MEng Chemical Engineering

Year 2

CHEN20151 Safety and Reliability Engineering

Professor Stuart Holmes

Coursework:
HAZOP MEG Reclamation
Group LL:
Ana Carmem Guilherme Bacchin ID
Ana Maria Garcia Lima ID
Bernardo de S Rollemberg ID
Gabriel Vasconcelos de Souza ID
Gabriela Filipini Ferreira ID 9571232
Maximiano Kanda Ferraz ID
Raphael de Souza Rodrigues ID

Manchester: December 2014.

SUMMARY

Hazard and operability (HAZOP) methodology is a technique used worldwide for studying
not only the hazards of a system, but also its operability problems, by exploring the effects
of any deviations from design intentions. The methodology consists of finding deviations
in existing or planned processes, and afterwards, analyzing its causes, consequences, the
safeguards designed and propose actions if necessary. To conduct this study, it is
necessary a group of specialized professionals, e.g., process engineers that are qualified
for the specific task and process. Therefore, they consist of the HAZOP team. A HAZOP
study is proposed for a Mono-Ethylene Glycol (MEG) Reclamation plant, where it is
important to recover MEG from gas production industrial scale plants since this compound
prevents the formation of hydrates that can clog the equipment. Also, MEG is an
antifreeze and anticorrosion agent.

INDEX

1.
2.
3.
4.

Introduction
MEG Reclamation Pilot Plat
Design Intention
Reports
4.1. Secretary
4.2. Mechanical Engineer
4.3. Process Engineer 1
4.4. Process Engineer 2
4.5. Process Engineer 3
4.6. Process Engineer 4
4.7. Instrument Engineer
5. HAZOP
6. Bibliography
7. Annex

1. INTRODUCTION

In the 1960s, the chemical industry in the United Kingdom was expanding,
increasing both the scale and the range of materials manufactured and handled. Also,
there were economic pressures encouraging construction of larger plants that could be
built and run with basic control and operating systems. But a downside of these trends
was the potential for large scale incidents with major consequences, such as fatalities and
complete loss of production.1
The HAZard and OPerability HAZOP (HAZOP) technique originated in the Heavy
Organic Chemicals (HOC) Division of Imperial Chemical Industries (ICI), a British chemical
company and the largest manufacturer in Britain for much of its history. Trevor Asher
Kletz was a British author on the topic of chemical engineering safety and the main
promoter of HAZOP. He was the companys safety advisor from the 1960s to the 1980s. 1
In the 1960s, it was decided to apply some of the principles in a critical
examination of the design of a new phenol plant for the HOC Division and a small team
worked for several months on the lines diagram. The outcome was that the questioning
technique used uncovered many potential problems. As the method was considered too
detailed and time consuming, it was decided that it was better to search for deviations.
The method was further refined within the company, under the name operability studies
and in the 1970s, it was offered a safety course by the Institution of Chemical Engineers
(IChemE) at Teesside Polytechnic. The term HAZOP was first used in formal publications by
Kletz and by the 1980s, the hazard and operability studies had become an expected part
of chemical engineering degree courses in the UK.1
By the 1990s, the technique was in use worldwide with descriptions in publications
of the Center for Chemical Process Safety of the American Institute of Chemical Engineers
(AIChemE). This encouraged its adoption in the USA and around the world. So the position
today is that HAZOP study is a well stablished and proven method, used in many industries
and many countries.1
A hazard and operability study (HAZOP) is a formal and effective procedure for
identifying hazards in industrial units, being the most widely used worldwide. It is carried
out by a team, usually including a chairman, secretary, engineers and others during a set
of meetings. The technique aims to identify hazards and operability problems in a process
plant and its methodology is based on qualitative procedure, which generates a structured
and systematic set of deviations through the appropriate use of guidewords and
parameters.2,3,4

In order to identify deviations, the team generates a list of guidewords to each

section of the process, such as No (meaning complete negation of design intention),
More (qualitative increase), Less (qualitative decrease), Reverse (logical opposite of
the design intention), etc. Also, they need to consider appropriate parameters which apply
to the guideword, such as Flow, Temperature, Pressure, Composition, etc.
The purpose of a HAZOP is to investigate thoroughly and methodically each
segment of a process aimed at discovering the possible deviations from normal operating
conditions, identifying the causes responsible for the abnormalities and their
consequences, in different points of the system (nods). Thus, this study suggests measures
to eliminate or control the hazard of these points.5
HAZOP method is applicable to planned and existing processes, and for continuous
ones, information such a piping and instrumentation diagram (P&ID) is required. After
pointing deviations and its causes and consequences, it can be decided whether designed
safeguards are sufficient, or additional actions are necessary to reduce risk to an
acceptable level. Hence, the system being studied can then be modified to improve its
safety. The modified design should then be subject to another HAZOP, to ensure that no
new hazards have been added. 5
The focus is both for safety issues, identifying hazards that can endanger operators
and equipment, as well as the operability problems, which can affect the efficiency of the
production process, the environment and product quality. 6
Summarizing the HAZOP study in steps:

Identification of process deviations;

Determination of potential causes of deviations;
Determination of potential consequences of deviations;
Identification of safeguards to prevent occurrence of deviations;
Definition of actions to reduce the risks to acceptable levels;
Report.

Some of the benefits of using this method are: improvement in operational

performance of the company, always in safe conditions; improvement in quality of the
project under the aspects of safety, health and environment; proposed guidelines for risk
management actions for rescuing both environmental and health and safety at work;
identification of issues of product quality and service, which are associated with
operational deviations.

