Senior Hazop

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

(HAZOP) Safety Assessment on
Adipic Acid Production Plant
By: Group 11
Group Members Student ID
Lee Chee Hoong 023217
Ng Han Xiang 023319
Cassandra Tay Chu Mei 023730
Vikram Abiruben 024134
Module Convenor: DDr. Lam Hon Loong

th
Submission Date: 27 of March 2017
Table of Contents
1.0 Introduction ............................................................................................

1.1 HAZOP ................................................................................................. 1
1.2 Summary.............................................................................................. 2
2.0 Nomenclature ....................................................................................... 3
3.0 Risk Occurrence and Injury Description Rating (ODR) .......................... 4
4.0 Inherent Safety ..................................................................................... 5
5.0 HAZOP Table ......................................................................................... 6
5.1 Reactors ............................................................................................... 7
5.2 Separation Units .................................................................................. 21
5.3 Utilities and Storage Tanks ................................................................... 59
6.0 Process Control Diagram for Selected Units ........................................ 99
7.0 Materials Safety and Handling Method .............................................. 102
8.0 Emergency Evacuation Plan/Response ............................................. 107
9.0 Conclusion ........................................................................................ 110
10.0 References ...................................................................................... 111
11.0 Appendix ......................................................................................... 112
1.0 Introduction
1.1 HAZOP
In every chemical plant design, a crucial factor that must be considered is

the process safety of the proposed plant. The reason for this is because the
consequences when safety is disregarded have the risk of being disastrous, costing
both huge economic loses and worse, human lives. An additional factor to be
considered is the operability analysis that should be done to avoid incurring
economic loses which happens when the process deviates from the set operating
range. Thus, a Hazard and Operability Study (HAZOP) is a good method which
combines both factors and can be used to analyse the possible dangers and
deviations that may occur for each unit in the process inclusive of any and all
utilities. For each component that is to be analysed, safeguards as well as
immediate actions and recommendations are suggested to control, reduce or
remove the possibility of unwanted deviations and to ensure that the operators will
be prepared to handle the situation.
Originally, the HAZOP technique was developed to analyse chemical process

systems and mining operation process but has later been extended to other type of
complex operations such as nuclear power plant operation and incorporate with
various software to record and study about the deviation and consequence.
A typical steps of conducting a HAZOP study:
1. Familiarisation with background documentation

2. Planning of the workshop meeting in a pre-meeting with the customer in
order to identify HAZOP strategy, division of the subsystems/nodes (e.g. line,
pump, vessel, compressor), choose relevant Piping and Instrument Diagrams
(P&ID), and identifying guide words
3. Accomplishment of the HAZOP review
4. Documentation of observations into information and actions point, document
findings on the P&IDs.
5. Draft report for client review.
6. Final HAZOP report.
1
1.2 Summary
This report is done with the objective of creating a comprehensive HAZOP

analysis for the proposed design of an Adipic acid production plant. For every
HAZOP table made, the corresponding unit name and node is stated along with its
design intent, operating conditions as well as the inlet and outlet stream. A
brainstorming session by the design team is done to evaluate all possible hazard
and operability of every component. Each individual unit in this proposed plant is
analysed for possible deviations for each parameter and the source of it by using
the conventional ‘guide word’ method. Each deviation was evaluated based upon
plant operating efficiency and equipment safety risks while the recommendations
and safeguards were suggested based on published literature available. With the
purpose of providing a comprehensive and organised HAZOP report, the tables are
organised in three main sections whereby the first section are the reactors, followed
by separators and finally utilities. This following HAZOP study evaluates on an
equipment basis instead of line basis. (i.e. a study on the equipment as well as its
input and output stream; as opposed to a single stream).
A few assumptions had been made for all equipment in this study:
1. Equipment are all operating in same level, i.e. No Potential Energy Change.
Comment - Impractical to real case as they have different dimensions and
height.
2. Pipe Friction and Flows pattern are neglected. i.e. No Energy Losses in Piping
or Conveying.
Comment – Impractical in real industry as pipe friction and bends will cost
significant losses
3. Equipment with perfect Insulation. No Heat Loss in Reactor.

Comment: Heat loss to the surrounding is zero(0) (i.e. Reactor).
Overall, HAZOP study focus on the system or the process, hence producing a
comprehensive information on hazards and errors in the system design. It is an
important tool used to understand the benefits as well as the costs and limitations
of the method before making the decision to use it in a particular circumstance.
2
2.0 Nomenclature
The following abbreviation will be used in the HAZOP Table.
LG Level glass
LI Level indicator
LIA Level indicator alarm
LIC Level indicator and controller
LICA Level indicator controller alarm
MAWP Maximum Allowable Working Pressure
PI Pressure indicator
PIC Pressure indicator and controller
PICA Pressure indicator controller alarm
PAD Pressure alarm device
PSV Pressure safety valve
SIS Safety interlock system
TA Temperature alarm
TIC Temperature indicator and controller
TICA Temperature indicator controller alarm
FI Flow indicator
FIA Flow indicator alarm
FICA Flow indicator controller alarm
HLA High level alarm
LLA Low level alarm
3
3.0 Risk Occurrence and Injury
Description Rating (ODR)
A risk occurrence and injury description rating is used to classify the severity
of each deviation and its consequences. Further information regarding the rating
can be found in Table 1. The risk occurrence factor ranges from 1 to 4 signifies how
likely the event is going to happen and a higher occurrence (O) rating shows that
an event is more likely to happen. The safety description factor (D) also ranges
from 1-4 and represents how much the event compromises the safety of plant
personnel. The risk occurrence and safety description factor is combined to give a
rating (R) which ranges from A to D where A indicates an accepted event severity
and D represents a very severe event. The ratings for each event are given in
three columns O, D and R in the HAZOP tables. R rating only takes into account
human safety factors.
Table 1: Risk Occurrence and Injury Description Rating Factors
Safety 1- Minor first- 2- Injuries that 3- Severe 4-High

Description (D) aid injuries requires Injuries Emergency,
Risk physician’s Severe
Occurrence (O) attention Casualties
1-Not expected to (A)Acceptable (A)Acceptable (A)Acceptable (B)Acceptable

occur with Proper
Control
2-Rarely occurs (A)Acceptable (A)Acceptable (B)Acceptable (C)Must be

with Proper Well Monitored
Control and Controlled
3-Occurs frequently (A)Acceptable (B)Acceptable (C)Must be (D) Strict

with Proper Well Monitored Safeguards to
Control and Controlled be Imposed
4-Occurs very often (B)Acceptable (C)Must be (D) Strict (D) Strict

with Proper Well Monitored Safeguards to Safeguards to
Control and Controlled be Imposed be Imposed
4
4.0 Inherent Safety
Inherent safety is to design a process that manipulates the physical
properties of chemicals and equipment units to prevent accidents and lessen the
danger rather than to control the process. This is usually done during the initial
stage in process design. More often than not, it is more cost effective, especially
when it involves decreasing the operating system of a unit. Furthermore,
implementing inherent safety in the process design makes it more tolerant to
human errors when managing the plant. Four main words are typically used to
describe inherent safety which are, intensification, substitution, attenuation
and simplification.
Generally, the safety of a process is dependent on the various layers of

protection. The process design features is the first layer followed by consequent
layers which includes control systems, alarms, safety shutdown systems and an
emergency response plan. Inherent safety has been applied for this proposed plant
during the process design. For example, the reactor used in our process was
designed to include a cooling jacket around it so as to be able to control the
temperature of the reactor seeing that the air oxidation of cyclohexane is very
exothermic which poses a fire hazard. The subsequent layers of protection can be
seen in the HAZOP tables provided. For each unit, a form of control system is
installed in order to regulate and deviation that occur on the set operating
condition. Plus, an emergency evacuation plan has also been prepared to ensure
that the staffs are well equipped to handle and respond appropriately to an
emergency. These are all part of designing an inherently safer chemical plant.
Figure 1: Multilayer Protection
5
5.0 HAZOP Table
HAZOP tables for different unit classes were compiled into different sections for
ease of referencing. The equipment HAZOP tables were classified as follows:
1. Reactors
- This section will discuss about the main reacting units in the plant
2. Separation Units
- This section includes all separation equipment in the process such as flash
drums, membrane units and distillation units.
3. Utilities and Storage Tanks

- This section covers storage vessels and utility equipment such as heat
exchangers, pumps and compressors.
6
5.1 HAZOP
5.1.1 Catalytic Oxidation Reactor 1 (R-01)
5.1.2 Catalytic Oxidation Reactor 2 (R-02)
7
Project: HAZOP for Adipic Acid Production Plant
HAZOP team: Group 11 th Stream Inlet: 4, 6
Meeting Date: 20 of March 2017
Node: Catalytic Oxidation Reactor 1 Node No. R-01 Stream Outlet: 7, 10
Design Intent: Cyclohexane is reacted with air in a catalytic packed bed reactor at 150˚C and 10 atm. Under the controlled condition of the
reactor, cyclohexane is oxidised by the oxygen in the air to form Cyclohexanol, Cyclohexanone (KA oil) and water which are the component
in the liquid effluent of the unit along with the unreacted cyclohexane. The excess air will emit as the vapour effluent. Since the reaction is
exothermic, a cooling jacket is installed on the reactor to maintain an optimum operating temperature for favourable conversion.
Parameter Guide Deviation Causes Consequences Safeguard Action Recommendatio O D R

Word n
Flow NO No Flow -Blockage or -No reactant -Install FI on -Troubleshoot -Periodic 2 1 A
Plugging of inlet input stream and replace the inspection and
(Stream 1-4) -No reaction damaged maintenance to
-Install FA pipelines ensure the
-No output / on input integrity of
zero production stream pipelines
LESS Low Flow -Leakage in -Insufficient -Install LI to -Increase the -Periodic 2 1 A

pipelines (Stream supply for observe the input flowrate inspection and
1-4, 5-7, 11-12) reaction bed height by adjusting maintenance to
the valve or ensure the
-Pump P-01 failure -Reduced -Install FIC pump P-01 integrity of
production pipelines
-Partial blockage -Bed level -Install FA
on pipelines
(Stream 1-4, 5-7, reduction
11-12
MORE High Flow -Excessive input -Imbalance on -Install LI to -Manually close -Regular testing 3 1 A
of cyclohexane the control set observe bed control valve and inspection on
height control valve
8
-Valve or pump P- point for level -Install FIC -Undergo
01malfunction and temperature evacuation
-Install FA procedure if
-Reactant level overflow
increases
-Hazard of
explosion
Temperature LESS Low -Insufficient -Lower -Install TIC -Increase -Review 3 1 A

Temperatur heating at the production rate burner fuel temperature loop
e furnace -Install FIC input and feed
-Product to control regulating system
-Low feed inlet discharge the flowrate -Increase the
temperature to temperature is of the heating duty of -Secondary
the preheater lower coolant the preheater preheater as
according to /heating utility support
-Formation of temperature
-Flowrate of by-product is changes -Inspect and
coolant in cooling encouraged control the
jacket is too high -Composition of flowrate of the
coolant
product formed
-Feed preheater is affected -Check
malfunction preheater
condition
MORE High -Excessive heating -High pressure -Install -Reduce burner -Review 3 1 A
Temperatur at the furnace and temperature pressure fuel input temperature loop
e build up causes safety valve/ and feed
vessels rupture rupture disc -Increase regulating system
cooling water
-Conversion rate -Install TICA input
is affected
-High feed inlet -Possible -Reduce
temperature to heating duty of
preheater HE-01 runaway the preheater
reaction HE-01
9
-Too much reactor -Decrease input
feedstock input flowrate by
using valve
-Feed preheater -Check output

