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
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
ii
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
iii
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
iv
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
1
Figure 7. 1 P&ID for lignin processing
Figure 7. 2 P&ID for resin processing

Figure 7. 3 P&ID for utility plant

7.2.CONTROL TABLE
Tabulation for controller in this plant can be seen in the table 7.1.
Table 7. 1 Tabulation for Control System in Resin Production
Process
Controlled
Equipment
Parameter
Censor
Controller
Controlling
Controller Procedure
Variable (Final
Element)
Compresso
Outlet
Liquid
Pressure
Globe Valve at
When the fluids pressure from outlet compressor exceeding
r (C-101,
Pressure
Coloumn
Indicator
Inlet Flow
maximum point/ reaching minimum point, Liquid Column
C-102)
Control
will give an electric signal to PC, then the PC will receive
(PC-101)
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.
Outlet Flow
Orifice
Flow
Globe Valve at
When the flow from outlet compressor exceeding maximum
Indicator
Inlet Flow
point/ reaching minimum point, orifice will give an electric
Control
signal to FIC, then the FIC will receive signal and will send
(FIC 101)
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-
Outlet Flow
Orifice
Flow
Globe Valve at
When the waste flow from outlet dryer exceeding maximum
101, D-
Control
Inlet Flow of
point/ reaching minimum point, Orifice will give an electric
201)
(FC-101)
Dry Air
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 (R101, R-102,

R-201)
Level
Chain
Level
When the liquids level on column exceeding maximum
Gauge
Indicator
point, Chain Gauge will give an electric signal to LI, then
(LI-
the LI will receive signal and will send signal to control
104/106/203
room, then operator will decrase raw material that enter to
the reactor.
Composition
Gas
Gas Liquid
Speed
When the composition of reactor product out of toleranced
Liquid
Chromatogr
Controlled
range, operator will change Speed Controlled Agitator
Chromato
ap
Agitator
& Globe Valve, then globe valve will open larger/lesser than
grap
& Globe Valve
before to change amount of fluid entering the column and
(GLC)
at input material
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
Temperature
Globe Valve at
When the reactor temperature exceeding maximum point/
ouple
Indicator
Outlet Flow
reaching minimum point, Thermocouple will give an electric
Control
signal to TC, then the TC will receive signal and will send
(TC-
pneumatic signal to final element (globe valve), then control
101/201)

of outlet flow. So, the rector temperature will be appropriate
with the specification.
Temperature
Thermoc
Flow
Globe Valve at
When the reactor temperature exceeding maximum point/
ouple
Control
Inlet Flow of
reaching minimum point, Thermocouple will give an electric
(FC-
Hot Utility
106/203)

of inlet flow of steam. So, the rector temperature will be
appropriate with the specification.
Inlet Flow
Orifice
Flow
Globe Valve
When the liquids level on column exceeding maximum
Control
point/ reaching minimum point, Orifice will give an electric
(FC-
101/102/103
/112/201/20
2)
of inlet flow of raw material. So, the rector level will be

appropriate with the specification.
Heat
Outlet
Thermoc
Temperature
Globe Valve at
When the fluids temperature from outlet of heat exchanger
Exchanger
Temperature
ouple
Indicator
Inlet flow of
exceeding maximum point/ reaching minimum point,
Control
fluid on shell
Thermocouple will give an electric signal to TC, then the TC
(HE-101)
(TC-102)
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
Level of
Chain
Level
Globe Valve
When the liquids level on column exceeding
Tank (TT-
liquid on
Gauge
Indicator
after the tank
maximum/minimum point, chain gauge will give an electric
101/102/10
tank
(LI-
signal to LI, then the LI will receive signal and will send
3/104/201/
101/102/103
signal to final element (globe valve), then control valve will
202)
/105/201/20
open larger than before to make liquid out (more than
2)
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
cant 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 plants
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:
15
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
R
C
ST
HE
BC
P/SP
R
FP
M
D
TOTAL
Quantity
3
2
27
1
7
19
1
4
1
2
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
20
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 doctors 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
Every time the
Hazards Frequency
works is done
Hazards Effect
Almost every time
Frequency
the works is done
Level of executor
job ability
Within
experience, never
done job before.
MEDIUM
Once from 1 until
100
Once from 10 until
100
Less Experience
PARAMETER
HIGH
MEDIUM
Middle
injuries, body
can still do the
work
Harm that
cause declining
in production
level
Human Resources
Death, Disability,
body dysfunction,
Major injuries
Asset
Major harm in
equipment,
production stop
Protection
Equipment
No protection
equipment in
environment that
has flammable
substance
Minimum
protection
equipment
Availability of
Evacuation Time
Less than 1 minute
Between 1 30
minutes
LOW
Once during the job
done
Once in 100 or more
Experienced, has
good ability and
often done that
works.
LOW
Minor Injuries
Minor harm, not