2. MEG RECLAMATION PILOT PLANT

Natural gas is extracted from deep under the ocean using long pipelines that are
exposed to extreme cold conditions. Besides this adverse condition, salt, water and
corrosion also attack the transport pipelines. The raw gas that passes through these
pipelines is mainly consisted of gas, oil and water. At lower temperatures and high
pressures, the water tends to form hydrates, which resembles ice molecules and when
they form they are very difficult to remove. Therefore, after a certain time, the hydrates
will block the process lines, causing disruption of the production. An alternative to avoid
this is to introduce Mono-Ethylene Glycol (MEG) into pipelines as an antifreeze and
anticorrosion agent. MEG is injected into a pipeline to prevent or inhibit the formation of
hydrates and it is able to do so by depressing its temperature of formation. However, to
perform this function, the MEG has to be kept continuously free of unwanted substances.
MEG is returned to the processing facilities with water and other dissolved salts.
These have to be removed from the MEG so it can to be re-injected into the gas
production pipeline by recycling.7
In the present work, the P&ID studied is from the MEG Reclamation pilot plant in
James Chadwick Building from The University Of Manchester. It was designed to replicate
the salt removal stage of Camerons PureMEGTM process. In an Oilfield situation the full
size MEG Reclamation Unit that was based on this Pilot Plant would be located on the
Oilrig.
Camerons plant is utilized to recover the MEG and water from a mixture of MEG,
water and salts. When the mixture contacts a heated recycle flow of MEG, MEG and water
are vaporized and separated by a distillation column. Salt accumulates, crystallizes and is
discharged from the process. The process occurs under vacuum to avoid the temperature
rising, because this could cause MEG degradation and encrustations on equipment.8
The PureMEG process has been designed to remove salts with minimum losses of
MEG, also removing water to achieve the purity of product desired. The process consists
of five main steps:

Pre-treatment
Flash separation
MEG regeneration
Salt management
Calcium removal

At the pre-treatment stage, rich MEG, dissolved gas and hydrocarbon liquids pass
through a three-phase separator vessel. The gas is flashed, and recovered hydrocarbon
liquids are sent to production separator, while rich MEG is sent to the flash separator.
There, it is in contact with a hot recycle flow of MEG, and the temperature is decreased by
vacuum operation. The MEG and water of the rich MEG are flashed and exit through the
top of the flash separator where they are sent to the MEG distillation column for
regeneration, while the salts are precipitated.
The distillation column also operates under vacuum and distills water, leaving
PureMEG produced at the bottom that is storage for reuse. The water is condensed and
collected to treatment. The salts from the flash separator are separated by gravity to the
bottom of the brine column, where they are transferred to the salt tank. As they are
mainly composed of sodium, potassium, calcium and magnesium, and calcium and
magnesium are not effectively precipitated, there is a separate calcium removal process.
Camerons PureMEG process applies specialist knowhow and patented design
features, which include:

Use of spiral-type heat exchangers that are more tolerant of salty conditions than
other types of exchangers.
Patented design of the flash separator to reduce the population of salt crystals in
the heated recycle stream.
Extraction and cleanup of the salt using a patented salt-management technology.
The result is a design that is best practice in extracting large quantities of salt with
reduced MEG losses, environmental impact and downtime.

Figure 1. PureMEGTM process from Cameron.

Figure 2. MEG Reclamation process from the James Chadwick Building (The University of
Manchester).

3. DESIGN INTENTION

The Design Intention describes how the model should be created and how it
should behave when it is changed. The design intent documentation is crucial to the postconstruction commissioning process (verifying the proper installation, operation, and
performance of energy-efficiency features), and it is the essence of communication and
contractual obligation between the building owner, architects, engineers, builders, and
commissioning agents. This section will describe the MEG Reclamation Design Intention.
For the MEG Reclamation Process in study, the feed mixture is composed by (MEG,
water and salt) from the MEG Pre-Treatment Process. The feed is storage in a Mixing Tank
(F101), typically at 60-70 kg/h, 30-70wt% MEG, 2-4wt% salt. Valves (V103, V105 e V106)
and the pump J100 control the input flux in F101. The temperature monitoring is
performed by TE100. The pressure inside the Mixing Tank is atmospheric. The pump J101
acts with valves (V108, V109, V110 and V111) to control the level of F101. The
temperature of J101 is always monitored by TE101 in case of overheat due to excess on
speed motor rotation. The pump J101 provides energy to drive the liquid from tank F101
to the Flash Separator vessel (K200). Valves V112, V113 also control the output flux which
goes to K200.
The pressure inside the Flash Separator must be between 0.2-0.3bara (PI202 and
PIC203 are responsible for controlling pressure values). The function of K200 is to vaporise
the MEG and water components of the feed and leave behind the salt component. At the
specified pressure, MEG degrades approximately above 165oC. If the pressure rises near
to atmospheric (1.0bara), MEG would degrade before it boiled off from the vessel. In this
case, the boiling point of MEG is approximately 200 oC, That is why the system should be
kept under vacuum to reduce the temperature in K200 (the vacuum pump J200 is
responsible for maintaining this pressure).
The Vacuum Pump J200 has two catch pots (K201 and K202) to prevent liquid
entering the pump and further damages. When K200 operates at the pressure 0.20.3bara, there will be no flammable atmosphere in it. If the pressure becomes high in
K200, a flammable atmosphere at a temperature above its flash point may be created,
depending on the MEG/Water ratio used. Then, filtered air (Z203) will be drawn into the
system via the valve (V222) to enable the control valve (PCV203) to operate.
At the Flash Separator K200, the temperature is controlled by a large recycle flow
(3,000-6,000 kg/h, 94%MEG, 1%H2O, 5%NaCl). The Recycle Pump J300 and the Recycle

