Powerpoint slides
Jim_Ak
ppt_assignmnt.zipBlending Instructions -Draft.pptx
ORIENTATION
Along with the East and West tank farms, pathways, catwalks and isle’s comes a degree of difficulty that only time and repetition can solve. All the while being mindful of your surroundings and the safety barricades, signs, bollards, procedures and contractors at work. Where’s the Hot House? Where’s the drum additive section? Where is Kettles 715, 716 and 717? We will answer these questions and along the way we will find the Blending highways high in the air that service some of the tanks that we will be blending. There are many areas of the plant here at HLP that a blender will visit throughout the Corse of a day while completing His or Her work. By far, understanding and adhering to all safety processes and procedures is the #1 task given to any Blending Operator!
The intent of this session is for the new operator to acquire a general knowledge of the Equipment and Blending units locations He or She will be tasked to operate on a daily bases.
A general understanding is really all we can expect to achieve in the training room as the highest level of knowledge is acquired in field operations.
BLENDING TOOLS AND EQUIPMENT
PD (positive displacement) pumps,centrifical pumps and diaphragm pumps. Drum pumps, DDU (Drum Decanting Unit) etc..
Gate valves, ball valves, check valves, control valves, Flap valves and PRV’s (pressure relief valves). Pneumatic, electrical, mechanically and manually operated etc..
Sensors/Indicators. Temperature, Product, Pig, Pressure and H2S sensors.
Filters/Strainer. Cartridge and sock filters. Screen mesh strainers (basket and inserts) etc..
Hand tools (gauging, drum and sampling tools) etc..
Control room servers and data screens/ HMI (Human Machine Interface) etc..
Even though most operators will never need to interact with the internal mechanics of most of these devices and tools, having a working knowledge of the equipment will serve them greatly while troubleshooting any difficulty He or She may be experiencing with any given task.
Even though most operators will never need to interfere with the internal mechanics of most of these devises, to have a working knowledge of the equipment will serve them greatly while trying to trouble shoot any difficulty He or She may be experiencing with any given task.
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Blending Units
ILB’s (Inline Blending Unit).
BBV’s (Batch Blending Unit).
DDU’s (Drum Decanting Unit).
TBU (Turbo Blending Unit).
SVU (Shel-visc Blending Unit).
Hot Oil Unit.
In this session we will be discussing how to Move a series of raw materials either one component at a time individually or multiple components simultaneously which will be the difference between Batch Blending and Inline blending. Inline blending under normal circumstances is a high volume blending process that utilizes multiple raw material tanks to introduce components simultaneously into a single discharge line with a inline mixer. The batch blending process is much more labor intensive involving drum or bag additives that generally have to be manually introduced either by drum decanter, hands on dumping or fork lift with drum handling devises.
In this session we will be discussing how to Move a series of raw materials either one component at a time individually or multiple components simultaneously which will be the difference between Batch Blending and Inline blending. Inline blending under normal circumstances is a high volume blending process that utilizes multiple raw material tanks to introduce components simultaneously into a single discharge line with a inline mixer. The batch blending process is much more labor intensive involving drum or bag additives that generally have to be manually introduced either by drum decanter, hands on dumping or fork lift with drum handling devises.
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Tanks and Vessels Data
Tank and Vessel data.
GSI ( GSI is our tank monitoring program that includes…. Product Names and Codes, Levels, Temperature, Flow rates, Specific Gravities, Gross and Net Gallons, etc.).
FMC Tank Overview
Tank/Vessel data plate.
Strapping Logs.
All the tank/vessel data an operator will need at HLP is available through a series of software programs such as GSI , Microsoft Excel and FMC tank overview. Tank strapping charts are also available in book binders located in the Control Room. Each individual tank/vessel has its basic data plate attached to it. GSI is the primary data supplier for tanks. Information includes Product Codes, Names, Volume (gross/net), Current Levels/Gauges, Temperature, Flow Rates and Alarm conditions ( high level, low level, high temp, low temp and communication failures). FMC receives it’s tank data from GSI and has much of the corresponding data. Tank strapping charts are available for converting hand gauges to gallon amounts but also have data such as gallons per inch, tank capacity and gauging depth. These charts are also available in computer form via Microsoft Excel Tank strappings on HLP’s shared drive.
All the tank/vessel data an operator will need at HLP is available through a series of software programs such as GSI , Microsoft Excel, FMC tank overview. Also, Tank strapping charts are available in Book binders located in the Control Room. Each individual Tank/vessel has its basic data plate attached to it. GSI is the primary data supplier for tanks. Information includes Product codes, Names, volume (gross/net), current levels/gauges, Temperature, Flow rates/GPM’s, Alarms if any ( high level, low level, high temp, low temp and communication failures. FMC has much of the corresponding information. ( Note FMC receives it data from GSI). Tank strapping charts are available for converting hand gauges to gallon amounts but also have data such ( gallons per inch, tank capacity and gauging depth). These charts are also available in computer form VIA, Microsoft Excel Tank strappings on HLP’s shared drive.
