This unit operation used in chemical industry for separation of component of liquid mixture, with the help of suitable liquid solvent.
Ravindra: where the solute from the feed solution is transferred into solvent, adding the raphinate phase which is rich into into feed. Solvent. Okay? And the extract phase, rich in solvent, used. Okay?
Ravindra: It does not gives you your product.
Ravindra: But
Ravindra: it it helps into get separate the 2 2 components. And this extraction is always coupled with other separation technique to force, separation, purpose. So we, we get extract phase and roughinate phase. The this both phases consist of solvent, which we add externally, and that solvent we need to separate using distillation or other separation technique.
Ravindra: So feed plus solvent equal to extract phase plus refinet phase. So a in feed equal to a is in refinet phase plus a in your
Ravindra: extract phase. So this is how we take material balance and component balance over extraction.
Ravindra: Okay, mixing and blending, you know, many time we need mixed product
Ravindra: and industry. So we use blender or mixer for for mixing the 2 components or more than 2 components. This operation carried out in industry to obtain mixed product into desire quantity. So initially, we take
Ravindra: week weeks.
Ravindra: mix it with concentrated seams, so that we can get the desired quantity and desired strength of desired product at the end.
Ravindra: How much we need is trim that we need to calculate
Ravindra: so material balance, feed one plus feed 2 plus feed. 3 gives you desire product and component balance. Feed a in feed string plus feed. A in concentrated string is equal to feed a in desired product.
Ravindra: This is how we get the component balance over
Ravindra: mixer or blender
Ravindra: in filtration. This operation is carried out in industry for separation of solid from suspension. In a liquid
Ravindra: we use filter medium
Ravindra: and based on filter medium. We. We separate
Ravindra: the solid
Ravindra: from liquid.
Ravindra: So centrifuge drum filter is the example.
Ravindra: So feed slary is equal to weight, solid plus filter
Ravindra: utterance. Balance on solid solid is very equal to solid in wet product, the solid in filtered, if any.
Ravindra: So this is how we take Montreal balance.
Ravindra: Okay, let me check
Ravindra: you. All are with me.
Ravindra: Okay? Any any doubt so far.
Bakshi.Manish: That is the filtration. Suppose we are doing filtration, some material would be deposited on the filter also.
Bakshi.Manish: Yeah, all that would be considered.
Ravindra: What we have assumed here initially.
Ravindra: Kelly, that we, we consider this as a steady state condition, so no accumulation within the within the operation.
Ravindra: This is what we assume, but it is ideal condition. But in, you know, in we used to use a filter cloth, so money may.
Bakshi.Manish: Well, that is.
Ravindra: Of materialistic on filter media, so that we need to consider. And when we take unsteady state balance at that time, we consider.
Ravindra: yeah. But this is for your understanding, purpose.
Bakshi.Manish: Rape!
Ravindra: Yeah.
Ravindra: okay, we will move towards next unit operation. That is drying. So you know, in industry, we need to perform any time. Any drying is nothing but removal of moisture from
Ravindra: the product. So we get tried product. And the
Ravindra: we use hot air or certain medium to for performing this task.
Ravindra: Generally, air is used as a
Ravindra: just communicate.
Ravindra: Yeah. Sorry. Sorry for the disturbance.
Ravindra: Okay. Now, in dry, we separate the moisture from the wet, wet product of wet solid. So for separating the moisture we use.
Ravindra: Oh.
Ravindra: maybe sun drying is we use, or maybe we use hot air to. So to remove the moisture.
Ravindra: so material balance, moisture removed from solid is equal to moisture added in the air
Ravindra: and overall material balance is wet, solid, is equal to
Ravindra: dry, solid
Ravindra: plus
Ravindra: moisture separated.
Ravindra: Okay.
Ravindra: so these are the some important unit operation that we are going to cover.
Ravindra: So if you want to ask any doubt you can.
Ravindra: If you have a doubt you please ask.
Ravindra: or will take a 5 min break. Then we again start with some numeric based on this unit operation
Ravindra: we'll solve. One numeric desk on each unit operation.
Bakshi.Manish: But rice.
Bakshi.Manish: Yeah.
Ravindra: We'll take 5 min break, and then we'll start.
Bakshi.Manish: One of you
Bakshi.Manish: if I wanted to convert to some other person
Bakshi.Manish: when
Bakshi.Manish: yes.
