COMBINING TRADITIONAL UOP HAZOP ANALYSIS · PDF fileCOMBINING TRADITIONAL UOP HAZOP(*) ANALYSIS WITH DYNAMIC SIMULATION ... Combining Traditional UOP HAZOP Analysis ... Cumene Normal

2015 Honeywell Users Group

Europe, Middle East and Africa

COMBINING TRADITIONAL UOP HAZOP(*) ANALYSIS WITH DYNAMIC

SIMULATION - A NEW PROCESS SAFETY / RISK ASSESSMENT TOOL

Bill Wiede & Scott Wozniak – UOP LLC, A Honeywell Company

© 2015 Honeywell. All rights reserved.

(*) Hazard and Operability

2 © 2015 Honeywell International All Rights Reserved

Combining Traditional UOP HAZOP Analysis

with Dynamic Simulation

• Determine consequences of deviations from normal design

• Can identify new, unrecognized hazards and issues

• HAZOP Teams can test effectiveness of strategies for emergency situations

• Provides significant Added Value to UOP HAZOP analysis and reports

• Allows additional Customer-driven analyses to be performed

• Shows UOP commitment to Process Design Safety & Reliability

A Process Safety / Risk Assessment Tool


•Rotating Equipment• Pressure Relief

• Process Control & Instrumentation

• Flowsheet Specialists (SATDSC)

UOP HAZOP Team

UOP

HAZOP

Team

OtherUOP SkillExperts

HAZOPMethodology

Expert

ProcessExpert

Customer/Contractor

TechnologyExpert


As Low As Reasonably Practical(ALARP)

Cost In

cre

asin

gR

isk Incre

asin

g

Magnitude of Risk

Intolerable

ALARP

Tolerable

Intolerable Levels of RiskAdverse risks are intolerable

Tolerable Levels of RiskA level of risk that is tolerable

Ideal Levels of RiskRisks are negligible or very small


Risk Ranking Process Hazard Analysis

Severity:

1. Catastrophic2. Severe3. Moderate4. Low

Likelihood:

1. Frequent2. Occasional3. Moderate4. Unlikely

1 2 3 4

1 D D C A

2 D C B A

3 C B A A

4 B A A A

Lik

elih

ood

Risk

RankingDefinition

D Risk not acceptable

C

Risk acceptable with additional administrative or engineering controls which lower the risk ranking to “A” or “B”

BRisk acceptable with additional administrative or engineering controls

ARisk acceptable even if no further action taken

NR Not Ranked (insufficient information)


Using Dynamic Simulation in UOP HAZOP

Dynamic Simulation Flowsheets (Templates)

• Constructed from Steady-State templates used in

Schedule A / Revamps

• Covers over 100 existing UOP Process Technologies

• Constructed for All New Process R&D Technologies


UOP Refining Processes

Treating

Treating

Hydrocracking

C4Isomerization

Gasoline

Kerosene& Jet Fuel

Diesel

To Black OilHydrocracking

DesaltedCrude Oil Atmospheric

Gas Oil

Middle Distillate

LightNaphtha

HeavyNaphtha

Kerosene

Hydrogen

Sulfur

From FCC

Lube Oils

Fuel Oil

CokeAsphalt

CrudeDistillation

VacuumDistillation

Cycle Oils

LPG

Hydrotreating

Hydrotreating

Hydrogen Purification

Reforming

Light NaphthaIsomerization

H2 PlantAmine Treating

GasConcentration

CatalyticCondensation

Treating

FCC

SelectiveHydrotreating

Treating

AlkylationSHP

Hydrotreating

Hydrotreating

Black Oil

Treating

Treating


UOP Petrochemical Processes

MethanolSynthesis

Methanolto Olefins

C3/C4Dehydrogenation

C 4Processes

Pressure SwingAdsorption

EBDehydrogenation

Oxidation& Cleavage

Hydrogenation

Isomerization& Transalkylation

OlefinRecovery

Alkylation

ParaffinDehydrogenation

n-ParaffinRecovery

MethanolEthylene

Propylene

MTBE

Mixed Xylenes

Butene-1

1,3 Butadiene

HeptenesOctenesNonenesDodecenes

High PurityHydrogen

Styrene

Phenol

Acetone

Cyclo-hexane

PETResin

Benzene, Tolueneo-Xylene, m-Xylene

NormalParaffins

LinearMono-Olefins

LinearAlkyl-benzene(LAB)

