Hazop Sample.pdf
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1. The document describes HAZOP (Hazard and Operability) studies conducted on various units in a terephthalic acid production plant, including the reactor, crystallizer, scrubber, and dryer. 2. For each unit, potential deviations in parameters like flow, pressure, and temperature are identified along with their possible consequences and causes. 3. Safeguards and required actions are recommended to address the deviations, such as installing alarms, safety valves, temperature sensors, and implementing monitoring and inspection procedures.
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Design of Methanol Water Distillation Column
Methanol is an essential feed stock for the manufacture of many industrial products such as adhesives and paints and it is widely used as a solvent in many chemical reactions. Crude methanol is obtained from steam reforming of natural gas and then a purification process is needed since it contains smaller and larger degree of impurities.
The purification process consists of two steps: a topping column used to remove the low boiling impurity called the light ends; and the remaining water methanol mixture is transferred to another column called the refining column where it is constantly boiled until separation occurs. Methanol rises to the top while the water accumulates in the bottom.
This document focuses on methanol water separation. A detailed design study for the distillation column is conducted where the separation occurs at atmospheric pressure with a total condenser and a partial reboiler.
Presentation hazop introduction
This document provides an overview of Hazard and Operability (HAZOP) studies, which are a technique used to identify potential hazards and operability problems in processes. It describes the origins, purpose, methodology, and typical components of a HAZOP study. Key aspects covered include identifying potential deviations from normal operating conditions using guidewords, determining causes and consequences of deviations, evaluating existing safeguards, and developing recommendations to address identified hazards. The document also outlines the HAZOP process, including defining nodes to segment the system, assigning a team to conduct the study, and systematically analyzing each node using guidewords across parameters.
Hazop Study
A Hazard and Operability (HAZOP) study is a systematic technique used to identify potential hazards and operability problems in processes. It involves a multidisciplinary team systematically examining a process or operation using guidewords to identify deviations from the design intent and hazards associated with those deviations. The document provides an overview of HAZOP studies, including their objectives, methodology, terminology, and examples of their application.
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HAZOP - AN INTEGRATED SAFETY ASSESSMENT STUDY
This document discusses Hazard and Operability Studies (HAZOP). It provides an overview of the HAZOP methodology, including that it involves a team systematically using guidewords to identify deviations from the design intent and their potential causes and consequences. The document also gives examples of applying the HAZOP technique to analyze specific components, like conducting a HAZOP study on a shell and tube heat exchanger using relevant guidewords. Overall, the HAZOP method aims to identify hazards as well as operability problems for improved safety and operations.
Recommended
Design of Methanol Water Distillation Column
Methanol is an essential feed stock for the manufacture of many industrial products such as adhesives and paints and it is widely used as a solvent in many chemical reactions. Crude methanol is obtained from steam reforming of natural gas and then a purification process is needed since it contains smaller and larger degree of impurities.
The purification process consists of two steps: a topping column used to remove the low boiling impurity called the light ends; and the remaining water methanol mixture is transferred to another column called the refining column where it is constantly boiled until separation occurs. Methanol rises to the top while the water accumulates in the bottom.
This document focuses on methanol water separation. A detailed design study for the distillation column is conducted where the separation occurs at atmospheric pressure with a total condenser and a partial reboiler.
Presentation hazop introduction
This document provides an overview of Hazard and Operability (HAZOP) studies, which are a technique used to identify potential hazards and operability problems in processes. It describes the origins, purpose, methodology, and typical components of a HAZOP study. Key aspects covered include identifying potential deviations from normal operating conditions using guidewords, determining causes and consequences of deviations, evaluating existing safeguards, and developing recommendations to address identified hazards. The document also outlines the HAZOP process, including defining nodes to segment the system, assigning a team to conduct the study, and systematically analyzing each node using guidewords across parameters.
Hazop Study
A Hazard and Operability (HAZOP) study is a systematic technique used to identify potential hazards and operability problems in processes. It involves a multidisciplinary team systematically examining a process or operation using guidewords to identify deviations from the design intent and hazards associated with those deviations. The document provides an overview of HAZOP studies, including their objectives, methodology, terminology, and examples of their application.
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Introduction to Process Modeling/Simulation Software.
