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
3 © 2015 Honeywell International All Rights Reserved
•Rotating Equipment• Pressure Relief
• Process Control & Instrumentation
• Flowsheet Specialists (SATDSC)
UOP HAZOP Team
UOP
HAZOP
Team
OtherUOP SkillExperts
HAZOPMethodology
Expert
ProcessExpert
Customer/Contractor
TechnologyExpert
4 © 2015 Honeywell International All Rights Reserved
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
5 © 2015 Honeywell International All Rights Reserved
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)
6 © 2015 Honeywell International All Rights Reserved
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
7 © 2015 Honeywell International All Rights Reserved
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
8 © 2015 Honeywell International All Rights Reserved
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
9 © 2015 Honeywell International All Rights Reserved
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
10 © 2015 Honeywell International All Rights Reserved
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
11 © 2015 Honeywell International All Rights Reserved
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
12 © 2015 Honeywell International All Rights Reserved
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)
13 © 2015 Honeywell International All Rights Reserved
UOP Phenol Process13
Spent Air
Air
AMS
Acetone
Phenol
Residue
H2
Phenol and Acetone
Purification
OxidationConcentration
AMS Hydrogenation
DecompositionNeutralization
Cumene
14 © 2015 Honeywell International All Rights Reserved
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
15 © 2015 Honeywell International All Rights Reserved
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
16 © 2015 Honeywell International All Rights Reserved
Dynamic Upset-Valve Stroke Times
Isolation ValveTime to Close
Air Feed ValveTime to Close
No. 1 Tank Pressure
17 © 2015 Honeywell International All Rights Reserved
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