Hazard and Operability Study (HAZOP) Safety Assessment On: University of Nottingham Malaysia Campus H82PLD Coursework 2

University of Nottingham Malaysia Campus
H82PLD Coursework 2
Hazard and Operability Study (HAZOP)

Safety Assessment on
Benzaldehyde Production Plant

By Group 6
Group Members Student ID

Nadia Suraya Crowe 025135
Celina Lim Hui En 024959
Yap Ze Kai 025097
Hii Min Tiin 024134
Kong Wei Hern 017168
Module Convenor: Dr. Lam Hon Loong

Submission Date: 23th of March 2017
1
Table of contents
Topic Pages
1.0 Introduction 3-4

1.1 Hazop
1.2 Summary
2.0 Nomenclature 5
3.0 Risk Occurrence and Injury Description Rating 6-7
4.0 Inherent Safety 8-9
5.0 Hazop table 10-105
6.0 Process control diagram for pump 106
7.0 MSDS and Evacuation 107-110
8.0 Bow Tie Diagram 111
9.0 Emergency Contact 109
10.0 Conclusion 110
11.0 Appendix 111-127
12.0 References 128
2
1.0 Introduction
1.1 Hazop
In every chemical plant, profitability and process safety are the most important
issues to be considered. The reason behind this is that the consequences are huge.
Economic losses may cause a company to shut down the production immediately
due to insufficient fund while disregarding process safety will cause human losses.
Due to the fact that the cost of an accident is often much greater than the cost of
analysis, HAZOP is performed in every chemical plant to prevent accident from
happening and to minimize the negative effects.
Hazard and operability study (HAZOP) is a detailed examination of complex

processes to identify and evaluate problems that may cause economic losses,
injuries and contaminations to the environment. The intention of performing HAZOP
is to identify errors which might arise during the production and suggest ways to
prevent it from happening. The technique of performing HAZOP is qualitative and
aims to stimulate imaginations from the team to foresee the errors which might
arise.
HAZOP is usually performed in 4 basic steps:
1. Form a HAZOP team and every team members must be familiar with the
whole production.
2. Gather ideas from every member to identify potential issues that might arise
during the production. Every equipment is analyzed in this step.
3. Identify any hazards which might arise due to the errors.
4. Suggest ways to prevent the accident from happening or suggest immediate
action to minimize the negative effect if an accident happened.
Once the four steps above have been completed, a final HAZOP report is produced.
3
1.2 Summary
The main objective of this report is to produce a comprehensive HAZOP report to
analyze every possible accident that could happen to any equipment in our
benzaldehyde production plant. For each HAZOP table, changes in different
parameters such as temperature, pressure, level and flow are analyzed in details.
The diagram of respective equipment in our process flow diagram is also cropped
out to provide a clearer image of what is happening in the equipment. The causes
of each deviation are also listed out in the HAZOP table. Recommendations and
safeguards are also provided in each case based on different proposed literature.
Our HAZOP table consists mainly of three parts:
1. Reactors
2. Separation units and mixer
3. Storage tank and utilities
The table is organized in this way to provide a smooth flow of the overview of the
equipment used in our benzaldehyde production plant.
Overall, HAZOP study focuses on the possible errors that might arise during the
production, hence creating a guideline of the actions that should be taken when the
accidents happened. HAZOP is also an important tool to understand the limitations
of each method before making decision to use it in a particular circumstances.
4
2.0 Nomenclature
The following abbreviation will be used in the HAZOP Table.
LG Level glass
LI Level indicator
LIA Level indicator alarm
LIC Level indicator and controller
LICA Level indicator controller alarm
MAW Maximum Allowable Working Pressure
PI Pressure indicator
PIC Pressure indicator and controller
PICA Pressure indicator controller alarm
PAD Pressure alarm device
PSV Pressure safety valve
SIS Safety interlock system
TA Temperature alarm
TIC Temperature indicator and controller
TICA Temperature indicator controller alarm
FI Flow indicator
FIA Flow indicator alarm
FICA Flow indicator controller alarm
HLA High level alarm
LLA Low level alarm
5
3.0 Risk occurrence and Injury Description Rating (ODR)
To classify the occurrence of an incident and their seriousness in terms of

threatening the safety of humans and the plant, we can use the risk
occurrence and injury description rating.
The table below demonstrates how we classified all incidents in the HAZOP
table. Safety description (D) is used to express the seriousness of the safety
issue for example (1) means that the injury is minor and can be treated on
the spot by a first-aid-kit whereas (4) means that death will occur.
The risk occurrence (O) is used to express how frequent the certain incident
will occur. For example, (1) represents an incident that is least likely to
happen such as the pipes getting scratched by birds or wild animals whereas
(4) represents an incident that is very frequent such as some heat losses
occurring in the pipes during material transfer.
Both the safety description and risk occurrence are used to tabulate whether
the incident is acceptable or not. For example, if the safety description (D) is
ranked 4 and the risk occurrence (O) is ranked as 4 as well, the result is not
acceptable. Stringent safeguards must be set, maintained and constantly
monitored to prevent this incident from happening again.
6
Table 1: Risk Occurrence and Injury Description Rating
Factors
Safety 1- Minor 2-Injuries 3-Severe 4-Very severe,

Description injuries that that may injuries that high emergency
(D) can be require a require the casualties/death
treated by doctor hospital
Risk first-aid-kit
Occurrence on the spot
(O)
1-Least (A)Acceptable (A)Acceptable (A)Acceptable (B)Acceptable if
expected to proper precautions
happen are taken
2-Rarely (A)Acceptable (A)Acceptable (B)Acceptable (C)May be
occurs if proper accepted if care is
precautions taken to monitor
are taken and control this
issue
3-Frequent (A)Acceptable (B)Acceptable (C)May be (D)Not acceptable.
if proper accepted if Stringent
precautions care is taken safeguards must
are taken to monitor be set, maintained
and control and constantly
this issue monitored
4-Very (B)Acceptable (C)May be (D) Not (D)Not acceptable.
frequent if proper accepted if acceptable. Stringent
precautions care is taken Stringent safeguards must
are taken to monitor safeguards be set, maintained
and control must be set, and constantly
this issue maintained monitored
and
constantly
monitored
7
4.0 Inherent Safety
Inherent means existing in something as a permanent and inseparable element

whereas safety refers to ‘built in’ not ‘added on’. An inherently safer design is one
that avoids hazards instead of controlling them, particularly by reducing the amount
of hazardous material and the number of hazardous operations in the plant. It may
not always be feasible to eliminate or lessen hazards, but the Inherent Safety
Process philosophy requires that this be attempted before moving on to
specification of risk management equipment and procedures.
Inherent safety based on the following strategies (ISAS) which are

Intensification, substitution, attenuation and simplification. Intensification
simply means to minimize something like reducing size of the equipment or using
smaller quantities. Substitution means replace material with a less hazardous
substance. Attenuation is moderation and limitations of effects. By using a less
hazardous form of material or facilities which minimize the impact of a release.
Simplification means reduce the complexity in design facilities and make operating
errors less likely to happen.
Besides the 4 main strategies in inherent safety process design, it followed by 6

layers of protection analysis (LOPA). ‘Conceptually, LOPA is used to understand
how a process deviation can lead to a hazardous consequence if not interrupted by
the successful operation of a safeguard called an independent protection layer (IPL).
An IPL is a safeguard that can prevent a scenario from propagating to a
consequence of concern without being adversely affected by either the initiating
event or by the action (or inaction) of any other protection layer in the same
scenario’. (Willey, 2018)
The first layer of protection refers to basic process control (BPCS) and followed
by the rest of the layers which is alarms, safety interlock system (SIS), relief,
containment and emergency response. BPCS is responsible for normal operation of
the plant. Alarms is used for visual indication. SIS also known as Emergency
shutdown system (ESS), is an automatic action usually stops part of plant operation
to achieve safe conditions. Relief refer to safety relief valve, such as rupture disk.
Containment is use to moderate the impact of spill or an escape. Last layer of LOPA
is emergency response, all plant should have emergency response plan. The first 4
layers are automation then the last 2 layers are depending on human action.
Based on our process, for example, Stream 46 in our process flow diagram
sheets which eventually link to storage tank, but for the hydrogen storage tank, we
will install a safety valve and rupture disks (relief). In case the pressure is too high
which the safety valve cannot adjust, the rupture disk will rupture and release the
8
hydrogen gas to the environment. Other than that, we will install control panel for
simplification, simplify method which is easier for control.
Emergency Response
Containment
Relief
SIS
Alarm
BPC
S
Figure 1: Layer of protection analysis (LOPA)
9
5.0 HAZOP Table
1. Reactors
- This section will discuss about the main reacting equipment in the
plant
2. Separation Units
- This section includes all separation equipment in the process such
as flash drums, distillation column, mixer and decanter.
3. Utilities and Storage Tank
- This section covers storage vessels and utility equipment such

as heat exchangers, pumps and valves.
10
PFD (Process Flow Diagram)
11
Project: HAZOP for Benzaldehyde Production Plant
HAZOP Team: Group 6 Meeting Date: 10th of March 2018 Stream Inlet: 7 Jacketed Stream inlet: 10
Node: Packed Bed Reactor Node No. E2 Stream Outlet: 11, 46 Jacketed Stream outlet: 8
Design Intent: Packed bed reactor with catalyst iron-copper binary oxides and additive pyridine. Oxidation of toluene to benzaldehyde takes place
here. Reaction is exothermic; therefore, a cooling loop is employed. Operating temperature and pressure are 463K and 1Mpa. (thevespiary.org)
Parameter Guide Deviation Causes Consequences Safeguard Action Recommendations O D R

Word
Flow NO No flow -Blockage of the -No reactants enter -Install FI on -Check and -Constant checking 2 1 A
streams before reactor the input locate the of the pipelines and
entering the streams to blockages in the their conditions
reactor such as -No monitor the streams and
(Streams 1-7) production/reaction flows through unblock them -Constant
the indicator maintenance and
-Accumulation of -Loss of reactants washing for mixers
reactants in mixer if leakage occurs -Install FA on -Increase the
and no flow to resulting in loss of the input speed of mixing -Constant checking
reactor (S6) money streams which to unblock the on the functions of
will notify and accumulation in the pumps and their
-Pump not alert the the mixer conditions
functioning at workers on
inlet, no reactants site regarding -Change pump -Constant checking
added to the the flow issue for potential areas in
process (streams -Adjust the the pipes that may
1-4) pumps to have blockages
increase flowrate
LESS Less flow -Pipe not -Reduced -Install LI to -Adjust the -Constant 3 1 A
functioning well or production observe the valves to maintenance and
leakage (Streams -Insufficient level increase the inspection on the
1-7) reactants constantly flowrate conditions of the
pipes
-Install FIC -Replace pipe
and FA
12
MORE More flow -Pump flow was -Too much -Install LI to -Adjust the -Control valves must 2 1 A
adjusted too high reactants may observe the valves or pumps be constantly tested
at the beginning enter reactor, level accordingly to
(P1, P2) leading to hazards constantly decrease -Pump must be
such as explosions flowrate monitored at all
-Install FIC times
-The pipes may not and FA -Stop production
be able to and evacuate if
withstand the overflow
excess amount of
reactants
-Reactions in
reactor may not
occur according to
expectations
Temperature Less Low -Coolant flowrate -Reactions in -Install TI on -Increase -Install another 3 1 A
temperature in the jacketed reactor incomplete S6 and S7 to heating duty of preheater just in
stream too high detect if any preheater (H1) case first preheater
-Products required changes in the is malfunctioning
-Coolant not being able to temperatures -Lower the
temperature too be produced flowrate of the -Review temperature
low -Install FIC to coolants loop and feed
-Product discharge enable the regulating system
-Preheater (H1) temperature is flowrate of -Check and
malfunctioning lower coolant to be adjust preheater
adjusted conditions
-Alternate accordingly
reactions may take
place forming
other products
More High -Flowrate of -Too high -Install TICA -Increase the -Review temperature 3 1 A
temperature coolant too low temperature may coolant flowrate loop and feed
destroy equipment -Install regulating system
-Temperature of pressure
13
coolant used too -By-products may safety valve/ -Reduce coolant
high be formed rupture disc temperature
-Preheater (H1) -Reactants may be -Decrease

