Chapter 9-Safety

Production of 100,000 Tonnes Per Year of Butyl Acetate
CHAPTER 9
SAFETY & LOSS PREVENTION
9.1 INTRODUCTION
Environment and safety is the most important aspect that has to be considered
by all company when designing chemical plant. Environmental health concerns all
aspects of the natural and built environment that may affect human health. Other terms
that refer to the discipline of environmental health are including environmental public
health and also environmental health and protection. Meanwhile, safety gives the
meaning of the state of being safe, the condition of being protected against social,
spiritual, financial, political, emotional, occupational, psychological, educational or other
types of consequences of failure, damage, error, accident, harm or any other event
which could be considered non-desirable. This can take the form of being protected
from the event or from exposure to something that causes health or economical losses
which can conclude protection of people or of processions.
In the n-Butyl acetate production plant, where it is handled, used, stored or

transported, precautions must be taken to ensure the awareness of the employees of its
properties, toxicity, and safety precautions which include the following:
i) N-Butyl acetate properties.

ii) Health hazards related with n-Butyl acetate.
iii) Physical hazards, the potential for fire and explosion.
iv) Safe work and good housekeeping practices.
v) The importance of protection from n-butyl acetate contact; the proper
clothing and cleaning requirements.
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vi) Signs and symptoms of n-butyl acetate exposure and action to be taken
and medical conditions aggravated by exposure to n-butyl acetate.
vii) The care that must be applied whenever and wherever n-butyl acetate is
used, handled, stored and transported.
viii) Emergency procedures for leaks, spills, and fires, including protective
clothing to be worn in such instances.
ix) The availability of written n-butyl acetate usage, health hazard and
training program procedures.
x) The need for and the requirements of the medical surveillance program.
Besides n-butyl acetate, methyl acetate, methanol and n-butanol should also be
considered in safety because all the substances have the acidic properties, and both
are corrosive and flammable and thus certain precautions are necessary if it is to be
stored and handled safely. This can be achieved by ensuring that the storage and safe
operating procedures are followed.
Environment impact is the impacts or effects released from the chemical plant
during the operation. An environmental impact (EIA) is the possible impact whether it is
positive or negative that a proposed project may have on the environment. The
International Association for Impact Assessment (IAIA) defines an environmental impact
assessment as the process of identifying, predicting, evaluating and mitigating the
biophysical, social, and other relevant effects of development proposals prior to major
decisions being taken and commitments made. EIAs are unique in that they do not
require adherence to a predetermined environmental outcome, but rather they require
decision makers to account for environmental values in their decisions and to justify
those decisions in light of detailed environmental studies and public comments on the
potential environmental impacts of the proposal.
The International Organization for Standardization (ISO) Standard 14011 covers

EIA and includes key steps for carrying out the assessment. These steps include the
scope of EIA. EIAs have often been criticized for having too narrow spatial and
temporal scope. At present, no procedure has been specified for determining a system
boundary for the assessment. The system boundary refers to the spatial and temporal
boundary of the proposal‟s effects. This boundary is determined by the applicant and
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the lead assessor, but in practice, almost all EIAs address the direct, on-site effects
alone.
9.2OCCUPATIONAL SAFETY AND HEALTH ACT (OSHA) 1994
Occupational Safety and Health Act (OSHA) was enacted on 25th February
1994 with the intent to ensure safety, health and welfare of everyone at workplace. It
was promulgated based on the self-regulation concept with the primary responsibility of
ensuring safety and health at the workplace lying with those who create the risks and
work with the risks. This consultative process extends to where safety and health
programs are implemented with both employers and employees representative as
members of safety and health committee. Every employer must prepare a statement of
policy on health and safety, together with the arrangements for the policy. All
manufacturing processes are to some extent hazardous, but in chemical processes
there are additional, special, hazards, associated with the chemicals used and the
process conditions. Thus, the designer must be aware of the hazards, and ensure,
throughout the application of engineering practice, that the risks are reduced to
acceptable level. 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 slight, must be reported at once to your immediate supervisor. This
is for protection to insure that proper records are made of the accident.
2. All employees are responsible for their fellow employee‟s as well as their own
and it is a part of their responsibilities. Defective 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 specific areas designated for
smoking by plant management. Matches or lighters shall not be carried into the
plant and must be left in the lockers rooms or other specific areas.
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4. It is mandatory to all employees working in the plant to wear personal

protective equipment (PPE) provided by the plant management while in the
plant.
5. If anyone enters the plant without thePPE, it is the responsibility of the
operator in that department to kindly ask him or her to leave and then notify
the supervisor of this action.
6. Horseplay can only lead to accidents and will not be tolerated in the plant.
Horseplay will be charged with disciplinary action including discharging from
the premise.
7. Possession or use of liquor or illegal drugs is not permitted on the plant
premises and anyone under the influence of it will not be permitted to enter
the plant.
8. Visitor must register to the main office, sign a release paper, and briefed with
the plant safety rules before they are allowed to enter the plant. Visitor
cannot enter the plant areas that are experiencing production problems.
9. Consult the supervisor about the safety procedures of the plant and do not
act without proper understanding of the procedures.
9.3 EMERGENCY RESPONSE PLAN (ERP)
In an emergency response plan, emergencygives the meaning of accidents or serious

precursors to accidents with possible consequences for employees, the environment or
property, such as accidental releases to the atmosphere, water or soil, fires and
explosions. A major emergency is the one which has the potential to cause serious
injury or loss of life and/or property, and which tends to cause disruption inside and/or
outside the works and to require the use of outside resources. The main objective of the
emergency plan is that the organization itself, in co-operation with the community
rescue services (fire brigade, local authorities, etc.) shall be able to deal efficiently with
emergency situations and limit dangers.
The first line of defend is a well-trained operating crew, who know everything
that can go wrong and what to do about it. However, the project engineer must realize
the limits of what operators can be expected to do and should back them up with
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physical facilities (automatic control, safety valves, interlocks) which will take over the
more difficult portions of the burden of safety. In addition, the site manager would be
responsible for establishing an emergency plan with an emergency organization, and
be responsible for initiating emergency drills.
Communication is a crucial factor in handling an emergency. When an incident

occurs, it is necessary to immediately raise the alarm, to declare an emergency, to
inform the works emergency services and threatened areas within the works and the
neighboring areas. Thus an Emergency Control Centre would be provided, where it
would be linked by telephone to all essential points within the plant and to outside
services. It is vital that this telephone system would function in the emergency.
The Emergency Control Centre would have plans which indicate:

(i) Inventories of hazardous materials in the plant
(ii) Fire water system and other firefighting equipment
(iii) Safety equipment
(iv) Plant entrances and road system
(v) Assembly points
(vi) Areas affected by hazard and so forth.
A Works Incident Controller would be appointed and it is his function to proceed

to the scene of the incident and to take control of it.
The Incident Controller main function is to direct all operations at the scene of
incident:
(i) Rescue and firefighting operations, until the arrival of the fire brigade,
when he should hand over control to a senior fire officer
(ii) Search for casualties;
(iii) Evacuation of non-essential workers to assembly areas.
(iv) In addition, a Site Main Controller would also be appointed and his
function is to go to the Emergency Control Center and take overall
control of the emergency in the works. Some of the duties of a site main
controller listed in the HSE Emergency Procedures Guide are listed as
follows;
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 Plant control/shutdown
 Leak control
 Hazard reduction
 Traffic control
 Evacuation
In the communication of an emergency, when a serious accident occurs, it is

highly desirable for the alarm to be raised as quickly as possible. Prompt action will, in
many cases, forestall the development of a full emergency. Some crucial aspects of
raising the alarm are including the authority to raise the alarm, the training of personnel,
and the alarm system. An efficient policy is to allow any employee to raise the alarm
and all personnel would be specifically trained in this aspect to make this policy be
more effective.
On declaration of an emergency, it is necessary for all personnel to know the

procedures to be followed and these are outlined in the emergency response plan.
The procedures to be followed are:
a) All members of the workforce return to their normal place of work,

provided it is safe to do so.
b) Personnel who are in charge of plants and departments, and who are
nominated to other duties go to their offices to await instructions from the
Emergency Control Center.
c) Senior managers nominated as key personnel go to the Emergency
Control Center from which, acting on the advice of the Works Incident
Controller, they issue instructions.
The items to be considered in an emergency response plant are listed below;
 Emergency organization chart with phone numbers and addresses.

 Risk assessment of expected emergencies
 Map of the facility layout
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 Identification of location of key emergency equipment, supplies, shelters,

assembly
 Areas, evacuation routes and communication and command center
 List of outside agencies with phone numbers and addresses
 Identification and location of alarm systems
 Shutdown and start-up procedures
 Control of visitors and news media
When an emergency occurs, it would be necessary to evacuate all personnel

not directly involved in dealing with the incident from the affected area. On evacuation,
people should go to pre-assigned assembly points, which are located in safe places.
Each assembly point would be manned by a nominated person. It would be his duty to
record the names of those reaching the point and to keep communication with the Site
Main Controller in order to help locate missing personnel and to receive further
instructions on evacuation.
9.4 FIRE DETECTION AND PROTECTION
Generally, all fires have a common trait. They begin as little fires and become larger.
The objectives of fire protection are to contain, control, and extinguish. Success is best
achieved using three aspects of fire response: (1) early detection, (2) immediate
response, and (3) appropriate action.
All fires release heat and most fuel fires display flames and generate smoke.
However, the chemicals exist in the n-butyl acetate plant (i.e. butanol, methyl acetate,
butyl acetate and methanol) generatefires with less heat, the flames are nearly invisible
to the naked eye during daytime, and there is very little smoke. Early detection of the
fire requires different technology than early detection of gasoline and diesel fires.
As the protection against the potential fire occurrence, fire extinguishers must be
available in the plant. Fire extinguishers are placed at every building in the n-butyl
acetate plant and the types of fire extinguishers suitable are FCC, dry carbon dioxide
and foam whereby water type is not suitable for the chemicals in the plant.
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In addition, the following fire protection principles should be applied.
a) All rooms and spaces should be kept clear of combustible material

and rubbish
b) Roads and access roads should always be kept clear and passable
c) Fire protection equipment should always be in its proper place and
should not be blocked or rendered unusable. Fire protection equipment
may only be used for its intended purpose
d) All personnel should be well trained and safety conscious. All
personnel should also receive basic fire protection training.
The following list can be used as a guide on suitable actions that should be
carried out in the event of a fire.
a) Immediately eliminate ignition sources.
b) An immediate evacuation from the fire area should be done. All
personnel (as well as visitors) should follow the appropriate evacuation
routes
c) Roads should be controlled and be accessible for the emergency
team. Crowd control should be applied and access to the fire area
should be restricted.
d) An adequate supply of water is ensured for the firefighting effort.
e) If water is unsuitable for putting out the fire, apply dry chemical foam
for small fires and hydrocarbon-type foam for large fires or carbon
dioxide sprays.
f) Use the necessary firefighting equipment and personal protective
equipment (PPE).
9.5 VAPOR CONTROL
The first measure in early detection of chemical fires must necessarily rely on
the presence of chemical vapor. If chemical vapor is present in the n-butyl acetate plant
(i.e. butanol, methyl acetate, methanol and butyl acetate vapor), one must assume that
ignition is possible. Once ignition occurs, combustion will produce either a fire or an
explosion. The ignition depends on ambient temperature, the energy of the ignition
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source, and whether vapor is confined or unconfined. If ambient temperature is above

