Chapter 9 - Safety and Loss Prevention

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CHAPTER 9

ENVIROMENTAL AND SAFETY CONSIDERATION

9.1 INTRODUCTION

Malaysia has a wide range of laws and regulations for the purpose of managing

environmental. Environmental Quality Act (EQA), incepted in 1974 was establish in

order to protect and focus on various aspects of the environment prevention including

health and safety issues.

9.1.1 Environmental Quality Act

The main framework environmental legislation in Malaysia is the 1974 Environmental

Quality Act. The EQA employs a regulatory framework based upon the issuing of

licenses and the prescription of premises to be regulated.

The minister will cooperate with the Environment Quality Council in order to

prescribe any premises which conducted in an illegal condition. The conditions for

the occupation and use of these prescribed premises are attached to the license by

the Director General, who is the licensing authority. Among the power of Director

General is grant, renew, transfer and revoke the license of the illegal premises.

In exercising this power, the Director General is bound to consider factors

such as the practicability and efficacy of imposing new and varied conditions, the

economic life of existing installations, the cost of complying with conditions and the

nature of the industry concerned.



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9.1.2 Department of Occupational Safety and Health (DOSH)

The Department of Occupational Safety and Health (DOSH) is a department under

the Ministry of Human Resources. The department’s organisation structure consists

of its head office and 13 state offices is responsible for ensuring the occupational

safety, health and welfare of people at work as well as protecting other people from

the safety and health hazards arising from the activities of various sectors which

include:

Manufacturing

Mining and Quarrying

Construction

Hotels and Restaurants Agriculture, Forestry and Fishing

Transport, Storage and Communication

Public Services and Statutory Authorities

Utilities -Gas, Electricity, Water and Sanitary Services

DOSH is responsible to study and review the policies and legislations of

occupational safety and health. This is either conducted by way of analyzing the

present policy concerning Occupational Safety and Health. Besides that, DOSH is

also responsible to review and involved in drafting or legislating new Industry

Regulations, Guidelines and Codes of Practice. In other words, the main function of

DOSH is to regulate and govern the activities of the related parties by way of issuing

licences to the operator or owner of the factory or machinery. Apart from that, DOSH

is also involved in:

Conducting research and technical analysis on issues related to

occupational safety and health at the workplace.

Carry out promotional and publicity programs to employers, workers and the

general public to foster and increase the awareness of occupational safety

and health.

Provide advisory service and information to government and private

agencies pertaining to management and technical aspects of occupational

safety and health.

Become a secretariat for the National Council regarding occupational safety

and health.



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Among the regulations and acts contain inside the Department Of Safety & Health

(DOSH):

Arrangement of sections

Occupational Safety & Health Act 1994

Occupational Safety & Health (Employers’ safety & Health General Policy

Statements)(Exception) Regulations 1995

Occupational Safety & Health (Control of Industrial Major Accident Hazards)

Regulations 1996

Occupational Safety & Health (Safety & health Committee) Regulation 1996

Occupational Safety & Health Classification, Packing & Labelling of

hazardous chemicals) Regulation 1997

Occupational Safety & Health (Safety & Health Officer) Regulations 1997

Occupational Safety & Health (Safety & Health Officer) order 1997

Occupational Safety & Health (Use & Standard of Exposure of Chemical

Hazardous to Health) Regulation 2000

9.1.3 Air Quality

For the air pollution problem which cause by the industrial sources, it was classified

under the Environmental Quality (Clean Air) Regulations 1978. This regulations also

included in the Environmental Quality Act which must be followed for all the

industries. The regulations prescribe permissible concentrations of air impurities in

the conduct of a trade or the operation of fuel burning equipment. Occupiers of

industrial premises are required to use best practicable means of preventing

emissions of hazardous or offensive substances.

The approval of the Director-General of the Department of Environment is

required before they can construct, install or re-site an incinerator. The regulationsrestrict open burning, and smoke emissions by occupiers of industrial premises.

Occupiers are required as directed by the Director-General to provide means of

readily ascertaining smoke discharges. Facilities may not be operated if air pollution

control equipment is not in proper operation.

The license of the occupiers also will be withdrawn if they are found not to

comply with the conditions set up by the department of Environment. Besides that,

there are also another factors which will cause the license of the occupiers may beissued such as there is no practicable means of compliance with acceptable



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conditions, compliance with the standards would involve prohibitive costs, and other

variables. The control of air pollution is also prescribed by several other regulations

such as:

Environmental Quality (Prescribed Activities)

(Environmental Impact Assessment) Order 1987

Environment Quality (Clean Air) Regulations 1978 [P.U (A) 280/78]

Environmental Quality (Clean Air) (Amendment) Regulations 2000 [P.U (A)

309/00]

9.1.4 Recommended Malaysian Air Quality Guideline

An air pollution index system normally includes the major air pollutants which could

cause potential harm to human health should they reach unsafe levels. The

pollutants included in Malaysia's API are ozone (O3), carbon monoxide (CO),

nitrogen dioxide (NO2), sulphur dioxide (SO2) and suspended particulate matter less

than 10 microns in size (pm 10).

Generally, an air pollution index system is developed in easily understood

ranges of values, instead of using the actual concentrations of air pollutants, as a

means for reporting the quality of air or level of air pollution. To reflect the status of

the air quality and its effects on human health, the ranges of index values could then

be categorized as follows:

Good

Moderate

Unhealthy

Very unhealthy

Hazardous



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9.2 ENVIRONMENTAL IMPACT ASSESSMENT

Since the first system of Environmental Impact Assessment (EIA) was established in

the USA in the 1970, EIA systems have been set up worldwide and become a

powerful environmental safeguard in the project planning processes. More than 55

countries have established formal EIA systems, and some reports claim that over

100 countries have instituted some EIA measures.

Malaysia has been quicker than many developed countries to adopt and

adapt environmental impact assessment. As a result of the Environmental Quality Act

1974 and the Third Malaysia Plan, Malaysia has established a Department of

Environment and an Environmental Quality Council, Section 34A of the

Environmental Quality (Amendment) Act 1984 extended environmental impact

assessment legislation in 1986 to require assessment for all public or private projects

likely to have major environmental effects.

In 1988 full implementation with environmental impact assessment was

made mandatory for certain industrial developments. The aim of the environmental

impact assessment is to assess the overall impact on the environment of

development projects proposed by the public and private sectors. The objectives of

environmental impact assessment are:

To identify the environmental costs and benefits of the project to the

community.

To examine and select the best from the project options available.

To identify and incorporate into the project plan appropriate abatement and

mitigating measures.

To predict significant residual environmental impacts.

To determine the significant residual environmental impacts predicted



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9.3 SAFETY CONSIDERATION

Safety is one of most important factors underconsideration in designing plant

especially for the chemical plant. Because of the awareness, chemicla industry has

become the most safety industry compared to other industries. But, even with all

precaution measured taken, accident could still happened. These accidents have

the potential to cause a damage and also result in the loss of lives and financial

resources.

Safety and loss prevention has now become as important as production itself.

In the past, it is link to the effort to avoid accident with the focus on worker safety.

Now the term ‘safety’ has been changed to ‘prevention losses’. The focus has been

shift to avoiding accident happenstances by tackling the root of the problem. The

advancement in technology has made it possible to detect hazard and to evaluate

technical and engineering design characteristic. When dealing with chemicals, users

need to know and understand their nature. Accidents have happened in the pasts

that are cause by the ignorance of handlers to the nature of the materials that they

handled.

Several of the components found in the production of n-butyl acetate that are

dangerous and must be dealt with carefully. The details regarding the safety and

prevention procedure of each component used in the process are always availble in

Material Safety Data Sheet which also known as MSDS.

9.3.1 Material Safety Data Sheet (MSDS)

Material Safety Data Sheet or simply known as (MSDS) is one of the most important

references used during an industrial hygiene.study involving toxic chemical. Among

the data provided iside these sheet are hazard identification, potential effect to

health, stability and reactivity of the chemical, handling and storage of the chemical,

disposal consideration, fire fighting measures of the chemical and a few terms which

will be discuss later in these chapter. The Material Safety Data Sheet are available

from:

The chemical manufacturer.

A commercial source.

A private library developed by the chemical plant.



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MSDS for a substance is not primarily intended for use by the general

consumer, focusing instead on the hazards of working with the material in an

occupational setting. The industrial hygiene or safety professional must interpret and

toxicological properties in order for them to determine the hazards associated with

the chemical. These properties are also used to develop a strategy for the proper

control and handling og these chemicals.

