Rev:03

UoN CEE HAZID WORKBOOK Date: Sep 2017

UoN HAZID WORKBOOK

PROJECT TITLE: Water Gas Shift Process

PROJECT GROUP No. Group 28

PROCESS OPTION DESCRIPTION:

PROJECT TEAM MEMBERS Jordan Glass

Sukhraj Sahota
Joseph West
Rebecca Tan
Aleksei Sukhov
Yaxuan Li

REVISION
DATE

Reference: CEEDG101 UoN CEE HAZID Procedure

 Rev:03
UoN CEE HAZID WORKBOOK Date: Sep 2017
 Rev:03
UoN CEE HAZID WORKBOOK Date: Sep 2017

MATERIALS ASSESSMENT DATA SHEET

Regulation (EC) No 1272/2008 - DATE: 21/2/2018 COMPILED BY: PROJECT GROUP REVISION No.
Classification, Labelling and Packaging R.TAN 28
of Substances and Mixtures
Symbol(s)

MSDS Phase?
Available? (Gas, Liq,
Solid etc.)

GHS 08; Systemic Health Issues

GHS 01: Unstable/Explosive

GHS 04:Compressed Gas

NOTABLE HAZARD STATEMENTS NOTABLE PRECAUTIONARY STATEMENTS

GHS 07: Irritant/Toxic

GHS 09: Environment

GHS 02: Flammable

GHS 05: Corrosive

GHS 03: Oxidising

GHS 06: Toxic

Yes Gas X X H220: Extremely H280: Contains P210: Keep away from P377: Leaking gas fire: P381: Eliminate P403: Store in a
flammable gas gas under heat, hot surfaces, Do not extinguish, all ignition well-ventilated
pressure; may sparks, open flames unless leak can be sources if safe to place
explode if heated and other ignition stopped safely do so
sources. No smoking

Yes Gas X X X X H220: Extremely H280: Contains H331: Toxic if H360D: May H372: Causes P202: Do not handle P210: Keep away from P260: Do not P377: Leaking gas P403: Store in a
flammable gas gas under inhaled damage the damage to until all safety heat, hot surfaces, breathe fire: Do not well-ventilated
pressure; may unborn child organs through precautions have been sparks, open flames and gas/vapours extinguish, unless place
explode if heated prolonged or read and other ignition sources. leak can be
repeated understood No smoking stopped safely
exposure

Yes Gas X H280: Contains P403: Store in a well-

gas under ventilated place
pressure; may
explode if
heated

No Liq

No Gas

Yes Solid X H315: Causes H319: Causes H335: May cause P261: Avoid breathing
skin irritation serious eye respiratory dust/fume/gas/mist/va
irritation irritation pours/spray

Yes Solid X X H302: Harmful if H410: Very toxic P273: Avoid release to P501: Dispose of
swallowed to aquatic life the environment contents/container to a
with long lasting licensed disposal
effects company

Yes Solid X H410: Very toxic P271: Use only P501: Dispose of
to aquatic life outdoors or in a well- contents/container to a
with long lasting ventilated area licensed disposal
effects company

Page 3 of 9
 Rev:03
UoN CEE HAZID WORKBOOK Date: Sep 2017

MATERIALS ASSESSMENT DATA SHEET

Regulation (EC) No 1272/2008 - DATE: 21/2/2018 COMPILED BY: PROJECT GROUP REVISION No.
Classification, Labelling and Packaging R.TAN 28
of Substances and Mixtures
Symbol(s)

MSDS Phase?
Available? (Gas, Liq,
Solid etc.)

GHS 08; Systemic Health Issues

GHS 01: Unstable/Explosive

GHS 04:Compressed Gas

NOTABLE HAZARD STATEMENTS NOTABLE PRECAUTIONARY STATEMENTS

GHS 07: Irritant/Toxic

GHS 09: Environment

GHS 02: Flammable

GHS 05: Corrosive

GHS 03: Oxidising

GHS 06: Toxic

Page 4 of 9
 UoN CEE HAZID WORKBOOK Rev:03
Date: September 2017

HAZARDS INVENTORY
PROJECT: DATE:21/2/2018

OPTION: REVISION No:

PFD Drawing No:
GROUP No. 28 SECTIONS PRESENT COMPILIED BY: R.TAN

Section 1: Reactor Delivery and Heat Exchangers

Section 2: Condenser & Flash Separator

SPECIFIC HAZARDS COMMENTS

Section 3:

Section 4:

Section 5:
Flammable Materials X X Hydrogen gas may ignite due to an invisible spark
Toxic Substances X X Carbon Monoxide gas is highly toxic
Gases under High Pressure X X
Liquids under High Pressure X X
Hot Fluids X
Cryogenic Fluids
Oxidising Materials
Material

Reactive/Unstable Materials
Explosive Substances
Corrosive Materials
Poisonous Materials X X
Biological Hazardous Materials X X
Ecotoxic Materials X Catalysts in reactors used are toxic to biological organisms
Combustible Dusts

High Speed Rotational Equipment

Equipment Under Pressure X X Pressure drop of cooling water over condenser
Equipment at High Temperature X
Equipment