HE-01 malfunction valve condition
and for piping
-Blockage or blockage
plugging of
reactor outlet
Pressure LESS Low -Low input -Possible -Install PIC -Increase -Safety 1 1 A
Pressure amount of feed backflow or no flowrate of inspections on
flow due to -Install PA input streams piping and vessels
pressure regularly
-Leakage in piping difference -Seal the
(Stream 1-4) or vessel, perform -Input inert gas to
vessels -Lower amount emergency increase pressure
of product shutdown and
formed restart
-Pump P-01 failure -Inefficient heat -Check and

transfer inspect for
pump P-01
condition
- Low reactor -Install a

temperature heating jacket
for the reactor
-Pressure vent -Inspect and

valve is opened close the valve
/malfunction
MORE High -Excessive input -Possible -Install -Reduce -Install a cooling 2 4 C

Pressure amount of feed leakage/ rupture pressure feedstock/ input jacket
and loss of safety valve/ flowrate
containment of rupture disc -Perform
-Blockage of hot flammable -Check output emergency
reactor outlet liquid or gas -Install PICA valve condition evacuation plan if
(Stream 10) and for piping the situation is
blockage uncontrollable
10
-The flow
become more
turbulent
-Preheater HE-01 -Bursting of pipe -Seal the
heating duty is too vessel, perform
high due to excessive emergency
extension shutdown and
-Temperature
runaway -Potential fire restart
and explosion
hazard
Reaction NO No Reaction -Blockage of one -Heavy -Heavily -Perform -Consider 2 1 A
or more input Economical monitor emergency installing multiple
stream losses input stream shutdown to piping/ process
flowrates reduce steam as spare
-Process need to equipment utilities
restart for the -Frequent damage
entire plant maintenance -Installing two
-Unexpected of relevant -Regular check smaller reactor in
complete closure -Accumulation of piping up on the valve parallel instead of
of valve unreacted solid one large reactor
feedstock in for faster reaction
-Possible input reactor -Perform
stream piping -Steady state emergency
rupture shutdown to
operation reduce
severely equipment
disrupted damage
-Feed condition is -Increase

deviates too much heating duty of
from the desired preheater HE-
condition (eg. Not 01
heated up)
-Perform
emergency
shutdown to
reduce
equipment
damage
11
LESS Less -Too little -Product quality -Monitor -Inspect and -Consider 3 1 A
Reaction feedstock/ one of compromised reactor increase installing multiple
the input stream output feedstock input piping/ process
has insufficient stream flowrate steam as spare
amount -Unreacted solid composition utilities
-One or more feed particles -Monitor -Check input
input streams may damage reactor stream for -Regular checking
partially downstream operating blockages and and inspection on
blocked/interrupti equipment conditions clear blockage piping
on -Economical
-Input stream -Ensure valve is
valve closed losses open
-Not enough -Check burner

heating duty from operating
burner conditions and
increase
heating duty
-Not enough -Decrease

pressure in output flowrate
reactor
-Increase input
flowrate
MORE More -Excessive -Reaction -Monitor on -Check and -Install cooling 3 1 A

reaction feedstock runaway the flowrate correct the jacket
on input feedstock input
-Excessive -Overflow of streams flowrate
pressure due to reactants -Monitor
high flowrate of
feedstock reactor
output
-Excessive heating stream -Decrease
for preheater composition burner fuel
input
Composition NO No -Cyclohexane -Reaction -Heavily -Troubleshoot -Consider multiple 1 2 A

feedstock input stopped due to monitor and perform feed inlet to
compromised
12
(closed main reactant input stream correction if reactor as spare
valve/blocked missing flowrates possible for emergency
pipe/rupture)
-Economical -Frequent -If problem is
losses maintenance severe, perform
of relevant plant shutdown
-Steady state piping to reduce losses
operation
-Input stream severely -Increase input
lacking pressure disrupted stream
pressure
No air input -Process air input -Reactor -Heavily -Troubleshoot -Consider multiple 1 2 A
compromised conversion may monitor and perform process air stream
(closed change input stream correction if inlet to reactor as
valve/blocked -Product quality flowrates possible spare for
pipe/rupture) compromised -Frequent emergency
maintenance -If problem is
-Possible of relevant severe, perform
formation of piping plant shutdown
large amount of to reduce losses
side product
OTHER Undesired -Contamination of -Product quality -Heavily -Troubleshoot -Feed regulation 1 2 A

THAN composition feedstock compromised monitor and perform and purification to
input and correction if eliminate
-Excessive -Possible output possible impurities
presence of formation of stream
impurities large amount of flowrates -If problem is -Regular cleaning
side product severe, perform of vessel
-Frequent plant shutdown
-Degradation of maintenance to reduce losses
catalyst of relevant
piping
-Regular
replacement
of catalyst
Other - Reactor -Corrosion due to -Worker safety -Perform -Perform -Consider using 2 3 B
vessel/ corrosive compromised frequent emergency safer materials of
piping components maintenance shutdown construction for
13
leakage or formed at high and safety the vessel and
rupture temperature and -Possible loss of checks -Refer and pipes
pressure containment of follow safety
high pressure -Prepare and evacuation
and temperature proper protocols
-Vessel integrity evacuation
compromised due protocols for -Replace
to thermal effects emergency ruptured
or fatigue situations components
safely
14
HAZOP team: Group 11 th Stream Inlet: 22, 24
Node: Catalytic Oxidation Reactor 2 Node No. R-02 Stream Outlet: 25
Design Intent: Cyclohexanol and Cyclohexanone (KA oil) is reacted with Nitric Acid in a catalytic packed bed reactor at 90˚C and 1.5 atm.
Under the controlled condition of the reactor, Cyclohexanol and Cyclohexanone are oxidised by nitric acid to form Adipic Acid, water and off-
gas. Adipic Acid is further oxidised to form Glutaric Acid and Succinic Acid. Since the reaction is exothermic, a cooling jacket is installed on
the reactor to maintain an optimum operating temperature for favourable conversion.
Parameter Guide Deviation Causes Consequences Safeguard Action Recommendation O D R

Word
Flow NO No Flow -Blockage or -No reactant -Install FI on -Troubleshoot -Periodic 2 1 A
Plugging of inlet input stream and replace the inspection and
(Stream 21-22) -No reaction damaged maintenance to
-Install FA on pipelines ensure the
-No output / input stream integrity of
zero production -Leak detector pipelines
LESS Low Flow -Leakage in -Insufficient -Install LI to -Increase the Same as no flow 2 1 A
pipelines (Stream supply for observe the input flowrate
21-22, 24-25) reaction bed height by adjusting the
valve or pump
-Pump P-03 failure -Reduced -Install FIC
production
-Partial blockage on -Bed level -Install FA
pipeline
reduction
MORE High Flow -Excessive input of -Imbalance on -Install LI to -Manually close -Regular testing 3 1 A
KA oil the control set observe bed control valve and inspection on
point for level height control valve
15
-Valve or pump P-03 and -Install FIC -Undergo
malfunction temperature evacuation
-Install FA procedure if
-Reactant level overflow
increases
-Hazard of
explosion
Temperature LESS Low -Insufficient heating -Lower -Install TIC -Increase -Review 3 1 A
Temperature at the furnace production rate burner fuel temperature loop
-Install FIC input and feed
-Product to control the regulating system
-Low feed inlet discharge flowrate of -Increase the
temperature to the temperature is the coolant heating duty of -Secondary
preheater HE-02 lower according to the preheater preheater as
temperature /heating utility support
-Formation of changes
-Flowrate of coolant by-product is -Inspect and
in cooling jacket is encouraged control the
too high -Composition of flowrate of the
coolant
product formed
-Feed preheater is affected -Check
malfunction preheater
condition
MORE High -Excessive heating -High pressure -Install -Reduce burner -Review 3 1 A
Temperature at the furnace and pressure fuel input temperature loop
temperature safety valve/ and feed
build up causes rupture disc -Increase regulating system
vessels rupture cooling water
-Install TICA flowrate
-Conversion
-High feed inlet rate is affected -Reduce heating
temperature to duty of the
preheater preheater
16
-Too much reactor -Possible -Decrease input
feedstock input runaway flowrate by
reaction using valve
-Feed preheater HE- -Check output

02 malfunction valve condition
and for piping
-Blockage or blockage
plugging of reactor
outlet
Pressure LESS Low -Low input amount -Possible -Install PIC -Increase -Safety inspections 1 1 A
Pressure of feed backflow or no flowrate of input on piping and
flow due to -Install PA streams vessels regularly
pressure
-Leakage in piping difference -Seal the -Input inert gas to
(Stream 21-22) or vessel, perform increase pressure
vessels -Lower amount emergency
of product shutdown and
formed restart
-Pump P-03 failure -Inefficient -Check and

heat transfer inspect for
pump condition
- Low reactor -Install a

temperature heating jacket
for the reactor
-Pressure vent valve -Inspect and

is opened close the valve
/malfunction
MORE High -Excessive input -Possible -Install -Reduce -Install a cooling 2 4 C

Pressure amount of KA oil leakage/ pressure feedstock/ input jacket
rupture and safety valve/ flowrate
loss of rupture disc -Perform
-Blockage of reactor containment of -Check output emergency
outlet flammable/ -Install PICA valve condition evacuation plan if
harmful liquid and for piping the situation is
or gas blockage uncontrollable
17
-Preheater HE-03 -The flow -Seal the
heating duty is too become more vessel, perform
high turbulent emergency
-Temperature -Bursting of shutdown and
runaway pipe due to restart
excessive
extension
-Potential fire
and explosion
hazard
Reaction NO No Reaction -Blockage of one or -Heavy -Heavily -Perform -Consider installing 2 1 A

more input stream Economical monitor input emergency multiple piping/
losses stream shutdown to process steam as
flowrates reduce spare utilities
-Process need equipment
to restart for -Frequent damage -Installing two
the entire plant maintenance smaller reactor in
-Unexpected of relevant -Regular check parallel instead of
complete closure of -Accumulation piping up on the valve one large reactor
valve of unreacted for faster reaction
solid feedstock
-Feed condition is in reactor -Increase
deviates too much -Steady state heating duty of
from the desired Heater HE-02
condition (eg. Not operation
heated up) severely -Perform
disrupted emergency
shutdown to
reduce
equipment
damage
LESS Less -Too little feedstock/ -Product quality -Monitor -Inspect and -Consider installing 3 1 A
Reaction one of the input compromised reactor increase multiple piping/
stream has -Unreacted output feedstock input process steam as
insufficient amount solid feed stream flowrate spare utilities
particles may composition
damage
18
-One or more input downstream -Monitor -Check input -Regular checking
streams partially equipment reactor stream for and inspection on
blocked/interruption operating blockages and piping
-Economical conditions clear blockage
losses
-Input stream valve -Ensure valve is
closed open
-Not enough heating -Check burner

duty from burner operating
conditions and
increase heating
duty
-Not enough -Decrease

pressure in reactor output flowrate
-Increase input
flowrate
MORE More -Excessive feedstock -Reaction -Monitor on -Check and -Install cooling 3 1 A
reaction runaway the flowrate correct the jacket
on input feedstock input
-Excessive pressure -Overflow of streams flowrate
due to high flowrate reactants -Monitor
of feedstock
reactor
-Excessive heating output -Decrease
for preheater HE-02 stream burner fuel
composition input
Composition NO No feedstock -Cyclohexane input -Reaction -Heavily -Troubleshoot -Consider multiple 1 2 A

compromised stopped due to monitor input and perform feed inlet to
(closed main reactant stream correction if reactor as spare
valve/blocked missing flowrates possible for emergency
pipe/rupture)
-Economical -Frequent -If problem is
losses maintenance severe, perform
of relevant plant shutdown
piping to reduce losses
19
-Steady state
operation
disrupted
No acid -Nitric Acid input -Reactor -Monitor -Troubleshoot -Consider multiple 1 2 A

input compromised conversion may input stream and perform process nitric acid
(closed change flowrates correction if stream inlet to
valve/blocked -Frequent possible reactor as spare
pipe/rupture) -Product quality maintenance -If problem is for emergency
compromised of relevant severe, perform
-Possible piping plant shutdown
formation of to reduce losses
large amount
-Input stream line of side product -Increase input
lacking pressure stream pressure
OTHER Undesired -Contamination of -Product quality -Heavily -Troubleshoot -Feed regulation 1 2 A