the flash point, and if there is a large amount of vapor space in a container, tank, room,
building, or enclosure, then explosion is more likely. If ambient temperature is below the
flash point, if potential ignition sources are low energy, and if vapor can readily escape
to atmosphere, then explosion is less likely.
Hence, vapor detector must be placed in every building in the n-butyl acetate
plant. This type of detector can be combined with the fire/smoke detector and will detect
the unusual vapor and smoke level in the buildings and give the necessary alarm to rhe
operator and everyone in the plant.
9.6 STORAGE TANK SAFETY FEATURES
Best practice for tank storage of chemical uses internal or external floating roofs
to minimize methanol vapor space within the tank and to reduce the amount of air that
can mix with that vapor and control the volume of vapor emission from tanks. Besides
that, inert gas blanketing can be used to prevent formation of explosive atmospheres
within tank vapor spaces. Dry nitrogen is the preferred inert gas for blanketing. Blanket
gas should be free of carbon dioxide to avoid corrosion in the presence of moist air, and
to avoid product contamination that could increase methanol acidity. It is recommended
that the outside of methanol tanks to be painted with heat reflecting paint. This measure
will reduce vapor losses from the tanks.
Bounding and pit is also necessary a safety feature for the storage tanks in the
n-butyl acetate plant. This feature is useful when spillage occurs, and it will prevent the
chemicals spilled from spreading further from the storage tanks.
9.7 PRESSURE RELIEF SYSTEM
Tank internal pressure can be controlled using pressure or vacuum relief valves. Vents
may or may not be configured with flame arresters, depending on the specific
circumstances of the hazard. Pressure relief valves are sized to a fire case and, if
possible, should be piped to relieve into a flare header. If configured to relieve to
atmosphere, then it is strongly recommended that Process Safety Valves (PSVs), be
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configured to breathe to atmosphere through flame arresters. In addition to fire safety, it

is recommended that local regulations for limiting hydrocarbon emissions be considered
when configuring tank vents and pressure relief devices.
9.8 SMOKING, VEHICLE ACCESS AND MISCELLANEOUS IGNITION SOURCES
Smoking must be restricted to a designated location that is free of potential chemical

vapor.
Vehicle access must be strictly controlled and enforced.
Use of non-sparking tools is highly recommended.

Radios, telephones, portable instrumentation, computers, calculators, and other
electronic equipment should have fire-safe rating prior to being used in a methanol-
containing area.
As a rule of thumb, allow at least 20 feet (7 meters) of no ignition source

perimeter around storage areas containing individual small volume containers such as
cans, buckets, barrels, and totes of chemicals (i.e.butanol, methyl acetate, methanol
and, butyl actetate). Allow at least 50 feet (17 meters) of no ignition source perimeter
around storage and logistics areas containing and/or handling larger volumes of
chemicals(i.e., individual tanker trucks, rail cars, and small storage tanks). Allow at least
200 feet (70 meters) of no ignition source perimeter for logistics terminals that
simultaneously load or unload multiple trucks, multiple rail cars, barges, ships, and
large-volume storage tanks.
9.9 PRECAUTIONS FOR SPILLAGE AND LEAKS
Engineering controls associated with methanol storage tanks are including overfill
protection by means of visible and audible high-level alarms, secondary containment
systems, such as dikes, bunds, or berms, vapor detectors and alarms, and explosive
gas detectors to detect and warn of fire and explosion hazards in the event of a release.
The chemicals (butanol, methyl acetate, methanol and butyl acetate) must be stored in
a beamed, diked, or bounded, well-ventilated area that shall be capable of containing at
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least 110% of the volume of the largest storage tank in the contained area. Following a
leak inside the containment area, the chemicals should ideally be completely covered
with alcohol resistant foam. If the containment area is adequately sized, the chemicals
spill can be diluted with at least four parts water to one part chemicals to reduce the risk
of fire.
Operation and maintenance procedures to prevent leaks and spills should

include periodic visual inspections and nondestructive testing of the condition of tanks,
valves, pipes, hoses, and dikes, as well as preventative maintenance of mechanical,
electrical, and structural components, and detection and alarms systems. The methanol
handling, containment, and control system must be maintained so as to be continually
fit for continued usage. Written procedures for loading and transferring methanol, as
well steps necessary for emergency shut-off, should be developed and reinforced
through periodic training of operating personnel.
Workers must be trained to handle all the chemicals in a safe manner. Systems
and procedures that protect the employees, the plant, and the environment should be
implemented.
Spillage kits must be available in all areas where the chemicals are handled,
stored, or used. A complete spillage kit must include various types and sizes of sorbent
materials such as vermiculite or activated carbon, sorbent pads, a plastic (non-
sparking) shovel to disperse the sorbent materials, yellow caution tape or other barrier
devices to isolate the area, and a drum or container to place the collected waste
material. Personal protection equipment for the responders should, at a minimum,
include chemical splash goggles and face shield, butyl or nitrile gloves, rubber boots,
chemical resistance coveralls, and provision for supplied fresh breathing air. Air
purifying respirators with organic vapor cartridges should never be used for protection
against the chemicals vapor.
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The following steps can be used as a guide on actions to be taken in the occurrence of
spillage and leaks.
1. Determine the amount of the spilled material. The amount of spillage
will determine whether an evacuation is needed or not.
2. If an evacuation is needed, personnel are required to immediately
evacuate themselves from the area where leakage occurs. In any
situation, all personnel should be familiar with and in access of the
necessary PPE.
3. If the leak poses a danger to the environment, the material run-off
should be controlled.
4. Determine the nearest materials that may be extremely affected or
react with the spilled material.
5. If the leakage is of a flammable material, all ignition sources around
the leak should be controlled. This includes responding apparatus, pilot
lights, cigarettes, utilities, and vehicles.
6. If the leak is of a poisonous or toxic nature, it should be isolated and
contained. If possible, the leakage should be covered with sand, dirt, or
other appropriate material to prevent it from vaporizing and to prevent its
run-off by rain or other sources.
9.10 PRECAUTIONS FOR EXPLOSIONS
An explosion hazard is thought to exist,andone or more of the following measures must

