TK 15 Report Assignment 3

PRELIMINARY DESIGN OF SODIUM CARBONATE PLANT
Report Assignment 3
GROUP TK-15
GROUP PERSONNEL:
ARDINA AYU WULANDARI (1706104363)
BILQIS NUR FADHILAH (1606871341)
DAVID KRISTIANTO (1606908035)
MUHAMMAD DAFFA (1606907801)
YOHANES PANDU WICAKSONO (1606907814)
CHEMICAL ENGINEERING DEPARTMENT

ENGINEERING FACULTY
UNIVERSITAS INDONESIA
NOVEMBER 2019
EXECUTIVE SUMMARY
This assignment’s objective is to do the piping size calculation based on
the plant layout, instrumentation for each equipment in the process and utility plant,
discuss one of crucial aspect of a chemical plant, which is related to health, safety,
and environment or known as HSE analysis, and plant layout overall 2D drawing.
The area for piping and instrumentation is divided into five (5) area. Area
100 is the brine purification process, area 200 is the Solvay process that consists of
two main absorber columns. The area 300 is the lime section process, that is consist
of lime stone calcination and Ca(OH)2 process. The area 400 is the sodium
bicarbonate calcination and the final product storing. Lastly, area 500 is the utility
area.
For piping sizing will be presented in this assignment for all area in the
plant. The piping should take into the account of the liquid flowing flowrate inside,
type of the fluid, the distance of the fluid must travel, the pressure and temperature
condition of each fluid in the process. Those parameter is being considered for the
diameter size, schedule, and the material that is going to be used for each pipe
design.
Each of the process is requires process control system, since this is the
engineering discipline with architectures, mechanisms, and algorithms to maintain
the output of a specific within a desired range. Therefore, the process control is very
important aspect in the plant. Process control is consist of automation and enabling
operators to operate the process from the control room. The process control is
conducted to aim the seven objectives in process control through the usage of 5
control variables. In each control loop, the determination of control variable,
manipulated variable , final element, and control procedure must be made. Process
and instrumentation diagram has to be made for all the process in the plant.
HSE is required to ensure the production process that has hazardless effect
to the workers, equipment, and environment. In order to achieve a good work
environment, HSE needs to construct HAZID and HAZOP. Hazard Identification
(HAZID) is a preventive analysis about the dangers that might happen by
considering whole involved aspects. By doing HAZID analysis, it can identify
hazards associated with the defined system and to asses the source of hazards,
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events, or sets of circumstances which may cause the hazards and their potential
consequences, generate a comprehensive list of hazards based on those events and
circumstances that might lead to possible unwanted consequences, and also identify
possible risk reducing measure. HAZOP has a purpose to recognize some aspects,
including potential hazard and any kinds of operability problems in every process
caused by process design intent deviations in active plant or a new-operable plant.
HAZOP will analyze how the deviation of parameter (flow, pressure, temperature,
etc.) can influence the safety of the process.
To measure and estimate risk from the materials used, Material Safety Data
Sheet (MSDS) should be provided to give information on the potential hazards
(health, fire, reactivity and environmental) and how to work safely with the
chemical product. To ensure the safety of the employee, plant analyze Personal
Protection Equipment (PPE) to protect them from any hazards. By using PPE in the
plant can minimize exposure to serious workplace injuries and illnesses. Personal
protective equipment may include items such as gloves, safety glasses and shoes,
earplugs earmuffs, hard hats, respirators, or coveralls, vests and full body suits.
If hazards happen, off-grid should have emergency procedure to make
everything safe and under control again as soon as possible, both the workers,
equipment, and process itself. Most emergencies require urgent intervention to
prevent a worsening of the situation, although in some situations, mitigation may
not be possible. Off-grid plant make emergency operating procedure and train the
workers. Off-grid plant provide emergency alarm, fire-fighting equipment, design
emergency escape route and procedure.
The plant location is located in Jl. Brotonegoro, Kebomas, Gresik, East
Java, with the area total of the plant is of the plant is 26,793.06 m2. This area is
chosen because it is close to the raw material such as the calcium carbonate,
limestone, and ammonia. This plant is also close to the center of the East Java and
close to Gresik Port. The plant layout will be made in 2D layou
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LIST OF CONTENTS
EXECUTIVE SUMMARY ................................................................................... ii

LIST OF CONTENTS ......................................................................................... iv
LIST OF FIGURES ............................................................................................. vi
LIST OF TABLE ................................................................................................ vii
CHAPTER 1 PIPING AND INSTRUMENTATION DIAGRAM .................. 1
1.1 Pipeline Specification ............................................................................... 1
1.2 Utility Piping and Instrumentation Diagram ............................................ 5
1.3 Utility Control Tabulation ........................................................................ 6
1.4 Production Process Piping and Instrumentation Diagram ........................ 7
1.5 Production Process Control Tabulation .................................................. 11
CHAPTER 2 HEALTH, SAFETY, AND ENVIRONMENTAL
PROTECTION .................................................................................................... 15
2.1. Hazard Identification Study (HAZID) ................................................... 15
2.2. Hazard and Operability Study (HAZOP) ............................................... 25
2.3. Operational Details ................................................................................. 37
2.1.1. Commissioning ............................................................................... 37
2.1.2. Start-up Procedure........................................................................... 40
2.1.3. Shutdown Procedure ....................................................................... 40
2.4. Personal Protective Equipment .............................................................. 42
2.4.1. Head Protection ............................................................................... 42
2.4.2. Eye and Face Protection .................................................................. 43
2.4.3. Foot and Leg Protection .................................................................. 45
2.4.4. Hand and Arm Protection................................................................ 45
2.4.5. Hand and Arm Protection................................................................ 47
2.4.6. Ear Protection .................................................................................. 48
2.5. Material Safety Data Sheet (MSDS) ...................................................... 49
2.6. Area Classification ................................................................................. 55
2.7. Emergency Action Plan .......................................................................... 57
2.1.4. Evacuation Procedures, Escape Routes, and Floor Plans ............... 58
2.1.5. Medical Emergency Plan ................................................................ 59
2.1.6. Emergency Alarm and Fire Fighting Strategy ................................ 59
2.1.7. Emergency Operation Training ....................................................... 63
2.8. Waste Management ................................................................................ 66
2.1.8. Solid Waste ..................................................................................... 66
2.1.9. Sound .............................................................................................. 67
CHAPTER 3 PLANT LAYOUT ..................................................................... 69
3.1. Plant Location ......................................................................................... 69
3.2. Plant Layout ........................................................................................... 70
3.2.1. General Consideration of Plant Layout ........................................... 70
3.2.2. Safe Range Between Equipment ..................................................... 71
3.2.3. Area Classification Layout .............................................................. 74
3.2.4. Overall 2D Plant Layout ................................................................. 75
CHAPTER 4 CONCLUSION ......................................................................... 79
REFERENCES .................................................................................................... 81
APPENDICES ..................................................................................................... 82
APPENDIX A Ammonia MSDS ..................................................................... 82
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APPENDIX B Brine Solution MSDS .............................................................. 90
APPENDIX C Limestone MSDS .................................................................... 96
APPENDIX D Calcium Oxide MSDS ........................................................... 100
APPENDIX E Sodium Carbonate MSDS ..................................................... 108
APPENDIX F Polyacrylamide MSDS ........................................................... 114
APPENDIX G Carbon Dioxide MSDS ......................................................... 118
APPENDIX H Ammonium Hydroxide MSDS .............................................. 126
APPENDIX I Sodium Bicarbonate MSDS ................................................... 133
APPENDIX J Ammonium Chloride MSDS .................................................. 140
APPENDIX K Calcium Hydroxide MSDS ................................................... 145
APPENDIX L Calcium Chloride MSDS ....................................................... 150
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LIST OF FIGURES
Figure 1.1 P&ID Area 500 (Utilities) .................................................................... 5

Figure 1.2 P&ID Area 100 ..................................................................................... 7
Figure 1.3 P&ID Area 200 ..................................................................................... 8
Figure 1.4 P&ID Area 300 ..................................................................................... 9
Figure 1.5 P&ID Area 400 ................................................................................... 10
Figure 2.1 The General HAZID Process Scheme ................................................ 15
Figure 2.2 Safety Helmet ..................................................................................... 43
Figure 2.3 Safety Glasses .................................................................................... 44
Figure 2.4 Safety Shoes ....................................................................................... 45
Figure 2.5 Vinyl Gloves for Laboratory Uses ..................................................... 46
Figure 2.6 Heat Resistance Gloves ..................................................................... 47
Figure 2.7 Lab Coat for Laboratory Worker ....................................................... 48
Figure 2.8 Earmuff for Ear Protection ................................................................ 49
Figure 2.9 NPFA Warning Diamond ................................................................... 51
Figure 2.10 HMIS Labeling System .................................................................... 51
Figure 2.11 Process area classification ................................................................ 56
Figure 2.12 Area classification............................................................................. 57
Figure 2.13 Audible Alarm .................................................................................. 60
Figure 2.14 Visible Alarm.................................................................................... 61
Figure 2.15 Fire Extinguisher............................................................................... 62
Figure 2.16 Fire Hydrant ...................................................................................... 62
Figure 2.17 Combination of Safety Shower and Eyewash Station ...................... 63
Figure 3.1 Plant Location (Source: Google Earth) ............................................... 70
Figure 3.2 Wind Flow Direction .......................................................................... 71
Figure 3.3 Battery limit between storage tanks and vessels ................................. 72
Figure 3.4 Outside battery limit values ................................................................ 73
Figure 3.5 Inside battery limit values ................................................................... 73
Figure 3. 6 Area Classification ............................................................................. 75
Figure 3.7 2D Plant Layout .................................................................................. 76
Figure 3.8 Plant Layout Area ............................................................................... 77
Figure 3.9 Plant Layout Zoom ............................................................................. 78
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LIST OF TABLE
Table 1.1 Pipeline Spesification Area 100 ............................................................. 2

Table 1.6 Plant Control Area 500 (Utilities Area) ................................................. 6
Table 1.7 Plant Control Area 100 ......................................................................... 11
Table 1.10 Plant Control Area 400 ....................................................................... 14
Table 2.1 Hazard Effect Parameter for HAZID ................................................... 16
Table 2.2 Hazard Frequency Parameter for HAZID ............................................ 16
Table 2.3 Hazard Index Based on Frequency and Severity.................................. 16
Table 2.4 Plant Hazard Identification (HAZID).................................................. 17
Table 2.5 HAZOP in Sodium Carbonate Plant ................................................... 27
Table 2.6 Hazard Classification ........................................................................... 51
Table 2.7 NFPA Parameter for Personal Protection ............................................. 53
Table 2.8 HMIS Parameter on Personal Protection.............................................. 54
Table 3.1 Minimum Distance between equipment ............................................... 74
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1 CHAPTER 1
PIPING AND INSTRUMENTATION DIAGRAM
1.1 Pipeline Specification

Pipeline is a line of pipe with pumps, valves, and control devices for
conveying fluids. It can also be used for structural applications. It is used in plants
to transport fluids from one point to another.
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Table 1.1 Pipeline Spesification Area 100

