CHAPTER 7

PLANT SAFETY AND LAYOUT

EXECUTIVE SUMMARY

Table 1: HAZOP Study on Reactor

Parameter

Guideword

Possible Causes 1. Material fouling in the pipe or mixer. Pipe leakage. Pump failure. Final element (valve) malfunction.

Possible Consequences 1. Different reaction will occur; the single raw material will undergo undesired reaction at such pressure and temperature. The product of the undesired reaction will contaminate the production line and impose problems such as corrosion to other subsystems. Loss of profit.

Action Required 1. 2. 3. 4. Pipe cleaning (pigging). Pipe leak testing and maintenance. Pump maintenance. Valve testing and maintenance.

Safeguard 1. Install auxiliary system for pump and final element in the flow control system. Install alarm system for no flow detection.

NO FLOW

2. 3. 4.

2.

2.

Raw material flow

3.

OVERFLOW

1. 2. 3.

Faulty control system. Unresponsive pump. Final element (control valve) malfunction.

1. 2. 3.

Unbalanced reaction in the reactor. Excessive raw material contaminates the product. Pipe rupture or overfilled reactor.

1.

2.

Valve testing and maintenance/ replacement. Pump maintenance/ replacement.

1.

2.

Install auxiliary system for pump and final element in the flow control system. Install level control system in the reactor.

Reaction Temperature

HIGH

1. 2. 3. 4.

Uncontrolled heating. Unresponsive heating system. Unresponsive cooling system. Scaling of carbonates on the reactor wall surface.

1. 2. 3.

Undesired reactions producing unwanted products. Product contamination and quality deterioration. Rupture of reactor due to overpressure.

1. 2. 3.

Reduce heating of the reactor. Increase rate of cooling of reactor. Reduce reactor pressure by opening the pressure relief valve.

1. 2. 3.

Install cooling system. Install pressure control system. Install pressure relief valve.

1. Cooling Jacket Flow NO FLOW 2.

Unresponsive/failed control valve. Plugged cooling coils.

1. 2.

Loss of cooling. Possible runaway.

1.

2.

Valve testing and maintenance/ replacement. Clean cooling coil.

1. 2.

Set inlet control valve to fail open. Set outlet control valve to fail close.

1. Cooling Jacket Flow HIGH

Unresponsive/failed control valve.

1. 2. 3.

Reactor cools, reactant concentration builds. Amount of unreacted material increases. Loss of production time.

1.

Valve testing and maintenance/ replacement.

1.

Install auxiliary system for final element in the flow control system.

Cooling Jacket Flow

1. 2. LOW

Fouling on cooling line. Unresponsive control valve.

1. 2. 3.

In the event of overheating, cooling is insufficient. Overheating of reactor causes overpressure. Overpressure can cause reactor rupture.

1.

Valve testing and maintenance/ replacement. 2. Clean cooling coil.

1.

Install flow control system with auxiliary unit.

Table 2: HAZOP Study on Heat Exchanger

Parameter Feed Flow

Guideword NO FLOW

Possible Causes

Possible Consequences 1. 2. 3. No heat transfer activities occurs Desired temperature is not achieved Process line will be interrupted especially reaction section.

Action Required

Safeguard

1. 2. 3. 4.

Material fouling in the pipe or mixer. Pipe leakage. Pump failure. Final element (valve) malfunction

1. 2.
3. 4.

Pipe cleaning (pigging). Pipe leak testing and maintenance. Pump maintenance. Valve testing and maintenance.

1.

Install auxiliary system for final element in the flow control system.

Feed Flow

HIGH FLOW

1.

Unresponsive/failed control valve.

1.

Process line will be interrupted especially reaction section.

1.

Valve testing and maintenance.

1. 2.

Install orifice plate

Install auxiliary system for final element in the flow control system.
Install check valve or butterfly valve to achieve directional flow.

Feed Flow

REVERSE FLOW

1. 2.

Failure at the coolant source. Higher pressure at outlet.

1. 2.