be taken:
1. Avoidance or restriction of the formation an explosive atmosphere.
2. Avoidance of effective ignition sources.
3. Avoidance of hazardous effects of an explosion.
While the two first measures are intended to exclude the possibility of an
explosion occurring, the third measure is intended to reduce the effect of an explosion
that has occurred to a harmless extent. A combination of these options may be practical
or required and the technical measures should always be accompanied by
organizational measures. In the case of flammable gases, vapors and mists, avoiding
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the formation of explosive atmospheres has priority over avoiding ignition sources and
measures of constructional explosion protection measures.
Table 9.1: Summary of response to accident at the n-Butyl Acetate plant.
 Liquid very quickly evaporates, even at

low temperatures, and forms vapour
(fumes) which can catch fire and burn
with explosive violence
 Invisible vapour spreads easily and can
be set on fire by many sources such as
pilot lights, welding equipment, and
electrical motors and switches.
Fire hazard (Extremely flammable)  Do not enter any enclosed or confined
fire space without proper protective
equipment.
 Extinguish with foam, dry chemical or
carbon dioxide.
 Use water in flooding quantities as fog,
solid streams of water may be
ineffective. Cool exposed containers
with water.
 Eye contact can be avoided by wearing
chemical goggles
 Skin contact can be minimized by
Personal Protective wearing protective clothing
 Wear approved respiratory equipment
Equipment
when working with this material unless
ventilation is adequate to keep airborne
concentrations below recommended
exposure standards
Eyes  Wash eyes immediately, thoroughly

with plenty of water.
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 Skin contact may cause drying or

defatting of the skin
Skin  Remove clothing and shoes if
contaminated. Wash skin with soap
and water.
 The vapour or fumes from this material
may cause respiratory irritation
 Move the person to fresh air
Inhalation  If not breathing, give artificial
respiration
 If breathing is difficult, give oxygen. Get
medical attention if symptoms continue
 The chemicals can directly enter the
lungs, if swallowed or if subsequently
vomited
 Can cause severe injury or death
Ingestion  If swallowed, do not induce vomiting
 Give the person a glass of water or milk
and get immediate medical attention
 Never give anything by mouth to an
unconscious person.
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 If n-butyl acetate has been spilled, it can be removed

safely for disposal
 All spill activities must meet the requirements of the
OSHA Hazardous Waste Operations and Emergency
Response
 If the concentration of n-butyl acetate in air
surrounding the spill has not been determined, assume
the worst case and use the highest level of respiratory
Spillage and protective clothing
 Before attempting to clean up the spill, be sure that the
flow of liquid has been stopped and that all sources of
ignition are eliminated
 Small spills can be removed by covering the spill with
sand or a suitable absorbent
 If the spill is on a hard surface, the area should be
scrubbed with soap and water after the bulk of the n-
butyl acetate has been removed.
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9.11 HAZARDS AND OPERABILITY STUDIES (HAZOP)
A Hazard and Operability (HAZOP) study is a structured and systematic examination of

a planned or existing process or operation in order to identify and evaluate problems
that may represent risks to personnel or equipment, or prevent efficient operation. The
HAZOP study is a formal procedure to identify hazards in a chemical process facility.
The procedure is effective in identifying hazards and is well accepted by the chemical
industry. The basic idea is to let the mind go free in a controlled fashion in order to
consider all the possible ways that process and operational failures can occur.
The HAZOP technique was initially developed to analyze chemical process

systems, but has later been extended to other types of systems and also to complex
operations and to software systems. A HAZOP is a qualitative technique based on
guide-words and is carried out by a multi-disciplinary team (HAZOP team) during a set
of meetings.
The HAZOP study should preferably be carried out as early in the design phase
as possible - to have influence on the design. On the other hand; to carry out a HAZOP
we need a rather complete design. As a compromise, the HAZOP is usually carried out
as a final check when the detailed design has been completed. A HAZOP study may
also be conducted on an existing facility to identify modifications that should be
implemented to reduce risk and operability problems.
If HAZOP is started too late in a project, it can lose effectiveness because:

1. There may be a tendency not to challenge an already existing
design.
2. Changes may too late, possibly requiring redesign of the process.
3. There may be loss of operability and design decision data used to
generate the design.
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The objectives of HAZOP study are:

1. To identify areas of the design that may possess a significant hazard
potential
2. To identify and study features of the design that influences the
probability of a hazardous incident occurring.
3. To familiarize the study team with the design information available
4. To ensure that a systematic study is made of the areas of significant
hazard potential.
5. To identify design information not currently available to the team.
6. To provide a mechanism for feedback to the client of the study team„s
detailed comments. (Sydney Lipton and Jeremiah Lynch, 1994)
The advantages of HAZOP study to the design application:

1. Early identification of problems areas when conceptual design stage.
2. Identifies need for emergency procedures to mitigate.
3. Provide essential information for safety case, such as on the hazards
identified and effectiveness of safety systems.
4. Through examination of hazard and operability problems when applied
at detailed stage.
5. Meets legislative requirements.
6. Identifies need for commissioning, operating and maintenance
procedures for safe and reliable operations.
The study is based on a set of „guide words„(identifying possible deviations). The

Chemical Industries Association has published a Guide to Hazard and Operability
Studies, CIA (1979b) that gives a comprehensive description of the technique and
examples of the HAZOP application. The seven guide words recommended in the CIA
booklet are as follows: NO or NOT, MORE, LESS, AS WELL AS, PART OF,
REVERSE, and OTHER THAN.
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Table 9.2: A HAZOP study contains the following important features

