Process Safety

(CPE 615)
PRODUCTION OF TETRADECENE
DRYING OIL
Mohamad Khairul Azwanizam Bin Baharuddin (2013416656)
Ahmad Fatthul Hadi Bin Abd Mubin (2013600546)
NurulSyahibah Bin Che Man (2013812424)
Jude Maxwell Sylvester (2013694948)

Background of the Process

In the process of making drying oil, the raw material used is acetylated castor oil

(ACO),also known as palmitic acid is thermally cracked to produce 1tetradecene,referred to as drying oil and acetic acid.
However, there is an undesired reaction in which the drying oil dimer to form 1octacosene (gum).

Process Selection: Thermal cracking of ACO to Drying Oil

Advantages

No catalyst needed.
Raw material used is

affordable and not

expensive.
Higher production
yield and purity
Limited equipment
used.

Disadvantages

Gum (by product) must

be removed to achieved
high purity product.

Process Flow Diagram

Hazard Identification
1. Material Safety Data Sheet (MSDS)

Hierarchy for very hazardous substances to low hazardous

substances

1. Acetic Acid
2.Tetradecene
3. Palmitic Acid
4. Gum

PLANT MAINTAINABILITY

What is mean by plant maintainability??

Is refer to the method, strategies and practices to

keep the industrial factory running efficiently. This can

be included with the regular check of equipment to
make sure they are functioning properly

Safe Maintenance Work Flow

1. Organising
2. Workplace
3. Handling the stuff
4. Operation of maintenance
5. Recheck

Organising
1.The employer should have play their responsiblities in

assigning the workers to do the maintainance

2. The workers need to have a great talent in order to do

the maintenance
3. The worker need to cooperate with employer as they

know and understand it exact nature and hazard

involved

Workplace
1.Only selected people only can be allowed to do

maintenance at workplace as they responsible for the

operation of maintenance
2. The working area should have a proper sign as to

mention to other workers that the maintenance is under

operation
3. The area need to secure tightly as making

announcement to other workers that some place have to

do maintenance and need to use other route.

Handling the stuff

1.To handle the equipment at workplace it should have

personal protective equipment

Protective clothing
glove
goggle
Safety boot
Heat resistance for high temperature

Operation of maintenance
1.The workers need to follow the procedure to do the

maintenance
2. The operation work should be discussed and making

decision together between worker of maintenance

Recheck
1.Before operation is ready to proceed as normal, the

workers maintenance need to make sure that all the

equipment is under safe condition
2. Only after when the test toward equipment is operate

successfully

Emergency Shutdown Reactor

1.Shut off reactant feed to the reactor to stop reactions.
2. Turn off pump that direct in or out of the reactor
3. Close connecting valve that flow direction toward reactor
4. Open safety valve to drain all fluid from reactor
5. Determine possible cause for reactor damage like
leakage need to change the tube and piping blockage need
to clean piping

6. Apply tag equipment like under maintenance

7. The reactor must be test before start up
Star up Operation
1. Check reactor are operable
2. Make sure piping (feed, outlet stream and piping inside
reactor) is in good condition)
3.Check/record the required measurements i.e
temperature, flow rate and pressure at feed stream

Emergency Shutdown distillation column

1. Shut down cooling and heating sources i.e condenser and
reboiler and other equipment supply to the column
2. Stop feed completely from entering the column
4. Flush liquid/off-spec product out of the column.
5.Bring back the column to room temperature by letting it
cool down.
.

7. Use water to clean up the tank from any liquid

residue and particulates.
8. Bring back the column from vacuum distillation to
atmospheric pressure by opening up the manhole.
9. Eliminate undesirable materials

Startup Distillation Column

1. Make sure all stream connecting with column in a good
condition.
2. Introduce the feed to the column and also introduce
heating and cooling sources which are the condenser for
vapor change to liquid and boiler for liquid change to vapor
3. Analyze and record for measurement of the temperature,
pressure for feed, bottom and distillate

EMERGENCY PLANNING

Hazard
Identificati
on
Fire Hazard

Description
Palmatic acid,

Tetradecene, Acetic
acid and Gum are all
flammable in the
presence of heat or
flame.
The most flammable
substance is acetic acid
which has only has a
flash point of 40OC and
the least flammable
material is gum as it is
in a solid form.

On-site
emergency
planning
All the plant

workers or
employees should
know how to use
various type of fire
extinguishers.
All employees
should be well
trained in
conducting
evacuation
procedures.
All employees
should be trained
conducting in
shutdown
procedures and
alarm system.
Members of the
team appointed
should wear
protective suits for
extreme
temperature.

Off-site emergency
planning
Key personnel

provide official
information and
instructions to the
general public.
Warning system :
long siren
followed by a
short siren will
alert people
about a fire has
occured.
Information system :
the public should
be inform to take
protective
measures through
radio/television in
case the fire
becomes severe
and dangerous to
the public.
Fire department
should be inform
immediately to assist
in fire-fighting services
and police department

Hazard
Identification
Explosion hazard

Description
Only acetic acid
can caused an
explosion if it is
mix with the air
or if it is reacted
with chlorine and
trifluoride will
sometimes
caused explosion
as their reaction
is very violent.

