PET Production Plant Safety & Process Optimization for Equipolymer, Italy

Scope

• Conducted Process Safety Analysis by HAZOP (Hazard and Operability Analysis) and FMECA (Failure Mode, Effects & Criticality Analysis) to identify potential risks and suggest corrective actions for plant safety.

• Process Optimization to evaluate production stages to enhance operational efficiency, particularly focusing on reactor performance, heat management, and ethylene glycol recovery strategies.

• Document Requirements:

  • Process Flow Diagrams (PFDs) and Piping and Instrumentation Diagrams (P&IDs)

  • Equipment design and operation manuals

  • Safety data sheet

  • Instrument datasheet

  • Identification of Hazardous area

  • Maintenance and inspection records

  • Historical production and safety data logs

  • Incident and near-miss reports for analysis

• Compliance & Risk Mitigation to ensure compliance with international safety standards 

Process

1. Definition 

   • Defined scope and objectives for PET plant

   • Defined responsibilities for 

2. Preparation 

   • Planed the study 

   • Collected data 

3. Examination (HAZOP)

   • Defined the design intent 

   • Identified deviation by using guide words on each element 

   • Identified consequences and causes 

   • Identified protection, detection, and indicating mechanisms 

   • Identified possible remedial and mitigating measures 

   • Agreed actions 

4. FMECA Study:

   • Evaluated failure mode

   • Evaluated potential equipment failures and their impact on process efficiency.

   • Assigning Severity ranks

   • Identified potential causes and current controls

   • Prioritized failures using the Risk Priority Number (RPN)

   • Provided corrective actions.

5. Process Evaluation:

   • Detailed assessment of the PET production process, from MEG and TPA mixing to pelletization of final products.

   • Analysis of key streams and equipment, including reactors, heat exchangers, and distillation columns.

   • Analysis of controllers and alarms system

6. Process Optimization:

   • Recommended control system enhancements for temperature and pressure management in disc reactors and condensation tanks.

   • Suggested ethylene glycol recovery strategies to improve material efficiency and sustainability.

5. Development of an Implementation Plan for the model to optimize process controllers.

6. Documentation

6. • Record the examination 

   • Produce the report of the studies 

   • Produce final report

Outcomes

• Enhanced Safety & Reliability and Reduced risks by up to 53% through HAZOP 

• Achieved up to 64% improvement in plant reliability after FMECA recommended actions

• Improved Process Efficiency by Optimizing temperature, pressure, and flow parameters for higher PET yield and product quality.

• Sustainability Benefits include maximized ethylene glycol recovery and minimized waste.

• Cost Savings by reduced operational disruptions and equipment maintenance costs.

Deliverables:

• HAZOP and FMECA analysis

• Comprehensive HAZOP and FMECA reports with detailed recommendations.

• All diagrams such as Bowtie diagram, P&ID, PFD, layouts, safety sheets, etc.

• Risk analysis charts.

• Improvement plans for control systems and equipment maintenance.