Features Meaning
Intention Defines how the part or process is expected to operate
Guide Words Simple word used to qualify the intention in order to guide and
stimulate creative thinking.
Deviations Departures from the intention discovered by systematic application
of guide words.
Causes Reasons that deviations might occur
Consequences Results of deviations if they occur.
Action Prevention, mitigation and control
- Prevent causes.
- Mitigate the consequences.
- Control action such as provide alarms to indicate things getting out
of control:
Define control actions to get back into Control.
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Table 9.3: Hazop study on reactor (CSTR-100& CSTR-101)
Parameter: flow
Guide Deviations Possible causes Consequences Action required
word
No/ none No flow into 1) inlet valve malfunction 1)no reaction occur 1)Install filter with maintenance
reactor 2) blockage or leakage in 2)dropping of rate reaction procedures.
pipe inlet to reactor 2) Maintenance on pipeline and
valves.
No outlet flow 1)Reactor tank Reactor breaks down. 1)Stop the operation
from reactor empty 2) Check feed valve.
Less Less flow input 1) valve partially open 1) Production target fails. 1)Make regular inspection on valve
to reactor 2)pipe blockage 2)increasing rate of reaction 2) Install check valve.
More More flow 1) control valve failure 1)Too much output 1) Inspection on control valve.
input to reactor 2)operator fails to take 2)less effective for next 2) Install check valve.
action on alarm equipment
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Parameter: Temperature
Guide Deviation Possible causes Consequences Action required

word
Low Low Cooling water valve Reaction is incomplete/ no 1) Install temperature sensor and
temperature malfunction reaction occurred alarm.
2) Install controller handle.
High High Cooling water valve 1)Deactivated catalyst 1) Install temperature sensor and
temperature malfunction 2)Incomplete reaction alarm.
2) Install controller handle
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Parameter: Pressure
Guide Deviation Possible causes Consequences Action required

word
Low Low pressure -Reactor leakage 1. Decline in reaction rate. 1) Install pressure sensor and
-Pressure valve fully open 2. Temperature drop. alarm.
3. Less or no production. 2) Check the pressure valve.
4. Reversible flow occurs.
High High 1. Outlet pipeline blockage. 1. Runaway reaction. 1) Install pressure sensor and
pressure 2. Pressure valve 2. Pressure builds up. alarm.
malfunction 2) Check the pressure valve.
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Table 9.4: Hazop study on heat exchanger
Guide Deviations Possible causes Consequences Action required
word
Low Less heat Pipe blockage or increase in the resistance -Install temperature sensor and
supply to fouling on tube to heat transfer across the alarm.
stream heat exchanger -Check temperature control valve.
High High Failure of cooling Temperature of process -Install temperature sensor and
temperature water valve fluid increase alarm.
on stream -Check temperature control valve.
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Parameter: Pressure
Deviations Possible causes Consequences Action required
(Guide
word)
Low Tube leakage -Wasting the utilities and - Install pressure sensor
the stream is may low and alarm.
temperature not achieve - Check control valve.
temperature required
-Decrease of stream
flowrate
High Fouling in tube Reduce heat transfer - Install pressure sensor

coefficient and efficiency of and alarm.
heat exchanger - Check control valve.
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Table 9.5: Hazop study on distillation columns
Parameter: Flow
(Guide word)
No -Failure of the previous unit -Operation failure. 1) Install filter with
-Pipe broken. -Effect further process. maintenance procedures
-Pipe plugging. 2) Install check valve
More -Control valve is not working -Level increase in the 1) Install filter with
properly and cause too much column. maintenance procedures
flow to distillation column. -Flooding will at the stages 2) Install check valve
inside the column
Less -Failure of the previous unit -The efficiency of the 1) Install filter with
-Pipe broken. column will reduce and thus maintenance procedures
-Pipe plugging. reduce the purity of the 2) Install check valve
product at the outlet stream. 3) Check the pipes.
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(Guide word)
More -Less steam supply at the -The composition at the 1) Check control valve.
reboiler. distillate will varies. 2) Install check valve.
-Control valve damaged. 3) Install temperature sensor
and alarm.
Less -Pipe broken. -The composition at the 1) Check control valve.
-Pipe plugging. distillate will varies. 2) Install check valve.
3) Install temperature sensor
and alarm.
Parameter: Level at Condenser

(Guide word)
No -Failure of the previous unit -No operation at the 1) Shut down the process
-Pipe broken. condenser. 2) Shut down the process
-Pipe plugging. -Will damaged the 3) Maintenance and
equipment. inspection of the pipes.
-The operation of the
process will ruin.
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More -Pipe broken at the inlet of the -Will reduce the quality of 1) Pipe maintenance on inlet
condenser. the product. stream
-Control valve are not working -Flow to the column as
properly. reflux flow will increase.
2) Inspection on valve at
outlet stream of
condenser
Less -Pipe broken and/or plugging at -Increase pressure inside 1) Pipe maintenance on inlet
the outlet of the condenser. the column. stream
-Flow to the column as
reflux flow will decrease. 2) Inspection on valve at
-Decrease the purity if the outlet stream of condenser.
product.
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Parameter: Level at reboiler

(Guide word)
No -Failure of the previous unit -No operation at the 1) Install check valve.
-Pipe broken. reboiler. 2) Maintenance and
-Pipe plugging. -Will damaged the inspection of the pipes.
equipment.
-The operation of the
process will ruin.
More -Steam suppliedtoinsufficiently. -no steam in reboiler 1) Inspection on thecontrol

valve.
2) Install check valve.
Less -valve on inlet stream is -Flow out of the reboiler to 1) Inspection on the control
malfunction the column will increase. valve.
-Decrease the purity if the 2) Install check valve.
product.
462
Table 9.6: HAZOP analysis for decanters.
Process Possible
Deviations Possible causes Action required
parameter consequences
 Pumping system fails Install back up control

No  Control valve not working Production failure.
valve.
 Blockage in piping system.
 Control valve not working Install back up control

Flow Less Production failure.
 Blockage in piping system. valve.
 High pressure Install back up flow

More Failure in controller.  Less purity in controller and control
product. valve.
Pipe leaking in transfer from high

