Abe 120 Reviewerrrrrrrr
Abe 120 Reviewerrrrrrrr
TOPIC 1
- is a creative activity and is defined as the synthesis, the putting together of ideas to Design
achieve a desired purpose. Also, it can be defined as the creation of manufacturing
process to fulfill a particular need.
- decisions tend to focus mainly on equipment selection though, rather than on Detailed Design
changes to the flowsheet.
- When considering possible ways of achieving the objective the designer will be Design Constraints
constrained by many factors which are called the___________
- over which the designer has some control Internal constraints
- fixed, invariable. External constraints
TOPIC 2
2.1. Activity Symbols
2.2. Types of process charts
- if the flow rates are involved the PFD is called a Combined Flowsheet
- shows the arrangement of the process equipment, piping, pumps, instruments, Piping and
valves and other fittings. Instrumentation Diagram
(P&ID)
- Used to summarize and detail the interrelationship of utilities such as air, water Utility Flowsheet
(various types), steam (various types), heat transfer mediums, process vents and
purges, safety relief blow-down, etc., to the basic process.
- is a document highlighting information on the types and levels of protection Process Safeguarding
offered by the devices installed and their interrelation to demonstrate the plant’s Flow Diagram (PSFD)
safety.
- To reduce detailed written descriptions on flowsheets Flowsheet Symbols
- Pipe through which material flow: Steam, raw materials, and final product Major Process /
Instrument supply
- the instrument is connected directly to the process: a meter inserted to a pipe, Minor process /
material that passes through (the instrument measures the material and displays a flow Connection to process
reading.)
- pressured air ranging from 3-15 psi is sent through a tube. The pressure quantity is Pneumatic
a signal that indicates the value of a variable.
- electronic signals indicate the value of a variable transmitted between two Electric / electronic
instruments
- hydraulic fluid, which represents a signal, sent to a tube Hydraulic
- tube carries fluid that expands and contracts as the temperature to which it is Capillary tubing
exposed changes.
- can be developed to suit the particular process, or as is customary a master coding Equipment Designation
can be established and followed for all projects.
TOPIC 2
- The layout problem occurs because of many developments including: • change in product design
• introduction of new
product
• obsolescence of facilities
• changes in demand
• market changes
• competitive cost
reduction
• frequent accidents
• adoption of new safety
standards
• decision to build a new
plant
- According to the principle of flow, the layout plan arranges the work area for Flow patterns
each operation or process to have an overall smooth flow through the production /
service facility.
- The basic types of flow patterns that are employed in designing the layout are: ✓ I-flow,
✓ L-flow,
✓ U- flow,
✓ S-flow, and
✓ O - flow
- Simplest form of flow I-Flow
- When straight line flow chart is to be accommodated. L-Flow
- very popular as a combination of receiving and dispatch U-Flow
- Easier for supervision (compared to I&L flows)
- When the production line is long and zigzagging on the production floor is S-Flow
required and provides efficient utilization of space and is compact enough to allow
effective supervision.
- When it is desired to terminate the flow near where it is originated and used O-Flow
where process or operations are performed on a rotary table or a rotary handling
system.
- Basic types of layouts • Product or line layout
• Process or functional
layout
• Cellular or group
layout
• ‘Fixed Position’
Layout
- This type of layout is developed for product focused systems Product or line layout
- Developed for process focused systems. Process or Functional
layout
- It is a special type of functional layout in which the facilities are clubbed together Cellular or group layout
into cells.
- This is suitable for producing single, large, high-cost components or products. Fixed Position’ Layout
- includes design, variety, quantity, the necessary operations, and their sequence. The material factor
- includes direct workers, supervision and service help, safety and manpower The main factor
utilization.
- includes the process, producing equipment and tools and their utilization The machinery factor
- includes inter and intradepartmental transport and handling at the various The movement factor
operations, storage and inspection, the materials handling equipment.
- includes permanent and temporary storage and delays and their locations. The waiting factor
- include service relating to employee facilities such as parking lot, locker rooms, The service factors
toilets, waiting rooms etc.; service relating to materials in terms of quality,
production control, scheduling, dispatching, waste control; and service relating to
machinery such as maintenance.
- includes outside and inside building features and utility distribution and The building factor
equipment.