affect production
level
Protection
equipment is
sufficient available
and installation has
good insulated
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
Unloading CO2
Liquid, H2SO4,
NaOH, EPC
Unloading Black
Liquor &
Loading Product
to storage tank
Maintenance
Unit Operation
Hazards Potential
Hazards Effect Hazard Level Possibility Level Risk
Prevention
Final Risk
Leaking on the pipe
Material Loss,
Pollution to the
Environment
Do a routine
inspection on the pipe
Direct Exposure to skin, eyes,

and other organs
Healthy
Problem, Injury
Using PPE, Obey the

SOP and Using
Trained Workers
Raw Material Spill and

Scattered
Material Loss,
Fouling on the
equipment
Clear the SOP, Using

Trained Workers
Direct Exposure to skin, eyes,

and other organs
Irritation
Using PPE, Obey the

SOP and Using
Trained Workers
Slip during inspection
Minor Injury
Fall fron the high place

during maintenance activity
Major Injury,
Death
Electirc Shock
Burn, Death
Exposure from high

temperature Unit
Burn Injury
Overpressure
Explosion,
Production
Stop
M
Using PPE, Obey the
SOP and Using
Trained Workers
M
M
M
Do a routine
inspection on the
Pressure relief device,
using trained worker
30
Control System Failure
Slack Worker
Conveyor Jam
Material
Transport on Belt
Conveyor
Fire and
damage on
equipmnet,
Production
Stop
Minor/Major
Injury,
inefficient
process
Material
transport
stopped,
wasting time
Control system
inspection and
monitoring
periodically
Using PPE, Obey the

SOP and Using
Trained Workers
Conveyor inspection
and monitoring
periodically
Material is being scattered
Pollution
Power Failure
Material
transport
stopped
Using PPE, Obey the

SOP and Using
Trained Workers
Do a routine
inspection on the
Power system
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
Losses lower than U.S.
$ 100,000
No damage to the
environment
Accident was not fatal

Losses between US$
100.000 to 1.000.000
Minor damage to the
environment
Fatal accident
Losses greater than
US$ 1.000.000
Considerable damage
to the environment
Asset
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
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
to produce utility steam
High Operating
Temperature and
Pressure, Corrosion
Overheated on
the tube,
Overpressure
Likely
Install Temperature
alarm system, Install
PSV, routine
maintenance
Likely
Monitor Temperature
of hot air, do a
routine maintenance,
do not exceed
maximum capacity,
provide system spark
detection
Location
Reboiler
Dryer
to remove water
content on lignin
High operating
Temperature
(Increase Capacity)
Fire, Deposite
of dust,
autoignition
Severe
Severe
33
Heat Exchanger
Storage Tank
Filter Press
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
to store material
Defficiency on the
welded joint,
Exposure to the
wind, Corrosion
Leaking, Crack
and material
exposure
Cracking Material,
High Pressure
Operation, Exceed
Maximum Capacity
Failure during
press operation
which lead to
catasthropic
event
to separate liquid and

solid
Severe
Severe
Severe
Likely
Make a local
shutdown system on
the HE and
compressor
Likely
Make sure the Vessel

is properly design,
Do a routine
maintenance and
weld inspection
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
No or not
More
Less
As well as
Part of
Reverse
Other than
Early
Late
Before
After
Meaning
Complete negation of
the design intent
Quantitative increase
Quantitative decrease
Qualitative
modification/increase
Qualitative
modification/decrease
Logical opposite of
the design intent
Complete substitution
Relative to the clock
time
Relative to the clock
time
Relating to order or
sequence
Relating to order or
sequence
Here is the HAZOP analysis in this plant:
36
Table 9. 7 HAZOP in Production Unit
Equipment: Reactor
Deviation
No.
Guide
Word
Element
Cause
Concequences
High flow input, low

flow output
Higher
Flooding
Use level
indicator
Level
2
Lower
Lower
Temperature
Low flow input, high

flow output
Short resident time,

reaction doesn't occur
optimally
Steam flow too low
Reaction not optimum
Action Required
Action
Assigned to
Close input valve and open

output valve as high as
possible in order to increase
output flow
Operator
Open input valve as high as

possible and close output
valve in order to decrease
output flow
Operator
Increase steam flow
Operator
Safeguards
Use flow
controller
Table 9. 8 HAZOP in Production Unit (continued)
Equipment: Heat Exchanger

Deviation
No.
Guide
Word
Element
Lower
Temperature
Cause
Concequences
Safeguards
Action Required
Action
Assigned to
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.
1
Deviation
Guide
Element
Word
Less
Level
More
Pressure
Cause
Consequence
Safeguards
Action Required
Action
Assigned to
Raw materials do not reach
Raw materials
Engineers can check
Design rotary dryer
Technician
maximum capacity of unit.
process have finished
dryer condition before the
with low level
before the time
process
sensor
Explosion of rotary
Engineers can check
Design rotary dryer
dryer
with pressure sensor
Input reach over
Technician
process
3
More
Less
Temperature
Lubricant
Sun quasar and
Engineers can check
Locate Rotary dryer
environmental temperature
in place with
shine the Rotary dryer
process and can make
sufficient
causing temperature rise.
preventive action
temperature
Stop machine
Engineer change lubricant
Give task to certain
operation, and extent
peridically
engineer
Prepare extent generator
Buy reserve
Lubricantless
Increase of Pressure
Technician
Technician
production time
5
Less
Power
Extinguish of power
Extent of production
time
Technician
generator
38
Equipment: Compressor
No.
1
Deviation
Guide
Element
Word
More
Flow rate
Less
Not
fully
vapour
phase
Cause
Concequences
Safeguards
Action Required
Compressor control
system failure,high
input flow
Over-pressure
Check controller
annually, use flow
control
Low input
flowrate,FIC failure
Compressor
Failure
Use flow control
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 input valve in