malfunctioning affected by reactants input
temperature thus using valve
-Outlet stream affecting the
from reactor may reactions -Reduce heating
be plugged duty of
resulting in the -Runaway reaction preheater (H1)
building up of may occur leading
reactants in to explosions
reactor and
additional heat
released
Pressure Less Low Pressure -Low input of feed -Reactions may be -Install PIC -Increase input -Perform inspections 2 1 A
incomplete and PA of feed on all pumps and
-Leakages in pipes vessels constantly
(Streams 1-7) -Certain conditions -Seal the valves -Have secondary
for the reactions to stop the pumps as backup
-Pumps (P1, P2) may not be met leakages in the
failure pipes
-Possible backflow
in the pipes -Stop the pumps
from working,
replace them
and restart the
process
More High -Too much feed in -Pipes may not be -Install -Reduce amount -Install pressure 2 4 C
Pressure input to reactor able to withstand pressure of feed in the valves that can help
the pressure safety valve/ input to reactor to remove excess
-Outlet streams rupture disc pressure
from reactor (S47, -Reactor may not -Clear blockages
S11) may be be able to -Install PICA in all pipes -Do constant
blocked withstand the large connected to checking on the
pressure resulting reactor pressure conditions
14
-Inlet temperature in explosions of the reactors
of feed into -Reduce heating
reactor (S7) may duty of -Ensure that the
be too high preheater (H1) pressure of the
streams entering and
exiting the reactor is
controlled
Reaction No No reaction -Input streams to -No production -Input stream -Emergency -Consider installing 2 1 A
reactor (S7) is to reactor shutdown on the multiple piping/
blocked -Heavy losses for must be whole operation process steam as
plant economically monitored and spare utilities
-Input stream checked -Check the
pipe is -Waste of energy constantly reactor to -Installing two
malfunctioning and electricity determine what smaller reactor in
-Pipes must be went wrong parallel instead of
-Feed condition -Accumulated constantly one large reactor for
not following the unreacted maintained faster reaction
desired condition reactants in the
reactor
Less Less reaction -Too little feed -Incomplete -Constantly -Change the -Consider installing 3 1 A
input to reactor reaction monitor pressure of the multiple piping/
reactor reactor if it is process steam as
-Temperature of -Product operating not according to spare utilities
reactants in the compositions are conditions the desired
inlet stream (S7) not as what is conditions -Installing two
is too low required -Monitor the smaller reactor in
flowrate of -Increase parallel instead of
-Pressure in the -Less product is feed input to heating duty of one large reactor for
reactor not produced reactor preheater (H1) faster reaction
according to
desired conditions -Unable to meet -Increase the
customer amount of feed
expectations to the reactor
-Unreacted solid
15
feed particles may
damage
downstream
equipment
More More -Too much -Overflow of -Monitor the -Decrease the -Constantly maintain 3 1 A
reaction reactants in the products input reactant amount of the amount of
reactor stream into reactant added reactants that enter
-By-products may the reactor into reactor the reactor
-Temperature of be produced due to
reactants are too more reaction -Decrease the -Ensure
high heating duty of temperature of
preheater (H1) reactants are
not too high
before allowing
them to enter
reactor
-Increase the
output flowrate
of product from
reactor
Composition No No feedstock -Reactants input -Reaction unable to -Monitor the -Stop the -Use more than 1 1 2 A
into reactor is proceed due to no input stream process if unable inlet stream to
stopped or reactants entering flowrates to change the reactor
blocked the reactor (Streams 1-7) equipment on
time
-Pipe rupture -Loss of money -Check all
pipes before -Increase the
-Pumps not -Wastage of commencing speed of mixing
functioning electricity and operation to reduce
energy accumulation of
-Accumulation of -Check all reactants in
reactants in mixer - pumps before mixer before
before entering starting entering reactor
reactor operation
-Change
16
-Constantly pipes/pumps
wash mixer that are spoiled
Other Undesired - Contamination of -Product quality -Heavily -Troubleshoot -Feed regulation and 1 2 A
than Composition feedstock compromised monitor input and perform purification to
and output correction if eliminate impurities
-Excessive -Less product is stream possible
presence of formed, more by- flowrates into -Regular cleaning of
impurities in products are reactor -If problem is vessel
reactants formed instead severe, perform
-Monitor plant shutdown
-Pipes may accumulation to reduce losses
contain impurities of substances
or accumulation of in pipes
previous reactants
-Ensure
feedstock is
pure before
commencing
operation
-Purchase
reactants from
trusted
manufacturers
Other - -Reactor -Constant contact -Reactor may spoil -Prepare -Change the -Use materials not 2 3 B
parts like with reactants easily proper damages parts easily corroded by
vessel or that are chemicals evacuation of the reactor chemicals
pipes -High maintenance protocols for
damages -Constant required all the emergency -Perform -Use materials that
reactions time, expensive situations emergency are strong and need
happening within shutdown low maintenance
the reactor -Production may -Constant
be halted once the maintenance -Refer and -Purchase a good
-Corroded by reactor stops and safety follow safety and quality reactor made
products or by- functioning checks on evacuation of good long-lasting
17
products formed properly reactor protocols materials and parts
-Humidity in the
reactor causes
damages to
reactor pipes and
vessels
18
5.2 Separation Units
5.2.1 Flash Drum (E3)
5.2.2 Distillation Column 1 (E4)
5.2.5 Decanter (E5)
19
Project: HAZOP for Production of Benzaldehyde
HAZOP team: Group 6 Meeting Date: 10th of March 2018 Stream Inlet: S12
Node: Flash Drum Node No. E3 Stream Outlet: S13, S15
Design Intent: Feed is obtained from the reactor. The feed contained mostly toluene, hydrogen peroxide, water, benzaldehyde, benzyl
alcohol and benzoic acid. The flash drum is used to separates unreacted reactants back to the reactor. The top product contained mainly
toluene, hydrogen peroxide and water. The bottom product contained mainly benzaldehyde, benzyl alcohol and benzoic acid. The flash drum
operates at 463K at 100kPa.
Parameter Guide Deviation Causes Consequences Safeguard Action Recommendation O D R

word
Temperature Less Lower -Low heat -Incomplete -Installation of -Increase -Maintenance of heat 2 1 A
temperature duty of H1 separation temperature heat duty of exchanger and flash drum
indicator H1 to be done regularly
-Heater H1 -Bottom stream controller (TIC) -Repair
malfunction contains more at the feed heater H1.
impurities stream
More Higher -Heating -Separation -Installation of -Decrease -Maintenance of heat

temperature duty of H1 is efficiency temperature heat duty of exchanger and flash drum
too high decrease indicator H1 to be done regularly
-High input controller (TIC) -Inspect the
stream -More undesired at the feed temperature
temperature products at top stream of inlet
stream stream
20
Pressure Less Lower -Valve -Inefficient -Installation of -Immediately -Maintenance of valve 3 1 A
Pressure malfunction separation due pressure check and and flash drum to be
(Valve, V2) to changes in the indicator (PI) repair valve if done regularly
boiling point of it is found
-Pipe
components faulty -Constant checkup on
leakage pipeline
(Stream,
-Immediately
S12)
check and
repair
pipeline if it is
found faulty
More Higher -Valve -Pressure build -Installation of -Monitor and -Install pressure relief 2 3 B
pressure malfunction up in flash drum pressure perform valve (PRV) for
(Valve, V2) may lead indicator control bypass to emergency
damage/failure (PIC) in tube relief
-Pipe is side and shell pressure in -Maintenance of valve
partially -Inefficient side streams the stream and flash drum to be
blocked separation due done regularly
(Stream, to changes in -Installation of
S13 & S15) boiling point of pressure relief -Constant checkup on
components bypass stream pipeline
for input
streams
Flow None No feed flow -Pipeline -Chemical -Installation of -Make sure -Install backup valve 1 1 A
rate ruptured or spillage into flow indicator the valve is in case the valve
blocked workplace control alarm open malfunction
(Stream, (FICA)
S12) -Separation does -Check and -Constant checkup on
not occur repair pipeline for leakage
-Valve is immediately and blockage
closed if the pipe is
ruptured
Less Less feed -Valve -Chemical -Installation of -Perform -Install backup valve 3 1 A
flow rate malfunction spillage into flow indicator checkup on in case the valve
workplace control alarm valve and malfunction
21
-Pipeline (FICA) pipe, then
leakage or -Separation repair -Constant checkup on
partially efficiency -Regular immediately pipeline for leakage
blocked decreases maintenance if the and blockage
(Stream, and checkup of equipment is
S12) equipment and found faulty
pipe
Less bottom -Output -Separation -Installation of -Decrease -Install a slight glass 1 2 A

liquid flow stream efficiency flow indicator feed flow rate to visually monitor the
rate pipeline is decreases control alarm to prevent column level
partially (FICA) over flooding
blocked -Column level of flash drum.
increases -Installation of
level indicator -Immediately
control alarm check and
(LICA) repair the
pipeline
More More feed -High flow -Backflow into -Installation of -Inspect and -Install backup valve 3 2 B
flow rate rate output feed stream may flow indicator resolve any in case the valve
stream from occur control alarm issues with malfunction
the reactor (FICA) reactor (E2)
(E2) -Column level -Constant checkup on
will increases -Installation of pipeline for leakage
level indicator and blockage
control alarm
(LICA)
-Installation of
proportional –
integral-
derivative
controller (PID
controller)
22
Project: HAZOP for benzaldehyde production plant
HAZOP team: Group 6 Meeting date: 12March2018 Stream inlet: S17
Node: Distillation column 1 Node no:E4 Stream outlet: S18 and S24
Design intent: E4 is a distillation column which is used to separate unreacted toluene from the other components. This column operates at 70°C and
20kPa. The top products are toluene, water and hydrogen peroxide which is further sent to the decanter for another separation. The bottom products will
be benzoic acid, benzyl alcohol and benzaldehyde which are sent for further separation.

word
Temperature Less Lower -Heat -Separation of -Installation -Replace or -Regular maintenance of 3 1 A
temperature exchanger, the column and of TIC and repair heat the heat exchanger to
H3 the quality of TIA in the exchanger, prevent fouling
malfunction products are column H3
affected -Monitor the
-Reboil, H5 -Inspect and temperature indicator
duty below -Flooding of the adjust constantly
set point column due to reboiler’s
excess liquid duty
-The column
may be
damaged due to
flooding
More Higher -Heat - Separation of -Installation -Replace or -Regular maintenance of 3 2 B
temperature exchanger, the column and of TIC and repair heat the heat exchanger to
H3 the quality of TIA in the exchanger, prevent fouling
malfunction products are column H3
affected -Monitor the
-Reboiler, -Inspect and temperature indicator
H5 duty -High adjust constantly
above set temperature reboiler’s
point may damage duty
the distillation
column
23
Pressure Less Low pressure -Valve, V3 -Low pressure Installation -Repair or -Regular maintenance of 2 3 B
in the column malfunction affects the of PIC and replace the the pipeline and the valve
chemical PIA in the valve, V3
-Leakage in properties of distillation -Monitor the pressure
the D.C. the components column -Repair the indicator constantly
in the D.C. pipeline once
-Leakage in causing the leakage
the pipeline separation to be is identified
ineffective
-Stop the
-Leakage of the feed stream
chemicals such if needed
as toluene will
cause irritation
and death if the
amount inhaled
is large enough
More High pressure -Valve, V3 -High pressure Installation -Repair or -Regular maintenance of 2 4 C
in the column malfunction affects the of PIC and replace the the pipeline and valve
chemical PIA in the valve, V3
-Blockage in properties of distillation -Monitor the pressure
the D.C. the components column -Repair the indicator constantly
in the D.C. pipeline once
-Blockage in causing the blockage
the pipeline separation to be is identified
ineffective
-Stop the
-High pressure feed stream
may cause if needed
explosion which
may damage
the column
Flow No No feed flow -Valve, V3 - Economic Installation -Repair or -Regular maintenance of 2 1 A

rate malfunction losses of (flow replace the the pipeline and valve
indicator valve, V3
24
-Leakage/ -Wastage of control)FIC -Monitor the flow indicator
blockage in energy and -Repair the constantly
the pipeline utility pipeline once
the leakage/
-No separation blockage is
occurs identified
Less Less feed flow -Valve, V3 -Quality of Installation -Repair the -Regular maintenance of 2 1 A
rate malfunction separation is of (flow pipeline once the pipeline and valve
affected indicator the leakage/
- Leakage/ control)FIC blockage is -Monitor the flow indicator
blockage in -Spillage of identified constantly
the pipeline hazardous
chemicals such
as toluene and
benzyl alcohol
More High feed flow -Valve, V3 -Quality of Installation -Repair or -Regular maintenance of 2 3 B
rate malfunction separation is of (flow replace the the valve
affected indicator valve, V3
control)FIC -Monitor the flow indicator
-High pressure -Stop the constantly
may cause flow rate of
explosion which feed stream
may damage if needed
the column and
cause serious
injuries
Level Less Low level in -Leakage in -Quality of Installation -Repair the -Regular maintenance of 2 3 B
the column the pipeline separation is of level pipeline once the pipeline
affected indicator the leakage/ -Monitor the level indicator
-D.C. blockage is constantly
malfunction -Desired identified
25
product -Repair or
composition replace the
can’t be D.C. if
achieved needed
-Stop the
feed flow
rate
More High level in -Blockage in -Desired -Installation -Repair the -Regular maintenance of 2 3 B
the column the exit product of level pipeline once the pipeline
stream composition indicator the leakage/
pipeline can’t be blockage is -Monitor the level indicator
(S18 and achieved -Installation identified constantly
S24) of an extra
-Flooding of pipeline to -Stop the -Install a sight glass level
column may relief the feed flow gauge
cause pressure high rate if
being built up pressure needed
-High pressure
may cause
explosion and
damage the
D.C.
26
Node: Distillation Column 2 Node No. E7 Stream Outlet: S28, S33
Design Intent: The type of distillation column used for DC-02 is a tray column. It is mainly used to separate the main product which is Benzaldehyde from
the mixture of Benzyl Alcohol and Benzoic acid. The operating temperature and pressure of the column is 135 oC and 20kPa respectively. The top product
main collected is Benzaldehyde and small amount of the Benzyl Alcohol which sent to Benzaldehyde storage tank while the bottom product is Benzyl Alcohol
and Benzoic Acid mixture which will be sent to next Distillation Column to be separate out. A total condenser and partial reboiler is used for this distillation
column.
Parameters Guide Deviation Causes Consequences Safeguard Action Recommendation O D R

