Tk5 Report Assignment5

UNIVERSITAS INDONESIA

PRELIMINARY DESIGN OF BIOBASED SYNTHETIC RESIN

PRODUCTION

GROUP 5 (REGULAR)

MEMBERS:

AHMAD FAISAL (1006660491)

ANDIKA BAGUS PERMANA (1006660503)

DIAN IKRAMINA (1006660535)

DIMAS RISKA IRAWAN (1006660541)

MEYDA ASTRIA (1006679743)

FACULTY OF ENGINEERING

CHEMICAL ENGINEERING DEPARTMENT

DEPOK

NOVEMBER 2013

ii Universitas Indonesia

TABLE OF CONTENTS

TABLE OF CONTENTS ........................................................................................ ii

LIST OF TABLES ................................................................................................. iv

CHAPTER VII ........................................................................................................ 1

CONTROL AND INSTRUMENTATION ............................................................. 1

7.1. PIPING AND INSTRUMENTATION DIAGRAM ................................ 1

7.2. CONTROL TABLE ................................................................................. 5

7.3. START UP PROCEDURES .................................................................. 11

7.4. SHUT DOWN PROCEDURES ............................................................. 13

CHAPTER VIII ..................................................................................................... 15

PLANT LAYOUT AND PIPING DESIGN ......................................................... 15

CHAPTER IX ....................................................................................................... 22

HEALTH, SAFETY, AND ENVIRONMENT ..................................................... 22

9.1. HEALTH ASPECT .................................................................................... 22

9.1.1. Health and Safety Aspects of Plant..................................................... 22

9.1.2. Basic Principles of Safety at Work ..................................................... 22

9.1.3. Behaviour in the Workplace ............................................................... 22

9.1.4. Safe Work Behavior............................................................................ 23

9.1.5. Safety Program at Work ..................................................................... 24

9.1.6. Personal Protective Equipment (PPE) ................................................ 25

9.1.7. Work Safety Analysis ......................................................................... 26

9.2. HIRA .......................................................................................................... 27

9.3. HAZID ....................................................................................................... 31

9.4. HAZOP ...................................................................................................... 34

9.5. WASTE MANAGEMENT ........................................................................ 41

9.6. ESCAPE ROUTE ...................................................................................... 42

9.7. EMERGENCY ........................................................................................... 43

REFERENCES ...................................................................................................... 44

APPENDIX ........................................................................................................... 45

K. Controller Explanation ........................................................................... 45

iii Universitas Indonesia

LIST OF FIGURES

Figure 7. 1 P&ID for lignin processing ................................................................... 2

Figure 7. 2 P&ID for resin processing .................................................................... 3

Figure 7. 3 P&ID for utility plant ........................................................................... 4

Figure 8. 1 Communication links among product, process, ahedule, and layout

design (Apple Plant Layout (Page 25)) ................................................................. 15

Figure 8. 2 Advantages of Product Layout (Apple Plant Layout (Page 40)) ........ 16

Figure 8. 3 Product Layout (Apple Plant Layout (Page 38)) ................................ 16

Figure 8. 4 Plant dividing zone ............................................................................. 17

Figure 8. 5 2D Plant layout ................................................................................... 20

Figure 8. 6 3D Plant layout ................................................................................... 21

Figure 8. 7 Figure 8. 6 3D Plant layout (continued) ............................................. 21

Figure 9. 1 PPE for employees .............................................................................. 26

Figure 9. 2 (a) (b) (c) Muster point for this plant. ................................................. 42

iv Universitas Indonesia

LIST OF TABLES

Table 7. 1 Tabulation for Control System in Resin Production .............................. 6

Table 8. 1 Total of Equipment Needs ................................................................... 17

Table 9. 1 Parameters to Determine Hazard Level Possibilities ........................... 28

Table 9. 2 Hazard Identification and Risk Assesment .......................................... 29

Table 9. 3 HAZID Parameters In Determining The Danger Effect ...................... 31

Table 9. 4 HAZID Parameters Hazard Frequency ................................................ 31

Table 9. 5 Hazard Identification of Bio Based Resin Plant .................................. 32

Table 9. 6 HAZOP Parameter ............................................................................... 35

Table 9. 7 HAZOP in Production Unit ................................................................. 36

Table 9. 8 HAZOP in Production Unit (continued) .............................................. 36

Table 9. 9 HAZOP in Production Unit (continued) .............................................. 37

Table 9. 10 HAZOP in Production Unit (continued) ............................................ 38




Table 9. 14 Waste Treatement for Resin Production ........................................... 41

1 Universitas Indonesia

CHAPTER VII

CONTROL AND INSTRUMENTATION

7.1.PIPING AND INSTRUMENTATION DIAGRAM

P&ID for this plant can be seen in table 7.1, 7.2, and 7.3 below

2

Universitas Indonesia

Figure 7. 1 P&ID for lignin processing

3


Figure 7. 2 P&ID for resin processing

4


Figure 7. 3 P&ID for utility plant

5


7.2.CONTROL TABLE

Tabulation for controller in this plant can be seen in the table 7.1.

6


Table 7. 1 Tabulation for Control System in Resin Production

Process

Equipment

Controlled

Parameter

Censor

Controller Controlling

Variable (Final

Element)

Controller Procedure

Compresso

r (C-101,

C-102)

Outlet

Pressure

Liquid

Coloumn

Pressure

Indicator

Control

(PC-101)

Globe Valve at

Inlet Flow

When the fluid’s pressure from outlet compressor exceeding

maximum point/ reaching minimum point, Liquid Column

will give an electric signal to PC, then the PC will receive

signal and will send pneumatic signal to final element (globe

valve), then globe valve will open larger/lesser than before

to change amount of fluid entering the compressor. So, the

outlet pressure from compressor will be appropriate with the

specification.

7


Outlet Flow Orifice Flow

Indicator

Control

(FIC 101)

Globe Valve at

Inlet Flow

When the flow from outlet compressor exceeding maximum

point/ reaching minimum point, orifice will give an electric

signal to FIC, then the FIC will receive signal and will send

pneumatic signal to final element (globe valve), then globe

valve will open larger/lesser than before to change amount

of fluid entering the compressor. So, the outlet flow from

compressor will be appropriate with the specification.

Dryer (D-

101, D-

201)

Outlet Flow Orifice Flow

Control

(FC-101)

Globe Valve at

Inlet Flow of

Dry Air

When the waste flow from outlet dryer exceeding maximum

point/ reaching minimum point, Orifice will give an electric

signal to FC, then the FC will receive signal and will send

pneumatic signal to final element (globe valve), then globe

valve will open larger/lesser than before to increase/decrease

the dry air supply. So, the outlet temperature from dryer will

be appropriate with the specification.

Reactor (R-

101, R-102,

R-201)

Level Chain

Gauge

Level

Indicator

(LI-

104/106/203

)

When the liquid’s level on column exceeding maximum

point, Chain Gauge will give an electric signal to LI, then

the LI will receive signal and will send signal to control

room, then operator will decrase raw material that enter to

the reactor.

8


Composition Gas

Liquid

Chromato

grap

(GLC)

Gas Liquid

Chromatogr

ap

Speed

Controlled

Agitator

& Globe Valve

at input material

When the composition of reactor product out of toleranced

range, operator will change Speed Controlled Agitator

& Globe Valve, then globe valve will open larger/lesser than

before to change amount of fluid entering the column and

Speed Controlled Agitator will rotate more/less fast than

before to fasten/slower homogenity process of product. So,

the composition of product will be appropriate with the

specification.

Temperature Thermoc

ouple

Temperature

Indicator

Control

(TC-

101/201)

Globe Valve at

Outlet Flow

When the reactor temperature exceeding maximum point/

reaching minimum point, Thermocouple will give an electric

signal to TC, then the TC will receive signal and will send

pneumatic signal to final element (globe valve), then control


of outlet flow. So, the rector temperature will be appropriate

with the specification.