Equipment at Low Temperature

Lifting Equipment
Ionising Radiation Present
General Non-Ionised Radiation Present

Exothermic Reaction X The water gas shift reaction is a mildly exothermic reaction
Endothermic Reaction
Runaway Reaction
Catalyst Poisoning X May occur if temperatures exceed the maximum operating temperature of
catalysts
Explosive Reaction
Process

High Pressure X X
Low Pressure/Vacuum
Pressure Cycling
High Temperature X
Low Temperature
Temperature Cycling

Ground Conditions
Transport/Traffic
Natural Hazards
Manual Operations
Sampling
Other

Maintenance X X
Working At Height
Noise

Page 5 of 9
 UoN CEE HAZID WORKBOOK Rev:03
Date: September 2017

PROJECT: Water Gas Shift Process HAZID DATE: 2/24/2018

PFD DRAWING No. Mo. 001 PROJECT GROUP No.: Group 28

PARTICIPANTS: J.Glass, S.Sahota, J.West, R.Tan, A.Sukhov and Y.Li

FACILITY SECTION No.: 1 of 2 PARTICIPANTS SIGNATURES: JG, SS, JW, RT, AS and YL

FACILITY SECTION DESCRIPTION From inlet mixing till the second Heat Echanger REVISION: first

Hazard Consequence Ranking Assuming

Controls in Place
Action/Consideration in Design Process to Mitigate Hazard Consequences

No. Specific Hazard Potential Mechanism(s) for Hazard Potential Hazard Consequences Proposed Mitigation Controls In Place Likelihood Severity Risk Unique Description of Actions/Consideration Action Assigned To: Action Required Issue Status Action Outcome
From Hazard Inventory Exposure (Dropdown) (Dropdown) Rating Action Completion Date (Open/Closed)
No.
1 Flammable Nature of Hydrogen (H2) Containment Failure because of multiple valve Jet fires resulting in radiant heat with Regular surveys to be carried out to check valves that are expected to 2 3 6 1.1 Review appropriate design code for hydrogen J.Glass 3/31/2018 OPEN
failure/ loss of isolation leading to gas leakages potential to cause fatalities and secondary be closed during normal operating conditions to ensure they are handling. Appropriate materials that follow industry
events resulting in failure of supporting sealed. Use of an acoustic detection and quantification device to standards are to be used for piping and valves to keep
structures and equipment damage. determine the conditioning of valves and their tendency to leak. the system isolated. Industrial standards to be
Scheduled monthly valve inspection with the record of conditioning followed for testing and maintenance; all of the
and specific values for the leakage quantities. Annual consultant visits requirements included with piping specification.
to advise maintenance team and suggest valve swaps.

2 Systemic Health Issues associated with Carbon
Monoxide(CO)
Containment Failure because of corrosion of
valves/ pipe welding's/ flanges
Carbon monoxide primarily causes adverse Non-corrosive materials can be used in the design; drying agents and 1 3 3 1.2 Elimination the potential mechanism for hazard S.Sahota 3/20/2018 OPEN
effects by combining with haemoglobin thus  moisture barrier products used. Scheduled monitoring of the state of exposure can be by using non-corrosive materials in
preventing the blood from  pipes and valves for levels of corrosion. Leaks are identified and the design. Coating parts with non corrosive material
carrying oxygen. This leads to oxygen  managed according to the industrial standards. e.g. painting or adding grease in cracks of the valves,
will lead to minimising corrosion in a temporary way,
starvation by the body and causes   sufficient enough for maintenance during shutdowns.
suffocation. 

3 Irritant Nature of Copper (ll) oxide Maintenance work when the catalyst has to be Hazard Statements Harmful or Lethal if Follow industrial procedures for the catalyst replacing. When handing 2 3 6 1.3 The structure of the catalyst may be designed to Y.Li 3/20/2018 OPEN
replaced/ maintained Swallowed. Can cause irritation of eyes, skin, the catalyst, Personal has to wear appropriate protective wear or minimise the exposure to the hazard. Structure
and respiratory tract. Avoid contact with eyes special team of well train engineers should perform this activity. designed to have no mobile dust particles.
and skin. Avoid breathing dusts.

4 Toxic Nature of Copper (ll) oxide and Zinc (ll) 1.4 OPEN
oxide to the aquatic life

5 Gas Under high pressure (Syngas and Steam)
and Equipment under high pressure (Two
reactors) Process stream
under high pressure (15.5barg)
Process deviation resulting in overpressure due
to process control system failure of Specific
Pressure Regulator along side extensive erosion
Release of all of the reactants and products,
energy; potential of secondary impact of fire
caused by hydrogen presence
Appropriate design codes put in place when considering materials for 1 3 3 1.5 Confirm that appropriate material had been specified J.West OPEN
Piping and Instrumentation. Reactors should be capable to withstand for Reactors one R001A and two R002A, all of the
pressure higher than operational ones, pressure relief systems are well pipes and similarly for both of the Heat Exchangers
designed and if engaged, the process fluid fluid is dealt with E001A and E002A. Industry standard cleaning and
appropriately. testing requirements are included within the piping
specification.