Inner Nominal
Pipe Outer Diameter Length
Material Diameter Thickness (mm) Pipe Size Schedule
Name (mm) (ft)
(mm) (inch)
100 Carbon Steel 0.44 5.93 5.49 3.00 40 6.2
101 Carbon Steel 5.24 10.73 5.49 3.00 40 176.8
102 Carbon Steel 5.26 10.75 5.49 3.00 40 16.6
103 Carbon Steel 42.67 48.16 5.49 3.00 40 198.2
105 Carbon Steel 16.7 21.65 5.49 3.00 40 15.75
107 Carbon Steel 47.23 52.72 5.49 3.00 40 42.65
108 Carbon Steel 47.23 52.72 5.49 3.00 40 114.83
109 Carbon Steel 173.21 181.39 8.18 8.00 40 44.78
110 Carbon Steel 173.21 181.39 8.18 8.00 40 44.78
111 Carbon Steel 180.57 188.75 8.18 8.00 40 55.48
112 Carbon Steel 180.54 188.72 8.18 8.00 40 15.09
113 Carbon Steel 180.54 188.72 8.18 8.00 40 6.92
114 Carbon Steel 180.54 188.72 8.18 8.00 40 36.09
115 Carbon Steel 178.76 186.94 8.18 8.00 40 16.17
116 Carbon Steel 178.77 186.95 8.18 8.00 40 16.6
117 Carbon Steel 317.67 328.79 11.13 14.00 40 19.13
118 Carbon Steel 317.67 328.79 11.13 14.00 40 20.76
119 Carbon Steel 322.20 333.32 11.13 14.00 40 15.09
3
Inner Nominal
Name (mm) (ft)
(mm) (inch)
200 Carbon Steel 125,35 131,91 6,55 5,00 40 133.86
201 Carbon Steel 185,76 193,94 8,18 8,00 40 17.39
202 Carbon Steel 185,76 193,94 8,18 8,00 40 15.42
206 Duplex SS 519,60 537,07 17,48 24,00 40 148.55
205 Duplex SS 571,94 589,42 17,48 24,00 40 23.95
207 Carbon Steel 136,32 143,43 7,11 6,00 40 24.28
208 Carbon Steel 53,62 59,11 5,49 3,00 40 108.04
210 Carbon Steel 193,90 202,07 8,18 8,00 40 159.32
Inner Nominal
Name (mm) (ft)
(mm) (inch)
304 Duplex SS 415.71 429.99 14.28 18.00 40 17.72
306 Duplex SS 462.28 477.37 15.09 20.00 40 164.04
310 Carbon Steel 47.44 52.92 5.49 3.00 40 198.23
311 Carbon Steel 18.44 23.92 5.49 3.00 40 9.84
313 Carbon Steel 18.44 23.92 5.49 3.00 0 9.84
314 Carbon Steel 18.44 23.92 5.49 3.00 40 32.80
4
Inner Nominal
Name (mm) (ft)
(mm) (inch)
401 Carbon Steel 568.15 585.62 17.48 24.00 40 11.48
402 Duplex SS 405.58 419.85 14.28 18.00 40 6.56
403 Carbon Steel 610.10 627.57 17.48 32.00 40 300.53
Inner Nominal
Name (mm) (ft)
(mm) (inch)
500 Carbon Steel 1.46 6.94 5.49 3.00 40 5.84
501 Carbon Steel 1.46 6.94 5.49 3.00 40 6.56
502 Carbon Steel 473.07 488.16 15.09 20.00 40 55.12
503 Carbon Steel 473.07 488.16 15.09 20.00 40 55.12
504 Carbon Steel 1.50 6.98 5.49 3.00 40 27.03
505 Carbon Steel 4.06 9.54 5.49 3.00 40 168.04
506 Carbon Steel 4.01 9.49 5.49 3.00 40 9.08
507 Carbon Steel 4.01 9.49 5.49 3.00 40 336.28
508 Carbon Steel 91.06 97.08 6.02 4.00 40 18.37
509 Carbon Steel 91.06 97.08 6.02 4.00 40 16.47
510 Carbon Steel 492.49 509.97 17.48 24.00 40 159.32
511 Carbon Steel 91.06 97.08 6.02 4.00 40 32.80
512 Carbon Steel 54.38 59.87 5.49 3.00 40 27.00
5
1.2 Utility Piping and Instrumentation Diagram
Figure 1.1 P&ID Area 500 (Utilities)
6
1.3 Utility Control Tabulation

Table 1.6 Plant Control Area 500 (Utilities Area)
Process Controlled Controlling

Controller Function Control Procedure
Equipment Parameter Parameter
When the level of column reach higher than 80% of column

Water Level Control Flow of water to height, the valve opening is controlled to lower the flow rate
Vessel (V- Level Liquid Level Indicator prevent flooding inside and to prevent the flooding inside column. And when the level of
500) Control drought Water Vessel column reach lower than 20% of column height, the valve
will open to emit the flow rate to prevent drought column
Control the concentration of
Analyzer
Concentratio Disinfectant stream output Mixer to ensure Analyzer will emit pneumatic signal to Analyzer Indicator
Indicator
n Flow the desired output Control to control the flow of stream before entering Mixer
Control
Disinfectant concentration
Mixer (M- When the level of column reach higher than 80% of column
500) Level Control Flow of water to height, the valve opening is controlled to lower the flow rate
Level Liquid Level Indicator prevent flooding and drought to prevent the flooding inside column. And when the level of
Control inside Disinfectant Mixer column reach lower than 20% of column height, the valve
will open to emit the flow rate to prevent drought column
When the level of column reach higher than 80% of basin
Control Flow of make-up
Cooling Level height, the valve opening is controlled to lower the flow rate
water to prevent flooding and
Tower (TE- Level Liquid Level Indicator to prevent the flooding inside column. And when the level of
drought inside Cooling Tower
500) Control column reach lower than 20% of basin height, the valve will
Basin
open to emit the flow rate to prevent drought column
7
1.4 Production Process Piping and Instrumentation Diagram
Figure 1.2 P&ID Area 100
8
9
10
11
1.5 Production Process Control Tabulation
Table 1.7 Plant Control Area 100
Process Controlled Manipulated

Final Element Objective Process Control Action of Controller
Equipment Variable Variable
Mixer Control the flow of the water to When solid-water ratio is above the optimal
VLV-100,
(M-100, M- Flow Rate Flow fulfill the requirement of solid- operation, the opening valve will be increased to
VLV-101
101) water ratio increase the flow of water.
When the feed flow is decreasing below the
Brine Control the flow of the stream to
VLV-102, optimal mass flow rate, the opening valve will
Reactor Flow Rate Flow generate MgCO3, CaCO3, and
VLV-103 be increased to generate solid compound of
(R-100) Na2SO4
MgCO3 dan CaCO3 and Na2SO4 aqueous.
When the level of decanter reach higher than
Control flow of product out from
Decanter Liquid output 80% of bottom space in decanter, the opening
Level VLV-106 decanter to prevent flooding
(FL-100) flow valve will be increased to prevent the flooding
inside decanter
output decanter.
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Process Controlled Manipulated Final

Objective Process Control Action of Controller
Equipment Variable Variable Element
Control the temperature of
When the temperature of ammonia is below
brine reactor outlet before
Hot Fluid the required operating condition in absorber
Temperature VLV-104 entering heat exchanger to
Flow (60oC), the opening valve will be increased
ensure the required temperature
to increase brine reactor outlet flow.
of ammonia flow is achieved
Control the temperature of
When the temperature of lean brine is below
cooling water before entering
Cooling the required operating condition in absorber
Temperature VLV-105 heat exchanger to ensure the
Water Flow column (60oC), the opening valve will be
desired temperature of lean
increased to increase cooling water flow.
brine flow is achieved
Absorber When the pressure of column is above the
(T-200) required operating condition (3.2 atm), the
Control the pressure of valve will be opened to decrease the
Vapor Outlet VLV-201,
Pressure absorber column by reducing pressure column. Vapor flow component is
Flow VLV-202
exceed pressure mainly carbon dioxide which is corrosive.
When the main valve VLV-201 is raptured,
valve VLV-202 will be opened.
When the level of absorber reach higher
Control the bottom level of than 80% of bottom space, the opening
Liquid Outlet
Level VLV-203 absorber column by increasing valve will be increased. This action is also
Flow
the liquid outlet flow to prevent any vapor or air in pump which
may cause cavitation.
13
Table 1.8 Plant Control Area 200 (cont’d)

When the pressure of column is above the
required operating condition (3.2 atm), the
Control the pressure of valve will be opened to decrease the
Absorber Vapor Outlet VLV-204,
Pressure absorber column by reducing pressure column. Vapor flow component is
(T-201) Flow VLV-205
exceed pressure mainly ammonia which is corrosive. When
the main valve VLV-204 is raptured, valve
VLV-205 will be opened.
Control the flow of the feed to
fulfill the requirement of When NH4Cl-Ca(OH)2 ratio is above the
Feed Inlet VLV-206,
Flow NH4Cl-Ca(OH)2 ratio in optimal operation, the opening valve will be
Flow VLV-208
reaction kinetics, so ammonia increased to increase the flow inlet of feed.
will be produced as a revocery
Pre-Limer When the pressure of pre limer reactor is
(R-200) above the required operating condition (1
Control the pressure of pre atm), the valve will be opened to decrease
Vapor Outlet VLV-207,
Pressure limer reactor by reducing the pressure reactor. Vapor flow component
Flow VLV-208
exceed pressure is mainly ammonia which is corrosive.
When the main valve VLV-207 is raptured,
valve VLV-208 will be opened.
14

Control the flow of the water to When solid-water ratio is above the optimal
Mixer
Flow Rate Flow VLV-300 fulfill the requirement of solid- operation, the opening valve will be increased
(M-300)
water ratio to increase the flow of water.
Control the temperature in the When the temperature of rotary kiln is below
Rotary Kiln Fuel Gas VLV-301, rotary kiln to achive the the required operating condition (1100°C),
Temperature
(DD-300) Flow VLV-302 optimum CaCO3 decomposition the opening valve will be increased to
temperature maintain the decomposition temperature.

Control the temperature in the When the temperature of rotary dryer is
Rotary
rotary dryer to achive the below the required operating condition
Dryer Temperature Dry Air Flow VLV-400
optimum NaHCO3 (165°C), the opening valve will be increased
(E-401)
decomposition temperature to maintain the decomposition temperature.
2 CHAPTER 2
HEALTH, SAFETY, AND ENVIRONMENTAL PROTECTION
2.1. Hazard Identification Study (HAZID)
Hazard Identification (HAZID) is a qualitative technique for the early

identification of potential hazards and threats effecting people, the environment,
assets or reputation. The major benefit of a HAZID study is to provide essential
input to project development decisions. It is a means of identifying and describing
HSE hazards and threats at the earliest practicable stage of a development or
venture. Hazard Identification is performed for the objectives listed below:
• To identify hazards associated with the defined system and to assess the
sources of hazards, events, or sets of circumstances which may cause the
hazards and their potential consequences.
• To generate a comprehensive list of hazards based on those events and
circumstances that might lead to possible unwanted consequences.
• To identify possible risk reducing measure.
HAZID is a consequence-driven, and it assumes that an event will occur and
consequently requires rigorous analysis of the sequence of events for it to occur.
Identification of hazards cover various aspects such as the environment, assets, and
human resource. The general scheme of HAZID process is shown on Figure 1.1
below.
Figure 2.1 The General HAZID Process Scheme

(Source: Halliburton, 2015)
16
Hazards are identified from each area of the plant and office. Plant area will
be divided into several nodes based on process occurred on each node to enable a
detail analysis of hazards and their causes. After listed from each node, we analyze
hazard effect and frequency based on parameters listed in Table 2.1 and 2.2:
Table 2.1 Hazard Effect Parameter for HAZID
Parameter Severe Major Minor

Human Resources Fatal accident Non-fatal accident No accident
Losses between
Losses more than Losses less than
Asset US$ 100,000 –
US$ 1,000,000 US$ 100,000
1,000,000
Environment Major damage Minor damage No damage
(Source: McKay, 2017)
Table 2.2 Hazard Frequency Parameter for HAZID
Parameter Most Likely Unlikely

More than 10
Hazard 1-10 times in Once in 10
times in 10
Frequency 10 years years
years
(Source: McKay, 2017)
The identification of hazard is stimulated by guidewords, which formulate

scenarios where the design intent may be violated and therefore centers on the
lateral thought processes. The objective is to define how an event could happen and
what would then be the consequence. Hazard index is then measured as the product
of severity and frequency, is shown below.
Table 2.3 Hazard Index Based on Frequency and Severity
Severity
Frequency Minor Major Severe
Very Likely Medium High Extreme
Likely Low High Extreme
Unlikely Low Medium High
(Source: Queensland Coke & Energy, 2018)
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The HAZID analysis of the plant is shown in the following table.

