Common operations failure modes in the process industries

The Abnormal Situation Management^® (ASM^®) Consortium (This research study was sponsored by the Abnormal Situation Management (ASM) Consortium. ASM^® and Abnormal Situation Management^® are registered trademarks of Honeywell International, Inc.) funded a study to investigate common failure modes and root causes associated with operations practices. The study team analyzed 20 public and 12 private incident reports using the TapRoot^® methodology to identify root causes. These root causes were mapped to operations practice failures. This paper describes the top ten operations failure modes identified in the analysis. Specific recommendations include how to analyze plant incident reports to better understand the sources of systemic failures and improve plant operating practices.     

Overexpression of ATP sulfurylase in Indian mustard: effects on tolerance and accumulation of twelve metals

Indian mustard [Brassica juncea (L.) Czern.] transgenics overexpressing ATP sulfurylase (APS plants) were shown previously to have higher levels of total thiols, S, and Se. The present study explores the effect of ATP sulfurylase overexpression on tolerance and accumulation of other metals, both oxyanions and cations, reasoning that some anions may react directly with ATP sulfurylase, while other ions may be bound by its thiol end products. The APS transgenics were compared with wild-type plants with respect to tolerance and accumulation of As, Cd, Cr, Cu, Hg, Mn, Mo, Ni, Pb, V, W, and Zn, supplied individually in agar medium (seedlings) or in hydroponics (mature plants). At the seedling stage, APS transgenics were more tolerant than wild type to As(III), As(V), Cd, Cu, Hg, and Zn, but less tolerant to Mo and V. The APS seedlings had up to 2.5-fold higher shoot concentrations of As(III), As(V), Hg, Mo, Pb, and V, and somewhat lower Cr levels. Mature APS plants contained up to 2.5-fold higher shoot concentrations of Cd, Cr, Cu, Mo, V, and W than wild type. They also contained 1.5- to 2-fold higher levels of the essential elements Fe, Mo, and S in most of the treatments. Mature APS plants showed no differences in metal tolerance compared with the wild type. Overexpression of ATP sulfurylase may be a promising approach to create plants with enhanced phytoextraction capacity for mixtures of metals.     

Differences in Evaporation Between a Floating Pan and Class A Pan on Land1

Abstract: Research was conducted to develop a method for obtaining floating pan evaporation rates in a small (less than 10,000 m²) wetland, lagoon, or pond. Floating pan and land pan evaporation data were collected from March 1 to August 31, 2005, at a small natural wetland located in the alluvium of the Canadian River near Norman, Oklahoma, at the U.S. Geological Survey Norman Landfill Toxic Substances Hydrology Research Site. Floating pan evaporation rates were compared with evaporation rates from a nearby standard Class A evaporation pan on land. Floating pan evaporation rates were significantly less than land pan evaporation rates for the entire period and on a monthly basis. Results indicated that the use of a floating evaporation pan in a small free‐water surface better simulates actual physical conditions on the water surface that control evaporation. Floating pan to land pan ratios were 0.82 for March, 0.87 for April, 0.85 for May, 0.85 for June, 0.79 for July, and 0.69 for August.     

Determination of specific gravity of municipal solid waste

This investigation was conducted to evaluate experimental determination of specific gravity (G_s) of municipal solid waste (MSW). Water pycnometry, typically used for testing soils was adapted for testing MSW using a large flask with 2000 mL capacity and specimens with 100–350 g masses. Tests were conducted on manufactured waste samples prepared using US waste constituent components; fresh wastes obtained prior and subsequent to compaction at an MSW landfill; and wastes obtained from various depths at the same landfill. Factors that influence specific gravity were investigated including waste particle size, compaction, and combined decomposition and stress history. The measured average specific gravities were 1.377 and 1.530 for as-prepared/uncompacted and compacted manufactured wastes, respectively; 1.072 and 1.258 for uncompacted and compacted fresh wastes, respectively; and 2.201 for old wastes. The average organic content and degree of decomposition were 77.2% and 0%, respectively for fresh wastes and 22.8% and 88.3%, respectively for old wastes. The G_s increased with decreasing particle size, compaction, and increasing waste age. For fresh wastes, reductions in particle size and compaction caused occluded intraparticle pores to be exposed and waste particles to be deformed resulting in increases in specific gravity. For old wastes, the high G_s resulted from loss of biodegradable components that have low G_s as well as potential access to previously occluded pores and deformation of particles due to both degradation processes and applied mechanical stresses. The G_s was correlated to the degree of decomposition with a linear relationship. Unlike soils, the G_s for MSW was not unique, but varied in a landfill environment due both to physical/mechanical processes and biochemical processes. Specific gravity testing is recommended to be conducted not only using representative waste composition, but also using representative compaction, stress, and degradation states.     