THAN composition feedstock compromised monitor input and perform and purification to
and output correction if eliminate
-Possible stream possible impurities
formation of flowrates
large amount -If problem is -Regular cleaning
of side product -Frequent severe, perform of vessel
maintenance plant shutdown
-Degradation of of relevant to reduce losses
catalyst piping
-Regular
replacement
of catalyst
Other - Reactor -Corrosion due to -Worker safety -Perform -Perform -Consider using 2 3 B
vessel/ corrosive acid compromised frequent emergency safer materials of
piping feedstock and maintenance shutdown if construction for
leakage or product -Possible loss and safety condition the vessel and
rupture of containment checks permits pipes which can
-Vessel integrity withstand high
compromised due to -Prepare -Refer and corrosion
fatigue proper follow safety
evacuation and evacuation
protocols for
20
emergency protocols
situations
-Replace leaking
or ruptured
components
safely
21
5.2 Separation Units
5.2.1 Distillation Column 1 (DC-01)
5.2.2 Distillation Column 2 (DC-02)
5.2.3 Decanter (E-03)
5.2.4 Flash Drum (FD-01)
5.2.5 Membrane Separation Unit (MS-01)
5.2.6 Crystallizer (C-01 & C-02)
5.2.7 Crystallizer (C-03 & C-04)
5.2.8 Rotary Drum Filter (RF-01)
5.2.9 Dryer (D-01)
5.2.10 Sieve (S-01)
22
Project: HAZOP for Production of Adipic Acid
HAZOP team: Group 11 th Stream Inlet: 13
Node: Distillation Column 1 Node No. DC-01 Stream Outlet: 14, 18
Design Intent: The type of distillation column used for DC-01 is a tray column. It is mainly used to separate the unreacted cyclohexane from
o
KA-oil produced in R-01. The operating temperature and pressure of the column is 120 C and 2 atm respectively. The top product collected is
cyclohexane and water while the bottom product is KA-oil mixture and water which will be sent to a KA-oil storage. A partial condenser and
thermosiphon reboiler is used for this distillation column.

Word
Temperature Less Lower -High reflux ratio -Quality of -Install -Decrease reflux -Regular inspection 3 1 A
temperature separation is temperature ratio and maintenance
affected indicator of the safeguard
-Reboiler (RB-01) -Flooding of control -Inspect and installed
duty below set point adjust reboiler
column -Install (RB-01) duty -Regular
proportional– maintenance of
integral– RB-01
derivative(PI
D) controller
More Higher -Low reflux ratio -Quality of -Install -Increase reflux -Regular inspection 2 2 A
temperature separation is temperature ratio and maintenance
affected indicator of the safeguard
-Reboiler (RB-01) control -Inspect and installed
duty above set point adjust reboiler
-Install flow (RB-01) duty -Regular
indicator maintenance of
-Low cooling water control to -Increase RB-01
flow in condenser monitor the amount of
cooling water cooling utility -Regular
flow in passing through maintenance of
condenser CO-01 CO-01
-Install
proportional–
integral–
23
derivative(PI
D) controller
Pressure Less Low column -Pump (P-02) -Low pressure -Install -Repair or -Regular 1 2 A
pressure malfunction affects the pressure substitute P-02 maintenance of
boiling points indicator pipes
-Column leakage of components control -Fix any
which leakages -Consider installing
subsequently -Install a back-up pump in
-Pipeline (stream -Evacuate the
will affect the proportional– the event that
13) leakage area
separation integral– pump P-02
-Low reflux ratio process. derivative(PI -Increase reflux malfunctions
-Components D) controller ratio
leaking into
workspace area
poses fire
hazard
More High column -Reboiler (RB-01) -High column -Install high -Inspect and -Constantly 2 3 B
pressure duty above set point pressure may pressure adjust reboiler monitor column
cause an indicator (RB-01) duty pressure
explosion alarm
-Feed flowrate is -Column -Install high -Decrease feed
above set point flowrate by
pressure above pressure reducing
set point will indicator pump(P-02)
change the control efficiency
boiling points
of components, -Install -Evacuate the
affecting relieve valve area
separation at stream 14
process
-Have an
emergency
evacuation
plan
prepared
-Install
proportional–
24
integral–
derivative(PI
D) controller
Flow rate None No feed flow -Pump (P-02) failure -No separation -Install flow -Replace -Consider installing 1 1 A
rate causing no liquid indicator pump(P-02) a back-up pump in
flow -Economic control the event that
losses pump P-02
-pipeline leakage -Have an -Evacuate the malfunctions
(stream 11-13) -Spillage of emergency area
products into evacuation
workspace area plan
prepared
Less Less feed -Pipeline leakage -Quality of -Install flow -Inspect and fix -Consider replacing 2 1 A
flow rate (stream 11-13) separation is indicator any leakages in P-02 if damaged
affected control the pipeline
-Pump(P-02) -Level of -Have an -Increase pump
malfunction or efficiency
decreased efficiency column will emergency
decrease evacuation
plan
-Spillage of prepared
hazardous
chemicals into
workspace
More More feed -Increased efficiency -Flooding of -Install flow -Decrease -Install pressure 2 2 A
flow rate of P-02 column indicator pump(P-02) indicator control
control efficiency
-Quality of -Regular inspection
separation is -Install and maintenance
-Decrease reflux
affected relieve valve of the safeguard
ratio to reduce
at stream 14 installed
column pressure
-Increase in
column
pressure
Less Less liquid -High reboil ratio -Increase in -Install flow -Decrease reboil -Regular 2 2 A
bottom flow column indicator ratio maintenance and
rate pressure and control in cleaning of column
level both bottom
25
-Blockage due to -Quality of and reboiler -Resolve any -Monitor column
fouling in bottom separation is stream pipe blockage. pressure closely
stream pipes affected
More More liquid -Low reboil ratio -Recycle -Install flow -Increase reboil NONE 2 2 A
bottom flow stream to R-02 indicator ratio
rate increases which control in
will affect the both bottom
second step and reboiler
reaction stream
process
Level Less Low level of -Pump(P-02) -Separations -Install low -Repair or -Regular 2 1 A
liquid in malfunction efficiency level substitute P-02 maintenance of
column decreases indicator pipes
-Pipeline (stream -Desired control -Fix any minor -Consider installing
11-13) leakage leakages
product -Install flow a back-up pump in
-Low feed flowrate composition not indicator -Inspect R-01 the event that
from R-01 achieved control to pump P-06
monitor inlet malfunctions
-Components flowrate
leaking into
-Bottom liquid -Decrease
workspace area -Fix a pump
flowrate too much bottom liquid
poses fire control such
flowrate
hazard as a flow
switch to
redirect the
flow to a
backup pump
More High Level of -High feed flowrate -Flooding of -Install a -Decrease feed -Install a sight 3 1 A
liquid in column and level flowrate or glass level gauge
column puking occurs indicator increase bottom
where liquid is alarm liquid flowrate -Ensure that the
forced out of control valve can
-Bottom output pipe the top column -Install -Resolve any be manually
blocked control valve pipe blockage. overrode in event
for feed inlet
26
-High Reflux ratio -Decreasing -Install flow -Decrease reflux that the automatic
separations indicator ratio controller fails
efficiency control to
monitor inlet
-Pressure build- flowrate
up restricting
rise of vapour -Install
through liquid. overflow
piping
-Backflow to
feed inlet
occurs
27
Node: Distillation Column 2 Node No. DC-02 Stream Outlet: 46, 47
Design Intent: The type of distillation column used for DC-02 is a tray column. This column is utilised mainly for the separation of unreacted
o
nitric acid to be recovered and reused with the fresh nitric acid feed. The column is operated at 120 C and 1.5 atm. The top product will be
nitric acid which will be sent to recycle treatment to be further purified in order to be mixed back with the fresh nitric acid feed whereas the
bottom product will be water, adipic acid, cyclohexanone, cyclohexanol, glutaric and succinic acid. The bottom stream will be recycled back into
reactor 2. A partial condenser and thermosiphon reboiler is used for this distillation column.
Parameter Guide Deviation Causes Consequence Safeguard Action Recommendatio O D R

Word s n
Temperature Less Lower -HE-05 malfunction -Quality of -Install -Replace or -Regular 3 1 A
temperature separation is temperature repair HE-05 maintenance of
affected indicator HE-05
-Reboiler (RB-02) -Flooding of control -Inspect and -Regular
duty below set point adjust reboiler
column -Install (RB-02) duty inspection and
proportional maintenance of
-High reflux ratio –integral– -Decrease the safeguard
derivative(PI reflux ratio installed
D) controller
-Regular
maintenance of
RB-02
More Higher -Low reflux ratio -Quality of -Install -Increase reflux -Regular 3 1 A
temperature separation is temperature ratio inspection and
affected indicator maintenance of
-Reboiler (RB-02) control -Inspect and the safeguard
duty above set adjust reboiler installed
point -Install flow (RB-02) duty
indicator -Regular
-Low cooling water control to -Increase maintenance of
flow in condenser monitor the amount of RB-02
cooling cooling utility
water flow in passing through -Regular
condenser CO-02 maintenance of
CO-02
28
-Install
proportional
–integral–
derivative(PI
D) controller
Pressure Less Low column -Pump (P-06) -Low pressure -Install -Repair or -Regular 1 2 A
pressure malfunction affects the pressure substitute P-06 maintenance of
boiling points indicator pipes
-Column leakage of components control -Fix any
which leakages -Consider
subsequently -Install installing a back-
-Pipeline (stream -Evacuate the
will affect the proportional up pump in the
45) leakage area
separation –integral– event that pump
-Low reflux ratio process. derivative(PI -Increase reflux P-06 malfunctions
-Components D) controller ratio
leaking into
workspace
area poses fire
hazard
More High column -Reboiler (RB-02) -High column -Install high -Inspect and -Constantly 2 3 B
pressure duty above set pressure may pressure adjust reboiler monitor column
point cause an indicator (RB-02) duty pressure
explosion alarm
-Feed flowrate is -Column -Install high -Decrease feed
above set point flowrate by
pressure above pressure reducing
set point will indicator pump(P-06)
change the control efficiency
boiling points
of components, -Install -Evacuate the
affecting pressure area
separation relief valve
process at stream 46
-Have an
emergency
evacuation
29
plan
prepared
-Install
proportional
–integral–
derivative(PI
D) controller
Flow rate None No feed flow -Pump (P-06) -No separation -Install flow -Replace -Consider 2 1 A
rate failure causing no indicator pump(P-06) installing a back-
liquid flow -Economic control up pump in the
losses event that pump
-No feed from RF- -Have an -Inspect and P-06 malfunctions
01 -Spillage of emergency resolve issue
products into evacuation with RF-01 if
workspace plan any
area prepared
-pipeline leakage -Evacuate the
(stream 43-45) area
Less Less feed -Pipeline leakage -Quality of -Install flow -Inspect and fix -Consider 3 1 A
flow rate (stream 43-45) separation is indicator any leakages in replacing P-06 if
affected control the pipeline damaged
-Pump(P-06) -Level of -Have an -Increase pump
malfunction or efficiency
decreased efficiency column will emergency
decrease evacuation
plan
-Spillage of prepared
hazardous
chemicals into
workspace
More More feed -Increased -Flooding of -Install flow -Decrease -Install pressure 2 3 B
flow rate efficiency of P-06 column indicator pump(P-06) indicator control
control efficiency
30
-Quality of -Install -Decrease -Regular
separation is relieve valve reflux ratio to inspection and
affected at stream 46 reduce column maintenance of
pressure the safeguard
-Increase in installed
column
pressure
Less Less bottom -High reboil ratio -Recycle -Install flow -Decrease -Regular 2 2 A
liquid flow stream to R-02 indicator reboil ratio maintenance and
rate decreases control in cleaning of column
which in turn both bottom
less product and reboiler -Monitor column
-Blockage due to will be stream -Resolve any pressure closely
fouling in bottom produced pipe blockage.
stream pipes -Increase in
column
pressure and
level
-Quality of
separation is
affected
More More -Low reboil ratio -Recycle -Install flow -Increase reboil NONE 2 2 A
bottom stream to R-02 indicator ratio
liquid flow increases control in
rate which will both bottom
affect the and reboiler
second step stream
reaction
process
Level Less Low level of -Pump(P-06) -Separations -Install low -Repair or -Regular 3 1 A
liquid in malfunction efficiency level substitute P-06 maintenance of
column decreases indicator pipes
-Pipeline (stream -Desired control -Fix any minor -Consider
43-45) leakage leakages
product installing a back-
31
-Low feed flowrate composition -Install flow -Inspect RF-01 up pump in the
from RF-01 not achieved indicator event that pump
control to P-06 malfunctions
-Components monitor inlet
-Bottom liquid leaking into flowrate -Decrease
workspace
flowrate too much bottom liquid
area poses fire -Fix a pump flowrate
hazard control such
as a flow
switch to
redirect the
flow to a
backup
pump
More High Level -High feed flowrate -Flooding of -Install a -Decrease feed -Install a sight 3 2 B
of liquid in column and level flowrate or glass level gauge
column puking occurs indicator increase bottom
where liquid is alarm liquid flowrate -Ensure that the
forced out of control valve can
-Bottom output pipe the top column -Install -Resolve any be manually
blocked control valve pipe blockage. overrode in event
-Decreasing for feed inlet that the automatic
-High Reflux ratio separations -Decrease controller fails
efficiency -Install flow reflux ratio
indicator
-Pressure control to
build-up monitor inlet
restricting rise flowrate
of vapour
through liquid. -Install
overflow
-Backflow to piping
feed inlet
occurs
Reaction - Corrosion in -Input stream -Integrity of -Constantly None -Perform regular 2 1 A

