Lubrizol Engineering Co-op (May 2014 - December 2014)
![Picture](/uploads/2/5/9/9/25990105/7028206.jpg?107)
My first engineering internship was with an outstanding company named Lubrizol, which is a specialty chemical company. I was located at the Deer Park, TX site where Lubrizol makes fuel additives and other chemical products mainly through a batch process. First, I had the opportunity to work in the Environmental Department during Summer 2014 where I completed three major projects: Emissions Detection, a Reportable Quantity Spreadsheet Tool, and a Permit Exemptions Tracking Spreadsheet. Second, I had the opportunity to work in a Production Unit during Fall 2014 where I completed another three major projects: Emissions Mitigation, Chillers Improvement, and a Catalyst Change Out Procedure. Below you can find more details on my major projects. In addition to my projects, I participated in several Lubrizol events, such as the Lubrizol Bowling League, the Gulf Coast Sports Challenge, and the Lubrizol Elementary School Mentor Program. Both my work experiences and my company participation helped me have a well-rounded internship!
![Picture](/uploads/2/5/9/9/25990105/1440084662.png)
Chillers Improvement
Since 1998, the chillers in my production unit that supply chill water to hot reactors have experienced a lot of maintenance issues and downtime losses, costing almost $1 million. The objective of the Chillers Improvement Project was to determine if any changes could be made to decrease the downtime or if new chillers needed to be installed. To learn about the chiller system, I collaborated with unit process engineers, operators, training foremen, and chiller contractors to understand how the chillers operate and to pinpoint problems in the field that could be causing the downtime and maintenance issues. During my investigation, I implemented short term solutions, including engineering controls such as labeling the chiller equipment and updating P&IDs as well as administrative controls such as creating a training Power Point for the operators. After my investigation, I implemented long term solutions, including a Management of Change (MOC) form to replace failing equipment and automate valves as well as Vendor Quotes for new chillers as a last resort reference. Through short and long term endeavors, the chillers are successfully running, operations understands more about the system, and alternatives have been documented if future changes are needed.
Since 1998, the chillers in my production unit that supply chill water to hot reactors have experienced a lot of maintenance issues and downtime losses, costing almost $1 million. The objective of the Chillers Improvement Project was to determine if any changes could be made to decrease the downtime or if new chillers needed to be installed. To learn about the chiller system, I collaborated with unit process engineers, operators, training foremen, and chiller contractors to understand how the chillers operate and to pinpoint problems in the field that could be causing the downtime and maintenance issues. During my investigation, I implemented short term solutions, including engineering controls such as labeling the chiller equipment and updating P&IDs as well as administrative controls such as creating a training Power Point for the operators. After my investigation, I implemented long term solutions, including a Management of Change (MOC) form to replace failing equipment and automate valves as well as Vendor Quotes for new chillers as a last resort reference. Through short and long term endeavors, the chillers are successfully running, operations understands more about the system, and alternatives have been documented if future changes are needed.
![Picture](/uploads/2/5/9/9/25990105/9646890.png?373)
Catalyst Change Out Procedure
The converter in my production unit contains three catalyst beds that when exhausted have to be changed out. The previous 2008 change out was not fully completed, not completed correctly, and not well documented. Therefore, the objective of my project was to facilitate the 2014 change out process by creating diagrams and instructions to assist the operators and contractors in completing the job safely and effectively. To create a diagram with instructions in Microsoft Visio, I consulted multiple resources, including vendor drawings, material invoices, and unit personnel. After then observing the week long 2014 change out, I wrote a report to document the 2014 obstacles, procedures, and future recommendations. With diagrams, instructions, and teamwork, not only was the 2014 Catalyst Change Out safely and successfully completed with converter rates returning to ideal, but also documentation will now be available to aid further change outs.
The converter in my production unit contains three catalyst beds that when exhausted have to be changed out. The previous 2008 change out was not fully completed, not completed correctly, and not well documented. Therefore, the objective of my project was to facilitate the 2014 change out process by creating diagrams and instructions to assist the operators and contractors in completing the job safely and effectively. To create a diagram with instructions in Microsoft Visio, I consulted multiple resources, including vendor drawings, material invoices, and unit personnel. After then observing the week long 2014 change out, I wrote a report to document the 2014 obstacles, procedures, and future recommendations. With diagrams, instructions, and teamwork, not only was the 2014 Catalyst Change Out safely and successfully completed with converter rates returning to ideal, but also documentation will now be available to aid further change outs.
Emissions Detection and Mitigation
TBA
TBA
Reportable Quantity (RQ) Spreadsheet Tool
Environmental sometimes experiences a communication gap with the production units on how to report spills. According to Environmental, all spills should be reported in the incident tracking system, while certain large spills classified as Reportable Quantities (RQs) should be immediately reported to Environmental. RQs are amounts of hazardous substances that have the potential to negatively impact people and the environment, so they must be reported to regulatory agencies like the EPA and TCEQ within required time limits. Therefore, the objective of the Reportable Quantities Project was to develop a tool to identify possible RQ spills and then to train the operators how to use the tool to know when to immediately contact Environmental. I collected lots of data, such as regulatory reportable quantities, atmospheric equipment, operating conditions, and common spill scenarios, in order to run calculations to see what conditions reach an RQ. At the end of my term, the operators were trained on the RQ Spreadsheet Tool to establish better understanding and communication of RQs between Environmental and the production units.
Environmental sometimes experiences a communication gap with the production units on how to report spills. According to Environmental, all spills should be reported in the incident tracking system, while certain large spills classified as Reportable Quantities (RQs) should be immediately reported to Environmental. RQs are amounts of hazardous substances that have the potential to negatively impact people and the environment, so they must be reported to regulatory agencies like the EPA and TCEQ within required time limits. Therefore, the objective of the Reportable Quantities Project was to develop a tool to identify possible RQ spills and then to train the operators how to use the tool to know when to immediately contact Environmental. I collected lots of data, such as regulatory reportable quantities, atmospheric equipment, operating conditions, and common spill scenarios, in order to run calculations to see what conditions reach an RQ. At the end of my term, the operators were trained on the RQ Spreadsheet Tool to establish better understanding and communication of RQs between Environmental and the production units.