Bakshi.Manish: but then, you know
Bakshi.Manish: or no.
Ravindra: Okay, I'm back. Okay, all. All of you
Ravindra: are here
Ravindra: so that we can start.
Bakshi.Manish: Nil.
Ravindra: Okay
Ravindra: Now we'll start with.
Ravindra: start with. I hope my screen is visible.
Bakshi.Manish: Yes, son.
Ravindra: Okay, so we'll start with the mixing problem.
Ravindra: So we need to
Ravindra: form 1,000 kg, mix acid consisting 40% h, 2. So 4, 45%. Hno, 3 and 15% water is to be produced by strengthening waste acid of composition, 30% h, 2 SO, 4, 36%. Hno, 3 and 34% water. By wait, we are using concentrating this weak acid, using concentrated sulfuric acid of strength, 95%.
Ravindra: And the concentrated nitric acid of strength, 80% are available for this purpose. So how many? Kilogram of spent acid, concentrated acid are required together to produce 1,000 kg, these are mixed acid. So let me show you how to solve this problem.
Ravindra: So we'll start with basis first.st
Ravindra: Okay, so basis is, are desired as this acid.
Ravindra: so we need to produce 1,000 kg.
Ravindra: Desired acid
Ravindra: desired as seed
Ravindra: of strength.
Ravindra: 40%
Ravindra: h, 2 s. Of 4 and
Ravindra: 45% HNO, 3.
Ravindra: That is nitric acid.
Ravindra: Okay, so let me draw a schematic diagram so that you'll get better idea.
Ravindra: So what we have. We have
Ravindra: West, acid
Ravindra: waste acid. It contains
Ravindra: 30%
Ravindra: h, 2 SO, 4 and 36%
Ravindra: HMO. 3.
Ravindra: We need to concentrate this acid to
Ravindra: 1,000 kg.
Ravindra: Desired acid.
Ravindra: which contains 40%
Ravindra: h, 2,
Ravindra: and so forth.
Ravindra: and
Ravindra: 45%.
Ravindra: No. 3.
Ravindra: Okay, so this is mixing.
Ravindra: And to increase the concentration, we have 2 concentrated acid
Ravindra: concentrated
Ravindra: h, 2 SO, 4.
Ravindra: It contains
Ravindra: 95% h, 2 SO, 4, 95%,
Ravindra: and so forth, and other one is
Ravindra: concentrated HNO, 3
Ravindra: it contains.
Ravindra: and
Ravindra: and HNO. 3.
Bakshi.Manish: I have a bad day. Good afternoon, boss.
Ravindra: Yeah. So you.
Ravindra: we need to mix this acid 3 acid in a proportion. So at the end we get desert. 1,000 Kg desires mix acid. So let us assume so let's.
Bakshi.Manish: Polio was.
Ravindra: XB.
Bakshi.Manish: Guys huh?
Ravindra: West, as simple.
Bakshi.Manish: That way.
Bakshi.Manish: I didn't believe.
Ravindra: And please mute yourself.
Ravindra: X. Be the waste acid.
Ravindra: Why be the
Ravindra: concentrated
Ravindra: H. 2 SO, 4,
Ravindra: and Z. With the
Ravindra: concentrated
Ravindra: HNO, 3.
Ravindra: So we need to mix this all 3 stream. This is X,
Ravindra: this is y. This is Z
Ravindra: in such a way that we'll get 1,000 kg, desires so overall material balance will be
Ravindra: overall. Material balance
Ravindra: will be input equal to output. So input is x
Ravindra: plus y plus z is equal to 1,000.
Ravindra: This is your equation number one. So we have 3 unknowns. So we need to form 3 equation to solve. Okay.
Ravindra: so second balance is so 1 1st is overall material balance. Second, one is
Ravindra: material balance
Ravindra: on
Ravindra: sulfuric acid.
Ravindra: So sulfuric acid present in 2 streams only
Ravindra: to input stream X,
Ravindra: and why?
Ravindra: And in output one stream, so balance will be
Ravindra: point
Ravindra: 3rd T.
Ravindra: X
Ravindra: plus
Ravindra: point
Ravindra: 95.
Ravindra: Why
Ravindra: is equal to
Ravindra: 1,000
Ravindra: into point 40,
Ravindra: equation 2,
Ravindra: then 3rd equation will be
Ravindra: material balance on
Ravindra: at Cherno. 3,
Ravindra: so HNO, 3, present in 2 stream X and Z, so
Ravindra: point
Ravindra: 36
Ravindra: eggs
Ravindra: plus
Ravindra: point
Ravindra: it.