9


Temperature Thermoc

ouple

Flow

Control

(FC-

106/203)

Globe Valve at

Inlet Flow of

Hot Utility

When the reactor temperature exceeding maximum point/

reaching minimum point, Thermocouple will give an electric




of inlet flow of steam. So, the rector temperature will be

appropriate with the specification.

Inlet Flow Orifice Flow

Control

(FC-

101/102/103

/112/201/20

2)

Globe Valve When the liquid’s level on column exceeding maximum

point/ reaching minimum point, Orifice will give an electric




of inlet flow of raw material. So, the rector level will be

appropriate with the specification.

Heat

Exchanger

(HE-101)

Outlet

Temperature

Thermoc

ouple

Temperature

Indicator

Control

(TC-102)

Globe Valve at

Inlet flow of

fluid on shell

When the fluid’s temperature from outlet of heat exchanger

exceeding maximum point/ reaching minimum point,

Thermocouple will give an electric signal to TC, then the TC

will receive signal and will send pneumatic signal to final

10


element (globe valve), then the globe valve which control

the shell flow will open larger/smaller. So, the outlet

temperature from heat exchanger will be appropriate with

the specification.

Storage

Tank (TT-

101/102/10

3/104/201/

202)

Level of

liquid on

tank

Chain

Gauge

Level

Indicator

(LI-

101/102/103

/105/201/20

2)

Globe Valve

after the tank

When the liquid’s level on column exceeding

maximum/minimum point, chain gauge will give an electric

signal to LI, then the LI will receive signal and will send

signal to final element (globe valve), then control valve will

open larger than before to make liquid out (more than

before) from the column.

11


7.3.START UP PROCEDURES

Commissioning and start-up is the final step before production runs in a

processing plant. In order to make sure the plant is going to run smooth and

sound, all related and essential equipment and their components must be checked

and commissioned. The procedures described in this Section shall be carried out

at the completion of construction and before initial operation of the Unit. The

phase initial start-up will be done according to the following steps:

A. Operational Check Out

The main purpose of this step is to make sure all equipment and lines

have been installed properly. In our case, the main activity on this step is

to check line by line between the flowsheet and located item, identifying

the location of instrument, indicating all the valve (especially for check

valve regarding their direction of flow), checking pumps, compressors and

waste treatment unit.

B. Mechanical Testing

The main purpose of this step is to make sure that all the equipment

has met their specification design. The testing will be done on by

hydrostatic testing. Hydrostatic pressure testing of the Unit shall be

performed to prove strength of the materials and weld integrity after

completion of the construction. All equipment and utilities which have

connection to pressure accumulation is tested using fluid (fresh water with

corrosion inhibitor for liquid pipelines and equipment; air for gas pipelines

and equipment). We use temporary blanks and blinds to let fluid flow to

the tested equipment. Normally all the fluid is using water, but since in our

plant, there is a line which operates on the temperature below 5oC, we

can’t use water as a testing fluid (IPS-E-PR-280 Standard) in that stream,

in this case we use anti-freezing solution at appropriate strength as a

testing fluid to tested that stream.

After completion of hydrostatic testing, all temporary blanks and

blinds shall be removed and all lines completely drained. Valves, orifice

plates, expansion joints and short pieces of piping which have been

12


removed shall be reinstalled with proper and undamaged gaskets in place.

Valves which were closed solely for hydrostatic testing shall be opened.

And then, temporary piping supports shall be removed so that insulation

and painting may be completed.

C. Flushing of Lines

All fluid handling equipment particularly piping system, should be

thoroughly cleaned of scale and the internal debris which accumulates

during construction. This is accomplished by blowing or washing with air,

steam, water and other suitable medium.

D. Utility Commissioning

All utilities such as various types of steam, hot water, boiler feed

water and electricity shall be commissioned. Typically, we have to make

sure that all the valves are properly installed, the total water needed for the

hot fluid and the steam is enough for main operations and for the

electricity, we have to make sure that the electricity mapping should be

clear and provide proper electricity current and the capacity for our plant’s

operations.

E. Adjusting Operation Condition

On the basis of laboratory tests, operating conditions can be adjusted

to meet specifications on the products as well as product yields.

F. Trial of Overall Process

This step is meant to be for testing the operation reliability and

continuity for a certain period of time. The test is done partially to the

equipment to see the smoothness and stableness of its operation. In this

test which usually using water and air, it must be done in loop that is

continuously recycled for approximately 2 to 3 weeks. With this step being

done, we can foresee the operation reliability of all elements of the process

and confidently start up the overall process.

13


7.4.SHUT DOWN PROCEDURES

1. Manually Initiated Shutdown

The process shutdown is done on purpose to let the maintenance process

on the equipment. Actually the procedure is the same as stopping equipment

when the process has done, since our plant is a batch process. Typical

procedure shutdown process can be seen on the following step:

1) Close all the inlet valve to stop inlet feed to enter the equipment

2) Shutting down heating and cooling sources

3) Flooded with water or a solvent to remove deposit on the reactor

4) Purge with steam or gas to remove vapor

5) Cooling (or heating) the column

6) Bringing the column to atmospheric pressure

7) Eliminating undesirable materials (cleaning process)

8) Preparing for opening to atmosphere

2. Process Shutdown (PSD)

A process shutdown is defined as the automatic isolation and de-activation

of all or part of a process. During a PSD the process remains pressurized. In

our case PSD consists of field-mounted sensors, valves and trip relays, a

system logic unit for processing of incoming signals, alarm and HMI units.

The system is able to process all input signals and activating outputs in

accordance with the applicable Cause and Effect. In our plant, the PSD is

integrated with the control system such as pressure control and level control.

When the pressure is far from its set point, and potentially harm the

equipment, human or environment, the PSD will automatically initiate. For

example, when the level of the liquid on the storage tank is far from the High

Level allowed, there will be an alarm on the operating room for the operator

to take action, but if in some cases, the level is still getting higher, until the

highest point. The process shutdown will automatically initiate to prevent the

losses.

3. Emergency Shutdown (ESD)

14


The Emergency Shutdown System (ESD) shall minimize the

consequences of emergency situations, related to typically uncontrolled

flooding, escape of hydrocarbons, or outbreak of fire in hydrocarbon carrying

areas or areas which may otherwise be hazardous. Traditionally risk analyses

have concluded that the ESD system is in need of a high Safety Integrity

Level, typically SIL 2 or 3.

An emergency shutdown systems represent a layer of protection

mitigating and preventing the occurrence of hazardous situation. An ESD

system must be highly reliable. During emergency situation, it is a must to

shutdown the plant in safety way.

The situations that initial the emergency shutdown such as:

- An electric power failure

- The temperature of reactor outlet is higher than 100 0C

- Manual alarm

- Compressor failure

- Feed failure to any hot equipment such as reactor, dryer, and reboiler

The main objectives of emergency shutdown are as follows :

- To shutdown the plant safely

- To minimize emissions

- To prevent over pressure in the equipment

- To protect equipment from damage

Shutdown processes are performed by these following steps :

- Shutdown all transportation of gas and liquid

- Decrease the pressure and temperature of any equipment

- Perform electrical isolation

- Start all safety equipment


CHAPTER VIII

PLANT LAYOUT AND PIPING DESIGN

Plant layout has several objectives:

1. Minimize investment in equipment

2. Minimize overall production time

3. Utilize existing spacr most effectively

4. Provide for employee convenience, safety, and operation

5. Minimize material handling cost

6. Minimize variation in types of material equipment

7. Facilitate the manufacturing process

8. Facilitate the organizational structure

Figure 8. 1 Communication links among product, process, ahedule, and layout design (Apple

Plant Layout (Page 25))

From figure above we know that layout design is related to product design,

shedule design, and process design. In order to make the product we want, layout

design must accommodate shedule design of our plant and how the process run

productively. In process design, we also should consider to the plan of material

flow pattern, equipment and space requirement, and storage requirement.