INDEX:
Course Objectives
Introduction to Aspen Plus
User Interface & Getting Help
Physical Properties
Introduction to Flowsheet
Unit Operation Models
Reporting Results
Case Studies I, II and III
Case Study IV
Conclusion
Process Safety
The document discusses Process Safety Management (PSM) systems. It explains that PSM systems are comprehensive management systems used to avoid incidents in hazardous industries like chemical plants. The document outlines the 14 elements of a PSM system, which include employee participation, process hazard analysis, operating procedures, contractor control, training, mechanical integrity, management of change, emergency response planning, and compliance audits. It also provides details on each of the 14 elements and how they work together in a PSM system's plan-do-check-act framework.
HAZOP - AN INTEGRATED SAFETY ASSESSMENT STUDY
This document discusses Hazard and Operability Studies (HAZOP). It provides an overview of the HAZOP methodology, including that it involves a team systematically using guidewords to identify deviations from the design intent and their potential causes and consequences. The document also gives examples of applying the HAZOP technique to analyze specific components, like conducting a HAZOP study on a shell and tube heat exchanger using relevant guidewords. Overall, the HAZOP method aims to identify hazards as well as operability problems for improved safety and operations.
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The document describes a hazard and operability (HAZOP) study for a proposed olefin dimerization unit. A HAZOP study identifies potential hazards and operating problems by systematically applying guide words like "no," "more," and "less" to process parameters at critical locations. The summary provides results of applying the guide words to the line section from an intermediate storage tank to a buffer/settling tank. Deviations considered include no flow, more flow, and the presence of water or other impurities. Potential causes and consequences of each deviation are examined along with recommended actions.
Hazop analysis
A Hazard and Operability (HAZOP) study is a structured technique used to identify potential problems in processes. It involves dividing a system into nodes and having a team apply guide words like "no", "more", "less" to process parameters at each node to identify possible deviations from design intent. The team then analyzes the causes and consequences of deviations and recommends actions. Key aspects of a HAZOP include composing a multidisciplinary team, using guide words and parameters at study nodes, and documenting results in a report with worksheets.
Design of packed columns
Packed columns are used for distillation, gas absorption, and liquid-liquid extraction. They have continuous gas-liquid contact through a packed bed, unlike plate columns which have stage-wise contact. Packed columns depend on good liquid and gas distribution, and have lower holdup but higher pressure drop than plate columns. This document provides details on packed column components, design procedures such as selecting packing and determining height, and examples of absorption and stripping processes in packed columns.
HAZOP AND OPERABILITY STUDY
The document discusses various techniques for hazard identification and risk assessment, including Hazard and Operability Studies (HAZOP), Failure Mode and Effects Analysis (FMEA), and safety audits. It provides details on how to conduct HAZOPs, including composing the team, using guide words to identify deviations from the process's intentions, and documenting the results. The document also discusses how to apply these techniques at different stages of a project's lifecycle to identify hazards, their causes and consequences, and remedial actions needed to control risks.
Hazop Hazard and Operability Study
A Hazard and Operability (HAZOP) study is a structured and systematic examination of a planned or existing process or operation in order to identify and evaluate problems that may represent risks to personnel or equipment, or prevent efficient operation.
The HAZOP technique was initially developed to analyze chemical process systems, but has later been extended to other types of systems and also to complex operations and to software systems.
PROCESS STORAGE TANK LAH & LAHH LEVEL CALCULATION
The document contains parameters for a process storage tank including a diameter of 14 feet, height of 18 feet, normal liquid level of 6 feet, and pump inflow of 250 USGPM. It details calculations for the liquid alarm high-high level of 14.74 feet based on filling the tank from the overfill level to that point within 15 minutes, and liquid alarm high level of 8.23 feet calculated from filling within 45 minutes.
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This document provides an overview of HAZOP (Hazard and Operability) studies. It defines key terms like hazard, risk, and PHA. It explains that a HAZOP is a systematic technique used to identify potential problems in a process. It should be performed by a multidisciplinary team and involves analyzing deviations from the design intent using guidewords at nodes on piping and instrumentation diagrams. The team evaluates causes, consequences and recommends safeguards to address any issues identified.
