Plant Design CP5062 HAZOP Example for Hui Bee
Short Description
Example on how to conduct HAZOP study on distillation column...
Description
2.3
Systemati System aticc Safety Safety Anal Analysi ysiss (HAZO (HAZOP) P) on Dist Distill illat ation ion Proc Process ess in in Acetone Manufacturing Process
One of the commonly used safety analysis systems in process design is HAZOP. HAZOP stands for Hazard and Operability Study. In typical scenarios, a HAZOP study is conducted by a team comprising of specialists in different fields (varying from process engineers to plant manager). The team uses a series of guide words to identify possible deviations from the intended design or operation of a given process. After identifying such deviations, there then comes about the discussion on how the deviations occur, consequences of these deviations, reliability of existing safeguards in preventing or mitigating the issue and possibly recommending additional safeguards safeguards into the system. In this report, the HAZOP study will be conducted on the second distillation distil lation column (IPA Column, C-101).
2.3. 2. 3.1 1
PFD PF D of of Dis Disti till llat atio ion n
Before performing HAZOP on the distillation itself, a draft Process Flow Diagram (PFD) with complete control loops are to be drawn. Following heuristics, there are to be these main control loops in a distillation column set-up (with other considerations of the usage of cascade loops and safety relief valves):
Flowrate of feed
Flowrate of reflux
Level in distillation column
Level in overhead accumulator
Temperature of boil up return
Pressure in distillation column
Differential pressure across distillation column
The following is assumed:
All control valves have a by-pass by-pass valve as well as isolation valves present but not drawn drawn into the PFD No proper level alarms for the process transmitter has been determined yet The pressure control systems are done separately separ ately through the use control valves PCV-101 and PCV-102
The preliminary PFD is shown in the following page.
40
PC 102
PC 101
PT 102 PT 101
PRV-101
PCV-101 LT 102
V-102
TT 101
LC 102
TC 101 TT 102
E-106
TC 102
TCV-102 FC 101
FT 101
FT 102
FC 102
CWS
CWR Bottoms from C-100
To Flare
PCV-102
C-101 FCV-101 P-102
PD 101
FCV-102
IPA for Recycle
P-103 TC 103
LCV-102
TT 103
FT 103
FC 103
LT 101
LC 101
Steam Inlet E-107
FCV-103
Steam Outlet LCV-101
Water for Discharge
Figure 2.3.1.1: PFD of Distillation Column Column C-101 with control control loops
2.3. 2. 3.2 2
HAZO HA ZOP P of of Dist Distil illa lati tion on
In this HAZOP analysis, there will be three parameters evaluated; (1) Level, (2) Temperature and (3) Pressure. These parameters have been assoc iated with a series of guidewords, forming a deviation. These deviations are as such and a HAZOP will be done done for each of them (in the following order): 1. 2. 3. 4. 5. 6.
High level in C-101 Low level in C-101 No level in C-101 High level in V-102 High temper eraature in C-1 -10 01 Low te temperature in in CC-101
7. 8. 9. 10. 11. 12.
High temper erat atu ure in V-102 Low te temperature in in VV-102 High pressure in C-101 Low pre press ssu ure in CC-10 101 1 Hig Hi gh pre press ssu ure in VV-10 102 2 Low pre press ssu ure in VV-1 102
The HAZOP analysis made for the 12 deviations are presented in a table format per deviation in the followin following g pages. pages.
41
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. n s l a l e i c e l a a e v l l v f d a s l a r a 3 a n v a d a v l 0 l p y o ( e 1 l - o r . t p s r t u P t n s e n l m i n d s e o i s u t a o c f a p a c c n p e r r u 2 e p e h t i n h 0 k e h c t t ) d p a 1 o i o n n o b V n n m i s s C a t u a k a a F l r p l l l r d a u a o p e t t g u s w e s s i s n t u a n f I I n k c a e c a ) h ) o n a c b b t b i o e t o , h o t f 1 o 0 t t n , i p 1 g 1 n 0 t e o - i t r 1 C e - a r e , t h C t n n e . T w t o , l a m e 2 u l f r l u 0 o d r x 1 e o c s t - t u s l a e f V n o c n r o p , c e o i r l t e e e m a h 1 l u h r d 0 l t d t a i t c 1 l . s o x s l - i o 1 a r r C d t l 0 u C t P e n f 1 n ) o ) o e h a t c r b c C