Ravindra: Z is equal to
Ravindra: 4 50,
Ravindra: equation 3.
Ravindra: Now, we know we have 3 equations, and 3 are known.
Ravindra: Now, we can solve this equation to get XYZ.
Ravindra: The best is
Ravindra: foam.
Ravindra: Here find YZ is equal to
Ravindra: 4 50,
Ravindra: minus
Ravindra: point 36 x divided by
Ravindra: point
Ravindra: 8,
Ravindra: and here y equal to
Ravindra: 400,
Ravindra: minus
Ravindra: point 30 x divided by
Ravindra: point 95. Put this both value of
Ravindra: y and Z in equation one. So we'll get
Ravindra: x
Ravindra: plus
Ravindra: 400 minus point 3
Ravindra: x upon point 95
Ravindra: plus
Ravindra: sorry 4 50
Ravindra: 4 50 minus point 36 x
Ravindra: divided by point 8
Ravindra: equal to 1,000.
Ravindra: You solve this, you will get one. Answer of x equal. 2.
Ravindra: Okay. Put this value of X in equation 3. You will get Z. Put this value of X in Equation 2, you will get. Y
Ravindra: won't let you look
Ravindra: with the end of this.
Ravindra: Okay, now you fall it.
Ravindra: Take a calculator and try to solve it. It's very easy to solve, I guess calculation
Ravindra: you can do
Ravindra: but try to solve yourself, because this kind of problem will be there in your final examination.
Ravindra: Pretty hard.
Ravindra: Wonderful thing.
Ravindra: Looks like
Ravindra: find X, find y, and find Z.
Ravindra: If you have doubt, then ask if you don't have doubt, try to solve it and tell me the answer of XYZ.
Ravindra: So that we can go ahead with second unit operation.
Ravindra: Manish.
Ravindra: Are you calculating?
Ravindra: Get done.
Chetan Bhoyar: Yes, 7.
Ravindra: And Raj.
Ravindra: okay.
Ravindra: a budget.
Ravindra: Are you calculating?
Ravindra: Okay, can anybody
Ravindra: enable XYZ value?
Ravindra: Okay, I assume that you have calculated the value of XYZ.
Ravindra: So, now you know how to solve mixing problem. So let let us take the one more example with
Ravindra: with different unit operation. Okay?
Ravindra: Okay, so we have. The extraction problem.
Ravindra: Then we have your operator problem to you. Operator.
Ravindra: So we'll solve. The extraction problem. First, st
Ravindra: okay.
Ravindra: let me add
Ravindra: homepage here.
Ravindra: Okay, so we have. The extraction problem. Groundnut seeds contain 45% oil and 45% solid heart feed to expeller. That is, extraction column. The kick coming out from extractor is found to contain 80% solid in 5% weight find the percentage recovery of oil. So
Ravindra: we'll start with the basis.
Ravindra: Okay, so we'll start with the basis
Ravindra: 100
Ravindra: KG
Ravindra: ground nut.
Ravindra: See? It is
Ravindra: okay.
Ravindra: So we are feeding this to extraction column
Ravindra: 100 kg.
Ravindra: serious.
Ravindra: So it contains.
Ravindra: it's 45% oil and 45% solid.
Ravindra: 45% oil
Ravindra: and 45%
Ravindra: solid.
Ravindra: So in extraction. The cake is coming out
Ravindra: and click content.
Ravindra: 80% solid, 5% oil.
Ravindra: 5% oil. And
Ravindra: we are extracting
Ravindra: oil
Ravindra: record.
Ravindra: Okay.
Ravindra: so overall material balance will be
Ravindra: overall, material balance will be
Ravindra: 100
Ravindra: is equal to
Ravindra: oil recovered
Ravindra: plus cake of 10.
Ravindra: Message.
Ravindra: Okay, so let us assume this oil recovered as a X and K. Copten as a y.
Ravindra: Okay.
Ravindra: so 100 is equal to
Ravindra: X plus y
Ravindra: ends.
Ravindra: Solid balance.
Ravindra: Things are
Ravindra: is equal to
Ravindra: solid in cake
Ravindra: equal to solidine.
Ravindra: Seals.