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1) Distillation is a method used to separate components of a liquid solution based on differences in how the components distribute between the vapor and liquid phases when heated to their boiling points.
2) Raoult's law describes vapor-liquid equilibrium for ideal solutions, relating the partial pressure of a component in vapor phase to its mole fraction in the liquid phase. Boiling point diagrams can be constructed using vapor pressure data.
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0 INTRODUCTION/PURPOSE
1 SCOPE
2 FIELD OF APPLICATION
3 DEFINITIONS
4 GENERAL CONSIDERATIONS
4.1 Separation Efficiency
5 SUMMARY OF TYPES AVAILABLE
5.1 Direct Vapor Injection
5.2 External Generation of Vapor
5.3 Thermosyphon Reboilers
5.4 Forced Circulation Boiler
5.5 Suppressed Vaporization Boiler
5.6 Kettle Reboiler
5.7 Bayonet Tube Vaporizer
5.8 Internal Boiler
6 COMPRESSIBLE FLOW IN PIPES OF CONSTANT
CROSS-SECTION
6.1 Isothermal Flow
6.2 Adiabatic Flow
6.3 Estimation of Pressure Drop for Adiabatic
FIGURES
1(a) EQUILIBRIUM RELATIONSHIPS IN SQUAT KETTLE
REBOILER
1(b) EQUILIBRIUM RELATIONSHIPS IN LONG NARROW KETTLE REBOILER
1(c) EQUILIBRIUM RELATIONSHIPS IN THERMOSYPHON AND FORCED CIRCULATION REBOILER
2 DIRECT VAPOR INJECTION
3 EXTERNAL GENERATION OF VAPOR
4 VERTICAL THERMOSYPHON REBOILER
5 HORIZONTAL THERMOSYPHON REBOILER
6 FORCED CIRCULATION BOILER
7 SUPPRESSED VAPORIZATION BOILER
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This is course on Plant Simulation will show you how to setup hypothetical compounds, oil assays, blends, and petroleum characterization using the Oil Manager of Aspen HYSYS.
You will learn about:
Hypothetical Compounds (Hypos)
Estimation of hypo compound data
Models via Chemical Structure UNIFAC Component Builder
Basis conversion/cloning of existing components
Input of Petroleum Assay and Crude Oils
Typical Bulk Properties (Molar Weight, Density, Viscosity)
Distillation curves such as TBP (Total Boiling Point)
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This is a "workshop-based" course, there is about 25% theory and about 75% work!
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Factors affecting distillation column operation
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Hazop analysis complete report
A HAZOP (Hazard and Operability) study is a systematic technique used to identify potential hazards and operability problems in processes. It involves a team reviewing a process and its design to identify possible deviations from safe operation. The document outlines the HAZOP process including preparation, terminology, meeting procedures, follow up actions and documentation. Key aspects include selecting a team with relevant expertise, gathering process information, using guide words to identify deviations, assessing risks, recommending safeguards, and documenting actions.
Reflux ratio
This document discusses reflux ratios in distillation columns. It defines total, minimum, and optimum reflux ratios. Total reflux uses all overhead vapor as reflux, allowing calculation of minimum required plates. Minimum reflux is the maximum ratio requiring infinite plates for desired separation. Optimum reflux minimizes total costs by balancing fixed costs that decrease with higher reflux against increasing operating costs.
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Loop Reactors
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Based on the information provided, a hydrocarbon system and petroleum refining process type have been selected. The recommended property package is NRTL.
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FULL COURSE:
https://courses.chemicalengineeringguy.com/p/flash-distillation-in-chemical-process-engineering/
Introduction:
Binary Distillation is one of the most important Mass Transfer Operations used extensively in the Chemical industry.
Understanding the concept behind Gas-Gas, Liquid-Liquid and the Gas-Liquid mass transfer interaction will allow you to understand and model Distillation Columns, Flashes, Batch Distillator, Tray Columns and Packed column, etc...
We will cover:
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Application of Distillation in the Industry
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Material and Energy Balances for flash systems
Adiabatic and Isothermal Operation
Animations and Software Simulation for Flash Distillation Systems (ASPEN PLUS/HYSYS)
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All theory is taught and backed with exercises, solved problems, and proposed problems for homework/individual study.