There are severeal kinds of plant layout, fixed product, product, group, and

process layout. Ours is product layout because of sevelar reasons below:

16


Figure 8. 2 Advantages of Product Layout (Apple Plant Layout (Page 40))

Figure 8. 3 Product Layout (Apple Plant Layout (Page 38))

17


Table 8. 1 Total of Equipment Needs

Equipment

Code Quantity

R 3

C 2

ST 27

HE 1

BC 7

P/SP 19

R 1

FP 4

M 1

D 2

TOTAL 67

We can see this plant layout in fugure 8.5 until 8.7, below is the zone for

this plant.

Figure 8. 4 Plant dividing zone

a. First Zone

First zone is office area, clinic, mosque, mass, etc. This area is quite

safe and does not nedd safety equipment or PPE (Personal Protective

Equipment). Planning layout in this zone should not obey exact rule for

distance between building. There are only total distance area from process

zone, at least 60 m. At this plant, we use distance between 65-70 m.

18


b. Second Zone

Second zone is process area that danger enough where all worker are

suggested to wear minimum standart PPE (Personal Protective Equipment)

that consist of shoes, earplug, helm, and glasses.

This zone is necessary to design the layout specifically because it

consists of process units. Part in this zone include:

a. Vessel section which is the main unit in the precipitation, re-slurry

formation, and epoxidation process. Included in the severe categories

hazid, where the distance to the other units is approximately 20-40

meters.

b. Non thermal separation unit which is the main unit in separating

process without high temperature waste to environment, consisting of

four filter press. Including severe category (extremely dangerous) in

hazid, the distance to the unit or other building around 20-40 meters.

c. Thermal separation unit is also classified as category severe, consisting

of rotary dryer to evaporate water at quite high temperature (120 0C).

Distance to other units around 20-40 meters. Rotary dryer there are two

units, the distance between the unit is about 10 meters, while the

distance dryer column with its own dry air generator of about 2-5

meters.

d. Exchanger units section are also classified as severe category,

consisting of heat exchanger to exchange two stream including very

low temperature and reboiler to heat water to steam as hot utility.

Distance to other units around 20-40 meters. Heat exchanger and

reboiler there are one unit each, while the distance reboiler with its own

heat generator of about 2-5 meters.

e. In addition to the above units are also buildings-buildings such as

warehouses, control room, garage, workshop, and others. Distance to

the unit processes about 30-60 meters.

19


c. Third Zone

Third zone is the raw material area, because there are harmful

parameters in this zone such as NaOH and H2SO4, this zone includes in

hazid severe categories (extremely dangerous). So, Distance to other units

around 20-40 meters. In this area are required to wear PPE anyone with a

standard such as the two zones.

d. Fourth Zone

Fourth zone is the waste material area, because there are harmful

parameters in this zone such as delignin black liquor containing H2SO4 and

mixture of NaOH and EPC this zone includes in hazid severe categories

(extremely dangerous). So, Distance to other units around 20-40 meters and

placed far from point that worker concentrate area. In this area are required

to wear PPE anyone with a standard such as the three zones.

e. Fifth Zone

Fifth zone is the product area, there are loading and unloading

process. Because there are harmful parameters in this zone such as

accident by heavy vehicle and manual work, this zone includes in hazid

severe categories (extremely dangerous). So, Distance to other units

around 20-40 meters. In this area are required to wear PPE anyone with a

standard such as the two zones.


Figure 8. 5 2D Plant layout

21


Figure 8. 6 3D Plant layout

Figure 8. 7 Figure 8. 8 3D Plant layout (continued)

22


CHAPTER IX

HEALTH, SAFETY, AND ENVIRONMENT

9.1.HEALTH ASPECT

9.1.1. Health and Safety Aspects of Plant

Personal safety and security is an important factor in carrying out an

activity all the time everywhere. In a corporate environment, safety is the

responsibility of the management company and the employees. Guidelines for

Occupational Health and Safety are essential so the conditions that created

have no accidents (zero accident) as well as healthy environment are

achieved.

9.1.2. Basic Principles of Safety at Work

The entire workers either directly or indirectly shall made the OSH as s

lifestyle while they are in the factory environment so it is important to live up

to the principles of OSH:

a. Company prioritize the creation of a safe working environment and safety.

b. Safety is also the size of job performance. Corrective action against unsafe

conditions must be done with safe work attitude.

c. Any accident or injury without the slightest regard to the consequences

report to Chief of OSH.

d. If in doubt or lack of clear procedures, ensure work procedures are

performed safely by getting information or knowledge work teams.

e. Shall not modify, change, move, use, or operate the equipment without

permission of company authorized officer.

f. All equipment brought into the area of companyt must obtain a safe

statement and suitable label from the related fields to be used.

9.1.3. Behaviour in the Workplace

Jobs that safe and efficient require that all employees comply with

company regulations and fully master the mental as well as the physical

abilities during work tasks. At any time, the following acts are prohibited:

a. Smoking in the factory, except at a designated place;

23


b. Bantering roughly;

c. Make the other people surprised;

d. Fooling around with the compressed air or work equipment;

e. Fighting each other;

f. Come to work drunk under the influence of alcohol or narcotics or any

other dangerous drugs.

g. For ensuring safety in the workplace is maximum, an employee must

notify the employer/supervisor directly, if he was taking medication under

a doctor’s advice that may result in loss of control over the physical and

mental abilities.

h. Carrying and storing firearms or other weapons and flammable/ explosive

materials except for the purposes of the plant.

i. Turning on/run production machinery or the other equipment without

authorized permission.

9.1.4. Safe Work Behavior

According to the ILO (International Labor Organization), there is a duty

and the right of work in a safe condition to prevent major accidents. Here is

the obligation of workers:

1. Workers have to do their job safely and not compromise their ability, or

the ability of others, to do so. Workers and their representatives should

cooperate with the management of work in promoting safely awareness

and two-way communication on security issues, as well as in the

investigation of major accidents or near misses that could cause a major

accident.

2. Workers are required to immediately report to management any work

situation which they believe could lead to deviations from normal

operating conditions, in particular the situation could develop into a

major accident.

3. If workers in grave danger installation have reasonable justification to

believe that there is a real and serious danger to workers, the public or the

environment, they shall, within the scope of their work, stop the activity

24


as a safe way. As soon as possible after that, workers must notify the

worker or improve alarm management, as appropriate.

4. Workers should not be placed at any disadvantage because of the actions

mentioned above.

Meanwhile, workers’ rights are as follows:

1. Workers and their representatives should have the right to receive

comprehensive information of relevance to the hazards and risks

connected with their workplace. In particular, they should be informed

about:

a) the name and chemical composition of hazardous materials;

b) the hazardous nature of these substance;

c) the danger of the installation and the precautions to be taken;

d) full details of contingency plans for dealing with major accidents at

the site;

e) full details of their emergency duties in the event of a major

accident.

2. Workers and their representatives should be consulted before decisions

are taken on issues relevant to the great danger. In particular, this

includes hazard and risk assessment, failure assessment and examination

of the deviations from normal operating conditions.

In Indonesia there are Safety Act 1 to 1970 which also regulates the

obligations and right of workers, namely:

1. The use of appropriate safety equipment regulations.

2. Demand for health insurance and workplace safety systems.

3. Compliance with workplace rules and giving clear information about

safety in the workplace.

9.1.5. Safety Program at Work

The management has a responsibility to provide a safe and healthy

working environment to make a program of Occupational Safety and Health

Guidance for both short-term and long-term future for the benefit and safety

of all components of the plant, namely:

25


a) Training of safety and health at every new employee and corporate guests.

b) Checking the existing hydrant system within and outside the area of each

plant once a month.

c) Checking the emergency evacuation system every once in a month.

d) Regular meeting every day for 30 minutes before and after the operation

with the operator to discuss the work activities in the day.

e) Monthly inspection of OSH every once in two months.

f) Availability of trained health personnel.

g) Monthly inspection of OSH to the workings of the operating systems and

factory workers.

h) Regular meetings of occupational health and safety committee every

month.

i) The medical examination of all workers on a regular basis.

j) Conducting in-depth investigation of the accident and any corrective

action that may be taken.