- includes versatility, flexibility and expansion The change factor
- The overall layout design procedure can be considered to be composed of four Phase I: Location
phases: Phase II: General Overall
Layout
Phase III: Detailed layout
Phase IV: Installation
TOPIC 2
2.5. Mass and Energy Balance
- The law of conservation of mass leads to what is called a __________ Mass or a Material
balance
- is very useful tool to represent an entire input and output energy flow in any The Sankey diagram
energy equipment or system such as boiler, fired heaters, furnaces after carrying out
energy balance calculation.
- can be expressed in many ways weight/ weight Concentrations
- (w/w) weight/volume (w/v) molar concentration (M) mole fraction
- is the number of molecular weights of the solute expressed in kg in 1 m3 of the Molar Concentration
solution
- is the ratio of the number of moles of the solute to the total number of moles of all Mole fraction
species present in the solution
- means a mass of the material equal to its molecular weight in kilograms Mole
- Energy takes many forms, such as heat kinetic energy chemical energy potential Energy Balances
energy but because of interconversions it is not always easy to isolate separate
constituents of energy balances
- The most common important energy form is _________ Heat energy
- is the heat required to change, at constant temperature, the physical state of Latent heat
materials from solid to liquid, liquid to gas, or solid to gas
- is that heat which when added or subtracted from materials changes their Sensible heat
temperature and thus can be sensed
TOPIC 3
3.1. Materials Handling Equipment
3.2. Performance Analysis
3.3. Power requirements of Plant Equipment
- To do it safely and economically, different types of tackles, gadgets and Mechanical handling of
equipment are used, when the materials handling is referred to as ________ materials
- is the art and science involving the moving, packaging and storing of Materials handling
substances in any form
- is the movement and storage of materials at the lowest possible cost using
proper methods and equipment
- is the moving of materials or product by any means, including storage, and
all movements except processing operations and inspection
- is the art and science of conveying, elevating, positioning transporting,
packaging and storing of materials
- Improve efficiency of a production system by ensuring the right quantity of Importance of Materials
materials delivered at the right place at the right time most economically Handling
- Cut down indirect labor cost
- Reduce damage of materials during storage and movement
- Maximize space utilization by proper storage of materials and thereby reduce
storage and handling cost
- Minimize accident during materials handling
- Reduce overall cost by improving materials handling
- Improve customer services by supplying materials in a manner convenient for
handlings
- Increase efficiency and sale ability of plant and equipment with integral
material handling features
- Principles of Material Handling Certain • Planning Principle
• Standardization Principle
• Work Principle
• Ergonomic Principle
• Unit Load Principle
• Space Utilization Principle
• System Principle
• Automation Principle
• Environmental Principle
• Life Cycle Cost Principle
- All material handling should be the result of a deliberate plan where the Planning Principle
needs, performance objectives and functional specification of the proposed
methods are completely defined at the outset
- Material handling methods, equipment, controls and software should be Standardization Principle
standardized within the limits of achieving overall performance objectives and
without sacrificing needed flexibility, modularity, and throughput
- Material handling work should be minimized without sacrificing Work Principle Material
productivity or the level of service required of the operation
- Human capabilities and limitations must be recognized and respected in the Ergonomic Principle
design of material handling tasks and equipment to ensure safe and effective
operations Ergonomics is the science that seeks to adapt work or working
conditions to suit the abilities of the human worker
- Unit loads shall be appropriately sized and configured in away which Unit Load Principle
achieves the material flow and inventory objectives at each stage in the supply
chain
- Effective and efficient use must be made of all available space. Space in Space Utilization Principle
material handling is three dimensional and therefore is counted as cubic space Effective
- Material movement and storage activities should be fully integrated to form a System Principle
coordinated, operational system that spans receiving, inspection, storage,
production, assembly, packaging, unitizing, order selection, shipping,
transportation and the handling of returns
- Material handling operations should be mechanized and/or automated where Automation Principle
feasible to improve operational efficiency, increase responsiveness, improve
consistency and predictability, decrease operating costs, and eliminate repetitive
or potentially unsafe manual labor
- Environmental impact and energy consumption should be considered as Environmental Principle
criteria when designing or selecting alternative equipment and material handling
systems
- A thorough economic analysis should account for the entire life cycle of all Life Cycle Cost Principle
material handling equipment and resulting system
- is an important decision as it affects both cost and efficiency of handling system
Selection of Material Handling
Equipment
- The following factors are to be considered while selecting material handling • Properties of the material
equipment. • Layout and characteristics
of the building
• Production flow
• Cost considerations
• Nature of operations
• Engineering factors
• Equipment reliability
- Whether it is solid, liquid or gas, and in what size, shape and weight it is to be Properties of the Material
moved, are important considerations and can already lead to a preliminary
elimination from the range of available equipment under review
- availability of space for handling Layout and characteristics of
the building
- If the flow is constant between two fixed positions that are not likely to change, Production flow
fixed equipment such as conveyors or chutes can be successfully used
- Initial investment and operating and maintenance costs are the major cost to Cost considerations
be considered.