At the end of the course:
You will be able to understand mass transfer mechanism and processes behind Flash Distillation.
You will be able to continue with Batch Distillation, Fractional Distillation, Continuous Distillation and further courses such as Multi-Component Distillation, Reactive Distillation and Azeotropic Distillation.
About your instructor:
I majored in Chemical Engineering with a minor in Industrial Engineering back in 2012.
I worked as a Process Design/Operation Engineer in INEOS Koln, mostly on the petrochemical area relating to naphtha treating.
There I designed and modeled several processes relating separation of isopentane/pentane mixtures, catalytic reactors and separation processes such as distillation columns, flash separation devices and transportation of tank-trucks of product.
Types and design of the towers trays
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A. Bubble Cap Tray.
B. Sieve Tray.
C. Dual flow tray.
D. Valve Tray.
Comparsion of Common Tray Types
hazop 2nd half edited.docx
This document describes potential hazards identified in a hazard and operability study (HAZOP) for the production of 2-ethyl hexanol. It lists 26 items related to various pieces of equipment in the process. For each item, it identifies a deviation from normal operating conditions, the potential cause, and the consequences. It also identifies the control valve or relief valve that would be used to address the hazard and sends alerts to the control room. Regular maintenance and inspections are recommended to be carried out by operations managers and supervisors.
Process control
The document discusses batch and continuous manufacturing processes. It defines batch processes as those that operate on discrete quantities of materials in a non-continuous manner, with periods of inactivity between batches. Continuous processes receive and process raw materials into finished units in an uninterrupted flow. Batch processes are useful for small volumes of specialty chemicals and allow scheduling maintenance between batches, while continuous processes are better for large volumes and bulk chemicals with fewer startups/shutdowns. The document also discusses controlling temperature and pressure in batch processes, as well as controlling fluid flow and storage vessel levels in continuous processes. Valve positioners are described as a way to reduce hysteresis in control valves and improve response time.
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HAZOP Basics
Basic understanding of HAZOP it covers:
-Basic understanding of HAZOP
-HAZOP requirements
-How it works
-Case study
-HAZOP team
-Advantage & disadvantage
HAZOP I Hazard and operability study I Risk Assessment I Gaurav Singh Rajput
The document describes a hazard and operability (HAZOP) study for a proposed olefin dimerization unit. A HAZOP study identifies potential hazards and operating problems by systematically applying guide words like "no," "more," and "less" to process parameters at critical locations. The summary provides results of applying the guide words to the line section from an intermediate storage tank to a buffer/settling tank. Deviations considered include no flow, more flow, and the presence of water or other impurities. Potential causes and consequences of each deviation are examined along with recommended actions.
Hazop analysis
A Hazard and Operability (HAZOP) study is a structured technique used to identify potential problems in processes. It involves dividing a system into nodes and having a team apply guide words like "no", "more", "less" to process parameters at each node to identify possible deviations from design intent. The team then analyzes the causes and consequences of deviations and recommends actions. Key aspects of a HAZOP include composing a multidisciplinary team, using guide words and parameters at study nodes, and documenting results in a report with worksheets.
Design of packed columns
Packed columns are used for distillation, gas absorption, and liquid-liquid extraction. They have continuous gas-liquid contact through a packed bed, unlike plate columns which have stage-wise contact. Packed columns depend on good liquid and gas distribution, and have lower holdup but higher pressure drop than plate columns. This document provides details on packed column components, design procedures such as selecting packing and determining height, and examples of absorption and stripping processes in packed columns.
HAZOP AND OPERABILITY STUDY
The document discusses various techniques for hazard identification and risk assessment, including Hazard and Operability Studies (HAZOP), Failure Mode and Effects Analysis (FMEA), and safety audits. It provides details on how to conduct HAZOPs, including composing the team, using guide words to identify deviations from the process's intentions, and documenting the results. The document also discusses how to apply these techniques at different stages of a project's lifecycle to identify hazards, their causes and consequences, and remedial actions needed to control risks.
Hazop Hazard and Operability Study
A Hazard and Operability (HAZOP) study is a structured and systematic examination of a planned or existing process or operation in order to identify and evaluate problems that may represent risks to personnel or equipment, or prevent efficient operation.