Heat Exchanger H300 are responsible for the flux and temperature of the recycle flow. The
steam system provides heat to H300.
At the top of Flash Separator K200, the exiting vapour is composed of MEG and
water. This mixture is cooled in Condenser C201 and Sub-Cooler C301. The temperature of
C201 and C203 is controlled by the flux of cool water via valves V221 and V306. The liquid
salt free MEG-water mixture passes to the Condensate Separator Tank (K300), where the
level is controlled by LLHS306, LSL305 and J400 (reciprocating pump). The salt free MEGwater is pumped to the Storage Tank R500. When required, MEG-water can be pumped
via J500 back to the storage tank F101.
The particles of salt formed in the Flash Separator (K200) fall under gravity through
the Downcomer (E200) into the Salt Tank (R400). Sections in E200 are filled with saltsaturated sodium chloride brine (26wt% NaCl in water, density 1,200 kg/m3) to wash MEG
residues from the crystals. Samples are collected when required trough six different points
in E200 with conductivity probes (CT200, CT300-304). The sampling receiver (R404) is
designed to be evacuated by the same vacuum line (J200). This line is then isolated and
the required valves (V400-V410) are opened to sample a section of the Downcomer E200.
The pressure is monitored by PI400-403.
The bleed receiver (R403) is bigger than the sampling receiver (R404) in order to
remove larger quantities from the Downcorner section, but both works in the same way.
The salt pump J401 is responsible to pump the salt crystals at the bottom of E200 into a
Brine Tank (R401) where water is added to dissolve the salt and produce a salt-saturated
brine. Brine is directed back into the Salt Tank to maintain a recirculating flow of brine
through the Salt Loop. The temperature of this unit and of the pump is well controlled by
TE400-TE410.
The Chemical Dosing Tank F100 has a Barium Chloride, Calcium Chloride and
Sodium Acetate solution. The pump J100 controls the flux into the Flash Separator and
Storage tank to test their effect on the process. This tank is responsible for controlling the
salt concentration at the feed of K200.

4. REPORTS

4.1.

Secretary report

Secretary: Ana Carmem Guilherme Bacchin

Date: 5th, 6th, 12th, 13th,18th,20th, 26th, 27th
November and 3rd, 9th, 10th December
- 2014
Time: Various
Cc list:
Ana Carmem G. Bacchin Secretary
Bernardo de S
Process Engineer
Rollemberg
Maximiano K. Ferraz
Process Engineer

Location:

James Chadwick building and

Learning Commons study rooms.

Gabriela F. Ferreira
Ana Maria G. Lima
Gabriel Vasconcelos
de Souza
Raphael de Souza
Rodrigues
Comments

Chairperson
Process Engineer
Process Engineer
Mechanical Engineer

Item
1.0
Previous minutes.
1.1 The group defined who will carry out each role during the study project.
The division of roles between members was made in agreement to all.

Action

1.2

The Secretary was responsible for booking study rooms once per week Secretary
(3 hours) at the Learning Commons for weekly meeting. One shared
paste on Dropbox was created to information/reports done so
far/questions being easily accessible among the group.

1.3

All members received a task to work until the second meeting. The task All
consisted on a research about the MEG Reclamation Process,
specifically the process equipment and instrumentation control. The
aim was a further discussion for the safety process analyse.
Comprehension of the process.
All members have discussed the MEG Reclamation process. The second
meeting was dedicated on sharing the knowledge about the chemical
process. All engineering have spoken during 5-10 minutes about their
own report. Concepts have been discussed. They also found some
mistakes on P&ID of the MEG Reclamation Rig. The meeting was
dedicated to clarify the whole process to the group.

2.0
2.1

2.2

There were some questions about the process raised by the engineering All
group. After long discussion, the group have solved most of them. The
other ones were noted for further clarification with members of staff
and demonstrators during the tutorial period.

2.3

3.0
3.1

In the third meeting, the remaining questions were solved. Therefore, Chairperson
there was a complete understanding of the process in study. Then, the
Chairperson wrote a summary, introduction, a brief explanation about
the MEG Pilot Plant Reclamation and safety conduct in laboratories for
been included in the final work.
Identification of nodes.
There were fourteen different nodes highlighted in the P&ID. Each node
was identified with a specific colour. A virtual version was downloaded
on Dropbox like a pdf document.

3.2

The nodes were analysed carefully by the group. Two of them were All
chosen to be studied in future meetings because they were considered
to have a higher degree of complexity. Therefore, it will need the
contribution of the entire study group. The first one was from Chemical
Dosing Tank (F100) to the Flash Separator (K200), passing through
pump (J100). The second one was from the Downcomer (E200) to the
Receivers (R403 and R404).

3.3

The other nodes were divided among engineers, each one responsible Engineering
for the existing nodes in the area on which conducted the report. The
deadline to work in the own node was 9th December, when it will be a
meeting for discuss and put all the analyses together. This task was
advised to be done asap.

3.4

Engineers have consciousness that they can ask for help to any member
of the group and convene a special meeting for any particular case
when necessary.

4.0
4.1

4.2

5.0

Hazard and Operability analysis (HAZOP)

Deviations were raised by the engineering. Then, the cause, safeguards All
and action were analysed for each deviation. However, there were
many suppositions and different ideas. Then, the group decided to
make a reorganisation of the nodes.
The mechanical engineering organized all the valves in tables. The Engineering
group decided which of them could be the most important to analyse
first. The hazard and operability analysis performed together were
completed and later discussion about all HAZOPs were performed.
Final Meeting
The last meeting was dedicated to review, formatting and printing.

All

4.2.