9.1.6. Personal Protective Equipment (PPE)

All employees must wear PPE that is provided for the cleanliness of the

direct labor is considered by the company and has been adapted to the

conditions of employment of each;

a) Employees working in factories must wear full PPE, as already provided,

such as: gloves, masks, work clothing, headgear, safety glasses, and safety

shoes.

b) Ring or any personal jewelery should not be worn when working or being

around machinery.

26


Figure 9. 1 PPE for employees

9.1.7. Work Safety Analysis

In the safety analysis is usually done based on the rules and codes of

conduct, both international and local levels. In Indonesia alone in providing

job safety analysis should be based on the level of regulation following:

ILO Code of Practice for Prevention of Major Industrial Accidents

Law of Safety Act No. 1 of 1970

Per.05/Men/1996 tentangof the Safety Management System and

Occupational Health.

Analysis of safety and health as a reference, referral, and information

standards that help reduce, avoid, minimize, and protect against accidents in

the production process and prevent losses in the production process. Loss is a

fatal accident that resulted in death and disability for the employee or

employees, damage to major appliances and supporting the process of

production, loss of missing or damaged raw materials and supplementary

materials processes, and the loss or damage of the product resulting in loss

materially to business owners and business owners with or consortium of

investors.

27


Safety analysis includes several things: availability sheet MSDS (Material

Safety Data Sheets) on the properties and physic-chemical properties of raw

materials, auxiliary materials, or materials supporting the production process

used. Aside from the safety analysis is also the Safety Assessment sheet

covering sheet Hazard Identification and Risk Assessment (HIRA), Hazard

Identification (HAZID), Hazard Operability Studies (HAZOP), while for the

food processing industry should also be included Hazard Analysis and

Critical Control Point (HACCP).

9.2.HIRA

HIRA (Hazard Identification and Risk Assessment) is an identification of

dangerous and risk study on special and daily activity in operation and production

in industry process. Stages to make HIRA are:

a. Sorting activities into smaller sub-activities and specific

b. Identification of hazards potential for each sub activities

c. Determination possible risks (hazzards effect and its level possibilities)

d. Determination prevention and control to against hazards.

e. Summary for hazards and risk potential for each activity.

f. Summary for all activities.

Identification hazards and risk potential in HIRA to determine risk level,

control, and final risk, where risk is combination of hazards effect and its

possibility.

Risk = Hazard Level x Hazard Effect

Hazards level consists of high, medium, and low hazards. Permanent hazards

effect consists of high, medium, and low too. In this table below, we will know

the parameter to determine hazards level.

From the steps above, then the risks to activity matrix obtained in this plant,

where the risk is the result of the frequency of hazards with existing activities and

consequences listed in the following matrix:

28


Table 9. 1 Parameters to Determine Hazard Level Possibilities

PARAMETER HIGH MEDIUM LOW

Hazards Frequency Every time the

works is done

Once from 1 until

100

Once during the job

done

Hazards Effect

Frequency

Almost every time

the works is done

Once from 10 until

100 Once in 100 or more

Level of executor

job ability

Within

experience, never

done job before.

Less Experience

Experienced, has

good ability and

often done that

works.

PARAMETER HIGH MEDIUM LOW

Human Resources

Death, Disability,

body dysfunction,

Major injuries

Middle

injuries, body

can still do the

work

Minor Injuries

Asset

Major harm in

equipment,

production stop

Harm that

cause declining

in production

level

Minor harm, not

affect production

level

Protection

Equipment

No protection

equipment in

environment that

has flammable

substance

Minimum

protection

equipment

Protection

equipment is

sufficient available

and installation has

good insulated

Availability of

Evacuation Time Less than 1 minute

Between 1 – 30

minutes

More than 30

minute

So from these two tables, it can be made a 3 x 3 matrix that indicates the level of

risk for the following analysis of the HIRA.

The following table show the detail of HIRA of our plant;

29


Table 9. 2 Hazard Identification and Risk Assesment

Type of Activity Hazards Potential Hazards Effect Hazard Level Possibility Level Risk Prevention Final Risk

Unloading CO2

Liquid, H2SO4,

NaOH, EPC

Leaking on the pipe

Material Loss,

Pollution to the

Environment

L M L Do a routine

inspection on the pipe L

Direct Exposure to skin, eyes,

and other organs

Healthy

Problem, Injury M M M

Using PPE, Obey the

SOP and Using

Trained Workers

L

Unloading Black

Liquor &

Loading Product

to storage tank

Raw Material Spill and

Scattered

Material Loss,

Fouling on the

equipment

L H M Clear the SOP, Using

Trained Workers L

Direct Exposure to skin, eyes,

and other organs Irritation M M M

Using PPE, Obey the

SOP and Using

Trained Workers

L

Maintenance

Slip during inspection Minor Injury M M M

Using PPE, Obey the

SOP and Using

Trained Workers

M

Fall fron the high place

during maintenance activity

Major Injury,

Death H M H M

Electirc Shock Burn, Death H M H M

Exposure from high

temperature Unit Burn Injury M M M M

Unit Operation Overpressure

Explosion,

Production

Stop

H L M

Do a routine

inspection on the

Pressure relief device,

using trained worker

L

30


Control System Failure

Fire and

damage on

equipmnet,

Production

Stop

M M M

Control system

inspection and

monitoring

periodically

L

Slack Worker

Minor/Major

Injury,

inefficient

process

M L L

Using PPE, Obey the

SOP and Using

Trained Workers

L

Material

Transport on Belt

Conveyor

Conveyor Jam

Material

transport

stopped,

wasting time

M M M

Conveyor inspection

and monitoring

periodically

M

Material is being scattered Pollution M H H

Using PPE, Obey the

SOP and Using

Trained Workers

M

Power Failure

Material

transport

stopped

L L L

Do a routine

inspection on the

Power system

L

31


9.3.HAZID

HAZID is an identification of hazards (Hazard Identification), analysis of the

prevention of hazards in industrial installations/plants. All aspects of industrial

installations/plants that are:

1. Data installation information industry (PFD, P&ID, Lay Out, meteorological

data, social data about cultural community, a record of events)

2. Location (operating facilities, support facilities)

3. Risk (HR, environment, assets, image)

4. Trigger factors Danger (process operations, transportation, geography and

meteorology, socio-cultural)

5. Potential hazards (fire and huge explosions, drowning, environmental

pollution)

Table 9.3 is showing the HAZID parameters in determining the danger effect.

Meanwhile table 9.4 is showing the HAZID parameters hazard frequency for our

plant.

Table 9. 3 HAZID Parameters In Determining The Danger Effect

PARAMETERS MINOR MAJOR SEVERE

Human Resources No accidents Accident was not fatal Fatal accident

Asset Losses lower than U.S.

$ 100,000

Losses between US$

100.000 to 1.000.000

Losses greater than

US$ 1.000.000

Environment No damage to the

environment

Minor damage to the

environment

Considerable damage

to the environment

Table 9. 4 HAZID Parameters Hazard Frequency

Hazard

Frequency

MOST LIKELY UNLIKELY

More than 10

times in 10 years

Between 1 s / d 10

times in 10 years

Less than 1 time in

10 years

The table below show the detail of our Hazard Identification on the certain unit of

our plant.

