Problem Statement:: ZZZZZZ Yyyyyy 25 Nov. 2020 Process Plant Safety and Environment XXXXX

Assignment-1
Name zzzzzz Student Id yyyyyy Date of Submission 25th Nov. 2020

Course B.Tech in Chemical Engineering Subject Process Plant Safety and Environment Subject Code xxxxx
Problem Statement:
Page 1 of 19
Assignment-1
1. Process Flow Diagram:
Process flow diagram of 300 TPD sulphuric acid plant has been prepared.
Please refer attached PDF file named:
ProcessFlowDiagram.pdf
Page 2 of 19
Assignment-1
2. Hazards and Risks involved in the process:
Following hazards and risks has been identified in 300 TPD Sulphuric Acid Plan:
 In molten sulphur pit Molten sulphur may evolve HYDROGEN SULFIDE (toxic gas) which may
accumulate in storage container vapor space. High concentration may cause immediate
unconsciousness - death may result unless victim is promptly and successfully resuscitated. Hydrogen
sulphide causes eye irritation.
The recommended airborne exposure limit as per NIOSH is 10 ppm, which should not be exceeded
during any 10-minute work period.
 Sulphuric acid is an aggressive oxidizer. Appropriate safeguards to prevent the tank’s material from
degrading, becoming brittle, and cracking—which could result in leaks or tank failure.
 SO2 is a throat and nose irritant and causes breathing problems if high concentrations are inhaled.
Damage to vegetation and animals. Hence, we have to control release of SO2 in to air via proper
scrubbing system to atmosphere through chimney.
 SO3 combines with water vapour in the atmosphere to form sulfuric acid mist. Proper prevention to be
taken care to eliminate release of SO3 to environment.
 Since sulphuric acid is an aggressive oxidizer, hence proper selection of material for piping, valves,
pump must be taken care during detail engineering of plant.
Page 3 of 19
Assignment-1
3. Hazop Study:
3.1. Methodology:
HAZOP study has been carried out based on system design using the Process Flow Diagram (PFD). HAZOP
study involved following steps:
a) Node Identification and Marking: This step involves bifurcation of complete process in to various study nodes on the
Process Flow Diagram.
b) HAZOP Study: The study was performed by considering each of the study nodes and by generating questions in a
structural, yet creative manner to identify deviations from intended design. Following activities have been
performed during the during the HAZOP study:
 Defining the design intent of the node
 Identifying a deviation from the intent by applying guidewords.
 Identifying possible causes and consequences of the deviation. A deviation can be considered “meaningful” if it
has a credible cause and result in harmful consequences.
 Identifying safeguards, if any.
 Providing a risk ranking to the hazards based on its safety/ environment/ economic impacts severity and the
likelihood.
 Identifying recommendation, if no safeguard is provided or safeguards are insufficient.
Page 4 of 19
Assignment-1
Table-1: Guidewords Used for HAZOP
Guideword Code No.
Not 01
More 02
Less 03
As Well As 04
Part Of 05
Other Than 06
Utility Failure 08
Before 09
After 10
Start-up / Shutdown 11
Drawing Error / Engineering Issues 12
Special Causes / Common Causes for complete plant 13
Page 5 of 19
Assignment-1
3.2. Hazop Pre-Concessions:
3.2.1. Throughout the HAZOP study, the following rules have been adopted:
 In principle, considered single failure at one time.
 The manufacturing of equipment, material & tolerances are as per specification and also properly
inspected.
 Plant will be well maintained and operated in accordance with acceptable standards.
 No design work / quantitative assessment has been performed during HAZOP study.
 Equipment are deemed suitable for the specified design conditions.
3.2.2. The following items have been not considered:
 Simultaneous occurrence of two unrelated incidents.
 Simultaneous failure of more than one independent device.
 Operator’s negligence (except common human error)
 Natural calamity.
 Object falling from sky.
 Sabotage
Page 6 of 19
Assignment-1
3.3. Risk Ranking:
The identified hazards have been assessed and ranked according to their severity using the risk matrix
presented below. The HAZOP risk ranking is performed for consequence to Local Community & Reputation,
Health & Safety Staff, Environmental and Business Impact.
Table-2: Risk Prioritisation Matrix
Risk Prioritisation Matrix
Severity
Likelihood Insignificant Minor Serious Major Catastrophic
1 2 4 6 10
Likely 10 10 20 40 60 100
Possible 6 6 12 24 36 60
Unlikely 4 4 8 16 24 40
Very Unlikely 2 2 4 8 12 20
Extreme Unlikely 1 1 2 4 6 10
Page 7 of 19
Assignment-1
Table-3: Risk Ranking Consequences
Risk Ranking Consequences
Severity
Likelihood
Insignificant Minor Serious Major Catastrophic
Local Community & Limited Serious