e l l s m o i i t V m u r o l l l n a r t l w l d o i y i u l e i n t e n i t d r . n s a V r a n e e x t v a w r s r a w w x l n o C s m h e e e u i e u h a t c o t v r l o g d l e F e l u n 6 t u r v b a i , n ( r f c o p f o 0 f t u r i p i t h l d e u e r 1 s h e t u o x a c r o a d n e r l o r l a c v i r u w w v o i v d s E u l a l u u g p t a o i r e d n a f r ) b e f n o o r e l v e i o i n v e p s y n c l f 7 h o a u s d b r t r 3 a e l y 0 l c e r s a n a 6 s u 0 o u p f g u e h r o m 1 i i a a t r y r 1 r 0 e t e s m a t h o c m 1 r c e t - n l u c e l h e E r p n n t t r m r P p ( e y d o u n i a s r i . v n E r l o l . r o a o , u o a p t l d l t ) c y f 3 i c f e f n r n a e i a n l e t l r n l n p l y / o e a e , e v e u g t v o t a 0 e i u i a t o t w f t n s o t r l u o s n i e 1 n r h r . e h . i l s c g t u n i e - s q u c i t b o i e o 2 o a 1 i V r e s m u e a c e i e n t h s h s a F ) s 0 d e i r n d H l d 0 a e s r l f u T 1 e W T 2 2 1 e n n s C u f c e e o e t r r ) s e r 0 l ) 0 a - ) i ) n h a F ( i t h t p b e r p o c V ) c o c 1 e r a 1 c C b y b a s u s E ) f 3 o r e 0 g l i 1 n - i o b V t a e e r C h F ( s g n i e s e v c s u l a x e v n o l n i t o r a c t n e s n i o g c n g n i y i t t l . l u p p 7 i u s r a t 0 F e r s 1
e . u ) e d h d t e n 2 a 0 x f b / o u d r 1 l g l o V f n ) C e r i l u o c 3 g o 0 F ( o n 1 s e i i c y e h P l f ( v i T a d t i . e v c r v m u l e r o o l a i r t e o r p a r f n n o t o r t s p c o r u m m y e t a o u l l t p e p t r a o u i t a L s v t f
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, r n t g t e C a t n t m e c i i f h e l r g e r v i t e v u o h t l m e o o s t a c i r e l e e n v n e v l e a h o . n r p n f t s r o i o y t g e t t i e i r i t l t e r l n t e u s a e i e a r h e t a l l t r e h u l a t a i t t b p i o u t e a r a r s r d s r w i p u m e H n e d o d o s a l r o p t s r n u e r A c f a f p e s m e r h p T s t e e r d n t h t u p f a e e e t l l m i s t o r l o t l p i d a u a r a . r l t t w t u o e 1 s p 1 s o s ) s o s p 0 0 t c n e n s I I T 1 m 1 1 c e e e 0 ) r ) x e C b h a T ( 1 t t C e h t p
s i s y l a n a P O Z A H 1 0 1 . e C n n o i e N r u t a e l e g r d s l e d u n i i V e i r d l e p y d r e d l t w l d u o f a l i n t e r . e m a s i n t o s t t l n a e o t c e s l w m l r a r r n n n h o y i e h o i i g e u e u e i l e e l t r l n h 6 h t s ( w f c h e l r n i , t e b e p i i g o 0 t c v a k n e . i r i g f ) r r e 4 o i r 1 s d t u u o d o u i h t 0 r u H b t l n s n e . a d i e e : n s t 0 e u c s E b r 0 a , e w h v 2 i a s l 1 r o i e r o e e u 5 1 r e u , o u h t e v h 0 r l t E - t . e e e o a n p s r t u r 2 1 s b d g a p h y e c a . d C s i g p r a r a u r u s r n a o i a 3 s t e f t y . u e e m d a e e a c a n e e n . s p e l e h l m p l 2 m V o c o r c i p r e l t 1 e u a m h l e y a 0 a p n d d o m m b e p l m r i y r n . l m e n a i d l a b u e r e r n , 1 t t e b l a w t o y v n a e n p f t e o t o n n n - c t h n p l e n a r t a i r r t e t v n , 6 l e e g C m u g i 1 o b e a e e i e o g e 0 o o T
r i u r r n s 0 h l n r 1 u u r i n h h h i t i b h q n q e p a s e t i 1 u u g o g t f s o e e m e e t e i l s i o m h h r s s a E c l s s s t s m o h s s h e u m T T C e n I H u t H 2 t n n l u e e s e ) o 0 l e ) l o a p r h r a ) f o h ) ) t a n o o e e r r c r p t d c 1 r a f a c e c p t c b o t t c f x e e o r t u e t u a r ( e d p 0 0 m e 1 t e C t . a f i o ) d 4 e s 0 m 1 m o E r t e t t o r n b e i l h m i o g o b i r H f e r
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. e n y e a v a l v c m l e a d . o m e t p n o v d v d a r l t v h a o n f l a a o n a L t c t a l e 2 i s l v t i L r o h y l l r A t s t 0 v o c a o t n k 1 y n r . - w c o L c r c t n r s o c e e e e n d l V e o c d i r h t h d o p a n r c n e t r n f c e u r h a o o i r 3 r k 3 a t L n f l f e p e u 0 1 f 0 l e c i a h u o A 2 A v n t d b 1 e P e P L o i n a g l e 0 I e n r c e 1 e v f h e p s s V a k t n C e o a F r a a l t g m l r d r V n n u u a a C w t o e e s t p i e t n p o e p e s w s s n L l e n a n t u c E i S p f p s v I e o a e ) a ) i t u r r u ) a n b m c t r o p d a h t b i c