- whether handling is temporary or permanent, whether the flow is continuous Nature of operations
or intermittent and material flow pattern-vertical or horizontal.
- door and ceiling dimensions, floor space, floor conditions and structural Engineering factors
strength.
- Broadly material handling equipment’s can be classified into two categories, (a) Fixed path equipments,
namely: (b) Variable path equipments.
- which move in a fixed path. Conveyors, monorail devices, chutes, and pulley Fixed path equipments
drive equipments belong to this category.
- have no restrictions in the direction of movement, although their size is a Variable path equipments
factor to be given due consideration. This category includes trucks, forklifts,
mobile cranes, and industrial tractors.
- useful for moving material between two fixed workstations, either CONVEYORS
continuously or intermittently.
- ✓ Unit/Bulk + On-Floor + Accumulate Chute Conveyor
- ✓ Inexpensive
- ✓ Used to link two handling devices
- ✓ Used to provide accumulation in shipping areas
- ✓ Used to convey items between floors
- ✓ Difficult to control the position of the items
- ✓ Bridge mounted on tracks that are located on opposite walls of the facility Bridge crane
- ✓ Enables three-dimensional handling
- ✓ Top riding (heavier loads) or underhung (more versatile) versions of the crane
- ✓ Underhung crane can transfer loads and interface with other MHS (e.g.,
monorail systems)
- ✓ Single leg, double leg, and mobile types of gantry cranes Gantry crane
- ✓ Similar to a bridge crane except that it is floor supported at one or both Single, double, mobile leg
ends instead of overhead (wall) supported gantry
- ✓ Used to span a smaller portion of the work area as compared to a bridge crane
- ✓ The supports can be fixed in position, or they can travel on runways
- ✓ Can be used outdoors when “floor” supported at both ends
- ✓ Similar to a bridge crane except that, instead of a hoist, it uses a mast with Stacker crane
forks or a platform to handle unit loads
- ✓ Considered “fork trucks on a rail”
- ✓ Used for storing and retrieving unit loads in storage racks, especially in high-
rise applications in which the racks are more than 50 feet high
- ✓ Can be controlled remotely or by an operator in a cab on the mast
- ✓ Can be rack supported
- ‘dead’ containers (e.g., Cartons, barrels, skids, pallets) which hold the Containers
material to be transported but do not move themselves, or
- ‘live’ containers (e.g., wagons, wheelbarrows or computer self-driven
containers).
- An advantage of robots is that they can perform in a hostile environment such Robots
as unhealthy conditions or carry-on arduous tasks such as the repetitive
movement of heavy materials.
- affecting handling include the following: size (width, depth, height); weight Characteristics of Materials
(weight per item, or per unit volume); shape (round, square, long, rectangular,
irregular); and other (slippery, fragile, sticky, explosive, frozen).
- is either a single unit of an item, or multiple units so arranged or restricted that Unit Load
they can be handled as a single unit and maintain their integrity.
- Basic ways of restraining a unit load: • Self-restraining
• Platforms
• Sheets
• Reusable containers
• Disposable containers
• Racks
• Load stabilization
- Unit load design involves determining the: • Type, size, weight, and
configuration of the load
• Equipment and method
used to handle the load
• Methods of forming (or
building) and breaking
down the load.