Mechanical Engineer report

Mechanical Engineer: Raphael de Souza Rodrigues

According to The Pressure Systems Safety Regulations 2000, Pressure System is

defined as a system comprising one or more pressure vessels of rigid construction, and its
associated pipework and protective devices, to which a transportable pressure receptacle
is, or is intended to be, connected; or a pipeline and its protective devices. The difference
between them is that the last one doesnt have a transportable pressure receptacle.
Pipeline and pipework mean a system with one or more pipes associated to pressure
containing components as valves, pumps and compressors, but the pipework does not
include a pipeline or any protective device. The pressure system deals with relevant fluids
(steam, fluids or mixture of fluids at pressures greater than 0.5 bars above atmospheric)
and all devices of the system must work into the safe operating limits, so systems failure
problems are less likely to occur. For that, there must be details about devices fatigue and
creep life, acceptable working pressure, temperatures, flow rates and discharge
capacities, corrosion allowances, volume capacities and materials of construction.
In a pressure system, pressure vessels are mostly metal containers, usually
spheroid or cylindrical, capable of withstanding various loadings. They are designed to
keep gases or liquids at a pressure different from ambient. Pressure vessels are used as
industrial compressed air receivers, domestic hot water storage tanks, diving cylinders,
recompression chambers, distillation towers, pressure reactors, autoclaves, and many
other in mining operations, oil refineries and petrochemical plants, nuclear reactor vessels
and storage vessels for liquefied gases such as ammonia, chlorine, propane and butane.
A vessel or containment system can be designed to withstand any pressure to
which it may be subjected. More usually it is designed to withstand predetermined
maximum and minimum pressures and then provide with a reliable relief device that will
protect the system against any pressure outside this range. The relief device should be
independent of any pressure measurement or control and ideally should not share the
same piping connection. The relief device should only function in the event of some
recognized abnormal contingency and should not be required during normal operating
modes, e.g. start-up or shut-down. The most commonly used relief devices are safety
valves and bursting discs, either singly or in combination, although other devices that can
be used in special circumstances, as atmospheric vents, pressure/vacuum breather valves,
emergency vents, liquid seal, weak roof to shell attachment, explosion hatches, explosion
panels, breaking pins, pressure surge devices and combinations of relief devices.

In the MEG Rig plant some of the pressure and relief systems components can be
observed. There are pressure vessels as the feed tank, the flash separator, the condensate
separator tank, the downcomer, the salt tank and brine tank, that must have the process
variables watched, and pressure is one of the most important, specially for the
downcomer and the flash separator; There is a high risk of explosion if the pressure rises
into the flash vessel, because as the relief valve draws the air to decrease the pressure
again, an explosive gas atmosphere is created.
We can also observe in the plant different valves. Globe valves regulate flow in a
pipeline, consisting of a movable disk-type element and a stationary ring seat in a
generally spherical body. Ball valves, mostly used in shut off applications, are valves with a
spherical disc which controls the flow through it. The sphere has a hole, or port, through
the middle so that when the port is in line with both ends of the valve, flow will occur.
When the valve is closed, the hole is perpendicular to the end of the valve, and flow is
blocked. Needle valves consist on a threaded stem with a conical end. Stems with fine
threaded have a slow linear movement when they turn, therefore a great number of turns
are needed to have a full flow section. This makes the needle valve suitable for regulating
flow, with a minimal waste and without cavitation at important differential pressures.
Non-return valves allow the fluid to flow in only one direction. This valve works
automatically and usually is not controlled by a person or external controls. In the MEG
Rig plant there are other valves kinds, as valve with rotary pneumatic actuator, pressure
control valve, angle pattern relief valve and general valves.

Figure 3. From left to right: Ball valve, needle valve, non-return valve and globe valve.
About relief systems in the plant, there are vents to a safe location, and the size of
the vent should take account of the maximum filling and emptying rate and the breathing
of the tank due to changes in atmospheric pressure and temperature. Some storage tanks
are provided with a combined vent and overflow pipe. This practice is definitely not
recommended, since the tank vent may be required precisely when the tank is
overflowing and the restriction applied by the overflowing liquid will seriously reduce the
capacity of the vent. Besides the vents there are manual drain points, manual bleed
points, drains and one air extraction vent duct. Most of relief system devices are
compromised to deal with pressure, temperature and flow problems.

4.3.

Process Engineer 1 report

Process Engineer 1: Ana Maria Garcia Lima

Centrifugal pump is one of the most used mechanical pumping devices in the
world. The work of a centrifugal pump is not complicated. It essentially converts the
kinetic energy, which came from an input engine, to the hydrodynamic energy of the flow.
The fluid enters through eye of the casing, then it pass through to a rotating device, the
impeller, when the flow gains velocity and pressure. This difference induces fluid in a
control volume over the system.

Figure 4. Cut-away views of a centrifugal pump.

In the heart of a centrifugal pump we have an impeller which is a device that
rotates and transfer energy to the fluid. The impeller has a numerous of rounded vanes
suited inside the covered plates. This device is always submerged in water and when it is
made to rotate, the flow surrounding it also rotates. Since the water rotational energy is
transferred to the flow, the system will have a pressure difference that will help to absorb
fresh water stream into the cycle again and then, the process will be able to continue. The
process described above is called priming.
Impeller is mounted on the bearings that have to be fitted at the exit side of the
impeller. It cannot be fitted on the entrance side because it will block the flow. For high
flow rate pumps, a bearing housing with cooling oil is necessary for improving the life of
the bearings. Impeller and casing are the main components of a small capacity centrifugal
pump. But for larger ones, we have to add diffuser blades in order to reduce the velocity.

During the process inside a centrifugal pump, the flow is pushed radially from the
impeller to the casing, where the impeller is fitted inside. As a result, the fluid will be
collected inside it and then pumped to the discharge nozzle. The casing has an increasing
area along the flow direction which helps to accommodate newly added water stream and
to reduce the exit fluid speed. A consequence of this reduction of fluid rate is the increase
of the static pressure, which is demand to overcome the resistance of the pumping
system. If the pressure at the entrance of the impeller goes under the vapour pressure of
the water, the water will start to boil forming vapour bubbles. These bubbles will move
forward with the fluid and will break in a high pressure region in a phenomenon known as
cavitation. So, the pump has a limit to its suction head since more the entrance head,
lesser should be the pressure at the entrance to lift the water.
However cavitation can be avoided by careful pump selection. The term NPSH (Net
Positive Suction Head) helps the designer to choose the right pump in order to completely
avoid it. For a given pumping system it will have an NPSH called 'Available NPSH'. Pump
manufacturer will specify the 'Required NPSH' the minimum NPSH required for the
pump safe operation . In order to work without Cavitation the pump 'Available NPSH'
should be greater than its 'Required NPSH'.
As well as various devices, the centrifugal pump also has problems some of the
difficulties faced in it are: cavitation (the NPSH of the system is too low for the selected
pump), wear of the impeller (can be worsened by suspended solids), corrosion inside the
pump by the fluid properties, overheating due to low flow and lack of prime (centrifugal
pumps must be filled with the fluid to be pumped in order to operate).
The reduction in efficiency of a pump can be a signal of pump losses that can be
distinguished in mechanical losses and hydraulic losses. The mechanical pieces of the
pump consists of bearings, shaft seals, and gear, depending on pump type and all these
components all cause friction loss. The hydraulic losses arise on the fluid and they occur
because of friction or because the fluid must change direction and velocity. This is due to
cross-section changes and the passage through the rotating impeller.
In the MEG reclamation process we have a few centrifugal pumps to control the
flow rate throughout the plant. In the pre-treatment stage, where the feed is stored in the
mixing tank with a pump providing energy to mix the components and drive the solution
to the flash separator, we have pumps responsible for moving a precise volume of fluid in
a specified time period providing an accurate flow rate. Thus, we can conclude that the
use of centrifugal pumps are very important during the MEG reclamation because they are
responsible for providing the exactly flow rate to the rest of the system.