Difficult to control the temperature flowing out Cooling is not effective for next equipment.

1.

Maintain driving force by increasing inlet pressure.

1.

Feed Flow

LOW FLOW

1. 2. 3. 4.

Material fouling in the pipe or mixer. Pipe leakage. Unresponsive pump. Final element (valve) malfunction

1. 2.

Desired temperature is not achieved Process line will be interrupted especially reaction section.

1. 2.
3. 4.

Pipe cleaning (pigging). Pipe leak testing and maintenance. Pump maintenance. Valve testing and maintenance.

1.

Install auxiliary system for final element in the flow control system.

Pressure

HIGH PRESSURE

1. 2.

Malfunctioned pump. Jammed outlet.

1. 2.

Wall of the heat exchanger will crack. Rupture of the vessel.

1. 2.

Reduce inlet pressure. Increase outlet discharge.

3.

Bleed valves installation to ensure discharge of fluid when there is overpressure.

Pressure

LOW PRESSURE

1. 2.

Leak at vessel body. Insufficient feed flow.

1. 2. 3.

Rupture or cracking of tube. Rupture of vessel. Leaking of material.

1.

Isolate equipment for maintenance (welding, etc.)

2.

Install pressure control system at both the streams.

Guide Word Temperature

Deviation MORE

Possible Causes 1. 2. 3. Excessive heat from hot stream. Increased flow rate of hot stream. Reduced flow rate of cold stream.

Possible Consequences 1. 2. 3. Pressure will increase Explosion will occur Failure of other equipment

Action Require 1. 2. 3. Increase cold stream flow rate. Reduce hot stream flow rate. Check for obstruction/leaking at cold stream pipeline. 1. Install temperature/flow control system.

Temperature

LESS

1. 2. 3.

Excessive heat sink from cold stream. No/low flow of hot stream. High flow rate of cold stream.

1. 2.

Condensation inside the shell section. Corrosion of the shell wall.

1. 2.

Control cold and hot stream flow. Check for obstruction/leaking at hot stream pipeline.

1.

Install temperature/flow control system.

Table 3: HAZOP Study on Distillation Column

Parameter Feed Flow

Guideword HIGH FLOW

Possible Causes 1. Unresponsive/failed control valve.

Possible Consequences 1. 2. 3. Excess flow to T-101: off specification products. Weeping, dumping and flooding could occur. Inefficient distillation process.

Action Required 1. 2. Reduce feed flow rate. Increase reboiler duty.

Safeguard 1. Install high flow/level alarm.

Feed Flow

LOW FLOW

1.

Unresponsive/failed control valve.

1. 2. 3.

Drop in liquid level in T-100. Temperature rise in T-100. Product decomposition.

1. 2.

Increase feed flow rate. Decrease reboiler duty.

1.

Install low flow/level alarm.

Feed Flow

NO FLOW

1. 2.

Unresponsive/failed control valve. Leaking in feed pipeline. Overflow or flooding in the column.

1. 2. 3. 1. 2.

Drop in liquid level in T-100. Temperature rise in T-100. Loss of production. Reduced efficiency of distillation process. Product contamination.

1. 2.

Decrease reboiler duty. Relieve column pressure

1. 2.

Install low flow/level alarm. Install Pressure relief valve Add check valve/butterfly valve for one directional flow.

Feed Flow

REVERSE FLOW

1.

1. 2.

Increase reboiler and condenser duty. Reduce reflux rate.

1.

Temperature

HIGH

1. 2.

Overheating of reboiler. Low feed flow rate.

1. 2.

Product decomposition. Flooding.

1. 2.

Reduce reboiler duty. Increase feed flow rate.

1.

Add high temperature alarm.

Temperature

LOW

1. 2.

Reduced reboiler duty. Dumping, weeping.

1.

Reduced performance of distillation column.

1.

Increase reboiler duty.

1.

Install temperature/flow control system.

Pressure

HIGH

1. 2. 3.

