Fydp Slide Lukman
-
Upload
apiskai3096 -
Category
Documents
-
view
234 -
download
0
Transcript of Fydp Slide Lukman
-
7/28/2019 Fydp Slide Lukman
1/13
-
7/28/2019 Fydp Slide Lukman
2/13
PROCESS SAFETY AND LOSS
PREVENTIONHazard and Operability Studies
-
7/28/2019 Fydp Slide Lukman
3/13
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
-
7/28/2019 Fydp Slide Lukman
4/13
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
-
7/28/2019 Fydp Slide Lukman
5/13
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
-
7/28/2019 Fydp Slide Lukman
6/13
PROCESS SAFETY AND LOSS
PREVENTIONPlant Layout
-
7/28/2019 Fydp Slide Lukman
7/13
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
-
7/28/2019 Fydp Slide Lukman
8/13
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.
-
7/28/2019 Fydp Slide Lukman
9/13
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.
-
7/28/2019 Fydp Slide Lukman
10/13
MAJOR EQUIPMENTS
-
7/28/2019 Fydp Slide Lukman
11/13
R-101
C-103
C-102
R-102
C-101
Unit Operations
-
7/28/2019 Fydp Slide Lukman
12/13
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
-
7/28/2019 Fydp Slide Lukman
13/13
Q&A Session
Thank you