9.3.1.1 Material Safety Data Sheet (MSDS): Acetic Acid

Acetic acid is one of our raw material which will fed together with the butanol in the

beggining of the process. We have to take a serious consideration when dealing

with this acid because the acetic acid is classified as a corrosive substance. The

hazards of solutions of acetic acid depend on the concentration. The solutions at

more than 25% acetic acid are handled in a fume hood because of the pungent and

corrosive vapour.

Table 9.1: Lists the EU Classification of Acetic Acid Solutions

Hazards that may be produced by acetic acid are:

Concentrated acetic acid can be ignited with difficulty in the laboratory. It

becomes a flammable risk if the ambient temperature exceeds 39 °C

(102 °F), and can form explosive mixtures with air above this temperature.

Dilute acetic acid, in the form of vinegar is harmless. However, ingestion ofstronger or higher concentrated acetic acid is dangerous to human and

animal life. It can cause severe damage to the digestive system, and a

potentially lethal change in the acidity of the blood.

a) Potential Acute Health Effects

Inhalation

Inhalation of concentrated vapors may cause serious damage to the lining of

the nose, throat, and lungs and also cause difficult to breath.

Concentration

(% by weight)Molarity Classification

10 –25% 1.67 –4.16 mol/L Irritant (Xi)

25 –90% 4.16 –14.99 mol/L Corrosive (C)

>90% >14.99 mol/L Corrosive (C) Flammable (F)



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Ingestion

Swallowing can cause severe injury which leading to death. Symptoms

cause by ingestion include sore throat, vomiting, and diarrhea. Ingestion as

little as 1.0 ml of acetic acid will result in perforation of the esophagus.

Skin Contact

Direct contact with concentrated acetic acid solution may cause serious

damage to the skin. An effects may include redness, pain, skin burns. High

vapor concentrations of acetic acid solution may cause skin sensitization.

Eye Contact

Eye contact with concentrated solutions may cause severe eye damage

followed by loss of sight. Exposure to vapor may cause intense watering and

irritation to eyes

Chronic Exposure

Repeated or prolonged exposures may cause darkening of the skin, erosion

of exposed front teeth and chronic inflammation of the nose, throat, and

bronchial tubes.

Aggravation of Pre-existing Conditions

Persons with pre-existing skin disorders or eye problems, or impaired

respiratory function may be more susceptible to the effects of the substance.

b) Fire Fighting Measures

Fire

In order to avoid fire occur at our plant, we have to follow the following

several procedures or limitation such as a flash point must at temperature of

40oC (104oF), an autoignition temperature must at 427oC (801oF), flammable

limits in air % by volume in the range of lel: 4.0 and uel: 16.0.

Explosion

Above flash point, vapor-air mixtures are explosive within flammable limits

noted above. Vapors can flow along surfaces to distant ignition source and

flash back. Contact with strong oxidizers may cause fire. Reacts with most

metals to produce hydrogen gas, which can form an explosive mixture with

air.



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Fire Extinguishing Media

Water, dry chemical, foam or carbon dioxide. Water spray may be used to

keep fire exposed containers cool.

c) Handling and Storage

A method of handling, storage and using the raw material and product is very

important to ensure that the acetic acid are always in good condition

therefore it can be use for the long time period. There are several procedure

in handling and storage the acetic acid such as protect it against physical

damage, store in a cool, dry well-ventilated location and away from any area

where the fire hazard may be acute. Outside or detached storage is

preferred. Separate from incompatibles. Containers should be bonded and

grounded for transfers to avoid static sparks. Storage and use areas should

be no smoking areas. Use non-sparking type tools and equipment, including

explosion proof ventilation. Protect from freezing. Store above 17oC (63oF).

Containers of this material may be hazardous when empty since they retain

product residues (vapors, liquid) and observe all warnings and precautions

listed for the product.

d) Stability and Reactivity

Stability

Acetic acid are stable under ordinary conditions of use and storage. Heat

and sunlight can contribute to instability. Releases heat and toxic when

mixed with water. Acetic acid contracts slightly upon freezing which may

cause the container to burst.

Hazardous Decomposition Products

Carbon dioxide and carbon monoxide may form when heated to

decomposition. May also release toxic and irritating vapors.

Incompatibilities

Acetic Acid is incompatible with chromic acid, nitric acid, ethylene glycol,

perchloric acid, phosphorous trichloride, oxidizers, sodium peroxide, strong

caustics, most metals (except aluminum), carbonates, hydroxides, oxides,

and phosphates.





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9.3.1.2 Material Safety Data Sheet (MSDS): Butanol

Butanol also one of our raw material which fed together with the acetic acid. Besides

acetic acid, butanol are also classified as the dangerous and hazard componenet

that potential in giving harm to people and also environment. Among of danger

produce by butanol are:

Liquid butanol is extremely irritating to the eyes. Direct contact to the skin

can also cause irritation. Irritation of the respiratory pathways occurs only at

very high concentrations which is higher than 2400 ppm.

With a flash point of 29°C or 84°F, butanol can cause a moderate fire

hazard. It is slightly more flammable than kerosene or diesel fuel but less

flammable than many other common organic solvents. The depressant effect

on the central nervous system is a potential hazard when working with

butanol in enclosed spaces, although the odour threshold in range of 0.2 –30

ppm, is far below the concentration which would have any neurological

effect.

Butanol is of low toxicity to aquatic vertebrates and invertebrates. It is rapidly

biodegraded in water, although an estimated 83% partitions to air where it isdegraded by hydroxyl radicals with a half-life of 1.2 –2.3 days. It has low

potential to bioaccumulate. A potential hazard of significant discharges to

watercourses is the rise in chemical oxygen demand (COD) associated with

its biodegradation.


Inhalation

Butyl alcohols have produced few cases of poisoning in industry because of

their low volatility. Causes irritation to upper respiratory tract. Difficult

breathing, coughing, headache, dizziness, and drowsiness may occur. May

be absorbed into the bloodstream with symptoms similar to ingestion.

Ingestion

May have narcotic effect. May cause abdominal pain, nausea, headache,

dizziness, and diarrhea. Large doses may affect kidneys and liver. May

affect hearing. Estimated mean lethal dose is 3 - 7 ounces.



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Skin Contact

An irritant to the skin, causing a loss of natural oils. Can be absorbed

through skin with symptoms paralleling those from ingestion.

Eye Contact

Vapors can be irritating, causing tearing and pain. Splashes cause

inflammation and blurred vision.

Chronic Exposure

Prolonged skin contact may cause drying and cracking of skin. Hearing loss

has been reported in workers chronically exposed to butyl alcohol. May

affect sense of balance, liver and kidneys.


Persons with pre-existing skin disorders or eye problems, or impaired liver,

kidney or respiratory function may be more susceptible to the effects of the

substance.


Fire

To prevent any fire occur, several procedure or limitation must be taken such

as make sure that flash point temperature around 37oC or 99oF, autoignition

temperature around 343oC or 649oF, Flammable limits in air % by volume

(lel: 1.4; uel: 11.2) and prevent from exposed the substance to heat or flame

in order to avoid dangerous fire hazard.

Explosion



flash back.


The medium that can be used to overcome the fire are dry chemical, foam or

carbon dioxide. Water spray may be used to keep fire exposed containers

cool.



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The principle of handling and storage n-butanol is slightly similar with acetic

acid such as protect it against physical damage, store in a cool, dry well-

ventilated location and away it from any area where the fire hazard may be

acute. Outside or detached storage is preferred to keep the n-butanol.

Separate from incompatibles. Containers should be bonded and grounded

for transfers to avoid static sparks. Storage and use areas should be No-

Smoking areas. Use non-sparking type tools and equipment, including

explosion proof ventilation. Containers of this material may be hazardous

when empty since they retain product residues (vapors, liquid). All the steps

must be seriously follow by the person in-charge in order to keep the n-

butanol in good condition.


Stability

Stable under ordinary conditions of use and storage.



decomposition.

Incompatibilities

Strong oxidizers, strong mineral acids, halogens, aluminum, chromium

trioxide, alkali metals.

Conditions to Avoid

Heat, flames, ignition sources and incompatibles.

e) Disposal Considerations

n-Butanol should be handled as hazardous waste and sent to any disposal

approced waste facility such as Kualiti Alam Sdn. Bhd. Processing, use or

contamination of this product may change the waste management options.

Dispose of container and unused contents in accordance with federal, state

and local requirements.



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f) Ecological Information

Environmental Fate

When released into the soil, this material is expected to readily biodegrade.

