LIST OF TABLES

Table 2.1: Description of Gasification Process Based on Schematic Diagram 9

Table 2.2: Description of Fischer-Tropsch Process Based on Schematic Diagram 10

Table 2.3: Description of Hydrocracking Process Based on Schematic Diagram 11

Table 2.4: Description of Isomerization Process Based on Schematic Diagram 12

Table 3.1: HAZOP Guide Words and Meanings 14

Table 4.1: Failure Rate Date for Various Selected Process Component 33

Table 4.2: Some Symbols Used in HAZAN Analysis and Its Descriptions 34

Table 4.3: Calculations for HAZAN Analysis 34

Table 4.4: Overall failure rate and mean time between failures (MTBF) 42

Table 4.5: Related Variable Cost that used in QRA Calculation 43

Table 4.6: Related Fix Operating Cost that used in QRA Calculation 44

Table 4.7: Quantitative Risk Assessment of Unit Operation 45

LIST OF FIGURES

Figure 2.0: Overall Flowchart of Branched Paraffin Production 8

Figure 2.1: Schematic Diagram of the Gasification Process 9

Figure 2.2: Schematic Diagram of the Fisher-Tropsch Process 10

Figure 2.3: Schematic Diagram of the Hydrocracking Process 11

Figure 2.4: Schematic Diagram of the Isomerization Process 12

Figure 3.1: Fluidized Bed Gasifier (R100) Before HAZOP Analysis 14

Figure 3.2: Fluidized Bed Gasifier (R100) After HAZOP Analysis 16

Figure 3.3: Acid Gas Scrubber (AGS200) Before HAZOP Analysis 17

Figure 3.4: Acid Gas Scrubber (AGS200) After HAZOP Analysis 19

Figure 3.5: Multi-tubular Fixed Bed Reactor (R300) Before HAZOP Analysis 19

Figure 3.6: Multi-tubular Fixed Bed Reactor (R300) After HAZOP Analysis 22

Figure 3.7: Hydrocracking Reactor (R400) Before HAZOP Analysis 22

Figure 3.8: Hydrocracking Reactor (R400) After HAZOP Analysis 24

Figure 3.9: Isomerization Reactor (R500) Before HAZOP Analysis 25

Figure 3.10: Isomerization Reactor (R500) After HAZOP Analysis 27

Figure 3.11: Distillation Column (DC600) Before HAZOP Analysis 27

Figure 3.12: Distillation Column (DC600) After HAZOP Analysis 30

Figure 3.13: Storage Tank (ST700) Before HAZOP Analysis 30

Figure 3.14: Storage Tank (ST700) After HAZOP Analysis 32

Figure 4.1: HAZAN Analysis of Entrained Flow Gasifier 35

Figure 4.2: HAZAN Analysis of Acid Gas Scrubber 36

Figure 4.3: HAZAN Analysis of Multi-tubular Fixed Bed Reactor 37

Figure 4.4: HAZAN Analysis of Hydrocracking Reactor 38

Figure 4.5: HAZAN Analysis of Isomerization Reactor 39

Figure 4.6: HAZAN Analysis of Distillation Column 40

Figure 4.7: HAZAN Analysis of Storage Tank 41

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EXECUTIVE SUMMARY

In this HAZOP and HAZAN part of our Branched Paraffin Synthesis Plant Design Project, we

discussed about several things such as types of hazards in industries; risk management plan; as

well as hazard operability (HAZOP) and hazard analysis (HAZAN) of our plant. There are few types

of hazards such as heat and temperature, pressure, electrical, mechanical, toxic material, fire and

explosion, and noise. Hence, it is very important to identify every single types of hazards in the

plant.

The Risk Management Plan defines how risks associated with the project will be identified,

analysed, and managed. There are four categories of Risk Management Plan. It outlines how risk

management activities will be performed, recorded, and monitored throughout the lifecycle of the

project and provides templates and practices for recording and prioritizing risks by the Risk

Manager and/or Risk Management Team. First is the role of safety personnel, where they should

be able to solve problems that may arise and prevent accidents regarding technical, legal, and

administrative activities. Second is the personal protective equipment (PPE). This equipment helps

to protect a person from damage. Then next is assessing the plant safety and practices. The safety

assessing is a means to design and construct an accident free facility by analysing accident

frequencies and severity. Fourth, they need to plan for emergencies so that the effect of any

accident can be minimized by providing emergency relief (rescue) in the shortest time possible to

the victim.

Hazard and operability (HAZOP) is a technique for identifying hazards without waiting for

an accident to occur. A HAZOP is a systematic procedure to analyse the hazards associated with

each process pipeline, applying the following guide words: NONE, MORE OF, LESS OF, REVERSE,

OTHER THAN, PART OF, MORE THAN. It 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.

Hazard analysis (HAZAN) is a technique for estimating the probability and consequences of

a hazard. The term Hazard Analysis (HAZAN) covers a range of techniques which are, as the

phrase implies, used to analyse hazards. Typically, this includes analysing the consequences of

hazards and the safeguards for hazard prevention or mitigation. Many hazard techniques have

been developed for a variety of different end requirements such as Fault Tree Analysis (FTA),

Event Tree Analysis (ETA), Failure Modes, Effects and Criticality Analysis (FMECA) and Hazard and

operability (HAZOP). Due to the overall failure rate of entire plant is high, hence a proper

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prevention steps and maintenance of the equipment and device is necessary in order to increase

reliability and reduce the occurrence of failure in the plant.

Besides HAZOP and HAZAN, Quantitative Risk Assessment (QRA) also need to be done to

numerically determine quantitative estimates of risks, given the parameters defining them. QRA is

primarily concerned with determining the potential loss of life (PLL) caused by undesired events.

The value of the potential losses with processing or the destruction of property or data needs to

be determined so that the probability of the occurrence of the risk failure can be estimated. Hence,

the annual loss expectancy is calculated.