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7/28/2019 Fydp Slide Lukman

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PROCESS SAFETY AND LOSS

PREVENTIONHazard and Operability Studies


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HAZOP Analysis

A Hazard and Operability(HAZOP) study is a systematicexamination to identify andevaluate safety hazards andoperability problems

which, although might not behazardous.

Based on guide-words and iscarried out by a multi-disciplinary team (HAZOPteam).

HAZOP Study Procedures

TeamDiscussion

Requirement: PFD P&ID

SOP

to identify

Possible Deviations Causes Consequences

Action required


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Study Nodes

Reactor

Phase

Separator

Absorption

Column

Study Node

Study Node

Study Node

Node 1: Reactor (R-101)

Node 2: Distillation Column (C-102)

Node 3: Heat Exchanger (E-1)

For this HAZOP study it is limited

to THREE (3) process lines, in

which TWO (2) of the process

lines must be connected to ONE

(1) major equipment


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Process Section: Reactor R-101

Node 1: Stream S7

Process parameter: Flow

Guide

word

Possible causes Possible consequences Required actions

No Use of fail closedtyped control valve

Fracture of pipeNo feedstock supplied, no productproduced as no reaction taken

place

Reactor shutdown

Employ fail opened typed control valveInstall emergency shutdown (ESD) valve or shutdownplant immediately

Less Leakage in pipingBlockage in pumpsControl valve failedpartially

opened/closed

position

Reduced rate of reactionInconsistent production rateReduced amount of process fluids

to R-101

Install flow indicatorInstall low flow or low level alarm to R-101Install check valve to stream S-7

More Control valve failsopen

Increased amount of processfluids to R-101 and over spillage

Install flow indicator

Install high flow alarm and relief valveReverse Backflow due to

backpressure in

reactor

Reduced amount of feedstock,thus reduced yielded product

Install check valve or flow indicator and alarm toacknowledge the changes in flow

Regular inspection and maintenance of valve


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PROCESS SAFETY AND LOSS

PREVENTIONPlant Layout


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Plant Layout

Main

road

Chemical Storage Units

Reactor System

Loading

and

unloadin

g bay

Utility SectionsGate 1Gate 2

Gate 3

Flare

Raw materials

Future expansion site 2 / Assembly area 2

Future

expansion site 1

/ Assembly Area

1

Training

Center/Seminar /

Conference

Room

Administration and Technical Services

Parking Canteen

Prayer Hall

Clinic

Main Power Supply

Guard

House

Wastewater

treatment plant

LaboratoryFuture expansion

site 3

Fire station

Separation SectionMaintenance

Warehouse

Control building

Minor Equipments

Housing

Gate 4

Process Area Non-Process Area

Cost Operation Maintenance Safety


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Conclusion

The design of the high purity ethylbenzene with a capacity of 500,000 ton per year is successfully completed.

Approach to Conceptual Design, Environmental and Safety issues,Process and Mechanical design of equipments, EconomicsEvaluation, Instrumentations and Control is proposed based onliteratures, handbooks and real industry application.

The plant layout was designed to integrate plant wide controlstrategy. The total capital investment of the plant is approximatelyRM76, 000, 000.

The proposed plant design is economically justified,operationally feasible and profitable.


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Recommendations

Ethyl benzene production technologies and processes should bekept recent and economical to optimize the profits.

Cost reduction program should be introduced from Day 1 of plantoperation.

Employee Career Development Plan in place to ensure knowledgeprogression in the company.


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MAJOR EQUIPMENTS


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R-101

C-103

C-102

R-102

C-101

Unit Operations


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Packed Bed ReactorOperating Pressure 3500 kPa

OperatingTemperature

2200C

Reactor Diameter 3.96 m

Reactor Height 7.1 m

Volume 29.12 m3

Thickness 66 mm

Number of Baffle 5 baffles

Number of tube 2215 tubes

Material of Cons. Shell and Tube - CS

Grade 2B


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Q&A Session

Thank you

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