word
Temperature Less Lower -High reflux ratio -Purity of -Install -Decrease reflux -Regular inspection 3 1 A
temperature -Reboiler (E8) Benzaldehyde is temperature ratio and maintenance of
duty below set affected indicator controller -Adjust reboiler the safeguard
point -Flooding of column -Install (E8) duty controller
-Quality of separation proportional- -Regular
is affected integral-derivative maintenance of
controller (PID) reflux drum and
reboiler
More Higher -Low reflux ratio -Quality of separation -Install -Increase reflux -Regular inspection 2 2 A
temperature -Reboiler (E8) is affected temperature ratio and maintenance of
duty above set indicator controller -Inspect and the safeguard
point -Install flow adjust reboiler controller
-Low cooling indicator control to duty -Regular
water flow in monitor the cooling -Increase amount maintenance of
condenser water flow in of cooling utility reflux drum and
27
condenser passing through reboiler
-Install PID condenser -Regular
controller maintenance of
condenser
Pressure Low Low column -Column leakage -Low pressure affects -Install pressure -Fix those leakage -Regular 1 2 A
pressure -Pipeline (S27) the boiling points of indicator controller pipe maintenance of
leakage components which -Install PID -Evacuate the area pipelines
-Low reflux ratio subsequently will controller -Increase reflux -consider installing
affect the separation ratio a pump before
process. -Shut down the entering the
-Components leaking operation of distillation column
into workspace area distillation column
poses fire hazard
High High -Reboiler (E8) -High column -Install high -Inspect and -Monitor column 2 3 B
column duty above set pressure may cause pressure indicator adjust reboiler pressure frequently
pressure point an explosion alarm duty
-Feed flowrate -Column pressure -Install high -Evacuate the area
higher than set above the set point pressure indicator immediately
point will alter the boiling controller
point of each -Install relieve
components, affects valve at stream 28
the purity of -Have emergency
benzaldehyde evacuation plan
prepared
-Install (PID)
controller
Flowrate None No feed -Pipeline leakage -No separation -Install flow -Evacuate the area -Consider installing 1 1 A
flowrate from stream 26 -Spillage of mixture indicator controller -Close the valve at a valve before
to 27 into workplace area -Have emergency V3, before entering the
-Decrease amount of evacuation been entering distillation column
product per hour prepared distillation column 2
1
Less Less feed -Pipeline leakage -Quality of separation -Install flow -Inspect and fix -Consider installing 2 1 A
flowrate from stream 26 is affected indicator controller any leakage a valve before
to 27 -Spillage of mixture -Have emergency pipelines entering the
into workplace area evacuation been distillation column
28
-Decrease amount of prepared 2
product per hour
More More feed -Low reboil ratio -Quality of separation -Install flow -Decrease reflux -Regular 2 2 A
flowrate from distillation is affected indicator controller ratio to reduce maintenance and
column 1 -flooding of column -Install relieve column pressure inspection of the
-effect the separation valve at stream 27 safeguard
quality -Install pressure installation
indicator controller
Less Less liquid -High reboil ratio -Increase in column -Install flow -Resolve any pipe -Monitor column 2 2 A
bottom -Blockage due to pressure and level indicator controller blockage pressure frequently
flowrate fouling in bottom -Quality of separation in both bottom and -Decrease reboil -Regular
stream pipes is affected reboiler stream ratio maintenance and
cleaning of column
More More liquid -Low reboil ratio -It will carry to -Install flow -Increase reboil -Monitor column 2 2 A
bottom distillation column 3 indicator controller ratio pressure frequently
flowrate and affects the feed in both bottom and -Regular
flowrate reboiler stream maintenance and
cleaning of column
Level Less Low level of -Heat exchanger -Separations -Install low level -Fix any pipe -Regular 2 1 A
liquid in H6 malfunction efficiency decreases indicator control leakage maintenance of
column -Pipeline (stream -Desired product -Decrease bottom pipes
26,27) leakage composition not -Install flow liquid flowrate -Make sure heat
-Low feed achieved indicator control to -Inspect heat exchanger (H7)
flowrate from -Components leaking monitor inlet exchanger H6 well function
distillation into workplace area flowrate
column 1 poses fire hazard
-Bottom liquid
flowrate too
many
More High level -High feed -Flooding of column -Install a level -Decrease feed -Install a sight 3 1 A
of liquid in flowrate and puking occurs indicator alarm flowrate or glass level gauge
column -Bottom output where liquid is forced increase bottom -Make sure the
pipe fouling out of the top column -Install control liquid flowrate valve can be
valve for feed inlet control manually
-Decrease the -Fix any pipe when the automatic
product flowrate -Install flow blockage controller fails
29
-Decrease the indicator control to -Decrease reflux
separation efficiency monitor inlet ratio
-Backflow to feed flowrate
inlet occurs
-Pressure build up -Install overflow
restricting vapour rise piping
through liquid
30
Node: Distillation Column 3 Node No. E11 Stream Outlet: S37, S42
Design Intent: The type of distillation column used for DC-03 is also a tray column. It is mainly used to separate Benzyl Alcohol from the mixture of
Benzoic acid. The operating temperature and pressure of the column is 167 oC and 20kPa respectively. The top product main collected is Benzyl
Alcohol and small amount of the Benzoic Acid which sent to Benzyl Alcohol storage tank while the bottom product is mainly Benzoic Acid which will be
sent to Benzoic Acid storage tank. A total condenser and partial reboiler is used for this distillation column.

word
Temperature Less Lower -High reflux -Flooding of column -Install temperature -Decrease reflux -Regular inspection 3 1 A
temperatur ratio -Quality of separation is indicator controller ratio and maintenance of
e -Reboiler (E11) affected -Install -Adjust reboiler the safeguard
duty below set proportional- (E11) duty controller
point integral-derivative -Regular
controller (PID) maintenance of
reflux drum and
reboiler
More Higher -Low reflux -Quality of separation is -Install temperature -Increase reflux -Regular inspection 2 2 A
temperatur ratio affected indicator controller ratio and maintenance of
e -Reboiler (E11) -Install flow -Inspect and the safeguard
duty above set indicator control to adjust reboiler controller
point monitor the cooling duty -Regular
-Low cooling water flow in -Increase amount maintenance of
water flow in condenser of cooling utility reflux drum and
31
condenser -Install PID passing through reboiler
controller condenser -Regular
maintenance of
condenser
Pressure Low Low column -Column -Low pressure affects -Install pressure -Fix those leakage Regular 1 2 A
pressure leakage the boiling points of indicator controller pipe maintenance of
-Pipeline (S36) components which -Install PID -Evacuate the area pipelines
leakage subsequently will affect controller -Increase reflux -consider installing
-Low reflux the separation process. ratio a pump before
ratio -Components leaking -Shut down the entering the
into workspace area operation of distillation column
poses fire hazard distillation column
High High -Reboiler (E11) -High column pressure -Install high -Inspect and -Monitor column 2 3 B
column duty above set may cause an explosion pressure indicator adjust reboiler pressure frequently
pressure point -Column pressure alarm duty
-Feed flowrate above the set point will -Install high -Evacuate the area
higher than set alter the boiling point of pressure indicator immediately
point each components, controller
affects the purity of -Install relieve
benzyl alcohol valve at stream 28
-Have emergency
evacuation plan
prepared
-Install (PID)
controller
Flowrate None No feed -Pipeline -No separation -Install flow -Evacuate the area -Consider installing 1 1 A
flowrate leakage from -Spillage of mixture into indicator controller -Close the valve at a valve before
stream 35 to 36 workplace area -Have emergency V3, before entering entering the
-Decrease amount of evacuation been distillation column distillation column
product per hour prepared 1 3
-Install valve before
entering distillation
column 3
Less Less feed -Pipeline -Quality of separation is -Install flow -Inspect and fix -Consider installing 2 1 A
flowrate leakage from affected indicator controller any leakage a valve before
stream 35 to 36 -Spillage of mixture into -Have emergency pipelines entering the
32
workplace area evacuation been distillation column
-Decrease amount of prepared 3
product per hour
More More feed -Low reboil -Quality of separation is -Install flow -Decrease reflux -Regular 2 2 A
flowrate ratio from affected indicator controller ratio to reduce maintenance and
distillation -Flooding of column -Install relieve column pressure inspection of the
column 1 -Affect the separation valve at stream 36 safeguard
quality -Install pressure installation
indicator controller
Less Less liquid -High reboil -Increase in column -Install flow -Resolve any pipe -Monitor column 2 2 A
bottom ratio pressure and level indicator controller blockage pressure frequently
flowrate -Blockage due -Quality of separation is in both bottom and -Decrease reboil -Regular
to fouling in affected reboiler stream ratio maintenance and
bottom stream cleaning of column
pipes
More More liquid -Low reboil -Affects the purity of -Install flow -Increase reboil -Monitor flow 2 2 A
bottom ratio benzoic acid in storage indicator controller ratio indicator regularly
flowrate tank in both bottom and
reboiler stream
Level Less Low level of -Heat -Separations efficiency -Install low level -Fix any pipe -Regular 2 1 A
liquid in exchanger (H9) decreases indicator control leakage maintenance of
column malfunction -Desired product -Decrease bottom pipes
-Pipeline composition not -Install flow liquid flowrate
(stream 35,36) achieved indicator control to -Inspect heat -Make sure heat
leakage -Components leaking monitor inlet exchanger H6 exchanger (H9)
-Low feed into workplace area flowrate well function
flowrate from poses fire hazard
distillation
column 2
-Bottom liquid
flowrate too
many
More High level -High feed -Flooding of column and -Install a level -Decrease feed -Install a sight 3 1 A
of liquid in flowrate puking occurs where indicator alarm flowrate or glass level gauge
column -Bottom output liquid is forced out of increase bottom -Make sure the
pipe fouling the top column -Install control liquid flowrate valve can be
33
valve for feed inlet control manually
-Decrease the product -Fix any pipe when the automatic
flowrate -Install flow blockage controller fails
-Decrease the indicator control to
separation efficiency monitor inlet -Decrease reflux
-Backflow to feed inlet flowrate ratio
occurs
-Pressure build up -Install overflow
restricting vapour rise piping
through liquid
34
HAZOP team: Group 6 Meeting date:12 March2018 Stream inlet: S19
Node: Decanter Node no:E5 Stream outlet: S20,S21,S23
Design intent: E5 is a decanter which is used to separate toluene from water and hydrogen peroxide. The operating condition for the decanter is 43°C and
20kPa. The bottom product will be unreacted toluene which will be stored in storage tank. A small amount of water is found at the bottom product too due
to 99% separation ratio for water. The top product will be mainly water and hydrogen peroxide.

word
Temperature Less Lower -Low input -Quality of -Installation -Repair or -Regular maintenance 2 1 A
temperature stream separation of of TIC and replace the of the condenser
temperature products is TIA in the condenser
affected decanter -Monitor the
-Condenser, -Stop the flow temperature indicator
H4 - Composition rate of feed constantly
malfunction of the mixtures stream into the
will be affected D.C.
35
More Higher -High input - Quality of -Installation -Replace or -Regular maintenance 2 3 B
temperature stream separation of of TIC and repair the of the condenser
temperature products is TIA in the condenser
affected decanter -Monitor the
-Condenser, -Stop the flow temperature indicator
H4 -Composition of rate of feed constantly
malfunction the mixtures stream into the
will be affected D.C. if needed
-High
temperature
may damage
the decanter
-High
temperature
may causes
toluene to
vaporize and is
harmful if
inhaled
Pressure Less Low pressure -Leakage in -Low pressure -Installation -Repair the -Regular maintenance 2 3 B
in the the pipeline affects the of PIC and pipeline once the of the pipeline
decanter (S18 and chemical PIA in the leakage is
S19) properties of decanter identified -Monitor the pressure
the components indicator constantly
in the decanter -Have an -Stop the feed
causing emergency stream if needed
separation to be evacuation
ineffective plan ready -Evacuate the
area if needed
-Leakage of the
chemicals such
as toluene will
cause irritation
and death if the
amount inhaled
36
is large enough
More High pressure -Blockage in -High pressure -Installation -Repair the -Regular maintenance 2 4 C
in the column the output affects the of PIC and pipeline once the of the pipeline
pipeline chemical PIA in the blockage is
properties of decanter identified -Monitor the pressure
the components indicator constantly
in the decanter -Have an -Stop the feed
causing emergency stream if needed -Install a pressure
separation to be evacuation relief stream
ineffective plan ready -Evacuate the
area if needed
-High pressure
may cause
explosion which
may damage
the decanter
and cause
serious injuries
Flow None No feed flow -Valve, V3 - Economic Installation -Repair or -Regular maintenance 2 1 A
rate malfunction losses of (flow replace the of the pipeline and the
indicator valve, V3 valve
-Leakage/ -Wastage of control)FIC
blockage in energy and -Repair the -Monitor the flow
the pipeline utility pipeline once the indicator constantly
(S18 and leakage/
S19) -No separation blockage is
occurs identified
Less Less feed flow -Valve, V3 -Quality of Installation -Repair the -Regular maintenance 2 1 A
37
rate malfunction separation is of (flow pipeline once the of the pipeline and the
affected indicator leakage/ valve
- Leakage/ control)FIC blockage is
blockage in -Spillage of identified -Monitor the flow
the pipeline hazardous indicator constantly
(S18 and chemicals such
S19) as toluene and
benzyl alcohol
More High feed flow -Valve, V3 -Quality of Installation -Repair or -Regular maintenance 2 2 A
rate malfunction separation is of (flow replace the of the valve
affected indicator valve, V3
control)FIC -Monitor the flow
-High pressure indicator constantly
may cause
explosion which
could damage
the column
38
5.3 Utilities and Storage Tanks
5.3.1 Toluene Storage Tank

5.3.2 Benzaldehyde Storage Tank
5.3.3 Benzyl Alcohol Storage Tank
5.3.4 Benzoic Acid Storage Tank
5.3.5 Valve (V1)
5.3.6 Valve (V2)
5.3.7 Valve (V3)
5.3.8 Pump (P-01)
5.3.9 Pump (P-02)
5.3.10 Pump (P-03)
5.3.11 Pump (P-04)
5.3.12 Pump (P-05)
5.3.13 Pump (P-06)
5.3.14 Pump (P-07)
5.3.15 Heat Exchanger (Heater) (H1)
5.3.16 Heat Exchanger (Cooler) (H2)
5.3.17 Heat Exchanger (Cooler) (H3)
39
HAZOP Team: Group 6 Meeting Date: 10th of March 2018 Stream Inlet: 22
Node: TOL Storage tank Node No. E6 Stream Outlet: -
Design Intent: A storage tank, to store the toluene from the decanter. The product entering the storage tank is at 43 °C. The product entering the
storage tank is in liquid form.