Less pressure separator to medium Less purity in product Install low pressure alarm
Pressure pressure separator
More Increased pumping capacity Wall cracked Install high pressure alarm
463
9.12 Material Safety Data Sheet (MSDS)
As required by law, OSH Act 1994 under USECHH (Use and Standards of
Exposure of Chemical Hazardous to Health) Regulations 2000. Under this law,
Material Safety Data Sheet (MSDS) shall be kept in a workplace to each
location where that chemical is used and shall be easily accessible to the
employees.
The MSDS for all chemicals involved in the n-butyl acetate plant can be
viewed in the appendices.
9.13 PLANT STARTUP AND SHUT DOWN PROCEDURES
9.13.1 Plant startup procedures
Many potential hazards can be realized during start-up or shut-down of

plant or process. Specific operating procedures should be provided
which take account of all eventualities. For some specific plant items,
start-up is known to present particular additional hazards for examples
on Furnaces; explosions may occur if ignition of fuel is delayed. The
start-up and shut-down procedures should be ordered and phased so
that interlinked plant operations can resume or cease in a safe and
controlled manner.
There are commissioning processes to conduct plant start-up

safely. Firstly, preparation and planning among Commissioning Manager
or Lead Commissioning Engineer with commissioning team and support
team to provide training and information compilation. They also need to
come out with the safety and risk assessment, commissioning strategy
development procedures and checklist development detailed plan and
also budget preparation.
464
Second stage is mechanical completion and integrity checking. During these

stages, all valves and pumps may have inspection on its reliability. Some tests
should be done in these stages. Some of the tests are:
a. Pressure testing
Pressure testing of piping and equipment for mechanical strength and adequacy
of joints is normally done by the construction crew
b. Dry run testing of power equipment
Mechanical testing of equipment such as pumps, compressors, furnace and

other power equipments should be conductedby the manufacturer„s
representative with the presence of operation team„s member who can become
familiar with the equipment operation and who can judge the adequacy of the
tests.
c. Hot test
Certain equipments should be tested to ensure leak-tightness at high

temperature and after temperature reversals. Temperature reversal is referring
to the condition at which temperature change rapidly from hot to cold and vice
versa. Loop reactor which is cooled at high temperature by heat-transfer liquid
should be given a hot test at close to operating temperature before being
charged with catalysts. Leaks in such equipment may develop at high
temperature or after a temperature. Reversal could lead to contamination or
poisoning of a valuable charge of catalysts, resulting in unnecessary delays for
recatalyzing the reaction
d. Closed loop dynamic testing with safe fluids
It includes the operation of the equipment or system with air, water, inert gas or
similar safe fluids. These tests represent the first dynamic test of the plant, allow
flow testing of equipment, and give the first indication of the response of control
465
loops and familiarizing the operators with the equipment in the plant prior to the
introduction of hazardous chemicals.
e. Solvent testing
Closed-loop testing of process equipment using a safe solvent or the solvent to

be used in the process should be performed at conditions close to expected
operating conditions.
f. Process fluids testing
May be carried out where such process fluids are available. In such a test, some
of the fluids will be handled in the plant equipment at design temperature and
pressure but reaction are avoided.
Third stage is the pre-commissioning and operational testing. On this stage,

steam and other utilities are introduced to generate energy and electrical power
such as boiler which needs at least two day to build-up the heat. In the butyl
acetate plant, reactors must first introduced to hot steam to activate the catalyst
in its condition 650oC. Besides that, dry running trials and hot running trials are
also performed in this stage. Before the full operation take place, safe-fluid
dynamic testing and process fluid test should be done. The equipment such as
distillation columnsthat operate in high pressure must build the pressure inside
by closing the pressure valve. While the pressure has increased near the
maximum pressure design, pressure valve should open slowly to maintain the
pressure.
The fourth or last stage is start-up and initial operation. On this stage,theprocess
fluid is introduced. Team commissioning must make sure that all equipmentsare
ready and fit with its reliability for full operation to take place. Usually, team of
JKKP (Department of Safety & Health - DOSH) inspector inspects all pressure
vessels and high pressure boilers to meet the safety standard to operate.
466
9.13.2 Plant shut down procedures
In plant operation the start-up and shutdown for equipment is an important

procedure to ensure all equipment will work properly and safety. The accident
that occurs in petrochemical plant took place during transient operation such as
start-up and shutdown. Effective shut-down procedures, which are easy to
implement, are essential to deal with emergency situations. Much equipment will
be operating away from their normal design condition during start-up and
shutdown and inevitably, most plants procedure off-spec products and
unwanted intermediates during these times. If during the detail process design
transient operation such as startup and shutdown are not contemplated, the
plant may not suitably designed for the unsteady state condition that arise soon
after the commissioning of the plant
Each plant under care and control of the owner will need a plant turnaround
management process documents tailored to its specific needs. These need
include;
 Type of plant
 Geographical location
 Size of plant
 General complexity of the expected plant outage
The document is dynamics and should be reviewed at the end of each

turnaround to ensure it is consistent with the needs of the facility.
Prior to the shutdown, gather maintenance and support staff to review the
shutdown procedure. Make a list of all personnel with up-to-date contact
information, and inform them if they may be on 24-hour call during the
shutdown.
In shutdown process, air test is applied by releasing air process and it does not
take a short time. Hence, the shutdown needs to be coordinated properly and
effectively. After detecting the leaking points, air is released from the vessels
467
and pipelines. This willtakearound 2 hours. After air pressure is lesser,

maintenance fitters welded the leaking points. Upon completion and satisfied
with the workmanship of the maintenance team, the air test is repeated and held
at 1.2 bar. The leaking point is then sprayed. The procedure is repeated until no
air can escape the leaking point.
After air test done, shutdown process is continued with steam test. Steam test is
almost similar to air test butinstead of injecting air, steam is injected into the
vessels and pipelines. Steam test is conducted to check if there is any leakage
in the vessels and pipelines. But unlike air test, steam test is easier to detect
leak because steam will visibly shoot out from the leaking point when the
pressure is set high (about 1.5 to 2 bars). It is not necessary to maintain the
steam pressure higher than 2 bars as it is already more than sufficient.
For this n-butyl acetate plant, steam test is conducted at the beginning and at
the end of the shutdown. The final steam test is carried out to double check
before the plant start-up. Both steam tests have their own downside whereby
the first test will delay the cooling of vessels because steam is hot. Another
downside which applied for both earlier and later steam tests were the amount
of water produced as condensate from the steam. During plant cleaning,
existence of water is not really a problem but however, during plant start-up,
water has to be fully drained before pumping the fluid into plant.
Shutdown activity requires a lot of water for cleaning purposes. In addition to