order to decrease
output flow
Open input valve in
order to increase output
flow
Close the input valve,
shutdown machine,
check the compessor
Action
Assigned to
Operator,
technician
operator,
technician
Operator,
technician
Equipment: Pump-Screw pump

No.
Deviation
Guide
Element
Word
More
Less
Flow
rate
Cause
High
flowrate
Low
Flowrate
Concequences
Over-working
Cavitation
Safeguards
Use flow
control
Use flow
control
Action
Assigned to
Action Required
Decrease flowrate
Increase flowrate,control vessel level containing
pumped fluid in order to maintain fluid level
Operator,
technician
Operator,
technician
39
No.
1
Deviation
Guide word
Element
Other than
Flow in (feed)
specification
Cause
Equipment: Mixer
Concequences
Safeguards
Action required
Action
assigned to
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
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
Speed Indicator
Input more power,

redesign the mixer
with adding more
impeller
operator
Speed Indicator
adjust set point to

lower rotation speed
operator
Other than
spesification
Flow out
(output)
Mixture evenly
mixed
Less
Rotation
Speed
Mistake when
setting the set
point of Belt
Conveyor
More
Rotation
Speed
same as (3)
Need more time to mix

feed material
Mixture in mixer gush out.
Mixture spilled to the floor,
it makes the floor slippery
40
No.
Deviation
Guide
Element
Word
More Belt speed
Cause
Equipment: Belt Conveyor

Concequences
Safeguards
Less
Belt speed
Action
Assigned to
Improper set point,
There will be
Calculate the set point
Make parallel system for the
Engineer,
machine is not in good
material queue to
accurately, clean the
process. Do scale removal
technician
condition so there is
the next process
machine periodically
periodically and rinse the
deviation with the set point

2
Action Required
Energy supply too low
chemicals well
Production will be
Ensure that electricity
Use small generator if
too slow
supply is stable
needed to stabilize electricity
Technician
supply
Table 11.1 HAZOP Storage Tank
Equipment: Storage Tank

No.
1
Deviation
Guide
Element
Word
More
Level
Less
Cause
Concequences
High input flowrate,low

output flowrate
Flooding
Low input flowrate,high

output flowrate
Flowrate
decreases
Safeguards
Level
Indicator
Action Required
Action
Assigned to
Decrease input
flow,increase output flow
Operator,
technician
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
Solid-Liquid phase:
Delignificated Liquor
Solid phase:
Packaging Material: Cardboard,
Electronic Part: Wire, PCB
Broken Casing
Broken Filter
powder
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, nonflocculent, 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 .
Sell to Pulping Industry
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.euroinox.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. Perrys 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
44
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 dont 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
Transfer from Black Liquor Storage Tank ST-101
Transfer from Liquid CO2 Storage Tank ST-102
Agitate without heating
agitate with heating
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
Transfer from Filter Press FP-101
Transfer from H2SO4 Storage Tank ST-103
50
Recycle from Filter Press FP-103
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
Transfer from EPC Storage Tank ST-202
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

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UNIVERSITAS INDONESIA

PRELIMINARY DESIGN OF BIOBASED SYNTHETIC RESIN

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

Figure 7. 1 P&ID for lignin processing

Figure 7. 2 P&ID for resin processing

Figure 7. 3 P&ID for utility plant

Table 7. 1 Tabulation for Control System in Resin Production

When the fluids 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

When the flow from outlet compressor exceeding maximum

point/ reaching minimum point, orifice will give an electric

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

When the waste flow from outlet dryer exceeding maximum

point/ reaching minimum point, Orifice will give an electric

Reactor (R101, R-102,

When the liquids 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

When the composition of reactor product out of toleranced

range, operator will change Speed Controlled Agitator

& Globe Valve

before to change amount of fluid entering the column and

Speed Controlled Agitator will rotate more/less fast than

When the reactor temperature exceeding maximum point/

reaching minimum point, Thermocouple will give an electric

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

valve will open larger/lesser than before to change amount

When the reactor temperature exceeding maximum point/

reaching minimum point, Thermocouple will give an electric

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

When the liquids level on column exceeding maximum

point/ reaching minimum point, Orifice will give an electric

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

valve will open larger/lesser than before to change amount

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

When the fluids 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

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

When the liquids level on column exceeding

after the tank

maximum/minimum point, chain gauge will give an electric

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

open larger than before to make liquid out (more than

before) from the column.

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