Table 2.4 Plant Hazard Identification (HAZID)
Existing
No Location Description Cause Hazards Severity Frequency Prevention
Control
Sound Installing silencer
Friction in moving pollution can on equipment
- Minor Likely
parts of pump damage which emit noise,
hearing using earplugs
Blocked pump suction/
Strict working
discharge, overly high
procedure,
pressure, improper Pump
- Major Likely ensuring no
Facilitate the impeller adjustment in explosion
1 Pump ignition source
motion of fluids assembly, ignition
nearby
source nearby
Operation control
Throttling flow from Pressure Cavitation &
Minor Likely & monitoring of
pump suction control pump damage
suction flow
Driver power Strict working
Electrical hazard & Regular
of pump is not Minor Likely prcedure based on
physical injury Maintenance
locked SOP
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Table 2.4 Plant Hazard Identification (HAZID) (Cont’d-1)
Existing
Control
Monitoring and
Corrosion of tube,
To increase or Leakage, maintenance
shell, or gasket; Temperature
Heat decrease the process frequently, change
2 mixing of fluids, high and pressure Major Likely
Exchanger temperature of disruption, gaskets
pressure and control
fluid explosion periodically,
temperature of HE
regular cleaning
Material Monitoring and
Leakage,
To transport selection, maintenance
3 Piping Corrosion plugging, Major Likely
fluid corrosion frequently, using
failure
allowance corrosion inhibitor
Low
Checking
Overflow for cooling temperature
Cooling Unit to provide Level and periodically the
4 water which release to and high Major Likely
Tower cooling water flow control temperature and
environment capacity of
pressure
cooling water
The powder
gets in the
Limestone PPE protection for
To store lime eye,
and Powder overflow, Regular the worker, and
5 stone and respiratory Minor Unlikely
Na2CO3 holes (corrosion) Maintenance equipment
Na2CO3 system, eaten
Silo checking regulary
if carried by
wind
19

Existing
Control
Material
Monitoring the
Brine, To store raw selection,
Equipment flow and level
NH3 brine, and NH3 corrosion
6 Overflowing, leaking damage, Minor Unlikely control frequently,
Storage make up for allowance,
flooding using corrosion
Tank process flow and
inhibitor
level control
For separating Sludge carry Cleaning up the
clean brine and over to the sedimentation/
Level, flow
7 Decanter sludge (liquid- No sludge cleans up outlet of clean Minor Likely sludge regularly,
control
liquid brine, inspection of level
separation) overflow control
For CO2
Temperature Monitoring and
Rotary production and High temperature and Overheating,
8 and pressure Severe Unlikely Maintenance
Kiln limestone pressure explosion
control frequently
calcination
For sodium
bicarbonate Monitoring and
Rotary Temperature
9 calcination to High temperature Overheating Major Unlikely Maintenance
Dryer control
natrium frequently
carbonate
20

Existing
Control
Material
selection,
Corrosion inhibitor,
Corrosion of the shell, corrosion
For Solvay Leakage, monitoring and
10 Absorber high temperature and allowance, Major Likely
process explosion maintenance
pressure temperature
frequently
and pressure
control
Change the worn
Slip that occurs Worn (aus)
rubber lagging,
between the belt and on the
Monitoring add tension belt
the pulley components, rubber Minor Likely
Regularly conveyor, plug
roller does not spin, bottom belt
belt cleaner at the
overcapacity conveyor
To load solid end of the runway
Belt that has been Set the material to
11
Conveyor crushed through fall in the middle,
Worn (aus)
a belt Material loading fall is install additional
on the
not right in the middle, Monitoring components for
rubber Minor Likely
roller and belt do not Regularly the belt and roller
bottom belt
touch always attached or
conveyor
in touch with the
fitting
21
Existing
Control
Create a material
container at the
To transport bottom,
Speed change
Bucket CaO to mixer Monitoring ensuringthe load is
12 suddenly of the bucket, Material spill Minor Likely
Conveyor and Na2CO3 to regularly treated
overflowing
vessel under the
maximum design
load
Cleaning the
The sedimentation is
Monitoring BOTV and agitator
stuck in the bottom of Agitator Stuck Minor Likely
regularly routinely, to avoid
the mixer
high sedimentation
Overcapacity/ Flow Flow control

To mix two Material spill, Major Likely
13 Mixer overflowing Control regularly
components
Corrosion
Material
inhibitor,
Monitoring selection,
Corrosion of the shell Major Likely monitoring and
regulary corrosion
maintenance
allowance
frequently
22
Existing
Control
Loud opeartion Used earmuff for

- Noise Minor Likely
process protection
Rotary To seperating Checking flow

Slurry coming out of Flow
14 Drum NaHCO3 and Leakage Minor Likely control regularly to
the vent Control
Filter NH4Cl avoid overflow.
Worn out valves Monitoring Production Checking valves

Major Likely
(abrasion) regularly Loss regularly
To lower the
Fin Fan Loud opeartion Used earmuff for
15 temperature in - Noise Minor Likely
Cooler process protection
process
Reactor To purified Temperature, Monitoring and
High temperature and
16 Brine brine before pressure, Explosion Severe Unlikely Maintenance
pressure
Purification processing flow control frequently
23
Existing
Control
Reactor To recovery Temperature, Monitoring and

High temperature and
17 NH3 NH3 from pressure, Explosion Severe Unlikely Maintenance
pressure
Recovery process flow control frequently
Dust from the Using PPE for

To crushing the Nature of the material - Minor Likely
process safety
Na2CO3 to
18 Ball Mill
powdery
Overcapacity, blunt Monitoring Blade changes and
component Spillout, stuck Minor Likely
blade Regulary clean regulary
Used earmuff for

19 Blower To flow the gas Loud operation noise - Noise Minor Likely
protection
Seperating dust Claning the fan

Unclean fan,
20 Cyclone from rotary kiln - Noise Major Likely and use ear muff as
equipment operation
and rotary dyer protection
24
Existing
Control
Providing slippery
Office and Minor
Slippery floor and Circuit Slipped and Most and floor sign - Frequent
21 Office Plant and
short circuit Maintenance Fire Likely monitoring and
Administration Major
maintenance
Provide training to
the operator about
To control the working
Control Error in operating System will be
22 operation in - Major Unlikely procedure and
Room procedure shut down
the plant oblige supervisors to
perform daily
briefing before work
The contain of Monitoring flow and
Over capacity of the Flow and
Waste Area for the pool will Minor Likely level control
pool level control
23 Treatment treating the spill frequently
Area waste Environmental Monitoring
Leakage of the pool Monitoring Minor Likely
pollution frequently
25
2.2. Hazard and Operability Study (HAZOP)
Hazard and Operability Study (HAZOP) is a structured, systematic

examination of a process or operation that takes place and is still in the planning
stages in which aims to identify and evaluate problems that may pose a danger to
the individual employees, equipment operation, or efficiency of the process
operation. HAZOP is the identification of irregularities or deviations that occur in
the operation of an industrial installation, along with the consequent undesirable
effects concerning safety, operability, and environment. The possible deviations are
generated by rigorous questioning, prompted by a series of standard ‘guideword’
applied to intended design. HAZOP is done on planning stage for new installation
and before doing equipment modification or adding new installation. HAZOP is
usually called systematic analysis for industry critical installation design, the
effects, and potential deviations that occur together with possible hazard potential
occurrence. The objectives of doing HAZOP are:
1. To identify safety, hazard, and operational problems that are related to process
which immediately threatens safety of workers or operation.
2. To determine the severity of identified problem effect.
3. To identify and evaluate the engineering and procedural safeguards.
4. To recommend additional engineering and procedural safeguards.
HAZOP is performed by a group of experts from multiple disciplines and
led by an experienced safety specialist or training consultants. The main HAZOP
procedures are (Timmerhaus, 1991):
1. Collecting all process lineation for each process in the plant.
2. Process breakdown into little and more detail sub-process. To clarify the
breakdown of sub-process is given nodes in upper-ends of each sub-process.
There is no particular rule about limiting the distance of process.
3. Searching all possibilities of deviation in each process through uses of
systematic questions (HAZOP model for question is made by using keywords,
intended to make the analysis process easier).
4. Scoring for each negative effect that caused by every deviation mentioned
before. The criterion of harmful degrees for those negative effects is determined
by safety and efficiencies operational condition of the plant in normal condition.
26
5. Determination of overcome action to every deviation happened.

There are two groups of keywords to emphasize systematic question in HAZOP
procedure, which are
1. Primary Keywords
Primary keyword is every word that is related to condition or parameter of a
process. For example: flow, pressure, temperature, viscosity, corrosion, erosion,
level, density, relief, composition, addition, and reaction
2. Secondary Keywords
Secondary keywords is every word which is merged with primary keyword will
shows probability of deviation that can be happened For example: no, more, less,
reverse, and as well as.
The HAZOP analysis of this plant is shown on the table below.
27
Table 2.5 HAZOP in Sodium Carbonate Plant

Operation Unit
No Parameter Deviation Possible Causes Effect Prevention/Action Control
Unit Code
Process flow is
None Pump clogged
hampered
P-100, Processing liquid
P-101, Pump blockage,
supply hampered,
P-102, plugging or
low water supply to
P-103, Low blocking in pump Installing a control
next unit and there
P-200, so feed flowrate valve before pump
might possibility of
P-300 is too low to maintain the
cavitation Flow
1 Pump P-500, Flow High water supply flow, regular
Control
P-501, to next unit. When maintenance and
P-502, Excessive the fluid flow is too control periodically
P-503, impeller fast, the pump will and clean the pump
P-504, High performance, run out of fluid and
P-505, feed flowrate is could cause heat
P-506, too high and fires at the
pump so the pump
can be broken
28
Table 2.5 HAZOP in Sodium Carbonate Plant (Cont’d-1)

Operation Unit
Unit Code
E-100, Mass flow of hot Final (outlet) Controlling the
E-101, or cold stream is temperature of the inlet flow of hot
Heat Low/ Temperature
2 E-200, Temperature not suitable, too streams is not the and cold stream,
Exchanger High Control
E-400 much fouling, too same as target cleaning up fouling
A/B much heat loss temperature regularly
Control flow rate
Valve is not of the inlet stream
working The water is on the with level
Low properly, very low low level transmitter that
therefore the (drought) emit pneumatic
liquid very low signal to prevent
drought Level
3 Cooling Tower TE-500 Level
Control flow rate Control
Valve is not of the inlet stream
working with level
The water is
High properly, transmitter that
flooding
therefore the emit pneumatic
liquid is flooding signal to prevent
flooding
29

Operation Unit
Unit Code
Control flow rate
of the outlet stream
Valve is not with level
working transmitter that
High properly, Flooding emit pneumatic
therefore the signal to prevent
liquid is flooding flooding if it reach
the HHLL (High
High Liquid Level) Level
4 Decanter FL-100 Level
Control flow rate Control
of the outlet stream
Valve is not with level
working transmitter that
Low properly, NaCl carry over emit pneumatic
therefore the signal to prevent
liquid very low NaCl if it reach the
LLLL (Low Low
Liquid Level)
Mass flow of fuel The calcination of Control the flow
Low/ Temperature
5 Rotary Kiln DD-300 Temperature gas is to low/ limestone is not rate of the fuel gas
High Control
high optimum inlet stream
30

Operation Unit
Unit Code
Too little vapor Disruption of Pressure
Low controlling via
inside reaction conversion
vapor outlet,
control valve, and Pressure
Pressure Disruption of
Too many vapor Installation of Control
High reaction conversion, relief valve,
inside
explosion increase the inlet
stream
Insufficient Vortex on liquid
Condition
Absorber flow rate, discharge, loss of
5 T-200 monitoring and
NH3 and NaCl Low outflow is greater performance, work
control, decrease
than inflow, injury, drought on
the flow rate outlet
faulty level absorber column
Inflow is greater Level
Level
than outflow, Unfinished Control
Condition
over capacity, mixture overflow
monitoring and
High outlet isolated or to the next
control, decrease
blocked, faulty process, mixture
the inlet rate using
level spill, work injury
measurement
31

