ERT 322 SAFETY & LOSS PREVENTION HAZOP

1. ERT 322SAFETY & LOSS PREVENTION HAZOP Prepared by; Miss Syazwani Mahmad Puzi School of Bioprocess Engineering

2. I suppose that I should have done that HAZOP Study!

3. A scenario… You and your family are on a road trip by using a car in the middle of the night. You were replying a text message while driving at 100 km/h and it was raining heavily. The car hits a deep hole and one of your tire blows. You hit the brake, but due to slippery road and your car tire thread was thin, the car skidded and was thrown off the road.

4. Points to ponder What was the cause of the accident? What was the consequence of the event? What can we do to prevent all those things to happen in the first place? What other possible accidents might happen on the road trip? Can we be prepared before the accident occurs?

5. Can we make it more systematic?

6. OBJECTIVES • To evaluate hazard and operability studies methods • To synthesis HAZOP session

7. What is hazard?

8. How to reduce the possibility of hazard? 1. Remove hazard (use public transport) 2. Reduce the frequency (follow rules, car in good conditions, physically alert, route selection) 3. Consequence – prepare for hazard (airbag, seat belt)

9. Hazard Identification (HAZID) • Can be performed during initial design or ongoing operation of the process. • Hazard identification (HAZID) methods: 1. Process hazard checklist 2. Hazard surveys 3. Hazard and operability (HAZOP) studies 4. Safety review

10. Process Hazard Checklists • List of possible problems and areas to be checked. • Checklist should be applied only during the preliminary stages of HAZID. • Refer to Figure 10-2.

11. Hazards Surveys • 2 most popular forms of hazard survey: 1. Dow Fire and Explosion Index (F&EI) 2. Dow Chemical Exposure Index (CEI) • Refer to Figure 10-3 and 10-4.

15. Example 10-1 Your plant is considering the installation of a new railcar tank unloading facility. The facility will unload nominal 25,000-gal tank cars containing either pure butadiene or cyclohexane. The unloading system will be equipped with an emergency shutdown system with remotely operated block valves. The unloading operation will be done by computer control. The railcars are inerted with nitrogen to a pressure of 40 psig, and the railcar relief system has a set pressure of 75 psig. The unloading operating instructions are written and have been reviewed by the corporate technical staff. A reactive chemicals review has already been completed on the proposed facility. Combustible gas detectors will be located at the unloading station. A deluge system will be installed at the unloading site with an excellent water supply. A diking system will surround three sides of the facility, with any spills directed to a covered impounding area. Determine the Dow F&EI for this operation, and determine the minimum spacing from adjacent units.

18. F&EI value = 106 • Refer to Table 10.2, which means this unloading station is an intermediate hazard. • By refering to Dow index booklet, for this case, the radius is 90ft • Thus, the unloading station must be located a minimum of 90ft from any other equipment or process.

19. Hazard & Operability Studies (HAZOP) • The HAZOP procedure: • Begin with a detailed flow sheet. Break the flow sheet into a number of process units. Thus the reactor area might be one unit, and the storage tank another. Select a unit for study. • 2. Choose a study node (vessel, line, operating instruction). • 3. Describe the design intent of the study node. For example, vessel V-1 is designed to store the benzene feedstock and provide it on demand to the reactor. • 4. Pick a process parameter: flow, level, temperature, pressure, concentration, pH, viscosity, state (solid, liquid, or gas), agitation, volume, reaction, sample, component, start, stop, stability, power, inert.

20. 5. Apply a guide word to the process parameter to suggest possible deviations. • 6. If the deviation is applicable, determine possible causes and note any protective systems. • 7. Evaluate the consequences of the deviation (if any). • 8. Recommend action (what? by whom? by when?) • 9. Record all information.

24. Simple Example of a HAZOP Study Diammonium Phosphate (DAP) Production • Phosphoric acid and ammonia are mixed, and a non-hazardous product, diammonium phosphate (DAP), results if the reaction of ammonia is complete. If too little phosphoric acid is added, the reaction is incomplete, and ammonia is produced. Too little ammonia available to the reactor results in a safe but undesirable product. • Both chemicals will be used in large quantities and in concentrated form. Due to the highly corrosive nature of both chemicals, the project team was assigned to investigate the hazards posed to staff from the reaction resulting from study line 1 (phosphoric acid delivery line).

25. Production of DAP (continuous process) Valve A Phosphoric Acid Study line 1 Phosphoric acid delivery line Valve C Valve B Ammonia Diammonium Phosphate (DAP) Reactor

26. HAZOP Study Report on line 1 of DAP

27. Example 10-2 Consider the reactor system shown in Figure 10-8. The reaction is exothermic, so a cooling system is provided to remove the excess energy of reaction. In the event that the cooling function is lost, the temperature of the reactor would increase. This would lead to an increase in reaction rate, leading to additional energy release. The result would be a runaway reaction with pressures exceeding the bursting pressure of the reactor vessel. The temperature within the reactor is measured and is used to control the cooling water flowrate by a valve. Perform a HAZOP study on this unit to improve the safety of the process. Use as study nodes the cooling coil (process parameters: flow and temperature) and the stirrer (process parameter: agitation).

31. SAFETY REVIEWS • 2 types of safety review: the formal and the informal • The informal safety review is used for small changes to existing process • The formal safety review is used for new processes, substantial changes in existing process and process that need an updated review. • The formal report includes the following sections: 1. Introduction 2. Raw material & products 3. Equipment setup 4.Procedures 5. Safety checklist 6. MSDS

32. ASSIGNMENT 1-submit on 9 MAY 2014 BEFORE 12.00PM The hydrolysis of acetic anhydride is being studied in a laboratory-scale continuously stirred tank reactor (CSTR). In this reaction acetic anhydride [(CH3CO)2O reacts with water to produce acetic acid (CH3COOH). The concentration of acetic anhydride at any time in the CSTR is determined by titration with sodium hydroxide. Because the titration procedure requires time (relative to the hydrolysis reaction time), it is necessary to quench the hydrolysis reaction as soon as the sample is taken. The quenching is achieved by adding an excess of aniline to the sample. The quench reaction is

33. The quenching reaction also forms acetic acid, but in a different stoichiometric ratio than the hydrolysis reaction. Thus it is possible to determine the acetic anhydride concentration at the time the sample was taken. The initial experimental design is shown in Figure 10-14. Water and acetic anhydride are gravity-fed from reservoirs and through a set of rotameters. The water is mixed with the acetic anhydride just before it enters the reactor. Water is also circulated by a centrifugal pump from the temperature bath through coils in the reactor vessel. This maintains the reactor temperature at a fixed value. A temperature controller in the water bath maintains the temperature to within 1°F of the desired temperature. a. Develop a safety checklist for use before operation of this experiment. b. Perform a HAZOP study on the intention “reactant flow to reactor” for your analysis. What specific recommendations can you make to improve the safety of this experiment?