column contains various equipment is monitor and thorough
acids that are compromised corrosion cleaning of column
corrosive levels in
column
32
Temperature Less Lower -High reflux ratio -Quality of -Install -Decrease -Regular 3 1 A
temperature separation is temperature reflux ratio inspection and
affected indicator maintenance of
-Reboiler (RB-01) control -Inspect and the safeguard
duty below set point -Flooding of adjust reboiler installed
column -Install (RB-01) duty
proportional -Regular
–integral– maintenance of
derivative(PI RB-01
D) controller
33
Node: Decanter Node No. E-03 Stream Outlet: 15, 17
Design Intent: The top product from DC-01 is further purified here to remove the excess water which does not form an azeotrope with
o
cyclohexane. The remaining cyclohexane is sent to a storage tank which will then be recycled back into R-01. This unit is operated at 110 C
and 2atm.

Word
Temperature More Higher -High input -Separation -Install -Inspect output -None 2 1 A
temperature stream efficiency temperature stream of DC-01
temperature decreases controller at
feed stream
Pressure Less Lower -Pipeline -Chemical -Install pressure -Repair -Maintain pipelines 2 2 A
pressure (stream 14) spillage into indicator control damaged pipe regularly
leakage workspace
-Have an -Evacuate the
-Inefficient emergency area
separations due evacuation plan
to changes in the prepared
boiling point of
the components
More Higher -High feed -Pressure build- -Have an -Decrease the -Install high 3 2 B
Pressure flowrate up in unit which emergency flowrate of feed pressure alarm
may lead to an evacuation plan
-No output explosion prepared -Check output -Install anti
flow stream for any backflow device at
-Backflow into -Install high blockage feed stream
feed stream may pressure
occur, affecting indicator control
the whole system
-Install
-Inefficient proportional–
separations due integral–
to changes in the derivative(PID)
controller
34
boiling point of
the components -Install pressure
relief valve
Flow rate None No feed flow -Pipeline -Chemical -Install flow -Replace -Regular 1 2 A
rate (stream 14) spillage into indicator control ruptured maintenance of
rupture workspace alarm pipeline pipelines
-Unchecked -Have an
-Pipeline -Inspect
(stream 14) pipeline blockage emergency pipelines
blockage due might lead to evacuation plan (stream 14) and
to fouling pipeline rupture prepared clear any
-Separation does blockage
-No feed -Inspect DC-01
from DC-01 not occur for any issues
-Evacuate the
area
Less Less feed -Pipeline -Minor chemical -Install flow -Repair any -Regular 2 2 A
flow rate (stream 14) spillage into indicator control damage to the maintenance of
leakage workspace pipelines pipelines
-Install
-Less output -Less separation proportional– -Inspect DC-01
flow from can occur integral– for any issues
DC-01 derivative(PID)
-Separation controller
efficiency
-Clean-up any
decreases
minor spillage
or evacuate the
area if it is a
major spillage
35
More More feed -High -Backflow into -Install flow -Inspect and -Split feed streams
flow rate flowrate of feed stream may indicator control resolve any on parallel modules
output occur issue with DC-
stream from -Install level 01
DC-02 -Column level will indicator alarm
increase
-Install
proportional–
integral–
derivative(PID)
controller
-Install control
valve in stream
14
Level Less Low liquid -Low feed -Less separation -Install sight -Inspect cause -Regular 2 1 A
level in flowrate can occur glass to visually of low feed maintenance of
column monitor liquid flowrate pipelines
-Chemical level in column
-Pipeline spillage into -Repair pipeline -Have an
(stream 14) workspace -Install level leakage emergency
leakage indicator control evacuation plan
prepared
-Install control -Evacuate area
valve to control if large spillage
output flowrate occurs
-Pipeline
(stream 14)
blockage
36
Node: Flash Drum Node No. FD-01 Stream Outlet: 27, 28
Design Intent: Harmful gases which are part of the output stream from reactor R-02 is removed using a flash drum and sent for waste gas
treatment. The top product will be NO, NO2, N2O and CO2 whereas the bottom product will be water, nitric acid, succinic acid, glutaric acid,
adipic acid, cyclohexanone and cyclohexanol. The flash drum is operated at 120˚C and 1.5 atm.

Word
Temperature Less Lower -Low heat -Incomplete -Install -Increase heat -Maintenance for 3 1 A
temperature duty of HE- separation temperature duty of HE-04 HE-04 as well as
04 controller at FD-01 to be done
feed stream regularly
-Output stream
-Heater HE- will contain more -Repair heater
04 impurities. HE-04
malfunction
More Higher -Heating -Separation -Install -Decrease heat -Maintenance for 2 2 A

temperature duty of HE- efficiency temperature duty of HE-04 HE-04 as well as
04 too high decreases controller at FD-01 to be done
feed stream regularly
-Other
-High input -Inspect output
stream components stream of R-02
temperature might be
vapourised out
the top stream
Pressure Less Lower -Install pressure -Repair -Consider having a 1 1 A

pressure indicator control damaged pipe back-up pump in
37
-Pipeline -Chemical -Have an -Evacuate the the event that P-04
(stream 25- spillage into emergency area fails completely
26) leakage workspace evacuation plan
prepared
-Pump P-04 -Repair or -Maintain pipelines
malfunction replace pump P-
-Inefficient and pumps regularly
04
separations due
to changes in the
-Efficiency of boiling point of -Increase
P-04 the components efficiency of
decreased pump P-04
More Higher -High pump -Pressure build- -Have an -Decrease -Install high 2 1 A
Pressure (P-04) up in flash drum emergency efficiency of P- pressure alarm
efficiency which may lead evacuation plan 04
to an explosion prepared
-Install anti
-High feed -Decrease the backflow device at
flowrate -Backflow into -Install high flowrate of feed feed stream
feed stream may pressure
occur, affecting indicator control
-No output the whole system -Check output
flow stream for any
-Install blockage
-Inefficient proportional–
separations due integral– -Evacuate the
to changes in the derivative(PID) area
boiling point of controller
the components
-Install pressure
relief valve
38
Flow rate None No feed flow -Pipeline -Chemical -Install flow -Replace -Regular 2 1 A
rate (stream 25- spillage into indicator control ruptured maintenance of
26) rupture workspace alarm pipeline pipelines
-Unchecked -Have an
-Pipeline -Inspect
(stream 25- pipeline blockage emergency pipelines
26) blockage might lead to evacuation plan (stream 25-26)
due to pipeline rupture prepared and clear any
fouling blockage
-Separation does
-No feed not occur -Inspect R-02

from R-02 for any issues
-Evacuate the
area
Less Less feed -Pipeline -Minor chemical -Install flow -Repair any -Regular 3 1 A
flow rate (stream25- spillage into indicator control damage to the maintenance of
26) leakage workspace pipelines pipelines
-Install
-Less output -Less separation proportional– -Inspect R-02 -Consider installing

flow from R- can occur integral– for any issues a back-up pump as
02 derivative(PID) a support if P-04
controller malfunctions
-Separation
-Decreased efficiency -Increase
efficiency or decreases efficiency of
malfunction pump P-06
of pump P-04
39
-Clean-up any
minor spillage
or evacuate the
area if it is a
major spillage
More More feed -High -Backflow into -Install flow -Inspect and -Split feed streams 3 2 B
flow rate flowrate of feed stream may indicator control resolve any on parallel modules
output occur issue with R-02
stream from
R-02 -Install level
-Column level will indicator alarm
increase
-Install
proportional–
integral–
derivative(PID)
controller
-Install control
valve in stream
26
Less Less bottom -Output -Separation -Install flow -Decrease feed -Regular 1 2 A
liquid flow stream efficiency indicator control flowrate to maintenance of FD-
rate blocked decreased prevent over 01
flooding of FD-
-Install level 01
-Column level indicator alarm -Install a sight glass
increases to visually monitor
the column level
40
-Install a relief
system to
entrain the
extra liquid
hold-up
Level Less Low liquid -Low feed -Less separation -Install sight -Inspect cause -Regular 2 1 A
level in flowrate can occur glass to visually of low feed maintenance of
column monitor liquid flowrate pipelines
level in column
-Chemical
-Pipeline spillage into -Repair pipeline -Have an
(stream 25- workspace -Install level leakage emergency
26) leakage indicator control evacuation plan
prepared
-Install control -Evacuate area
if large spillage
valve to control occurs
output flowrate
More High liquid -High feed -Flooding of -Install high -Decrease feed -Regular 2 1 A
level in flowrate column level indicator flowrate maintenance of
column alarm pipelines
-Backflow into
-Pipeline
(stream 28) feed stream -Install high
blockage level indicator
control
-Install sight
glass to visually
monitor liquid
level in column
41
Node: Membrane Separator Unit Node No. MS-01 Stream Outlet: 31, 32
Design Intent: The purpose of this membrane separator is purely to remove excess water and to concentrate the mixture from the output
stream of FD-01. A membrane with high selectivity is used to separate 99% of water from the mixture. This is to enhance the efficiency of the
o
crystalliser and to allow for easier precipitation of the acids. The membrane separator is operated at 70 C and 3.0 to 1.5 atm. This pressure
difference is the driving force for the separation to occur.