32


Table 9. 5 Hazard Identification of Bio Based Resin Plant

Location Description Cause Hazard

Potential

Hazard

Effect

Frequency of

Hazard Prevention

Vessel Pressure Vessel

too much CO2

Loading,

Defficiency of

welded joint

Overpressure

which lead to

explosion,

Rupture on the

Body of Vessel

Severe Likely

Install PSV to release

gas when over

pressure occur

Compressor &

Pump to pump liquid too much noise

Ear Injury due

to exposure to

the noise

Severe Most

Provide Ear Plug for

Operator and

Engineer

Reboiler to produce utility steam

High Operating

Temperature and

Pressure, Corrosion

Overheated on

the tube,

Overpressure

Severe Likely

Install Temperature

alarm system, Install

PSV, routine

maintenance

Dryer to remove water

content on lignin

High operating

Temperature

(Increase Capacity)

Fire, Deposite

of dust,

autoignition

Severe Likely

Monitor Temperature

of hot air, do a

routine maintenance,

do not exceed

maximum capacity,

provide system spark

detection

33


Heat Exchanger

to heat CO2 liquid and

change its phase into

Gas

Steam Inlet Valve

fail to open

There is still

liquid phase

which lead to

compressor

damage

Severe Likely

Make a local

shutdown system on

the HE and

compressor

Storage Tank to store material

Defficiency on the

welded joint,

Exposure to the

wind, Corrosion

Leaking, Crack

and material

exposure

Severe Likely

Make sure the Vessel

is properly design,

Do a routine

maintenance and

weld inspection

Filter Press to separate liquid and

solid

Cracking Material,

High Pressure

Operation, Exceed

Maximum Capacity

Failure during

press operation

which lead to

catasthropic

event

Severe Likely

Make sure the Vessel

is properly design,

Do a routine

maintenance,

Inspection on

Mounting Bolt and

Frame,

34


9.4.HAZOP

Hazard and Operability Studies (HAZOP) was first developed by ICI, a

British chemical company. Hence, HAZOP is more often implemented in the

chemical industry. But along with the increasing need for hazard analysis

techniques, several other industries, such as food industry, pharmaceutical, and

mining (including oil and gas drilling offshore), also began to implement many

HAZOP.

The main purpose of HAZOP is to identify:

The dangers (hazards) are a potential (especially that endanger human

health and the environment)

All sorts of problems operational capability (operability) on each process

as a result of irregularities against the design goals (design intent)

processes in plants as well as plants that have new activity / will be

operated.

HAZOP is the identification of irregularities / deviations that occur in the

operation of an industrial plant operations including the identification of failures

that lead to uncontrollable circumstances. HAZOP is usually done at the

planning stage for a new industrial installations and is usually done prior to

installation modification or addition of new equipment from the old installation.

HAZOP is usually called a systematic analysis of the critical condition of

industrial plant design, its influence, and potential irregularities that occurred

along with the magnitude of the potential danger posed.

For HAZOP, there are a few parameter that we use in HAZOP, meaning

for each parameter can be seen in table 9.6 . For each unit, there is deviation that

are not write because we consider that deviations have probability very low.

35


Table 9. 6 HAZOP Parameter

Guide

word

Meaning

No or not Complete negation of

the design intent

More Quantitative increase

Less Quantitative decrease

As well as Qualitative

modification/increase

Part of Qualitative

modification/decrease

Reverse Logical opposite of

the design intent

Other than Complete substitution

Early Relative to the clock

time

Late Relative to the clock

time

Before Relating to order or

sequence

After Relating to order or

sequence

Here is the HAZOP analysis in this plant:

36


Table 9. 7 HAZOP in Production Unit

Equipment: Reactor

Deviation

Cause Concequences Safeguards Action Required Action

Assigned to No. Guide

Word Element

1 Higher

Level

High flow input, low

flow output Flooding

Use level

indicator

Close input valve and open

output valve as high as

possible in order to increase

output flow

Operator

2 Lower Low flow input, high

flow output

Short resident time,

reaction doesn't occur

optimally

Open input valve as high as

possible and close output

valve in order to decrease

output flow

Operator

3 Lower Temperature Steam flow too low Reaction not optimum Use flow

controller Increase steam flow Operator

Table 9. 8 HAZOP in Production Unit (continued)

Equipment: Heat Exchanger

Deviation



Word Element

2 Lower Temperature Low hot

water flow

Fluid temperature

isn't specified

Adjust flow hot water from

reactor jacket to optimum

condition

Increase steam

flow from reboiler Operator

37



Equipment: Dryer

No.

Deviation Cause Consequence Safeguards Action Required Action

Assigned to Guide

Word

Element

1 Less Level Raw materials do not reach

maximum capacity of unit.

Raw materials

process have finished

before the time

Engineers can check

dryer condition before the

process

Design rotary dryer

with low level

sensor

Technician

2 More Pressure Input reach over Explosion of rotary

dryer

Engineers can check


process

Design rotary dryer

with pressure sensor

Technician

3 More Temperature Sun quasar and

environmental temperature

shine the Rotary dryer

causing temperature rise.

Increase of Pressure Engineers can check


process and can make

preventive action

Locate Rotary dryer

in place with

sufficient

temperature

Technician

4 Less Lubricant Lubricantless Stop machine

operation, and extent

production time

Engineer change lubricant

peridically

Give task to certain

engineer

Technician

5 Less Power Extinguish of power Extent of production

time

Prepare extent generator Buy reserve

generator

Technician

38



Equipment: Compressor

Deviation

Cause

Concequences

Safeguards

Action Required

Action

Assigned to

No.

Guide

Word Element

1 More

Flow rate

Compressor control

system failure,high

input flow

Over-pressure

Check controller

annually, use flow

control

Close input valve in

order to decrease

output flow

Operator,

technician

2 Less Low input

flowrate,FIC failure

Compressor

Failure Use flow control

Open input valve in

order to increase output

flow

operator,

technician

3 Not

fully

vapour

phase

there is liquid or solid

phase that enter the

compressor

Compressor

failure

For C-101, ensure that

all CO2 from HE has

become vapour

Close the input valve,

shutdown machine,

check the compessor

Operator,

technician


Equipment: Pump-Screw pump

Deviation



Word Element

1 More Flow

rate

High

flowrate Over-working

Use flow

control Decrease flowrate

Operator,

technician

2 Less Low

Flowrate Cavitation

Use flow

control

Increase flowrate,control vessel level containing

pumped fluid in order to maintain fluid level

Operator,

technician

39



Equipment: Mixer

No. Deviation Cause Concequences Safeguards Action required Action

assigned to Guide word Element

1 Other than

specification

Flow in (feed) Inhibition, or no

flow of any one

or more inlet

Mixture to be imperfect,

does not meet safety

standards, and / or do not

meet market specifications.

Technicians check the

input into the mixer

every time the batch

process is done

Designing the

controller / monitor

centralized

Technician

2 Other than

spesification

Flow out

(output)

Mixture evenly

mixed

Strength resin does not

conform to the

specifications

Technicians ensure

agitator and residence

time running perfectly

Make sure the size of

solids meet

specifications

Technician

3 Less Rotation

Speed

Mistake when

setting the set

point of Belt

Conveyor

Need more time to mix

feed material Speed Indicator

Input more power,

redesign the mixer

with adding more

impeller

operator

4 More Rotation

Speed same as (3)

Mixture in mixer gush out.