Reputation Adverse health
annoyance, annoyance, Reversible
No annoyance effect, one or
health effect
No injuries No injuries more fatalities
Health & Safety Staff 1 fatality on Several

Severe injuries,
Severe injuries, the site, fatalities on the
First ais cases, Permanent explosion or site, explosion
Temporary impairment or fire with or fire with
Limited injuries
impairment fire with limited moderate serious
consequences consequences consequences
Environmental Limited
Limited
Minor release or Pollution on the pollution Sever pollution
environment
spill site outside the outside the site
annoyance
site
Business Impacts Financial loss

Financial loss < Financial loss < Financial loss < Financial loss >
<
10,000/- 1,00,000/- 10,00,000/- 1,00,00,000/-
1,00,00,000/-
Page 8 of 19
Assignment-1
Table-4: Risk Classification & Control Measures
Risk Classification & Required Control Measures
Immediately stope activities.

V V Extreme High Risk
[Redesign needed]
IV IV High Risk Immediate implementation of risk reduction measures Unacceptable
Implementation of risk reduction measures

III III Moderate Risk
[Short term actions allowed before implementing permanent]
II II Low Risk Attention required
Acceptable
Very limited risk
I I Extreme Low Risk
[No risk reduction measures required]
Page 9 of 19
Assignment-1
3.4. List of Nodes:
The facility under consideration has been divided in to several nodes, which are logical systems, based on
process and the operating conditions. The result for all the nodes has been shown in the Follow Up Action
List. Refer below table for details of the nodes and their respective graphics from Process Flow Diagram.
Table-5: Node List
Node No-1: Node No-2:
Sulphur melting area Sulphur Burner with Waste Heat Boiler and Steam
Drum along with Hot Gas Filter.
Node No-3:
Node No-4:
Convertor with Super Heater and Static Mixture
All heat exchanging equipment.
Page 10 of 19
Assignment-1

All Towers with Main Air Blower Acid circulation system
Page 11 of 19
Assignment-1

Scrubbing system before chimney. Chimney
Page 12 of 19
Assignment-1
Node No-9:
Final Acid Storage and Dispatch.
Page 13 of 19
Assignment-1
4. Follow Up Action List:
Based on HAZOP study, following recommendations have been identified with respect to safety aspect and risk
involved in the process are captured in below table.
Table-5: Follow Up Action List

Page 14 of 19
Assignment-1
S. Node Risk
Cause Recommendations
No. No. Ranking
Steam supply fail for short period is not issue but for long
1.) 1 Steam supply fail 4 period will make sulphur to solidify. Plant owner to make
ensure by pass steam supply system is available.
Sulphur Melter pit shade shall be well ventilated and a oxygen

Generation of sulphur or
2.) 1 24 analyser shall be installed to ensure that level of oxygen is
Hydrogen Sulphite
adequate.
Plant owner to ensure that steam piping system is well tested

3.) 1 Steam leak from piping system 8 and certified from regulatory authority like IBR (Indian Boiler
Regulation)
Boiler shall be well equipment with pressure safety devices

High temperature inside Waste
4.) 2 24 and temperature measuring devices. Proper maintenance and
Heat Boiler
calibration is recommended for all safety devices.
Hot surfaces shall be proper insulated with suitable material.