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. e n e a v l v c l e a v d v d a l v l a n n l o a v a t o y r l l r s t n o t k n r . o t n s c o e e c l n d c i h o p a c e n f c e u r h r k t 2 a f e p l e c a 0 h u o 1 t d b o i n a - g e e n r c s s V a k n e a C l r a F l r n u a o d e e t s t s s w e s n n a n t u c E i I a e n ) a ) a h t b i b m o t , C w o r 1 x u n l e . 0 l f m e 1 w 2 - e u h r l t l C f o e o 0 1 o T o c t t V , t e a l c e n n h i o u r u t d d i t t o g n n n i 2 n o e o 0 c m r s a i t 1 e e e t 2 - e r d h p 0 V t t n a e 1 l c n c - i s o u r m a t T l . a e d L C n e 1 o r 0 ) v ) e r a o c t s 1 b l p
2 r l 0 o e - d x d d o l t l 1 f l u e l i l e y e v l - l n e i l o l u l x i e V d i i t w l v a f i g y t V o u l e h r e l a t C v w n e n w n n c r a e t r f e u F n o c o t u c t i v b a . e m ( e u f r o i e r c i r e c r n o e a l i l d q p o p . h t l e u a e m c u e e d i u t 1 f w c . v l l w w a d o o r h g o l d v i s r u l 2 f t o l a y n 0 o ) v o o , e n o f a a t n a t 0 c n c f n . r p 1 r e r l o u 1 v f u 1 i n i 7 r o e p e 0 e r p e c 3 s - l p o - l t o u t 0 s c e C r s 1 l c 0 i n r h m w s m o o r o 1 t V o y u 1 y e a r m - l e u o t u a g c m u d t a t t s l d e o u o o C l h n E e s a m P t m n p e i e p h a e t t u n . p s r o s ( c i r r g n a l o u a i , a e a t e e r b p r u l r d e s ) p c n f 3 i n l v l v u t n i c e t a a n x g i l r n h m d d y n l d i r y r r o a 0 e i l e i a u a i c t u g a u r e x / e w e e a t l o s n T p t l e u u r i e s 1 n h s n s c e v t b . i e e m o o i l e t o s p i V a r u s a t t m a m s a e f e e e h l a h l e p s t a ) r a r i c e d F t n d u u L a i T e v L o W r 2 s e c C A u v o o e e f s s r r e h h r ) e f e P ) l r a a n ) 0 e t ) y t f ) F a ( d t t p b l e r I c a d c c i a 1 r s b b s o E ) f o 3 g r e 0 n l i 1 i - t o V a e b r C h e F g ( o n i e r n v o s u l a l e v n o l t i t t i o r l c t n e s n i o g c n g n i y i t t l . l u p p 7 i u s r a t 0 F e r s 1
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y r a e C t m m . t o p d i f w s t o e n r h t o i L t a f o o m l a c s t e t L s e 2 i t i n e a l h l h 0 v a o c h t a r i n t t A 1 y t L - w c t r c r r e e w e e V e d o e r h r h t o n d l t l u r n t r a t f a o i r 3 t a a d d . L o u 0 r n f l e f 1 e e L n i 1 a f e 0 A 2 A v p t n e P e L A P l 1 m c I e v p - t e 0 e T t e e r C 1 f h e m t u a h o t g u e l t t r l V i d a g t i n p a a n p C w t n w t o r e i o s ) p e e r e L l n T 1 p t p s f v e S I t p u e o m i 0 ) r r u ) n a e e b t r o p d a T ( 1 t c
p m u . p n o n i o t a e t i n i l v a c w t o n l f e v m e u r p m o i t n i 3 0 M 1 ) c P l l A o i s m y P l w l I o u r a t f n t d n y e o o e i n u t a u x t o q n m d u c i l u f e u t e s o . 2 e d a r r 0 g n o a e a m l 1 r p o n c - m i p e c a r a y l r s h e c V d e u d i c w e i n o v o e h r l t e o p c r a u w l o e p l t v d y a f v n m e e r e e l u i n l c i r e c . n s p s b w e i o i e s 2 f t a t o f l e d c l 0 s i u u 1 L a i a L u s f s ) a n ) f v e e c l e r a d c i V
e t a r w o l 7 m f n 0 a e 1 m e - h t u t l s E l r l o o c o e r r l t i t o t n o n n o o i c c b e o x o r t u t o l f 1 3 t n 0 e 0 i r 1 1 l - g n C o C i o t T a T c e ) f ) a h b o d l V u . d n e 1 o i i r 0 u r w l u d 1 t q e e - d i a c C v l e e r m w e u t f o o e d l a o l f r n r d p e i i r y e e m r r a n u e o u o c e u t q t t o t i g l n a t d p d e l a e a i r r r e u . f e l c u e i v 7 p s o e f e w f r p l f r o 0 m l o a e e 1 i l e - w w n v a t d n l r o E o g i o r l e u e r o o i t t s t e n e w w a a s l i t r r o r e l . e i a L o h e u T L d 2 t n p e b s ) 0 ) e e a f g e r b n e e s ) c e r 1 o e r t u e t u a d r e ( p 0 0 m e 1 t C e t . a f o ) i 4 d 0 e s m 1 m o E r t t e t o r n b l e i i o w m b o o r L f e r