Operation Unit
Unit Code
Too little vapor Disruption of Pressure
Low controlling via
inside reaction conversion
vapor outlet,
control valve, and Pressure
Pressure Disruption of
Too many vapor Installation of Control
High reaction conversion, relief valve,
inside
explosion increase the inlet
stream
Insufficient Vortex on liquid
Absorber Condition
flow rate, discharge, loss of
6 NH4OH and T-200 monitoring and
Low outflow is greater performance, work
CO2 control, decrease
than inflow, injury, drought on
faulty level absorber column
Inflow is greater Level
Level
than outflow, Unfinished Control
Condition
over capacity, mixture overflow
monitoring and
High outlet isolated or to the next
control, decrease
blocked, faulty process, mixture
the inlet rate using
level spill, work injury
measurement
32

Operation Unit
Unit Code
Condition
Vortex on liquid
Insufficient monitoring and
discharge, loss of
flow rate, control, decrease
performance, work
Low outflow is greater the flow rate outlet
injury, risk of
than inflow, using pump
pump running dry
faulty level variable frequency
(damage)
drive
Level
Level Inflow is greater
Control
than outflow, Condition
Unfinished
Water over capacity, monitoring and
mixture overflow
7 Sanitation M-500 outlet control, decrease
High to the next
Mixer isolated or the inlet rate using
process, mixture
blocked, faulty pump variable
spill, work injury
level frequency drive
measurement
Insufficient
The water is not
flow rate,
Low clean enough for Controlling the
Properties outflow is greater Analyzer
water sanitation disinfectant flow to
of Water than inflow Control
the mixer
Inflow is greater The disinfectant is
High
than outflow, overflow
33

Operation Unit
Unit Code
The reaction does
Insufficient
not go well since Increase the water
flow rate,
Low the optimum flow rate to the
outflow is greater
condition is not mixer tank
Mixer than inflow Flow
8 M-100 Flow maintained
Polyacrylamide Control
Inflow is greater
Decrease the water
than outflow, Water is overflow
High flow rate to the
over capacity in mixer tank
mixer tank
The reaction does
Insufficient
not go well since Increase the water
flow rate,
Low the optimum flow rate to the
outflow is greater
condition is not mixer tank Flow
9 Mixer Na2CO3 M-101 Flow than inflow
maintained Control
Inflow is greater Decrease the water
Water is overflow
High than outflow, flow rate to the
in mixer tank
over capacity mixer tank
34

Operation Unit
Unit Code
Vortex on liquid
Insufficient discharge, loss of
Condition
flow rate, performance,
monitoring and
Low outflow is greater flooding, work
control, decrease
than inflow, injury, risk of
faulty level pump running dry
(damage)
Reactor Brine Level
10 R-100 Level Inflow is greater
Purification Control
than outflow,
Unfinished
over capacity, Condition
mixture overflow
outlet monitoring and
High to the next
isolated or control, decrease
process, mixture
blocked, faulty the inlet rate
spill, work injury
level
measurement
The reaction does
Insufficient Condition
not go well since
Reactor NH3 flow rate of monitoring and Flow
11 R-200 Flow Low the optimum
Recovery Ca(OH)2 and control, decrease Control
condition is not
NH4Cl the flow rate outlet
maintained
35

Operation Unit
Unit Code
The overflow of the
Inflow of greater Ca(OH)2 and
Condition
Ca(OH)2 and NH4Cl, The
monitoring and Flow
Flow High NH4Cl reaction does not go
control, decrease Control
over capacity well since the
the inlet rate
optimum condition
is not maintained
Pressure
controlling via
vapor outlet,
control valve, and
Too little vapor Disruption of
Reactor NH3 Low Installation of
12 R-200 inside reaction conversion
Recovery relief valve,
increase the inlet
stream, increase the
Pressure
Pressure inlet stream
Control
Pressure
controlling via
vapor outlet,
Disruption of
Too many vapor control valve, and
High reaction conversion,
inside Installation of
explosion
relief valve,
increase the inlet
stream
36

Operation Unit
Unit Code
Final (outlet)
Mass flow of the temperature of the Controlling the
Low/ Temperature
13 Fin Fan Cooler E-402 Temperature cold stream is not streams is not the inlet flow of cold
High Control
suitable same as target stream
temperature
Final (outlet)
Mass flow of the temperature of the Controlling the
Mixer Lime Low/ Temperature
14 M-300 Temperature water stream is streams is not the inlet flow of water
Slaker Tank High Control
not suitable same as target stream
temperature
37
2.3. Operational Details
The operating standard is the main key to run a plant with long operating
life. Standard operational procedure is needed will ensure the unit operation is
operating with standard condition. There are three (3) parts, commissioning, start
up (the steps needed to start the process and plant operation) and shut down (the
steps needed to stop the process and plant operation). In the start-up process, it is
needed to execute each step accordingly to ensure no leakage, damages, and
troubles in the plant operation. In the shutdown process, this plant needs to execute
each step accordingly to ensure there are no reaction, contact, and other activities
in the plant.
Several operating activities would be conducted at the same time during the
start-up and shut-down period; while others need a predeceasing activity to be
executed. It is necessary to pay special attention to the Vendor’s or Licensor’s
instruction manuals and the operating manual shall be reviewed carefully to be in
congruent with the Vendor’s or Licensor’s instructions. All start-up and shut-down
procedures shall be prepared in detailed step-wise activities which will be
performed by the operators with simplified start-up/shut-down sketches.
2.1.1. Commissioning
Commissioning is required before start up and shut down procedure. This
process is needed to ensure the system is working according the system and ready
for operation. Commissioning are included mechanical checking, utilities
commissioning, and operational testing.
2.3.1.1.Mechanical Completion and Integrity Checking
This process involves P&ID, electrical systems, checkout down by
appropriately qualified personnel (Electricians and instrumentation technicians),
pressure testing, cleaning and flushing, and lastly machinery checkout.
a. Piping and Instrumentation
The main purpose of this step is to make sure all equipment and lines have
been installed properly as it shown in P&ID. P&ID needed to be check equipment
by equipmentand line by line with P&ID as the reference. This process is also
needed to identify the location of the equipment, check all of the valve condition,
checking pump, compressor condition, and venting system.
38
All instrumentation system should be checked against the design data as well
as to be checked for installation, calibration and operation to verification of alarms
and trips. The purpose of this activity is to ensure that all instrumentation, alarm
settings, microprocessor signals and hardwire trips pertaining to the installation are
functional. This will also check that signals from the field instrumentation are
displayed locally and are being correctly relayed to the computer interface rack, as
well as to the computer system. In all steps make sure that the operator is wearing
the standard PPE and have memorized MSDS and evacuation route. The general
start up activity for every segment in the production process includes:
b. Pressure Testing
The pressure leak is tested by inserting a pressurized fluid which aims to
ensure connections in the equipment perfect and no leaks. The fluid is inert fluid.
For fluid system consists of water, air, and nitrogen. Leak test is done at the
maximum normal operating pressure or 90% of design pressure. Leakage is
characterized by a decrease in pressure. To find out the leak’s location, we use gas
as a fluid. It will make soap solution superimposed into the connection. If there are
bubbles, there is a leak.
All Equipment for liquid handling especially piping system should be
thoroughly cleaned from scaling and the internal debris which accumulates during
construction. This is accomplished by blowing or washing with air, steam, water
and other suitable medium.
c. Cleaning and Flushing
Ensure there are no construction debris left in pipes of vessels - welding rods,
bolts, gloves, rags, etc. Before flushing is started, the process needs to be checked
thoroughly to ensure screens have been installed in front of pump suctions.
Regardless of whether pipes are cleaned with water, steam, air, or nitrogen, flow
velocities should be high enough to ensure that pipes will be suitably scoured. Need
to ensure that the debris from one piece of equipment will not simply be flushed
into another
d. Machinery Checking for Safety Aspect
The entire plant equipment must be checked in terms if safety aspect. Every
equipment should be ensured that the equipment’s are ready to be operated. All
39
equipment signals, alarms, output devices, and communication devices need to be

tested so that it can operate correctly. This process is included:
• Indicate the location of all critical valves including valves at critical vent and
drain locations
• Check control valves, valves, and globe valves to see that they are installed
properly with respect to flow. Ensure functioning control valves, switching
valves, controllers, emergency shutdown system, etc. Ensure manual valves are
in proper positions.
• Check power supply’s functionality.
• Pumps are ready for operation: aligned, lubricated, proper rotation.
• All plant lines and equipment must be flushed, cleaned, and dewatered.
• Complete functional testing all rotating equipment.
• Do final inspection of vessels and column.
• Ensure there is no leak or any disfunctional.
2.3.1.2.Utilities Commissioning
All utilities are needed to be commissioned. Typically, this process is
including:
• Check supply pressures of all services (steam, cooling water).
• At the most distant points, open drains, vent valves or pipe flanges and purge
until fluids come out clean and rust free.
• Purge/blow out lines to each piece of equipment.
• Circulate water to waste water system until water lines clear and clean.
• Flush waste water and drain systems to ensure no blockages.
• Check operation of steam traps.
• Drain condensate to waste water until it is clean.
2.3.1.3.Operational Testing
At the operational testing, the plant needs to be tested using the actual
operating conditions. This stage lasts for 2-3 weeks after all the equipment have
been independently checked or tested. Air and water tests should be set up in a
closed loop with fluid continuously recycled, with loops as large as possible. The
loop should ideally be the same loop that will be subject to solvent testing. Tests
should continue for several days in order to give all shifts a chance to conduct the
40
same tests. All shifts should be given the opportunity to start up and shutdown each
closed loop test.
2.1.2. Start-up Procedure
The start up procedure is needed after the commissioning process is done.
Then the plant is cleared for startup process. The startup process is:
1. Make sure all the raw material is enough for the operation
2. Check the electricity supply.
3. All parameters in instrument which need controls must be set, such as pressure
and temperature.
4. Prepare the bacteria needed for the seed and production fermenters.
5. Prepare the fermenter for the process. This step is to maintain the temperature
and pressure in reactor to avoid the shock in reactor.
6. Open all inlet valves to flow the inlet stream.
7. Open utility valve for cooling water, air, and fuel.
8. Turn on all rotating equipment such as pump, and compressor.
9. The preconditioning is 1 – 2 hours to see if the reaction occurs or not.
10. If the reaction does not occur, the start up procedure should be repeated.
2.1.3. Shutdown Procedure
There are three types of shutdown procedure, such as initiated shutdown, process
shutdown, and emergency shutdown.
2.3.3.1 Initiated Shutdown
Initiated shutdown is required to maintain the equipment process in plant.
The procedure of the initiated shutdown is the same as stopping equipment when
the process is done. The steps of shutdown process are:
1. Close all the inlet raw material valve
2. Shut down heating and cooling sources
3. Flooded with water or a solvent to remove deposit on the fermenter
4. Purge with steam or gas to remove
5. Eliminating undesirable materials (cleaning process)
6. After an hour, stabilize the temperature of fermenter (prevent thermal shock)
7. Pressure trapped between two closed valves or closed process equipment loops
should be released immediately
41
8. Bring the vessel to atmospheric pressure

