Safety, Risk & Environmental Management

CME8021

Safety
HAZOP
Workshop
John Dalton
Room C527

Engineering Design Centre

CEAM, Merz Court
www.edc.ncl.ac.uk
[email protected]
0191 222 8556

Groups:

There are 19 students this year,

You have been divided (alphabetically)
into 4 groups

1
HAZOP Workshop Assessment
● We will spend about 1 hour today doing the
workshop under my guidance

● You should then spend another:

3 hours as a group together developing the
HAZOP,
- listing your recommended actions and
preparing for the:

30 minute oral group assessment

HAZOP Workshop Assessment

● Each group is required to submit a
pro-forma sheet showing the study
- The HAZOP Log sheet(s)

● Also a maximum one side of A-4

listing the major actions from the study
together with a few words of
justification on a second A-4 page

● This is not a written report

2
Your Group hands in:
Logsheets (minimum of 1 sheet)

1 side of A4, listing Actions

1 side of A4, listing

Justifications
Names: Group No.
Justifications
Major Actions
1) Reasons why .....
2)
3)
4) ...

The mark is given to your group. The mark is based on the oral session.

HAZOP Workshop Assessment

● The deadline for handing in the HAZOP
study is:
– Last Friday before Easter
Friday 15 March 2012

● Your group will receive a mark based on

the oral session
– NOT the study that you hand in

● The mark will count for 20% of the total

CME8021 mark

3
HAZOP Workshop Assessment
What is expected of you:
● HAZOP is normally carried out by experienced
engineers
- You do not have that level of experience – yet!
● During the oral exam we will discuss your
findings, and
● Discuss any aspects of the plant that you may
have overlooked
● We will be looking for a level of understanding
that you have picked up by attending the lecture,
the workshop and whatever study your group has
done in addition

HAZOP Workshop Assessment

What is expected of you:
● Your group will be expected to justify and explain
- justify your HAZOP conclusions, and
- explain your rationale

● Warning! - HAZOP can be highly subjective

● There are many potential right answers,

(more a set of correct logical assumptions), but

● There are very many wrong answers

- Usually as a result of not strictly following the
method as you have been shown

4
 HAZOP Workshop Assessment

×
This is worth repeating:
● You are NOT marked on what you hand in
- This is just some evidence that as a group,
you have considered the problem


● You are marked on the 30 minute oral session:
- We sit round a table and discuss your HAZOP
findings
- Your group will be assigned a mark
based on this discussion

H2 Purge Ethyl Acetate

Flue Gas 18 Process Flow Diagram
20 13
Basis: 8000 hrs/year

Superheater 19

17

Vaporiser
Ethanol
12
2a 3 4 7
1 2 15

9
Fuel and Air

14

8 10

11 16

Line Number 1 2 2a 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
Ethyl Acetate (kg/h) - - - - 1971 1971 4922 443 4495 443 4928 - 4938 1971 2957 79 2878 - - - 1971
Ethanol (kg/h) 3385 7094 7094 7094 9567 9567 6182 345.2 5836.8 345 6192 3719 2473 2473 - - - - - - 2473
Acetaldehyde (kg/h) - - - - 562 562 629 217.8 411.2 149 560 - 560 560 - - - 69 67 2 552
Hydrogen (kg/h) - - - - 5 5 149.9 149.9 - - - - - - - - - 149.8 144.8 5 5
Methane (kg/h) - - - - 1 1 30 30 - - - - - - - - - 30 29 1 1
Iso-propyl Alcohol (kg/h) - 437 437 437 437 437 546 24.4 521.6 24.4 546 437 107 - 109 109 - - - - -
Carbon Monoxide (kg/h) - - - - 1.7 1.7 53 53 - - - - - - - - - 53 51 2 2
Carbon Dioxide (kg/h) - - - - 1 1 28 28 - - - - - - - - - 28 27 1 1
Total mass flow (kg/h) 3385 7531 7531 7531 12546 12546 12546 1291.2 11254.6 961.4 12216 4146 8070 5004 3066 188 2878 329.8 319 11 5015
Pressure (bar) 1.01 1.01 4.14 4.14 4.14 4.14 4.14 4.14 4.14 4.14 1.01 1.01 10.0 10.0 10.0 1.01 1.01 4.14 4.14 4.14 4.14
Temperature (°C) 25 - - - - 300 250 -10 50 -10 72 78 - - - 40 40 -10 -10 -10 -
Enthalpy (kJ/kg) - - - - - - - - - - - - - - - - - - - - -
Density (kg/m3) 785 - - - - 4.44 3.90 0.751 - - - - - - - - - 0.7 0.7 0.7 -
Viscosity (CP) - - - - - 0.014 0.020 - - - - - - - - - - 0.008 0.008 0.008 -
Vapour Fraction 0.00 0.00 0.00 1.00 1.00 1.00 1.00 0.89 0.00 0.00 0.00 0.00 0.00 1.00 0.00 0.00 0.00 1.00 1.00 1.00 1.00