Ravindra: there is no solid in oil recovered, so the best way is to find such component, and this component is called unchanging component or tie component
Ravindra: so 100
Ravindra: into point 45 is equal to point 80.
Ravindra: Why? So y will be
Ravindra: 100 into point 45 due to identify point 8. This will be our Y, so value of Y is
Ravindra: okay, let me calculate.
Ravindra: Welcome to
Ravindra: it is 56.25
Ravindra: kg.
Ravindra: so
Ravindra: because in New Hampshire
Ravindra: oil
Ravindra: in cake
Ravindra: is equal to.
Ravindra: So 5% oil is there. So total kick
Ravindra: k is 56.25 into
Ravindra: point 0 5 is oil in cake so multiplied by point 0
Ravindra: 5. So this is 2 point
Ravindra: 81 kg.
Ravindra: so this much oil is wasted in terms of cake, so oil recovered will be
Ravindra: so. Oil
Ravindra: recovered
Ravindra: will be
Ravindra: so, oil
Ravindra: extracted.
Ravindra: plus oil in cake.
Ravindra: So oil recovered, oil
Ravindra: recovered will be
Ravindra: not total oil. Sorry or not. All record the oil balance the oil in
Ravindra: feed
Ravindra: equal to oil extracted plus oil
Ravindra: oil in cake, so oil in feed is equal to point 45,
Ravindra: deployed by 100 is equal to x
Ravindra: plus
Ravindra: 2.81,
Ravindra: so X will be
Ravindra: 45 minus 2.81.
Ravindra: This will. This much oil is extracted
Ravindra: is recovered.
Ravindra: that is.
Ravindra: 42 point
Ravindra: 1 9 KG,
Ravindra: so percentage recovery will be
Ravindra: to percentage
Ravindra: recovery
Ravindra: will be
Ravindra: oil extracted, that is 42.19, divided by oil in feet
Ravindra: into 100,
Ravindra: that is 93 point
Ravindra: 7 25%.
Ravindra: This is your percentage recovery. If you minus this.
Ravindra: oh.
Ravindra: from 100.
Ravindra: So percentage loss will be
Ravindra: 6.27% or 25%
Ravindra: like this.
Ravindra: Okay, this is how we solve this kind of problem.
Ravindra: Any any doubt so far?
Ravindra: No.
Ravindra: Hello!
Ravindra: You can ask doubt if you have.
Ravindra: I'll share my ppt with you
Ravindra: after after this session, and do you? If you have any doubt you can ask.
Ravindra: Okay? So we can go. I I think there is no doubt. So we can go ahead
Ravindra: a different problem. Okay? So we have a second problem, and your operator is filled with for 15,000 kg. Per hour. The solution containing 10% nacl and 15% any average
Ravindra: and rest water in the operation water is evaporated and Nacl is precipitated as a crystal. The thick liquor leaving the U operator contained 45%, any oh, and 2% nacl and rest water. Calculate kg, per hour. Water. You operated kg. Per hour, salt precipitate, and kg, per hour, thick liquor octet.
Ravindra: So let us solve this problem.
Ravindra: So we start with the basis.
Ravindra: So basis is
Ravindra: 15,000 kg. Per hour feed.
Ravindra: Who
Ravindra: you have curator.
Ravindra: Okay?
Ravindra: So let us draw a schematic diagram.
Ravindra: Eva per editor.
Ravindra: There's a fear.
Ravindra: 10,000
Ravindra: kg. Per hour.
Ravindra: So in the operation
Ravindra: it is evaporated, the clicker is obtained and salt is precipitated.
Ravindra: See if you've got
Ravindra: water you operated
Ravindra: and Nacl
Ravindra: recipient did.
Ravindra: Okay.
Ravindra: so let me write the composition. So feed content, 10% Nacl
Ravindra: and 15% on average
Ravindra: water, you operated key clicker consists of
Ravindra: 45%. Any cl.
Ravindra: any of 45%
Ravindra: and 2 person. Nsc.
Ravindra: okay.
Ravindra: okay, so let us assume, let's
Ravindra: assume
Ravindra: eggs.
Ravindra: Kg, per hour
Ravindra: water you operated.
Ravindra: Okay, please remember, we need to find
Ravindra: the number of unknowns and based on number of unknown, we need to derive equations. So if we have 3 unknowns, we need to form 3 equations. If we have 2 unknowns. We need to have 2 equations. So why will will be the Kg per hour
Ravindra: clicker update.