9. Shut down the electricity
2.3.3.2 Process Shutdown
A process shutdown is defined as the automatic isolation and deactivation
of all or part of a process. During a PSD, the process remains pressurized. In the
plant, PSD consists of field-mounted sensors, valves and trip relays, a system logic
unit for processing of incoming signals, alarm and HMI units. The system can
process all input signals and activate outputs in accordance with the applicable
Cause and Effect. PSD is integrated with the control system, such as pressure
control and temperature control. When the pressure is far from its set point, and
potentially harms the equipment, human, or environment, the PSD will
automatically initiate. For example, when the temperature of the reactor is far from
the maximum temperature allowed, there will be an alarm on the operating room
for the operator to take action, but if in some cases, the level is still getting higher,
until the highest point. The process shutdown will automatically initiate to prevent
the losses.
2.3.3.3 Emergency Shutdown
The Emergency Shutdown System (ESD) will minimize the consequences
of emergency situations, related to typically uncontrolled flooding or outbreak of
fire in hazardous areas. Risk analyses have concluded that the ESD system needs a
high Safety Integrity Level, typically SIL 2 or 3. An emergency shutdown system
represent a layer of protection mitigating and preventing the occurrence of
hazardous situation. An ESD system must be highly reliable. During emergency, it
is a must to shut down the plant in safeties way. The situations that initiate the
emergency shutdown, such as
1. Electric power failure
2. The temperature of fermenter outlet is higher than design temperature
3. Manual alarm
4. Pump or compressor failure
The main objectives of emergency shutdown are:
1. To shut down the plant safely
2. To minimize the emission
42
3. To prevent overpressure condition in the equipment

4. To protect equipment from damage
Shutdown process is performed by these following steps:
1. Shutdown all transportation of gas and liquid
2. Decrease the pressure and temperature of any equipment
3. Perform electrical isolation
4. Start all safety equipment
2.4. Personal Protective Equipment
Personal protective equipment, commonly referred to a s "PPE", is

equipment worn to minimize exposure to serious workplace injuries and illnesses.
These injuries and illnesses may result from contact with chemical, radiological,
physical, electrical, mechanical, or other workplace hazards. Personal protective
equipment may include items such as gloves, safety glasses and shoes, earplugs or
muffs, hard hats, respirators, or coveralls, vests and full body suits. All personal
protective equipment should be safely designed and constructed, and should be
maintained in a clean and reliable fashion. It should fit comfortably, encouraging
worker use. If the personal protective equipment does not fit properly, it can make
the difference between being safely covered or dangerously exposed. When
engineering, work practice, and administrative controls are not feasible or do not
provide sufficient protection, employers must provide personal protective
equipment to their workers. Furthermore, American National Standard Institute
(ANSI) has been preparing two (2) categories of safety standard for PPE.
• General Equipment: personal protection equipment as minimum
requirements to enter the plant are safety helmet, mask, and safety shoes.
• Special Equipment: Personal Protection Equipment (PPE) is used in
accordance with the needs of employees in the workplace each based on
hazard and risk. For example: safety goggles, welding goggles, respirator,
mask, ear protection, gloves, earplugs, and so on.
2.4.1. Head Protection
Protecting employees from potential head injuries is a key element of any
safety program. A head injury can impair an employee for life or it can be fatal.
Wearing a safety helmet or hard hat is one of the easiest ways to protect an
43
employee's head from injury. Hard caps can protect employees from impact and
penetration hazards as well as from electrical shock and burn hazards. The standard
for safety helmet is ANSI Z89.1. Employees wear head protection if any of the
following apply:
• Objects might fall from above and strike them on the head;
• They might bump their heads against fixed objects, such as exposed pipes
or beams; or
• There is a possibility of accidental head contact with electrical hazards.
Figure 2.2 Safety Helmet

Source: http:/catpower.pro
2.4.2. Eye and Face Protection

Employees can be exposed to a large number of hazards that pose danger to
eyes and face. OSHA requires employers to ensure that employees have appropriate
eye or face protection if they are exposed to eye or face hazards from flying
particles, liquid chemicals, acids or caustic liquids, chemical gases or vapors,
potentially infected material or potentially harmful light radiation.
Many occupational eye injuries occur because workers are not wearing any
eye protection while others result from wearing improper or poorly fitting eye
protection. Employers must be sure that their employees wear appropriate eye and
face protection and that the selected form of protection is appropriate to the work
being performed and properly fits each worker exposed to the hazard. Some of the
most common types of eye and face protection include the following:
44
• Safety spectacles. These protective eyeglasses have safety frames

constructed of metal or plastic and impact-resistant lenses. Side shields are
available on some models.
• Goggles. These are tight-fitting eye protection that completely cover the
eyes, eye sockets and the facial area immediately surrounding the eyes and
provide protection from impact, dust and splashes. Some goggles will fit
over corrective lenses.
• Welding shields. Constructed of vulcanized fiber or fiberglass and fitted
with a filtered lens, welding shields protect eyes from burns caused by
infrared or intense radiant light; they also protect both the eyes and face
from flying sparks, metal spatter and slag chips produced during welding,
brazing, soldering and cutting operations. OSHA requires filter lenses to
have a shade number appropriate to protect from specific hazards of the
work being performed in order to protect against harmful light radiation.
• Laser safety goggles. These specialty goggles protect against intense
concentrations of light produced by lasers. The type of laser safety goggles
an employer chooses will depend upon the equipment and operating
conditions in the workplace.
• Face shields. These transparent sheets of plastic extend from the eyebrows
to below the chin and across the entire width of the employee's head. Some
are polarized for glare protection. Face shields protect against nuisance
dusts and potential splashes or sprays of hazardous liquids but will not
provide adequate protection against impact hazards. Face shields used in
combination with goggles or safety spectacles will provide additional
protection against impact hazards.
Figure 2.3 Safety Glasses

Source: https://solarlight.com
45
2.4.3. Foot and Leg Protection

According to one survey, most of the workers in selected occupations who
suffered foot injuries were not wearing protective footwear. Furthermore, most of
their employers did not require them to wear safety shoes. The typical foot injury
was caused by objects falling fewer than 4 feet and the median weight was about
65 pounds. Most workers were injured while performing their normal job activities
at their work sites. It becomes the main reason, the foot and leg protection must
meet certain requirement.
Safety footwear must meet ANSI minimum compression and impact
performance standards in ANSI Z41-1991 (American National Standard for
Personal Protection-Protective Footwear) or provide equivalent protection. This
kind of protection will include the safety shoes. The metal insoles of some safety
shoes protect against puncture wounds. Safety shoes may also be designed to be
electrically conductive to prevent the buildup of static electricity in areas with the
potential for explosive atmospheres or nonconductive to protect workers from
workplace electrical hazards.
Figure 2.4 Safety Shoes

Source: https://ehs.ucsc.edu/programs
2.4.4. Hand and Arm Protection

If a workplace hazard assessment reveals that employees face potential
injury to hands and arms that cannot be eliminated through engineering and work
practice controls, employers must ensure that employees wear appropriate
protection. Potential hazards include skin absorption of harmful substances,
chemical or thermal burns, electrical dangers, bruises, abrasions, cuts, punctures,
fractures and amputations. Protective equipment includes gloves, finger guards and
arm coverings or elbow-length gloves.
46
Rubber is considered one of the best materials for insulating gloves and
sleeves and must conform to ANSI standards (copies available from ANSI, 1430
Broadway, New York, NY 10018). Other glove and clothing materials such as
latex, nitrile, butyl rubber, neoprene, etc. are available. Each material is thoroughly
tested and rated against specific chemical compounds.
Employers should explore all possible engineering and work practice
controls to eliminate hazards and use PPE to provide additional protection against
hazards that cannot be completely eliminated through other means. For example,
machine guards may eliminate a hazard. Installing a barrier to prevent workers from
placing their hands at the point of contact between a table saw blade and the item
being cut is another method. Gloves made of a wide variety of materials are
designed for many types of workplace hazards. Gloves fall into four groups:
• Gloves made of leather, canvas or metal mesh;
• Fabric and coated fabric gloves;
• Chemical-and liquid-resistant gloves;
• Insulating rubber gloves
Figure 2.5 Vinyl Gloves for Laboratory Uses

Source: https://ehs.ucsc.edu/programs/
47
Figure 2.6 Heat Resistance Gloves

Source: https://ehs.ucsc.edu/programs
2.4.5. Hand and Arm Protection

Employees who face possible bodily injury of any kind that cannot be
eliminated through engineering, work practice or administrative controls, must
wear appropriate body protection while performing their jobs. In addition to cuts
and radiation, the following are examples of workplace hazards that could cause
bodily injury:
• Temperature extremes;
• Hot splashes from molten metals and other hot liquids;
• Potential impacts from tools, machinery and materials;
• Hazardous chemicals.
Body protection garments for chemical plants are chosen thoroughly to
protect worker from biological agents, radioactive agents, or hazardous chemical.
A lab coat is the minimum required body protection. Lab coats protect the body
against incidental exposure to hazardous agents and minimize potential for
“transferring” hazardous agents to other areas through contaminated clothing. Body
protection garments are also needed to enhance a person’s visibility. There are two
common ANSI standards associated with high visibility (HV) clothing, ANSI 107
and ANSI 207.
If a hazard assessment indicates a need for full body protection against toxic
substances or harmful physical agents, the clothing should be carefully inspected
before each use, it must fit each worker properly and it must function properly and
48
for the purpose for which it is intended. Protective clothing comes in a variety of
materials, each effective against particular hazards, such as:
• Paper-like fiber used for disposable suits provide protection against dust and
splashes
• Treated wool and cotton adapts well to changing temperatures, is
comfortable, and fire-resistant and protects against dust, abrasions and
rough and irritating surfaces
• Duck is a closely woven cotton fabric that protects against cuts and bruises
when handling heavy, sharp or rough materials
• Leather is often used to protect against dry heat and flames
• Rubber, rubberized fabrics, neoprene and plastics protect against certain
chemicals and physical hazards. When chemical or physical hazards are
present, check with the clothing manufacturer to ensure that the material
selected will provide protection against the specific hazard
Figure 2.7 Lab Coat for Laboratory Worker

Source: https://ehs.ucsc.edu/programs/
2.4.6. Ear Protection
Determining the need to provide hearing protection for employees can be
challenging. Employee exposure to excessive noise depends upon a number of
factors, including:
• The loudness of the noise as measured in decibels (dB).
• The duration of each employee's exposure to the noise.
• Whether employees move between work areas with different noise levels.
• Whether noise is generated from one or multiple sources.
Generally, the louder the noise, the shorter the exposure time before hearing
protection is required. For instance, employees may be exposed to a noise level of
49
90 dB for 8 hours per day (unless they experience a Standard Threshold Shift)
before hearing protection is required. On the other hand, if it reaches 115 dB hearing
protection is required if the anticipated exposure exceeds 15 minutes.
For a more detailed discussion of the requirements for a comprehensive
hearing conservation program, see OSHA Publication 3074 (2002), “Hearing
Conservation” or refer to the OSHA standard at 29 CFR 1910.95, Occupational
Noise Exposure, section (c). Noises are considered continuous if the interval
between occurrences of the maximum noise level is one second or less. Noises not
meeting this definition are considered impact or impulse noises (loud momentary
explosions of sound) and exposures to this type of noise must not exceed 140 dB.
Figure 2.8 Earmuff for Ear Protection

Source: amazon.com/3M-Earmuff-Protectors-Hearing-Protection
2.5. Material Safety Data Sheet (MSDS)
A Material Safety Data Sheet (MSDS) is a document that contains

information on the potential hazards (health, fire, reactivity and environmental) and
how to work safely with the chemical product. It is an essential starting point for
the development of a complete health and safety program. It also contains
information on the use, storage, handling and emergency procedures all related to
the hazards of the material. The MSDS contains much more information about the
material than the label. MSDSs are prepared by the supplier or manufacturer of the
material. It is intended to tell what the hazards of the product are, how to use the
product safely, what to expect if the recommendations are not followed, what to do
50
if accidents occur, how to recognize symptoms of overexposure, and what to do if

such incidents occur.
There are nine (9) categories of information that must be present on an
MSDS. These categories are specified in the Controlled Products Regulations.
1. Product Information: product identifier (name), manufacturer and suppliers
names, addresses, and emergency phone numbers
2. Hazardous Ingredients
3. Physical Data
4. Fire or Explosion Hazard Data
5. Reactivity Data: information on the chemical instability of a product and the
substances it may react with
6. Toxicological Properties: health effects
7. Preventive Measures
8. First Aid Measures
9. Preparation Information: who is responsible for preparation and date of
preparation of MSDS
Traditionally the intended readers of MSDSs were occupational hygienists
and safety professionals. Now the audience also includes employers, workers,
supervisors, nurses, doctors, emergency responders and workers. To ensure that
MSDS users can quickly find the information that they need, the information should
be in an easy-to-read format and written in a clear, precise and understandable manner.
For most people who work with controlled products, there are some sections
that are more important than others. There are several procedures in understanding
MSDS, such as read the name of the chemical, know the hazards, understand safe
handling and storage instructions, as well as understand what to do in an emergency.
One of the requirements manufacturers have in supplying the chemicals is to
put a proper and complete label on the container, which provide information regarding
the hazards associated with using the material. There are two common symbols used
on labels to quickly provide information of the relative hazards of a material. One is
called the National Fire Protection Association (NFPA) warning diamond, which
appears on the following figure.
51
Figure 2.9 NPFA Warning Diamond