Word
Temperature Less Low -Low temperature of -May affect -Installation -Insulate all -Enhance storage tank 2 1 A
temperature inlet feed (S22) tank’s lifespan of TIC pipes resistance to drastic
because of condenser temperature changes
(H4) -Lower the by using heat resistant
cooling duty of materials
-Heat losses in the condenser
pipes -Build storage tank in
remote, low light facility
area
Pressure Less Low -Leakage in storage -Loss of -Install PIC -Replace all -Constant maintenance 1 1 A
pressure tank component spoilt pipes on all equipment
stored in the
-Leakage in pipes tank/vessel. -Use an
alternate
-Leakage of storage tank
component to
working area
may cause fire
More More -Pump placed before -Damages pipes -Install PICA -Replace the -Constant maintenance 2 4 C
pressure the storage tank (P4) and storage pumps if spoilt on all equipment
may be tanks
malfunctioning -Build storage tank in
-Some products may area
vaporize
Level More High level -Faulty level -Products may -Install PI -Purge the -Prepare secondary 2 1 A
40
measurement overflow components tanks as a precaution in
-Use a case of overflow
-Loss of secondary
products storage tank -Constant monitoring of
the level in the storage
-Waste money tank
Corrosion Storage -Concentration of -Damage the -Follow -Stop the plant -Use good quality 2 1 A
tank walls product too high storage tank proper guide operation storage tanks that are
corroded book and chemically resistant to
-Temperature and -Storage tank controls -Use a new desired products
pressure conditions may have cracks storage tank
support corrosion and leaks -Have a secondary tank
process -Chang the on standby
temperature and
pressure
conditions
41
Node: Benzaldehyde Storage tank Node No. E9 Stream Outlet: -
Design Intent: A storage tank, to store the top product of the distillation column mainly consists of benzaldehyde and low percentage of benzyl
alcohol. The top product entering the storage tank at 108°C at atmospheric pressure. The top product entering the storage tank is in liquid form.

Word
Temperature Less Low -Low temperature -May affect -Installation -Insulate all -Enhance storage tank 2 1 A
temperature of inlet feed (S31) tank’s lifespan of TIC pipes resistance to drastic
because of temperature changes by
condenser (H7) -Lower the using heat resistant
cooling duty materials
-Heat losses in the of condenser
area
Pressure Less Low -Leakage in -Loss of -Install PIC -Replace all -Constant maintenance on 1 1 A
pressure storage tank component spoilt pipes all equipment
stored in the
alternate
component to
working area
may cause fire
More More -Pump placed -Damages -Install PICA -Replace the -Constant maintenance on 2 4 C
pressure before the storage pipes and pumps if all equipment
tank (P5) may be storage tanks spoilt
malfunctioning -Build storage tank in
-Some products area
may vaporize
Level More High level -Faulty level -Products may -Install PI -Purge the -Prepare secondary tanks 2 1 A
42
measurement overflow components as a precaution in case of
-Use a overflow
-Loss of secondary
products storage tank -Constant monitoring of the
level in the storage tank
-Waste money
Corrosion Storage -Concentration of -Damage the -Follow proper -Stop the -Use good quality storage 2 1 A
tank walls product too high storage tank guide book plant tanks that are chemically
corroded and controls operation resistant to desired
-Temperature and -Storage tank products
pressure may have -Use a new
conditions support cracks and storage tank -Have a secondary tank on
corrosion process leaks standby
-Chang the
temperature
and pressure
conditions
43
Node: Benzyl Alcohol Storage tank Node No. E12 Stream Outlet: -
Design Intent: A storage tank, to store the top product of the distillation column mainly consists of benzyl alcohol and low percentage of benzoic acid.
The top product entering the storage tank is at 140 °C and at atmospheric pressure. The top product entering the storage tank is in liquid form.

Word
Temperature Less Low -Low temperature of -May affect -Installation of -Insulate all -Enhance storage tank 2 1 A
temperature inlet feed (S40) tank’s lifespan TIC pipes resistance to drastic
because of condenser temperature changes
(H10) -Lower the by using heat resistant
cooling duty of materials
-Heat losses in the condenser
remote, low light
facility area
Pressure Less Low pressure -Leakage in storage -Loss of -Install PIC -Replace all -Constant 1 1 A
tank component spoilt pipes maintenance on all
stored in the equipment
alternate
component to
working area
may cause fire
More More -Pump placed before -Damages -Install PICA -Replace the -Constant 2 4 C
pressure the storage tank (P6) pipes and pumps if spoilt maintenance on all
may be storage tanks equipment
malfunctioning
-Build storage tank in
-Some products may remote, low light
44
vaporize facility area
measurement overflow components tanks as a precaution
-Use a secondary in case of overflow
-Loss of storage tank
products -Constant monitoring
of the level in the
-Waste money storage tank
Corrosion Storage tank -Concentration of -Damage the -Follow proper -Stop the plant -Use good quality 2 1 A
walls product too high storage tank guide book and operation storage tanks that are
corroded controls chemically resistant to
-Temperature and -Storage tank -Use a new desired products
pressure conditions may have storage tank
support corrosion cracks and -Have a secondary
process leaks -Chang the tank on standby
temperature
and pressure
conditions
45
Node: Benzoic acid Storage tank Node No. E13 Stream Outlet: -
Design Intent: A storage tank, to store the bottom product of the distillation column mainly consists of benzoic acid and low percentage of benzyl
alcohol. The bottom product entering the storage tank is at 192 °C at atmospheric pressure. The bottom product entering the storage tank is in liquid
form.

Word
Temperature High High -High temperature -May affect -Installation of -Insulate all -Enhance storage tank 2 1 A
temperature of inlet feed (S45) tank’s lifespan TIC pipes resistance to drastic
because of reboiler temperature changes
(H11) -Vaporisation of -Reduce by using heat resistant
products heating duty of materials
-Heat gained from reboiler
surroundings -Build storage tank in
remote, low light
facility area
Pressure Less Low -Leakage in storage -Loss of -Install PIC -Replace all -Constant 1 1 A
pressure tank component spoilt pipes maintenance on all
stored in the equipment
alternate
component to
working area
may cause fire
More More -Pump placed -Damages pipes -Install PICA -Replace the -Constant 2 4 C
pressure before the storage and storage pumps if spoilt maintenance on all
tank (P7) may be tanks equipment
malfunctioning
-Build storage tank in
46
-Some products remote, low light
may vaporize facility area
measurement overflow components tanks as a precaution
-Use a in case of overflow
-Loss of products secondary
storage tank -Constant monitoring
-Waste money of the level in the
storage tank
Corrosion Storage -Concentration of -Damage the -Follow proper -Stop the plant -Use good quality 2 1 A
tank walls product too high storage tank guide book and operation storage tanks that are
corroded controls chemically resistant to
-Temperature and -Storage tank -Use a new desired products
pressure conditions may have cracks storage tank
support corrosion and leaks -Have a secondary
process -Chang the tank on standby
temperature
and pressure
conditions
47
Project: HAZOP for Benzaldehyde production plant
HAZOP Team: Group 6 Meeting Date: 10th of March 2018 Stream Inlet: S9
Node: Valve Node no.: V1 Stream Outlet: S10
Design Intent: Decrease pressure of jacketed water from 101.32Kpa to 1.27Kpa

Word
Flow None No Flow -Valve -Jacketed water does -Install FICA in -Open valve -Regular 2 3 B
inadvertently not flow through and valve to manually maintenance of
closes cool the reactor and it monitor flow valves and pipes
may overheat causing
explosion
-Find blockage
-Blockage in -Install TICA in and -Regular checking
stream (S9) reactor troubleshoot of FIC and for
-Blockage may cause blockages
rupture in pipe
-Shutdown
operations
and evacuate
if necessary
Less Less Flow -Partial -Inadequate amount of -Install FIC on -Open valve -Regular 2 2 A
blockage in cooling water to valve to with FIC maintenance of
stream (S9) reactor causing monitor flow valve controllers
reaction to overheat,
may cause explosion
-Lower
48
-Valve is unable -Install TICA in temperature -Regular monitoring
to open Reactor with TICA of FIC and checking
properly for blockages
-Check for
blockages and
remove
More More Flow -Valve is unable -Too much cooling -Install FIC on -Close valve -Regular 2 1 A
to close enough water surrounds valve to with FIC maintenance of
to regulate flow reactor, causing monitor flow valve controls
reaction temp to be
inadequate, hence less
product forms -Raise
-Install TICA in temperature -Regular checking
reactor with TICA of temperature in
reactor
Temperature Less Lower -Cooling water -Reaction may not -Install TIC -Raise -Regular checking 2 1 A
Temperature stream is too take place due to and in both temperature of TIC in both
cool (S9) inadequate valve and of stream and streams and reactor
temperature in reactor reactor using
reaction, therefore less TIC
product forms
More Higher -Cooling water -Reactor may overheat -Install TIC in -Lower -Regular checking 2 3 B
Temperature stream is not causing explosion valve temperature of temperature in
low enough in valve using both valve and
(S9) TIC reactor
-Corrosion of pipes -Install TICA in

and reactor reactor
-Lower -Regular
temperature maintenance of
49
in reactor pipes and reactor,
using TICA replace when
and shutdown necessary
and evacuate
if necessary
Pressure Less Lower -Valve opens -Flow of jacketed -Install PIC in -Close valve -Regular checking 2 3 B
Pressure too much stream is not high output stream proper of valve controls
unintentionally enough and hence the (S10) amount and PIC
reactor overheats
-Install TICA in -Lower -Regular checking

-May cause explosion reactor temperature of temperature in
using TICA reactor
and evacuate
and shutdown
if necessary
More Higher -Valve closes -Flow of jacketed -Install PIC on -Open valve -Regular checking 2 1 A
Pressure too much water is too high output stream to needed of PIC and TIC
unintentionally causing reactor temp (S10) level
to be too low, hence
reaction may not occur
and less product forms -Regular
-Install TIC on -Lower maintenance of
reactor temperature valve pressure
of jacketed controller
water
50
Design Intent: Decrease pressure of reactor output feed from 1000Kpa to 100Kpa

Word
Flow None No Flow -Valve -Reaction mixture -Install FICA -Open valve -Regular 2 3 B
inadvertently doesn’t flow in valve to manually maintenance of
closes through valve monitor flow valves and pipes
and there may be
rupture in pipe
(S11) -Find blockage
-Blockage in and -Regular checking
stream (S11) troubleshoot of FIC and for
blockages
-Blockage may
cause rupture in
valve -Shutdown
operations and
evacuate if
necessary
Less Less Flow -Partial blockage -Inadequate flow -Install FIC -Open valve -Regular 2 2 A
in stream (S11) of reaction on valve to with FICA maintenance of
mixture through monitor flow valve controllers
valve causing less
product to collect
-Valve is unable at final stage -Check for
to open properly blockages and -Regular monitoring
51
remove of FIC and checking
for blockages
More More Flow -Valve is unable -Too much -Install FIC -Close valve -Regular 2 1 A
to close enough to reaction mixture on valve to with FIC maintenance of
regulate flow passes through monitor flow valve controls
the valves
causing
overheating -Raise
-Install TICA temperature -Regular checking
in reactor with TICA of temperature in
reactor
Temperature Less Lower -Reactor -Flow of mixture -Install TIC -Raise -Regular checking 2 1 A
Temperature temperature is too becomes lower and in both temperature of of TIC in both
low resulting in hence the valve and stream and streams and reactor
low input stream amount of reactor reactor using
temperature product collected TIC
decreases.
-Regular checking
-Install FIC of FIC
in output -Raise flow
stream rate using FIC
(S12)
More Higher -Temperature of -May cause -Install TIC -Lower -Regular checking 2 3 B
Temperature output reactor overheating and in valve temperature in of temperature in
stream is too high potential valve using both valve and
explosion TIC reactor
-Install TICA
in pipes
-Corrosion of -Lower -Regular
pipes and reactor temperature in maintenance of
reactor using pipes and reactor,
52
TICA and replace when
shutdown and necessary
evacuate if
necessary
Pressure Less Lower -Valve opens too -Flow of stream is -Install PIC -Close valve -Regular checking 2 3 B
Pressure much not high enough in output proper amount of valve controls
unintentionally and hence not stream and PIC
enough product (S12)
goes into
distillation -Increase
column, less pressure of -Regular checking
product forms -Install FIC stream of FIC
in output
stream
(S12)
More Higher -Valve closes too -Flow of stream is -Install PIC -Open valve to -Regular checking 2 3 B
Pressure much too high, in output proper amount of valve controls
unintentionally pressure into stream and PIC
distillation (S12)
column is too
high
Composition Imbalance Lower -Imbalance of -Corrosion of -Check levels -Dilute when -Regular checking 2 3 B
Concentration chemicals in the pipes/valves of necessary or of input chemical
mixture concentratio add chemicals concentrations
n regularly when
necessary
-Explosion due to
improper
chemical mixture
53
Design Intent: Decrease pressure of feed from 100Kpa to 20kPa

Word
Flow None No Flow -Valve inadvertently -Reaction mixture -Install FICA -Open valve -Regular maintenance 2 3 B
closes doesn’t flow through in valve to manually of valves and pipes
valve and there may monitor flow
be rupture in pipe
(S16)
-Blockage in stream -Find -Regular checking of
(S16) blockage and FIC and for blockages
troubleshoot
-Blockage may cause
rupture in valve
-Shutdown
operations
and
evacuate if
necessary
Less Less Flow -Partial blockage in -Inadequate flow of -Install FIC -Open valve -Regular maintenance 2 2 A
stream (S16) reaction mixture on valve to with FICA of valve controllers
through valve monitor flow
causing less product
54
-Valve is unable to to collect at final -Check for -Regular monitoring of
open properly stage blockages FIC and checking for
and remove blockages
More More Flow -Valve is unable to -Too much reaction -Install FIC -Close valve -Regular maintenance 2 1 A
close enough to mixture passes on valve to with FIC of valve controls
regulate flow through the valves monitor flow
causing overheating
-Raise -Regular checking of