5
 H2 Purge Ethyl Acetate
Catalyst must have Hydrogen Rich
Flue Gas 18 Process Flow Diagram
a Non-Oxidising 20 CO, Methane 13
Reducing Atmosphere
Basis: 8000 hrs/year
i.e. No Oxygen 5% H2 Reducing Atmosphere
Superheater 5% H2 Protects
the Catalyst 19 Distillation
300°C 17 Column

Vaporiser T=-10°C
Ethyl Acetate
Ethanol
12
2a 3 4 7
1 2 15
Fridge

9
Fuel and Air Catalyst Pellets
Ethyl Acetate Nickel
14
Acetaldehyde Cobalt
Iso-propyl Alcohol Endothermic 8 10
Hydrogen 300-250 °C
trace Methane Further Distillation Further Distillation
CO, also CO2
some residual Ethanol 11 16

Unreacted Ethanol
Line Number 1 2 2a 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
Ethyl Acetate (kg/h) - - - - 1971 1971 4922 443 4495 443 4928 - 4938 1971 2957 79 2878 - - - 1971
Ethanol (kg/h) 3385 7094 7094 7094 9567 9567 6182 345.2 5836.8 345 6192 3719 2473 2473 - - - - - - 2473
Acetaldehyde (kg/h) - - - - 562 562 629 217.8 411.2 149 560 - 560 560 - - - 69 67 2 552
Hydrogen (kg/h) - - - - 5 5 149.9 149.9 - - - - - - - - - 149.8 144.8 5 5
Methane (kg/h) - - - - 1 1 30 30 - - - - - - - - - 30 29 1 1
Iso-propyl Alcohol (kg/h) - 437 437 437 437 437 546 24.4 521.6 24.4 546 437 107 - 109 109 - - - - -
Carbon Monoxide (kg/h) - - - - 1.7 1.7 53 53 - - - - - - - - - 53 51 2 2
Carbon Dioxide (kg/h) - - - - 1 1 28 28 - - - - - - - - - 28 27 1 1
Total mass flow (kg/h) 3385 7531 7531 7531 12546 12546 12546 1291.2 11254.6 961.4 12216 4146 8070 5004 3066 188 2878 329.8 319 11 5015
Pressure (bar) 1.01 1.01 4.14 4.14 4.14 4.14 4.14 4.14 4.14 4.14 1.01 1.01 10.0 10.0 10.0 1.01 1.01 4.14 4.14 4.14 4.14
Temperature (°C) 25 - - - - 300 250 -10 50 -10 72 78 - - - 40 40 -10 -10 -10 -
Enthalpy (kJ/kg) - - - - - - - - - - - - - - - - - - - - -
Density (kg/m3) 785 - - - - 4.44 3.90 0.751 - - - - - - - - - 0.7 0.7 0.7 -
Viscosity (CP) - - - - - 0.014 0.020 - - - - - - - - - - 0.008 0.008 0.008 -
Vapour Fraction 0.00 0.00 0.00 1.00 1.00 1.00 1.00 0.89 0.00 0.00 0.00 0.00 0.00 1.00 0.00 0.00 0.00 1.00 1.00 1.00 1.00