When released into the soil, this material is expected to leach into

groundwater. When released into the soil, this material may evaporate to a

moderate extent. When released to water, this material is expected to quickly

evaporate. When released into water, this material is expected to readily

biodegrade. This material has a log octanol-water partition coefficient of less

than 3.0. This material is not expected to significantly bioaccumulate. When

released into the air, this material is expected to be readily degraded by

reaction with photochemically produced hydroxyl radicals. When released

into the air, this material is expected to have a half-life between 1 and 10

days.

Environmental Toxicity

The LC50/96-hour values for fish are over 100 mg/l. The EC50/48-hour

values for daphnia are over 100 mg/l. This material is not expected to be

toxic to aquatic life.



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9.3.1.3 Material Safety Data Sheet (MSDS): Butyl Acetate

Butyl acetate is the product that produced by our plant. In order to keep our product

in a good condition, we have to take a few prevention steps for safety of our product.

This is because butyl acetate is classified as very hazardous in case of ingestion.

Butyl acetate is stable under recommended storage conditions. However, exposure

to elevated temperatures can cause the product to decompose. Decomposition

products can include toxic gases such as carbon monoxide and carbon dioxide.

Butyl acetate, both liquid and vapor, is flammable. Flammable mixtures may exist

within the vapor space of n-butyl acetate containers, even at room temperature.

Keep containers closed. Minimize sources of ignition, such as static build-up, heat,

spark, or open flame. The bioconcentration potential for n-butyl acetate is low, and it

is readily biodegradable. The potential for mobility in soil is very high. n-Butyl

acetate is slightly toxic in aquatic organisms on an acute basis. Because these

components have many negative impacts, especially to human health and the

environment, the prevention steps should be taken to avoid any untoward accident

from occured.


Inhalation

Causes irritation to the respiratory tract. Symptoms may include coughing,

shortness of breath. High concentrations have a narcotic effect.

Ingestion

Irritant to tissues. Sore throat, abdominal pain, nausea, vomiting, diarrhea

are the symptoms. Expected to have a narcotic effect. One ounce may

produce severe poisoning.

Skin Contact

This material degreases the skin. Irritation and discoloration of the skin are

symptoms. Skin allergy occasionally develops. Persons who have become

allergic can develop rash upon future exposure to low levels.

Eye Contact

Vapors cause eye irritation. Splashes cause severe irritation, possible

corneal burns and eye damage.



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Chronic Exposure

Repeated or prolonged skin contact may defat the skin and produce irritation

and dermatitis. Kidney and liver damage are reported in animals.


Persons with pre-existing skin disorders or eye problems, or impaired liver,

kidney or respiratory function may be more susceptible to the effects of the

substance.


Fire

To prevent any fire occur, several procedure or limitation must be taken such

as make sure that flash point temperature around 26oC or 79oF, autoignition

temperature around 425oC or 79oF, Flammable limits in air % by volume (lel:

1.7; uel: 7.6).

Explosion



flash back. Sensitive to static discharge.


Use dry chemical, alcohol foam or carbon dioxide. Water may be ineffective.

Water spray may be used to keep fire exposed containers cool.


The procedure of handling and storage butyl acetate is protect it against

physical damage, store in a cool, dry well-ventilated location and away fromany area where the fire hazard may be acute. Outside or detached storage is

preferred. Separate from incompatibles. Containers should be bonded and

grounded for transfers to avoid static sparks. Storage and use areas should

be No Smoking areas. Use non-sparking type tools and equipment, including

explosion proof ventilation. Do Not attempt to clean empty containers since

residue is difficult to remove. Do not pressurize, cut, weld, braze, solder, drill,

grind or expose such containers to heat, sparks, flame, static electricity or

other sources of ignition: they may explode and cause injury or death.Containers of this material may be hazardous when empty since they retain



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product residues (vapors, liquid); observe all warnings and precautions listed

for the product.


Stability

Stable under ordinary conditions of use and storage.



decomposition.

Incompatibilities

Dangerous when exposed to heat or flame; can react with oxidizing

materials, strong alkalis, acids, nitrates and potassium-tert-butoxide.

Conditions to Avoid

Heat, flames, ignition sources and incompatibles.

e) Disposal Considerations

n-butyl Acetate should be handled as hazardous waste and sent to any

disposal approced waste facility such as Kualiti Alam Sdn. Bhd. Processing,

use or contamination of this product may change the waste management

options. Dispose of container and unused contents in accordance with

federal, state and local requirements.

f) Ecological Information

Environmental Fate:

When released into the soil, this material is expected to readily biodegrade.When released into the soil, this material may leach into groundwater. When

released into the soil, this material is expected to have a half-life of less than

1 day. When released into water, this material is expected to readily

biodegrade. When released into the water, this material is expected to have

a half-life between 1 and 10 days. This material has an estimated

bioconcentration factor (BCF) of less than 100. When released into the air,

this material may be moderately degraded by reaction with photochemically

produced hydroxyl radicals.



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Environmental Toxicity

96 Hr LC50 fathead minnow: 18 mg/L (flow-through)

96 Hr LC50 bluegill: 100 mg/L (Static)

96 Hr EC50 freshwater algae (Scenedesmus subspicatus): 320 mg/L

48 Hr EC50 water flea: 44 mg/L.

9.3.1.4 Material Safety Data Sheet (MSDS): Sulphuric Acid

Sulphuric acid is served as the enzyme in orde to increase up the reaction between

the butanol and acetic acid. Besides acting as the catalyst, it also can harm people

who dealing with it. Therefore, the material safety data sheet of sulphuric acid show

the term that we have to focus in order to prevent any accident or damage occured

regarding of these chemicals.


Eye contact

Immediate pain, severe burns and corneal damage, which may result in

permanent blindness.

Skin contact

Causes burns, and brownish or yellow stains. Concentrated solutions may

cause second or third degree burns with severe necrosis. Prolonged and

repeated exposure to dilute solutions may cause irritation, redness, pain and

drying and cracking of the skin.

Inhalation

Causes respiratory irritation and at high concentrations may cause severe

injury, burns, or death. Effects of exposure may be delayed.

Ingestion

Causes severe irritation or burns of the mouth, throat, and esophagus.





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e) Ecological Information

Avoid release to the environment. Prevent contamination of soil, drains or

surface water, use appropriate containment method to avoid environmental

contamination.



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9.4 HAZARD ANALYSIS

There are 3 types of analysis provided for the purpose of identified the hazard.

Among of analysis are:

Hazard And Operability Studies (HAZOP) Analysis.

Fault Tree Analysis (FTA)

Event Tree Analysis (ETA)

9.4.1 Hazard And Operability Studies (HAZOP) Analysis.

Hazard and operability study (HAZOP) is a procedure for the systematic critical

examination of the operability of a process. The potential hazard may arise from

deviations from the intended design conditions.

HAZOP is particularly suitable for complex processes and facilities where

potential exists for making operability improvements. It provides better

understanding about the plant operations and should lead to improved plant

efficiency.

A formal operability study is the systematic study of the design vessel by

vessel and line by line using Guide Words / Key words to help generate thought

about the deviations from the intended operating conditions can cause situations.

9.4.1.1 Example of HAZOP Analysis

Node : Raw material of butanol to reactor

Intention : Transfer of butanol to reactor for reaction with acetic acid



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Table 9.2: Example of HAZOP Analysis

Parameter Causes ConsequencesRecommendation

Action

No flow

Deposited of

solidified raw

material of Butanol

inside the pipe or

mixer.

Leakage of pipe

connecting storagetank and mixer or

mixer and reactor.

Insufficient raw

material of Butanol.

Raw material of

Butanol cannot be

transferred to the

reactor.

Unreacted raw

material of Acetic Acid

will contaminate

product of Butyl

Acetate.

Periodic

maintenance of

Pump (P-100).

Add alarm system

at the reactor if the

failure occur.

Install level

controller at storage

tank of Butanol.

Install flow

controller at pipe

that connecting

storage tank of

Butanol and reactor.

Over flow

Pump (P-100) notoperate properly.

Excessive transfer

of raw material

(Butanol)

Damage the pipe thatconnecting the storage

tank and reactor.

Raw material transfer

in high pressure

condition.

Periodic

maintenance of

Pump (P-100).

Set the limitation of

transfer at the

storage tank.

High

Temperature

Excessive reactants

in reactor.

Scaling of

carbonated on the

steel surface.

Reactor running at

higher temperature.(out of range).

Quality of product

deteriorate.

Add alarm system

at the reactor if thefailure occur.

Install cooling

system at the

reactor.



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9.5 WASTEWATER TREATMENT

9.5.1 Introduction of Wastewater

Wastewater is generated by five major sources: human and animal wastes,household wastes, industrial wastes, storm water runoff, and groundwater

infiltration. This wastewater is characterized in terms of its physical, chemical and

biological characteristics. Only industrial wastes that will discussed here.