The HAZOP technique was initially developed to analyze chemical process systems, but has later been extended to other types of systems and also to complex operations and to software systems.
PROCESS STORAGE TANK LAH & LAHH LEVEL CALCULATION
The document contains parameters for a process storage tank including a diameter of 14 feet, height of 18 feet, normal liquid level of 6 feet, and pump inflow of 250 USGPM. It details calculations for the liquid alarm high-high level of 14.74 feet based on filling the tank from the overfill level to that point within 15 minutes, and liquid alarm high level of 8.23 feet calculated from filling within 45 minutes.
Hydrogenation Reactor Design Considerations
Fixed Bed Reactor Internals
Inlet Distributor Design
Debris Collector Design
Inert Balls
Catalyst Separation Screens
Catalyst Bed Supports
Outlet Collector
Liquid Re-distributor
Catalyst Un-Loading Connections
Void Space
Hazop Fundamentals Online Training iFluids
This document provides an overview of HAZOP (Hazard and Operability) studies. It defines key terms like hazard, risk, and PHA. It explains that a HAZOP is a systematic technique used to identify potential problems in a process. It should be performed by a multidisciplinary team and involves analyzing deviations from the design intent using guidewords at nodes on piping and instrumentation diagrams. The team evaluates causes, consequences and recommends safeguards to address any issues identified.
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1) Distillation is a method used to separate components of a liquid solution based on differences in how the components distribute between the vapor and liquid phases when heated to their boiling points.
2) Raoult's law describes vapor-liquid equilibrium for ideal solutions, relating the partial pressure of a component in vapor phase to its mole fraction in the liquid phase. Boiling point diagrams can be constructed using vapor pressure data.
3) Equilibrium or flash distillation involves heating a liquid mixture to partially vaporize it in a single stage, separating the vapor and liquid which approach equilibrium compositions.
Selection of Reboilers for Distillation Columns
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0 INTRODUCTION/PURPOSE
1 SCOPE
2 FIELD OF APPLICATION
3 DEFINITIONS
4 GENERAL CONSIDERATIONS
4.1 Separation Efficiency
5 SUMMARY OF TYPES AVAILABLE
5.1 Direct Vapor Injection
5.2 External Generation of Vapor
5.3 Thermosyphon Reboilers
5.4 Forced Circulation Boiler
5.5 Suppressed Vaporization Boiler
5.6 Kettle Reboiler
5.7 Bayonet Tube Vaporizer
5.8 Internal Boiler
6 COMPRESSIBLE FLOW IN PIPES OF CONSTANT
CROSS-SECTION
6.1 Isothermal Flow
6.2 Adiabatic Flow
6.3 Estimation of Pressure Drop for Adiabatic
FIGURES
1(a) EQUILIBRIUM RELATIONSHIPS IN SQUAT KETTLE
REBOILER
1(b) EQUILIBRIUM RELATIONSHIPS IN LONG NARROW KETTLE REBOILER
1(c) EQUILIBRIUM RELATIONSHIPS IN THERMOSYPHON AND FORCED CIRCULATION REBOILER
2 DIRECT VAPOR INJECTION
3 EXTERNAL GENERATION OF VAPOR
4 VERTICAL THERMOSYPHON REBOILER
5 HORIZONTAL THERMOSYPHON REBOILER
6 FORCED CIRCULATION BOILER
7 SUPPRESSED VAPORIZATION BOILER
8 KETTLE REBOILER
9 BAYONET TUBE VAPORIZER
10 INTERNAL REBOILER
TABLES
1 MURPHREE EFFICIENCY OF A REBOILER
Aspen HYSYS - Petroleum Assays and Oil Characterization (Slideshare)
This is course on Plant Simulation will show you how to setup hypothetical compounds, oil assays, blends, and petroleum characterization using the Oil Manager of Aspen HYSYS.
