To design a petrochemical plant that produces 330,000 MT of Polyethylene

Terephthalate (PET) from Terephthalic Acid (PTA) and Ethylene Glycol (EG).

PROJECT BACKGROUND

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

OBJECTIVE

INTRODUCTION

INTRODUCTION

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

To design a petrochemical plant that produces 330,000 MT of Polyethylene

Terephthalate (PET) from Terephthalic Acid (PTA) and Ethylene Glycol (EG).

PROJECT BACKGROUND

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

OBJECTIVE

INTRODUCTION

SAFETY &

LOSS PREVENTION

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

•None of design intent is achieved.No

•Quantitative increase MORE

•Quantitative decreaseLESS•The logical opposite of the intentionREVERSE•An additional activity occurAS WELL AS

•Only some of design intent is achievedPART OF

•Complete substitution OTHER THAN

HAZOP ANALYSIS

Node 1 •Methanator (R105) including incoming line discharge from heat exchanger (E117)

Node 2 •Ammonia Converter (R106) including incoming line discharge from heat exchanger (E105)

Node 3 •Ammonia Separator (V106) including incoming line discharge from cooler (E120)

HAZOP Study Nodes

HAZOP ANALYSIS

Node 1

HAZOP ANALYSIS : NODE 1

Guide Word

Deviation Possible Causes Consequences Safeguards Recommendations

Parameter : Flow

NO No Flow

1. Line (S22) leakage. 2. Loss of feed supply.3. Blockage inside pipeline (S22).

1. No process gas into the reactor2. Release of toxic material.

1. Flow indicator is provided.2. Perform regular schedule inspection on process line.

1. Install gas detection system is provided.2. Install No Flow alarm

HAZOP

LESS Less Flow

1. Partially plug line.2. Control valve failure. 3. Line (S22) leakage.

1. Pressure drop inside the reactor (R105)2. Less process gas into reactor.

1. Flow indicator is provided.2. Perform regular schedule inspection on process line.

1. Install gas detection system is provided.

Guide Word

Deviation Possible Causes Consequences Safeguards Recommendations

Parameter : Flow

HAZOP

Guide Word

Deviation Possible Causes Consequences Safeguards Recommendations

Parameter : Flow

MOREMore Flow

1. Control valve failure.

1. Over pressure inside the reactor.2. May lead to reactor explosion3. Undesired product quality

1. Flow indicator is provided.2. Perform regular schedule inspection on process line.

1. Install gas detection system is provided.2. Install high flow alarm.

REVERSEReverse

Flow

1. Back pressure.2. Failure of pressure controller.3. Compressor trips.

1. Reverse flow from reactor (R105)2. Less of product yield.

1. Flow indicator is provided.2. regular schedule inspection on process line.

1. Install Non-return/check valve

HAZOP

Guide Word

Deviation Possible Causes Consequences Safeguards Recommendations

Parameter : Temperature

HIGHHigh

Tempera-ture

1. Failure of cooler.2. Poor heat transfer in the cooler.3. HE (E117) failure.

1. Less of product goes to the storage.

1. Temperature indicator is provided.2. High temperature alarm is provided.

1. Install high temperature alarm.

LOWLow

Tempera-ture

1. Malfunction of heat exchanger (E117)

1. Rate of reaction is reduced.

1. Temperature indicator is provided.

1. Install low temperature alarm.

HAZOP

Guide Word

Deviation Possible Causes Consequences Safeguards Recommendations

Parameter : Pressure

LOWLow

Pressure

1. Compressor failure.2. Pipe leakage.

1. Impact to reactor.2. May lead to reverse flow.

1. Pressure indicator is provided to notify operator.

1. Install high temperature alarm.2. Install Low pressure alarm.

HIGHHigh

Pressure

1. Failure of pressure relief valve.2. More process gas into the reactor.

3. Pipe blockage.

1. Pipe vibration.2. May lead to explosion.

1. Pressure indicator is provided to notify operator.

1. Install high pressure alarm.2. Install emergency shutdown system.

PLANT LAYOUT