TOPIC 4
4.1. Hazard Analysis and Critical Control Point (HACCP)
4.2. Good Manufacturing Practices (GMP)
4.3. Other Standards
- is a systematic approach to identifying, evaluating, and controlling food HACCP (Hazard Analysis and
safety hazards. Critical Control Point)
- is a system that identifies and monitors specific foodborne hazards biological,
chemical, or physical properties that can adversely affect the safety of the food
product
- This hazard analysis serves as the basis for establishing CCPs (Critical Control
- identify those points in the process that must be controlled to ensure the safety Points)
of the food
- the presence of a hazard that does not pose the likelihood of causing an Acceptable Level
unacceptable health risk
- any point in a specific food system at which loss of control does not lead to an Control point
unacceptable health risk.
- a point at which loss of control may result in an unacceptable health risk Critical control point
- the maximum or minimum value to which a physical, biological, or chemical Critical Limit
parameter must be controlled at a critical control point to minimize the risk that
the identified food safety hazard may occur
- failure to meet a required critical limit for a critical control point. Deviation
- a written document delineating the formal procedures for following the HACCP plan
HACCP principles developed by The National Advisory Committee on
Microbiological Criteria in Foods
- a biological, chemical, or physical property that may cause an unacceptable Hazard
consumer health risk
- a planned sequence of observations of measurement of critical limits Monitoring
designed to produce an accurate record and intended to ensure that the critical
limit maintains product safety. Continuous monitoring means an uninterrupted
record of data
- an action to eliminate, eliminate, or reduce a hazard and prevent Preventive measure
recontamination through practical means.
- an estimate of the likely occurrence of a hazard Risk
- any ingredient historically associated with a known microbiological hazard Sensitive ingredient
that causes or contributes to producing a potentially hazardous food as defined
in the Food Code
- methods, procedures, and tests used to determine if the HACCP system is in Verification
use in compliance with the HACCP plan
- Seven principle of HACCP • Principle 1. Conduct a
hazard analysis
• Principle 2. Determine
the Critical Control
Points
• Principle 3. Establish
critical limit(s)
• Principle 4. Establish
monitoring procedures
• Principle 5. Establish
corrective actions
• Principle 6. Establish
verification procedures
• Principle 7. Establish
record keeping and
documentation
procedures
- Identify the potential hazard(s) associated with food production at all stages, Principle 1. Conduct a hazard
from primary production, processing, manufacture, and distribution until the analysis
point of consumption
- Determine the points, procedures, or operational steps that can be controlled Principle 2. Determine the
to eliminate the hazard(s) or minimize its likelihood of occurrence Critical Control Points
- Optimal limits must be specified and validated for each Critical Control Point Principle 3. Establish critical
In some cases, more than one critical limit will be elaborated at a particular limit(s)
step
- The adjustments should be taken before a deviation occurs Data derived from Principle 4. Establish
monitoring must be evaluated by a designated person with knowledge and monitoring procedures
authority to carry out corrective actions when indicated
- Specific corrective actions must be developed for each CCP in the HACCP Principle 5. Establish
system to deal with deviations when they occur corrective actions
- Verification and auditing methods, procedures, and tests, including random Principle 6. Establish
sampling and analysis, can be used to determine if the HACCP system is working verification procedures
correctly
- Efficient and accurate record keeping is essential to the application of a Principle 7. Establish record
HACCP system keeping and documentation
procedures
- Development of HACCP plan • The Team
• Training
• Product description
and Intended use
• Flow Diagram
- Selecting a team of members drawn from various disciplines in the food The Team
processing operation
- HACCP training has now been accepted as the most cost effective means Training
of controlling hazards related to microbiological, physical, and chemical
contamination of foods
- The HACCP team needs to have a complete understanding of the product, its Product description and
intended use, the ingredients used, the composition of the product, and the Intended use
processing steps
- Food processing is a continuous flow of food ingredients from “farm to fork” Flow Diagram
- breaks up the process into sequential steps that assist further evaluation
- Types of Hazards: • Biological hazards
• Chemical hazards
• Physical hazards
- include microbiological organisms such as bacteria, viruses, fungi, and Biological hazards
parasites.
- Chemical contaminants in food may be naturally occurring or may be added Chemical hazards
during food processing
- Illness and injury can result from foreign objects in food Physical hazards
- Soures of hazards • Raw Materials
• Processing Steps
• Machinery
• Handling of Food
• Environmental
Conditions
- the first principle of the HACCP program, is necessary to identify those Hazard Analysis
hazards that must be eliminated or reduced to an acceptable level to produce
safe food.