that, "Cleaning in Progress" (CIP) for the shell and tube heat exchanger also
needs to be conducted. CIP is carried out to remove the scale and carbon
deposited inside the shell and tube in order to improve the heat transfer.
The annual or seasonal plant shutdown is the perfect time to inspect all the
equipment, make necessary repairs, and to prepare it for the layoff. Following a
step-by-step inspection, repair and maintenance procedure can ensure a safe
and reliable restart.
468
9.14 WASTE MANAGEMENT
The n-butyl acetate plant operates for 360 days per year and is shut-down in the
remaining 5 days for maintenance purposes. During the maintenance, a large
amount of water is used for cleaning and thus waste-water is generated. The
waste water contains small amount of hydrocarbons i.e. methanol, methyl
acetate, n-butanol and n-butyl acetate.
The waste-water will undergo two phases of treatment which are

pre-treatment and final treatment. For the pre-treatment, distillation method is
chosen. The process involved in this method is the separation of the heavy and
light component. The pre-treated waste-water will then be delivered to
Centralized Utility Facilities (CUF) for final treatment.
CUF is a project implemented by PETRONAS to support its

development plan in turning Malaysia into a regional petrochemical centre. CUF
is located strategically near two Integrated Petrochemical Complexes (IPCs) in
Kerteh, Terengganu and Gebeng, Pahang and the waste-water from the n-butyl
acetate plant will be delivered to the CUF at the IPC in Kerteh.
During the plant operation, gas will be released to the environment

and may cause pollution. To overcome the problem, the biofiltration system is
applied by installing filters and the gas will be filtered before it is released to the
environment.
469
9.15 PLANT LAYOUT CONSIDERATION
The economic construction and efficient operation of a process unit will depend
on how well the plant and equipment specified on the process flow-sheet is laid
out. There are several factors where must take consideration when laying out
the plant:
 Cost
The cost of construction can be minimized by adopting a layout that gives the
shortest ran of connecting pipe between equipment, and the least amount of
structural steel work. However, this will not necessarily be the best
arrangement for operation and maintenance.
 Convenience of operation
Equipment that needs to have frequent operator attention should be located
convenient to the control room. Valves, sample points, and instruments should
be located at convenient positions and heights. Sufficient working space and
headroom must be provided to allow easy access to equipment
 Convenience of maintenance
Heat exchangers need to be sited so that the tube bundles can be easily
withdrawn for cleaning and tube replacement. Vessels that require frequent
replacement of catalyst or packing should be located on the outside of
buildings. Equipment that requires dismantling for maintenance, such as
compressors and large pumps, should be placed under cover.
 Safety
Blast walls may be needed to isolate potentially hazardous equipment, and
confine the effects of an explosion. At least two escape routes for operators
must be provided from each level in process buildings.
 Future expansion
Equipment should be located so that it can be conveniently tied in with any
future expansion of the process. Space should be left on pipe alleys for future
needs, and service pipes over-sized to allow for future requirements.
470
9.16 PLANT LAYOUT
Plant layout refers to the arrangement of physical facilities such as machinery,

equipment, furniture etc. within the factory building in such a manner so as to have
quickest flow of material at the lowest cost and with the least amount of handling in
processing the product from the receipt of material to the delivered of the finished
product. According to Riggs, “the overall objective of plant layout is to design a physical
arrangement that most economically meets the required output – quantity and quality.”
According to Mecklenburgh (1985), “Plant layout ideally involves the process unit and
ancillary buildings should be laid out to give the most economical flow of material and
personal around the site”. Plant layout is an important decision as it represents long-
term commitment and important in order to determine the value of the total operation of
a company, such as processes, instrumentation, storage, reservoir, transport, and
administration.
A good plant layout will consider many aspects such as environment, worker,
cost, efficiency and many more. Therefore, it is very important to prepare a complete
plant layout specifically. Layout planning requires a broad range of knowledge including
latest and sophisticated technology in order to ensure the plant will be run under the
greatest efficient and at the same time, the worker will expose to the lowest amount of
hazard as possible.
These kind of knowledge can be acquires from a specific research in industry or

can be straightly acquires from an experienced engineers and also from consultants. In
order to design a plant there are steps that must be follow otherwise the plant will not
be suitable to build and run. The first is recognizing a societal or engineering need. This
step can be done by doing serious research about market demand, running cost,
market potential and many more. The next step is to create potential solution in order to
meet this need. This can be done by setting the objective or goal and re-confirm the
objectives as the time progresses. This can be done by analysis of the values that been
recorded during the progress until the end of the design stage.
There are significant amount of consideration that must be taken seriously. Firstly, the
most important thing is Health and Safety Hazards. Hazard can exist invidious ways
and time. Therefore, as an engineer, it is important to well recognize the source of
hazard, exposure of hazard, and controlling the exposure of hazard. Therefore,
471
hazardous process must be located at a safe distance from other buildings.