Mixture spilled to the floor,

it makes the floor slippery

Speed Indicator adjust set point to

lower rotation speed operator

40



Equipment: Belt Conveyor

No. Deviation Cause Concequences Safeguards Action Required Action

Assigned to Guide

Word

Element

1 More Belt speed Improper set point,

machine is not in good

condition so there is

deviation with the set point

There will be

material queue to

the next process

Calculate the set point

accurately, clean the

machine periodically

Make parallel system for the

process. Do scale removal

periodically and rinse the

chemicals well

Engineer,

technician

2 Less Belt speed Energy supply too low Production will be

too slow

Ensure that electricity

supply is stable

Use small generator if

needed to stabilize electricity

supply

Technician

Table 11.1 HAZOP Storage Tank

Equipment: Storage Tank

Deviation



Word Element

1 More

Level

High input flowrate,low

output flowrate Flooding

Level

Indicator

Decrease input

flow,increase output flow

Operator,

technician

2 Less Low input flowrate,high

output flowrate

Flowrate

decreases

Increase input

flow,decrease output flow

operator,

technician

41


9.5.WASTE MANAGEMENT

At this resin production, there are some waste generated include liquid phase

waste and solid-liquid waste. These are description of the waste that are generated

and method towaste treatement:

Table 9. 14 Waste Treatement for Resin Production

Waste Action Required

Liquid phase:

Base Epoxy

Using physical-chemical such as:

Distillation so that the NaOH and Epichlorohidrin

can be reused

Removal of the compound from waste water by

reverse osmosis (hyperfiltration) can be successful,

depending on the type of membrane used.

Cellulose acetate membranes yielded 40 - 60%

separation of NaOH, while cross-linked

epichlorohidrin and aromatic polyamine membranes

yielded 80 - 90% separation

Microorganism decomposition approaches:

In awater treatment facility of a plant manufacturing

organic chemicals, a typical removal efficiency for

base epoxy was 76%, using an aerated, non-

flocculent, biological stabilization process. After

conversion to an activated sludge facility, the

removal efficiency increased to 96% .

There are two reports on anaerobic biodegradation.

Typical base waste removal efficiencies for an

anaerobic lagoon treatment facility, with a retention

time of 15 days, were 50% after loading with dilute

waste, and 69 and 74% after loading with

concentrated wastes.

In closed bottle studies, base waste was completely

degraded anaerobically by an acetate-enriched

culture, derived from a seed of domestic sludge.

The culture started to use cross-fed base waste, after

4 days, at a rate of 200 mg/litre per day. In a mixed

reactor with a 20-day retention time, seeded by the

same culture, 56% removal was achieved in the 20

days following 70 days of acclimation to a final

waste concentration of 10 000 mg/litre .

Solid-Liquid phase:

Delignificated Liquor

Sell to Pulping Industry

Solid phase:

Packaging Material: Cardboard,

Electronic Part: Wire, PCB

Broken Casing

Broken Filter

powder

Recycle

Using service from other company

Reuse

42


9.6.ESCAPE ROUTE

Should the emergency situation occurs, all employees have to get out from

the plant immediately and go to the nearest muster point. In this plant, muster

points have been declared in some places. First, one points are next to prayer

room (musholla). Second, one points is next to control room. Then, one point

which is near to gymnasium. Lastly, the one is next to loading service point.

Muster points for this plant can be seen in figure.

(a)

(b)

Figure 9. 2 (a) (b) (c) Muster point for this plant.

43


(c)

9.7.EMERGENCY

The situations that initial the emergency shutdown such as:

a. An electric power failure

b. The temperature of reactor outlet is higher than 100 0C

c. Manual alarm

d. Compressor failure

e. Feed failure to any hot equipment such as reactor, dryer, and reboiler

If there is an emergency situation, then the plant will be shutdown as stated in

emergency shutdown procedure in chapter VII. Worker can follow escape route to

save themselves. But, for overall condition, if the there is emergency situation

happened, and emergency shutdown has been initiated, our plant will not cause

any extreme damage for human.


REFERENCES

Branan, Carl. 2002. Rules of thumb for chemical engineers. Elsevier.

Cussler, L., G.D. Moggridge. 2011. Chemical Product Design. USA: Cambridge

University Press.

Dow. “Product Safety Assesment (PSA): Epichlorohydrin”.

http://www.dow.com/productsafety/finder/epi.htm (17 Sept 2013)

Euro-Inox. 2004. Stainless Stell: Table of Technical Properties.http://www.euro-

inox.org/pdf/map/Tables_TechnicalProperties_EN.pdf

Ingram, David. “The Difference Between Process and product Layout

Manufacturing”. http://smallbusiness.chron.com/difference-between-

process-product-layout-manufacturing-15991.html (17 Apr 2013)

Perry, Robert H. 1999. Perry’s Chemical Engineers’ Handbook. McGraw-Hill

Companies, Inc

Repository USU. 2011. Appendix: Pabrik Pupuk. Medan: USU

RockTenn. 2012. Safety Data Sheet Black Liquor. Norcross: RockTenn

Manufacture

Smith, Robin. 2007. Chemical process Design and Integration, 2nd Edition. UK:

University of Manchester

45


APPENDIX

K. Controller Explanation

a. Procedure Fix

Process States Batch processing usually involves imposing the proper sequence

of states on the process. Precipitation reaction sequence must be as follows:

1. Transfer 53,3 ton of Black Liquor from black liquor storage tank to

Precipitation Reactor. The process state is “transfer from Black Liquor Storage

Tank ST-101.”

2. Transfer 1,3 ton of CO2 gas from CO2 storage tank to Precipitation Reactor.

The process state is “transfer from Liquid CO2 Storage Tank ST-102.”

3. Agitate for 15 minutes. The process state is “agitate without heating.”

4. Heat (with agitation) to 45oC (open hot utility). The process state is “agitate

with heating.”

For many batch processes, process state representations are a very convenient

mechanism for representing the batch logic. A grid or table can be constructed,

with the process states as rows and the discrete device states as columns (or vice

versa). For each process state, the state of every discrete device is specified to be

one of the following:

1. Device state 0, which may be valve closed, agitator off, and so on

2. Device state 1, which may be valve open, agitator on, and so on

3. No change or don’t care

For each process state, the various discrete devices are expected to be in a

specified device state.

For process state “transfer from Black Liquor Storage Tank ST-101,” the device

states might be as follows:

A. Black Liquor Storage Tank ST-101 discharge valve: open

B. Precipitation Reactor R-101 inlet valve: open

C. Black Liquor Storage Tank SP-101 transfer pump: running

D. Precipitation Reactor R-101 agitator: off

46


E. Precipitation Reactor R-101 heating valve: closed

F. Liquid CO2 Storage Tank ST-102 discharge valve: open

G. Liquid CO2 Storage Tank C-101 compressor: running

For process state “transfer from Liquid CO2 Storage Tank ST-102,” the device


A. Black Liquor Storage Tank ST-101 discharge valve: open

B. Precipitation Reactor R-101 inlet valve: open

C. Black Liquor Storage Tank SP-101 transfer pump: running

D. Precipitation Reactor R-101 agitator: off

E. Precipitation Reactor R-101 heating valve: closed

F. Liquid CO2 Storage Tank ST-102 discharge valve: open

G. Liquid CO2 Storage Tank C-101 compressor: running

For process state “agitate without heating” the device states might be as follows:

A. Black Liquor Storage Tank ST-101 discharge valve: close

B. Precipitation Reactor R-101 inlet valve: close

C. Black Liquor Storage Tank SP-101 transfer pump: off

D. Precipitation Reactor R-101 agitator: running

E. Precipitation Reactor R-101 heating valve: close

F. Liquid CO2 Storage Tank ST-102 discharge valve: close

G. Liquid CO2 Storage Tank C-101 compressor: off

For process state “agitate with heating” the device states might be as follows:

A. Black Liquor Storage Tank ST-101 discharge valve: close

B. Precipitation Reactor R-101 inlet valve: close

C. Black Liquor Storage Tank ST-101 transfer pump: off

D. Precipitation Reactor R-101 agitator: running

E. Precipitation Reactor R-101 heating valve: open

F. Liquid CO2 Storage Tank ST-102 discharge valve: close

G. Liquid CO2 Storage Tank C-101 compressor: off

47


A B C D E F G

Transfer from Black Liquor Storage Tank ST-101 1 1 1 0 0 1 1

Transfer from Liquid CO2 Storage Tank ST-102 1 1 1 0 0 1 1

Agitate without heating 0 0 0 1 0 0 0

agitate with heating 0 0 0 1 1 0 0

A= ST-101 discharge valve

B= R-101 inlet valve

C= SP-101 transfer pump

D= R-101 agitator

E= R-101 heating valve

F= ST-102 discharge valve

G= C-101 compressor

Re-slurry reaction sequence must be as follows:

1. Transfer 8 ton of Acid Lignin from black Filter Press to Re-Slurry Reactor. The

process state is “transfer from Filter Press FP-101.”