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Product Mixing Capabilities
Mixers and agitation tools/devices.
Pneumatic (air sparge ).
Tank/vessel prop mixers.
Inline jet mixers.
Tank/vessel circulation capability.
Inline mixers (homogenizers).
To take multiple components (raw materials) from different vessels/drums and marry them (homogeneously) into one finished product tank successfully is the purpose of this session. Different finish product tanks have either one or multiple mixing capabilities. When available, used in tandem and correctly, will create the maximum amount of turbulence in the tank. This can make all the difference in blending time and efficiency.
To take multiple components (raw materials) from different vessels/drums and marry them (homogeneously) into one finished product tank successfully is the purpose of this session. Different finish product tanks have either one or multiple mixing capabilities. When available, used in tandem and correctly, will create the maximum amount of turbulence in the tank. This can make all the difference in blending time and efficiency.
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Temperature controls
Temperature control/heating capabilities.
Tank/Vessel Jackets (Hot Oil or Steam).
Tank/Vessel internal coils (Hot oil or Steam).
Portable Drum Jackets. (Electrical Drum Heating bands).
Heat Tracing.
Hot House.
Steam Boiler.
Hot Oil unit.
In this session we will discuss the benefits and effects of temperature control and temperature control devices/tools that play a critical role in the blending process. There are certain raw materials that are very difficult if not impossible to pump without a certain degree of heat involved. Some raw materials are received in a solid state at low temperature and need to be heated in order to achieve pumping capability. Finish product materials such as Gear oils, Heavy duty engine oils etc. are also pumped more efficiently at a certain temperature. There are many heating processes used at HLP.
In this session we will discuss the benefits and effects of temperature control and temperature control devises/tools that play a critical role in the blending process. There are certain raw materials that are very difficult if not impossible to pump without a certain degree of heat involved. Some raw materials are received in a sold state at low temperature and need to be heated in order to achieve pumping capability. Finish product materials such as Gear oils, Heavy duty engine oils etc. are also pumped more efficiently at a certain temperature. There are many heating processes used at HLP.
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Weights And Measures
Product weights and metering devices.
Load cells (mass/weight).
Mechanical meters (volume).
Micro Motion meters (mass).
Digital and analog meters (volume).
Drum scales (mass/weights).
Forklift Scales (mass/weights).
In this session we will introduce new operators to the different scaling/metering methods and devises. As any good formula will call for just the right amount of Base oils, detergents, viscosity enhancers, inhibitors, etc. of many different types. These components are carefully added to any given blend at a predetermined percent/ratio. In doing this the components will need to be measured to the exact ratio that the formula calls for. We will discuss the many different devises that assist the blending process in doing so. Although it will not be necessary for a Blending operator to fully understand the internal mechanics of these meters/scaling devises, Knowledge of their functions and limits will allow an operator to avoid unnecessary damages to the unit and assist He or She in assuring the proper targets are reached.
In this session we will introduce new operators to the different scaling/metering methods and devices. As any good formula will call for just the right amount of Base oils, detergents, viscosity enhancers and inhibitors of many different types. These components are carefully added to any given blend at a predetermined percent/ratio. In doing this the components will need to be measured to the exact ratio that the formula calls for. We will discuss the many different devises that assist the blending process in doing so. Although it will not be necessary for an Blending operator to understand the internal mechanics of these meters/scaling devises, Knowledge of their functions and limits will allow an operator to avoid unnecessary damages to the unit and assist He or She in assuring the proper targets are reached.
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Drum pumping/Additive handling
DDU’S ( Drum Decanting unit).
Board Pumps.
Mini Bulk’s.
Portable Diaphragm Pumps.
Drum Dollies.
Manual Hand Crank Drum Pumps.
Mostly for the use in industrial lubricants (Gear oil’s Hydraulics oil’s, Turbine oil’s etc.) drummed, kegged, and bagged additives are received via box trailer. HLP has a number way to introduce these additives into the blends requiring them. Pumps and Decanting units are the primary units used but some times where these units are not feasible, manual handling devices such as (mechanized drum tilting units, potable diaphragm pumps and vacuum assisted lifting devices) are the required remedy. And on occasions good old fashion hands, arms, legs and back are required. In any case, non-bulk additives are required in a number of blends and in this session we will take a look at some of the ways they are added and handled.