Ravindra: and Z is the Kg per hour.
Ravindra: NA Cl
Ravindra: precipitate.
Ravindra: Okay, so overall material balance will be
Ravindra: x
Ravindra: plus y plus Z,
Ravindra: 15,000.
Ravindra: Equation one. Now, we need to form 2 more equations. So we'll take any wage balance.
Ravindra: So nh, in feed, that is
Ravindra: point 15
Ravindra: into
Ravindra: 15,000
Ravindra: is equal to N over H in 3 clicker.
Ravindra: That is point 45.
Ravindra: What?
Ravindra: So, anyway, she's not presenting any other stream. So we can directly take this.
Ravindra: So why.
Ravindra: 12 2
Ravindra: point 15 into 15,000,
Ravindra: divided by point 45.
Ravindra: So we'll get value of Y directly from this.
Ravindra: This part.
Ravindra: So value of y is
Ravindra: 5,000
Ravindra: kg. Per hour.
Ravindra: Okay.
Ravindra: now we'll find
Ravindra: NS.
Ravindra: In
Ravindra: thick liquor
Ravindra: is equal to
Ravindra: 0 point 0 2 into 5,000
Ravindra: is equal to
Ravindra: 100
Ravindra: kg. Per hour.
Ravindra: Now, Nacl, balance
Ravindra: so nacl in feed, that is
Ravindra: point one into 15,000
Ravindra: is equal to Nacl in thick clicker. That is
Ravindra: point 0 2 n. 2
Ravindra: 5,000
Ravindra: value is 100
Ravindra: is equal to
Ravindra: sorry plus
Ravindra: ncl
Ravindra: dissipated.
Ravindra: Okay, so any sale precipitate is
Ravindra: Ncl
Ravindra: is you could be.
Ravindra: It is equal to
Ravindra: 1,500,
Ravindra: minus 100,
Ravindra: equal to
Ravindra: 1,400 ag. Per hour.
Ravindra: That is
Ravindra: ZD equal.
Ravindra: We know y, we know Z. So x is equal to
Ravindra: 15,000,
Ravindra: minus 5,000,
Ravindra: plus
Ravindra: 1,400.
Ravindra: That is 8,600
Ravindra: page above.
Ravindra: So whatever you've operated is
Ravindra: 8,600 kg. Per hour.
Ravindra: The clicker opt in is
Ravindra: 5,000 kg. Per hour.
Ravindra: and
Ravindra: any sale precipitate is 1,400
Ravindra: pg. Proton.
Ravindra: So this is how we sort of
Ravindra: this problem.
Ravindra: Any any doubt in this.
Chetan Bhoyar: Nope.
Ravindra: Oh, okay.
Ravindra: do you want to solve some? More interesting problem.
Ravindra: So we have one
Ravindra: at last.
Ravindra: So this one
Ravindra: 3.4 or
Ravindra: or we can solve
Ravindra: this one.
Ravindra: Which problem you want to solve. You can say, if you wish.
Ravindra: This is recycles problem, recycle operation problem.
Ravindra: And
Ravindra: also, you have little ones.
Ravindra: And this one is U operators problem. So you can try uop operator problem.
Ravindra: You can try your operator.
Ravindra: Now, you, I I insist. You try.
Ravindra: I insist. You try to solve the 4 3rd problem.
Ravindra: And you operator system concentrating a week liquor from 5 to 50% solid handles, 100 kg. Of solid per hour. If the same system is concentrating the week liquor from 4 to
Ravindra: 35% find the capacity of system in terms of solid that can be handled per hour, assuming water operation capacity to be same in both cases.
Ravindra: Now I want you to try this one.
Santosh Kumar Palo: Like that.
Ravindra: Oils. I will show
Ravindra: living.
Ravindra: Okay, let me let me show you.
Ravindra: Okay, so basis is
Ravindra: the solid that can be handled
Ravindra: per hour is your basis. So basis 100 kg.
Ravindra: solid
Ravindra: handling capacity.
Ravindra: Okay, now we'll we'll solve case one
Ravindra: case one.
Ravindra: So in case one.
Ravindra: this, you operator is handling
Ravindra: 5% solid
Ravindra: who
Ravindra: 50% solid.
Ravindra: So water is evaporated.