The conversion of raw material to intermediate and final products in industrial

processes demands use of large quantities of water and this water becomes

contaminated wastewater. Often the industry will determine that it is safer and more

economical to treat its waste independent of domestic waste.

All developed countries impose restrictions on effluent quality that can be released.

Wastewater has to be fully treated before being allowed to run into a river and if

necessary, it must be pre-treated before flowing into sewer.

Wastewater treatment is designed to use natural purification processes (self-

purification processes of streams and rivers) to the maximum level possible. It is

also designed to complete these processes in a controlled environment rather than

over many miles of stream or river. Moreover, the treatment plant is also designed to

remove other contaminants that are not normally subjected to natural processes, as

well as treating the solids that are generated through the treatment unit steps. The

typical wastewater treatment plant is designed to achieve many different purposes:

Protect public health.

Protect public water supply.

Protect aquatic life.

Preserve the best uses of the waters.

Protect adjacent lands.



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9.5.2 Regulations for Wastewater Discharges

There are basically three categories of wastewater discharges:

Sanitary wastewaters from the public to a local publicly owned treatment

works (POTW) facility (wastewater treatment plant)

Industrial wastewater discharges from industry processes

Storm water runoff from municipalities, construction disturbances of land,

and industrial facilities.

The U.S. EPA, Kansas Department of Health and Environment (KDHE) and

POTW have regulations for the discharge of these wastewaters to groundwater (i.e.

septic systems), surface water (streams, ponds, river), and into municipal sewer

systems (POTWs). National regulations created:

Bans on flammables, oil/greases, and toxic vapors to wastewater

discharges.

Hazardous waste discharge notification.

Categorical standards for certain industries known to create problematic

wastewaters that can adversely impact POTWs operations or storm water.

Significant dischargers (defined by gallons of wastewater discharge) must

test/report biannually.

Permits for storm water discharges.

In August 1990, U.S. EPA established a discharge ban that imposed

restrictions on the following types of discharges:

Flammables – flashpoints less than 140oF.

Explosives.

Chemicals with potential to create toxic gases, fumes, or vapors.

Oil and grease.

Toxic materials that can cause pass through of contaminants or interfere in

the plants treatment process.

High levels of heavy metals or organic compounds.

Corrosives.

Hot temperatures that could produce disrupt treatment.

Reactive that could produce poisonous gas.



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9.5.2.1 Septic Systems

Any liquid industrial waste cannot be discharged into a septic system. It’s only

sanitary wastewater can be discharged to an onsite septic system. If the industrial

wastewater is not regulated as a hazardous waste, a septage hauler that collects

septage/wastewater for disposal at a sewer treatment plant can be used. If a

septage hauler is not available, it can be shipped offsite as a nonhazardous

industrial wastewater to an approved treatment/disposal facility.

9.5.2.2 Publicly Owned Treatment Works (POTWs)

Industrial wastewater can be discharged to a municipal sewer system after receiving

approval from the local sewer authority (or sewer treatment plant). Some industries

are ruled by federal categorical discharge standards that establish maximum

contaminant levels for wastewater from certain processes.

The sewer authorities or treatment plants require, through local sewer

ordinances, wastewater dischargers to comply with certain discharge limits and

sewer use permits. These ordinances are also called pre-treatment requirements for

indirect dischargers. Indirect means the wastewater goes through a sewer system to

a treatment plant and does not go directly to a river.

The sewer use permit is depending on the amount of wastewater discharges

or discharges of unit pollutants. If the volumes of discharges are large, then the

sewer use permit is required but if it vice versa, it is not required.



480

9.6 GENERAL SAFETY PROCEDURES

Ideally for service of a new plant, there should be sufficient site medical, fire and

security services. For ensuring safety, health and welfare of all workers at the plant,Occupational Safety and Health Act (OSHA) was enacted. All contractors,

employees and agents must tolerate and understand the Site Safety Rules &

Regulations before starting any work. Work cannot begin until a complete site safety

induction has been carried out. Based on the self regulation concept of ensuring

safety at workplace, primary responsibility lays on those who create the risks and

work with the risks. Thus, each worker must prepare a statement of policy on health

and safety, together with the arrangements for the policy. Due to hydrocarbon,

flammable and toxic materials handle in the plant, suggestions for safetyimprovements should be made to the member of the Company Health Safety

Committee represented by Chemical Operator. Before starting the plant, workers in

the plant should be informed in detail of the safety procedure. Some general

manuals that should be followed to ensure the safety in work field and work force

are listed below:

1. Each employee is expected to know and observe all plant safety. All

injuries, no matter how light, must be reported at once to your

immediate Supervisor. This is to ensure each worker protection and

assure that proper records of the accidents are made.

2. All employees are responsible for their colleagues as well as their

own. It is part of their job safety. Broken equipment, unsafe

conditions and unsafe practices must be reported to Supervisor as

soon as discovered.

3. There shall be no smoking at any time except in designated smoking

area given by Plant Management. Matches or lighters shall not be

carried into the plant and must be left in locker rooms.

4. It is mandatory that all workers at the plant area to wear hard hats

and safety glasses 100% all the time. In some plant area, other

protection may be required such as hearing protection.

5. If anyone of employee, management or visitor enters without this

proper safety equipment, the operator in that department is

responsible to kindly asks him or her to leave and check back in at



481

the main office. He or she should notify his/her supervisor of this

action.

6. Horseplay will not be tolerated in the plant. Horseplay can cause

immediate disciplinary action including discharge. Possession or use

of liquor illegal drugs is not permitted on the plant premises. Anyone

under the influenced of either will not be permitted on the plant

premises.

7. Visitor must apply permission at the main office, sign a release, and

be instructed of plant safety rules before they are allowed to enter the

plant. Visitor will not be taken into the plant areas that are

experiencing production problems. It is the duty of all employees to

challenge anyone not having temporary or permanent pass.

8. If workers are not sure of the correct and safe way to do a job, ask

the supervisor. The right way will be the safe way. Workers are not

expected to do any job that cannot be carefully understood.

9. All workers must know how to use all types of fire extinguishers, fire

hoses, fire blankets, and other personal protective equipment. (e.g.

water must not be used on fires around the electrical equipment since

water is a conductor that may result an electrocution of people).

10. Leakage from the light hydrocarbon gases valve can create a

hazardous condition. For safety purposes, isolation using a line blind

is needed.

9.6.1 Emergency Response Plan

Emergency is classified in two levels which are:

a) Level I is a minor, localized department or building incident that is resolved

through normal channels with existing plant resources and/or limited outside

help.

b) Level II is a major incident that disrupts multiple elements of the plant

community and requires close coordination of internal operational groups

and usually includes assistance from external organizations.



482

When emergency occur, the person-in-charge has to identify and clarify the

category of emergencies happen under either minor or major. Several types of

emergency that have been classified are:

Table 9.3: Types of emergencies in a plant

Types of emergencies Sources Available response time

Natural disaster 1) Flood Within an hours

Fire

1) chemical

2) ordinary structural

3) electrical

Immediately action

Chemical release 1) vapor chemical

2) liquid spill

Immediately action

Explosion 1) compressed gas

2) containerized liquid

Within a minute

Equipment 1) rupture/leak Immediately action

Facility failure

1) roof collapse

2) structure cracking

3) air pressure system

Immediately action

Utility failure

1) gas

2) electricity

3) cooling water

Immediately action

Product contamination

1) raw material

2) container

3) process equipment

Immediately action

(Reference: Practical Guide to Industrial Safety Methods for Process Safety

Professionals, Nicholas P. Cheremisinoff, 2001)



483

9.6.2 Reporting Emergency

When an emergency happen, an individual should stay calm and notify it to local

community and appropriate emergency response agencies. Steps can be taken areas follow:

1. Call 999 and stay calm.

2. Carefully explain the problem and location to the dispatcher.

3. Hang up the telephone when told to do so.

4. Keep calm and try to calm others.

9.7 GENERAL EVACUATION AND EMERGENCY PROCEDURES

Upon detection of hazards, decision has to be made. All building must be evacuated

when alarm sound and upon notification by safety, health and environmental

department, reactions are taken where each person must move to an assembly

marked area by themselves or service transportation. It has to be made sure that all

streets, fire lanes, hydrant areas and walkways should be clear at all time.

1. All the worker in all sector must leave the building to the nearest marked

exit and alert others to do the same.2. Assist those who need help exiting the building. Avoid using elevators in

cases of fire. Once outside proceed to a clear area that does not obstruct

emergency response personnel and away from the affected building.