2. Transfer 0,7 ton of H2SO4 from H2SO4 storage tank to Re-Slurry Reactor. The

process state is “transfer from H2SO4 Storage Tank ST-103.”

3. Recycle 6 ton of Wet Lignin from Filter Press to Re-Slurry Reactor. The

process state is “recycle from Filter Press FP-103.”

4. Agitate for 15 minutes. The process state is “agitate without heating.”


with heating.”









48



specified device state.

For process state “transfer from Filter Press FP-101,” the device states might be as

follows:

A. Filter Press FP -101 discharge valve: open

B. Re-Slurry Reactor R-102 inlet valve: open

C. Belt Conveyor BC-101: running

D. Re-Slurry Reactor R-102 agitator: off

E. Re-Slurry Reactor R-102 heating valve: closed

F. H2SO4 Storage Tank ST-103 discharge valve: open

G. H2SO4 Storage Tank P-101 transfer pump: running

H. Filter Press FP-103 discharge valve: open

I. Filter Press P-102 transfer pump: running

For process state “transfer from H2SO4 Storage Tank ST-103,” the device states

might be as follows:










For process state “recycle from Filter Press FP-103,” the device states might be as

follows:




49









A. Filter Press FP -101 discharge valve: close

B. Re-Slurry Reactor R-102 inlet valve: close

C. Belt Conveyor BC-101: off

D. Re-Slurry Reactor R-102 agitator: running

E. Re-Slurry Reactor R-102 heating valve: close

F. H2SO4 Storage Tank ST-103 discharge valve: close

G. H2SO4 Storage Tank P-101 transfer pump: off

H. Filter Press FP-103 discharge valve: close

I. Filter Press P-102 transfer pump: off


A. Filter Press FP -101 discharge valve: close

B. Re-Slurry Reactor R-102 inlet valve: close

C. Belt Conveyor BC-101: off

D. Re-Slurry Reactor R-102 agitator: running

E. Re-Slurry Reactor R-102 heating valve: open

F. H2SO4 Storage Tank ST-103 discharge valve: close

G. H2SO4 Storage Tank P-101 transfer pump: off

H. Filter Press FP-103 discharge valve: close

I. Filter Press P-102 transfer pump: off

A B C D E F G H I

Transfer from Filter Press FP-101 1 1 1 0 0 1 1 1 1

Transfer from H2SO4 Storage Tank ST-103 1 1 1 0 0 1 1 1 1

50


Recycle from Filter Press FP-103 1 1 1 0 0 1 1 1 1

Agitate without heating 0 0 0 1 0 0 0 0 0

agitate with heating 0 0 0 1 1 0 0 0 0

A= FP-101 discharge valve


C= BC-101 belt conveyor

D= R-102 agitator



G= P-101 transfer pump

H= FP-102 discharge valve

I = P-102 transfer pump

Epoxidation reaction sequence must be as follows:

1. Transfer 60 ton of L.NaOH from mixer to Epoxidation Reactor. The process

state is “transfer from Mixer M-201.”

2. Transfer 0,76 ton of EPC from EPC storage tank to Epoxidation Reactor. The

process state is “transfer from EPC Storage Tank ST-202.”

3. Agitate for one hour. The process state is “agitate without heating.”


with heating.”









51



specified device state. For process state “transfer from Mixer M-201,” the device


A. Mixer M-201 discharge valve: open

B. Epoxidation Reactor R-201 inlet valve: open

C. Mixer SP-201 transfer pump: running

D. Epoxidation Reactor R-201 agitator: off

E. Epoxidation Reactor R-201 heating valve: closed

F. EPC Storage Tank ST-202 discharge valve: open

G. EPC Storage Tank P-202 transfer pump: running

For process state “transfer from EPC Storage Tank ST-202.,” the device states


A. Mixer M-201 discharge valve: open

B. Epoxidation Reactor R-201 inlet valve: open

C. Mixer SP-201 transfer pump: running

D. Epoxidation Reactor R-201 agitator: off


F. EPC Storage Tank ST-202 discharge valve: open

G. EPC Storage Tank P-202 transfer pump: running


A. Mixer M-201 discharge valve: close

B. Epoxidation Reactor R-201 inlet valve: close

C. Mixer SP-201 transfer pump: off

D. Epoxidation Reactor R-201 agitator: running


F. EPC Storage Tank ST-202 discharge valve: close

G. EPC Storage Tank P-202 transfer pump: off


A. Mixer M-201 discharge valve: close

52


B. Epoxidation Reactor R-201 inlet valve: close

C. Mixer SP-201 transfer pump: off

D. Epoxidation Reactor R-201 agitator: running

E. Epoxidation Reactor R-201 heating valve: open

F. EPC Storage Tank ST-202 discharge valve: close

G. EPC Storage Tank P-202 transfer pump: off

A B C D E F G

Transfer from Mixer M-201 1 1 1 0 0 1 1

Transfer from EPC Storage Tank ST-202 1 1 1 0 0 1 1

Agitate without heating 0 0 0 1 0 0 0

agitate with heating 0 0 0 1 1 0 0

A= M-201 discharge valve


C= SP-201 transfer pump

D= R-201 agitator



G= P-202 transfer pump

This representation is easily understandable by those knowledgeable about the

process technology and is a convenient mechanism for conveying the process

requirements to the control engineers responsible for implementing the batch

logic. Many batch software packages also recognize process states. A

configuration tool is provided to define a process state. With such a mechanism,

the batch logic does not need to drive individual devices but can simply command

that the desired process state be achieved. The system software then drives the

discrete devices to the device states required for the target process state. This

normally includes the following:

1. Generating the necessary commands to drive each device to its proper state.

53


2. Monitoring the transition status of each device to determine when all devices

have attained their proper states.

3. Continuing to monitor the state of each device to ensure that the devices remain

in their proper states. Should any discrete device not remain in its target state,

failure logic must be initiated.

b. Batch Control System

Process States Batch processing usually involves imposing the proper sequence

of states on the process (Perry,1999). For example, a simple blending sequence


1. Transfer specified amount of material from tank A to tank R.The process

state is “transfer from A.”

2. Transfer specified amount of material from tank B to tank R.The process

state is “transfer from B.”

3. Agitate for specified time. The process state is “agitate without cooling.”

4. Cool (with agitation) to specified target temperature. The process state is

“agitate with cooling.”

For each process state, the various discrete devices are expected tobe in a

specified device state. For process state “transfer from A,” the device states might

be as follows:

1. Tank A discharge valve: open

2. Tank R inlet valve: open

3. Tank A transfer pump: running

4. Tank R agitator: off

54


5. Tank R cooling valve: closed


mechanism for representing the batch logic. A grid ortable can be constructed,


versa). For each process sstate, the state of every discrete device is specified to be





This representation is easily understandable by those knowledgeable about the

process technology and is a convenient mechanism for conveying the process

requirements to the control engineers responsible for implementing the batch

logic.

Regulatory Control For most batch processes, the discrete logic requirements

overshadow the continuous control requirements. For many batch processes, the

continuous control can be provided bysimple loops for flow, pressure, level, and

temperature. However, very sophisticated advanced control techniques are

occasionally applied. As temperature control is especially critical in reactors, the

simple feedback approach is replaced by model-based strategies that rival, ifnot

exceed, the sophistication of advanced control loops in continuous plants.

In some installations, alternative approaches for regulatory control may be

required. Where a variety of products are manufactured, thereactor may be

equipped with alternative heat removal capabilities, including the following:

1. Jacket filled with cooling water. Most such jackets are once through,but

some are recirculating.