Loss of overhead condenser. Excessive heat input from reboiler. Reboiler tube leak or

1. 2. 3. 4.

Over pressuring of column. Change of temperature profile. Product quality and controllability are disturbed. Redundancy in control loop and

1. 2. 3.

Reduce pressure. Reduce reboiler duty. Increase condenser duty.

1. 2.

Add high pressure alarm. Add additional independent high pressure indication and alarm to reflux drum.

4.

rupture. Overheads pressure controller fails control valve closed.

5.

set point limitation. Column rupture.

3.

Install pressure relief valve.

Pressure

LOW

1. 2. 3.

4.

Loss of heating medium. Low temperature feed. Overheads pressure controller fails control valve open. Excess overheads cooling.

1. 2. 3. 4. 5. 6.

Inefficient distillation. Deviation of temperature profile. Deviation in product specification. Contamination of product. Vacuuming inside column. Rupture of column.

1. 2. 3. 4.

Increase refluxed flow to column. Increase feed flow rate. Increase reboiler duty. Reduce condenser duty.

1. 2.

Install low pressure alarm. Install safety valve to stabilize pressure inside column.

Bottom Fluid Level

HIGH

1. 2. 3.

Bottom outlet pump fails. Excess feed to column. Overheads on total reflux.

1. 2.

Column flooding. Tray damage.

1.

2.

Check for pump malfunction, address the problem. Reduce feed and reflux flow rate.

3.

Install low level alarm for bottoms liquid.

Table 4: Types of Emergency and the Respective Response Plan

Types of emergencies Natural disaster

Sources 1) Flood

Available response time Within an hour

Response Plan Evacuate area with vehicles and move to higher altitude place.

Fire 1) chemical 2) ordinary structural 3) electrical

Immediate action

Chemical release 1) vapor chemical 2) liquid spill

Immediate action

Explosion 1) compressed gas 2) containerized liquid

Within a minute

1. Set off emergency siren/alarm to notify all personnel in plant vicinity. 2. Contact local fire and police department. 3. Control access to affected area. 4. Mitigate fire spread by engaging fireproof doors and firewall. 5. Smoke and toxic gases release from fire - notify personnel to put on oxygen masks. 1. Contain and collect liquid spill in a sump. 2. For vapor chemical release, sprinkler system is used to deactivate the vapor chemical by either using neutralization chemical or dissolution with water. 3. Remove contaminated clothing. 4. Skin contact need to be rinsed with water for 15 minutes. 5. If the situation is life threatening, announce for immediate evacuation of the area. 6. Emergency shutdown for all process equipment in the plant. 7. Announce to residents surrounding the plant area to stay indoors and ensure enclosed homes. 8. For denser than atmosphere vapor chemical release, move personnel to higher grounds. 9. For lighter than atmosphere vapor chemical release, move personnel to assembly point at lower grounds. 1. Announce for immediate evacuation.

Equipment 1) rupture/leak Facility failure 1) roof collapse 2) structure cracking 3) air pressure system Utility failure 1) gas 2) electricity 3) cooling water Product contamination 1) raw material 2) container 3) process equipment

Immediate action

1. Provide bleed line/ process bypass for the affected equipment. 2. If not available, shutdown all equipment in the same process line. 1. For roof collapse, ensure helmet is worn and evacuate the affected facility. If not possible, take cover under rigid materials such as desks for immediate cover, and then continue for evacuation. 2. For structure cracking, immediately evacuate the building. If not possible, take cover under rigid materials. 3. For air pressure system failure, set immediate evacuation alarm/siren. Disengage air pressure system from power source. 1. Immediate shutdown of all equipment under the affected utility. 2. Set evacuation alarm/siren. 3. Return for normal operation if the failure is resolved.

Immediate action

Immediate action

Immediate action

1. Stop raw material flow to container. 2. Stop material flow from container to process. 3. Cease/pause the production process at affected process equipment. 4. Resolve contamination problem.

Plant Layout:

Truck loading entrance

Emergency Exit

Main Entrance