Environmental and production consequences of using alum-amended poultry litter as a nutrient source for corn

Field trials were established to compare alum-treated poultry litter (ATPL), normal poultry litter (NPL), and triple superphosphate (TSP) as fertilizer sources for corn (Zea mays L.) when applied at rates based on current litter management strategies in Virginia. Trials were established in the Costal Plain and Piedmont physiographic regions near Painter and Orange, VA, respectively. Nitrogen-based applications of ATPL or NPL applied at rates estimated to supply 173 kg of plant-available nitrogen (PAN) ha(-1) resulted in significantly lower grain yields than treatments receiving commercial fertilizer at the same rate in 2000 and 2001 at Painter. These decreases in grain yield at the N-based application rates were attributed to inadequate N availability, resulting from overestimates of PAN as demonstrated by tissue N concentrations. However, at Orange no treatment effects on grain yield were observed. Applications of ATPL did not affect Al concentrations in corn ear-leaves at either location. Exchangeable soil Al concentrations were most elevated in treatments receiving only NH4NO3 as an N source. At N-based application rates, the ATPL resulted in lower Mehlich 1-extractable P (M1-P) and water-extractable soil phosphorus (H2O-P) concentrations compared to the application of NPL. A portion of this reduction could be attributed to lower rates of P applied in the N-based ATPL treatments. Runoff collected from treatments which received ATPL 2 d before conducting rainfall simulations contained 61 to 71% less dissolved reactive phosphorus (DRP) than treatments receiving NPL. These results show that ATPL may be used as a nutrient source for corn production without significant management alterations. Alum-treated poultry litter can also reduce the environmental impact of litter applications, primarily through minimizing the P status of soils receiving long-term applications of litter and reductions in runoff DRP losses shortly after application.     

A Quantitative Tool for Assessing the Integrity of Southern Coastal California Streams

We developed a benthic macroinvertebrate index of biological integrity (B-IBI) for the semiarid and populous southern California coastal region. Potential reference sites were screened from a pool of 275 sites, first with quantitative GIS landscape analysis at several spatial scales and then with local condition assessments (in-stream and riparian) that quantified stressors acting on study reaches. We screened 61 candidate metrics for inclusion in the B-IBI based on three criteria: sufficient range for scoring, responsiveness to watershed and reach-scale disturbance gradients, and minimal correlation with other responsive metrics. Final metrics included: percent collector-gatherer + collector-filterer individuals, percent noninsect taxa, percent tolerant taxa, Coleoptera richness, predator richness, percent intolerant individuals, and EPT richness. Three metrics had lower scores in chaparral reference sites than in mountain reference sites and were scored on separate scales in the B-IBI. Metrics were scored and assembled into a composite B-IBI, which was then divided into five roughly equal condition categories. PCA analysis was used to demonstrate that the B-IBI was sensitive to composite stressor gradients; we also confirmed that the B-IBI scores were not correlated with elevation, season, or watershed area. Application of the B-IBI to an independent validation dataset (69 sites) produced results congruent with the development dataset and a separate repeatability study at four sites in the region confirmed that the B-IBI scoring is precise. The SoCal B-IBI is an effective tool with strong performance characteristics and provides a practical means of evaluating biotic condition of streams in southern coastal California.