You will learn about:
Hypothetical Compounds (Hypos)
Estimation of hypo compound data
Models via Chemical Structure UNIFAC Component Builder
Basis conversion/cloning of existing components
Input of Petroleum Assay and Crude Oils
Typical Bulk Properties (Molar Weight, Density, Viscosity)
Distillation curves such as TBP (Total Boiling Point)
ASTM (D86, D1160, D86-D1160, D2887)
Chromatography
Light End
Oil Characterization
Using the Petroleum Assay Manager or the Oil Manager
Importing Assays: Existing Database
Creating Assays: Manually / Model
Cutting: Pseudocomponent generation
Blending of crude oils
Installing oils into Aspen HYSYS flowsheets
Getting Results (Plots, Graphs, Tables)
Property and Composition Tables
Distribution Plot (Off Gas, Light Short Run, Naphtha, Kerosene, Light Diesel, Heavy Diesel, Gasoil, Residue)
Oil Properties
Proper
Boiling Point Curves
Viscosity, Density, Molecular Weight Curves
This is helpful for students, teachers, engineers and researchers in the area of R&D, specially those in the Oil and Gas or Petroleum Refining industry.
This is a "workshop-based" course, there is about 25% theory and about 75% work!
At the end of the course you will be able to handle crude oils for your fractionation, refining, petrochemical process simulations!
Factors affecting distillation column operation
Factors affecting distillation column operation
Foaming
Entrainment
Weeping/Dumping
Flooding
Reboiler Temperature
Reduction in Vacuum
Hazop analysis complete report
A HAZOP (Hazard and Operability) study is a systematic technique used to identify potential hazards and operability problems in processes. It involves a team reviewing a process and its design to identify possible deviations from safe operation. The document outlines the HAZOP process including preparation, terminology, meeting procedures, follow up actions and documentation. Key aspects include selecting a team with relevant expertise, gathering process information, using guide words to identify deviations, assessing risks, recommending safeguards, and documenting actions.
Reflux ratio
This document discusses reflux ratios in distillation columns. It defines total, minimum, and optimum reflux ratios. Total reflux uses all overhead vapor as reflux, allowing calculation of minimum required plates. Minimum reflux is the maximum ratio requiring infinite plates for desired separation. Optimum reflux minimizes total costs by balancing fixed costs that decrease with higher reflux against increasing operating costs.
Reactor & Impeller Design in Hydrogenation
Hydrogenation Reactors
Stirred Vessels
Loop Reactors
Other reactor types
Appendix
- List of contact details for suppliers
- Information from supplier’s websites
Aspen HYSYS - Basic Course (SS)
Based on the information provided, a hydrocarbon system and petroleum refining process type have been selected. The recommended property package is NRTL.
Does this help summarize the recommended package? Let me know if you need any clarification or have additional questions!
Flash Distillation in Chemical and Process Engineering (Part 2 of 3)
FULL COURSE:
https://courses.chemicalengineeringguy.com/p/flash-distillation-in-chemical-process-engineering/
Introduction:
Binary Distillation is one of the most important Mass Transfer Operations used extensively in the Chemical industry.
Understanding the concept behind Gas-Gas, Liquid-Liquid and the Gas-Liquid mass transfer interaction will allow you to understand and model Distillation Columns, Flashes, Batch Distillator, Tray Columns and Packed column, etc...
We will cover:
REVIEW: Of Mass Transfer Basics (Equilibrium VLE Diagrams, Volatility, Raoult's Law, Azeotropes, etc..)
Distillation Theory - Concepts and Principles
Application of Distillation in the Industry
Equipment for Flashing Systems such as Flash Drums
Design & Operation of Flash Drums
Material and Energy Balances for flash systems
Adiabatic and Isothermal Operation
Animations and Software Simulation for Flash Distillation Systems (ASPEN PLUS/HYSYS)
Theory + Solved Problem Approach:
All theory is taught and backed with exercises, solved problems, and proposed problems for homework/individual study.
At the end of the course:
You will be able to understand mass transfer mechanism and processes behind Flash Distillation.
You will be able to continue with Batch Distillation, Fractional Distillation, Continuous Distillation and further courses such as Multi-Component Distillation, Reactive Distillation and Azeotropic Distillation.
About your instructor:
I majored in Chemical Engineering with a minor in Industrial Engineering back in 2012.
I worked as a Process Design/Operation Engineer in INEOS Koln, mostly on the petrochemical area relating to naphtha treating.
There I designed and modeled several processes relating separation of isopentane/pentane mixtures, catalytic reactors and separation processes such as distillation columns, flash separation devices and transportation of tank-trucks of product.