4.4.

Process Engineer 2 report

Process Engineer 2: Bernardo de S Rollemberg

Progressive Cavity Pump (scroll pump)16-21

Figure 5. Progressivity cavity pump and its components.

A progressive cavity pump is made basically of two parts: a rotor inside, in a helical
shape and a stator surrounding the rotor. The fluid goes into the cavities between these
two parts, through the suction housing flange, and, as the rotor spins, the fluid is pumped.
The flow rate is proportional to the rotation rate.
The pump does not work moving the fluid due to the friction, as it is generally
thought. In fact, what really pumps the fluid is the sealed cavity that works like a piston
pump, as it makes it able to pump at low rates, even at high pressures. This pump is
considered a positive displacement pump.

Figure 6. Cavities between the stator and the rotor.

This pump is mainly applied when dealing with fluid of very high viscosity, since the
pump works with low levels of shearing stress. However, it can work pretty well on fluids
of low viscosity, as well. In reality, this type of pump is often used when a constant flow is
needed independently of the liquid viscosity.

Figure 7. Graph comparison positive and centrifugal pumps.

Others advantages are its linear characteristic, which allows no backflow as its flow
rate always increases with speed, continuous and non-pulsation flow, availability in
different materials, the possibility to work with mixtures of high concentration of solids in
liquids and the requirement of less suction energy than other kinds of pumps, like
centrifugal pumps. On the other hand, progressive cavity pumps can have limited
production rates and limited temperature capacity.
In the MEG Reclamation process, this pump is responsible for pumping the slurry
salt-water mixture from the salt tank R400 to the brine tank R401. This specific kind of
pump was chosen among other options, due the high viscosity and the presence of solids
on the stream going out of the salt tank and entering the pump. This pump is also largely
used for fluids with abrasive solids, oil pumping, in the food and pharmaceutic industries.
A regular maintenance to this pump is required to occur every 4 months, due to its high
importance on the salt loop system in MEG reclamation process.

Figure 8. A real progressivity cavity pump.

4.5.

Process Engineer 3 report

Process Engineer 3: Maximiano Kanda Ferraz

Vacuum pumps are devices used to remove gas molecules from a sealed container
based on a system of vacuum suction. These types of pumps are capable of attaining
vacuum through the exhaustion of gas molecules out of the chamber or by condensation
of molecules to create a light vacuum. The vacuum pump changes the mechanical
strength of a rotation axis (piston or diaphragm) with the displacement of the pneumatic
rotary vane to force the removal of air and other gases contained in an enclosed space.22
In a vacuum, the absence of atmosphere has several effects on the materials
behavior, e.g., in a vacuum, water boils at room temperature. The lack of atmosphere
presents many challenges in the design and construction of vacuum pumps. One that
vacuum pumps face (and is the reason why many vacuum pumps can only achieve low
vacuums) is they have many sources of non-standard gas exits, so air can enter the
vacuum in unexpected ways. For example, some metals, such as aluminum and palladium
metals are very porous. Hence, the gas molecules can be trapped in the metal, enter or
leave through the pores, not reaching vacuum. As they have limited number of molecules,
a low level of vacuum can still form, but will never achieve widespread use of vacuum.
Stainless steel and titanium are more suitable for creating high level vacuum pumps.
Moreover, oils and greases are often used in a vacuum pump to ensure the lubrication of
moving parts and to maintain the operation of the pump, providing high pumping speed
but requiring filters.23 Water-based lubrication provide rough vacuum at low cost and dry
pumps require little maintenance. This is important because liquids may boil in the
absence of an atmosphere, producing gas molecules that destroy the vacuum. Plastics and
rubbers, used to create rings and other seals in pumps, may also cause similar problems.24
In the process, the two catch pots (K201 and K202, defined as the vacuum trap and
vacuum receiver respectively), work as containers sealingly connected to a vacuum pump
(J200). These vacuum chambers are connected to the collector tube through which the
gas is extracted by suction. It stands as a safeguard for the vacuum pump, because it
prevents reminiscent liquid entering the pump, which would damage it. The J200 pump is
a positive displacement rotary vane pump. It works in a process that involves expansion of
a cavity, allowing gases to flow in, and exhausting gas molecules to the atmosphere, after
the cavity is sealed off. Retractable vanes rotate eccentrically in a rigid cavity (stator).
Retractable vanes rotate eccentrically in a rigid cavity (stator). It operates between 50C100C and the nominal volume flow rate is 150 m/h. It is oil lubricated and air-cooled.