-Install TICA temperature temperature in reactor
in reactor with TICA
Temperature Less Lower -Reactor -Flow of mixture -Install TIC -Raise -Regular checking of 2 1 A
Temperature temperature is too becomes lower hence and in both temperature TIC in both streams
low resulting in low the amount of valve and of stream and reactor
input stream product collected reactor and reactor
temperature decreases. using TIC
-Regular checking of
-Install FIC FIC
in output -Raise flow
stream (S17) rate using
FIC
More Higher -Temperature of -May cause -Install TIC -Lower -Regular checking of 2 3 B
Temperature output reactor overheating and in valve temperature temperature in both
stream is too high potential explosion in valve valve and reactor
using TIC
-Install TICA
-Corrosion of pipes in pipes -Regular maintenance
and reactor -Lower of pipes and reactor,
temperature replace when
in reactor
55
using TICA necessary
and
shutdown
and
evacuate if
necessary
Pressure Less Lower -Valve opens too -Flow of stream is not -Install PIC -Close valve -Regular checking of 2 3 B
Pressure much high enough and in output proper valve controls and PIC
unintentionally hence not enough stream (S17) amount
product goes into
distillation column,
less product forms -Regular checking of
-Install FIC -Increase FIC
in output pressure of
stream (S17) stream
More Higher -Valve closes too -Flow of stream is too -Install PIC -Open valve -Regular checking of 2 1 A
Pressure much high, pressure into in output to proper valve controls and PIC
unintentionally distillation column is stream (S17) amount
too high
Composition Imbal Lower -Imbalance of -Corrosion of -Check levels -Dilute when -Regular checking of 2 3 B
ance Concentratio chemicals in the pipes/valves of necessary or input chemical
n mixture concentratio add concentrations
n regularly chemicals
when
-Explosion due to necessary
improper chemical
mixture
56
Node: Pump Node No. P1 Stream Outlet: 3
Design Intent: Increase pressure of the respective stream (S1) from 1atm to 1000kPa

Word
Temperature More Higher -Inlet temperature -May affect -Install a -Reduce the -Proper checking up on 3 1 A
temperature of components are pump working TIC on the inlet stream pumps condition before
high lifetime input stream temperature commencing operation
-Affects products -Do frequent -Check the temperature of

quality temperature the inlet stream to the
checks on pump constantly
the pumps
Pressure More High -Too much -May have -Install PIC -Decrease -Check pump pressure 3 2 B
pressure material injected leakages material constantly
into pump occurring -Install flowrate into
pressure pump -Check the conditions of
-Pump is -Desired relieve valve the pump periodically to
malfunctioning pressure is not -Open ensure safety
-High input obtained pressure
stream pressure -Pumps are relieve valve
easily damaged
-Pump may not

be able to
withstand the
high pressure
generated and
may burst
Less Low output -Pump is -Desired output -Installation -Increase the -Installation of a 3 1 A
pressure malfunctioning pressure is not of PICA & input stream secondary pump
57
met FIC flowrate to
-Pipes may have generate -Proper checking on
leakages -Reverse flow -Installation higher equipment
may occur of a one way pressure
valve. -Proper maintenance on all
-Pump may be -Repair or equipment periodically
damaged replace pump
or pipes that
are damaged
Flow None No flow -Blockages in the -Pump is -Install FICA -Unclog any -Monitor flow inlet to pump 1 1 A
input pipe damaged easily clogged pipes constantly
-No input to -Check pipes condition

pump resulting constantly
in the plant not
able to proceed
desired
operations
Less Less flow -Leakage in pump -Pump is -Install PICA -Replace spoilt -Monitor inlet flow to pump 3 1 A
or pipes damaged or FIC pump or pipes
-Reactants -Less products -Unclog the

accumulate in flow throughout accumulated
pump plant operation reactants in
pump
-Desired
production may
not be achieved
More More flow -Pump not -High pressure -Install PICA -Replace all -Check the pumps 3 2 B
functioning well drop or FIC damaged condition periodically
valves
-Flow control -Check flow control valve
valve is damaged condition constantly
-Use the
secondary
pump
58
prepared (if
any)
59
Design Intent: Increase pressure of the respective stream (S2) from 1atm to 1000kPa

Word
Temperature More Higher -Inlet -May affect -Install a TIC on -Reduce the inlet -Proper checking up 3 1 A
temperature temperature of pump working the input stream stream on pumps condition
components are lifetime temperature before commencing
high -Do frequent operation
-Affects temperature
products checks on the -Check the
quality pumps temperature of the
inlet stream to the
pump constantly
Pressure More High -Too much -May have -Install PIC -Decrease -Check pump 3 2 B
pressure material injected leakages material flowrate pressure constantly
into pump occurring -Install pressure into pump
relieve valve -Check the
-Pump is -Desired -Open pressure conditions of the
malfunctioning pressure is not relieve valve pump periodically to
obtained ensure safety
-High input
stream pressure -Pumps are
easily damaged
-Pump may not

be able to
withstand the
high pressure
generated and
may burst
60
Less Low output -Pump is -Desired output -Installation of -Increase the -Installation of a 3 1 A
pressure malfunctioning pressure is not PICA & FIC input stream secondary pump
met flowrate to
-Pipes may have -Installation of a generate higher -Proper checking on
leakages -Reverse flow one way valve. pressure equipment
may occur
-Repair or -Proper
-Pump may be replace pump or maintenance on all
damaged pipes that are equipment
damaged periodically
Flow None No flow -Blockages in the -Pump is -Install FICA -Unclog any -Monitor flow inlet 1 1 A
input pipe damaged easily clogged pipes to pump constantly
-No input to -Check pipes

pump resulting condition constantly
in the plant not
able to proceed
desired
operations
Less Less flow -Leakage in pump -Pump is -Install PICA or -Replace spoilt -Monitor inlet flow 3 1 A
or pipes damaged FIC pump or pipes to pump

pump
-Desired
production may
not be achieved
More More flow -Pump not -High pressure -Install PICA or -Replace all -Check the pumps 3 2 B
functioning well drop FIC damaged valves condition
periodically
-Flow control -Use the
valve is damaged secondary pump -Check flow control
prepared (if any) valve condition
constantly
61
Design Intent: Increase pressure of the respective stream

Word
Temperature More Higher -Inlet temperature -May affect -Install a TIC -Reduce the -Proper checking up on 3 1 A
temperature of components are pump working on the input inlet stream pumps condition before
high lifetime stream temperature commencing operation
-Heat exchanger -Affects -Do frequent -Reduce -Check the temperature of

(H12) heated the products temperature heating duty the inlet stream to the
materials to a quality checks on the of heat pump constantly
higher temperature pumps before exchanger
than desired -May affect the operation (H12) -Monitor heat exchanger
mixing of (H12) output flow (S47)
materials in the temperature constantly
mixer (E1)
Pressure More High -Too much material -May have -Install PIC -Decrease -Check pump pressure 3 2 B
pressure injected into pump leakages material constantly
occurring -Install flowrate into
-Pump is pressure pump -Check the conditions of
malfunctioning -Desired relieve valve the pump periodically to
pressure is not -Open ensure safety
-High input stream obtained pressure
pressure relieve valve
-Pumps are
easily damaged
62
-Pump may not
be able to
withstand the
high pressure
generated and
may burst
pressure malfunctioning pressure is not of PICA & FIC input stream secondary pump
met flowrate to
-Pipes may have -Installation generate -Proper checking on
leakages -Reverse flow of a one way higher equipment
may occur valve. pressure
-Proper maintenance on all
-Pump may be -Repair or equipment periodically
damaged replace pump
or pipes that
are damaged
Flow None No flow -Blockages in the -Pump is -Install FICA -Unclog any -Monitor flow inlet to 1 1 A
input pipe damaged easily clogged pipes pump constantly

in the plant not
able to proceed
desired
operations
Less Less flow -Leakage in pump -Pump is -Install PICA -Replace -Monitor inlet flow to 3 1 A
or pipes damaged or FIC spoilt pump or pump
pipes
-Reactants -Less products
accumulate in flow throughout -Unclog the
pump plant operation accumulated
reactants in
-Desired pump
production may
not be achieved
63
functioning well drop or FIC damaged condition periodically
valves
-Flow control valve -Check flow control valve
is damaged -Use the condition constantly
secondary
pump
prepared (if
any)
64
HAZOP Team: Group 6 Meeting Date: 13 March 2018 Stream Inlet: 21

Word
Temperature More Higher -Inlet -May affect -Install a TIC -Reduce the inlet -Proper checking up 3 1 A
temperature temperature of pump working on the input stream on pumps condition
components are lifetime stream temperature before commencing
high operation
-Affects -Do frequent
products temperature -Check the
quality checks on the temperature of the
pumps inlet stream to the
pump constantly
pressure material injected leakages material flowrate constantly
into pump occurring -Install into pump
pressure -Check the conditions
-Pump is -Desired relieve valve -Open pressure of the pump
malfunctioning pressure is not relieve valve periodically to ensure
obtained safety
-Decanter (E5) -Pumps are
not functioning as easily damaged -Ensure decanter
expected output flow (S21) is
-Pump may not according to desired
-High input be able to conditions before
stream pressure withstand the entering pump
high pressure
65
generated and
may burst
met flowrate to
-Pipes may have -Installation of generate higher -Proper checking on
leakages -Reverse flow a one-way pressure equipment
may occur valve.
-Decanter (E5) -Repair or -Proper maintenance
before the pump -Pump may be replace pump or on all equipment
is malfunctioning damaged pipes that are periodically
damaged
-Ensure decanter is
working properly
before allowing the
output to flow to the
pump

in the plant not
able to proceed
desired
operations
Less Less flow -Leakage in pump -Pump is -Install PICA or -Replace spoilt -Monitor inlet flow to 3 1 A
or pipes damaged FIC pump or pipes pump

pump
-Desired
production may
not be achieved
66
functioning well drop FIC damaged valves condition periodically
-Flow control -Use the -Check flow control

valve is damaged secondary pump valve condition
prepared (if any) constantly
67

Word
Temperature Low Lower -Inlet temperature -May affect -Install a TIC -Increase the -Proper checking up on 3 1 A
temperature of components are pump working on the input inlet stream pumps condition before
low lifetime stream temperature by commencing operation
adjusting the
-Condenser (H7) -Affects -Do frequent condenser (H7) -Check the temperature
not functioning as products temperature accordingly of the inlet stream to
expected quality checks on the the pump constantly
pumps
pressure material injected leakages material flowrate constantly
into pump occurring -Install into pump
pressure -Check the conditions of
-Pump is -Desired relieve valve -Open pressure the pump periodically to
malfunctioning pressure is not relieve valve ensure safety
obtained
-High input stream
pressure -Pumps are
easily damaged
-Pump may not

be able to
withstand the
high pressure
generated and
may burst
pressure malfunctioning pressure is not of PICA & FIC input stream secondary pump
68
met flowrate to
-Pipes may have -Installation generate higher -Proper checking on
leakages -Reverse flow of a one way pressure equipment
may occur valve.
-Repair or -Proper maintenance on
-Pump may be replace pump or all equipment
damaged pipes that are periodically
damaged
-Reflux drum (E8) -No input to -Replace reflux -Check pipes condition
not functioning pump resulting drum (E8) or constantly
properly resulting in the plant not stop operation
in inlet stream to able to proceed -Monitor equipment
pump (S30) being desired constantly
affected operations
Less Less flow -Leakage in pump -Pump is -Install PICA -Replace spoilt -Monitor inlet flow to 3 1 A
or pipes damaged or FIC pump or pipes pump

pump
-Desired
production may
not be achieved
functioning well drop or FIC damaged valves condition periodically
-Flow control valve -Use the -Check flow control

is damaged secondary pump valve condition
prepared (if any) constantly
69

Word
Temperature Low Lower -Inlet temperature -May affect -Install a TIC on -Increase the -Proper checking up 3 1 A
temperature of components are pump working the input stream inlet stream on pumps condition
low lifetime temperature by before commencing
-Do frequent adjusting the operation
-Condenser (H10) -Affects temperature condenser
not functioning as products checks on the (H10) -Check the
expected quality pumps accordingly temperature of the
inlet stream to the
pump constantly
pressure material injected leakages material constantly
into pump occurring -Install pressure flowrate into
relieve valve pump -Check the conditions
-Pump is -Desired of the pump
malfunctioning pressure is not -Open pressure periodically to ensure
obtained relieve valve safety
-High input stream
pressure -Pumps are
easily damaged
-Pump may not

be able to
withstand the
high pressure
generated and
70
may burst
met flowrate to
-Pipes may have -Installation of a generate higher -Proper checking on
leakages -Reverse flow one way valve. pressure equipment
may occur
-Repair or -Proper maintenance
-Pump may be replace pump on all equipment
damaged or pipes that periodically
are damaged
-Reflux drum (E11) -No input to -Replace reflux -Check pipes condition
not functioning pump resulting drum (E11) or constantly
properly resulting in the plant not stop operation
in inlet stream to able to proceed -Monitor equipment
pump (S30) being desired constantly
affected operations
Less Less flow -Leakage in pump -Pump is -Install PICA or -Replace spoilt -Monitor inlet flow to 3 1 A
or pipes damaged FIC pump or pipes pump

pump
-Desired
production may
not be achieved
functioning well drop FIC damaged condition periodically
valves
-Flow control valve -Check flow control
71
is damaged -Use the valve condition
secondary constantly
pump prepared
(if any)
72