3. Personnel cannot return to an evacuated building unless told to do so by

the local fire department, the local police, or the Environmental Health

and Safety Office.

4. Workers must report to designated assembly point.

5. Remain until an accurate headcount is taken.6. The Building/Facility Coordinator will take attendance and take into

account for all building occupants.



484

9.7.1 Fire

If a fire occurs on Butyl Acetate plant, take the following actions:

1. Activate the nearest fire alarm. Safe own self before someone else.2. Evacuate the building by the nearest safe exit and helps the disabled to

evacuate if necessary. Avoid using elevators.

3. Call the Fire Department at the designated emergency response number

(999). Give details and exact location of the fire. Remain on the phone

until told to hang up by the emergency operator.

4. Move to a clear area that is at least 600 feet from the affected building.

Keep streets and walkways free from people for emergency vehicles and

personnel to excess and clear the fire.5. Do not return to an evacuated building unless authorized by a Fire

Department.

9.7.2 Chemical Spill

If a chemical spill occurs on Butyl Acetate plant, take the following actions:

1. If the situation is threatening health and life, evacuate the area as fast as

you can. Close the doors and windows, and make a call, or to theDesignated Emergency Response Number (999). Activate the alarm.

2. Shut down all the equipment in the plant and restrict entry to the affected

area.

3. Remove contaminated clothing. Rinse from the chemical spill with water

for a minimum of 15 minutes.

4. Report and provide the following informations:

a. Full name

b. Name of spilled chemical (if known)c. Approximate amount of spilled chemical

d. Exact location of spillage

e. Injuries sustained (if any)

f. Actions taken

5. Stay calm.

6. Evacuate the building by the nearest safe exit and helps the disabled to

evacuate if necessary.



485



personnel to excess and clear the fire.

8. Do not return to an evacuated building unless authorized by a Fire

Department.

9.7.3 Explosion

If an explosion occurs on Butyl Acetate plant, take the following actions:

1. Safe own self. Take cover under tables or other objects in a jiffy that

helps to protect from falling glass and debris.

2. After less intense explosion, notify the Fire Department at the designatedemergency response number (999). Give details and describe the

location and nature of the emergency.

3. Activate the building fire alarm.

4. Evacuate the building by the nearest exit and helps the disabled to

evacuate if necessary.

5. Stay calm and avoid using elevators.



personnel to excess and clear the fire.


Department.

9.7.4 Facility Failure

If a facility failure occurs on Butyl Acetate plant, take the following actions:

1. Safe own self. Take cover under tables or other objects in a jiffy thathelps to protect from falling glass and debris.

2. After less intense condition, find exit from the building or scream to find

help.


4. Notify the Fire Department at the designated emergency response

number (999). Give details and describe the location and nature of the

emergency.


Department.



486

9.7.5 Utility Failure

If utility failure on Butyl Acetate plant, take the following actions:

1. Immediately shut down all the equipment that used the specified utility.2. Do inform the maintenance sector to check the problem.

9.8 PLANT SAFETY

9.8.1 Transportation

The distance of material transportation must be minimize whether to or from store or

during processing. Raw material and product traffic must be away from all other

traffic needed for engineering, canteen, construction and personnel. A safe handling

program must be installed and practiced by every personnel because unforeseen

events can create a big disaster due to human error. Personnel involving with

transportation of materials such as lorry and forklift are compulsory to follow the

handling procedures since they are closely related to the materials and other people

safety.

9.8.2 Chemical Storage

Location of chemical storage is important. The storage must be safe and have to be

made sure follow the hazards the chemical may cause. There are large amount of

chemicals used in a plant not only the raw material and products but also chemicals

used for other processes such as water treatment, cleaning and waste treatment.

Storage tank farm should not be located adjacent to urban development to eliminate

any possibility of Vapor Cloud Explosion (VPE), fireball or toxic cloud drift over

population.



487

9.8.3 Plant Location

For every chemical plant, it is important to provide safe and economical flow of

materials and people. A plant must be located far from community area which will

minimize the probability of harming the public in any possible way. For this Butyl

Acetate plant, the plant location selected is in Gebeng which is by itself an industrial

area and far from residential area. Usual accidents that may occur at a plant are

related to fire, explosion or vapour cloud and each of these factors can result in a

big disaster. To create more awareness among personnel, every chemicals used

can be labeled as dangerous. Simple education program explaining the chemical

characteristics and hazard produced by each chemicals and procedures to handle it

may be a good effort to control hazard.

9.8.4 Work Safety

In order to keep a plant safety at all times, some rules created must be followed.

The rules are usually the same rules all over a chemical plant:

1. Smoking and drinking are not allowed at the plant area

2. Eating is not allowed during work

3. Danger signs must be understood by workers

4. Safety instructions must be clear and placed at a place where all workers

can see and read

5. Personnel entering the plant must wear provided protective equipment and

reported any damages of the equipment

6. Do not work with a faulty equipment and each fault must be reported to

supervisor

7. Personnel are prohibited to enter other than their own work place withoutpermission or must bring someone who in-charge of the area

8. Seek for medical attention even for a small injuries

9. Accidents must be reported to person-in-charge at the working area

10. Each worker must know the location of fire alarms, fire extinguishers and

emergency routes



488

9.8.5 Personal Protective Equipment

9.8.5.1 Face and Eye Protection

Face and eye protection is a must if workers are exposed to eye or face hazards

from flying particles, molten metal, liquid chemicals, acids or caustic liquids,

chemical gases or vapours, potentially infected material or potentially harmful light

radiation. Eyes are easiest to be injured if workers are not wearing a proper or

poorly fitting eye protection. It is employer’s responsibility to make sure the

protections equipment selected are suitable and fits well to their workers.

9.8.5.2 Head Protection

By looking at the area of works, head protection equipment selected must be

suitable. Soft caps made by plastic or leather give protection from chemical splash

normally for quality control department when doing experiments. Safety helmet or

hard hat is one of way to protect workers head from injury. Safety helmet can protect

workers from impact and penetration hazards as well as from electrical shock and

burn hazards other than a danger of objects falling from above when working below

others.

9.8.5.3 Gloves

Many types of gloves are available for variety types of hazards. Different working

area needs different types of gloves material. It is essential that workers use gloves

specifically designed for the hazards and tasks found in their workplace because

gloves designed for one function may not protect against a different function even

though they may appear to be an appropriate protective device.

9.8.5.4 Foot and Leg Protection

Workers need a protection for their leg and foot to avoid injuries of falling objects,

rolling objects, crushing or penetrating materials. They also need a protection from

hot substances, corrosive or poisonous material to cover their body parts. Normal

walking shoes are the most unsuitable footwear because it offers little resistance to

corrosive materials and falling objects. Rubber boots are watertight and resistant to

most corrosive chemicals, but may be affected by many organic solvents.



489

9.8.5.5 Body Protection

Appropriate body protection must be wear while performing jobs. A jumpsuit or a

uniform made from a high quality material that did not affected by chemicals issuitable for most chemical plant. The body protection must be fitted to each worker

and gives comfort for them to perform works effectively and covered all parts of the

body that exposed to possible injuries. Other than jumpsuit, body protections include

laboratory coats, vests, jackets, aprons, surgical gowns and full body suits.



490

9.9 HAZARD AND OPERABILITY (HAZOP) STUDY

Hazard and operability study (HAZOP) is a formal systematic rigorous examination

to the process and engineering facets a production facility for identify cause and thesequence. It is technique for systematically reviewing the design and operation of a

system to identify potential hazards to people, property, environment, efficiency and

production. The objectives of HAZOP are as follows:

1. To identify hazards or deficiency and potential operability problems, this may

lead to hazard such as explosion, toxic, release and fire.

2. To identify and prevent hazards in process plants that are growing in

complexity with standards are not adequate.

3. To examine the inadequacies in the system by considering it as a fully

integrated dynamic unit.

4. To meet the legislative requirements.

5. To co-ordinate the various disciplines involved in the project and provide

means for systematic analysis of the system.

6. To reduce costs due to the operability problems and the complexity of the

plant or process



491

9.9.1 HAZOP Technique

Figure 9.1: HAZOP Techniques

(Source: Chemical Process Safety, 2nd Edition, Daniel A.Crowl)

Select a 'Sub System'

Applied a 'Property Word' (also refers to as a

Apply a 'Guide Word' to a property word to

give a 'Deviation'

Identify the 'Causes'

Identify the 'Consequences'

Identify the existing

Decide on any 'Action' to eliminateor mitigate the identified problems

Repeat for others guide word as relevant

Repeat for others Property Words as relevant

Repeat for all Sub System



492

The HAZOP procedure uses the following step to complete an analysis:

a) Begin with a detailed flow sheet. Break the flow sheet into a number of

process units. Select a unit for study.

b) Choose a study node (vessel, line, operating instruction).

c) Describe the design intent of study node.

d) Pick the process parameter (e.g. flow, level, temperature, pressure,

concentration, volume, reaction).

e) Apply a guide word to the process parameter to suggest the possible

deviations.

f) If the deviation is applicable, determine possible causes and note anyprotective system.

g) Evaluate the consequence of the deviation.

h) Recommended action.

i) Record all information.