Exposure of personnel with hot
5.) 2 36 Plant owner to ensure that proper display in local language
surfaces.
shall be installed near Waste Heat Boiler.
Plant owner to ensure that proper safety devices are installed

6.) 3 High pressure inside Convertor. 16
on convertor.
Hot surfaces shall be proper insulated with suitable material.

Exposure of personnel with hot
7.) 3 36 Plant owner to ensure that proper display in local language
surfaces.
shall be installed near Convertor.
8.) 4 High thermal expansion in 40 Plant owner to ensure that proper stress analysis of high
Page 15 of 19
Assignment-1
temperature piping / duct system to be performed during

connecting piping / duct system
detail engineering of plant.
Plant owner to ensure that proper flushing to be done during

9.) 4 No flow in heat exchangers 8
construction and commissioning phase.
Plant owner to ensure that there will be two blowers with

10.
5 Main Air Blower malfunctioning. 60 same required capacity as one main and one standby shall be
)
considered during detail engineering phase of plant.
Tower area shall be cover with splash wall along with acid
11. proof lining material and proper drainage system to ETP.
5 Acid leakage from tower 40
)
Eye wash with head shower shall installed near safe area.
 Plant owner to ensure that tower area is proper ventilated.

Building to be design with proper escape stair. Two
staircases are recommended at two end of tower building.
12.
5 SO2 / SO3 mist leak from system 60  PPE kit with oxygen cylinder shall be placed on each floor
)
for emergency.
 Plant owner to ensure that only trained persons are
allowed inside tower building.
 Plant owner to ensure that emergency plan considering

large spillage and accumulation of H2SO4 is prepared and
disposal / reprocessing provision are available.
13. Leakage from Acid Circulation
6 100  Tank shall be enclosed with in dyke wall with volumetric
) Tank
capacity of 1.10 times volume of tank.
 Acid proof brick lining is strongly recommended inside
dyke wall area.
Page 16 of 19
Assignment-1
 The dyke wall drainage shall be equipped with isolation

valve so that H2SO4 shall not go to ETP system directly.
 Eye wash with head shower shall installed near safe area.
 Plant owner to ensure that there will be two pumps with

same required capacity as one main and one standby shall
be considered during detail engineering phase of plant.
14. Acid circulation pump  Pump area shall be installed with overhead chain-pully
6 60
) malfunctioning. device.
 Pumping system shall be handled by trained persons only.
 Concentric double walled design with PTFE lining is

recommended for acid circulation line.
 All flanges are to be equipped with flange guard of PTFE
material.
15. Leakage / rupture of acid  Plant owner to ensure that only trained persons are
6 36
) circulation line allowed inside tower building.
 Plant owner to ensure that proper display of danger in
local language shall be installed near acid circulation
system.
16. 7 Scrubbing system malfunctioning 40  Plant owner to ensure that emergency plan considering
) failure of scrubbing system.
 A stand by scrubbing system is strongly recommended.
 Plant owner to ensure that proper scrubber system
Page 17 of 19
Assignment-1
maintenance schedule has been designed and

implemented.
 Close monitoring of scrubbing system is recommended.
 Plant owner to ensure that emergency plan considering

large spillage and accumulation of H2SO4 is prepared and
disposal / reprocessing provision are available.
 Tank shall be enclosed with in dyke wall with volumetric
capacity of 1.10 times volume of tank.
17.
9 Leakage from Acid Storage Tank 100
)  Acid proof brick lining is strongly recommended inside
dyke wall area.
 The dyke wall drainage shall be equipped with isolation
valve so that H2SO4 shall not go to ETP system directly.
 Plant owner to ensure that there will be two pumps with

same required capacity as one main and one standby shall
be considered during detail engineering phase of plant.
 Pump area shall be installed with overhead chain-pully
18. Acid circulation pump device.
9 60
) malfunctioning.
 Pumping system shall be handled by trained persons only.
 Pumping area shall be enclosed with splash wall with acid
proof brick lining with proper drainage system.
5. Role of Top Management:

Page 18 of 19
Assignment-1
Following are the recommended role of top management on output of HAZOP study.
 Top management should owner the recommendations given in study report.
 Form a committee that make sure that all recommendations of HAZOP study are implemented.
 Form a QC department to ensure that all equipment, devices & materials are within acceptable limit.
 Hire an external auditor to ensure that all the health and safety norms are being followed.
 Top management should hire reputed EPC (Engineering Procurement & Construction) consultant for detail
design of plant.
 Top management to create Health & Safety department to ensure safety of plant personals.
 Create various SOPs for operation and maintenance activities of plant.
 Hire experience personals for operation and maintenance of plant.
 Build a good culture for health & safety.
 Plan training time to time for plant safety, operation & maintenance activities.
Page 19 of 19

Problem Statement:: ZZZZZZ Yyyyyy 25 Nov. 2020 Process Plant Safety and Environment XXXXX

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Assignment-1

Name zzzzzz Student Id yyyyyy Date of Submission 25th Nov. 2020

1. Process Flow Diagram:

Please refer attached PDF file named:

2. Hazards and Risks involved in the process:

 Defining the design intent of the node

 Identifying a deviation from the intent by applying guidewords.

 Identifying safeguards, if any.

 Identifying recommendation, if no safeguard is provided or safeguards are insufficient.

Table-1: Guidewords Used for HAZOP

Guideword Code No.

Drawing Error / Engineering Issues 12

Special Causes / Common Causes for complete plant 13

3.2. Hazop Pre-Concessions:

 In principle, considered single failure at one time.

 Equipment are deemed suitable for the specified design conditions.

3.2.2. The following items have been not considered:

 Simultaneous occurrence of two unrelated incidents.

 Simultaneous failure of more than one independent device.

 Operator’s negligence (except common human error)

 Object falling from sky.

3.3. Risk Ranking:

Table-2: Risk Prioritisation Matrix

Risk Prioritisation Matrix

Likelihood Insignificant Minor Serious Major Catastrophic

Table-3: Risk Ranking Consequences

Risk Ranking Consequences

Local Community & Limited Serious

Health & Safety Staff 1 fatality on Several

Business Impacts Financial loss

Table-4: Risk Classification & Control Measures

Risk Classification & Required Control Measures

Immediately stope activities.

IV IV High Risk Immediate implementation of risk reduction measures Unacceptable

Implementation of risk reduction measures

II II Low Risk Attention required

3.4. List of Nodes:

Node No-5: Node No-6:

Node No-7: Node No-8:

4. Follow Up Action List:

Table-5: Follow Up Action List

Sulphur Melter pit shade shall be well ventilated and a oxygen

Plant owner to ensure that steam piping system is well tested

Boiler shall be well equipment with pressure safety devices

Hot surfaces shall be proper insulated with suitable material.

Plant owner to ensure that proper safety devices are installed

Hot surfaces shall be proper insulated with suitable material.

temperature piping / duct system to be performed during

Plant owner to ensure that proper flushing to be done during

Plant owner to ensure that there will be two blowers with

 Plant owner to ensure that tower area is proper ventilated.

 Plant owner to ensure that emergency plan considering

 The dyke wall drainage shall be equipped with isolation

 Plant owner to ensure that there will be two pumps with

 Concentric double walled design with PTFE lining is

maintenance schedule has been designed and

 Plant owner to ensure that emergency plan considering

 Plant owner to ensure that there will be two pumps with