Word
Temperature More Higher -Inlet temperature -May affect -Install a TIC on -Reduce the -Proper checking up 3 1 A
temperature of components are pump working the input stream inlet stream on pumps condition
high lifetime temperature before commencing
-Do frequent operation
-Heat exchanger -Affects temperature -Reduce
(H11) heated the products checks on the heating duty -Check the
materials to a quality pumps before of heat temperature of the
higher temperature operation exchanger inlet stream to the
than desired (H11) pump constantly
-Monitor heat
exchanger (H11)
output flow (S44)
temperature
constantly
Pressure More High -Too much material -May have -Install PIC -Decrease -Check pump pressure 3 2 B
pressure injected into pump leakages material constantly
occurring -Install pressure flowrate into
-Pump is relieve valve pump -Check the conditions
malfunctioning -Desired of the pump
pressure is not -Open periodically to ensure
-High input stream obtained pressure safety
pressure relieve valve
-Pumps are
easily damaged
73
-Pump may not
be able to
withstand the
high pressure
generated and
may burst
Less Low output -Pump is -Desired output -Installation of -Increase -Installation of a 3 1 A
pressure malfunctioning pressure is not PICA & FIC the input secondary pump
met stream
-Pipes may have -Installation of a flowrate to -Proper checking on
leakages -Reverse flow one way valve. generate equipment
may occur higher
pressure -Proper maintenance
-Pump may be on all equipment
damaged -Repair or periodically
replace
pump or
pipes that
are damaged
input pipe damaged easily clogged pump constantly
pipes
in the plant not
able to proceed
desired
operations
Less Less flow -Leakage in pump -Pump is -Install PICA or -Replace -Monitor inlet flow to 3 1 A
or pipes damaged FIC spoilt pump pump
or pipes
-Reactants -Less products
accumulate in pump flow throughout -Unclog the
plant operation accumulated
reactants in
-Desired pump
74
production may
not be achieved
functioning well drop FIC damaged condition periodically
valves
-Flow control valve -Check flow control
is damaged -Use the valve condition
secondary constantly
pump
prepared (if
any)
75
Node: Heat Exchanger (Heater) Node No. H1 Stream Outlet: S7
Design Intent: Feed contains toluene, hydrogen peroxide, water, benzaldehyde, benzoic acid and benzyl alcohol. The incoming feed is heated to 463K to
prepare the operating temperature of the reactor afterwards. Shell and tube heat exchanger is used.

word
Duty Less Less heating -Low flow rate of -Process -Installation -Increase the -Proper checking up 2 1 A
duty heating steam stream lacks of temperature flow rate of on heat exchanger
required heat. Indicator heating condition before
Controller (TIC) stream commencing
in the operation
-Input temperature -Reaction heat -Increase
of the heating steam inhibited due to exchanger heating duty -Check the flow rate
too low operating output by increasing of the inlet stream to
temperature not stream to stream flow the heat exchanger
achieved maintain rate constantly
utility stream
76
-Heat transfer flow rate
efficiency of the heat -Side reaction -Regular
exchanger is too low may occur in maintenance and
due to factors like reactor due to checkup of
fouling. shift of chemical equipment and pipe
equilibrium
-Design oversized
heat exchanger to
reduce fouling effect
Temperature Less Less outlet -Too little heating -Reaction -Installation -Increase -Proper checking up 3 1 A
temperature duty inhibited due to of temperature heating duty on heat exchanger
operating indicator (TI) in by increasing condition before
temperature not the outlet and steam flow commencing
achieved flow indicator rate operation
controller (FIC)
-Low inlet -Side reaction for the stream -Check the
temperature may occur in carrying the temperature of the
reactor due to heated inlet stream to the
shift of chemical stream. heat exchanger
equilibrium constantly
-Design oversized
heat exchanger to
More More outlet -Too much heating -Energy wastage -Installation -Reduce -Proper checking up 2 2 A
temperature duty of temperature heating duty on heat exchanger
-High inlet indicator (TI) in by reducing condition before
temperature outlet and steam flow commencing
FIC for rate operation
stream
carrying the -Check the
heated steam temperature of the
inlet stream to the
77
heat exchanger
constantly
Shell or tube -Process stream inlet -Potential -Installation of -Decrease -Install heat 3 1 A
side operating temperature above equipment temperature process exchanger with
temperature set point damage/failure indicator control stream inlet higher design
above (TIC) for input flow rate temperature
equipment -Utility stream inlet streams. acceptance.
design value temperature above -Decrease
set point steam flow
rate
Pressure Less Low -Inlet pressure of the -Lower heat -Installation of -Increase -Have secondary 3 1 A
Pressure process stream is transfer efficiency pressure pressure to pumps as backup
lower than the set indicator (PI) required
pressure profile amount -Constant
-Pipe leakage maintenance on
-Check if pipe pipeline
has any
leakage and
fix it
immediately
More High pressure -Inlet pressure of the -Potential -Installation of -Monitor and -Install pressure 2 3 B
process stream is equipment pressure perform relieve valves (PRV)
higher than the set damage/failure indicator control bypass to that can help to
pressure profile. (PIC) in tube relief pressure remove excess
-Undesired side and shell in the stream pressure
pressure at outlet side streams
stream
-Installation of
pressure relief
bypass stream
for input streams
Flow None No tube side -Valve is closed -Energy wastage -Installation of -Make sure -Installation of 1 1 A
process flow indicator the valve is backup heat
stream flow -Pipe is ruptured or -Heat exchanger control alarm open exchanger for
78
blocked may overheat (FICA) emergency
-Check and
-No supply of feed repair
(toluene, hydrogen immediately
peroxide) the ruptured
pipe
No shell side -Valve is closed -Process stream is -Installation of -Make sure -Constant checking of 1 1 A
heating steam not heated flow indicator the valve is the pipelines and
flow -Pipe is ruptured or control alarm open their conditions
blocked -Process stream (FICA)
-No supply of does not meet -Check and -Constant checking
water/Water pump is temperature -Regular repair the on the functions of
malfunction requirement maintenance and ruptured pipe the pumps and their
reaction in reactor checkup of conditions
is hindered equipment and
pipe
Less Less tube side -Valve malfunction -Lower heat -Installation of -Perform -Installation of 3 1 A
process transfer flow indicator checkup on backup heat
stream flow -Pipe is partially control alarm valve and exchanger for
blocked or ruptured (FICA) pipe, then emergency
-Overheating may repair
occur -Regular immediately if
maintenance and the equipment
checkup of is found faulty
equipment and
pipe
Less shell side -Pipe is partially -Lower heat -Installation of -Check -Constant checking of 3 1 A
heating steam blocked or ruptured transfer flow indicator leakage and the pipelines and
flow control alarm take their conditions
(FICA) corrective
-Shell side leakage measures -Constant checking
-Regular on the functions of
maintenance and the pumps and their
checkup of
equipment and
pipe
79
More High tube side -Valve -High pressure -Installation of -Decrease -Control valves must 3 1 A
process malfunction drop in tube side flow indicator inlet flow rate be constantly tested
stream flow control alarm of process
-High inlet process -Lower outlet (FICA) stream -Pump must be
stream flow rate temperature of monitored at all
process stream -Regular -Perform times
maintenance and checkup on
checkup of valve and
equipment and repair
pipe immediately if
found faulty
Higher shell -High flow rate of -High pressure -Installation of -Decrease -Control valves must 2 2 A
side heating heating steam drop in shell side flow indicator inlet flow rate be constantly tested
steam flow control alarm of heating
-Valve malfunction -Higher outlet (FICA) steam -Pump must be
temperature of monitored at all
process stream -Regular -Perform times
maintenance and checkup on
pipe immediately if
found faulty
80
Node: Heat Exchanger (Cooler) Node No. H2 Stream Outlet: S9
Design Intent: Feed contains steam. The incoming feed is cooled from 373.15K to 273.15K. With the help of throttling valve, saturated vapor
is able to cooled to saturated liquid. The cooled liquid is then used to absorb heat from the exothermic reaction in the reactor.

word
Duty Less Less cooling -Low flow rate of -Process -Installation -Increase the -Proper checking 2 1 A
duty coolant stream of temperature flow rate of up on heat
overheats/is not Indicator coolant exchanger
cooled enough Controller (TIC) stream condition before
-Input temperature in the -Check and commencing
of the coolant steam heat repair operation
too high exchanger equipment
output -Check the flow
-Reaction stream to rate of the inlet
81
-Heat transfer inhibited due to maintain stream to the heat
efficiency of the heat operating utility stream exchanger
exchanger is too low temperature not flow rate constantly
due to factors like achieved
fouling. -Regular
maintenance -Regular
-Side reaction and checkup of maintenance and
may occur in equipment and checkup of
reactor due to pipe equipment and pipe
shift of chemical
equilibrium -Design oversized
heat exchanger to
reduce fouling
effect
Temperature Less Less outlet -Coolant flowrate too -Reaction -Installation -Decrease -Proper checking 3 1 A
temperatur high inhibited due to of temperature flow rate of up on heat
e operating indicator (TI) in coolant exchanger
temperature not the outlet condition before
achieved commencing
-Installation of operation
-Process stream inlet flow indicator
temperature below -Side reaction controller (FIC) -Check the
set point may occur in for the stream temperature of the
reactor due to carrying the inlet stream to the
shift of chemical coolant. heat exchanger
equilibrium constantly
More More outlet -Process stream inlet -Product unable -Installation -Increase -Proper checking 2 2 A
temperatur temperature above to cooled to of temperature cooling duty up on heat
e set point desired indicator (TI) in by increasing exchanger
82
-Coolant temperature outlet and coolant flow condition before
temperature above FIC for rate commencing
set point -Equipment stream operation
-Heat transfer damage/failure carrying the
efficiency lower due heated steam -Check the
to factors such as temperature of the
fouling inlet stream to the
heat exchanger
constantly
-Design oversized
heat exchanger to
reduce fouling
effect
Shell or tube -Process stream inlet -Product unable -Installation of -Increase -Install heat 2 2 A
side temperature above to cooled to temperature coolant flow exchanger with
operating set point desired indicator rate higher design
temperature temperature control (TIC) temperature
above
-Coolant stream inlet for input -Reduce the acceptance.
equipment
design value temperature above streams. temperature
set point -Potential of process
equipment stream or
damage/failure coolant
Pressure Less Low -Inlet pressure of -Lower heat -Installation of -Increase -Have secondary 3 1 A
Pressure the process stream transfer pressure pressure to pumps as backup
is lower than the set efficiency indicator (PI) required
pressure profile amount -Constant
-Pipe leakage maintenance on
-Check if pipeline
pipe has any
83
leakage
More High -Inlet pressure of -Potential -Installation of -Monitor and -Install pressure 2 3 B
pressure the process stream equipment pressure perform relieve valves
is higher than the damage/failure indicator bypass to (PRV) that can help
set pressure profile. control (PIC) in relief to remove excess
-Undesired tube side and pressure in pressure
pressure at shell side the stream
outlet stream streams
-Installation of
pressure relief
bypass stream
for input
streams
Flow None No tube -Valve is closed -Energy -Installation of -Make sure -Installation of 1 1 A
side wastage flow indicator the valve is backup heat
process -Pipe is ruptured or control alarm open exchanger for
stream flow blocked (FICA) emergency
-No supply of feed -Check and
(water) repair
immediately
if the pipe is
ruptured
No shell -Valve is closed -Process stream -Installation of -Make sure -Constant checking 1 1 A
side coolant not cooled to flow indicator the valve is of the pipelines and
flow -Pipe is ruptured or desired control alarm open their conditions
blocked temperature (FICA)
-No supply of -Check and -Constant checking
coolant -Process stream -Regular repair the on the functions of
does not meet maintenance ruptured the pumps and
84
temperature and checkup of pipe their conditions
requirement of equipment and
reactor. pipe
Reaction is
hindered.
Less Less tube -Valve malfunction -Lower heat -Installation of -Perform -Installation of 3 1 A
side transfer flow indicator checkup on backup heat
process -Pipe is partially control alarm valve and exchanger for
stream flow blocked or ruptured (FICA) pipe, then emergency
-Process stream repair
not cooled to -Regular immediately
desired maintenance if the
temperature and checkup of equipment is
equipment and found faulty
pipe
Less shell -Pipe is partially -Lower heat -Installation of -Check -Constant checking 3 1 A
side coolant blocked or ruptured transfer flow indicator leakage and of the pipelines and
flow control alarm take their conditions
-Process stream (FICA) corrective
-Shell side leakage not cooled to measures -Constant checking
desired -Regular on the functions of
temperature maintenance the pumps and
and checkup of their
equipment and
pipe
More High tube -Valve -High pressure -Installation of -Decrease -Control valves 3 1 A
side malfunction drop in tube flow indicator inlet flow must be constantly
process side control alarm rate of tested
stream flow -High inlet process (FICA) process
stream flow rate -Higher outlet stream -Pump must be
temperature of -Regular monitored at all
process stream maintenance -Perform times
85
and checkup of checkup on
equipment and valve and
pipe repair
immediately
if found
faulty
Higher shell -High flow rate of -High pressure -Installation of -Decrease -Control valves 2 2 A
side coolant coolant inlet drop in shell flow indicator inlet flow must be constantly
flow side control alarm rate of tested
-Valve malfunction (FICA) heating
-Process stream steam -Pump must be
is cooled to -Regular monitored at all
below desired maintenance -Perform times
temperature and checkup of checkup on
pipe repair
immediately
if found
faulty
86
Node: Heat Exchanger (Cooler) Node No. H3 Stream Outlet: S16
Design Intent: Feed is obtained from bottom stream of the flash drum. The feed contained mostly toluene, water, benzaldehyde, benzyl
alcohol and benzoic acid. The incoming feed is cooled from 463K to 343.15K to prepare for the operating temperature of Distillation Column
1.