Figure 9. Rotary Vane Pump Schematic.25

The J200 maintains the flash separator (K200) at a low pressure (0.20.3 bara),
which is necessary to evaporate the MEG at a lower temperature than it degrades (165
C), since at 1.0 bara, MEG boils at 200 C. Through suction, the pump drives the mixed
vapor of MEG/Water from the flash separator to the condenser C201. This condenser is
connected to the vacuum trap K201, which provides the pressure differential. K201 is also
connected to a line that runs between the exit of the C201 and the condensate separator
tank K300. C201 sends feed to K300, which exits only MEG to its final destination, the
storage tank R500 (MEG is driven by the positive displacement diaphragm pump J400).
Focusing on the vacuum system, the control of the J200 pump is made by the
instrument HS200, an on-off switch present both inside rack and as a computer function.
The exit of the pump is a vent to a safe location and the entrance is connected to the
vacuum receiver K202. As mentioned before, the vacuum trap K201 and vacuum receiver
(K202) are auxiliary chambers to the vacuum pump, and cast out any liquid through ball
valves V213 and V214, preventing its entrance in the pump. There are several other
instruments in this section: a vacuum control valve with pneumatic positioner PCV203,
which is connected through an electrical cable to the pressure indicator controller PIC203,
is located between the catch pots. It controls the amount of vacuum provided; a ball valve
(V205) between the catch pots; a needle valve (V222) is connected with the K201 and kept
open. Air is allowed into the system via this valve, enabling the vacuum control valve
PCV203 to operate; Z203, a sintered filter, connected to the needle valve V222.
There is a line connecting K202 (and therefore to J200) to R403 bleed down and
R404 sampling receiver. This line is responsible to provide vacuum in the R403 and R404,
which is necessary for collection of salt crystals and remaining MEG that are going down
the downcomer. This line, has ball valves V409 and V411 and pressure indicators (with
diaphragm sealing to not disturb the vacuum) PI400, PI401, PI402, PI403 for safety.

4.6.

Process Engineer 4 report

Process Engineer 4: Gabriel Vasconcelos de Sousa

Heat exchangers are devices which general function is to transfer heat between
two fluids that are at different temperatures. Heat exchangers are commonly used in
practice in a wide range of applications, from heating and air-conditioning systems in a
household, to chemical processing and power production in large plants.26 The basic
component of a heat exchanger can be viewed as a tube with one fluid running through it
and another fluid flowing by on the outside and are classified according to:27
Flow arrangement: parallel flow and counter flow
The two fluids can flow in the same direction (known as parallel flow), in opposite
directions (counter flow or counter-current).

Figure 10. Flow arrangement: (a) parallel flow and (b) counter flow.
Type of construction: shell-and-tube and plate heat exchangers
In shell and tube heat exchangers, one fluid flows through a set of metal tubes
while the second fluid passes through a sealed shell that surrounds them. Plate heat
exchangers have lots of thin metal plates or fins with a large surface area (because that
exchanges heat more quickly).28

Figure 11. (a) Shell and tube heat exchanger and (b) Plate heat exchanger.

Plate Heat Exchanger

Advantages

Disadvantages

Simple and Compact in size; heat

transfer efficiency is higher; can be easily
cleaned; no extra space is required for
dismantling; capacity can be increased by
introducing plates in pairs; leaking plates
can be removed in pairs, if necessary
without replacement; maintenance is
simple; turbulent flow help to reduce
deposits which would interfere with heat
transfer.29

Initial cost is high since Titanium plates

are expensive; finding leakage is difficult
since pressure test is not as easy as tube
coolers; bonding material between plates
limits operating temperature of the cooler;
pressure drop caused by plate cooler is
higher than tube cooler; careful dismantling
and assembling to be done; over tightening
of the clamping bolts result in increased
pressure drop across the cooler; joints may
be deteriorated according to the operating
conditions.29

Shell and Tube Heat Exchanger

Advantages

Disadvantages

Less expensive as compared to Plate

type coolers; can be used in systems with
higher operating temperatures and
pressures; pressure drop across a tube
cooler is less; tube leaks are easily located
and plugged since pressure test is
comparatively easy; tubular coolers in
refrigeration system can act as receiver
also; using sacrificial anodes protects the
whole cooling system against corrosion;
tube coolers may be preferred for
lubricating oil cooling because of the
pressure differential.29

Heat transfer efficiency is less

compared to plate type cooler; cleaning
and maintenance is difficult since a tube
cooler requires enough clearance at one
end to remove the tube nest; capacity of
tube cooler cannot be increased; requires
more space in comparison to plate
coolers.29

The plate heat exchanger is used in the processes because the unit operates at low
pressure due to MEG degrades above approximately 165 oC. The heat exchanger H300 is
supplied with steam from the Chadwick Buildings Steam System and is used to provide
heat to the Flash Separator in a large recycle flow and the condensers C201 and C301 are
plate heat exchangers which function is to cool the vapour (MEG-water) to yield a liquid
salt-free MEG-water stream.

4.7.

Instrument Engineer report

Instrument Engineer: Gabriela Filipini Ferreira

The measurement of fluid flow constitutes an essential factor in many applications

in industry (in utilities and manufacturing sector), in agriculture, laboratories and others.
This measurement is an important application of the energy balance. The choice of a
flowmeter is done considering various factors, such as desired accuracy, fluid to be
measured, conditions of operation, ease and cost of construction, installation and
maintenance. Most meters operate on all the fluid in the pipe or channel and are known
as full-bore meters. Others, called insertion meters, measure the flow rate, or more
commonly, the fluid velocity, at one point only. The total flow rate, however, can often be
inferred with considerable accuracy from this single-point measurement.30,31
Full-bore meters include variable-head meters such as Venturi and orifice meters
and variable-area meters such as rotameters. Other full-bore measuring devices are Velement, magnetic, vortex shedding, turbine and positive-displacement meters, ultrasonic
meters, and mass flow devices such as Coriolis and thermal flowmeters. Insertion meters
consist of inserting a sensing element, which is small compared to the size of the flow
channel, into the flow stream. The local measured velocity must bear a constant and
known relationship to the average velocity of the fluid. Examples of insertion meters are
the Pitot tube, modified forms of magnetic meters, turbine meters, ultrasonic meters, and
thermal mass flowmeters. Advantages of insertion meters are generally cost and usually
effectiveness of measuring flow in large pipes. 30,31
The most used devices are designed based on the principle of differential pressure,
caused by the flow, as the Pitot tube, Venturi and Orifice Plate and also the variation of
flow area as the Rotameter. As industrial plants often contain a considerable number of
valves and connections, the knowledge of its resistance to fluid flow is necessary, because
these accidents produce friction that must be added to the friction arising from the flow in
the pipe only. Thus then one can predict the total load associated with the flow system.
Pitot Tube
The Pitot tube is a device that simultaneously measures the static pressure and the
stagnation pressure, so it enables to calculate the local velocity along a streamline by
using the Bernoulli equation. The Pitot tube can be inserted through a small hole in the
duct with the pitot connected to a U-tube water gauge or some other differential pressure
gauge for determining the velocity.