Ravindra: So we know that in this U operator 5% solid is there. So let me find feed
Ravindra: evaporator
Ravindra: is equal to
Ravindra: 100,
Ravindra: divided by point 0 5 is equal to
Ravindra: 2,000
Ravindra: kg. Per hour.
Santosh Kumar Palo: Pay me up.
Ravindra: This is your evaporator. Okay, so feed is 2,000 kg. Per hour.
Ravindra: So we know that in.
Santosh Kumar Palo: I have found that we are in Philadelphia for a little bit.
Ravindra: Somebody's talking, please, if you have a doubt.
Ravindra: please ask.
Santosh Kumar Palo: Huna.
Ravindra: Or or mute yourself
Ravindra: hooked us.
Ravindra: Now I'll I'll solve this problem.
Ravindra: Using our equation so
Ravindra: overall material balance will be
Ravindra: 2,000
Ravindra: is equal to
Ravindra: let us assume this as a x, and this is as y, so 2,000 equal to x plus y.
Ravindra: okay and solid balance.
Ravindra: a solid in feed, that is point 0 5 into 2,000
Ravindra: is equal to solidine.
Ravindra: geek.
Ravindra: or 3 clicker, that is, point 5
Ravindra: and 2 y, so y is equal to
Ravindra: 200
Ravindra: Egypt.
Ravindra: So X will be
Ravindra: 1,800
Ravindra: peach.
Ravindra: So water you operated is
Ravindra: 1,800
Ravindra: age.
Ravindra: Okay, so for second case, this is our basis.
Ravindra: So case 2 will be
Ravindra: case two's basis will be
Ravindra: 1,800 Kg.
Ravindra: Water.
Ravindra: You operated.
Ravindra: So
Ravindra: we have same system here
Ravindra: who is concentrating solid
Ravindra: 4% to
Ravindra: 40%
Ravindra: solid.
Ravindra: So what are your operation capacities? 1,800 kg. Per hour?
Ravindra: It's
Ravindra: fertile. Balance will be
Ravindra: feed
Ravindra: is equal to
Ravindra: 3 clicker
Ravindra: plus
Ravindra: 1,800.
Ravindra: This is equation one. So you can denote this term
Ravindra: this as by question or many any notation. Z,
Ravindra: okay, so
Ravindra: we don't know feed, so we assume feed here as a P,
Ravindra: so solid balance will be
Ravindra: so only the balance will be
Ravindra: point 0 4 p is equal to
Ravindra: point 4.
Ravindra: It's it.
Ravindra: Okay? And overall material balance will be
Ravindra: beep
Ravindra: is equal, all 2
Ravindra: Z.
Ravindra: Plus 1,800.
Ravindra: Now you have 2 equations.
Ravindra: one
Ravindra: end quote.
Ravindra: You can solve it for P. And Z.
Ravindra: Good point
Ravindra: 0 4 p. Equal to point
Ravindra: 4
Ravindra: into
Ravindra: heard the mistake here.
Ravindra: I'll put value of P.
Ravindra: Value of P. Nabo equation
Ravindra: from this.
Ravindra: Okay.
Ravindra: so
Ravindra: point
Ravindra: 4
Ravindra: into
Ravindra: Z, plus 1,800
Ravindra: equal to
Ravindra: point 4
Ravindra: Z. So I'll get Z. From this point.
Ravindra: Now let me calculate value of Z from here
Ravindra: point 0 4.
Ravindra: This is
Ravindra: point 0 4 said
Ravindra: bloods.
Ravindra: 72
Ravindra: is equal to
Ravindra: 1 4 0.
Ravindra: So this will be point 0 72 is equal to point 4
Ravindra: z. Minus
Ravindra: point 0 4 z.
Ravindra: So Z. Equal to
Ravindra: 72, divided by point
Ravindra: 36. So this will be
Ravindra: owned.
Ravindra: 200 kg. Will be your Z
Ravindra: to your Z contains 40% solid.
Ravindra: This
Ravindra: so solid
Ravindra: in
Ravindra: 3 clicker
Ravindra: is equal to
Ravindra: pick each.
Ravindra: So this is your solid handling capacity for this. You offer everything each.
Ravindra: So this is how we can solve this kind of problem.
Ravindra: Any doubt so far.
Ravindra: if you have a doubt, you can ask, please.
Ravindra: or else we can go ahead.
Ravindra: Okay, I guess. No doubt. So we can go ahead.
Ravindra: Different problem.
Ravindra: Okay, now, we can solve 12 problem.