6 Gas Under high pressure (Syngas and Steam)
and Equipment under high pressure (Two Heat
Exchangers) Process stream
under high pressure (15.5barg)
7 High Pressure Steam
Containment Failure because of overpressuring
the process fluid in the heat exchanger
Containment failure of steam piping, heat
exchanger to external environment due to
corrosion
Quantitative risk assessments as well as employing specialist 3 3 9 1.6 Institute of Petroleum gives further recommendations R.Tan 31/06/2018 OPEN
consultants to undertake computerised dynamic simulations of the for the assumptions to be made when modelling the
pressures generated within the units in the event of a tube failure. fluid dynamic aspects of tube rupture. One
These simulations make a number of simplifying assumptions, but the dimensional modelling can be considered as with the
accuracy of their modelling predictions is unknown assumptions provided, this should help to ensure that
The consequences range from catastrophic sufficiently accurate predictions are made when
failure of the heat exchanger shell with considering risks.
associated mechanical damage to nearby
process plant, fires, personnel injury and
mechanical damage as a result of
pressurisation of the cooling water system.
Release of steam and other reactants, energy Site steam piping and specification and standards to be used . 1 2 2 1.7 Ensure the requirement to insulate high temperature
lines are addressed within the piping specification

8 High Temperature of Process fluid out of the 1.8

reactor 1

9 1.9

10 2.0

11 2.1

12 2.2

13 2.3

14

15

Page 6 of 9
 UoN CEE HAZID WORKBOOK Rev:03
Date: September 2017

PROJECT: Water Gas Shift Process HAZID DATE: 2/24/2018

PFD DRAWING No. Mo. 001 PROJECT GROUP No.: Group 28

PARTICIPANTS: J.Glass, S.Sahota, J.West, R.Tan, A.Sukhov and Y.Li

FACILITY SECTION No.: 1 of 2 PARTICIPANTS SIGNATURES: JG, SS, JW, RT, AS and YL

FACILITY SECTION DESCRIPTION From inlet mixing till the second Heat Echanger REVISION: first

Hazard Consequence Ranking Assuming

Controls in Place
Action/Consideration in Design Process to Mitigate Hazard Consequences

No. Specific Hazard Potential Mechanism(s) for Hazard Potential Hazard Consequences Proposed Mitigation Controls In Place Likelihood Severity Risk Unique Description of Actions/Consideration Action Assigned To: Action Required Issue Status Action Outcome
From Hazard Inventory Exposure (Dropdown) (Dropdown) Rating Action Completion Date (Open/Closed)
No.
16

17

18

19

20

21

22

23

24

25

26

27

28

29

30

31

32

Page 7 of 9
 UoN CEE HAZID WORKBOOK Rev:03
Date: September 2017

PROJECT: Water Gas Shift Process HAZID DATE: 2/24/2018

PFD DRAWING No. Mo. 001 PROJECT GROUP No.: Group 28

PARTICIPANTS: J.Glass, S.Sahota, J.West, R.Tan, A.Sukhov and Y.Li

FACILITY SECTION No.: 1 of 2 PARTICIPANTS SIGNATURES: JG, SS, JW, RT, AS and YL

FACILITY SECTION DESCRIPTION From inlet mixing till the second Heat Echanger REVISION: first

Hazard Consequence Ranking Assuming

Controls in Place
Action/Consideration in Design Process to Mitigate Hazard Consequences

No. Specific Hazard Potential Mechanism(s) for Hazard Potential Hazard Consequences Proposed Mitigation Controls In Place Likelihood Severity Risk Unique Description of Actions/Consideration Action Assigned To: Action Required Issue Status Action Outcome
From Hazard Inventory Exposure (Dropdown) (Dropdown) Rating Action Completion Date (Open/Closed)
No.
33

34

35

36

37

38

39

40

41

42

43

44

45

46

47

48

49

Page 8 of 9
 UoN CEE HAZID WORKBOOK Rev:03
Date: September 2017

PROJECT: Water Gas Shift Process HAZID DATE: 2/24/2018

PFD DRAWING No. Mo. 001 PROJECT GROUP No.: Group 28

PARTICIPANTS: J.Glass, S.Sahota, J.West, R.Tan, A.Sukhov and Y.Li

FACILITY SECTION No.: 1 of 2 PARTICIPANTS SIGNATURES: JG, SS, JW, RT, AS and YL

FACILITY SECTION DESCRIPTION From inlet mixing till the second Heat Echanger REVISION: first

Hazard Consequence Ranking Assuming

Controls in Place
Action/Consideration in Design Process to Mitigate Hazard Consequences

No. Specific Hazard Potential Mechanism(s) for Hazard Potential Hazard Consequences Proposed Mitigation Controls In Place Likelihood Severity Risk Unique Description of Actions/Consideration Action Assigned To: Action Required Issue Status Action Outcome
From Hazard Inventory Exposure (Dropdown) (Dropdown) Rating Action Completion Date (Open/Closed)
No.
50

51

52

53

54

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