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. e n y e a v a l v c m l e a . o m e t p o v d v d a r l t v h o n f l d c t a a o n a L t i i a l s n v t 2 L r o a h y l l r A t v s t o e 0 a o t n k 1 w n l r . c o L c r t n r s c o c e e e n d l V e o y c d i h t d o p h c a n r c n e t n f c e u r h a o e i r 3 r k t L n r l u 0 3 l a e p c e f 1 f e a 0 i A h u o A 2 P v n t d b 1 e P e I L o i n a g l e 0 r e n r c e 1 e v e p s s V a k t o n C h e f a F r a a l t g m l r d r V n n u u a a C w t o e e s t p i e t n p o e p e s w s s n L l e n a n t u c E i S p f p s v I e o a e ) a ) i t u r r u ) a n b m c t r o p d a h t b i c p o t m w r , . o e u 3 e l p n 0 t . o e w 2 n i 1 t - a r h o 0 o a l 1 e t C w . t i e o i T l n v t t o r V l , f e a l l e c u n a c i i o w t r m o d d i t o n b i n 2 t l n a n f e e e o r e t v o 0 c s e t s e 1 m r e e e h r u 2 t d h p V t m p t g 0 a o t l n 1 c n c i - i n s o i u i 3 a r r l d 0 e T L e C t M n t 1 o ) v r ) o n ) e p c P a c e b l
s i s y l a n a P O Z A H 2 0 1 V n i e r u t a e l r l u e i o o l d t l p e a s i l w l n e i e m b a n x v a e w r n i l e a y g l t u a o e t l h a a c u i i g n a f w v b r i o t m n a o i e c i o v a m l d r t p h t u a l a 2 d l L o a w d n r u o w v u r : t o i o A 0 a s 8 l t ) n o l r . e r 1 f c 7 e p p r P - 3 e 2 o I . e 0 s c e v r s e 0 e 3 V m f s r 1 . c l 2 y e a - l o i e u d n 1 t n e o t l h t E e e n l P n . l e t t u n . p s ( c h a i , 2 e e a . b r u p u ) i , o l f 3 i n e t a e v n v d c 0 y m i 1 e o r a 0 e l T e i l u i c l c f m u e r
t o s f V y 1 n h c s e - s t b u o i c a s w p e a i V r r t u e e e e e o s s e r r r c d n m n d L a i W i C c u o r L u e e f w e r ) r ) f ) a o c c t e e l o f o d a F ( d h t h t p b l E ) f o 3 g r e 0 n l i 1 i - t o V a e b r C h e F g ( o n i e r n v o s u l a e n l v o l t i t i o l t r t n c s n i e o g c n g n i y i t t l . l u p p 7 i u s r a t 0 F e r s 1
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l l o e i , r t t C e T k r . n u c i s e e w P c P e 0 m m r a r o s g g l r r f s f 0 n s 1 o p l n a o e i n r a o u d w e s l a f - 0 r s e l e 1 r t r t o s 1 a a t H h p e b e a d e n u n e C n f e s n c . d s . i e r h e p e u e r d C a r a d x t . u d c p e n l m f g t u y m h o e n t e n t r n e d s e h t a o o o a o n f n r o . e l e i e e f c s s e r s g a 0 o f o i t f a e s e t e i p n p t t l e a v a c i i r e a h h 0 s m r s e S m r u 7 r o s u a p d t p d r r t f 1 l o t o e 0 1 m g e m e f i t n n n s a o 1 n p n a a m h i p 0 i r h l i o t a C i t 1 g g 1 n o e e i o s o t t t r i i t s s e v E h 0 o c i c n r a i n t , a o u i h h u e g t e d r 1 C i r r t e u c a b s i R a t . l s e n h a a c s o m t a s o c l i n a u C g i s o i d l e n p - l h h p r n l t r l l t t e r r n , t o m h a ) e n e d d a o r n i o o o o ) e u i g t b t i e c p c m A t H l c t s H n s v e a a m m c n e r o h n H . r a I e n t n r n A 1 r u o n I e e I I c e h 1 t u l A s g e e t t c e 0 p i ) h n h ) P 0 n t ) ) n H o a P ( 1 o h b y s t i t a ( 1 i i s b f a o c i n
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: m e t 1 s e y v e 0 1 S i - h l l g . e C o r n i r h n t t n o m a m o l s l u d e u C n o o p c a s o e e s r c e e l c l h i h t 1 t 0 o r w n 1 n - i P 1 i T e c 0 r P e r i 1 s u u a V s n s s e B C e h s e r r ) a P p w p . n . . t d y . t n e p y e t d c t p r r c c c a e n m u u n m t u o u n n e f e a a u t u h f e l p d f e l h d f i i p a n c s e r l a n c o u l o e g e h a r c u c r i r i y u u y m i u m i n f f o v t m i a s f f 6 s t n b u b u s n a y y o o a i l l l i e e 0 e e o m o o m o t t r y s n a s a 1 r a t n a c c e ’ ’ e m t m a e s i y p o e o r s s i n t d e r e 1 e 1 a E t p u i d e t u m d 0 0 h h r a o a a n n u u u s t 1 t m s 1 7 d e s e z z a a n n n - i i e n - e s r s i i 0 e s n C a e r f e r t t r a i i r e e t C n 1 r h f u u e n n p u - g e n t p n e s n e s d e r s a a E a r s s o s o s c d o c o c c d i c i n l e e e e n n r n m u u s e t t l r e r i s r o e e i h e a u u d d a a s p r r l p a c . p r r g i d l y e s u a s u e i r r h e w a e a e r i i r