Word
Temperature More Higher -Excessive -Separation -Install -Inspect HC- -Replace any 2 2 A
temperature heat efficiency Temperature 01 for any damaged membrane
influenced by decreases indicator control damage
weather -Keep membrane
-Surface separator unit in an
-Cooler HC-01 temperature area that is
malfunction increases protected from the
weather
-Membrane will
be damaged -
Pressure Less Lower -Pipe leakage -Inefficient -Install pressure -Inspect and -Regular 1 1 A
pressure separation control repair maintenance on
leakage pipeline and
-Separator -Low outlet separator
unit leakage flowrate
-Consider having a
-Decreased -Increase back-up pump to
efficiency of efficiency of replace P-05 in case
pump P-05 P-05 of any failure
More Higher -Increased -Column pressure -Install pressure -Decrease -Monitor pressure of 2 2 A
pressure efficiency of increases indicator control pump P-05 unit constantly
pump P-05 alarm efficiency
-Inefficient -Perform regular
separation maintenance on
42
-Outlet flow is -Install relief -Inspect for membrane
blocked -Column valve any separation unit
overflows and obstruction
leaks out -Maintenance at outlet
on pressure pipeline
-High pressure relief valve
-High inlet drop across the -Inspect the
flowrate unit cause of
high inlet
flowrate
Flow rate None No feed flow -Pipeline -Chemical -Have an -Evacuate -Regular 1 2 A
rate (stream 28- spillage into emergency the area if maintenance of
30) rupture workspace evacuation plan major pipelines
prepared spillage
-Inefficient occur
separation which
-No feed from will affect the -Inspect FD-
FD-01 crystallisation 01 for any
process issue
Less Low flow rate -Pump P-05 -Uneconomical -Install flow -Inspect and -Regular 2 1 A
malfunction separation indicator control repair or maintenance for
replace P-05 pipelines should be
-Pressure of unit -Install if necessary done
decreases which proportional–
affects separation integral–
-Pipeline -Inspect and
process derivative(PID)
(stream 28- controller repair any
30) leakage -Chemical leakages in
spillage into the pipeline
workspace
More More flow -Increased -Pressure of unit -Install flow -Decrease -Regular 2 2 A
rate efficiency of P- increases indicator control pump P-05 maintenance of
05 efficiency pumps should be
-Install done
proportional–
integral–
43
derivative(PID)
controller
44
HAZOP team: Group 11 Meeting Date: Stream Inlet: 33, 35
Node: Crystallizer Node No. C-01, C-02 Stream Outlet: 34,36
O
Design Intent: Mixture containing Adipic acid and other by-products is cooled down to 50 C, the crystallization of Adipic acid crystals will
occur. Succinic Acid and Glutaric Acid which are the by-product of the oxidation of KA oil will also precipitate under the same condition, but the
crystals form for the three type of acid is different in size.

Word
Flow NO No Flow -Blockage or -No -Install FI on -Troubleshoot -Regular checking 2 1 A
Plugging of inlet 33, crystallization the input and replace the on operating
35 stream damaged conditions
-Install FA on pipelines -Install safety
input stream valve
LESS Low Flow -Small inlet flow -Low outlet -Install FC -Check the -Regular checking 2 1 A
control valve flow valve opening on operating
opening and repair conditions
-Affect the -Install safety
product quality
valve
45
-Leakage in stream - Detect the
33-36 leakage and
repair
MORE High Flow -Large inlet flow -High flow rate -Install FIC -Check the -Regular checking 3 1 A
control valve damage the -Install FA performing of on operating
opening pipeline and flow control conditions
crystallizer valve -Install safety
-Hazard of valve
explosion
Temperature LESS Low -Low feed inlet -Affect the -Install TIC -Check and -Regular checking 3 1 A
Temperature stream 33, 35 quality of increase the and maintenance
temperature product temperature of -Operating
inlet stream
-Lower condition should be
production rate constant all times
46
MORE High -High feed inlet -Reduce -Install TICA -Decrease -Regular checking 3 1 A
Temperature stream 33, 35 crystallization -Install heating duty of and maintenance
temperature efficiency crystallizer
pressure -Operating
-High pressure safety valve -Repair the condition should be
built and damage constant all times
damage
crystallizer
Pressure LESS Low -Malfunction of -Lower rate of -Install PC -Check the -Regular checking 1 1 A
Pressure pump P-05 crystallisation pump and repair and maintenance
-Install one-
-Low feed input 33, -Loss of way valve -Increase feed -Operating
35 flow rate product from input flowrate condition should be
leakage constant all times
-Leakage in stream -Possible -Detect the
33-36 leakage and
backflow or no
repair
flow due to
pressure
difference
MORE High -Malfunction of -Affect the -Install PICA -Check the -Regular checking 2 4 C
Pressure pump P-05 quality of -Install pump and repair and maintenance
crystals
pressure
-Excessive input -Increase safety valve -Reduce input
amount of feed flowrate
temperature of
stream 33,35 the crystallizer
47
-Failure on pressure -Open the
control pressure relief
valve

Plugging of inlet crystallization the input and replace the on operating
33,35 stream damaged conditions
input stream valve
LESS Low flow -Small inlet flow -Low outlet -Install FC -Check the -Regular checking 2 1 A
rate control valve flow valve opening on operating
opening -Affect the and repair conditions
product quality -Install safety

valve
MORE High flow -Large inlet flow -High flow rate -Install FIC -Check the -Regular checking 3 1 A
rate control valve damage the performing of on operating
crystallizer -Install FA valve -Install safety
-Hazard of valve
explosion
Level HIGH High Level -High inlet stream -Affect product -Install LIC -Check and - Regular checking 2 1 A
33,35 flow rate quality -Install LC adjust inlet flow on operating
rate conditions
48
-Outlet stream -Check and -Use more fouling-
34,36 Blockage dislodge outlet resistant pipeline
blockage
LOW Low Level -Low inlet 33,35 -Affect product -Install LC -Check and - Regular checking 2 1 A
flow rate quality adjust flow rate on operating
-Components conditions
-Install FIC
leaking into -Use more fouling-
-Leakage in steam -Detect leakage
working area resistant pipeline
33-36 and repair
poses fire
hazard
49
HAZOP team: Group 11 Meeting Date: Stream Inlet: 38, 40
Node: Crystallizer Node No. C-03, C-04 Stream Outlet: 39, 41

O
Design Intent: Mixture containing Adipic acid and other by-products is cooled down to 20 C. The crystallization of Adipic acid crystals is
conducted by using forced circulation and surface-cooled.

Word
input stream valve
LESS Low Flow -Small inlet flow -Low outlet -Install FC -Check the -Regular checking 2 1 A
control valve flow valve opening on operating
opening and repair conditions
-Affect the -Install safety
-Leakage in stream product quality - Detect the
38-41 leakage and valve
repair
MORE High Flow -Large inlet flow -High flow rate -Install FIC -Check the -Regular checking 3 1 A
control valve damage the -Install FA performing of on operating
-Hazard of valve
explosion
50
Temperature LESS Low -Low feed inlet -Affect the -Install TIC -Check and -Regular checking 3 1 A
Temperature stream 38, 40 quality of increase the and maintenance
temperature product temperature of -Operating
inlet stream
-Lower condition should be
production rate constant all times
MORE High -High feed inlet -Reduce -Install TICA -Decrease -Regular checking 3 1 A
Temperature stream 38, 40 crystallization -Install heating duty of and maintenance
temperature efficiency crystallizer
pressure -Operating
-High pressure safety valve -Repair the condition should be
built and damage constant all times
damage
crystallizer
Pressure LESS Low -Malfunction of -Lower rate of -Install PC -Check the -Regular checking 1 1 A
Pressure pump P-05 crystallisation -Install one- pump and repair and maintenance
-Loss of way valve -Operating

-Low feed input 38, -Increase feed
product from condition should be
40 flow rate input flowrate
leakage constant all times
-Possible
-Leakage in stream -Detect the
38-41 backflow or no leakage and
flow due to repair
pressure
difference
MORE High -Malfunction of -Affect the -Install PICA -Check the -Regular checking 2 4 C
Pressure pump P-05 quality of -Install pump and repair and maintenance
crystals
pressure
safety valve
51
-Excessive input -Increase -Reduce input
amount of feed temperature of flowrate
stream 38, 40 the crystallizer
-Failure on pressure -Open the

control pressure relief
valve

input stream valve
LESS Low flow -Small inlet flow -Low outlet -Install FC -Check the -Regular checking 2 1 A
rate control valve flow valve opening on operating
opening -Affect the and repair conditions
product quality -Install safety

valve
MORE High flow -Large inlet flow -High flow rate -Install FIC -Check the -Regular checking 3 1 A
rate control valve damage the -Install FA performing of on operating
-Hazard of valve
explosion
Level HIGH High Level -High inlet stream -Affect product -Install LIC -Check and - Regular checking 2 1 A
38, 40 flow rate quality adjust inlet flow on operating
rate conditions
52
-Outlet stream 39, -Install LC -Check and -Use more fouling-
41 Blockage dislodge outlet resistant pipeline
blockage
LOW Low Level -Low inlet 38, 40 -Affect product -Install LC -Check and - Regular checking 2 1 A
flow rate quality -Install FIC adjust flow rate on operating
conditions
-Components
leaking into -Use more fouling-
-Leakage in steam -Detect leakage
working area resistant pipeline
38-41 and repair
poses fire
hazard
-Inlet stream 38, 40 -Check and
Blockage dislodge inlet
blockage
53
HAZOP team: Group 11 Meeting Date: Stream Inlet:42
Node: Rotary Drum Filter Node No. RF-01 Stream Outlet:43, 49
O
Design Intent: The filter operates at 20 C, 1atm. The mixture containing solids crystals of acids and liquid is fed into the rotary drum filter.
The filtrate is pulled through the wall of the drum by a vacuum, towards the center of the drum. The drum rotates such that the cake is dumped
to the discharge outlet.

Word
Flow NO No Flow -Flow control valve -Production -Install FICA -Check the -By-pass or 2 1 A
closed stop -Install FI valve, adjust alternate piping to
and repair the separator
-No separation
-Burst pipe -Replace with a -Check filtration
new pipe system and clean
-Feed lines and -Clear up the

valves are blocked pipe
LESS Low Flow -Small flow control -Reduce -Install FC -Check valve -Regular checking 2 1 A
valve opening efficiency of opening and on separator
separation repair operating
-Reduce conditions
-Leakage in vessel -Detect leakage
42, 43, 49 pressure and repair
MORE High Flow -Large flow control -High pressure -Install FC -Check valve -Regular checking 3 1 A
valve opening can damage -Install FICA opening and on operating
pipeline and repair conditions
filter -Install relief valve
54
-High flow control -Hazard of -Check valve -Split feed streams
valve opening explosion opening and to parallel
repair
Pressure LESS Low -Leakage of vessel -Outlet flow in -Install PICA -Detect the -Regular 1 1 A
Pressure 42, 43, 49 stream 43, 49 leakage and maintenance on
will be low repair pipeline and
-High pressure separator
-Increase the
drop -Install input flowrate
-Inefficient pressure
-Low amount of separation safety valve -Check relief
input 42 valve and repair
-Pressure relief
valve malfunction
MORE High -High inlet stream -High pressure -Install PICA -Reduce the -The pressure in 3 1 A
Pressure 42 flow rate in the column -Maintenance input flowrate vessel must be
can damage remain constant
on pressure
equipment
-Pressure relief relief valve -Check relief
valve malfunction -Potential of valve and repair
fire and
explosion
hazard
55
HAZOP team: Group 11 Meeting Date: Stream Inlet: 40
Node: Dryer Node No. D-01 Stream outlet:50, 51
O
Design Intent: Solid crystals are dried by air input at 130 C while passing through the rotating cylinder.

Word
Temperature Less Lower -Dryer malfunction -Composition of -Install TIC -Check the -Regular checking 3 1 A
temperature product is -Install FIC dryer, and on operating
affected repair it. conditions
to control the
-Low temperature if -Lower flow rate of -Reduce the
inlet stream 49 production rate the inlet temperature of
according the input stream
temperature
changes
More Higher -Hot external -Burns up -Regular -If temperature -Regular checking 3 1 A
temperature surface of dryer and products maintenance is too high, shut on operating
ductwork -High surface of streams it down conditions
immediately
temperature -Install TICA
-High temperature -Reduce the
of inlet stream 49 temperature of
input stream
Flow rate NO No flow rate -Flow control valve -Moisture -Install FC -Check valve -Regular checking 2 1 A
closed content remain and reopen it on operating
constant conditions
-Feed lines and -Troubleshoot
valves blocked -Pressure built and replace the
up in blocked damaged
pipe pipelines
-No drying
56
Less Low flow -Leakage -Low -Install FICA -Replace the -Regular checking 1 1 A
rate separation -Install LLA pipeline on dryer operating
efficiency conditions
-Small flow control in vessel -Check valve
valve opening -Low pressure opening and
repair it
Low hot air -Dryer malfunction -Cannot -Install FC -Check dryer -Regular checking 2 1 A
flow achieve desired -Install PC and repair it on dryer conditions
moisture
MORE High flow -Large flow control -Pressure on -Install FICA -Check valve -Regular checking 3 1 A
rate valve opening pipelines and -Install HLA opening and on dryer
cause damaged repair
in vessel -Install relief valve
-Hazard of -Split feed streams
explosion
in parallel
High hot air -Dryer malfunction -Cannot -Install FC -Check dryer -Regular checking 2 1 A
flow achieve desired -Install PC and repair it on dryer
moisture
57
HAZOP team: Group 11 Meeting Date: Stream Inlet: 51
Node: Sieve Node No. S-01 Stream Inlet:52, 53, 54
Design Intent: Adipic acid crystals, Succinic acid crystals and Glutaric acid crystals which are different in sizes are separated using a few
sieves with different pore size.