2. Heat exchanger in a pump-around loop.

3. Reflux condenser.

The heat removal capability to be used usually depends on the product being

manufactured. Therefore, regulatory loops must be configured for each possible

option, and sometimes for certain combinations of the possible options. These

loops are enabled and disabled depending on the product being manufactured.

55


The interface between continuous controls and sequence logic (discussed shortly)

is also important. For example, a feed might be metered into a reactor at a variable

rate, depending on another feed or possibly on reactor temperature. However, the

product recipe calls fora specified quantity of this feed. The flow must be totalized

(i.e., integrated), and when the flow total attains a specified value, the feed must

be terminated. The sequence logic must have access to operational parameters

such as controller modes. That is, the sequencelogic must be able to switch a

controller to manual, automatic, or cascade. Furthermore, the sequence logic must

be able to force the controller output to a specified value.

A. Compressor

Process control in the compressor is a control process that involves more than

one variable that needs to be controlled. Variables that are controlled from the

compressor is the input output flow rate and pressure.

1. Flow rate

The flow rate input is an important variable to be controlled in a

compressor. The flow rate input can affect timing. Sensors are used to

measure the flow rate is orificemeter. Flow rate is then controlled by the

controller input based on set point. Control the flow rate by the flow

control valve (FCV).

2. Pressure

Pressure is an important variable in the reactor. The pressure different in

compressor was kept at about set point, and do not be too excessive.

Pressure changes can occur due to the continuous input to compressor.

Excessive pressure can affect the quality of the product and can also be

dangerous when the compressor exploded because excess pressure. To

prevent excess pressure of the compressor is equipped with a relief valve

to increase/decrease the flow. Controlled variable is the pressure different.

When the pressure exceeds the set point, then the relief valve will open

thereby decreasing the flow in the compressor.

56


B. Dryer

Process control in the rotary dryer is a control process that involves more than

one variable that needs to be controlled. Variables that are controlled from the

rotary dryer is the input flow rate, composition, and pressure.

3. Flow rate

The flow rate input is an important variable to be controlled in a rotary

dryer. The flow rate input can affect timing and composition amount.

Sensors are used to measure the flow rate is orificemeter. Flow rate is then

controlled by the controller input based on set point. Control the flow rate

by the flow control valve (FCV).

4. Composition

The composition is a variable that can affect the vanillin powder

production of rotary dryer. The process of composition control is over the

direction of the contain of vanillin. Controlled variable is the composition

of the sample in the rotary dryer. The parameters controlled is rate of

evaporation. Sensor compositions using gas-solid chromatography (GSC).

When the results of the GSC analysis are deviations from the set point, the

parameters changed by the addition of rate of hot air into rotary dryer.

5. Pressure

Pressure is an important variable in the reactor. The pressure in rotary

dryer was kept at atmospheric pressure or above atmospheric pressure, but

do not be too excessive. Pressure changes can occur due to the continuous

input to rotary dryer. Excessive pressure can affect the quality of the

product and can also be dangerous when the rotary dryer exploded because

excess pressure. To prevent excess pressure of the rotary dryerr is

equipped with a relief valve to release the pressure in the reactor.

Controlled variable is the pressure inside. When the pressure exceeds the

set point, then the relief valve will open thereby releasing the pressure in

the rotary dryer.

C. Reactor R-101 & R-201 Control System

1. Temperature

57


The temperature need to be controlled to make sure the reaction on the

reactor goes well. The optimum temperature on the R-101 is 45oC while

on the R-201 is 70oC. so, the temperature need to be maintained on the

following temperature. The principle of temperature control is adjusting

the flow rate of the hot fluid (hot water) on the jacket. When the

temperature goes drop below set point, temperature sensor will transfer a

signal to the control valve of the hot fluid to automatically increase

opening of the valve to let more hot water flow through jacket. While

when the temperature rise above the set point, temperature sensor will

transfer a signal to the control valve of the hot fluid to automatically

decrease the opening of the valve.

2. Composition

The composition is a variable that can affect the production yield of

thereactor. The composition on the reactor affected by input material and

also by agitation process on the reactor. On the other hand, controlled

variable is the composition of the sample in the vessel while the

parameters are speedcontrolled agitator and also input material. Sensor

compositions using gas liquid chromatography(GLC). When the results of

the GLC analysis are deviations from the setpoint, the parameters

changed by the addition of agitation speed ofstirring. To get the desired

composition on the outlet of the product the agitation on the reactor need

to be controlled, since the agitation determine the homogenity of the

mixture and also the effectiveness of reaction. And then, the flow rate on

the input stream of this reactor is also should be maintained. The

composition measured will adjust the input flow and also the rotation of

agitator. So, the desired composition can be achieved.

3. Level

The level is one important variable but often forgotten in reactor tank.The

level sensor is needed in order to know whether the level of the fluid

issufficiently safe for the agitator to operate. If the level is too high, the

agitator is not able to homogenize the mixture all over the vessel. There

will be a dead zone on several part of vessel. so, it will lead to the low

58


efficiency reaction on the reactor. The parameters will becontrolled from

the level control is flow rate from the feed stream.Level sensors are using

floating sensor in the fluid surface. Thelevel of the fluid in the reactor is

controlled by the controller based on setpoint. Flow rate is then controlled

by the flow control valve (FCV) on the sameinput stream as the input of

the flow rate control.

4. Composition

To get the desired composition on the outlet of the product the agitation

on the reactor need to be controlled, since the agitation determine the

homogeneity of the mixture and also the effectiveness of reaction. And

then, the flow rate on the input stream of this reactor is also should be

maintained. The composition measured will adjust the input flow and also

the rotation of agitator. So, the desired composition can be achieved.

5. pH

On this reactor, pH need to be maintained at pH 2 to make sure the

precipitation of the lignin have highest yield (Per Tomani, 2001). To

maintain pH at 2, control pH need to be installed. There will be an

analyzer which can read the actual pH of the mixture on the reactor. If the

pH of the mixture is not 2, it will adjust opening of control valve on the

H2SO4 stream until the pH 2 is achieved.

D. Heat Exchanger HE-101

Controlled variable is the temperature of the mainproduct output heat

exchanger. The parameters are controlled steam flow rate orcooling water

into the heat exchanger.Temperature is one of the important variables to be

controlled. Heatexchangers are the main components that require temperature

control. Heatexchanger serves to exchange heat between the main product

with steam/coolingwater. Controlling the temperature of the product is

required to be maintained inaccordance with the main design.

The control system used for temperature control are feedback control system.

Process control using a thermocouple as a temperature sensor on theoutput of

main products in heat exchangers.The output of the thermocouple is then

analyzed by the controller based on set point. Then the controller controls the

59


flow rate of the flow control valve on the pipe steam/cooling water before it

enters the heat exchanger. Control valvecontrolling the flow rate of steam /

cooling water to adjust the flow rate of steam/cooling water with a

temperature set point to achieve the appropriate design.

E. Storage Tank

The parameter which has to be controlled on the storage tank is level control.

There will be several level sensors on the storage tank, such as:

1. LL (very low level liquid)

If the fluid level is reach LL, so we have to close the discharge valve of

the storage tank, to prevent air carried over on the liquid to the pump

which will damage the pump. In this state, we will use another storage

tank to provide raw material to the reactor.

2. Low Level Liquid

In this level, there will be an alarm to the control room to prepare the

transition between the storage tanks to transfer raw material.

3. High Level Liquid

In this level, there will be an alarm to the control room that the level are

reach the high level, which mean the charging process to the storage tank

have to be done. The operator should close the control valve on the input

stream to stop the charging process.

4. HH (Very High Level Control Liquid)

In this level, we have to close all the input to the storage tank, if the charging

still continuous, storage tank will be overfilled. The raw material will be

exposed to the environment. In this state, the valve will automatically close

60


Documents

Tk5 Report Assignment5