A Technical Audit of a Plantcan identify the bottlenecks to increased production, highlight equipment or operation which limit efficiency and direct the improvement of the on-stream factor.

In response to requirements, more and more often met in the Petrochemical & Fertilizer Industry, Bajpai Limitedhas decided to offer a Technical Audit Service.

Bajpai Limited is in a unique position to offer such a service as it has a highly experienced team of talented Chemical Engineers fully conversant with all process operating techniques and well versed in application of data evaluation design/engineering computer packages, etc.

FULL SCALE TECHNICAL AUDITS OF PROCESS PLANTS:

A technical audit of a plant can identify the bottlenecks to increased production, highlight equipment or operation which limit efficiency, and direct the improvement of the on-stream factor.

In response to requirements more and more often met in the petrochemical and fertilizer industry Bajpai Limited has decided to offer a Technical Audit Service as outlined below.

Bajpai Limited is in a unique position to offer such a service as it has a highly experienced team of talented chemical Engineers fully conversant with all process operating techniques and well versed in application of data evaluation design /engineering computer packages.

The Technical Audit Package will consist of a number of elements. It has the overriding aim of helping the owner to achieve optimum operating results at all times.

As a precursor to the audit, we will jointly with the owner define the criteria which shall govern the optimization, and the parameters, including unit prices, on which calculations shall be based. In a joint review it will furthermore be ascertained that the plant is adequately equipped with instrumentation, control systems, etc. for measurement of parameters allowing a meaningful evaluation of the operation and operational trends. Once this has been established and discussed with the owner, the package we offer for ongoing collaboration will consist of the following elements:

a) A full technical audit at regular intervals and discussions with the owner of the audit report.

b) In between audits, the owner may submit questions or data sheets to us for comments or advice.

c) We will analyze operating data submitted with a view to optimizing plant operation based on the criteria given by the owner and with a view to identifying any trends that may be of importance to continued plant operation. Results of this analysis will be reported to the owner.

d) The owner may, in case he experiences problems or foresees problems, submit information to us and request our analysis with a view if diagnosing the trouble or potential trouble.

e) Together with the owner we will set up procedures for collecting regular information about the plant operation. This will be inserted in special data sheets, copies of which will be sent to us for comments.

For a full technical audit, we will typically propose to proceed as follows:

a) FACT FINDING MISSION:

The technical audit is initiated by delegating one or two engineers to the plant for a period of approx. one week for collection of operating data from the plant for a review and discussion with the plant personnel of the problems they may have with the operation of the plant and of the plant sections which should be studied closer in order to achieve a better operations.

b) REPORT ON TECHNICAL AUDIT:

Based upon the information collected during the fact finding the mission and often supplemented with additional data submitted by the owner in the form of filled out standards input sheets, we prepare a report incorporating our recommendations. The main points of the report may be as Ammonia Plant Technical audit.

1. PRELIMINARY EVALUATION of the data received and establishment of a consistent set of operating data, using our advanced error-smoothing procedure.

2. ANALYSIS OF THE OPERATION of the complete plant as well as of the most important individual process steps such as:

2.1 CATALYTIC REACTORS:

For catalytic reactors our analysis will include an assessment of the activity, remaining lifetime of the catalyst, pressure drop, and general state of the catalyst.

2.2 HEAT RECOVERY EQUIPMENT AND BOLLERS:

For this type of equipment the analysis will typically cover an evaluation of the equipment with respect to fouling, and recommendation with respect to the improvements in operation which can be achieved by cleaning of the equipment.

MAIN ROTATING EQUIPMENT:

The efficiency of turbines and compressors will be established also in order to give an indication of possible process operating problems.

3. RECOMMENDATION FOR ADJUSTMENT OF OPERATING CONDITIONS:

Based on the analysis of the operation of the individual sections and the complete plant, we will investigate whether a more efficient operation can be obtained by adjusting the operation conditions. We will furthermore make a Review of Start-up and shutdown procedures applied with a view to suggesting possible improvements in order to shorten start-up time and time for restart after shutdowns.

4. RECOMMENDATION FOR MODIFICATIONS AND FOR REPLACEENTS:

The report will also include our recommendations for possible modifications which might be studied in order to improve the operation.

5. The report would also contain an Energy Audit of the plant aimed at accurately evaluating the input consumption per unit product, outlining possible areas of energy saving and recommending an action plan for energy saving eventually leading to very substantial cost savings and enhanced profitability.