word
Duty Less Less cooling -Low flow rate -Process -Installation -Increase the -Proper checking up 2 1 A
duty of coolant stream of temperature flow rate of on heat exchanger
overheats/is not Indicator coolant condition before
cooled enough Controller (TIC) in stream commencing
the operation
-Input heat -Check and
temperature of exchanger repair -Check the flow rate
the coolant output equipment of the inlet stream to
steam too high stream to the heat exchanger
maintain constantly
utility stream
-Heat transfer flow rate
efficiency of -Regular
the heat -Regular maintenance and
exchanger is maintenance and checkup of
too low due to checkup of equipment and pipe
factors like equipment and
fouling. pipe -Design oversized
heat exchanger to
87
Temperature Less Less outlet -Coolant Lower efficiency -Installation -Decrease -Proper checking up 3 1 A
temperature flowrate too of separating at of temperature flow rate of on heat exchanger
high the distillation indicator (TI) in coolant condition before
column the outlet commencing
afterwards. operation
-Process -Installation of
stream inlet flow indicator -Check the
temperature controller (FIC) temperature of the
below set for the stream inlet stream to the
point carrying the heat exchanger
coolant. constantly
More More outlet -Process -Product unable -Installation -Increase -Proper checking up 2 2 A
temperature stream inlet to cooled to of temperature cooling duty on heat exchanger
temperature desired indicator (TI) in by increasing condition before
above set temperature outlet and coolant flow commencing
point FIC for rate operation
-Coolant -Equipment stream
temperature damage/failure carrying the -Check the
above set heated steam temperature of the
point inlet stream to the
88
-Heat transfer heat exchanger
efficiency constantly
lower due to
factors such as -Design oversized
fouling heat exchanger to
Shell or tube -Process -Product unable -Installation of -Increase -Install heat 2 2 A
side operating stream inlet to cooled to temperature coolant flow exchanger with
temperature temperature desired indicator control rate higher design
above above set temperature (TIC) for input temperature
equipment
point streams. -Reduce the acceptance.
design value
temperature
-Coolant -Potential of process
stream inlet equipment stream or
temperature damage/failure coolant
above set
point
Pressure Less Low -Inlet pressure -Lower heat -Installation of -Increase -Have secondary 3 1 A
Pressure of the process transfer pressure indicator pressure to pumps as backup
stream is efficiency (PI) required
lower than the amount -Constant
set pressure maintenance on
profile -Check if pipeline
-Pipe leakage pipe has any
leakage
More High -Inlet pressure -Potential -Installation of -Monitor and -Install pressure 2 3 B
pressure of the process equipment pressure indicator perform relieve valves (PRV)
stream is damage/failure control (PIC) in bypass to that can help to
higher than tube side and relief remove excess
the set -Undesired shell side streams pressure in pressure
89
pressure pressure at the stream
profile. outlet stream -Installation of
pressure relief
bypass stream for
input streams
Flow None No tube side -Valve is -Energy wastage -Installation of -Make sure -Installation of 1 1 A
process closed flow indicator the valve is backup heat
stream flow control alarm open exchanger for
-Pipe is (FICA) emergency
ruptured or -Check and
blocked repair
-No supply of immediately
feed (water) if the pipe is
ruptured
No shell side -Valve is -Process stream -Installation of -Make sure -Constant checking 1 1 A
coolant flow closed not cooled to flow indicator the valve is of the pipelines and
desired control alarm open their conditions
-Pipe is temperature (FICA)
ruptured or -Check and -Constant checking
blocked -Process stream -Regular repair the on the functions of
-No supply of does not meet maintenance and ruptured pipe the pumps and their
coolant temperature checkup of conditions
requirement of equipment and
Distillation pipe
Column 1.
Separating
efficiency is
lower.
Less Less tube -Valve -Lower heat -Installation of -Perform -Installation of 3 1 A
side process malfunction transfer flow indicator checkup on backup heat
stream flow control alarm valve and exchanger for
-Pipe is (FICA) pipe, then emergency
90
partially -Process stream repair
blocked or not cooled to -Regular immediately
ruptured desired maintenance and if the
temperature checkup of equipment is
pipe
Less shell -Pipe is -Lower heat -Installation of -Check -Constant checking 3 1 A

side coolant partially transfer flow indicator leakage and of the pipelines and
flow blocked or control alarm take their conditions
ruptured -Process stream (FICA) corrective
not cooled to measures -Constant checking
desired -Regular on the functions of
-Shell side temperature maintenance and the pumps and their
leakage checkup of
equipment and
pipe
More High tube -Valve -High pressure -Installation of -Decrease -Control valves must 3 1 A
side process malfunction drop in tube side flow indicator inlet flow be constantly tested
stream flow control alarm rate of
-High inlet -Higher outlet (FICA) process -Pump must be
process temperature of stream monitored at all
stream flow process stream -Regular times
rate maintenance and -Perform
checkup of checkup on
pipe repair
immediately
if found
faulty
Higher shell -High flow rate -High pressure -Installation of -Decrease -Control valves must 2 2 A
side coolant of coolant inlet drop in shell side flow indicator inlet flow be constantly tested
flow control alarm rate of
91
-Valve -Process stream (FICA) heating -Pump must be
malfunction is cooled to steam monitored at all
below desired -Regular -Perform times
temperature maintenance and checkup on
pipe immediately
if found
faulty
92
HAZOP team: Group 6 Meeting date: 10th of March 2018 Stream inlet: S26
Node: Heat Exchanger (Heater) Node no:H6 Stream outlet: S27
Design intent: H6 is a heat exchanger which is used to increase the temperature of the mixtures in S26 from 95°C to 135°C. 135°C is the temperature
required for the distillation column (E7) to operate.

word
Temperature Less Low Reboiler,H5 The mixtures Installation -Increase the Regular maintenance 2 1 A
temperature at malfunction are unable to be of TIC at heating duty by on the heat exchanger
the inlet heated to the both the increasing the to prevent fouling
stream, S26 desired inlet and flow rate of
Low -Fouling temperature, outlet heated steam
temperature at 135°C which is stream
the outlet -Less heating the operating
stream, S27 duty conditions for
the distillation
column
More High Reboiler, H5 - The mixtures Installation -Immediately -Regular maintenance
temperature at malfunction are unable to be of TIC and stops the flow of of the heat exchanger 2 2 A
the inlet heated to the TIA at both feed stream if the to prevent fouling
stream, S26 desired the inlet and temperature is
High -Too much temperature, outlet above the set -Install a flow control
temperature at heating duty 135°C which is stream point valve at the outlet
the outlet the operating stream
stream, S27 -Fouling conditions for -Reduce the flow
the distillation rate of heated
column steam
93
-Energy
wastage
-High
temperature will
cause thermal
expansion
which may
damage the
distillation
column
Pressure Less Low pressure at -Leakage in the -Composition of Installation Repair the piping -Regular maintenance 1 1 A
the inlet piping system the mixtures of PIC at system once the of the piping system
stream, S26 may varies both the leakage is
Low pressure at inlet and identified -Monitor the pressure
the outlet -Heat transfer is outlet indicator constantly
stream, S27 inefficient stream
More High pressure -Feed stream -Composition of -Installation -Repair the piping -Regular maintenance 2 3 B
at the inlet entering at the mixtures of PIC and system once the of the piping system
stream, S26 higher pressure may varies PIA at both blockage is
than the set the inlet and identified -Monitor the pressure
point -High pressure outlet indicator constantly
may cause stream -Stop the flow
-Blockage in explosion and rate of feed
the piping damage the -Installation stream to prevent
system piping system of bypass pressure from
stream for building up
-Distillation pressure
column may be relief -Monitor and
damaged due to purpose perform bypass to
high pressure relief pressure in
the stream
Flow None No flow of the -Flow control -Wastage of Installation -Inspect the valve -Regular maintenance 2 1 A
inlet stream valve is closed energy and of FIC at the to make sure its of the piping system
utility inlet stream functionality
94
-Ruptured -Monitor the flow
piping -Repair the piping indicator constantly
-Open the valve

Less Less flow rate -Leakage -Incomplete Installation -Inspect and -Regular maintenance 2 1 A
at the inlet /blockage in the and inefficient of FIC at the repair the valve if of the piping system
stream piping system heat transfer inlet stream it is not
functioning -Monitor the flow
-Valve failure -Composition of indicator constantly
the top and -Repair the piping
bottom product system once the
may varies leakage
/blockage is
identified
More Higher flow rate -Flow control -Higher Installation -Inspect and -Regular maintenance 2 1 A
at the inlet valve pressure drop of FIC at the repair the valve if of the valve to ensure
stream malfunction which may inlet stream it is not its functionality
cause damage functioning
to the piping -Monitor the flow
system indicator constantly
95
HAZOP team: Group 6 Meeting Date: 10th of March Stream Inlet: S35
2018
Design Intent: Use to increase the temperature from 160oC to 167oC and steam mixture flowing into the next distillation column, E10.

word
Duty Less Less -Low flowrate -process stream -Installation of TIC in -Increase the -Clean the 2 2 A
heating from the reboiler lacks required the heat exchanger flowrate of the equipment regularly
duty of distillation heat output stream to heating stream
column maintain utility steam
-Gasifier operation -Increase
flowrate
-Input failure. heating duty by
temperature of increasing
heating steam is steam flowrate
too low
-Heat transfer is
altered due to
fouling
Temperature Less Less outlet -Moisture content -The gas -Installation of TI in -Increase -Clean the heat 3 1 A
temperatur in the inlet stream conversion rate outlet stream and FIC heating duty by exchanger regularly
e higher than set faces hindrance for stream carrying increasing to avoid fouling
standards the heated steam steam flowrate
-Low inlet
temperature
More More outlet -High heating duty -Waste of energy -Installation of TI in -Reduce -Make sure the 2 2 A
96
temperatur -High inlet outlet and FIC for heating duty by safeguard well
e temperature stream carrying the reducing steam function
heated steam flowrate
Temperatur -Process stream -Potential damage -Installation of TIC -Decrease inlet -Install heat 3 1 A
e above the inlet temperature caused to for input streams stream exchanger with
temperatur higher than set equipment due to flowrate higher design
e point thermal temperature
profile of expansion. -Monitor
acceptance.
the design -Heater control controls
failure -Potential regularly.
leakages and
ruptures in the
equipment
Pressure Less Low -Inlet pressure of -Heat transfer in -Installation of PI -Increase -Monitor the 3 1 A
pressure the process the heater is pressure to pressure indicator
stream is lower significantly lower required regularly
than set pressure amount
profile
More High -Inlet pressure of -Potential damage -Installation of PIC in -Monitor and -Install heat 2 3 B
pressure the process caused to the tube side and shell perform bypass exchangers with
stream is higher equipment side streams to relief higher design
than the set pressure in the pressure acceptance
pressure profile -Installation of stream
pressure relief bypass
streams for input
streams
Flow None No tube -Valve is closed -Energy wastage -Installation of FICA -Make sure the -Installing of an 1 1 A
side valve is open extra heat
-Pipe ruptured
process exchanger for
-Repair the
steam flow emergency
ruptured piping
97
No heating -Valve is closed -Reaction in the -Installation of FICA -Make sure the -Regular 1 1 A
steam flow gasifier faces valve is opened maintenance of the
-Pipe ruptured
hindrance pipe
-Repair the
ruptured piping
Less Less flow -Valve failure -Lower heat -Installation of FICA -Monitor valves -Regular 3 1 A
transfer and maintain it maintenance of the
-Piping leakage
pipe and valve
-Valve malfunction -Check valve
and take
corrective
measures
More Higher -Valve failure -High pressure -Installation of FICA -Monitor valves -Regular 3 1 A
flowrate drop and maintain it maintenance of the
-High inlet valve
flowrate -Causes damage -Decrease inlet
of pipe flow
-Lower outlet
temperature
Higher shell -Malfunctioning of -Higher pressure -Installation of FICA -Monitor valves -Regular 2 2 A
side valve drop and maintain it maintenance of the
flowrate valve
-High shell inlet -Increases erosion -Decrease inlet
flowrate -Higher outlet flow
temperature
98
Design Intent: Feed from the top stream of flash drum. Containing mainly toluene, hydrogen peroxide and water. The incoming feed is
heated to 463K to prepare the operating temperature of the reactor afterwards. Shell and tube heat exchanger is used.