(Source: NPFA, 2014)
The other is the Hazard Materials Information System (HMIS) system, which
is previewed on the following figure. Both systems use numerical rating of hazards in
each of three colored sections (health, fire/flammability, and reactivity hazard).
Figure 2.10 HMIS Labeling System

(Source: HMIS, 2014)
The classification of hazard based on NPFA uses numbers which span from
0 to 4, with the description listed below.
Table 2.6 Hazard Classification
Hazard Type Number Description

0 No significant risk to health
1 Irritation or minor reversible injury possible.
2 Temporary or minor injury may occur.
Health
Major injury likely unless prompt action is taken
(Blue) 3
and medical treatment is given.
Life-threatening, major or permanent damage may
4
result from single or repeated overexposures.
52
Table 2.6 Hazard Classification (cont’d)

0 Materials that will not burn.
Materials that must be preheated before ignition
1 will occur. Includes liquids, solids and semi solids
having a flash point above 200°F.
Materials which must be moderately heated or
exposed to high ambient temperatures before
2
ignition will occur. Includes liquids having a flash
Fire/ point at or above 100°F but below 200°F.
Flammability Materials capable of ignition under almost all
(Red) normal temperature conditions. Includes
3 flammable liquids with flash points below 73°F
and boiling points above 100°F, as well as liquids
with flash points between 73°F and 100°F.
Flammable gases, or very volatile flammable
liquids with flash points below 73°F, and boiling
4
points below 100°F. Materials may ignite
spontaneously with air.
Materials that are normally stable, even under fire
conditions, and will not react with water,
0
polymerize, decompose, condense, or self-react.
Non-explosives.
Reactivity
Materials that are normally stable but can become
(Yellow)
unstable (self-react) at high temperatures and
1 pressures. Materials may react non-violently with
water or undergo hazardous polymerization in the
absence of inhibitors.
53
Table 2.6 Hazard Classification (cont’d)

Materials that are unstable and may undergo
violent chemical changes at normal temperature
2 and pressure with low risk for explosion. Materials
may react violently with water or form peroxides
upon exposure to air.
Materials that may form explosive mixtures with
water and are capable of detonation or explosive
reaction in the presence of a strong initiating
3 source. Materials may polymerize, decompose,
self-react, or undergo other chemical change
abnormal temperature and pressure with moderate
risk of explosion.
Materials that are readily capable of explosive
water reaction, detonation or explosive
4
decomposition, polymerization, or self-reaction at
normal temperature and pressure.
(Source: NPFA, 2014)
Table 2.7 NFPA Parameter for Personal Protection
PERSONAL PROTECTION
OX Oxidizer: allows chemical to burn without air supply
₩ Reacts with water in an unusual or dangerous manner
SA Simple asphyxiant gas (N2, He, Ne, Ar, Kr, Xe)
(Source: NFPA, 2014)
54
Table 2.8 HMIS Parameter on Personal Protection
PERSONAL PROTECTION
A
L-Z Site-specific label. Information from supervisor or safety specialist for

handling instructions
(Source: NFPA, 2014)
55
The main substances involved in the plant include NH3, Brine and
limestone. The material safety data sheets are described in the appendix.
2.6. Area Classification
Area classification is a method of analyzing and classifying the environment

where explosive gas atmospheres may occur. The main purpose is to facilitate the
proper selection and installation of apparatus to be used safely in that environment,
taking into account the properties of the flammable materials that will be present.
DSEAR specifically extends the original scope of this analysis, to take into account
non-electrical sources of ignition, and mobile equipment that creates an ignition
risk.
Hazardous areas are classified into zones based on an assessment of the
frequency of the occurrence and duration of an explosive gas atmosphere, as
follows:
• Zone 0: An area in which an explosive gas atmosphere is present
continuously or for long periods;
• Zone 1: An area in which an explosive gas atmosphere is likely to occur in
normal operation;
• Zone 2: An area in which an explosive gas atmosphere is not likely to occur
in normal operation and, if it occurs, will only exist for a short time.
Various sources have tried to place time limits on to these zones, but none
have been officially adopted. The most common values used are:
• Zone 0: Explosive atmosphere for more than 1000h/yr.
• Zone 1: Explosive atmosphere for more than 10, but less than 1000 h/yr.
• Zone 2: Explosive atmosphere for less than 10h/yr, but still sufficiently
likely as to require controls over ignition sources.
Based on the overall look of the plant layout, therefore it can be showed the
zone classification as below. It is noted that the detail description of the plant layout
is discussed in the following section.
56
Figure 2.11 Process area classification
From the Figure 2.11, the are over the plan is classified by the process. Area
100 is area for brine purification. Area 200 is area for filtration process, on this
proces will be seperate product from solvay process. Area 300 area for lime section
procces, which is the process consists of calcination, cooling, and mixing to produce
CO2 and Ca(OH)2. Area 400 is area for NaHCO3 calcination using Rotary Drying
to produced Na2CO3. On this area also there is a ball mill that used to reducing size
of Na2CO3 product. And Area 500 is area for utilities, which the mainly process is
produced cooling water.
57
Figure 2.12 Area classification
Figure 2.12 is classified the area based on an assessment of the frequency

of the occurrence nd duration of an explosive gas atmosphere. it can be seen from
the figure xx, Area 400and area 500 are calssified into Zone 2, While, area 100 and
area 200 are classified into Zone 1. And 300 is very critical due to high pressure
processes with calcination process which its operate in very high temperatur, so that
it is classified into Zone 0.
2.7. Emergency Action Plan
An Emergency Action Plan (EAP) is a plan designed by coaches to assist

them in responding to emergency situations. The idea behind having such a plan
prepared in advance is that it will help you respond in a responsible and clear-
headed way if an emergency occurs. An EAP should be prepared for the facility or
site where you normally hold practices and for any facility or site where you
regularly host competitions. For away competitions, ask the host team or host
facility for a copy of their EAP.
An EAP can be simple or elaborate but should cover the following items:
1) Designate in advance who is in charge in the event of an emergency (this may
very well be you).
58
2) Have a cell phone with you and make sure the battery is fully charged. If this
is not possible, find out exactly where a telephone is located. Have spare
change in case you need to use a pay phone.
3) Have emergency telephone numbers with you (facility manager, fire, police,
ambulance, veterinarian) as well as contact numbers (parents/guardians, next
of kin, family doctor) for the participants.
4) Have a medical profile for each participant on hand so this information can
be provided to emergency medical personnel. Include a signed consent from
the parent/guardian to authorize medical treatment in an emergency in this
profile.
5) Prepare directions to provide to Emergency Medical Services (EMS) to
enable them to reach the site as rapidly as possible. You may want to include
information such as the closest major intersection, one way streets, or major
landmarks.
6) Have a first aid kit accessible and properly stocked at all times (all coaches
are strongly encouraged to pursue first aid training).
7) Designate a “call person” (the person who contacts medical authorities and
otherwise assists the person in charge) in advance. Be sure that your call
person can give emergency vehicles precise instructions to reach your facility
or site.
When an injury occurs, an EAP should be activated immediately if the
injured person is not breathing, does not have a pulse, is bleeding profusely, has
impaired consciousness, has injured the back, neck or head, or has a visible major
trauma to a limb.
2.1.4. Evacuation Procedures, Escape Routes, and Floor Plans
In the event of an emergency, people need to respond quickly; knowing
where to go and how to get there is often an important part of a quick response.
Depending on the type of emergency, people will either need to exit the building as
quickly as possible or be prepared to navigate to a safer part of the building. It is
important each person knows exactly where to go in the event of an emergency. An
EAP should contain an up-to-date floor plan for the entire property. The floor plan
59
should include clearly marked evacuation routes and all emergency exits should be
easily identifiable. There are several categories of emergencies:
• Emergencies Within the Building
For emergencies occurring inside of the facility (e.g., fires, power outages,
etc.), the main goal is to get everyone out of harm way. To achieve this goal,
staff should be aware of the fastest and safest way out of the building.
• Emergencies Outside of the Building
In most cases, when an emergency starts outside of the building, the safest
thing to do is find a safe place within the building. Most often, emergencies
outside of the building will be weather-related or natural disasters.
• Health Emergencies
If someone inside of the building is injured or harmed in some way, an EAP
should be initiated quickly. Staff should be prepared to respond to a wide
range of plausible health scares such as a heart attack, seizure, possible
drowning and more.
2.1.5. Medical Emergency Plan
Whenever an employee or visitor is injured or develops a medical
emergency condition on plant property, follow the protocol below and notify your
immediate supervisor as soon as possible. Medical emergency instruction:
• Dial the plant infirmary and inform the nurse of emergency and its location
in the plant.
• If the nurse cannot be reached, dial emergency call, and inform any hospital
or fire department of the medical emergency. Give the dispatcher the nature
and location in the plant of medical emergency.
• Unless you have been designated by management to be a first aid responder,
do not provide first aid. Make the victim as comfortable as possible until
medical help arrives.
2.1.6. Emergency Alarm and Fire Fighting Strategy
The emergency plan must include a way to alert employees, including
disabled workers. Therefore alarm systems are installed to indicate the abnormal
conditions and problems of the plant and equipment to the operators, enabling them
to take corrective action and bring the plant/equipment back to normal conditions,
60
it provides warning for necessary emergency action and reaction time for safe
escape of employees. The alarm has to be distinctive and recognized by all
employees as a signal to evacuate the work area or perform actions identified in the
plan.
All of alarm which used for evacuation system has been meet the alarm
system standard from OSHA. Type of alarms which used in this plant:
a. Audible Alarm
Audible alarm serves as the first sign of emergency, it consists of horn and
sirens. Horns produce penetrating high ambient noise levels that is very loud
and distinctive sound that immediately attracts and draws attention. Horns
can be useful to call attention to critical situations. Signals other than those
used for evacuation purposes do not have to produce the temporal coded
signal. Thus, sirens produce a loud piercing wail that makes them ideally
suitable for initiating a site-wide evacuation.
Figure 2.13 Audible Alarm

(Source: www.hughes-safety.com)
b. Visible Alarm
A visual alarm provides persons with hearing loss the same warning
delivered to hearing persons by an audible alarm. Visual alarms are flashing
lights used as fire alarm signals. The terms visual alarm signal, visible signal
device, and visible signaling appliance are used relatively interchangeably
within the fire protection community; the National Fire Protection
Association (NFPA) calls them visual notification appliances.
Visual alarm with steady lights is well suited for areas where ambient noise
makes audible signals difficult to hear, for an example in area where the
compressor is in. These types of lights come with different colored covers
for increased attention and can be ordered with rotating or flashing lights.
61
Strobe lights use high intensity flash tubes that are ideally suited for areas
where high ambient light levels make traditional rotating or flashing lights
difficult to distinguish or where ambient noise makes audible signals
difficult to hear.
Figure 2.14 Visible Alarm

