INTRODUCTION PROJECT BACKGROUND INTRODUCTION To design a petrochemical

INTRODUCTION PROJECT BACKGROUND INTRODUCTION § To design a petrochemical plant that produces 330, 000 MT of Polyethylene Terephthalate (PET) from Terephthalic Acid (PTA) and Ethylene Glycol (EG). OBJECTIVE § To evaluate critically and select the best technology in PET production § To propose a site for the plant erection § To analyze an economically feasible conceptual design § To address safety and environmental issues § To perform mass balances along with heat integration

BACKGROUND OF STUDY PROJECT Commercially known as anhydrous ammonia Ammonia is a colourless gas with a sharp, penetrating odour. The heart of ammonia manufacture is the Haber process One of the most essential material of the world nitrogen industry

USAGE OF AMMONIA Fertilizer products Household cleansing agent Manufacture synthetic fibers : nylon and rayon Neutralize acidic by-products of petroleum refining

INTRODUCTION PROJECT BACKGROUND SAFETY & OBJECTIVE LOSS PREVENTION § To design a petrochemical plant that produces 330, 000 MT of Polyethylene Terephthalate (PET) from Terephthalic Acid (PTA) and Ethylene Glycol (EG). § To evaluate critically and select the best technology in PET production § To propose a site for the plant erection § To analyze an economically feasible conceptual design § To address safety and environmental issues § To perform mass balances along with heat integration

HAZOP Objective of HAZOP To indentify potential hazards and potential operability problems that may arise from the deviations of design intent.

LIST OF HAZOP GUIDE WORDS No • None of design intent is achieved. MORE • Quantitative increase LESS • Quantitative decrease REVERSE AS WELL AS PART OF OTHER THAN • The logical opposite of the intention • An additional activity occur • Only some of design intent is achieved • Complete substitution

HAZOP ANALYSIS HAZOP Study Nodes • Methanator (R 105) including incoming line Node 1 discharge from heat exchanger (E 117) • Ammonia Converter (R 106) including incoming Node 2 line discharge from heat exchanger (E 105) • Ammonia Separator (V 106) including incoming Node 3 line discharge from cooler (E 120)

HAZOP ANALYSIS Node 1

HAZOP ANALYSIS : NODE 1 Parameter : Flow Guide Word NO Deviation No Flow Possible Causes Consequences Safeguards 1. Line (S 22) 1. No process gas 1. Flow indicator is leakage. into the reactor provided. 2. Loss of feed 2. Release of toxic 2. Perform regular supply. material. schedule inspection 3. Blockage inside pipeline (S 22). on process line. Recommendations 1. Install gas detection system is provided. 2. Install No Flow alarm

HAZOP Parameter : Flow Guide Word LESS Deviation Less Flow Possible Causes Consequences Safeguards 1. Partially plug 1. Pressure drop 1. Flow indicator is line. inside the reactor provided. 2. Control valve (R 105) 2. Perform regular failure. 2. Less process gas schedule inspection 3. Line (S 22) into reactor. on process line. leakage. Recommendations 1. Install gas detection system is provided.

HAZOP Parameter : Flow Guide Word MORE Deviation Possible Causes Consequences Safeguards Recommendations 1. Control valve 1. Over pressure 1. Flow indicator is 1. Install gas failure. inside the reactor. provided. detection system is More 2. May lead to 2. Perform regular provided. Flow reactor explosion schedule inspection 2. Install high flow 3. Undesired on process line. alarm. product quality REVERSE 1. Back pressure. 1. Reverse flow from 1. Flow indicator is 1. Install Non- 2. Failure of reactor (R 105) return/check valve Reverse pressure controller. 2. Less of product Flow 3. Compressor trips. yield. provided. 2. regular schedule inspection on process line.

HAZOP Parameter : Temperature Guide Word Deviation Low LOW Possible Causes Consequences Safeguards 1. Malfunction of 1. Rate of reaction is 1. Temperature heat exchanger reduced. Recommendations 1. Install low indicator is provided. temperature alarm. Tempera- (E 117) ture 1. Failure of cooler. 1. Less of product High HIGH Temperature 2. Poor heat 1. Temperature goes to the storage. indicator is provided. temperature alarm. transfer in the 2. High temperature cooler. alarm is provided. 3. HE (E 117) failure. 1. Install high

HAZOP Parameter : Pressure Guide Word LOW HIGH Deviation Low Pressure High Pressure Possible Causes Consequences Safeguards Recommendations 1. Compressor 1. Impact to reactor. 1. Pressure indicator 1. Install high failure. 2. May lead to is provided to notify temperature alarm. 2. Pipe leakage. reverse flow. operator. 2. Install Low pressure alarm. 1. Failure of 1. Pipe vibration. 1. Pressure indicator 1. Install high pressure relief 2. May lead to is provided to notify pressure alarm. valve. explosion. operator. 2. Install 2. More process emergency gas into the shutdown system. reactor. 3. Pipe blockage.

PLANT LAYOUT