o t e t r s s h r n , , . e r p p e e e a b s c e e i g g 1 s u h l s e c e r v 1 v a e g d e e n 0 0 s s c c o r I n r I e O 1 R d d w O 1 H m p c p ) e n p ) e n u v o ) e e a a ) n ) ) u e a a s l f b C f i c h t h a C f i b h t h c d v m l . p n n 0 n d i n u E l 0 m e f o l s r i f o d m e 1 u s u t o l - l a , e , a a u i a l l e 3 f 2 C o i x d , u h s t e r c 0 a c o c i 0 r a l u b n o r n r 1 c 1 e b i c u m f n l t - e i e s u m i - o t e l n . n s i g A v n r s o P f u 1 r n i V l n i l n P e w i e A p 0 e e a I C a o a r t m s 1 r v h h h l c 1 F l v t u d . t o n u u i r m f o t n e s , 0 i , s e C o s f s o e 1 r a e o t h e r t - e m s t t p c o t e r r n a a a g n W m C , s a o a n p n . e v e m a m n i o e b h t e n n e r i c n t e a u s e d r e r o H i m r l n e i o t c c t i n b n o r u i o t h . s e h i i i o u t i l u l n h t d C v t l s s t h q i y g i c o f t i o e s o a u o l r . n A c e p n g p o u w l i n i y n q a 1 1 u n t e i i e P d a i l s a 0 l v h u f e 0 I n t h l s r u v w 7 e t s e e n m 1 t t t e 1 a a e o h o o n r 0 f e h e p M l o l f 1 h t o r t T o c t I C h h i p C
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o s e h t T g k t i c P e a y m h r l o l r v p i a f r o u h t s l p e g s a t t u c i a n e n s n h e e a r r d k e p i c u y m p c t n s h o h t e a e r s o l g e o r f t e i t p t s e a r e a h s s t s s a p d r f o n g e t f p n p n a o I h i . i 7 g e t 0 n e r t r i i s o , a u h t u u o 1 r i d . o c - t s a a e s c o E a e s . l e h p n s t l n t r t r n r i e e a o r p o ) e e t i s l c m t s H H v i u n t e r . a o n n i t o e e u I s b p h I A 1 t 0 n t ) a m ) P a ( 1 i i s b y s e r v w i l : m e t 1 s e y v e 0 1 S i - h l l g . e C o r n i r h n t t n o m a m o l s l u d e u C n o o p c a s o e e s r c e e l c l h i h t 1 t 0 o r w n 1 n - i P 1 i e c 0 e r T r i P 1 s u u a V s n s s e B C e h s e r r ) a P p w p . n e m p r o f m t u r u o f u . l p d y d l t o e A c u r i t u i r 1 P I n y b u c e 0 i a t p f g . 1 n m o e f n d a i o s h C t i e d e t e n a t c r a , b n u u a z a x l n i m d l i p u r f i l e t u e e u n l f w o s r a s e o e s c r t s n b e c i e r n o e a h y l u e r n l p l i t c l s i u i r t h , n s w e 1 s t s e i i e r i v 0 e d c e c t r W n i O 1 p e f e a ) ) a C f i b h t H f e w r l u s l l i l o C A u p , f w x n . a i 2 t e l x u s v r 0 a r u u f e l e f 1 e f o o o r - e h u r t e t s v , r d p V l n s m o i a o e e C a v i o u v n q g t r F l c r a p f h i f o n l e l n t h o t i r w i o i g s u i g n H o m . l n r W h n u o f . s e c i c n i h c i n o x 2 n e i t t a t o 0 e u i i r l h f 1 t e e e l - h u c t s s h e s n g o r n V t t p e u e n , , r . o i f e d l m h l s n v w l n a a l c o e u o o u i 1 r l 0 e M l c b d f c s w 1
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r o t s T T i c P e P e e e l m m s r r f f r r r e d u o u o u a t a s l s l s r t o t o s s a a t s a d a n n s k n n e e e r g u e e e e e e a r a r e r o r r t g d c d c v a p i p n d u n r p l u e n w r w r s s f s n a n e e w o o v w e o u o o s a e s p t t p t 3 e l l l S m e a a h e e r o r t r r l o l d d p p 0 f g g e . e w e r a m i n p i n p i s 1 e n t n i 7 n o w w n m o r o e r m s s c 0 o o o o a C e i , , b i u l u e l i 1 e t e e F h t d . C d t i R a t . a n c c a a s : s E a e c s d l e e l n n h s h l n S e r c d n d l e n e n i f l a t a t o C s o e e e t t ) ) s i i o l o A t I H H a t t s s v v i P g r L L e r . r . . s n A 1 e a n A 1 e a o n t r s I I u B u n t c b w o t t e 0 ) 0 t ) l o ) i i P e P n n o n L a ( 1 i s b i r l a c a ( 1 i s : t h : t t e g y : l p m p m m p g m n u i r e e i b e C h r t t t m m m , t h e a s s e e g d e s l n i h t b o t t i y t x a y t t y t c h a S a u s S a m u e S a m v u a l n l l n o s t d l s n . f . l a e a o o A s i r s o a a o a l e r r s e f r d t m t r c s u r r u t i y A n n n l r a n n i u i u . m s n i d n 2 r n e . o n i o r o r n a 6 u s n n n 0 d o l a C e l C a 0 c e e C e 1 p 1 e e x r u 1 p v - u p v 0 m c s s p a s P p g s s a u O o l o