493

Table 9.4: Guide words, meaning and example of deviation

GUIDE WORD MEANING EXAMPLE OF DEVIATION

No (Not or None) The activity is not carried outor ceases No flow in pipe, no reactantcharged to process

More Of or High A quantitative increase in an

activity

More (higher, longer) quantity,flow,

temperature, pressure,concentration and time

Less of or Low A quantitative decrease in an

activity.Less (lower, shorter) of above

More than or As Well As

A further activity occurs in an

addition to the original

activity

Impurities present, extra phase

(solid or gas inliquid phase), extra unplanned

processoperation

Part ofThe incomplete performance

of an activity

Reduced strength, missing

component, operation only part

completed

Reverse Inversion of the activityBack flow or back pressure heat

rather than cool

Sooner or Later Than

An activity occurring at the

wrong time relative to other

activities

The activity occurs at the wrong

time

Other

Wrong material charged, nonroutineconditions, start up, shut

down, maintenance,cleaning, failure of services and

etc.



494

Table 9.5: Deviation and some typical causes

DEVIATION SOME TYPICAL CAUSES

No flow Isolation in error-wrong routing, -blockage- incorrectly fitted N.R.V-large leak-equipment failure (control valve, isolation valve, pump,vessel, etc.)- incorrect pressure differential-delivery sideoverpressure -vapour lock

Reverse flow Defective N.R.V-siphon effect- incorrect differential pressure- twoway flow- emergency venting- incorrect operation-pump reversed

Less flow Line restriction-partial blockage-defective pumps-cavitations-foulingof vessels-valves-restrictor or orifice plates-density or viscosityproblems-incorrect specification of process fluid-process turndown

More flow Increase pumping capacity-increased suction pressure-reduceddelivery head-greater fluid density-exchanger tube leaks -restriction orifice plates deleted-cross connection of system –control faults-control set wrong

More pressure Surge problems-interconnected H.P system-gas breakthrough-inadequate venting-thermal overpressure-failed open controlvalves, heating of blocked in system explosion-fire imbalance ofinput and output-external pressure-water hammer

Less pressure Vacuum condition-condensation-gas dissolving in liquid-restrictedpump/compressor suction line-undetected-leakage- vessel

drainage imbalance of input and output

Moretemperature

Ambient conditions-fouled or failed exchanger tubes-less cooling-cooling water failure-detective control-fire-reaction-control failure-connected source-energy from machines

Lesstemperature

Ambient conditions-reducing pressure-fouled or failed exchangertubes-loss of heating-rain-connected source

Densityviscosity

Incorrect material-incorrect temperature-extra phase

Composition Phase change-incorrect feed-incorrect or reversed ratio-incorrect

separation failures-change in reaction-emergencydischarge

Contamination Correct routing-interconnected systems-effect of corrosion-wrongadditives-ingress of air, water, lube oils-shutdown and start upconditions-carryover of solid-accumulation-inert gas failure-internalleaks



495

Table 9.6: HAZOP study on reactor (R-100)

Project name: Production of 50000 MTA of Butyl Acetate Prepared by: Razif Rodzi

Study Node ParameterDeviation

(Guide Word)Possible Causes Possible Consequences Action Require

PROCESSFLOW OFRAW

MATERIALTO THE

REACTOR

FlowNO

Deposited of solidified rawmaterial of Butanol inside

the pipe or mixer.Leakage of pipe connectingstorage tank and mixer ormixer and reactor.

Insufficient raw material ofButanol.

Raw material of Butanolcannot be transferred to the

reactor.Unreacted raw material of

Acetic Acid will contaminateproduct of Butyl Acetate.

Periodic maintenance ofPump (P-100).

Add alarm system at thereactor if the failure occurs.

Install level controller atstorage tank of Butanol.

Install flow controller at pipethat connecting storage tankof Butanol and reactor.

OVER

Pump (P-100) not operatesproperly.

Excessive transfer of rawmaterial (Butanol)

Damage the pipe that

connecting the storage tank

and reactor.

Raw material transfer in high

pressure condition.

Periodic maintenance ofPump (P-100).

Set the limitation of transferat the storage tank.

Temperature

HIGHExcessive reactants in

reactor.Scaling of carbonated on thesteel surface.

Reactor running at higher

temperature (out of range).Qualities of productdeteriorate.

Add alarm system at the

reactor if the failure occurs.Install cooling system at thereactor.

COOLINGJACKET

Flow LOW

Control valve fails close

Plugged cooling coils

Cooling water service failure

Controller fails and closesvalve

Loss of cooling, possiblerunaway.

Select valve to fail open.

Install filter withmaintenance procedure.

Install cooling water flowmeter and low flow alarm.



496

Air pressure fails, closingvalve

Check and monitor reliabilityof water service.

Place controller on criticalinstrumentation list.

HIGH

Control valve fails open.

Controller fails nad openvalve.

Reactor cools, reactantconcentration builds,possible runaway on heating.

Instruct operators andupdate procedure.

Place controller on critical

instrumentation list.

LOW

Partial plugged cooling line

Partial water source failure.

Control valve fails torespond

Diminished cooling, possiblerunaway.

Place controller on criticalinstrumentation list.

Install filter withmaintenance procedure.

Place valve on criticalinstrumentation list.

Temperature LOWLow water supplytemperature

None – Controller handles. None

HIGHHigh water supplytemperature

Cooling system capacitylimited, temperatureincreases.

Install high flow alarmand/or cooling water hightemperature alarm.

STIRRER Agitation NO

Stirrer motor malfunction.Power failure

No mixing, possibleaccumulation of unreactedmaterial.

Monomer feed continuespossible accumulation ofunreacted materials.

Interlock with feed line.Monomer feed valve mustfail closed on power loss.

MORE Stirrer motor controller fails,resulting high motor speed.

None. None.



497

Table 9.7: HAZOP study on heat exchanger (E-101)

Project name: Production of 50000 MTA of Butyl Acetate Prepared by: Khairul Hazwan



HEATEXCHANGER

Feed Flow NO

Pipe broken

Cooling tower not function

Pipe plugging

No heat transfer activitiesoccurs

Not achieve a desiretemperature

Affect further process(reaction)

Install flow indicator

Install temperature

indicator.Install backup cooling

water

MORE Valve not functioning

The hot fluid pipe ruptures

Affect further process(reaction)

Install flow indicator

Change new valve

Install orifice plate

REVERSE

Failure at the coolantsource.

Higher pressure at flow out

Difficult to control thetemperature flowing out

Cooling is not effective fornextequipment.

Install one way flow valveat the coolant flowing pipe

LESS Control valve not functioning

The coolant flow pipe isplugged

Same as the above Change a new controlvalve

Install a low flow alarm

PressureMORE Cool stream or cooling water

flow pipe and the hot fluidflow pipe fluid

Wall of the heat exchangerwill crack

Install high pressurealarm at both streams

LESS Rupture at the coolant flow Pipe will break and crack Install low pressurewarning device at both thestreams



498


(Guide Word) Possible Causes Possible Consequences Action Require

TemperatureMORE

Heat exchanger is notfunctioning

Temperature of the hot fluidis too high

Pressure will increase

Explosion will occur

Failure of other equipment

Install high temperaturewarning device at the outflow hot fluid stream

Repair the damage part ofheat exchanger

LESSNo temperature change atthe cool stream or coolingwater flow stream

Condensation occurs at thetube of the heat exchanger

Failure of other equipment Tube of heat exchangershould be cleaned often toremove the deposit



499

Table 9.8: HAZOP study on distillation column (T-100)

Project name: Production of 50000 MTA of Butyl Acetate Prepared by: Noor Baini Nabila



STREAM 10 Flow HIGH

Controller fails control

valve open.

Excess flow to T-100: off

specification products

Level in T-100 rises and hence

temperature falls.

Add independent high

flow alarm.

LOW

Failure of previous unit

(R-100).

Controller fails control

valve closed.

Drop in liquid level in T-100.

Temperature rise in T-100.

Loss of production.

Add low flow alarm.

NOController fails control

valve closed.

Drop in liquid level in T-100.

Temperature rise in T-100.

Loss of production.