Orifice Plate
Orifice plates are the flow measuring instruments most used in the chemical industry
because of its low cost, and ease to manufacture, installation and maintenance. This
flowmeter consists of a thin plate mounted between two flanges, having a hole diameter
smaller than the internal diameter of the tube, and that when placed perpendicular to the
flow of fluid starts to be a stricture to the flow. Pressure taps, one above and one below
the orifice plate, are installed and are connected to a manometer or differential pressure
transmitter.
Venturi
The Venturi flowmeter is a device for measuring flow in which the drag force is minimized.
In the Venturi meter, the velocity is increased, and the pressure decreased, in the
upstream cone. The pressure drop in the upstream cone is utilized to measure the rate of
flow through the instrument. The velocity is then decreased, and the original pressure
largely recovered, in the downstream cone. Because of its hydrodynamic shape, the
separation of the boundary layer hardly occurs, making the drag negligible and providing
an excellent pressure recovery. But some disadvantages are it is expensive, it occupies
considerable space, and its ratio of throat diameter to pipe diameter cannot be changed.
Rotameter
This flowmeter is an instrument for measuring the flow in which the pressure is constant
and the reading depends on a flow area that is variable. This device consists of a conical
tube with floating flowmeter, where the fluid flows upwardly exerting a force on the
bottom of the float. This float reaches an equilibrium position when a force directed
upward is equal to the gravitational force. The fluid flow area is the annular region
between the walls of the conical tube and the float. A calibration curve of the equipment
allows the knowledge of the flow, from the height reached by the float flowmeter.

Figure 12. Example of (a) Pitot Tube, (b) Orifice Plate, (c) Venturi and (d) Rotameter.

5. HAZOP

6. BIBLIOGRAPHY

HAZOP Course (My Manchester > BlackBoard > CHEN20151 Safety and Reliability
Engineering 2014).

Nolan, Dennis P.. (2012). Safety and Security Review for the Process Industries Application of HAZOP, PHA, What-if and SVA Reviews (3rd Edition). Elsevier. Online
version available at: http://app.knovel.com/hotlink/toc/id:kpSSRPIAH2/safetysecurity-review/safety-security-review

Nolan, D.P.. (1994). Application of HAZOP and What-If Safety Reviews to the
Petroleum, Petrochemical and Chemical Industries. William Andrew
Publishing/Noyes.
Online
version
available
at:
http://app.knovel.com/hotlink/toc/id:kpAHAZOPW6/
application-hazopwhat/application-hazop-what

Dunj, J.; Fthenakis, V.; Vlchez, J.A.; Arnaldos, J.. Hazard and operability (HAZOP)
analysis. A literature review. Journal of Hazardous Materials, n. 173, p. 19-32, 2010.

Dunj, J.; Fthenakis, V.M.; Darbra, R.M.; Vlchez, J.A.; Arnaldos, J.. Conducting
HAZOPs in continuous chemical processes: Part I. Criteria, tools and guidelines for
selecting nodes. Process Safety and Environmental Protection, n. 89, p. 214-223,
2011.

Rossing, N.L.; Lind, M.; Jensen, N.; Jrgensen, S.B.. A functional HAZOP methodology.
Computers and Chemical Engineering, n. 34, p. 244-253, 2010.

Coursework content of CHEN20151 Safety and Reliability Engineering 2014.

Cameron; PureMEG: MEG reclamation and regeneration technology; Process &

Compression Systems.

https://www.youtube.com/watch?v=BaEHVpKc-1Q How does a Centrifugal pump

works

10

http://www.learnengineering.org/2014/01/centrifugal-hydraulic-pumps.html

11

http://www.learnengineering.org/2013/03/centrifugal-pump.html

12

http://www.engineeringtoolbox.com/centrifugal-pumps-d_54.html

13

http://www.grundfos.com/content/dam/Global%20Site/Industries%20%26%20

solutions/industry/pdf/The_Centrifugal_Pump.pdf
14

http://www.coleparmer.com/Category/Metering_Pumps/4808

15

http://www.coleparmer.com/TechLibraryArticle/681

16

http://itdunyaweb.blogspot.co.uk/2011/08/advantages-and-disadvantages-of.html

17

http://blog.mx-pumps.com/2010/12/06/the-benefits-of-progressive-cavity-pumpscompared-to-other-pumping-systems/

18

http://www.libertyprocess.com/when_to_use_progressive_cavity_pumps.html

19

http://en.wikipedia.org/wiki/Progressive_cavity_pump#Specific_uses

20

http://www.imo-pump.com/brochures/BR00PCGP.pdf

21

http://petrowiki.org/Progressing_cavity_pump_(PCP)_systems

22

Cole-Parmer (2013). Vacuum Pumps. Available at: http://www.coleparmer.com/

Category/Vacuum_Pumps/6902 (Accessed: 10th November 2014).

23

Manuteno e Suprimentos (2014). Bombas a vcuo e suas aplicaes. Available at:

http://www.manutencaoesuprimentos.com.br/conteudo/3767-bombas-a-vacuo-esuas-aplicacoes/ (Accessed: 10th November 2014).

24

Martin G Broadhurst (1972). Use and replaceability of polychlorinated biphenyls.

Environmental Health Perspectives 2: 81102.