(Source: http://www.eufireandsecurity.com)
For firefighting, the plant has some equipment installed such as light fire
extinguisher (APAR), hydrant, and safety shower. Firefighting equipment is
equipment designed to extinguish fires or protect the user from fire. It may be used
by trained fire fighters, untrained users at the scene of a fire, or built into a building's
infrastructure. Firefighting equipment should consider some parameter such as:
• Appointment of fire wardens with subsequent training
• Location of safety shower, fire hose, extinguisher and water sources
• Access for emergency services
• Provision of firewater lagoons
There are several important aspects in firefighting equipment, which are:
1. Fire Extinguisher
Fire extinguisher is the equipment that is used to extinguish the fire in small
scale using water, dry chemical powder, foam, carbon dioxide, or other
substances. It usually comes in portable form, used to reduce their
destruction before firefighters arrive at the scene. Fire extinguisher which
will be used in the plant is class B fire extinguisher. This type usually used
for flammable liquids and gases considering that some materials in the plant
are flammable.
62
Figure 2.15 Fire Extinguisher

(Source: Occupational Safety & Health Administration, 2014)
2. Fire Hydrant
A fire hydrant is a visible fixture placed inside or outside a building, parking
area, industrial area, mine, roadside, etc. that is connected to the municipal
or a private water service network. Fire hydrants are designed to instantly
provide the water required by fire fighters to extinguish a fire. The water is
pressurized water which flows through pipes and fire hose to extinguish the
fire.
Figure 2.16 Fire Hydrant

(Source: oshonline.com)
3. Safety Shower and Eye Wash Station

Combination shower and eye-rinse stations is the proper emergency
equipment that can minimize workplace injuries and protecting employees.
The first 10 to 15 seconds after exposure to a hazardous substance,
especially a corrosive substance, are critical. Delaying treatment, even for a
63
few seconds, may cause serious injury. Emergency showers and eyewash
stations provide on-the-spot decontamination. They allow workers to flush
away hazardous substances that can cause injury. This equipment should
also provide a drainage system for the excess water and should not come
into contact with any electrical equipment that may become a hazard when
wet and should be protected from freezing when installing emergency
equipment outdoors. Whereas, an emergency blanket should be available
near the shower to prevent from shock and cover the place for removal of
clothes.
Figure 2.17 Combination of Safety Shower and Eyewash Station

(Source: eyewashdirect.com)
2.1.7. Emergency Operation Training

The emergency procedures should include instructions for dealing with
fires, leaks, and spills. The procedure should describe how to:
• Raise the alarm and call the fire brigade;
• Tackle a fire or control spills and leaks (when it is safe to do so);
• Evacuate the site, and if necessary nearby premises.
• Handle medical emergency or offering first aid
2.1.7.1. Fire
These instructions consist of a four-step procedure that employees should
follow during a fire. This procedure must be memorized by all employees.
Experience has demonstrated that the best response to a plant fire is first, to
sound the alarm, then let others know there is a fire, then to combat the fire if
64
possible, and finally, to evacuate if necessary. The plan works best when
expressed as an easily recalled acronym, such as SAFE
• S – Sound the alarm
Sound it yourself or call out to someone else to sound it. This allows the fire
department to be on its way while other activities are being performed.
• A – Alert others
Quickly tell others in the area of the fire. Do this in a calm, firm manner. Do
not cause a panic. Secure the area for the fire department. Close all doors
and windows to prevent the spread of smoke and flames. Call security to
give verification and information about location of fire.
• F – Fight the fire
Do this only in the case of a manageable fire, one that you have the training
and experience to fight. For example, fire in a wastebasket. If possible, two
employees should fight the fire together using two fire extinguishers. If you
have any doubt about your ability, then do not attempt to combat it.
• E – Evacuate the area
If necessary, the burned are should be evacuated until the authorities come.
2.1.7.2. Chemical Spill
This procedure outlines the steps to manage a chemical spill in order to
minimise the potential for injury and damage to the environment. Emergency
rocedures should consider the immediate danger to persons and ensure effective
containment and clean up, appropriate disposal of waste material and
notification to all relevant authorities. For major spill, the procedure is as
follows:
• Do not touch any harmful substance. Take precautions to protect yourself if
necessary.
• Raise the alarm – evacuate persons not involved in contamination from the
area. Isolate contaminated individuals and treat as per MSDS. Isolate
affected persons and keep on site. If required, summon the First Aid Officer.
• Contact authorities such as Lab Manager or Safety Coordinator or nearest
building warden. Advise to notify Emergency Services if necessary.
65
• Close doors to prevent further contamination. Secure the area to keep non-
emergency response personnel away from danger.
• Assist the emergency response personnel and supply the Material Safety
Data Sheet/s if the chemical/s are known.
• In conjunction with expert assistance, minimize the spread of contamination
and commence decontamination/clean up procedures.
And for minor spill,
• Containment - spills must be cleaned up promptly and thoroughly.
• Approach with care - many harmful chemicals lack color or offensive odors.
Never assume that they are harmless.
• Identify the chemical/s and hazards involved – check Material Safety Data
sheet.
• Use the information on the physical and chemical properties of the material
to judge response and/or evacuation procedures.
• Decontaminate equipment, clothing and personnel, including any victims,
on site if necessary.
• Dispose of contaminated equipment and materials only after receiving
specialist advice.
• Ensure emergency procedures are in place and practiced
2.1.7.3. Gas Leak
When suspecting there are a gas leak, safety procedures are as follow:
• Avoid inhaling vapors and contact with liquid or gas.
• Turn off the supply also close the emergency shutdown valve (ESDV)
• Never operate any valves when being panic, because a wrong action
although just a simple action will cause to another new emergency situation
• Close the doors, windows or any gaps to block off the air vents if the leak is
near the building. It is done to prevent the gas from getting into the building.
• Move and evacuate the people upwind from the gas leak-area.
• Avoid any action which could generate smoke, such as smoking, turning is
the vehicle engine, etc.
• Immediately call the local fire station.
66
• If in doubt, evacuate the building and inform the police as well as the
National Gas Emergency Service or your gas supplier.
• Gather with others in the muster point nearby.
2.1.7.4. Accident of Equipment
When there is accident from equipment, safety procedures are as follow:
• Check whether there is any leakage or not
• Move people away from the area and gather in assembly point
• Call the brigade, police and also ambulance
2.1.7.5. Medical Emergency
The direction provided in these procedures is intended to create a
standard set of protocols whenever an employee or visitor is injured or develops
a medical emergency condition on plant property.
• Notify the Incident Management Team (IMT) or dial the plant infirmary and
inform the nurse of emergency and its location in the plant.
• If the nurse cannot be reached, dial emergency call, and inform any hospital
or fire department of the medical emergency. Give the dispatcher the nature
and location in the plant of medical emergency.
• Unless you have been designated by management to be a first aid responder,
do not provide first aid. Make the victim as comfortable as possible until
medical help arrives.
2.8. Waste Management
Industrial activities usually give a residue from processing which is called

as waste. Waste of processing in industry has to be handling well or else it may give
damage that affect environment or sustainability of production in plant.
Government gives boundary for every industrial plant to process their waste based
on Human Safety Environment. The waste have been classified based on the type
or phase, which are solid waste, gas waste, and sound (noise) waste. Management
for the waste will be explained below.
2.1.8. Solid Waste
There are two process for solid waste handling, the first one is total
dispersion, the second one is separation of the suspended solids and liquid
67
dispersion. In this plant solid waste is handled by Separation of suspended solids

and liquid dispersion process is using physical separation of solid and liquid phases.
The liquid waste will be brought to the settling pond and the suspended solid will
be achieved in settling ponds. The solid particles can be used to build up the walls
as the deposit in the basin accumulates. The aqueous can be collected and being
control for concentration checking and adjustment of pH. The typical value of pH
of aqueous effluent is higher than 11.5 due to the alkalinity of OH ions from
Ca(OH)2.
2.1.9. Sound
Sound is generated by rotating equipments. Operation of rotary tools in the
plant, such as pumps and compressor motors drive is a source of noise. The noise
level rotary tools are depending on the type of rotary tools, capacity, performance,
area and equipment operating effectiveness of treatment or preventive maintenance
programs are conducted. To reduce the noise level, performed regular maintenance
and replacing parts causing noise.
Noise not only damage the health of personnel, can also damage to the
mechanical system on the appliance. To reduce the noise level, performed regular
maintenance and replacing parts causing noise. Workers need to use ear plugs if
they’re entering the plant area. Tools such as damper can be applied for equipments
or tools that can generate noise.
The noise standards set by the Ministry of Health is 60-70 dB and according
to the Ministry of Manpower Decree No. Kep.51/MEN/1999, the TLV (Threshold
Limit Value) for noise hazard is 85 dBA. Noise level exceeding the limit can cause
disorder includes physiological and psychological disorder. To overcome those
disorders, control of noise is needed by following procedures:
• Eliminate noise transmission to workers. To eliminate or reduce the
transmission of noise to do with insulation workers labor or machinery is to
shut down or isolate the machine or equipment that emits noise. Basically
to cover the noisy machines are as follows: Close the engine as close as
possible, rework the doors and all the holes are acoustic. If necessary, isolate
the machine from the floor to reduce vibration propagation.
68
• Eliminate the noise from the sound source. Eliminating noise from the
sound source can be done by putting the marinade in a vibration source.
Providing protection to employees. Efforts to protect employees from noise in the
work environment can be applied by wearing ear protection devices or personal
protective equipment, in the form of ear plugs and ear muffs.
69
3 CHAPTER 3
PLANT LAYOUT
3.1. Plant Location
Plant location takes a huge contribution on plant layout and operation of

process in a plant because its location will establish an efficient and effective
operation process and cost. There are several factors that should be considered
which affect the continuity of the production such as location accessibility, raw
material and labor source, proximity to markets, environmental condition,
electricity, water, public utilities, civil amenities, communication, and land
development availability. Based on those considerations, the plant will be
constructed in Jl. Brotonegoro, Kebomas, Gresik, East Java.
This area which organize by Gresik Industrial Estate (KIG) is facilitated
with waste water treatment plant, sewer system for rain water drainage, and port.
Moreover, most of the raw materials are produced in East Java, such as calcium
carbonate, limestone, and ammonia, hence this location selection is highly efficient
in cutting the transportation cost. In reaching the market of sodium carbonate which
mainly centered in Java Island, product will be distributed by truck through
Surabaya-Gresik highway, 8.3 km from plant location. If there is a consumer across
the island, this location is also supported with 6 km from Pelabuhan Gresik.
In supporting process and business operation, this location also equipped
with 400 telephone nertworks, electricity which is supplied by State Electricity
Company (PT PLN), and clean water from PT Petrokimia Gresik which taken from
Bengawan Solo river. The total are of the plant is 26,793.06 m2. The location
viewed from Google Earth is shown below.
70
Figure 3.1 Plant Location

(Source: Google Earth)
3.2. Plant Layout
3.2.1. General Consideration of Plant Layout

Plant layout or plot plan is made with the aim of reaching safety works,
maintenance , number of workers, construction cost, and the overall operating cost.
It is done with a plot of all equipments and machine, storage, buildings, and
operational route. The general principle is to watch for wind flow direction, and
classify the area based on potential hazard.
All equipments that produce flammable materials are located in downwind
side, while the ones which do not handle flammable and hazardous substances are
located in the upwind side. Equipments located on the downwind side include only
rotary kiln that have a burner and other equipment placed on the upwind side.
After that, classification of area is made to produce a simple area
classification layout. The equipments are arranged in the layout through the
consideration of minimum safe spacing between equipments and based on wind
flow direction which is to Northwest (BMKG, 2019).
71
Figure 3.2 Wind Flow Direction