Word
Temperature MORE High -Fouling -High surface -Install TC -Clean sieve -Insulate vessel 2 1 A
Temperature temperature -Maintenance with jacket
-High input stream of streams -Reduce input -Regular checking
51 temperature stream
on sieve
temperature
Flow rate NO No flow rate -Flow control valve -No productio -Install FC -Check valve -Regular checking 2 1 A
closed and reopen it and maintain
operating
-Feed lines and -Troubleshoot conditions
valves blocked and replace the
damaged
pipelines
LESS Low flow -Leakage -Low pressure -Install FICA -Check valve -Regular checking 1 1 A
rate -Install LLA opening and and maintain
repair it operating
in vessel conditions
-Small flow control -Increase pump
valve opening efficiency
58
MORE High flow -Large flow control -Pressure on -Install FICA -Check valve -Regular checking 3 1 A
rate valve opening pipelines and -Install HLA opening and and maintain
cause damaged repair operating
in vessel conditions
-Hazard of
explosion -Install relief valve
-Split feed streams
in parallel
Other - -Fouling -Crystals -Affect the -Ensure the -Clean the sieve -Regular checking 2 1 A
occur accumulated in the separation cleaning of immediately on sieve, and clean
sieve coefficient sieve the sieve when the
fouling is detected
59
5.3 Utilities and Storage Tanks
5.3.1 Cyclohexane Storage
5.3.2 KA oil Storage
5.3.3 Compressor (E-01)
5.3.4 Pump (P-01)
5.3.5 Pump (P-02)
5.3.6 Pump (P-03)
5.3.7 Pump (P-04)
5.3.8 Pump (P-05)
5.3.9 Pump (P-06)
5.3.10 Pump (P-07)
5.3.11 Heat Exchanger (Heater) (HE-01)
5.3.16 Heat Exchanger (Cooler) (HC-01)
60
HAZOP team: Group 11 th Stream Inlet:13
Node: Catalytic Cyclohexane storage tank Node No. Stream Outlet:14
Design Intent: To store and contain cyclohexane.

Word
Temperature More High - High temperature -the -Installation -Constant -Build storage tank 2 1 A
Temperature inlet feed cyclohexane of TIC checking of the in a remote and
. stored in the temperature low light facility in
- Internal fire vessel will and checking of the area
vaporise due to the design
the high controls.
temperature
profile.
-the high
temperature of
tank will pose a
fire hazard
Pressure LESS Low -Leakage in the -Loss of -Install PIC -Immediate -Constant checks 1 1 A
Pressure storage tank component repair of the for leakage.
stored in the equipment and
tank/vessel. restoration.
-output valve of the
vessel is open. -Leakage of
component to
-low pressure could working area
lead to foaming. may cause fire
61
MORE High -thermal over- -severe -keep -Check for valve -Build storage tank 2 4 C
Pressure pressure damage to storage tank failure. (open or in a remote and
piping and the away from closed) low light facility in
-the liquid vessel other -Maintain the area
cyclohexane might equipment or required
partially vaporise electrical temperature in -prepare vessel for
due to either high base area where the high pressure
pressure vessel is circumstances.
-install PICA located.
2 1 A
Level More High level Faulty level -Potential -Using or -Purging the -Proper
measurement. overflow of building component. arrangement or
component. more than positioning of the
-wastage of one storage storage tanks.
component. tank.
-Install a PI
Corrosion Vessel -change in design -Damage in -Follow -replace the -Proper 2 1 A

corroding specifications equipment proper guide equipment and arrangement of
due to -Change in book and install new the storage tanks.
component temperature and -Vessel may controls. equipment as
pressure settings. crack or soon as
rupture which possible.
leads to loss of
material
stored.
62
HAZOP team: Group 11 th Stream Inlet:16
Node: KA oil storage tank Node No. Stream Outlet:17
Design Intent: To store and contain Ketone-Alcohol oil.

Word
Temperature More High - High temperature - KA oil stored -Installation -Constant -Build storage tank 2 1 A
Temperature inlet feed. in the vessel of TIC checking of the in a remote and
. - Internal fire will vaporise temperature low light facility in
due to the high and checking of the area
temperature the design
profile. controls.
Pressure LESS Low - the component - Potential loss -Install PIC -Immediate -Constant checks 1 1 A
Pressure stored could of compoenet repair of the for leakage.
potentially leak. stored in the equipment and
tank/vessel. restoration.
-due to low pressure -if flammable - repair of the
the liquid held in the safety valves.
vessel might the component
condense. stored could
cause a flame.
MORE High - the storage tank - over flow of -keep - install an -Build storage tank 2 4 C
Pressure reaches maximum components storage tank indicated inside in a remote and
capacity to store > severe away from the tank to low light facility in
damage to other indicate the area
- Failure in valve 28 piping and equipment or overflow or
could potentially other electrical brimming
cause an overflow in equipment base
63
the vessel due to > high -install PICA > prepare
backflow. pressure vessel for high
pressure
circumstances.
2 1 A
Level More High level Faulty level -Potential -Using or -Replacing the -Proper
measurement. overflow of building component. arrangement or
component. more than positioning of the
-wastage of one storage storage tanks.
component. tank.
Corrosion Vessel -change in design -Damage in -Follow -replace the -Proper 2 1 A

corroding specifications equipment proper guide equipment and arrangement of
due to -Change in book and the storage tanks.
component temperature and -Vessel may controls.
pressure settings. crack or
rupture which
leads to loss of
material
stored.
64
Node: Compressor Node No. E-01 Stream Outlet: 6
Design Intent: To compress the air and increase the pressure until it reach the optimum pressure 10atm for the reaction.

Word
Temperature More Higher -Failure in coolers -May damage -Installation -Reduce input -Installing 2 2 A
Temperature for the specific compressor due of TIC in stream compressors with
stream. to thermal input stream. temperature to higher resistance
expansion required profile. to temperature.
-Reduced -Address the
efficiency of cause of
compressor. increased
temperature.
Pressure Less Low -Flow rate of the -Increase in > Installation -Monitor and 2 1 A
Pressure input stream is energy used to of PICA & FIC increase the
lower than set rate. compress the flow rate of the
components. input stream.
-Final
-Leakage in pipes. -Monitor all pipe
compression lines and
not up to set conduct repairs
standards. if needed.
-Blockage of pipes. -Proper

maintenance of
-Compressor failure equipment.
More High -Very high input -Potential -Installation -Monitor flow -Installing 2 2 A
Pressure stream pressure. leakage of of PIC rates of the compressors with
component input streams. higher resistance
to temperature.
65
Flow None No Flow -Control valve -High pressure -Installation -Check valve 1 1 A
failure drop of PICA & FIC opening
-Vibration -Monitor
causes damage compressor

to equipment settings
and piping.
Less Low Flow -Control valve -Compressor -Installation -Check valve 3 1 A

failure might be of PICA & FIC opening and
damaged. closing.
-Flow is in
-Leakage in the -Maintain and
piping. reverse. repair piping.
-Energy
required is
higher than set
standard.
More High Flow -Control valve -High pressure -Installation -Check valve 3 2 A
failure drop of PICA & FIC opening
-Vibration -Monitor
causes damage compressor

to equipment settings
and piping.
Composition Liquid Liquid input -Failure to separate -Potential -Check valve -Installing 3 1 A
higher than moisture from the damaging of opening and compressors with
set atmospheric air in the compressor closing. high liquid
standard. the upper stream. if liquid content composition
is too high. -Monitor all tolerances.
leakages.
-Shutdown the
compressor.
66
Node: Pump Node No. P-01 Stream Outlet: 11
Design Intent: To increase Stream pressure

Word
Temperature More High -Temperature on -Changes -Installation -Reduce input 3 1 A
Temperature component is high. temperature of of TIC in stream
components in input stream temperature
the column
-Frequent
-Affects quality temperature
of products checks
-Low
compressor
efficiency.
Pressure More High -Very high input -Required -Installation -Decrease the 3 2 B
Pressure stream pressure. pressure is not of PIC flow of the
reached. component.
-Install
-Potential pressure
leakage relief
valve/rupture
-Forms disc.
pressure waves
that damages
pump and
makes noise
-Cavitation
67
Less Low Output -Low input stream -More energy -Installation -Increase the -Proper checks and 3 1 A
Pressure flowrate required than of PICA & FIC stream flowrate maintenance of
perceived. equipment.
-Installation
-Spraying onto of a one way
the column is valve.
-Pipes may face > Check piping
inefficient.
leakage and condition and
blockage. -Reverse flow repair damages
-Damage
occurs to the
pump
Flow None No Flow -Flow Control valve -Pump faces -Installation -Check valve -Monitoring of inlet 1 1 A
failure. damage. of FICA opening flow.
-Blocked piping. -Replace burst

or blocked pipe
Less Low -Flow control valve -Pump -Check valve -Monitoring of inlet 3 1 A
Flowrate failure damaged. opening flow.
-Reverse flow
-Leakage. -Check for
-Desired leakage and
conduct repairs
production not -Installation if any.
achieved of PICA & FIC
-Energy
required is
higher than
perceived.
More High -Flow control valve -High pressure -Installation -Check valve 3 2 B
Flowrate failure drop of PICA & FIC opening.
68

Word
the column
-Frequent
of products checks
-Low
compressor
efficiency.
reached. component.
-Install
-Potential pressure
leakage relief
valve/rupture
-Forms disc.
pressure waves
that damages
pump and
makes noise
-Cavitation
69
-Installation
inefficient.
-Damage
occurs to the
pump

or blocked pipe
-Reverse flow
conduct repairs
-Energy
required is
higher than
perceived.
70

Word
the column
-Frequent
of products checks
-Low
compressor
efficiency.
reached. component.
-Install
-Potential pressure
leakage relief
valve/rupture
-Forms disc.
pressure waves
that damages
pump and
makes noise
-Cavitation
71
-Installation
inefficient.
-Damage
occurs to the
pump

or blocked pipe
-Reverse flow
conduct repairs
-Energy
required is
higher than
perceived.
More High -Flow control valve -High pressure -Installation -Check valve 3 2 A
72

Word
the column
-Frequent
of products checks
-Low
compressor
efficiency.
reached. component.
-Install
-Potential pressure
leakage relief
valve/rupture
-Forms disc.
pressure waves
that damages
pump and
makes noise
-Cavitation
73
-Installation
inefficient.
-Damage
occurs to the
pump

or blocked pipe
-Reverse flow
conduct repairs
-Energy
required is
higher than
perceived.
74

Word
the column
-Frequent
of products checks
-Low
compressor
efficiency.
reached. component.
-Install
-Potential pressure
leakage relief
valve/rupture
-Forms disc.
pressure waves
that damages
pump and
makes noise
-Cavitation
75
-Installation
inefficient.
-Damage
occurs to the
pump

or blocked pipe
-Reverse flow
conduct repairs
-Energy
required is
higher than
perceived.
More High -Flow control valve -High pressure -Installation -Check valve 3 2 A
76

Word
the column
-Frequent
of products checks
-Low
compressor
efficiency.
Pressure More High -Very high input -Required -Installation -Decrease the 3 2 A
reached. component.
-Install
-Potential pressure
leakage relief
valve/rupture
-Forms disc.
pressure waves
that damages
pump and
makes noise
-Cavitation
77
-Installation
inefficient.
-Damage
occurs to the
pump

or blocked pipe
-Reverse flow
conduct repairs
-Energy
required is
higher than
perceived.
78

Word
the column
-Frequent
of products checks
-Low
compressor
efficiency.
Pressure More High -Very high input -Required -Installation -Decrease the 3 2 A
reached. component.
-Install
-Potential pressure
leakage relief
valve/rupture
-Forms disc.
pressure waves
that damages
pump and
makes noise
-Cavitation
79
-Installation
inefficient.
-Damage
occurs to the
pump

or blocked pipe
-Reverse flow
conduct repairs
-Energy
required is
higher than
perceived.
80
Node: Heat Exchanger (Heater) Node No. HE-01 Stream Outlet: 4
Design Intent: Used to control steam temperature and steam flowing into Reactor 1.

