Preparing an Induction Manual - Report Example

Induction Manual Institution: Name: Abstract The induction report is about the analysis of PFD on a basis of cages in the incoming and outgoing streams in the Plant build by Thanatonous Enterprises in the Bloome in Western Australia. The Project involved two main parts. The first part centered on training the local people on operating equipment used in the analysis. The second part focused on achieving the required quantities of chemicals, processes and outputs as stated by followed standards. There were several processes such as vaporization, Liquid fraction, and so many others used in achieving the desired results. The streams were 30 in numbers. They had names from S1 to S30 with the associated part (B1 to B17). B1 was the entry point while B17 was the Exit one. For the main goal, there were excel sheets for both the Main and Heat streams that had quantities of all chemicals and processes used in the Induction process. The Mainstream had the following; 1. All Chemicals used in the project and their respective quantities. 2. All processes used in the project and their respective quantities. 3. Values for all equipment from S1 to S30 and as well as for B1 to B17 4. Temperature in Celsius degrees 5. Total flow 6. Mass fraction 7. Mole fraction 8. Mass flow 9. Entropy 10. Enthalpy 11. Substream for Mixed States 12. Density 13. Vapor fraction 14. Liquid fraction The Heat stream had the following; 1. Temperature (OC) at the Beginning of S6, S19, S20, and S21. 2. Temperature (OC) at the End of S6, S19, S20, and S21. 3. Quick calculations were in Watts for S6, S19, S20, and S21. The execution of the project by both Thanatonous Enterprises and the local people in Bloome took in into consideration the Land Use Act. The Act allowed 18 workers to work in the Project as a 15% of the total workforce was Indigenous. The Mainstream had quantities of several chemicals, processes and characteristics as shown in the Excel sheet attached. In the Heat streams, the beginning temperatures (o C) for S6, S19, S20, and S21 were 112.078, 180.52, 127.73, and 101.37. The temperatures (o C) at the end of the streams of the same order were 112.078, 180.52, 121.755, and 101.371. The quantities for calculations in Watts were 10502043, 26145737, 19295720, and 11392387 respectively. Table of Contents Abstract 2 Greeting Section 5 Company Description 6 Policy of Thanatonous Enterprises 7 Introduction 7 Hazards 14 Safety 18 Main Objectives 19 Objectives 19 Process Flow 22 Results 23 Conclusion 31 References 32 Greeting Section The Chief Executive Officer (CEO) of Thanatonous Enterprises introduced all workers to the new plant for a period of two weeks. In this time, an in-depth teaching on the operations of the factory occurred. The schedule was such as shown in Table 1. No. Item Duration 1. Introduction of workers of the Company who were responsible for training all incoming newcomers. 1/2 day 2. Introduction to the Australian - English language for the new comers to understand certain terms used in the plant operations 4 days 3. Explanation of all equipments used in the Project. 1/2 day 4. Explanation of safety measures while using several dangerous chemicals such as Sodium hydroxide (Na OH) and Chlorine (Cl.) 2 days 5. Description of all chemicals used in the Project such as Sodium Chloride (Na Cl) and Hydroxides (OH). 10 days 6. Explanation of main and Heat streams with terms such as Entropy, Enthalpy, and Mass flows. Other terms discussed are Vapor fraction, Toatal and Mole flow. States discussed are; Liquid, Solid, and Vapor. 2 days 7. Analysis of each equipment used in the Project for changes in Outflow and Inflow streams. 1 day 8. All the newcomers had to undergo tests to check if they understood the use of all equipments and objective of the Project. 1 day 9. Release of results and corrections followed at the end. 1 day Table 1: Greeting Schedule for newcomers All newcomers to the Induction Project will under extensive training on how to use the equipment that determines the PFD while relying on changes in outgoing and incoming flows. Company Description Thanatonous Enterprises is a company that specializes in the analysis of processes used in Induction with emphasis on Main and Heat streams for a long period since 2000. The company has successful projects that entail the operation of processes channeled at improving Induction over the years. It is a world-renowned company the operated in Australia especially in the Bloome region. The purpose of the Company is to analyze the PFD by determining the role of each tool used in the Induction process. The analysis has a basis of incoming and outgoing flows as the level of references in understanding the PFD. Over the years, the company the operations involve the use of several chemicals to come up with beats analysis of the PFD. The PFD is the determination of the role of each type of equipment in Induction. The equipment had letter S by code. The equipment has numbers such as from S1 to S30 standing for the stream and B1 to B17 for associated parts. B1 and B17 are the incoming and outgoing position of the entire PFD. Policy of Thanatonous Enterprises The policy of the company has a basis of upholding all legal requirements involved in all Projects. For example, in this project, there was the Land Use agreement that demanded that Thanatonous Enterprises employs the locals. The Company did exactly that. The indigenous people had their fair portion to work in the Project as required by the Land Use Agreement between the Locals and the Company. As part of the policy used in this Project, there 120 people