On-site
emergency
planning

Off-site
emergency
elanning

All employees should

Warning system :

be well trained in
conducting evacuation
procedures.
Emergency control
centre should all be
equip with walkietalkie to immeadiately
inform each other if
their is any
accident/incident
happen in the plant.
First-Aid or medical
teams should be
available to handle
any emergency.
All the employees
should wear protective
clothing such as
chemical suits, gloves
and boots to protect
from chemical spills.
Emergency control
centre should have
adequate number of
external telephones,
internal telephones

public address
system with the
police.
Off-site control room :
keep records of all
messages and
records of
attendance of
employees to assess
the missing person
during emergency.
Key personnel :
provide official
information and
instructions to the
general public.
Information system :
inform the public
about protective
measures that
should be taken
through
radio/televesion.
Specialized training to
doctors about chemical
hazards to help assist in
any emergency.
The police should help
assist in controlling traffic

Hazard
Identification
Toxic hazard

Description

On-site
emergency
planning

Off-site
emergency
planning

Palmatic acid,

Site controller

Specialized

Tetradecene and
Acetic acid has
toxic properties
which can be
harmful when
exposed to them.
The most toxic
substance is
acetic acid as it
is toxic to the
kidneys and
extremly
hazardous when
inhale or
contacted with
the skin.

should assess the

magnitude of the
situation and
decide if the plant
workers or
employees need to
be evacuated to the
assembly point.
Employees should
be explained the
means of reporting
any emergencies.
All the employees
should wear
protective clothing
such as chemical
suits, gloves and
boots to protect
from chemical
spills.
Person who is
trained in First-Aid
should be available

training of
doctors about
chemical hazards
to assist in any
emergency.
Arrangement of
stock of essential
medicines such
as antidotes and
special medicines
for hazardous
substances.
Warning system
with sirens must
be available to
indicate toxic
release.

Hazard
Identification
Health Hazard

Description

On-site
emergency
planning

Off-site
emergency
planning

Palmatic acid,

Safety glasses,

Off-site control

goggles or face
shields should be
used for eye
protection.
First-Aid
supplies should
be provided for
emergency use.
Medical teams
should be
available to
handle any
emergency.
Site controller
should look after
rehabilitation of
affected persons
on
discontinuation
of emergency.

room should act

as a focal point
of emergency
management.
Key personnel
should control all
the emergency
operations.
Specialized
training of
doctors about
chemical hazards
to help in
assisting any
emergency.

Tetradecene, Acetic
acid and Gum can
all cause health
hazard to people
when exposed to
them.
The most
hazardous
substances is
acetic acid as it can
caused irritation
( prolonged contact
will cause chronic
eye irritation),
ingestion and
problems in
inhalation. It is also
toxic to specific
organs such as
kidney.

SAFETY MANAGEMENT SYSTEM

Key Elements Of Successful Health and Safety Management

POLICY
The objectives of carrying out the safety management system
for Tetradecene Production Plant:
1. Safety and Health for every employees is high priority
2. Provide a safe work place and safe systems of
work for all workers
3. Decrease the human, political and financial
costs of having accidents in a particular chemical
plant.
4. To educate people and employees in the plant on
how to work safely.

PLANNING
- identify all of the potential major incidents.
- identify the schedule of material on site.
- regular inspection - identify all equipments / system condition.
- continuously seek ways to improve the health and safety of our
workforce and the community.
- clearly define the use of work permit
- training required, to increase the knowledge on safe operation
and let everyone in the plant to pay attention to their workplaces
and surrounding.
- Demonstrate all the control measurement to workers.
- make sure that all the emergency plan complied with the
OSH Regulation

Organising
-Responsible for the safety of the operation

-Responsible for making sufficient manpower

-Responsible for limiting the risks inherent in production
-Responsible for steering the Safety Manager
-Responsible for promoting the correct safety culture within
the organisation

-Responsible for realising the SMS

-Responsible for promoting the

correct safety culture within the

organisation of the members
-Responsible for the introduction of
the SMS to (new) members, customers
whereby the emphasis lies on drawing
attention to the obligation toward the
organization to report the incidents.

-Responsible for carrying out or instructing the carrying out of

an incident investigation
-Responsible for bringing noted risks to the attention of the
chairman of the board/owner/workers also
-Responsible for giving safety advice to the
board/owner/workers
-Responsible for promoting the correct safety culture within
the organisation
-Responsible for the communication with the organisation with
regard to safety matters

Control for occupational hazard

Commitment

- Safety Manager set a good safety example

- Attend the safety and health meeting
- continuously seek ways to improve the health and
safety
Communication
- use the effective communication
- important, flow of information regarding safety
matter to the organisation .
Competence
- ensuring of the employees maximize their
contribution of health and safety.

Measuring Performance
Proactive Monitoring

Reactive Monitoring

- monitor the achivement of

the policy/objective of
plant
- evaluating or judging if the
performance is sufficient to
achieve the function that
the system or control is
intended to achieve
- maintainance routine, do
inspections regularly as to
maintain the standard
performance of equipments

system that collect and

analyse
any
accidents,
unsafe activities which cause
injury and weakness of
standard performance.
- monitor all injuries/case of
ill-health
- monitor
the
sickness
absences.
- help to improve the weakness
of standard performance

Auditing and Reviewing

review the perfomance of plant continuosly- ensure

performance standard are being met

auditing - consist of qualifying auditors, scheduling,

documenting results and tracking recommendation.

- act as basis to improve the effectiveness of safety
matter at work place and safe systems of work for all
workers.