FACULTY OF CHEMICAL ENGINEERING

UiTM SHAH ALAM

PROCESS SAFETY

FORMALDEHYDE
PRODUCTION
 TEAM MEMBERS:

KAMILIA BT CHE MUHAMMAD FAIZ NOR ATIQAH BT

IDZAHAR B CHE LAH AZIZAN
2015249188 2014807942 2015837172

NUR LIYANA BT ROZIKIN NURUL NADIAH MUHAMMAD

2015282684 HASHIM
201567796
INTRODUCTION
 Colorless
Pungent odor
Flammable
Definition Formula = CH2O

Block Flow Chemical

Diagram Reaction
FORMALDEHYDE
FORMALDEHYDE
PRODUCTION
PRODUCTION

Manufacturing of
Process construction
Flow materials
Diagram & Application Production of
Process industrial resins
Description Cosmetics industry
 Flare
Deionized water

Air Makeup water

Makeup methanol
Reactor
Cooling Tower

Methanol

Product (Formalin)
 HIRARC
HAZARD IDENTIFICATION, RISK
ASSESSMENT & RISK CONTROL
Determining what risks or hazards exist
or are anticipated, their characteristics,
remoteness in time, duration period,
and possible outcomes.

HAZARD
IDENTIFICATION

Process Hazards checklists

Hazards surveys
Hazards and operability studies
Safety Review
 PROCESS HAZARD CHECKLISTS
Table 1.1: Process Hazard Checklists
A. HEALTH 1. Can anyone be suffocated or drowned due
to lack of oxygen, or atmospheric
contamination?

B. ELECTRICAL 1. Can anyone be injured by electric shock

due to the plant coming into contact with
live conductors?
2. Plant being too close to high tension
power lines?
3. All equipment properly labelled?
4. Tubing runs protected?
5. All equipment grounded?
6. Lack of insulation against water contact
shorting?
C. STABILITY 1. Can machine tip or roll over due to
outriggers not extending?
2. Control valve or interlock failure?
3. Set up on soft ground, uneven ground or
excessive slope?
4. Driving on rough surfaces, over potholes
or hitting fixed objects?
D. STRUCTURAL 1. Pin, cable or linkage failure?
2. Lifting excessive load in an untended
way?
E. HYDRAULIC 1. Hydraulic system failure?
2. Valve or relief valve failure?
F. EQUIPMENT 1. Any cause of pump failure?
2. Feed valves fail to open?
3. Heat exchanger tube leaks?

G. SAFETY HAZARD
-Slipping,tripping,
ergonomics, fire hazard from
flammable material, moving
part of machinery , vehicles,
lifting and manual handling
1. Can anyones hair, clothing, gloves, cleaning
apparatus or any other materials become
entangled in moving parts?
2. Crushing due to material falling from plant.
3. Cutting, stabbing & puncturing due to contact
with sharp or flying objects?
4. Parts of plant or worksite material
disintegrating or falling?
5. Can anyone be struck by moving objects due to
unexpected movement of plant?
6. Can anyone be injured due to the design of
seating or due to repetitive body movements?
7. Constrained body posture or the need for
excessive effort?
8. Poorly placed lighting?
9. Mismatch of plant with natural human
limitations?
10. Can anyone come into contact with objects at
high temperature or objects which can cause
fire or burning?
11. Can anyone be injured by explosion of gases,
vapours, liquids, dusts or other substances
triggered
 Analyze and evaluate the risk associated with
that hazard (risk analysis, and risk evaluation).

RISK DESCRIPTION ACTION

1-5 LOW A LOW hazard may be considered as acceptable

and further reduction may not be necessary.
Usually can be resolved quickly and efficiently
Severity(S)
with correct control.
Probability(P) 1 2 3 4

1 1 2 3 4 6-10 MEDIUM A MEDIUM risk requires a planned approach to

controlling the hazard and applies temporary
2 2 4 6 8
measures if required.

3 3 6 9 12
11-16 HIGH A HIGH risk requires immediate action to control
4 4 8 12 16 the hazard.
Table 1.2 : Risk Assessment and Control Measure
WHAT CAN WE DO?
Reactor, R-101 with alarm system and
shutdown system
Fault tree analysis for the event in figure below:
ETA of overpressure of Reactor, R-101
 At the Engineerin
source of g control
the hazard

Redesign
Elimination
Substitution RISK Isolation
Automation
CONTROL Barriers
Absorptions
Dilution
Personal Safe work procedures
Protective Supervision & training
Equipment Job rotation Administrativ
(PPE) Housekeeping, repair e control
& maintenance
programs
Hygiene
 ERP
EMERGENCY RESPONSE PLAN
 EMERGENCY RESPONSE PLAN
Step 1: Emergency Conditions Announcement
Step 2: Gathering Members of Emergency Response Team
Step 3: Prevention of Leaking, Emergency Shutdown and Protection
Step 4: Reporting to the Incident Commander
Step 5: Providing the Water Mist Facility
Step 6: Medical Treatment and Care
Step 7: Disaster Evaluation
Step 8: Communication and Support from External Authorities
Step 9: Eliminating the Disaster
Step 10: Deals with Problems Arise from the Incident
 EMERGENCY RESPONSE
PROCEDURE
1. GENERAL EVACUATION PROCEDURES 2. EMERGENCY RESPONSE TEAM 5. IN-CASE OF CHEMICAL SPILL

3. IN-CASE OF FIRE 4. IN-CASE OF EXPLOSION

6. IN-CASE UTILITY FAILURE
POSSIBLE EMERGENCY DEVICES AND
EQUIPMENT

EQUIPMENTS
I. GOGGLES
II. SAFETY HELMET
III. PROTECTIVE CLOTH
IV. GLOVES
V. SAFETY SHOES

DEVICES
I. ALARMS
II. GAS DETECTOR
III. FIRE EXTINGUISHER
IV. RELIEF VALVE
V. PERSONAL PROTECTIVE EQUIPMENT
PLANT LAYOUT
 EMERGENCY RESPONSE PLAN
Step 1: Emergency Conditions Announcement
Step 2: Gathering Members of Emergency Response
Team
Step 3: Prevention of Leaking, Emergency Shutdown
and Protection
Step 4: Reporting to the Incident Commander
Step 5: Providing the Water Mist Facility
Step 6: Medical Treatment and Care
Step 7: Disaster Evaluation
Step 8: Communication and Support from External
Authorities
Step 9: Eliminating the Disaster
Step 10: Deals with Problems Arise from the Incident
EMERGENCY RESPONSE
PROCEDURE
1. GENERAL EVACUATION
PROCEDURES
2. IN-CASE OF FIRE
3. IN-CASE OF EXPLOSION
4. IN-CASE OF CHEMICAL SPILL
5. IN-CASE UTILITY FAILURE
POSSIBLE EMERGENCY DEVICES AND
EQUIPMENT

Equipments
i. Goggles
ii. Safety Helmet
Iii. Protective Cloth
Iv. Gloves
v. Safety Shoes

Devices
i. Alarms
ii. Gas detector
iii. Fire extinguisher
iv. Relief valve
v. Personal Protective Equipment
PLANT LAYOUT
THANK YOU
Q&A session