University of Sheffield

Department of Chemical & Process Engineering

HAZOP RESULT SHEET

Plant: Biodiesel Production

Equipment: Transesterification CSTR

Tag No: G

Properties: Flow, Pressure Temperature

Guide Words: None, More, Less, Opposite, As well as, Other than

Special notes: None Line No. L1 Deviation No Flow Cause V1 shut, failure Pipe blockage Pipe leakage before line L1 Equipment failure before line L1 No reactants V1 more open than usual Pipe diameter Consequences Production ceased Equipment damage due to operation without material Action Bypass valve Valve should remain open on failure Regular maintenance Regular check

L1

More Flow

Reaction rate decreased

Flow control on oil fresh feed

L1

Less Flow

V1 partially shut Pipe leakage Tanks flip out due to electricity failure, V1 still open Excessive heating of feed stream by H1

L1

Opposite Flow

Less reactor yield Loss of feed material Contamination of feed Contamination of oil in fresh feed tank Overheating of reactor

Flow control on oil fresh feed Regular maintenance Use a non-return valve

L1

More Temperature

L1 L1

Less Temperature More Pressure

Lack of heating of feed stream by H1 Pipe blockage

Reduced conversion Reactor pressure increased, explosion hazard Less reactor yield Production ceased Equipment damage due to operation without material

Heat exchanger, HE1, to cool reactor Temperature control on L1 linked to V4 Temperature control on L1 linked to V4 Relief valve Regular maintenance Regular maintenance Bypass valve Valve should remain open on failure Regular maintenance Regular check

L1 L2

Less Pressure No Flow

L2

More Flow

L2

Less Flow

Pipe leakage V2 shut, failure Pipe blockage Pipe leakage before line L2 Equipment failure before line L2 No reactants V2 more open than usual Waste of raw material Pipe diameter feed, more recycle, waste energy, increase costs V2 partially shut Less reactor yield Pipe leakage Loss of feed material Contamination of feed

Feed flow control on V2

Feed flow control on V2 Regular maintenance

L2

Opposite Flow

L2

More Temperature

Tanks flip out due to electricity failure, V2 still open Excessive heating of feed stream by H2

Contamination of methanol in fresh feed tank Overheating of reactor

Use a non-return valve

L2 L2 L2 L3

Less Temperature More Pressure Less Pressure No Flow

Lack of heating of feed stream by H2 Pipe blockage Pipe leakage V3 shut, failure Pipe blockage

Reduced conversion Reactor pressure increase Less reactor yield No product Reactor level increased

Heat exchanger, HE1, to cool reactor Temperature control on L2 linked to V5 Temperature control on L2 linked to V5 Relief valve Regular maintenance Level control of reactor linked to V3 Regular maintenance Level control of reactor linked to V3 Level control of reactor linked to V3 Regular maintenance Bypass valve Flow control of cooling water depending on temperature of cooling water into HE1 Flow control of cooling water depending on temperature of cooling water into HE1

L3 L3

More Flow Less Flow

L3

More temperature

L3

Less temperature

V3 more open than usual Reactor level decreased Pipe diameter V3 partially shut Reactor level increased Pipe leakage Loss of products Contamination of products Cooling water flow Overheating of reactor system in HE1 failure Vapour formation in Lack of cooling water reactor increased flow in HE1 pressure explosion Cooling water pipe leak hazard Excessive cooling in Reduced rate of reaction HE1

L3

L3

L3

L3 L3

Reaction mixture as well as cooling water in reactor Cooling water as well as reaction mixture in cooling water stream in HE1 Another material in cooling water stream in HE1 More pressure Less pressure

Cooling water leakage into reactor products Reaction mixture leakage into cooling water stream Contamination

Reaction ruined Loss of products Reaction ruined Contamination of cooling water Loss of products Lack of cooling of reactor Pipe may burst loss of products Loss of products

Regular maintenance

Regular maintenance

Isolation of cooling water supply Regular maintenance Regular maintenance

Pipe blockage Pipe leakage

BEFORE
From Oil fresh feed and recycle from distillation column

Hot water in

Hot water in

V4

H1

Hot water out

L1
V1 V6

V5

Cooling water in Cooling water out

From Methanol fresh feed and recycle from flash vaporiser & fresh NaOH feed

H2

L2
Hot water out

V2

HE1

V3

L3

To flash separator

* Drawing not to scale For HAZOP purposes only

Anitha Nair April 2005 Department of Chemical and Process Engineering

AFTER
From Oil fresh feed and recycle from distillation column

Hot water in
V5

Hot water in

V4

H1
TC

Hot water out

L1
FC

L
V6

FC

Cooling water in Cooling water out

From Methanol fresh feed and recycle from flash vaporiser & fresh NaOH feed

TC

V3

V2

V1
LC

L2
Hot water out

HE1

V3

L3

To flash separator

* Drawing not to scale For HAZOP purposes only

Anitha Nair Thing Jin Suan April 2005 Department of Chemical and Process Engineering