Project: HAZOP Study for Distillation column

Design Intent: To purify formaldehyde as the bottom product, and unreacted methanol as overhead product.
Node: Feed (mixture of water, methanol and formaldehyde) from Absorber C-002 entering Distillation column C-003, including Reboiler (RB-1
(E-101), Reflux drum (RD-102), and Pump (P-007-1/2)
Operating Condition:
Op. Pressure: 101.3 KPa
Op. Temperature: 100 deg C (Column)
Drawing No:
Ref No.
N1.01

Parameter
Flow

Guideword
More

Cause
1. Malfunction of LCV001.

2. Malfunction of FCV001.
3. High reflux

N1.02

Flow

No/Less

1. LCV-001 stucked
close.
2. Clogging
3. Line leak at feed

N1.03
N1.04
N1.05

Flow
Pressure
Pressure

Reverse
High
Low

N/A

N01.6
N01.7

Vacuum
Temperature

High

1. Condenser failure.

2. Malfunction of FCV003.

N01.8

Temperature

Low

1. Reboiler failure.
2. Malfunction of FCV003.

3. Excessive reflux.
4. FCV-001 fails open

N01.9

Level

High

1. Blockage of distilation
outlet

2. Failure of active pump

P-005-001/2

3. Failure of FCV-002

N01.10

Level

Low

N01.11
N01.12
N01.13

Start-up/Operability
Shutdown/Maintenance
Corrosion/Erosion

High

N01.14
N01.15

Composition
Others

4. Low reflux causing

high level buit up in
reflux drum
1. FCV-002 stuck open

Low pH due to the

present of acid or salt in
the distillation overhead
system at the right
condition exist.

unreacted methanol as overhead product.

Absorber C-002 entering Distillation column C-003, including Reboiler (RB-103), Condenser

Date:
Node:

Node Rev. No.

Consequence

Safeguards

1. Overpressure within C-003

leading to flooding in the
Rectification section, in the worst
case explosion.
2. Product offspec.

No.
1

Drawing Rev. No.

Recommendations
Recommendation
Consider to install High flow
alarm and high high flow trip (after
LCV-001) to stop the flow.

1. FICA-1013 high flow

alarm.
2. FICA-1010
1. FCV-001
2. FICA-1013 high flow
alarm

No product, financial loss due to

shutdown.

Potential fire and explosion in the

presence of ignition source.

2
3

Consider to install Low flow

alarm.
Pressure gauge routine inspection.
Material selection

High temperature leading to high FICA 4008 high high

vapor pressure built up in the
temperature trip
reflux drum, in the worst case can
cause reflux drum rupture,leading
to potential fire/explosion hazard.

Consider to install High flow

alarm and high high flow trip (after
LCV-001) to stop the flow.

Product off spec and potential

overpressure

Incomplete separation leading to product offspec.

Incomplete separation leading to 1. FCV-001.
product offspec.

Recommend to install high

temperature alarm and flow control
valve at the outlet of RB-103 into
C-003.
Routine inspection and
maintenance.
Recommend to install low
temperature alarm at the outlet of
RB-103 into C-003.

Refer to More Flow.

1. FCV-003
2. FICA 1013
3. TICA-1006 low low
temperature trip
1. No product. High level built up 1.LT- 2005
2.
in the distilation column leading LICA 2005
3.
to rupture of distilation column Bypass

Consider to install High flow

alarm and high high flow trip (after
LCV-001) to stop the flow.

Consider to install High flow

alarm and high high flow trip (after
LCV-001) to stop the flow.

1. No product. High level built up 1.LT- 2005

in the distilation column leading 2. LICA 2005
to rupture of distilation column

Consider to install High flow

alarm and high high flow trip (after
LCV-001) to stop the flow.

1. Potential for liquid to backflow into the distillation column.

Consider to install high level

indicator controller at the reflux
drum.
To install a level low low trip to
trip the pump.

1. No product. High level built up 1. 2x100% pump P005in the distilation column leading 1/2
2.
to rupture of distilation column LICA 2005
3. LT2005

1. Potential for gas blowby

leading to pump cavitation.

1.LT- 2005
2. LICA 2005

Consider installing level control

valve (from C-003 to Pump P-0051/2)

1.Contribute to piping leaking

Chemical Injection such as

Corrosion Inhibitors which include
neutralizers.

Change of material from carbon

steel to stainless steel which is
much more durable to corrosion
and increases the life time of
the plant.

Installation of pH meter and low

pressure alarm.

2.Increasing and decreasing of

tower pressure drop.
3.Inadequate separation leading
to reduction in product capacity
and purities (product outspec)
4.Instrument issues such as the
leads line to instrumentation
plugging

15th Nov 2014

1

Recommendations
Action By

Project: HAZOP Study for Absorption Column for Nox

Design Intent: To remove unwanted reacction heat and to reduce the absorber tray temperatures to favour absorption.
Node: Cooling water inlet, cooling coils within the absorption column and cooling water outlet.
Operating Condition:
Op. Pressure: 950 Kpa (Column)
Op. Temperature: 8-65 DegC (Column), 28 degC (cooling water in)
Drawing No:
Ref No.

Parameter

N1.01

Flow

More

Cooling water inlet valve More cooling water leading to

stucked open.
product offspec.

N1.02

Flow

No/Less

1. Blockage of cooling
water inlet.
2. Cooling water inlet
valve stucked closed.

N1.03
N1.04

Flow
Pressure

Reverse
High

No foreseen hazard.
High pressure due to
higher pump discharge
pressure from cooling
water system.

N1.05

Pressure

Guideword

Low

Cause

Consequence

Loss of cooling water will lead to

Nox gas being reliefed to stack.

1. Line leak/rupture in the

absorption column, in the worst
case leading to offspec of
product.

1. Blockage of cooling
See N1.02 No/Less flow above.
water inlet.
2. Malfunction of cooling
water inlet valve

mperatures to favour absorption.

ater outlet.

Safeguards
No.
1. TIC to control the
1
cooling water inlet valve.
2.Low temperature alarm
3. SOP

1. Low Flow alarm at

inlet of cooling water
inlet.

Date:
Node:

9th Nov 2014

Node Rev. No.

Drawing Rev. No.

Recommendations
Recommendation
Action By
To connect Temperature columm Instrument/Control
indicator to FIC at make-up water. Engineer

Consider to install Column

temperature high alarm

Mechanical/Process/In
strument Engineer

Consider to install Column

temperature high trip.

Mechanical/Process/In
strument Engineer

Consider to install a pressure

relief valve (relieving liquid
pressure) at upstream of the
cooling water inlet.

Mechanical/Process/In
strument Engineer

1. start-up procedures for 4

cooling water system.

Consider to install a bypass valve

at the cooling water inlet.

Process/Mechanical
Engineer

Consider to introduce chemical

Process/Mechanical
injection (i.e. corrosion inhibitor, /Instrument Engineer
biocide, sodium hypochloride) into
cooling water supply to ensure that
the cooling water specs to be
maintained to avoid scaling,
corrosion and algae formation.