employed in 2014 with18 people being indigenous (15% of the entire workforce). Introduction The report is about an Induction that seeks to analyze the Process Flow while using incoming flows such as S1 and S2 at Basepoint B1. The output was at B17 through Stream 23. The Induction was a fast process with a safe source of heat. The process involved the use of several chemicals such as Sodium Chloride, Chlorine, and water. Other chemicals used are inTable 2. Table 2: Other chemicals used in the process. The following were the characteristics of chemical and processes in Induction. Table 3.0: Characteristics of chemical and processes No. Characteristics 1 Entropy 2 Enthalpy 3 Temperature in Celsius degrees 4 Pressure kPa. 5 Liquid fraction 6 Vapor fraction Particular Characteristics are in Table 4. Table 4: Particular Characteristics The flows determined in the Project are in Table 5. Table 5: Flows determined in the Project No. Flow 1 Total Flow (kmol/hr) 2 Total Flow (kg/hr) 3 Total Flow (cum/hr) 4 Mole flow (kmol/hr) Streams and List of Equipments used are in Table 6. Table 6: Streams and List of Equipments No. Stream Position Process Flow Chart To From State of Matter 1 S1 Input B1 N/A Liquid 2 S2 B1 3 S3 Intermediate B3 B2 4 S4 B4 B3 5 S5 B5 B4 6 S6 B5 N/A 7 S7 B5 8 S8 B6 Vapor 9 S9 B6 B5 Liquid 10 S10 B7 B6 11 S11 B6 B8 12 S12 B12 B4 13 S13 B9 B7 Vapor 14 S14 B10 B7 Liquid 15 S15 B17 B10 16 S16 B13 B10 Vapor 17 S17 B11 Vapor 18 S18 N/A B11 Liquid 19 S19 20 S20 B17 21 S21 B17 22 S22 B1 B9 23 S23 Output B17 B13 24 S24 Intermediate N/A B14 Vapor 25 S25 B15 B15 Liquid 26 S26 B13 B16 Mixed 27 S27 B14 B16 Liquid 28 S28 B15 B16 Mixed 29 S29 B16 B16 Liquid 30 S30 B8 B12 The following results reflect the Heat streams for the Project are in Table 7. Table 7: Heat streams for the Project S6 S19 S20 S21 QCALC Watt 10502043 26145737 19295720 11392387 Temperature at the Beginning - Celsius 112.078 180.5253 127.7301 101.3717 Temperature at the End - Celsius 112.078 180.5253 121.7557 101.3717 Scenario The process involved high speed, good control, and consistency. The place of interest was the West Kimberly region in Western Australia. Several people in the area who were not efficient at the Australian English language. In this region, Thanatonous Enterprises gave equal opportunities to all persons involved in the selection process of working in the plant where the PFD underwent critical analysis. There had to be strict provisions to avoid the occurrence of unfair treatment of locals as the Land Act gave a way forward on what to do. Several legal policies and documents were present in the execution of the study. For example, there was the Indigenous Land Use Agreement that gave some part of Western Kimberly to the Company for its activities. In this way, the local people had a participating role in the analysis of PFD after undergoing vigorous training on how to handle the chemicals and processes involved in the operations of Main and Heat streams. The CEO of Thanatonous focused on playing his role in line with the Land Act. The CEO had a commitment to avoiding any delays in the delivery of services. To achieve this, the CEO came up with measure as shown in Table 8. Table 8: Selected Processes and procedure in terms of formulae No. Process Procedure 1 Total Flow Calculation based on mass in Kilograms per hour 2 Density Calculation based on grams per cubic meter. L3 Vaporization Heating the given liquid to form vapor at the stated temperatures The Liquid phase had the stream from S1 to S7 as shown in Table 9. There is so much socio – economic unfairness in the area of Broome when it comes to education. Most people in the area who are local hardly reach university, as the problems are the lack of fees and no interests in it. However, other youth who would have wanted to study cannot as their parents or guardians do not wish them to do so. The belief is that the original values of the Aboriginals are under threat and by stopping one from studying, there is a high chance to maintain the tradition. The language in the area is Aboriginal English, which is a mixture of the local dialect and Australian English. It appears therefore that understanding the operations conducted in English were a problem occasionally. The result was the shyness that most of the Aboriginals showed at the workplace as the confidence and command of the English language was a challenge in its self for them. Most of the workers were in the unskilled categories, and so performed the related task Thanatonous Enterprises had a few well educated indigenous people from the area as most of the workers were the unlearned ones from the area. There was a facilitator employed to train specifically the indigenous people to train and induct them. The facilitator ensured that the people who worked for Thanatonous Enterprises had a good well being that enabled productivity to be high enough in favor of the company. Hazards There are several hazards that endanger life and property of the workers in one way or another. However, the CEO has a strategy on how to overcome these issues. These are in Table 1. Table 10: Hazards and Related Remedies. No. Hazard Degree Chemical or Item to watch out for Effects Remedies 1. Heat Fata 1. All chemicals heated to very high temperatures. 2. All equipments involving too much heat. Skin burns Wear of protective materials to shield the body from damage. 2. Chemical Burning Fatal. 1. Sodium Hydroxide (Na OH(aq)) 2. Hydrochloric acid (HCl (l)). 3. Aluminum III Oxide (Al2O3(l)) 1. Increase of risk of cancer of the skin. 2. Skin damage and peeling. 3. Pain at the exposure of radioactive material. 