Word
Duty Less Less Heating -Low flow rate of -Process -Installation -Increase the 2 2 A
Duty the heated steam. stream lacks of TIC in the flowrate of the
required heat. heat heating stream.
exchanger
-Input temperature -Gasifier output -Increase
of the heating operation stream to heating duty by
stream is too low. failure. maintain increasing
utility steam steam flowrate
flowrate
-Heat transfer is -Equipment
affected due to must be cleaned
factors like fouling. on a regular
basis.
Temperature Less Less outlet -Moisture content in -The gas -Installation -Increase 3 1 A
temperature the inlet stream conversion rate of TI in heating duty by
higher than set faces outlet and increasing
standards. hindrance. FIC for steam flowrate
stream
-Low inlet carrying the
temperature heated
steam.
More More outlet -High heating duty. -Energy -Installation -Reduce heating 2 2 A
temperature wastage. of TI in duty by
outlet and reducing steam
-High inlet FIC for flowrate
temperature stream
carrying the
81
heated
steam.
Temperature -Process stream -Potential -Installation -Decrease inlet -Install heat 3 1 A
above the inlet temperature damage caused of TIC for stream flowrate. exchangers with
temperature above set point to equipment input higher design
profile of the due to thermal streams. temperature
design. expansion. acceptance.
-Heater control -Monitor
failure. -Potential controls
regularly.
leakages and
ruptures in the
equipment.
Pressure Less Low -Inlet pressure of -Heat transfer -Installation -Increase 3 1 A

Pressure the process stream in the of PI. pressure to
is lower than the set significantly required
pressure profile. lower. amount.
More High -Inlet pressure of -Potential -Installation -Monitor and Install heat 2 3 B
Pressure the process stream damage caused of PIC in perform bypass exchangers with
is higher than the to the tube side and to relief higher design
set pressure profile. equipment. shell side pressure in the temperature
streams stream. acceptance.
-Installation
of pressure
relief bypass
streams for
input
streams.
Flow None No tube side -Valve is closed. -Energy -Make sure the -Installing of an 1 1 A
process wastage. valve is open. extra heat
stream flow -Installation exchanger for
-Ruptured piping. of FICA -Mend the emergency.
ruptured piping.
82
No heating -Valve is closed -Reaction in the -Open valve. 1 1 A
steam flow gasifier faces -Installation
hindrance.
-Ruptured piping of FICA -Mend ruptured
piping.
Less Less flow -Valve failure -Lower heat -Installation -Monitor valves 3 1 A
transfer of FICA and maintain it
-Piping leakage -Check valve

and take
-Valve malfunction corrective
measures
More Higher -Valve failure -High pressure -Monitor valves 3 1 A

flowrate drop. and maintain it
-Causes
-High inlet flow -Installation -Decrease inlet
damage of pipe flow
of FICA
-Lower outlet
temperature
Higher shell -Valve malfunction -Higher -Monitor valves 2 2 A

side flowrate pressure drop and maintain it
-Increases
-High shell inlet flow -Installation -Decrease inlet
erosion flow
of FICA
-Higher outlet
temperature
83
Design Intent: Used to control stream temperature flowing into Reactor 2.

Word
exchanger
flowrate
basis.
stream
temperature heated
steam.
temperature stream
carrying the
84
heated
steam.

regularly.
leakages and
ruptures in the
equipment.

streams stream. acceptance..
-Installation
of pressure
relief bypass
streams for
input
streams.
ruptured piping.
85
hindrance.
piping.

and take
measures

-Causes
damage of pipe flow
of FICA
-Lower outlet
temperature

-Increases
erosion flow
of FICA
-Higher outlet
temperature
86
Design Intent: Used to control nitric acid temperature flowing into Reactor.

Word
3Duty Less Less Heating -Low flow rate of -Process -Installation -Increase the 2 2 A
exchanger
flowrate
basis.
stream
temperature heated
steam.
temperature stream
carrying the
87
heated
steam.
regularly.
leakages and
ruptures in the
equipment.

-Installation
of pressure
relief bypass
streams for
input
streams.
ruptured piping.
88
hindrance.
piping.

and take
measures

-Causes
damage of pipe flow
of FICA
-Lower outlet
temperature

-Increases
erosion flow
of FICA
-Higher outlet
temperature
89
Design Intent: Used to control stream temperature flowing into Flash Drum.

Word
exchanger
flowrate
basis.
stream
temperature heated
steam.
temperature stream
carrying the
90
heated
steam.
regularly.
leakages and
ruptures in the
equipment.

More High -Inlet pressure of -Potential -Installation -Monitor and Install heat 2 3 A
-Installation
of pressure
relief bypass
streams for
input
streams.
ruptured piping.
91
hindrance.
piping.

and take
measures

-Causes
damage of pipe flow
of FICA
-Lower outlet
temperature

-Increases
erosion flow
of FICA
-Higher outlet
temperature
92
Design Intent: Used to control stream temperature flowing into Distillation Column 2.

Word
exchanger
flowrate
basis.
stream
temperature heated
steam.
temperature stream
carrying the
93
heated
steam.

regularly.
leakages and
ruptures in the
equipment.

More High -Inlet pressure of -Potential -Installation -Monitor and Install heat 2 3 A
-Installation
of pressure
relief bypass
streams for
input
streams.
ruptured piping.
94
hindrance.
piping.

and take
measures

-Causes
damage of pipe flow
of FICA
-Lower outlet
temperature

-Increases
erosion flow
of FICA
-Higher outlet
temperature
95
Node: Heat Exchanger (Cooler) Node No. HC-01 Stream Outlet: 29
o o
Design Intent: To cool down the components from 120 C to 70 C before entering membrane separator

Word
Temperature Less Low Outlet -Too much cooling -Hindered -Installation -Decrease flow -Regular 3 1 A
Temperature duty operating of TI at the of cooling water maintenance and
temperature for outlet stream cleaning
-Fouling reaction -Installation -Design oversized
-Product yield of FIC at the heat exchanger to

and quality inlet reduce fouling
compromised effect
to significant
values.
More High -Feed temperature -Product unable -Installation -Decrease flow 3 1 A

Temperature above set point to be cooled to of TIC rate of
desired feedstock
-Cooling water temperature -Decrease flow
temperature above -Damage rate of utility
set point stream
equipment due
to thermal
expansion
-Potential
leakage or
rupture
High Outlet -Too little cooling -Product yield -Installation -Check and - Review 2 2 A
Temperature duty and quality of TI at the repair heat temperature profile
compromised outlet stream exchanger around heat
of heat exchanger and
-Insufficient flow of exchanger -Increase flow install flow control
cooling water of cooling water of cooling water
96
-Higher -Installation
pressure of FIC at the
generated inlet
-High water inlet
temperature
Pressure Less Low -Feed pressure -Inefficient -Installation - Increase -Regular checking 2 1 A
Pressure below set point heat transfer of PI pressure of both and maintenance
streams of equipment
-Low flow rate -Detect and

Undetected leakage repair leakage
source
More High -Feed pressure -Pressure build -Installation -Perform bypass -Regular 2 2 A
pressure above set point up in pipeline of PIC maintenance of
piping
High flowrate of -Potential -Installation -Partially close
inlet damage to of pressure the valve at the
equipment relief bypass feed stream
-Partial streams for
condensation -Potential both feed
leakage of and utility
-Blockage of outlet containment streams -Inspect and
remove for any
blockage
Flow No No feedstock -Flow control valve -Energy and -Installation -Open flow 1 2 A
stream flow closed utility wastage of FIC control valve
-Blockage or -Monitor and

ruptured piping repair ruptured
pipe
-Clean the
equipment
97
Less Low feed -Flow control valve -Lower heat -Installation -Inspect and 2 2 A
flow rate malfunction transfer of FIC repair valve
-Changes in
composition
-Leakage -Repair ruptured
pipe
-Low inlet flow
Low utility -Flow control valve -Lower heat -Inspect and 1 1 A

stream flow malfunction transfer repair valve
-Feed not
cooled to
-Blockage of desired -Repair ruptured
pipelines temperature pipe
More More flow -Flow control valve -High pressure -Installation -Check and -Monitor flow rate 3 1 A
malfunction build up in of FICA repair valve constantly
stream
-Cause damage
to pipelines
-Inefficient
cooling
-Higher
temperature
outlet flow
-High inlet flow -Decrease inlet
flow
More utility -Flow control valve -High pressure -Inspect and 2 1 A

stream flow malfunction build up in repair valve
stream
98
-High inlet flow -Feed cooled to -Decrease inlet
the flow
temperature
below
operating
condition
99
6.0 Process Control Diagram for Selected
Units
6.1 Suggested Instrumentation Diagram for Reactor
Reactor
R-01
100
6.2 Suggested Instrumentation Diagram for Distillation
Column
PC
Coolant
PT
Pressure
Relieve
LC LT FC
FT
FC
FT
Stream 140
Distillation
Stream column V-134
130
TT TC TC
TT
LT
Reboiler
Steam
Stream 131
LC
101
6.3 Suggested Instrumentation Diagram for Pump
FC
Stream 2
FT
Stream 1 Pump-01 1
6.4 Suggested Instrumentation Diagram for Heat Exchanger
Stream 7
Ratio
Control
FRC FC FT
FT TT
Stream 3 Stream 4
TT HE-01
Heat Exchanger 1
Stream 8
102
7.0 Materials Safety and Handling
Methods
The hazard identification and corresponding handling methods of the chemicals
involved in this adipic acid production are stated below.
1) Cyclohexane
Hazard properties Descriptions Handling Method

Flammable Highly flammable in Use CO2, dry chemical,
presence of open flames or foam for extinction
and sparks, of heat.
Slightly explosive in
presence of open flames
and sparks.
Corrosive Causes skin irritation Rinse eyes or skin with
and eye irritation water for 15 minutes
and obtain medical
attention
Aspiration Toxicity It may cause respiratory Remove victim to fresh
tract irritation, nausea, air and keep at rest in a
increased respiration position comfortable for
rate, cause dizziness, breathing. If the victims
lethargy, somnolence, feel unwell, refer to
seizures/convulsions, poison centre or doctor
weakness, loss of
coordination and
judgement, trembling,
drowsiness.
Unconsciousness and
death may occur at high
exposures
2) Nitric Acid

and eye irritation of water for 15 minutes
and obtain medical
attention
Aspiration Toxicity Cause respiratory Remove victim to fresh
irritation (coughing, air
choking, or shortness of If breathing is difficult,
breath) give oxygen.
103
3) Adipic Acid

and eye irritation water for 15 minutes
and obtain medical
attention
Aspiration Toxicity Cause lung sensitizer Remove victim to fresh
air
If not breathing, give
artificial respiration
4) Cyclohexanol