l o v E s l l e T e 1 e e e f - l l e e l t L f d c c l l l e c l i e n r i e T o d i o i n u h a c Z o o t o r h r r h h L S r w t e e w t w t d o e e A o P 2 P P h h h s g h n 1 1 n e e e t t H s a c c 1 e s W n c 0 0 c w e c 0 i i i i n 0 n h i r e n s s 1 1 u v u 1 t r i s e 2 e u c a d w l 1 a d 0 l a - e s d i r d o i e i n B C e V B B e V e C x 1 r p r 1 n p u C o - v C o o a o ) V o 0 v n ) ) E e e i G a L t V l a P t c v t b L t 1 l e r u . . l s n e y y i s e s t t d d d d c c e l l c a c l e v n n r 1 i i n n r e e a e e e a e e e P 0 l u r f f u s v i i f f 1 e b h e c c l c h a n i a n i w t g c n b n n i g o o o i m m , i f , f i C p n t y y t f f l e l t h u e t u e n b L d , e o a a l l l e o t e r n : n 1 u s i u s r e s i 0 m o m o v a t c c w i 0 q ’ ’ t n m c 1 n e a u e , i . e e s g 1 e 1 e 1 s u l l u r h r h o d 2 t s 2 - e i l 0 0 . d n n u u r d p l t 1 t 1 o C n i i i 3 n 0 s s o a o u t . c o 1 r s s u l o n c n v 2 o w n i i e e p c C C q u i C n r n e e g V d r n e p e s l 1 l o a p i e p p e e h i n , 0 b r l c c t o u t i o u v t o e 1 r n a i i a d d u a b l , . T t t h - e m y l i o s e e l e d d a a l n o u s s l T c a c n b i c m r l t . C u r u r r h t d r h n d a e a e a n s e r s r e o n i d d , c , t t p p e u c e l P P i u x i i e e e e e e e d u b s m t H s s c c u s . d l l R e n W R e n W u . o m w c l l A s e o a r f i r o e ) r e r p e ) p n ) ) o o P h h I P L a t h b p r d u a t h b w f c u i r p e n u u l . o b l l l o f i l e p l o e i 1 i r d l u u 0 , f h s i w a , f 7 r d t a s 1 3 e i n 1 n u v e w 0 h A t t u s w h e 0 0 o s i b , a a 1 o . h c t q l t i i o C l s 1 1 i t d 6 , l - e w e a 0 t - e f E h o s a V n n v , s p 1 e T v i e e i o V l l . r c r v m t o h n a e l i l 1 u e u C a t g l e C l v v b s c E 0 c i s F P h s n f i u D f l n y a r a t s l o 1 o s i f o t n - e . e e l o o f e l C b l o t o r r r A l e 1 u s n o e C b . i u s s n g n H g t o u s n p 0 n W ) . r . f A s n a i e e 1 n n s e t i o o n n e e r w i i ( e d r a r c c h s I m o t a s , P o v d n u u l o n e i n e C i a s i l n e t n e V n u i o t o , n l o o e i r i i i a o c p o a n h h r d t t s s u m t t v m c o a c c o l l h a c n m c o a e o u e o s i t n g p o l g v i l n g p e d p l r s C u N u e a u u i n t n e t A / , a a o r i i l s f f e u h P u o t s c t l l y i c l s v s s v v v o o I c l t t n a c a r u s e e n r e o i o a a o o r u l o l e e c c w h n r i n e c h d n h U P D M l t s i M l t p
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d n E l e o l s r i , e u a l t , f e , c a 3 t e i h i , n 0 a r o c s c r n e . 1 b u n - e i e s u m r u H v n r s o . 2 u V l l o p 2 e a h A a o p 0 0 1 C a v c a 1 F l h v t . f o t e v - V i , s e r h o t r W m e e s t r r V o e a g n . a n o u n e e i m n s i o r i c n t s m s e c d n e i o d e t i i e n b n r o t t i i o u i l p h t a l s t h q l y g i c o f t i n u h n g p o u w l i g i u i n e t m d l f e h n h u u l e w 7 r a v c e t e a o p f s 0 l e e h M l o f 1 t o r c a h t
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x c T u i s l P e f l m d r e r e e r r l a f o u l s l r e r s a a t u h o r n e t n f g e a r e p i r d a p p c u c h u s n r n s i r h a i i e s s t d g o i e p t s r e a h e h a r i p d r t y u g e a T n p n t h . l h i p 1 i g t 0 n r i i s o o u , r h t u 2 1 d . a 0 - e r a a e c s l 1 u . e V l h n t l l n t e n e R a r a ) o t V P p e t i u u H s t s H . v r s r a n n m h l s I u t e t I A 2 t l u e i i 0 ) r r ) n i a P ( 1 i s b d w w p - s . V s e 1 0 R c 1 x P ( e V f e e v i m l u a l e r V r d o f x e t i u d l l e f e l e R l r a t e n r s i n u i e s s s r i e s r ) u P 1 s 0 e r ) a 1 p s x e u u d i n l f t n e n r a o s n u c i e r n o r u o e i s g t s n a e a z r i p r d s u f i i s s . 2 e e r p r 0 u 1 u p - t p r d l e V u v m r i u O u y b a r ) o a d m t n e r e n i s i l l i b V r s s u u u r l , f t s l u l i 2 t o u o e r p 0 a p s a p w m u 1 r e - e a v e r d p r v v t V l , i s o u e x - h e C a u h h d t v l l P l c f i t T f f o n a e u h . o b e 2 r o t r H n l t n g n . 0 i o l i i h n o n 1 t i c c a r o V l w u e n e i u s t t o u i s i a n h t e s s i h c t o d m e t m r n g p e u i c 2 t p u n i f e p c 0 r h . l s a v p 1 e g 2 a a l o a v i 0 e c t r n M l a V o h 1