Types and design of the towers trays
Types and design of the towers trays
A. Bubble Cap Tray.
B. Sieve Tray.
C. Dual flow tray.
D. Valve Tray.
Comparsion of Common Tray Types
What's hot (20)
HAZOP I Hazard and operability study I Risk Assessment I Gaurav Singh Rajput
HAZOP I Hazard and operability study I Risk Assessment I Gaurav Singh Rajput
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Hazop Sample.pdf
- 1. Reactor Table 6 Reactor HAZOP Sheet HAZOP STUDY RECORD SHEET PROJECT: TEREPHTHALIC ACID MAJOR UNIT: REACTOR Stream System : TPA Production Study node: Inlet to Reactor (Air + Acetic Acid + p- Xylene) Deviation Parameter Guide Word Possible consequences Possible causes Safeguard/ Action required Flow More 1. Upsetting process 2. Uncontrolled reaction 3. Excessive heat • Excess air • Excess Air Valve fully open • Install high flow alarm • Install dry air control valve after compressor. • Operator to continuously monitor pipe/valve condition and manually change valve position no • No reaction • No product • Pipe rupture • Valve fully closed • Blockage • Install feed flow meter • To be included in biweekly routine checkup procedure by Inspection Team Less • Less pressure • Less favorable product • Pipe leakage • Valve partially closed • Install low flow alarm • Operator to continuously monitor pipe/valve condition and manually change valve position Pressure More • High velocity of reactant • Overpressure • High temperature • Valve failure • Overheat • High pressure alarm • Install pressure safety valve (PSV) • Install high temperature alarm Less • Less reaction • Less favorable product • Leakage • Compressor failure • Insert safety valve • Install low pressure alarm Temperature More • Uncontrolled reaction • Mechanical failure • May cause explosion • Pressure increase Install temperature sensor
- 2. Crystallizer Table 7 Crystallizer HAZOP Sheet Less • Less pressure, less favorable product. • Low pressure • Install temperature sensor HAZOP STUDY RECORD SHEET PROJECT: TEREPHTHALIC ACID MAJOR UNIT : CRYSTALLIZER Stream System : TPA Production Study node: Outlet of Reactor TPA mixture Guide Word Deviation Possible Consequences Possible Causes Safeguard/Action required Flow More • Upsetting process • Increase demand for solvent • Increase in temperature • Uncontrolled reaction • Install high flow alarm • Regular monitoring by Control Team. No No product • Pipe rupture, valve fully closed, blockage • No reaction • To be included in biweekly routine checkup procedure by Inspection Team • Regular monitoring by Control Team • Operator to continuously monitor pipe/valve condition and manually change valve position Less • Less product form • Decrease in temperature • Low reaction rate • Pipe leakage • Valve partially closed • Install low flow alarm • To be included in biweekly routine checkup procedure by Inspection Team • Regular monitoring by Control Team
- 3. Scrubber Table 8 Scrubber HAZOP Sheet Dryer Table 9 Dryer HAZOP Sheet Item Guide word Deviation Possible consequences Possible causes Safeguard/ Action required S C R U B B E R Pressure More Low absorption rate Uncontrolled reaction Install pressure safety valve (PSV) Install high pressure alarm Less Less flow rate to the absorber Agitate absorption process Take longer time Low reaction rate Pipe leakage Install low flow alarm Operator to monitor pipe/valve condition Regular monitoring by Control Team Temperature More Increase in utility Uncontrolled process conditions Install temperature sensor Install auto-control valve for utility less Less pressure Take longer time for absorption process Low absorption rate Install temperature sensor Item Guide Word Deviation Possible Consequences Possible Causes Safeguard/ Action required D R Y E R Pressure More Low drying rate Uncontrolled air flowrate Install pressure safety valve (PSV) Install high pressure alarm Less Less flow rate to the dryer Improve steam flowrate to the process Take longer time Low drying rate Pipe leakage Install low flow alarm Operator to monitor pipe/valve condition Regular monitoring by Control Team More Increase in utility Uncontrolled drying process Install temperature sensor
- 4. Temperature Install auto-control valve for utility less Less pressure Longer time for drying process Low flowrate Install temperature sensor