word
Duty Less Less heating -Low flow rate -Process -Installation -Increase the -Proper checking 2 1 A
duty of heating stream lacks of temperature flow rate of up on heat
steam required heat. Indicator heating exchanger
Controller (TIC) stream condition before
in the commencing
-Input heat -Increase operation
temperature exchanger heating duty
of the heating -Reaction output by increasing -Check the flow
steam too low inhibited due to stream to stream flow rate of the inlet
operating maintain rate stream to the heat
temperature not utility stream exchanger
-Heat transfer achieved flow rate constantly
efficiency of
the heat -Regular
exchanger is -Side reaction maintenance -Regular
too low due to may occur in and checkup of maintenance and
factors like reactor due to equipment and checkup of
fouling. shift of chemical pipe equipment and pipe
equilibrium
-Design oversized
heat exchanger to
reduce fouling
99
effect
Temperature Less Less outlet -Too little -Reaction -Installation -Increase -Proper checking 3 1 A
temperature heating duty inhibited due to of temperature heating duty up on heat
operating indicator (TI) in by increasing exchanger
temperature not the outlet and steam flow condition before
achieved flow indicator rate commencing
controller (FIC) operation
-Low inlet -Side reaction for the stream
temperature may occur in carrying the -Check the
reactor due to heated temperature of the
shift of chemical stream. inlet stream to the
equilibrium heat exchanger
constantly
-Design oversized
heat exchanger to
reduce fouling
effect
More More outlet -Too much -Energy wastage -Installation -Reduce -Proper checking 2 2 A
temperature heating duty of temperature heating duty up on heat
-High inlet indicator (TI) in by reducing exchanger
temperature outlet and steam flow condition before
FIC for rate commencing
100
stream operation
carrying the
heated steam -Check the
temperature of the
inlet stream to the
heat exchanger
constantly
Shell or tube -Process -Potential -Installation of -Decrease -Install heat 3 1 A

side operating stream inlet equipment temperature process exchanger with
temperature temperature damage/failure indicator stream inlet higher design
above above set control (TIC) flow rate temperature
equipment
point for input acceptance.
design value
streams. -Decrease
-Utility stream steam flow
inlet rate
temperature
above set
point
Pressure Less Low -Inlet -Lower heat -Installation of -Increase -Have secondary 3 1 A
Pressure pressure of transfer efficiency pressure pressure to pumps as backup
the process indicator (PI) required
stream is amount -Constant
lower than the maintenance on
set pressure -Check if pipeline
profile pipe has any
-Pipe leakage leakage
More High -Inlet -Potential -Installation of -Monitor and -Install pressure 2 3 B

pressure pressure of equipment pressure perform relieve valves
the process damage/failure indicator bypass to (PRV) that can help
stream is control (PIC) in relief to remove excess
101
higher than -Undesired tube side and pressure in pressure
the set pressure at outlet shell side the stream
pressure stream streams
profile.
-Installation of
pressure relief
bypass stream
for input
streams
Flow None No tube side -Valve is -Energy wastage -Installation of -Make sure -Installation of 1 1 A
process closed flow indicator the valve is backup heat
stream flow -Heat exchanger control alarm open exchanger for
-Pipe is may overheat (FICA) emergency
ruptured or -Check and
blocked repair
-No supply of immediately
feed (toluene, the ruptured
hydrogen pipe
peroxide)
No shell side -Valve is -Process stream -Installation of -Make sure -Constant checking 1 1 A
heating closed is not heated flow indicator the valve is of the pipelines and
steam flow control alarm open their conditions
-Pipe is -Process stream (FICA)
ruptured or does not meet -Check and -Constant checking
blocked temperature -Regular repair the on the functions of
-No supply of requirement maintenance ruptured the pumps and
water reaction in and checkup of pipe their conditions
reactor is equipment and
hindered pipe
Less Less tube -Valve -Lower heat -Installation of -Perform -Installation of 3 1 A
side process malfunction transfer flow indicator checkup on backup heat
stream flow control alarm valve and exchanger for
102
-Pipe is (FICA) pipe, then emergency
partially -Overheating repair
blocked or may occur -Regular immediately
ruptured maintenance if the
and checkup of equipment is
pipe
Less shell -Pipe is -Lower heat -Installation of -Check -Constant checking 3 1 A

side heating partially transfer flow indicator leakage and of the pipelines and
steam flow blocked or control alarm take their conditions
ruptured (FICA) corrective
measures -Constant checking
-Regular on the functions of
-Shell side maintenance the pumps and
leakage and checkup of their
equipment and
pipe
More High tube -Valve -High pressure -Installation of -Decrease -Control valves 3 1 A
side process malfunction drop in tube side flow indicator inlet flow must be constantly
stream flow control alarm rate of tested
-High inlet -Lower outlet (FICA) process
process temperature of stream -Pump must be
stream flow process stream -Regular monitored at all
rate maintenance -Perform times
pipe repair
immediately
if found
faulty
103
Higher shell -High flow -High pressure -Installation of -Decrease -Control valves 2 2 A
side heating rate of drop in shell side flow indicator inlet flow must be constantly
steam flow heating steam control alarm rate of tested
-Higher outlet (FICA) heating
-Valve temperature of steam -Pump must be
malfunction process stream -Regular monitored at all
maintenance -Perform times
pipe repair
immediately
if found
faulty
104
6.0 Process Control Diagram for Selected Units
S3
S1
Figure 2: Recommended P&iD Drawings for Pump 1
105
7.0 Materials Safety and Handling Methods
The Hazard Identification and methods of handling each chemical in the process of producing
Benzaldehyde are stated below.
1.0 Benzaldehyde
Hazard Properties Description Handling Method
Combustible Highly combustible in the For small fires use dry chemical
presence of open flames and powder. For large fires, use
sparks. Produces Carbon water spray, fog or foam.
Monoxide and Carbon Dioxide
when combusted.
Corrosive Causes irritation to eyes and Wash for at least 15 minutes.

skin. Apply emollient to skin.
Aspiration Toxicity Hazardous when inhaled and Remove victim from area and
may cause trouble breathing. to fresh air, if troubles persist
Unconsciousness and death or they are unconscious, seek
may occur at high exposure medical advice.
rates.
2.0 Benzyl Alcohol
Combustible Highly combustible when in For small fires use dry chemical
contact with heat, a spark or powder. For large fires, use
an open flame. water spray, fog or foam.

106
rates.
3.0 Toluene
Flammable Flammable in presence of For small fires, use dry

heat, sparks and open flames. chemical powder. For large
Not flammable in presence of fires, use water spray or fog.
shocks.
Corrosive Causes irritation to eyes and Wash for at least 15

skin.
minutes. Apply emollient to
skin.
rates.
4.0 Benzoic Acid
Combustible May be combustible at high For small fires, use dry

temperatures. chemical powder. For large
fires, use water spray or fog.

107
rates.
5.0 Hydrogen Peroxide (30%)

Aspiration Toxicity Liquid or spray mist may Remove victim from area and
produce tissue damage to fresh air, if troubles persist
particularly on mucous or they are unconscious, seek
membranes of eyes, mouth medical advice.
and respiratory tract.
6.0 Hydrogen
Flammable Highly flammable when in Use CO2, dry chemical, water

contact with open flames, spray, or fog.
sparks.
rates.
108
109
8.0 Bow Tie Diagram
110
9.0 Emergency Contact
HOSPITAL
Hospital Shah Alam 0355263000
KPJ Klang Specialist Hospital 0333777888
Columbia Asia Extended Care Hospital 0355417833
Ambulance 112
FIRE DEPARTMENT
Balai Bomba dan Penyelamat Seri 0333734444
Shah Alam
Balai Bomba dan Penyelamat Seri 0333734444

Andalas
POLICE DEPARTMENT
Police Federal 999
HAZOP TEAM
Kong Wei Hern 016-7382949
Hii Min Tiin 014-5930243
Yap Ze Kai 016-4739203
Celina Lim Hui En 012-4839184
Nadia Suraya Crowe 016-3920482
111
10.0 Conclusion
This HAZOP report for our proposed design of benzaldehyde production plant
summarizes all the potential hazards that could arise during the production and
ways to prevent it from happening. Each equipment is carefully analysed and the
relevant hazards were identified along with the causes and consequences with
reasonable assumptions. Safeguards were also suggested to prevent accidents
from happening. An O-D-R (Risk occurrence and Safety Description Rating) was
used to represent how likely an incident will occur and how serious can the
consequences be. The materials used in our production plant are also evaluated
with reference to the MSDS (materials safety data sheet) and the proper
handling methods are suggested. A detailed evacuation plan is also prepared in
case any emergency happened.
This HAZOP report was done after several brainstorming sessions in our group
and aims to foresee every single issue that might arise during the production.
HAZOP is useful but at the same time it also poses a few drawbacks, table
below shows the advantages and some drawback of application of HAZOP.
Advantages Drawbacks
The HAZOP process is a systematic examination. A HAZOP focuses on single events rather than
combinations of possible events.
The team approach to a HAZOP makes it a The HAZOP focus on guide-words allows it to
multidisciplinary study. overlook some hazards
The HAZOP team utilizes operational experience. Training is essential for optimum results,
especially for the facilitator
HAZOP study results are recorded. HAZOPs are typically very time consuming and
thus expensive
For team members the process is easily learned
and performed
A HAZOP does not require considerable technical
expertise for technique formulation.
As a systematic process it provides rigor for
focusing on system elements and hazards.
The HAZOP process is a team effort with many
viewpoints.
Commercial software is available to assist in
HAZOP
112
11.0 Appendix
Back
Back
113
Back
Back
114
Back
Back
115
Back
116
Back
Back to E2
Back to H2
117
Back
Back
118
Back
Back
119
Back
Back
120
Back
Back
121
Back
122
Back
Back
123
Back
Back
124
Back
Back
125
Back
126
12.0 References
American Chemical Society. (2015). Risk Rating & Assessment - American
Chemical Society. [online] Available at:
https://www.acs.org/content/acs/en/about/governance/committees/chemicalsaf
ety/hazard-assessment/fundamentals/risk-assessment.html [Accessed 19 Mar.
2018].
Cholarisk. (2018). HAZOP Study | Hazard Identification and Risk Assessment.

[online] Available at: http://www.cholarisk.com/services/process-safety/qra-
hazop/ [Accessed 14 Mar. 2018].
Controlguru.com. (2018). Distillation: Major Disturbances & First-Level Control –

Control Guru. [online] Available at: https://controlguru.com/distillation-major-
disturbances-first-level-control/ [Accessed 11 Mar. 2018].
Hcheattransfer.com. (2018). heat exchanger fouling. [online] Available at:

http://www.hcheattransfer.com/fouling1.html [Accessed 14 Mar. 2018].
Klimes, M. (2016). Pump failure analysis. [online] Flow Control Network.

Available at: https://www.flowcontrolnetwork.com/pump-failure-analysis/
[Accessed 16 Mar. 2018].
OEM Panels. (n.d.). Pump Control Panel basics • OEM Panels. [online] Available
at: http://www.oempanels.com/pump-control-panel-basics [Accessed 17 Mar.
2018].
Separationprocesses.com. (n.d.). Plant Operations: Operational Difficulties.

[online] Available at:
http://www.separationprocesses.com/Operations/POT_Chp05h.htm [Accessed
15 Mar. 2018].
The national academics of science engineering medicine. (2012). The Use and
Storage of Methyl Isocyanate (MIC) at Bayer CropScience. [online] Available at:
https://doi.org/10.17226/13385 [Accessed 14 March 2018].
This Is What Valve Failure Looks Like (2014). This Is What Valve Failure Looks
Like, and Why You Should Care | PropertyCasualty360. [online]
PropertyCasualty360. Available at:
https://www.propertycasualty360.com/2014/06/25/this-is-what-valve-failure-
looks-like-and-why-you/?slreturn=20180222115559 [Accessed 15 Mar. 2018].
Willey, R. (2014). Layer of Protection Analysis. [online] science direct. Available

at: https://ac.els-cdn.com/S1877705814017263/1-s2.0-S1877705814017263-
main.pdf?_tid=88b75dd0-1f7d-4456-a1c1-
89b0ecb326bb&acdnat=1521170999_db0331f99f0b8dc17bd16812e4cb8a6e
[Accessed 18 March 2018].
127

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University of Nottingham Malaysia Campus

Hazard and Operability Study (HAZOP)

Benzaldehyde Production Plant

Group Members Student ID

Celina Lim Hui En 024959

Yap Ze Kai 025097

Hii Min Tiin 024134

Kong Wei Hern 017168

Module Convenor: Dr. Lam Hon Loong

1.0 Introduction 3-4

3.0 Risk Occurrence and Injury Description Rating 6-7

4.0 Inherent Safety 8-9

5.0 Hazop table 10-105

6.0 Process control diagram for pump 106

7.0 MSDS and Evacuation 107-110

8.0 Bow Tie Diagram 111

9.0 Emergency Contact 109

10.0 Conclusion 110

11.0 Appendix 111-127

12.0 References 128

Hazard and operability study (HAZOP) is a detailed examination of complex

HAZOP is usually performed in 4 basic steps:

LIA Level indicator alarm

LIC Level indicator and controller

LICA Level indicator controller alarm

MAW Maximum Allowable Working Pressure

PIC Pressure indicator and controller

PICA Pressure indicator controller alarm

PAD Pressure alarm device

PSV Pressure safety valve

SIS Safety interlock system

TIC Temperature indicator and controller

TICA Temperature indicator controller alarm

FIA Flow indicator alarm

FICA Flow indicator controller alarm

HLA High level alarm

LLA Low level alarm

To classify the occurrence of an incident and their seriousness in terms of

Safety 1- Minor 2-Injuries 3-Severe 4-Very severe,

Inherent means existing in something as a permanent and inseparable element

Inherent safety based on the following strategies (ISAS) which are

Besides the 4 main strategies in inherent safety process design, it followed by 6

Figure 1: Layer of protection analysis (LOPA)

3. Utilities and Storage Tank

- This section covers storage vessels and utility equipment such

Parameter Guide Deviation Causes Consequences Safeguard Action Recommendations O D R

-Preheater (H1) -Reactants may be -Decrease

5.2.1 Flash Drum (E3)

5.2.2 Distillation Column 1 (E4)

5.2.3 Distillation Column 2 (E7)

5.2.4 Distillation Column 3 (E11)

5.2.5 Decanter (E5)

Parameter Guide Deviation Causes Consequences Safeguard Action Recommendation O D R

More Higher -Heating -Separation -Installation of -Decrease -Maintenance of heat

Less bottom -Output -Separation -Installation of -Decrease -Install a slight glass 1 2 A

Parameter Guide Deviation Causes Consequences Safeguard Action Recommendation O D R

Flow No No feed flow -Valve, V3 - Economic Installation -Repair or -Regular maintenance of 2 1 A

Node: Distillation Column 2 Node No. E7 Stream Outlet: S28, S33

Parameters Guide Deviation Causes Consequences Safeguard Action Recommendation O D R

Parameters Guide Deviation Causes Consequences Safeguard Action Recommendation O D R

Parameter Guide Deviation Causes Consequences Safeguard Action Recommendation O D R

5.3.1 Toluene Storage Tank

Parameter Guide Deviation Causes Consequences Safeguard Action Recommendations O D R