s i s y l a n a P O Z A H 2 0 1 V n i e r u s s e r P h g i H : 1 1 . 2 . 3 . 2 e l b a T
8 5
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2 0 1 V , m u r D e x r u u s l s f e e r R P
2 0 1 V n i e r u s s e r P w o L
s d r a d u e g e d f e a n S m l a m n o o c i e t i R d d A
T P e m r f r o u a t l s a n n s e e e a r d c r p u n r w s e o o s t p e l e a r d p n r e g n p i w i o r s o , u l i e d . a t c a s l n h l n t e e n a o e t ) i H t s L . v r n A 2 e a I u t 0 t ) i P n a ( 1 i s
e l b a l i a v A s d r a u g e f a S g n i t s i x E
. e l b a l i a v a d r a u g e f a s g n i t s i x e o N
) L T . e m P e A 2 L u m r f ( r r 0 n u o e a d 1 l s v t m a n n s r x r T t e e l a u e e a r l L r d c p a f n f u n r w l o i e s r e t o o e t n s p a n e v l i n e a r d c e r e l l p n e g r e n w d o v p i n t w i o r e e s o o l , u l p a r l i e e t d e . . a d p w s a a c s l e l n o h l n l n n o e n a i , l a t o t o e t ) i i e g s H s t t s L . v i c n r a n t n i n A 2 e a I r t u I u t a e t 0 ) u ) i i P n h a ( 1 i s b t H d s : : t n a p s i m m d e l e m C h t t a e n i g s e . s t e v y r m y t h e m a l S S u a l n 2 u l n r e 0 d a h s o a l o o 1 r r t d c t i t i x a n n e T l n n i n u e . s o o n l r n e L f a s C e e 1 m C l n o e r r p e 0 s e s v c u s c n h e o l s 1 e l e l e l l w h t c l i e T o i i c c o o o h n t L r r w e P w m i P 1 t h u d n l 2 r e e d e t i c 0 t c 0 e c h i n v 1 1 u s s e - d w i - p x l a a C l m u e V e B V r 1 v B C t e l w 0 e ) t f ) o o a L t 1 l b L a e r l
s e c n e u q e s n o C e l b i s s o P
l l i . y f w p l f t o s o c t u t u e o n d h u r o n u r t i t b p e s f u n e o o a b c c t e s o n b i t u t e o i s c r a u l m s d f a i o e e h r h T g p t r . a t o l s r u t o o t l A p n e a ) a b v e s
- l e d . d l v e i e p r e o u l e g b r m h r h o d t i n n g f l o i , e i t l i n b l h t g e o r w i n n t v a i i 1 t t c e a e 0 s g b u l l s d i 1 n l r o d t i i t u r i c u l o p q w u u V p d i s n l 1 a p i o e 0 r l v t o e 1 r , . p e - e o o h v n n T C c n p e . o l m t s h n n d e t u e i b e m H l o n l u . o m W c N a l l r e i p ) o o c u i n ) a w f b m
n o i t a i v e D e f l o b ) a s i ( r e a s e V n d o u a o s i t s C N e i a / t i c v n o r e U P D
9 5
s i s y l a n a P O Z A H 2 0 1 V n i e r u s s e r P w o L : 2 1 . 2 . 3 . 2 e l b a T
l l e n l l i e s i r b l l s m . f i w l l o e w u . o u 2 o u u l s r , f r , d 2 r t r x e 0 s 0 f 7 e i u V w d 3 2 t u 1 u w 0 e t o u e o 0 a p l h q o m l x 1 r - 0 a l o 1 f h t l 1 1 - t p b V V u , i f u - e a e l p e a r h r a E h v f v t v n l n w e a V l , e i u m o m V l o r c h v d i e n l r e u C a C a u l u t o x t t W r l v e v r s s i c h F P l h n f n u i a d t u . d l i o s o , l e e r f o n f o i b s f e n s v t x x o t o e o r r W e A n u e u u i u t a r i a r . r r o t g n H r l g o l e n . e s i h e l . l t p f l f a l n o n n t o n e i u T i e i e h n a s a y c c h s s r r t o t a s . n e i n e o l a v w i e i s f r e t n c o t o , , n r n n e i r i i s i i s i i u a u l h h r t t i s s u m t t m l o c c o u t o p i i c o a e o u p h e o . n g p n a p u w r n g p e d p l u T r 2 u u u n n t o a a i i i s f e s y v c d . 0 n s n f l m a l l l s t v v d 1 e t i i t i 2 s n a v a u e e o a a h p o r f u c o u o h u 0 e r l e e M l o c d o b T s M l c h d n t b 1 p V
2.3.3
PFD of distillation process after HAZOP
From the HAZOP analysis performed on the 12 deviations, the required safeguards to be built onto the current preliminary PFD is as such (with further considerations made through observation and evaluation) with reference to the preliminary column PFD:
Introduce a parallel pump configuration for feed pump P-102
Introduce a parallel pump configuration for reflux pump P-103
Install a minimum flowline for feed pump P-102