25

Petrobras (2014). Noes de Bombas. Presentation, UO-BC/APMF/EIS.

26

engel, Y.A.. Introduction to Thermodynamics and Heat Transfer. 2nd edition, USA:
The McGraw-Hill, 2008.

27

http://web.mit.edu/16.unified/www/FALL/thermodynamics/notes/node131.html

28

http://www.explainthatstuff.com/how-heat-exchangers-work.html

29

http://marineengineeringonline.com/advantages-disadvantages-shell-tube-platetype-heat-exchangers/

30

Foust, A.S.; Wenzel, L.A.; Clump, C.W.; Maus, L.; Andersen, L.B.. Principles of unit
operations. 2nd edition, New York: John Wiley, 1980.

31

McCabe, W.L.; Smith, J.C.; Harriott, P.; Unit Operations of Chemical Engineering. 5th
edition, New York: McGraw-Hill, 1993.

1. ANNEX

It is always essential to know all the information about the substances present in the
process. Some of the main properties of the substances found in MEG Reclamation are present in
Table 1.

Table 1. Properties of the substances present in MEG Reclamation process.

*Standard Temperature and Pressure (usually 298.15 K and 1 bar)

It is important to know that the salts (Na, K, Mg and Ca) are conductors and that MEG is
miscible in water. Also, for the MEG, some safety properties are:

Flash Point = 110 C

Auto-ignition Point = 398 C
Lower Explosive Limit = 3.2 % (concentration in air)
Upper Explosive Limit = 15.3 % (concentration in air)

SAFE CONDUCT IN THE LABORATORY

Due to the characteristics of the work done in the laboratory, it can lead to accidents of
varying degrees, such as fire, explosion, poisoning and burns. Therefore, it must be provided
suitable action elements so these effects can be controlled.

Safe elements
When work begins in a laboratory, the first thing to do is to know the following:

Status of the outputs, e.g., emergency exits;

Status of safety features: eyewash, showers, fire extinguishers, fire blanket, first aid
kit, etc;
Status of waste containers;
General rules and instructions for action in case of accident.

Basic safety measures

Personal standards:

During the stay in the laboratory, one must compulsorily wear safety glasses and lab coat.
Contact lenses can be very dangerous.
Gloves should be used when handling dangerous products (toxic, corrosive, etc).
Long hair should be tide.
Do not enter with backpacks, coats, bags (use lockers).
It is strictly forbidden to smoke or eat or drink in the laboratory.
One cant ingest any chemicals or touch unlabeled ones.
One must wash hands and take off the lab coat before leaving the laboratory.

Standards for use of chemicals:

Avoid contact of chemicals with skin.

Do not pipette by mouth, utilize funnels to transfer liquids.
If one accidently drops an acid or other corrosive chemical, the responsible professor or technician
must be advised.

To detect the odor of a substance, the container should not be placed to face directly, using open
hand, it is possible to reach a small amount of steam to the nose.
The bottles must be closed immediately after use.
In preparing solutions, they should be stirred in a smooth and controlled manner to avoid
splashing.
The acids require special care. Handle with care, in the chapel. When it is necessary to dilute them,
never take water over acids, unlike, always acid in water.
Before using any product, one must look at the safety information of the label, in order to take
appropriate preventive measures.
When a substance is heated in a test tube, the open end of the tube should not be aimed at
anyone nearby to avoid accidents. Caution in the ignition lighters, keeping the flame lit for the
time strictly necessary.
In principle, if there is no other reliable information, it should be assumed that all chemicals are
toxic, and all organic solvents are flammable and must keep them away from the flames.

Standards for the use of instrumentation:

When chemical mass weight is determined, use a suitable recipient.

One should be keep the place where is working with instruments with electrical contacts perfectly
clean and dry. Read the instructions for use of instruments.
Glassware should be checked for possible cracks, especially before using vacuum or pressure.
Before using any product, one must look at the safety information from the label, in order to take
appropriate measures.
In the heating with heating jacket, it is necessary to have a wooden block or other material to cool
rapidly if necessary.
In reflux and distillation, the joints must be tight. Never leave the work station alone, especially
while it is carrying out a reaction, distillation or measurement.

Standards for waste:

In the laboratory, there are properly labeled containers where the appropriate waste generated
will be introduced.

Emergency standards:

In case one has to evacuate the lab, close the gas valve and exit in an orderly manner at all times
following any directions given by the responsible.

FIGURES LINKS

Figure 1: Coursework content of CHEN20151 Safety and Reliability Engineering 2014

Figure 2: http://www.c-a-m.com/~/media/1999835b6dfc462ead163ea4464a080f.ashx
Figure 3: Google
Figure 4: http://en.citizendium.org/wiki/File:Centrifugal_Pump.png
http://en.wikipedia.org/wiki/File:Centrifugal_Pump.png
Figure 5: http://www.netzschusa.com/images/Nemo/cutawaylabel.jpg
Figure 6: http://en.wikipedia.org/wiki/File:Progressive_cavity_pump_cavities.png
Figure 7: http://www.pumpschool.com/intro/pd%20vs%20centrif.pdf
Figure 8: http://www.flygt.com/en-us/Pumping/Products/Positive-displacementpumps/PublishingImages/Compact_Rang.jpg
Figure 9: From the presentation Petrobras (2014): Noes de Bombas. UO-BC/APMF/EIS
Figure 10: Google
Figure 11: Google
Figure 12: http://www.apexinst.com/products/method-2c-standard-pitot-tube/pt2c-24
http://www2.emersonprocess.com/en-us/brands/rosemount/flow/dp-flowproducts/other-orifice-products/pages/index.aspx;
http://www.wika.co.uk/flc_vt_bar_flc_vt_ws_en_co.WIKA;
http://www.kinginstrumentco.com/7200/7200.html
Figure 13: http://www.marineinsight.com/marine/marine-news/headline/globe-valveused-on-ships-design-and-maintenance/;
http://galleryhip.com/ball-valve.html