Considerations are also including future expansion of the site. Another factor that need
to be considered are construction and operation cost, appearance to surrounding,
safety and emergency consideration, process and economic considerations and also
convenience of operation maintenance.
9.16.1 Main Units of the Plant
Table 9.7: Description of Main Units of the Plant
Main unit of the Description for each unit

plant
Office and Office and administration is the place to do activities related with
Administration financial, billing, record keeping, physical distribution and others.
This building will be built at a place relatively far from hazard of
the process, so we suggest the office building is far away from
process plant area and product tank area. This building occupy
by large number of person. This is also are place where the
management is done and the contact with government, supplier,
branches and other company will be handled. Meeting of board
officers with the engineers, workers and customer also will be
held in this building.
Canteen and For the convenience of staffs and workers, the canteen and
Prayer Room prayer rooms are located near the office and administration
building
Security Room or Security room is the room for the security officers (guard) will be
Post Guard brief every day before work. This room authorized for the guard
only. This room is equipped with monitors for surveillance
cameras (CCTV) and control panel for security purposes. It is
situated near the administration building. This is the place where
all the movement inside and outside of the plant will be
monitored. Guard house is situated at every entrance to check
the incoming and outgoing vehicles.
Parking Lot and These are a relatively large separated open space that used for
472
Assembly Point parking and emergency assembly point. All of this space is
located near the entrances. The parking space is used by the
worker and staff and visitor. The emergency assembly point is
use during emergency cases such as fire and fire drill practice.
Fire Station Fire station is located near the warehouse and process plant
building. This is to makes it easier if something happen as
examples explosions from either building. Thus, time taken for an
explosion needs to be control will be reduced.
Laboratory The building is segregate into three parts. First part is cultivation
laboratory. This lab is for inoculums are prepared. The second
part of this laboratory is microorganism storage. Last part is
Research and Development laboratory (R & D).
Utilities Room The utility building such as pumps, reboiler, power generator and
cooling tower must be located near the plant. This is to make
sure that the plant operation will go on steadily and smoothly
Raw Material Tank This tank is located next to the process plant building and near to
the entrance gate. There are loading area near this tank for fast
and efficient flow of unloading process and loading process. The
purpose of this building is to store the raw material.
Product Tank This tank is located next to the process plant building. There are
shipping area near this tank for fast and efficient flow of
unloading process and loading process. The purpose of this
building is to store the product after complete all process.
Warehouse The warehouse is located next to the workshop. The purpose of
this building is to store the machine, raw materials and product
after packing. It also the parking place for the forklift and other
vehicles that used inside the plant.
Workshop The workshop building is located near to the fire station building.
This building is to make the repairing process for broken or
damaged equipment
473
Figure 9.1: Satellite view of Kerteh Industrial Area with the proposed site location (Courtesy of Wikimapia.com)
474
indicates the evacuation route in case of emergencies.)
Figure 9.2: Plant Layout for Production of Butyl Acetate
475

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Production of 100,000 Tonnes Per Year of Butyl Acetate

SAFETY & LOSS PREVENTION

In the n-Butyl acetate production plant, where it is handled, used, stored or

i) N-Butyl acetate properties.

The International Organization for Standardization (ISO) Standard 14011 covers

9.2OCCUPATIONAL SAFETY AND HEALTH ACT (OSHA) 1994

4. It is mandatory to all employees working in the plant to wear personal

9.3 EMERGENCY RESPONSE PLAN (ERP)

In an emergency response plan, emergencygives the meaning of accidents or serious

Communication is a crucial factor in handling an emergency. When an incident

The Emergency Control Centre would have plans which indicate:

A Works Incident Controller would be appointed and it is his function to proceed

In the communication of an emergency, when a serious accident occurs, it is

On declaration of an emergency, it is necessary for all personnel to know the

The procedures to be followed are:

a) All members of the workforce return to their normal place of work,

The items to be considered in an emergency response plant are listed below;

 Emergency organization chart with phone numbers and addresses.

 Identification of location of key emergency equipment, supplies, shelters,

When an emergency occurs, it would be necessary to evacuate all personnel

9.4 FIRE DETECTION AND PROTECTION

In addition, the following fire protection principles should be applied.

a) All rooms and spaces should be kept clear of combustible material

9.5 VAPOR CONTROL

source, and whether vapor is confined or unconfined. If ambient temperature is above

9.6 STORAGE TANK SAFETY FEATURES

9.7 PRESSURE RELIEF SYSTEM

configured to breathe to atmosphere through flame arresters. In addition to fire safety, it

9.8 SMOKING, VEHICLE ACCESS AND MISCELLANEOUS IGNITION SOURCES

Smoking must be restricted to a designated location that is free of potential chemical

Vehicle access must be strictly controlled and enforced.

Use of non-sparking tools is highly recommended.

As a rule of thumb, allow at least 20 feet (7 meters) of no ignition source

9.9 PRECAUTIONS FOR SPILLAGE AND LEAKS

Operation and maintenance procedures to prevent leaks and spills should

9.10 PRECAUTIONS FOR EXPLOSIONS

An explosion hazard is thought to exist,andone or more of the following measures must

Table 9.1: Summary of response to accident at the n-Butyl Acetate plant.

 Liquid very quickly evaporates, even at

Eyes  Wash eyes immediately, thoroughly

 Skin contact may cause drying or

 If n-butyl acetate has been spilled, it can be removed

9.11 HAZARDS AND OPERABILITY STUDIES (HAZOP)

A Hazard and Operability (HAZOP) study is a structured and systematic examination of

The HAZOP technique was initially developed to analyze chemical process

If HAZOP is started too late in a project, it can lose effectiveness because:

The objectives of HAZOP study are:

The advantages of HAZOP study to the design application:

The study is based on a set of „guide words„(identifying possible deviations). The

Table 9.2: A HAZOP study contains the following important features

Table 9.3: Hazop study on reactor (CSTR-100& CSTR-101)

Guide Deviation Possible causes Consequences Action required

Guide Deviation Possible causes Consequences Action required

Table 9.4: Hazop study on heat exchanger

High Fouling in tube Reduce heat transfer - Install pressure sensor

Table 9.5: Hazop study on distillation columns

Parameter: Level at Condenser

Deviations Possible causes Consequences Action required

Parameter: Level at reboiler

More -Steam suppliedtoinsufficiently. -no steam in reboiler 1) Inspection on thecontrol

Table 9.6: HAZOP analysis for decanters.

 Pumping system fails Install back up control

 Control valve not working Install back up control