Add low flow alarm.

REVERSEHigh pressure in stripper

returning material back to

R-100.

Destabilization of feed

composition

Add check valve.

Temperature HIGH Leaking exchangerallowing hot bottoms to

enter with feed.

Adversely affects T-100performance

Add high temperaturealarm

LOW Loss of heating. Loss of performance on T-100 Upgrade isolation.



500



DISTILLATION

COLUMNPressure HIGH

Loss of overhead condenser.

Excessive heat input from reboiler.

Reboiler tube leak or rupture.

Overheads pressure controller fails

control valve closed.

Over pressuring of T-100 to

relief condition.

Change of temperature profile.

Production loss.

Product quality and controllability

disturbs.

Add high pressure alarm.

Add additional independent

high pressure indication and

alarm to reflux drum.

Redundancy in control loop

and set point limitation.

LOW

Loss of heating medium.

Low temperature feed.

Overheads pressure controller fails

control valve open.

Excess overheads cooling.

Loss of performance: may force

shutdown.

Depressuring of column to flare.

Add low pressure alarm.

Temperature indication of

feed.

Reduce refluxed flow to

column

Temperatur

eHIGH

Excess heat on reboiler.

Fire case.

High upstream pressure due to high

pressure in R-100

Overpressuring of T-100.

Adversely affects T-100

performance.

Possible BLEVE (Boiling Liquid

Expanding Vapor Explosion).

Add high temperature alarm.

Review need for addition of

emergency depressurizing

system to prevent BLEVE in

fire case.

LOW

Loss of heating.

Low steam flow.

Adversely affects T-100

performance.Off specification products

Add backup heating

medium.Upgrade isolation.

Bottom

LevelHIGH

Bottom outlet pump fails.

Excess feed to column.

Overheads on total reflux.

Flow controller fails bottom outlet

control valve closed.

Column flooding.

Tray damage.

Add high bottoms level

alarm.



501

Table 9.9: HAZOP study on distillation column (T-101)

Project name: Production of 50000 MTA of Butyl Acetate Prepared by: Nabilah



DISTILLATIONCOLUMN

Flow NO

Pipe broken and plugging

Failure of previous equipment

Control valve failed close

Operation failure

Loss of feed to column

Not achieve a desire outputLevel decreased in the column

Temperature / pressuredincreased in the column.

Install control valve failedopen

Shutdown the plantInstall low alarm

LOWPipe broken and plugging


Cavity build up in control valve

Same as NO Install control valve failedopen

Shutdown the plant

Install low alarm

HIGH

Control valve failed open


Ineffective separation

Level increased in the column.

Product composition change

Install control valve failedclose

Install composition indicator.

Install flow indicator.

Install high alarm

REVERSEHigh pressure in column Same as NO Install non-return valve.

HIGH

A rise of pressure in feed

Failure of pressure control ofthe system

Off-specification of product.

Damage to sieve plate andrupture in line and column wall.

Pressure build-up

Install temperature indicator

Install shut down devices.

Install pressure relief valve.

Install high pressure alarm



502



TemperatureLOW

Less steam flow

Low steam pressure andtemperature

Exchanger tube in reboiler failure

Loss of heating.

Not achieve the desired product.

Ineffective separation process.

Thermal runaway

Upgrade isolation.

Install backup hot steamfor reboiler.

Install temperatureindicator.

Install low temperature

alarm

HIGH

Valve not functioning.

The hot fluid pipe ruptures.

More steam flow.

Same as LOW Particular attention toheat input and outputcontrol.

Install temperatureindicator.

Install high alarm

Pressure LOW

Feed pressure is dropped

Valve at top line failed open

Off-specification of product

Column vessel will dents due to theinternal pressure less thanatmospheric pressure

Install shut down devices.

Install pressure reliefvalve.

Regular maintenance ofvalves.

Install valve failed closeat top column

Install low pressure alarm

Level LOW

Outflow greater than inflow.

Control faulty level.

Inlets flow stop or blockage.

Cavity build up in the valve

Pump failure.

Not achieve the desired product.

Ineffective separation process.

Thermal runaway

Install level controller.

Install low level alarm.

Istall level indicator.

HIGH

Inflow greater than outflow.

Control faulty level measurement.

Blockage of outlet pipe.

Valve failed closed

Flooding in column.

Uncompleted separation.

Not achieve desired productseparation.

Install high level alarm

Install level indicator

Install valve failed open



503

Table 9.10: HAZOP study on heater (E-100)

Project name: Production of 50000 MTA of Butyl Acetate

Prepared by: Hasimah


(GuideWord)

Possible Causes Possible Consequences Action Require

INLET STREAMFlow NO

Failure of valve to open Process fluid temperaturenot increased accordingly.

Loss of heat transfer.

Install temperature indicatorat the process fluid outletstream.

Regular inspection on thevalve and flow controller.

Install low temperaturealarm.

MORE

Failure of steam inlet valveto close.

Failure of process fluidinlet valve to close.

Flow controller failure.

High temperature of processfluid outlet stream.

Low temperature of processfluid outlet stream.

Install temperature indicatorat the process fluid outletstream.

Install high or lowtemperature alarm.

Regular inspection on thepipelines, valve and flowcontroller.

LESS

Plugging on the pipelines.Leaking on the pipelines.

High temperature steammight damage the heatexchanger.


Low temperature of processfluid stream.

Regular inspection on thepipelines.

Install temperature indicatorat process fluid outletstream.

Install high or lowtemperature alarm.



504

Temperature HIGH

Failure of temperaturecontroller.

Fire occurs near the heatexchanger.


Install high temperaturealarm.

Install fire alarm.

Regular inspection on thecontrollers.

LOW

Heat loss to thesurroundings

Failure of temperature

controller.

Process fluid temperaturenot increased accordingly.

Regular inspection on thetemperature controller andpipelines.

Install insulation.

HEATEXCHANGER Temperature HIGH

Fire occurs near the heatexchanger.

Overflow of steam.

Increased pressure insidethe heat exchanger.

Heat exchanger mayexplode.


Install pressure relievedvalve.

Pressure HIGH

Overflow of fluid.

Increased temperatureinside the heat exchanger.

May cause explosion.

Damaged of heat exchanger.


Install pressure relievedvalve.



505

9.10 PLANT START UP AND SHUT DOWN

The most important part in a new plant is the plant start-up and shutdown. Many

potential hazards can occur due to small wrong step taken during the procedure

which may lead to destruction of the plant as a whole or to the equipment. Well

planned procedures are needed as a guide to make sure safety first during start-up

and shutdown. If hazards occurred, it will results in serious injury as well as costly

property damage. The procedures of the plant start-up must be safe and easily, yet

flexible enough to be carried out in several ways.

9.10.1 Initial Start Up

Initial start-up of a plant may take few days to complete. The phase may be

considered after the initial introduction of feed has begun or until all process

equipment in all sections are well functioning and has been placed online using

process feed. During plant start-up, the operating limit must not be exceeded to

make sure safety of the workers. Frequently samples and readings are taken and

analyzed to make sure plant operations are stable. Flow, temperature, pressure and

level are controlled well following the operating ranges.

Before plant start-up, the following items must be completed in the

processing unit after turnaround of the plant. Below is a part of the start-up

procedure that should be followed:

i. Pipeline from the finishing reactor and from the raw material supply

should been thoroughly cleaned from dirt and solid particle to prevent

compressor and pump from damage at initial start up.

ii. Make sure the tightness testing after repair has been done to ensure

leak free equipment and flanges are joints well with good gasket to

prevent leakage.

iii. All the liquid is cleaned to ensure the pump have the proper suction

strainers.

iv. Start the pump and watch the discharge pressure gauge. As soon the

pressure stabilizes, open discharge valve slowly. Fully open the valve

after the pressure is stabilizes.



506

9.10.2 The General Start Up

Preliminary preparation for start-up of a unit should include:

Final inspection of the unit operations should be made of their interior

for conformance to the requirement.

Turnaround work list checked again whether everything has been

completed and the associated line has been correctly resembled.

All the heat exchanger that were open up to the maintenance must

have undergone the hydrostatically test after it has been assembled.

The instruments control loops are checked from the transmission

from the plant signal to control system and also the alarm system

circuits to make sure that it has been correctly located.

All the level gauge glasses are confirmed clear and the operator can

easily record its reading.

The supply of reactant and chemicals are adequate.

Catalyst should be activated first and sufficient warm for reaction to

commence when flow of reactants is started.

All control valves are checked to determine it is functioning well.

The operability of pumps, compressor are checked.

All the utilities, power supply, steam supply and cooling water supply

are checked.