Corrosive Causes skin irritation Wash immediately with
and eye irritation water. Gently and
thoroughly wash the
contaminated skin with
running
water and non-abrasive
soap
Aspiration Toxicity Inhalation is toxic to Allow the victim to rest
lungs, mucous in a well-ventilated area.
membrane
5) Cyclohexanone

and eye irritation of water. Cover the
irritated skin with an
emollient
Aspiration Toxicity Cause respiratory If inhaled, remove to
irritation fresh air. If not
breathing, give artificial
respiration. If breathing
is difficult, give oxygen
Toxicity Toxic to kidneys, liver, If ingest substances, do
upper not induce vomiting,
respiratory tract, skin, never give anything by
eyes, central nervous mouth. Seek medical
system and cause attention.
damage
104
6) Glutaric acid

and eye irritation water. Cover the
irritated skin with an
emollient
irritation fresh air. If not
breathing, give artificial
respiration. If breathing
is difficult, give oxygen
7) Succinic acid

and eye irritation water. Gently and
thoroughly wash the
running
water and non-abrasive
soap
Aspiration Toxicity Cause respiratory Allow the victim to rest
irritation in a well-ventilated area.
Seek immediate medical
attention.
8) Carbon Dioxide

Asphyxiant It can displace oxygen in Remove to fresh air and
ambient atmosphere and keep at rest in a position
cause death in high comfortable for
concentrations. breathing.
Corrosive Contact with liquid Warm frostbite area with
carbon dioxide may warm water not to
cause cold exceed 41°C. Maintain
burns/frostbite skin warming for at least
15 minutes.
Respiration Increase respiration and Remove to fresh air and
heartbeat rate. keep at rest in a position
comfortable for
breathing
105
9) Nitrogen

Explosive Can cause explosion if Promptly isolate the
heated. scene by removing all
persons from the vicinity
of the incident if there is
a fire. Use water spray
to keep fire-exposed
containers
cool.
and cause rapid keep at rest in a position
suffocation. comfortable for
breathing.
Corrosive Causes skin irritation Immediately flush eyes
and eye irritation with water, Flush
plenty of water.
10) Nitrous oxide

ambient atmosphere and keep at rest in a position
cause death in high comfortable for
concentrations. breathing.
Corrosive Contact with liquid Warm frostbite area with
carbon dioxide may warm water not to
cause cold exceed 41°C. Maintain
burns/frostbite skin warming for at least
15 minutes.
Respiration Increase respiration and Remove to fresh air and
heartbeat rate. keep at rest in a position
comfortable for
breathing
Flammable Can cause intensive fire Use extinguishing media
and explosion. appropriate for
surrounding fire.
106
11) Nitrogen dioxide

Flammable Cause intensive fire and Use fire control
explosion measures appropriate
for the surrounding fire
Toxicity Fatal when inhaled Evacuate all personnel
from the danger area.
Use self-contained
breathing apparatus
(SCBA) and protective
clothing.
Corrosive Causes serious skin Immediately flush eyes
burns and eye damage with water, Flush
plenty of water.
12) Nitric oxide

Flammable Cause intensive fire and Use fire control
explosion measures appropriate
for the surrounding fire
burns and eye damage with water, flush
plenty of water. Get
medical attention
immediately
13) Acetic acid

burns and eye damage with water, flush
plenty of water
irritation (coughing, fresh air. If not
choking, or shortness of breathing, give artificial
breath) respiration. If breathing
is difficult, give oxygen.
Flammable Can cause fire in Use dry chemical

presence of open flames powder, alcohol foam,
and sparks. water spray or fog.
107
8.0 Emergency Evacuation Plan/Response
8.1 Escape Route
108
8.2 Emergency Contact
HOSPITAL
Hospital Shah Alam 0355263000
KPJ Klang Specialist Hospital 0333777888
Columbia Asia Extended Care 0355417833
Hospital
Ambulance 112
FIRE DEPARTMENT
Balai Bomba dan Penyelamat 0355194444
Shah Alam
Balai Bomba dan Penyelamat Seri 0333734444
Andalas
POLICE DEPARTMENT
Policia Federal 999
HAZOP TEAM
Lee Chee Hoong 0178854963
Ng Han Xiang 0172689745
Cassandra Tay Chu Mei 0112588975
Vikram Abiruben 0128974562
109
9.0 Conclusion
This report aims to present a comprehensive and extensive Hazard and
Operability Study (HAZOP) for the proposed design of Adipic Acid production plant
using Cyclohexane. The relevant risks and hazards on each equipment were
identified along with their causes and consequences with reasonable assumptions.
The extensive analysis of safety and operability of the plant is carried out through
“guide word” method and various team brainstorming sessions. The deviations are
evaluated based on humans and equipment safety risks as well as plant operation
efficiency. For each deviation, the potential causes and consequences are listed.
Analysis is carried out on a unit per unit basis and the results is incorporate with
appropriate safeguards, actions and recommendations for each event is also
presented clearly and comprehensively on the HAZOP tables. An O-D-R (Risk
Occurrence and Safety Description Rating) human safety rating system is used to
represent how much an event will compromise plant personnel safety. The
materials used in the process are also evaluated in terms of human hazards as well
as equipment safety issues and their respective handling methods are suggested.
The report also presents suggested process control and instrumentation layout for
main selected equipment.
HAZOP is useful but at the same time it also poses a few drawbacks, table below
shows the advantages and some drawback of application of HAZOP.
Advantages Drawbacks
The HAZOP process is a systematic examination. A HAZOP focuses on single events rather than
combinations of possible events.
The team approach to a HAZOP makes it a The HAZOP focus on guide-words allows it to overlook
multidisciplinary study. some hazards not related to a guide-word.
The HAZOP team utilizes operational experience. Training is essential for optimum results, especially for
the facilitator.
HAZOP study results are recorded. HAZOPs are typically very time consuming and thus
expensive.
For team members the process is easily learned and
performed.
A HAZOP does not require considerable technical
expertise for technique formulation.
As a systematic process it provides rigor for focusing
on system elements and hazards.
The HAZOP process is a team effort with many
viewpoints.
Commercial software is available to assist in HAZOP
110
10.0 References
1. 3M Industrial Group. CORROSION CONTROL (2016) [Online]
Available from: http://www.liquicel.com/applications/corrosion-control.cfm
th
[Accessed: 20 Mar. 2017]
2. Gordon McKay (NA) Process Safety Management and Risk Hazard Analysis [Online]
Available from:
http://www.cbme.ust.hk/safetycourse/download/09.1HAZOPStudyTrainingCourse.pdf
[Accessed: 20 Mar. 2017]
3. Nigel Hyatt (2004) Guidelines for Process Hazards Analysis, Hazards Identification &
Risk Analysis [Online] Available from: https://books.google.com.my/books?
id=HZOm9szj21EC&printsec=frontcover#v=on epage&q&f=false [Accessed: 18 Mar.
2017]
4. Roy C., Jim B. and Neil F. (2003) Dynamic Simulation – A New Hazop Tool [Online]
Available from: https://www.icheme.org/communities/special-interest-groups/safety
%20and%20loss%20prevention/resources/~/media/Documents/Subjec t
%20Groups/Safety_Loss_Prevention/WCCE/P50-001.pdf [Accessed: 10 Mar. 2017]
5. Martin Rausand 2005, ‘HAZOP - Hazard and Operability Study’. Available

from: http://frigg.ivt.ntnu.no/ross/slides/hazop.pdf [Accessed 18 Mar. 2017]
6. Crowl, D. and Louvar, J. (2017). 1-7 Inherent Safety | Introduction to Chemical

Process Safety | InformIT. [online] Informit.com. Available at:
http://www.informit.com/articles/article.aspx?p=1717264&seqNum=7 [Accessed
24 Mar. 2017].
7. Dam, G. (2017). DISTILLATION COLUMNS (or TOWERS) - DISTILLATION COLUMN

CONTROL. [online] Articles.compressionjobs.com. Available at:
http://articles.compressionjobs.com/articles/oilfield-101/2710-distillation-columns-
towers-column-control-?start=3 [Accessed 15 Mar. 2017].
8. Controlguru.com. (2017). Distillation: Major Disturbances & First-Level Control –

Control Guru. [online] Available at: http://controlguru.com/distillation-
major-disturbances-first-level-control/ [Accessed 15 Mar. 2017].
9. Rccostello.com. (2017). Factors Affecting Distillation Column Operation. [online]

Available at: http://www.rccostello.com/distil/distilop.htm [Accessed 16 Mar. 2017].
10. Sciencelab.com. (2017). ScienceLab: Chemicals & Laboratory Equipment. [online]

Available at: http://www.sciencelab.com/ [Accessed 13 Mar. 2017].
11. Praxair.com. (2017). Industrial Gases, Supply, Equipment & Services.

[online] Available at: http://www.praxair.com [Accessed 14 Mar. 2017].
111

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University of Nottingham Malaysia Campus

Hazard and Operability Study

Ng Han Xiang 023319

Cassandra Tay Chu Mei 023730

Vikram Abiruben 024134

Module Convenor: DDr. Lam Hon Loong

1.0 Introduction ............................................................................................

In every chemical plant design, a crucial factor that must be considered is

Originally, the HAZOP technique was developed to analyse chemical process

A typical steps of conducting a HAZOP study:

1. Familiarisation with background documentation

This report is done with the objective of creating a comprehensive HAZOP

3. Equipment with perfect Insulation. No Heat Loss in Reactor.

LIA Level indicator alarm

LIC Level indicator and controller

LICA Level indicator controller alarm

MAWP Maximum Allowable Working Pressure

PIC Pressure indicator and controller

PICA Pressure indicator controller alarm

PAD Pressure alarm device

PSV Pressure safety valve

SIS Safety interlock system

TIC Temperature indicator and controller

TICA Temperature indicator controller alarm

FIA Flow indicator alarm

FICA Flow indicator controller alarm

HLA High level alarm

LLA Low level alarm

Table 1: Risk Occurrence and Injury Description Rating Factors

Safety 1- Minor first- 2- Injuries that 3- Severe 4-High

1-Not expected to (A)Acceptable (A)Acceptable (A)Acceptable (B)Acceptable

2-Rarely occurs (A)Acceptable (A)Acceptable (B)Acceptable (C)Must be

3-Occurs frequently (A)Acceptable (B)Acceptable (C)Must be (D) Strict

4-Occurs very often (B)Acceptable (C)Must be (D) Strict (D) Strict

Generally, the safety of a process is dependent on the various layers of

Figure 1: Multilayer Protection

3. Utilities and Storage Tanks

5.1.1 Catalytic Oxidation Reactor 1 (R-01)

5.1.2 Catalytic Oxidation Reactor 2 (R-02)

Parameter Guide Deviation Causes Consequences Safeguard Action Recommendatio O D R

LESS Low Flow -Leakage in -Insufficient -Install LI to -Increase the -Periodic 2 1 A

Temperature LESS Low -Insufficient -Lower -Install TIC -Increase -Review 3 1 A

-Feed preheater -Check output

-Pump P-01 failure -Inefficient heat -Check and

- Low reactor -Install a

-Pressure vent -Inspect and

MORE High -Excessive input -Possible -Install -Reduce -Install a cooling 2 4 C

-Feed condition is -Increase

-Not enough -Check burner

-Not enough -Decrease

MORE More -Excessive -Reaction -Monitor on -Check and -Install cooling 3 1 A

Composition NO No -Cyclohexane -Reaction -Heavily -Troubleshoot -Consider multiple 1 2 A

OTHER Undesired -Contamination of -Product quality -Heavily -Troubleshoot -Feed regulation 1 2 A

Parameter Guide Deviation Causes Consequences Safeguard Action Recommendation O D R

-Feed preheater HE- -Check output

-Pump P-03 failure -Inefficient -Check and

- Low reactor -Install a

-Pressure vent valve -Inspect and

MORE High -Excessive input -Possible -Install -Reduce -Install a cooling 2 4 C

Reaction NO No Reaction -Blockage of one or -Heavy -Heavily -Perform -Consider installing 2 1 A

-Not enough heating -Check burner

-Not enough -Decrease

Composition NO No feedstock -Cyclohexane input -Reaction -Heavily -Troubleshoot -Consider multiple 1 2 A

No acid -Nitric Acid input -Reactor -Monitor -Troubleshoot -Consider multiple 1 2 A