Ravindra: Okay, we have solved the upper one. That is desired mixing problem. Now, we'll solve a distillation problem.
Ravindra: a feed to continuous fractionating column analyzed by weight is 28% benzene and 72% built. Only
Ravindra: the analysis of distillate shows 52
Ravindra: whoa.
Ravindra: 8% benzene and 5% benzene was found in bottom product, calculate amount of discrete and bottom product per 1,000 kg. Of feed per hour. Also calculate percentage recovery of benzene.
Ravindra: The basis is
Ravindra: 1,000 kg. Per hour.
Ravindra: Seed.
Ravindra: Okay? No. Problem. A block diagram
Ravindra: for distillation column.
Ravindra: This is 1,000 kg. Per hour
Ravindra: feed. So it consists of
Ravindra: 28%. Wednesday.
Ravindra: 72% only
Ravindra: it is still, it shows
Ravindra: 52% vindic
Ravindra: and bottom product shows
Ravindra: 1%.
Ravindra: Vinzi.
Ravindra: 35% wings in bottom.
Ravindra: So we need to calculate the quantity of distillate and quantity of bottom product of 10 and
Ravindra: the percentage recovery of benzene.
Ravindra: So let us assume
Ravindra: X, Kg, per hour
Ravindra: distillate
Ravindra: display it obtained.
Ravindra: and Y kg, per hour
Ravindra: bottom product of them.
Ravindra: Okay, so overall material balance will be input equal to output, that is, x plus y is equal to 1,000.
Ravindra: And let us start with component balance. That is, benzene balance.
Ravindra: benzene balance will be
Ravindra: benzene in feed, that is
Ravindra: point 28 into 1,000
Ravindra: is equal to.
Ravindra: I don't
Ravindra: thank you, madam.
Ravindra: Point 52
Ravindra: eggs.
Ravindra: plus
Ravindra: point 0 5 1.
Ravindra: So now we'll solve for X and Y
Ravindra: find this one with the afternoon.
Ravindra: So 2 80
Ravindra: is equal to point 52
Ravindra: into bracket, 1,000
Ravindra: minus y
Ravindra: plus
Ravindra: point 0 5 y.
Ravindra: Now, we'll solve this for y
Ravindra: just a minute. Yeah.
Ravindra: Now you solve for X and y.
Ravindra: and tell me the answer.
Ravindra: okay, I hope you have solved this problem
Ravindra: for X value of X and Y,
Ravindra: okay.
Ravindra: I hope you have solved this problem
Ravindra: now.
Ravindra: I think we must stop here. Now you you try to solve some more, some at home.
Ravindra: so I'll I'll share my puppity with you
Ravindra: so that you can solve more video so that you can try more sums.
Ravindra: and in next session
Ravindra: will will focus on, recycle, bypass, purch material balance with chemical reaction and energy balance.
Ravindra: If you any have any doubt. With this session you can ask.
Ravindra: Okay, that's it. Then.
Bakshi.Manish: So malicious.
Ravindra: Yeah. Manish.
Bakshi.Manish: So you are sharing numerical also now for following us.
Bakshi.Manish: So after solving, we can send to you.
Ravindra: You.
Bakshi.Manish: Mode.
Ravindra: The assessment. Then you can send.
Bakshi.Manish: Okay.
Ravindra: Oh.
Ravindra: if you try, if you try more numeric, it will give you idea.
Bakshi.Manish: Yeah, sir. Let me.
Ravindra: One or 2 example. It won't be clear to you.
Bakshi.Manish: And 8.
Ravindra: And in this subject the problems are very difficult to solve.
Ravindra: I am. I am taking very simple one.
Ravindra: So that you you have some idea
Ravindra: we'll we'll go ahead with with some difficult problem as well.
Bakshi.Manish: Right.
Ravindra: Oh.
Ravindra: maybe after maybe after
Ravindra: second in second session will go with certain difficult problem based on recycle, bypass, purge, and then with material balance, with chemical reaction and energy.
Ravindra: We'll try to sort.
Bakshi.Manish: Wait!
Ravindra: Okay. Now we'll we'll stop here.
Bakshi.Manish: Thank you.
Ravindra: Yeah, yeah.
Ravindra: Okay. Now, you can disconnect if you wish. Thank you. Thank you for joining.
Ravindra: Have a nice time.
Chetan Bhoyar: I'm getting up.