Ethylene Ethylbenzene

Benzene

PropyleneCumene

NormalParaffins

Benzene

Kerosene

CoalPetroleum Coke

bio-mass

Methane

Ethane

Propane

Butanes

Naphtha

Gas Oil

Gasoline & Aromatics

Olefins

Aromatics

Detergents

SteamCracking

OlefinCracking

HighSeverity FCC

Feedstocks

PropyleneRecovery

CatalyticCondensation

pX

SSPMeltPoly

PTA

NaphthaReforming

Alkylation

Alkylation

AromaticsRecovery

n-ParaffinRecovery


Column

Receiver

ReboilerVaporization

Indicator

ReboilerSump

SS-ExchangerOutlet Temps

TrimCondenser

Condenser

OverheadPump

RC-Reflux/FeedController

Reflux/FeedRatio Selector

Product Rate@ Main

Feed

Btms fromFeed-BtmsExchanger

MP SteamSource

MP SteamOutVLV-100

PIC-ColumnPressure

LIC-Receiver

FIC-Reflux

FC-MPSteam

SS-Reflux/Feed Ratio

Bottoms to SUMP

RCY-1

LIC-SUMP@ Main

RCY-2

SUMP Vapor

Boilup

SS-Bottoms

Feed-BottomsExchanger

RCY-3R

R

R

PSV

PowerSource

UNISIM Dynamic Conventional Column Model


Conventional Column –

Loss of Reflux

LIC

FI

PIC

FICHP

Steam

Condensate

BottomsCooler

Bottoms Trim Cooler

TrimCondenser

Condenser

ToStorage

FI

LIC

PIC

RefluxPumps

From FlowController

From PressureController

From Separator

To RegenerantVaporizer

From RegenerantVaporizer

FI

Reboiler

CoolingWater

CoolingWater


3”3”

Distributor

PG2066

PT206T

PIC206T

LIC206T

PDY2068

PDI2068

SC-132006

x212063A

x212063B

xZSC2033

xZSO2033

xY2033A

xY2033B

TT2049

TE2049

TW2049

XV2033

TI2049

UX

UX

S SR R

FIC2020

I090SLP

LC2019

LT2020

Vent

DE DE

6 6

5

Two Phase Flow

FF

MAG

4

D/PFF

1500

EL=4800

3”

8”

8”

3”

-I40PRO-240-B2AI-NI-NT

FC

¾”

8”-I40PRO-055-B2AI-NI-NT

4”-I

40P

RO

-056

-B2A

I-N

I-S

T

6”-I40PRO-243-B2AI-NI-NT

8”-I40PRO-240-B2AI-NI-NT6”-I40PRO-241-B2AI-NI-NT

2”-I40SLP- -MS-II-NC-NT

¾”

MS-II BIAI

24”

10”MW

ΔIS

SP

O

C

H

L

Expanded P&ID View –

Column Receiver


Dynamic Upset – Loss of Reflux

XV-2033 - Actuator Current Position (%)

Overhead Vapor Fraction

SUMP Liquid Level (%)

Reflux to Column (lb/hr)

Flow Through PRV (lb/hr)

Column Operating Pressure (psig)

Overhead Vapor Rate (lb/hr)

0.0 (lb/hr)


UOP Phenol Process13

Spent Air

Air

AMS

Acetone

Phenol

Residue

H2

Phenol and Acetone

Purification

OxidationConcentration

AMS Hydrogenation

DecompositionNeutralization

Cumene


UNISIM Dynamic Oxidizer Model

No. 1

Tank

Liquid from

No. 1 Tank

PI

1003

TIC

Vapor from

No. 1 Tank

From

No. 1 Tank PSVPSV

FI Vapor

FV-901

Air Feed

CV

UV-901

Isolation

Valve

Feed to No. 1 Tank

Air to

No. 1 Tank

FIC Air

Heat

Input


Expanded P&ID View –

Air Feed / Isolation Valves

UCI20I

PDALLI20I

Free Draining

PDI0902

8”

¾”P

8”

20”

FE090I

FIC090I

LYI002

FAL

FY090I

FV090I

Vent

De

FC16”

3/4”P

8”INS

6”

65 RO

20”

CRITPDAL

MIN

UCI20I

DEVent

SFC

FIC0902

HIC0902

FE0902

HV0902

3” Nitrogen3”

¾”P

Handwheel

InstrumentAir

HS090I

UCI20I

Reset

UY090I

UV090I

MIN

LO

4”

LocateNear Valve

FT0902

I

FT090I

PDT0902

POSLL S


Dynamic Upset-Valve Stroke Times

Isolation ValveTime to Close

Air Feed ValveTime to Close

No. 1 Tank Pressure


Ongoing Efforts

• Improve Knowledge Transfer

• Provide Support for Training Simulator Development (OTS)

• Utilize available OTS Dynamic UNISIM templates in

ALL UOP Process Safety Analyses

• Evaluate Honeywell Control Systems (e.g. PROFIT Design Studio)

17

Continued Growth between UOP Engineering and HPS


Thanks for Listening !

[email protected]

Documents

COMBINING TRADITIONAL UOP HAZOP ANALYSIS · PDF fileCOMBINING TRADITIONAL UOP HAZOP(*) ANALYSIS WITH DYNAMIC SIMULATION ... Combining Traditional UOP HAZOP Analysis ... Cumene Normal