Introduce a strainer each for all pumps
Introduce a pressure relief valve (sized for two-phase flow) immediatel y at the top outlet of the column C-101, venting off to flare Introduce a rupture disc parallel to the pressure relief valve at the reflux tank which will lead to the flare Introduce a composition analyser for feed, top product (before the pipeline splits between distillate and reflux lines) and bottom product Install separate transmitters to provide alarm signals (from their Basic Process Control System, BPCS, counter parts) for the following process parameters (For high and low) Pressure of column C-101 (For high and low) Pressure in reflux tank V-102 (For high and low) Level in column C-101 (For high and low) Level in reflux tank V-102 Temperature of vapour boil-up after reboiler E-107 (For high only) Temperature of top vapour flow out from column C-101 (For high only) Temperature of condensed fluid flow after condenser E-106 (For high and low) Install a temperature transmitter (and indicator) along the feed inlet line with alarms set at high and low limits Installer safety interlock systems for the following process parameters Low-low level switch for column C-101 which activates a solenoid valve that blocks liquid flow out of reboiler Low-low level switch for reflux tank V-102 which will switch off all reflux pumps High-high pressure switch for column C-101 which activates a solenoid valve that blocks steam flow into the reboiler High-high temperature switch for vapour boil-up flow from reboiler E-107 which activates a solenoid valve that blocks steam flow into the reboiler Ensure there are scheduled trips to ensure that all equipment are in proper operating conditions, to confirm if reading transmitted is that on-site, and to perform regular control valve stroke checks Employ a split range pressure controller scheme that controls PCV-101 and PCV-102 rather than to use two separate control schemes
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Main discussion pointers The main two recommendations from the HAZOP analysis that were not considered are the employment of a heat exchanger to cool the feed stream and to introduce additional back-up control valves parallel to their original ones. The former would be relatively unnecessary due to the fact that heat is generally lost over flow distance. Implementation of a heat exchanger would result to excessive energy and utility demands. If it is critically demanded that the stream is to be cooled, an exposed section of the piping coiled up as a heating coil can be implemented so as to exchange heat to the surroundings. For the latter idea, the idea of using extra control valves may cause confusions during operations which can result to miscommunications and process upsets. Also the idea of using a low selector switch between PC-101 (column pressure regulator) and TC-103 (temperature control of vapour outlet from reboiler) to then act as the master control for cascade controller FC-103 (steam inlet flow into reboiler) is not advisable. This is because the pressure in the column has its own BPCS to operate thus providing two conflicting signals may result to producing a vapour flowrate that is not desired; ultimately affecting the purity of the outlet streams. The edited overall IPA column PFD with all these considerations is presented as such:
PRV-101
PIT 101
PAH
PIT 101
PAL
To Flare
PC 101 PCV-101B
PCV-101A
TIT 102
TAH
TIT 103
E-106
TIT 102
TIT 103
CWS
CWR FIT 101
FIT 102
Bottoms from C-100
P-102A
TIT 101
TC 103
LIT 102
LAH
PIT 102
PAH
PAL
LAL
LIT 102
LSLL 102
LC 102
II
FC 102
P-103A AIT 102
C-101 FCV-101 AIT 101
TAL
V-102
TCV-103
FC 101
TAH
TIC 102
PSHH 101
PRV-102
P-103B
TAH
TAL
FCV-102
PDI 101
IPA for Recycle
HV-102
LCV-102 TSHH 104
P-102B
LIT 101
TIT 104
LAH
TAH
III TIT 104
TC 104 FIT 103
FC 103
LAL
Steam Inlet
LIT 101 LSLL 101 LC 101
FCV-103 UZV-101
E-107
HV-101
LCV-101
Steam Outlet
I
AIT 103
Water for Discharge
Figure 2.3.3.1: Edited PFD of C-101 with consideration of performed HAZOP analysis
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