1. Use gloves 2. Uses of foot wear to protect feet from acid and alkaline attack. 3 Corrosion Fatal 1. Hydrochloric acid (HCl (l)). 2. Aluminum III Oxide (Al2O3(l)) 3. Sodium Chloride (Na Cl (aq)). 4. Silicon II Oxide (SiO2(aq)) 1. Skin damage 2. Wounds. 3. Long term Cancer 3. 4. Piercing objects on ground. Fatal. Broken pipettes in the Laboratory. 1. Wounds at the feet as a result of piercing objects on ground. 1. Use of gumboots to protect the feet from piercing objects. 5. Too much light during explosive reactions Secondary. Volatile reactions between Acids and Anhydrides. 1. Partial blindness. 2. Full blindness after a long period of time. 1. Use of eye protecting glasses. 2. Use of diluted chemicals. 6. Burns. Secondary. Damage of the skin and hands. Use of lead made gloves to shield the hands. 7. Electrical shocks and Short circuits. Fatal. All un-insulated wires. 1. Death. 2. Destruction of property like that of the company. 1. Use of insulated electrical wires. 2. Use of insulators like rubber when using electricity in the induction process. 3. Continuous checkups on all electrical wires. 8. Falling objects in the laboratory. Fatal. Secondary. Loosely placed bottles and materials such as bottles that keep chemicals. 1. Damage of head and other body parts resulting to injuries. 2. Destruction of property on hitting or when hit on the ground. 3. Costs in terms of replacement. 1. Wearing of head gears or elements to shield the head. 2. Use of Sign posts that inform all workers and visitors about dangerous chemicals in the laboratory. Safety Several precautions existed in as far as the well-being and safety of the workers at Thanatonous mattered. For example, there were clear explanations concerning the reactions involved for several chemicals. The truth is that there were certain chemicals that were dangerous. The chemicals were Hydrochloric acid (HCl (l)) to mention a few. The chemical burns they were concentrated. The result was that several pole in the use of the chemicals had to wear protective clothes to shield them from body harm as they conducted reaction involved in the Induction process. The facilitator had a task of ensuring that all workers of the company were in the right place at the right time. The way of achieving this was using induction and training manuals that helped to explain to indigenous workers the operations and activities relating to the plant. The result was not having cases of hazard damages. The facilitator had to set up a team of indigenous people who would explain to their fellow workers the safety measures while working at the plant. The risk at the time was that suppose the native workers were unsafe, and then the operations of the company would be in serious jeopardy. The next thing would be falling productivity. The company would be in losses that in turn would affect the financial status of the Company. The CEO would face a challenge of not having followed the terms and conditions of the Land Use Agreements. In most cases, there would be a penalty placed on the company. The penalty would tarnish the image of the company and affect its future operations in the area. Main Objectives The purpose of the report is to analyze of PFD on a basis of incoming and outgoing streams. Objectives The objectives are; 1. To identify all processes involved in the Induction process such as Liquid and Vapor fraction. Others were Vaporization 2. To calculate the Enthalpy and entropy in various terms. Other needed values were the quantities of the Chemical used. 3. To determine the parameters of central and heat stream in Excel sheets. Table 11: Equipment in the Induction Plant There is the provision of pneumatic controls. Process Flow Figure 1 below shows the flow of the Induction Process. The Input is through Stream S1 and S2 entering B1 with an output at B17 with switch S23. Figure1. Process Flow for the Induction Results The results are for both Main and Heat streams. Mainstreams start from Figure 2 to Table 12. There were three states of matter in connection with the Induction Process. These were Liquid, Vapor, and a mixed state of Vapor and Liquid. The states of matter exist in Figure 2 below. Figure 2: States of matter involved in Induction. Table 14: Substream for mixed states from S1 to S18. Table 15: Continuation of mixed states from S18 to S23. Table 16: Values of Vapor Frac to Enthalpy in Watt for S1 to S18. Table 17: Continuation for Values of Vapor Frac to Enthalpy in Watt for S18 to S23. Table 18: Mass flow for all states from S1 to S18 for several chemicals. Table 19: Mass flow for all states from S18 to S23 for several chemicals. Table 20: Mass flow for all states from S1 to S18 for several chemicals. The last values are for Cumulative total flows. Table 21: Continuation of Mass flow for all states from S18 to S23 for several chemicals. The final values are for Cumulative total flows. Table 22: Enthalpy, Density, Vapor for S1 to S18. Conclusion The Mainstream had quantities of several chemicals, processes and characteristics as shown in the excel sheet attached. In the Heat streams, the beginning temperatures (o C) for S6, S19, S20, and S21 were 112.078, 180.52, 127.73, and 101.37. The temperatures (o C) at the end of the streams of the same order were 112.078, 180.52, 121.755, and 101.371. The quantities for calculations in Watts were 10502043, 26145737, 19295720, and 11392387 respectively. References Abad, G. (2011). 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San Diego, Academic Press. Zinn, S., & Semiatin, S. L. (1988). Elements Of Induction Heating Design, Control, And Applications. Metals Park, Ohio, Asm International. Read More