(Source: BMKG.go.id)
3.2.2. Safe Range Between Equipment

The second important thing to consider for plotting equipments are safe
range between equipment which usually called battery limit. The definition of
battery limit comprises one or more geographic boundaries, imaginary or real,
enclosing a plant or unit being engineered and/or erected, established for the
purpose of providing a means of specifically identifying certain portions of the
plant, related groups of equipment, or associated facilities. Battery limit is a defined
boundary between two areas of responsibility, which may be physical (e.g. a flange
on a pipe); or represented by a map coordinate; or some other means (for example
a point in time). These should be described in the most appropriate way (for
example, a drawing, map, or verbal description). Battery limit drawings or
definitions are often contained in an interface document. There are two types of battery
limit, inside battery limit (IBL) and outside battery limit (OBL). Inside Battery Limits
is defined as all equipment and associated components (piping, etc.) that act upon the
primary feed stream of a process. ISBL is functional-based and refers to equipment and
other components that are solely dedicated to a single process whether or not the
equipment is physically located within the geographical boundaries of the unit. Outside
Battery Limits (OSBL) is defined as utilities, common facilities, and other equipment
and components not included in the ISBL definition. OSBL refers to systems
72
(equipment pieces and associated components) that support several units. Typical
OSBL equipment includes cooling towers, water treatment facilities, tanks farms, etc.
Rules of thumb for safe range between equipment are applied for constructing
a plant layout. It can be inferred through the following figures.
Figure 3.3 Battery limit between storage tanks and vessels

(source: Process Control: GAPS Guidelines, 2010)
73
Figure 3.4 Outside battery limit values

Figure 3.5 Inside battery limit values

74
The value of minimum distance between equipments and areas are gathered
through the preceding figures, and tabulated as follow.
Table 3.1 Minimum Distance between equipment
Equipment Distance
Section
From Code To Code ft Meter
Brine Tank TK-101 Brine Reactor R-100 50 15.25
Ammonium
Area Brine Reactor R-100 TK-102 50 15.25
Tank
100
Heat Exchanger E-100 Heat Exchanger E-101 5 1.525
Ammonium Tank TK-102 Heat Exchanger E-100 50 15.25
Natrium
Ammonium
T-200 Bicarbonate T-201 15 4.575
Bicarbonate Reactor
Area Reactor
200 Natrium Bicarbonate Rotary Drum
T-201 F-200 25 7.625
Reactor Filter
Rotary Drum Filter F-200 Prelimer R-200 25 7.625
Rotary Kiln DD-300 Rotary Filter F-300 50 15.25
Area
300 Lime Milk
Rotary Filter F-300 V-300 50 15.25
Vessel
Area Rotary Dryer E-401 Fin fan Cooler E-402 15 4.575
400 Fin fan Cooler E-402 Ball Mill V-200 15 4.575
Water Vessel
Water Storage Tank TK-500 V-500 14.5 4.4225
Tank
Area Water Vessel Tank V-500 Cooling Tower CT-100 250 76.25
500 Sanitation Water
Cooling Tower CT-100 V-501 250 76.25
Tank
Sanitation Water Tank V-501 Control room 50 15.25
3.2.3. Area Classification Layout

Through the classification of area described in previous section, a brief plant
layout plotting all areas are to be made. The plant has the overall area of 26,793.06
m2 divided into 5 areas.
• Area 100 is the brine purification area
• Area 200 is the absorption column area
• Area 300 is Kiln area
• Area 400 is Na2CO3 Product area
• Area 500 is utility area
75
Figure 3. 6 Area Classification
3.2.4. Overall 2D Plant Layout

The plant has several stages in the process from unloading raw material to
end product and waste management. This plant separates the process into many
sections. First, the processes begin with several processes such as kilning limestone
and purifying brine. After that, brine will be on the absorption area and carbon
dioxide that comes from kiln go to the carbonation to make NaHCO3. Then,
NaHCO3 will be dried becoming solid. The other areas are for the utility. The figure
below represents the overall 2D plant layout.
76
Figure 3.7 2D Plant Layout
77
Figure 3.8 Plant Layout Area
78
Figure 3.9 Plant Layout Zoom
4 CHAPTER 4
CONCLUSION
1. Process control is conducted to control all process variables and aim seven
objectives in process control. The variables controlled are pressure,
temperature, level, flow, and analyzer parameter (concentration).
2. In each process control, determination of manipulated and controlled
variable, as well as controller and controlling procedure is made through the
whole process interpretation.
3. Process and Instrumentation Diagram is made for displaying control process
and piping. The components include instrumentation, process equipment
and stream number, and pipe size.
4. HAZID analysis identifies that most processes in the plant have major level
of severity, unlikely level of frequency, and overall medium hazard index.
Area 200 and 300 has the highest hazard index.
5. HAZOP analysis identifies that absorber and rotary kiln are the equipments
that must be concerned with a number of hazardous factors. The major
parameter deviations in overall processes are pressure and temperature, with
the major preventive actions are automatic controllers.
6. The plant has complex operational details due to a large number of
equipments. It covers the initial commissioning phase, which is consisted of
mechanical completion and integrity checking, utilities commissioning, and
operational testing, the start-up procedure, and the shutdown procedure.
7. Consideration of Material Safety Data Sheet is to be made to know the risk
regarding flammability, reactivity, and health for main substances used in
plant.
8. For worker protection from injuries and illnesses, the major personal
protective equipments used are gloves, safety glasses and shoes, earplugs or
muffs, hard hats, respirators, or coveralls, vests and full body suits.
9. In case of hazards conditions happen, emergency procedure is crucial to
make sure everything is safe and in under control again for the workers,
equipment, and process itself. Emergency operating procedure and train the
workers is needed. Emergency alarm and fire-fighting equipment also have
to provided, and also design emergency escape route and procedure is
needed.
10. Plant process generates several wastes. Wastes produced will be sent
directly to waste storage.
11. The plant will be built with total area of 26,793.06 m2. It consists of 5 areas
with different function and connected with each other.
12. Spacing between process instruments is ruled by Inside Battery Limit (IBL),
and the spacing between supporting facilities is ruled by Outside Battery
Limit (OBL). The main consideration of plant layout is area classification
and minimum equipment spacing.
REFERENCES
BMKG | Badan Meteorologi, Klimatologi, dan Geofisika. (2019). Prakiraan Angin
3000 Feet | BMKG. [online] Available at:
https://www.bmkg.go.id/cuaca/prakiraan-angin.bmkg [Accessed 22 Nov.
2019].
Branan, Carl. 2002. Rules of Thumb for Chemical Engineers. Houston: El- Sevier.
Braint. 2015. Additional Technical Readings for Equipment Layout. Depok:
Chemical and Bioprocess Engineering University of Indonesia
Canadian Centre for Occupational Health & Safety. (2017). OSH Answers Fact
Sheets. Dipetik November 12, 2017, dari
https://www.ccohs.ca/oshanswers/legisl/msdss.html
Cholamandalam MS Risk Services Limited. (t.thn.). Hazard Identification Studies
(HAZID). Diambil kembali dari http://www.cholarisk.com/services/process-
safety/qra-hazop/hazardidentification-studies-hazid/
Equine Canada and Coaching Association of Canada. (2012, May 2). Emergency
Action Plan (EAP). Dipetik November 12, 2018, dari https://horse.on.ca/wp-
content/uploads/2011/10/Emergency_Action_Plancopy.pdf
Environmental Protection Authority. (2012, May 30). Emergency procedures.
Diambil kembali dari https://www.worksafe.govt.nz/worksafe/information-
guidance/all-guidance-items/hsno/guidance-docs-epa/emergency-
procedures-template-pdf
Hse.gov.uk. (2017). Personal Protective Equipment (PPE). [online] Available at:
http://www.hse.gov.uk/toolbox/ppe.htm [Accessed 14 Nov. 2017].
Liebermann, E.T., 2008, A Working Guide to Process Equipment, 3ed, McGraw-
Hill, New York.
Seider, W. D., Seader, J. D. & Lewin, D. R. 2003. Product and Process Design
Principles, John Wiley and Sons, Inc.
United States Department of Labor. (t.thn.). Evacuation Plans and Procedures
eTool. Diambil kembali dari
https://www.osha.gov/SLTC/etools/evacuation/alarms.html
5 APPENDICES
APPENDIX A
Ammonia MSDS
83
84
85
86
87
88
89
APPENDIX B
Brine Solution MSDS
91
92
93
94
95
APPENDIX C
Limestone MSDS
97
98
99
APPENDIX D
Calcium Oxide MSDS

101
102
103
104
105
106
107
APPENDIX E
Sodium Carbonate MSDS

109
110
111
112
113
114
APPENDIX F
Polyacrylamide MSDS

115

116

117

APPENDIX G
Carbon Dioxide MSDS

119
120
121
122
123
124
125
APPENDIX H
Ammonium Hydroxide MSDS

127
128
129
130
131
132
APPENDIX I
Sodium Bicarbonate MSDS

134
135
136
137
138
139
APPENDIX J
Ammonium Chloride MSDS

141
142
143
144
APPENDIX K
Calcium Hydroxide MSDS

146
147
148
149
APPENDIX L
Calcium Chloride MSDS

151

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PRELIMINARY DESIGN OF SODIUM CARBONATE PLANT

CHEMICAL ENGINEERING DEPARTMENT

EXECUTIVE SUMMARY ................................................................................... ii

Figure 1.1 P&ID Area 500 (Utilities) .................................................................... 5

Table 1.1 Pipeline Spesification Area 100 ............................................................. 2

vii Universitas Indonesia

1.1 Pipeline Specification

Table 1.1 Pipeline Spesification Area 100

Table 1.2 Pipeline Spesification Area 200

Table 1.3 Pipeline Spesification Area 300

Table 1.4 Pipeline Spesification Area 400

Table 1.5 Pipeline Spesification Area 500

1.2 Utility Piping and Instrumentation Diagram

Figure 1.1 P&ID Area 500 (Utilities)

1.3 Utility Control Tabulation

Process Controlled Controlling

When the level of column reach higher than 80% of column

1.4 Production Process Piping and Instrumentation Diagram

Figure 1.2 P&ID Area 100

Figure 1.3 P&ID Area 200

Figure 1.4 P&ID Area 300

Figure 1.5 P&ID Area 400

1.5 Production Process Control Tabulation

Table 1.7 Plant Control Area 100

Process Controlled Manipulated

Table 1.8 Plant Control Area 200

Process Controlled Manipulated Final

Table 1.8 Plant Control Area 200 (cont’d)

Process Controlled Manipulated Final

Table 1.9 Plant Control Area 300

Process Controlled Manipulated Final

Table 1.10 Plant Control Area 400

Process Controlled Manipulated Final

2.1. Hazard Identification Study (HAZID)

Hazard Identification (HAZID) is a qualitative technique for the early

Figure 2.1 The General HAZID Process Scheme

Parameter Severe Major Minor

Table 2.2 Hazard Frequency Parameter for HAZID

Parameter Most Likely Unlikely

The identification of hazard is stimulated by guidewords, which formulate

The HAZID analysis of the plant is shown in the following table.

Table 2.4 Plant Hazard Identification (HAZID) (Cont’d-1)

Table 2.4 Plant Hazard Identification (HAZID) (Cont’d-2)

Table 2.4 Plant Hazard Identification (HAZID) (Cont’d-3)

Table 2.4 Plant Hazard Identification (HAZID) (Cont’d-4)

Overcapacity/ Flow Flow control

Table 2.4 Plant Hazard Identification (HAZID) (Cont’d-5)

Loud opeartion Used earmuff for

Rotary To seperating Checking flow

Worn out valves Monitoring Production Checking valves

Table 2.4 Plant Hazard Identification (HAZID) (Cont’d-6)

Reactor To recovery Temperature, Monitoring and

Dust from the Using PPE for

Used earmuff for

Seperating dust Claning the fan

Table 2.4 Plant Hazard Identification (HAZID) (Cont’d-7)

2.2. Hazard and Operability Study (HAZOP)

Hazard and Operability Study (HAZOP) is a structured, systematic

5. Determination of overcome action to every deviation happened.

Table 2.5 HAZOP in Sodium Carbonate Plant

Table 2.5 HAZOP in Sodium Carbonate Plant (Cont’d-1)

Table 2.5 HAZOP in Sodium Carbonate Plant (Cont’d-2)

Table 2.5 HAZOP in Sodium Carbonate Plant (Cont’d-3)