Mostly for the use in industrial lubricants (Gear oil’s Hydraulics oil’s, Turbine oil’s etc.) drummed, kegged, and bagged additives are received via box trailer. HLP has a number way to introduce these additives into the blends requiring them. Pumps and Decanting units are the primary units used but some times where these units are not feasible, manual handling devises such as (mechanized drum tilting units, potable diaphragm pumps and vacuum assisted lifting devises) are the required remedy. And on occasions good old fashion hands, arms, legs and back are required. In any case, non-bulk additives are required in a number of blends and in this session we will take a look at some of the ways they are added and handled.
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Raw materials Identifier
Base oils ( Three main Groups).
Detergents.
Viscosity Enhancers.
Anti-foams.
Dye’s.
Markers ( Rust inhibitors).
Pour Points.
Emulsifiers.
Polymers. (generally Bags and Kegs).
Most raw material products have their own unique quality's, (appearance, smell, consistency, and handling properties). Base oils in most cases but not all are generally light/clear in color, light in odor, thin in consistency/texture, with no metals (phosphates, calcium and zinc) and pump very efficiently. Detergents on the other hand are generally very dark in color, aggressive in odor, thick and thin in consistency/texture, high in metals and sometimes pump poorly at low temperatures but not always. Viscosity enhancers are generally medium in color, light in odor, very thick in consistency/texture and always pump poorly at low or average temperature. There are many other additives and finish products with similar properties that if not removed from the tanks, lines and equipment prior to the start of a non-compatible blend, the residual components can and will effect the results/outcome of that blend. During this session we will attain a general knowledge of these components and their effects and importance to the blending process.
Most raw material products have their own unique quality's, (appearance, smell, consistency, and handling properties). Base oils in most cases but not all are generally light/clear in color, light in odor, thin in consistency/texture, with no metals (phosphates, calcium and zinc) and pump very efficiently. Detergents on the other hand are generally very dark in color, aggressive in odor, thick and thin in consistency/texture, high in metals and sometimes pump poorly at low temperatures but not always. Viscosity enhancers are generally medium in color, light in odor, very thick in consistency/texture and always pump poorly at low or average temperature. There are many other additives and finish products with similar properties that if not removed from the tanks, lines and equipment prior to the start of a non-compatible blend, the residual components can and will effect the results/outcome of that blend. During this session we will attain a general knowledge of these components and their effects and importance to the blending process.
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Presentation1.pptx
Blend Center Training
Introduction to Blend Center Training
By
John Marksberry & Terry Jones
Purpose
Training is essential to the achievement of HLP and it’s employees.
HLP is committed to ensure all employees are well trained.
The purpose of this training is to provide employees with the tools and knowledge to perform their jobs at an optimal level.
HSSE
HLP is committed to keeping employees safe.
Goal Zero is obtainable.
Horseplay is not tolerated.
There are XXXX fire extinguishers in the blend center.
There are XXXX eyewash stations.
There are moving forklifts.
Tank Farm
Tank farm – the location of storage tanks.
HLP has 2 tank farms – East and West.
HLP has over 150 tanks.
Tanks consist of 3 types of products: finished goods, additives and base oils.
All tanks have high level alarms to sound in the event of a tank overfill.
Zinc containing additives have H2S monitors
Unit Locations
Highway Locations & Functions
Kinder Morgan/Headers
Day Tanks
Additive Tanks – 48
Base Oil Tanks -27
Cocktail Tanks – 4
Shell Vis Tanks – 2
Turbo Kettles – 1
Mini-bulks – 8
Dye Skids – 3
Tanks -100
Stack Tanks -5
Flush Oil Tanks - 5
Finished Product vs Additive vs Base Oil
Finished Product – a product that is blended XXXXXXXXXXXX
Additive - a substance added to something in small quantities, typically to improve or preserve it.
Base Oil – typically the performance of a finished product is primarily influenced by the quality and the viscosity of the base oil.
Tank Construction
Cone Bottom – cone bottom tanks are tanks with a cone bottom. These tanks provide a more complete drain when product is being drained from the tank.
Flat Bottom -
Min-Bulk /Cocktail Tanks
Mini-bulk – There are 12 mini-bulk tanks. Mini-bulks are small storage tanks filled with drum additives to feed ILB units.
Cocktail tanks - There are four cocktail tanks attached to ILB 3103. Cocktails prepared and stored in these cocktail tanks can be used as components in inline blends. The cocktail tanks can be used like a batch blender with limited batch functions.
Hot House
HLP has 3 hot house units.
Two units temperature set at 140°F
1 unit temperature set at 210°F
Hot house units are used to store drum additives at designated temperatures to ensure optimal decanting when dosing.
Hot house unit is selected according to Global Product Catalogue (GPC) recommendations
Recommendations are based off viscosity of product and chemical compound.
Control Room
Blend control room consist of:
4 ILB Units
2 BBV Units
1 Primary Client
Engineer Client PC