H2 Purge Ethyl Acetate

Flue Gas 18 Process Flow Diagram
20 13
Basis: 8000 hrs/year

Superheater 19

17

Vaporiser
Ethanol
12
2a 3 4 7
1 2 15

9
Fuel and Air

14

8 10

11 16

Line Number 1 2 2a 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
Ethyl Acetate (kg/h) - - - - 1971 1971 4922 443 4495 443 4928 - 4938 1971 2957 79 2878 - - - 1971
Ethanol (kg/h) 3385 7094 7094 7094 9567 9567 6182 345.2 5836.8 345 6192 3719 2473 2473 - - - - - - 2473
Acetaldehyde (kg/h) - - - - 562 562 629 217.8 411.2 149 560 - 560 560 - - - 69 67 2 552
Hydrogen (kg/h) - - - - 5 5 149.9 149.9 - - - - - - - - - 149.8 144.8 5 5
Methane (kg/h) - - - - 1 1 30 30 - - - - - - - - - 30 29 1 1
Iso-propyl Alcohol (kg/h) - 437 437 437 437 437 546 24.4 521.6 24.4 546 437 107 - 109 109 - - - - -
Carbon Monoxide (kg/h) - - - - 1.7 1.7 53 53 - - - - - - - - - 53 51 2 2
Carbon Dioxide (kg/h) - - - - 1 1 28 28 - - - - - - - - - 28 27 1 1
Total mass flow (kg/h) 3385 7531 7531 7531 12546 12546 12546 1291.2 11254.6 961.4 12216 4146 8070 5004 3066 188 2878 329.8 319 11 5015
Pressure (bar) 1.01 1.01 4.14 4.14 4.14 4.14 4.14 4.14 4.14 4.14 1.01 1.01 10.0 10.0 10.0 1.01 1.01 4.14 4.14 4.14 4.14
Temperature (°C) 25 - - - - 300 250 -10 50 -10 72 78 - - - 40 40 -10 -10 -10 -
Enthalpy (kJ/kg) - - - - - - - - - - - - - - - - - - - - -
Density (kg/m3) 785 - - - - 4.44 3.90 0.751 - - - - - - - - - 0.7 0.7 0.7 -
Viscosity (CP) - - - - - 0.014 0.020 - - - - - - - - - - 0.008 0.008 0.008 -
Vapour Fraction 0.00 0.00 0.00 1.00 1.00 1.00 1.00 0.89 0.00 0.00 0.00 0.00 0.00 1.00 0.00 0.00 0.00 1.00 1.00 1.00 1.00

6
 TT Temperature transmitter
SP Set point
FIC Flow indicating controller
FT Flow transmitter
R Fuel/air ratio setting

Look to this section and

immediate surrounding HAZOP this part for
plant for Causes Effect & Consequences

TT Temperature transmitter
SP Set point
FIC Flow indicating controller
FT Flow transmitter
R Fuel/air ratio setting

7
Look to this section and
immediate surrounding HAZOP this part for
plant for Causes Effect & Consequences

Cause, Effect, Consequence & Action

Start here with a
Do This Guideword + Parameter
Do This
1st 2nd

(Why?) (e.g. No Flow) (What will happen?)

creates creates
Cause(s) Effect Consequence
(How likely is this?) (Deviation) (How Serious?)

or
Stop this from If Serious, then
Mitigate this what can we
happening
do about it?

prefer but this !!! Action !!!

this is usually
OK

8
GUIDE WORD DEVIATION POSSIBLE CONSEQUENCES ACTION
CAUSES

NONE No FLOW 1. No hydrocarbon Loss of feed to reaction a) Ensure good

available at intermediate section and reduced output. communication with
storage. Polymer forms in heat storage
exchanger leading to
blockage. b) Install low level
alarm on settling
tank.

2. J1 pump fails (motor

fault, loss of drive, As for [1] Cover by [b]
corroded impeller)

3. Line blocked or As for [1] Cover by [b]

LCV fails / shuts or
isolation valve closed in J1 pump overheats c) Install kickback on
error. J1

4. Line fracture As for [1] Cover by [b]

Hydrocarbon discharged d) Regular patrolling

onto area next to public and inspection of
highway. pipeline.

The following slides are

simply resources to
illustrate system components
you may have no
experience of …. yet

9
10
 recirc H2

Ethanol in
vapour form
Ethanol in
liquid form

Ethanol in
superheated
gas form (300°C)

11
Typical Basic
Manual Valve

12