The onsite fire protection equipment such as extinguisher, water

hoses, nozzles and steam hoses are in place and ready for

immediate use.

The condition of drains is check to make sure that it is unplugged and

water is drained out from the equipment.

Removal of shutdown blinds and installation of running blinds.

For ensuring safe start-up, air has to be eliminated from any unit before

materials being introduced into it. A unit to be started up or operated safely must be

free from leaks whether materials could leak out or air could leak in. Thus, repair of

the leaks have to be done to ensure a leak-free unit. All flanges are then made sure

joints well with good gasket in order to prevent leakage.



507

9.10.3 Plant Start - Up Procedure

Before plant start-up, the following items must be completed in the processing unit

after turnaround of the plant. The start-up procedure should be followed as below:

Final inspection - made in the interiors for conformance to the

requirement before the man-ways covers are install on the distillation

tower and reactor.

Turnaround work list - everything has been completed and the

associated line has been correctly resembled.

Hydrostatically test - the equipment must test after it has been

assembled.

Check instrument control loops - control system and also the alarm

system circuits to make sure that it has been correctly located.

Check level gauges glasses - confirmed clear and the operator can

easily record its reading.

Check control valves - checked to determine it is functioning well.

Check utilities - power supply, steam supply and cooling water supply

are functional well.

Check onsite fire protection equipment - such as extinguishers, water

hoses, nozzles and steam hoses are in place and ready for

immediate use.

Check conditions of drains are unplugged - water is drained out from

the equipment.

Check flanges and man heads - have good gasket and are made up

tight.

Check safety valve header - blow-down, flare system are successfully

commissioned.

All blinds tested - for tightness and air freeing is available.



508

9.10.4 Plant Operation

A plant may be considered as entering into the next phase of operation once the

data evaluation has begun. The flow sheet figures may be compared with actual

operating data. Plant data are being collected and evaluated promptly and regularly.

Deviations from the expected process conditions must be investigated and the

reason for the deviation established must be justified. The operators must take

complete and accurate readings on the log sheets frequently as possible for suitable

intervals during the early start-up phase. Soon after the initial start-up, the data

should begin to accumulate. Analyses of various processes streams as well as final

product analyses will permit further evaluation of the operation.

9.10.5 Plant Shut Down Procedure

Plant shut down is essential to eliminate, minimize or control damage to plant

personnel or property only after all other types of preventive action have failed. This

is because when a unit or process is normally in operation and it has to be shut

down, then the whole plant has to be shut down. Plant shut down also essential for

maintenance once or twice a year. During the shutdown, all equipment must be left

in a safe condition. Preparation for shut down includes checking the following up to

the advanced planning.

i. Turnaround work list – prepared for repair, cleaning, inspection and

modification.

ii. Critical path monitoring chart – a detailed plan of the shut down and

turnaround schedule should be prepared, probably hour by hour schedule.

iii. Before shutting down:a. Firefighting equipment is located correctly

b. Personal protective equipment is available and in god conditions.

c. All special precaution is taken care, for example hoses laid at an

easy-to-use place for immediate use.

All items of the unit are check to be available - include blinds, hoses, etc.

Avoid any delay in mechanical work during the actual shut down, for example the

erection of scaffolding.





510

By referring to the plant layout provided in Figure 9.2, administration building

is the main and most visited building for many purposes in a plant. It should be

located on the public and safe side of security point and as close as possible to

main entrance. Other than that, it should be upwind of the plant venting fumes to the

atmosphere. Car parking facilities provided must to be adequate for all the plant

workers and near the main entrance to prevent any unwanted hazard to the

properties.

In a plant, canteen, medical centers, surau and personnel shops should be

located in a safe area within a short distance of the main concentration of workers.

The surrounding should be attractive and relaxing for workers to release some

stress from hectic workloads. Off loading of food supplies should not interfere with

other traffic.

Workshops and others that did not link to process materials should be

located together at the safe area and within easy access to process units. Direct

access should be provided for traffic purposes, which if possible should not pass

through any process area.

For quality control of products, a plant needs a laboratory to inspect the

products produced. Work laboratories should be located at a safe area near the

administration building where most facilities are completed.

Wastewater treatment, utilities plant and tank farms should be located near

the process area. This will reduce the piping cost for transferring the raw materials,

waste, and utilities to or from the plant area. Beside it, it should be beside a road

which will make it easier for loading and unloading of materials.

Gebeng is located in Pahang in the East coast of Malaysia. Every year

Pahang experiencing Northeast Monsoon that brings rain and wind. Thus, the

structure of the plant is placed in upwind direction. The structure of the plant is

enclosed at two sides and opened at another two sides. This is to make sure the

wind did not affect the plant and brings any inconvenience but can be used to help

to cool down process equipment during the process.



511

Guard House

Surau

Toilet

Tank FarmUtilities

PlantWaste Treatment Plant

Carparks Assembly Point

Warehouse

Control Room

Main

Entrance

Second

Entrance

Emergency Exit

Canteen Administration BuildingLaboratories

North

Distillation

Column 1Reactor

Heat

Exchanger

Distillation

Column 2

Future Expansion

Loading Area

Fire House

Heat

Exchanger

Maintenance

Workshop

Emergency

Route

Legend

Wind

Direction

Main Process Plant

Figure 9.2: Plant Layout



512

9.12 CONCLUSION

The most important department to refer for safety and health is the Department Of

Safety & Health (DOSH). Among the regulations and acts contain inside the

Department Of Safety & Health (DOSH):

Arrangement of sections

Occupational Safety & Health Act 1994

Occupational Safety & Health (Employers’ safety & Health General Policy

Statements)(Exception) Regulations 1995

Occupational Safety & Health (Control of Industrial Major Accident Hazards)

Regulations 1996

Occupational Safety & Health (Safety & health Committee) Regulation 1996

Occupational Safety & Health Classification, Packing & Labelling of

hazardous chemicals) Regulation 1997

Occupational Safety & Health (Safety & Health Officer) Regulations 1997

Occupational Safety & Health (Safety & Health Officer) order 1997

Occupational Safety & Health (Use & Standard of Exposure of Chemical

Hazardous to Health) Regulation 2000

Wastewater from the plant were treated using the Sequencing Batch Reactor

(SBR) wastewater treatment system, which gives more advantages compared to the

conventional wastewater treatment.

For plant safety and layout, HAZOP studies have been made for the major

equipments in the plant. HAZOP is important for each equipment safety in order to

cater any problems occur and before deciding whether to shut the plant or not. In

this chapter also, emergency response plan, start-up and shutdown procedures

have been listed out properly for workers of butyl acetate plan to follow. After some

considerations of site selection, wind direction, future expansion area and other

things, the best plant layout of butyl acetate plan has been properly made.



513

REFERENCES

Ujang Z., Christensen C.L., Milwertz L., Thomsen M.H., Vollertsen J., Hvitved-

Jacobsen T. 2002. Performance Analysis of Wastewater Stabilization Ponds

Using Respirometry in Malaysia (online) http://chem.eng.utm.my/staff/

zaini/images/lecture2/Performace%20Analysis%20of%20a%20wastewater%

20stabilization%20pond%20in%20Malaysia.pdf (1 Oktober 2010)

Sewage treatment (online) http://en.wiipedia.org/wiki/sewage_treatment (20 August

2010)

Environment Quality Chemicals Management (online) http://www.environment.

gov.au/settlements/chemicals/scheduled-waste/index.html (1 Oktober 2010)

Sewage Treatment the Information Centre for Water, Wastewater and Related

Environment Issues (online) http://www.euwfd.com/html/sewage _treatment.

html (1 Oktober 2010)

Mecklenburgh, J. C. 1973. Plant Layout a guide to the layout of process plant and

sites. Aylesbury: Leonard Hill Books in association with The Institution of

Chemical Engineer.

Sinnot, R. K. 1983. Chemical engineering design. 3rd Ed. Volume 6. United

Kingdom: Butterworth-Heinemann Publishers.

Flynn, A.M. & Theodore, L. 2002. Health, Safety and Accident Management in the

Chemical Process Industries. New York: Marcel Dekker, Inc.

Charles A. Wentz. 1998. Safety, Health and Environmental Protection. McGraw-Hill.

Daniel A. Crowl, Joseph F. Louvar. 2002. Chemical process safety fundamentals

with applications. 2nd Edition. USA: Prentice Hall, Inc

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http://en.wiipedia.org/wiki/sewage_treatment%20(20

http://www.euwfd.com/html/sewage%20_treatment.%20html%20(1





http://en.wiipedia.org/wiki/sewage_treatment%20(20







514

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Chapter 9 - Safety and Loss Prevention

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