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Maintenance Engineering

Assignment # 5

Hazop Study on Distillation Column

Submitted to:
Mr. Kareem bakhsh

Submitted By:
Ahmer Sohail

Roll No:
UW-15-ChE-BSc-007

Department of Chemical Engineering


Wah Engineering College

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Contents
1 Distillation column .................................................................................................................. 3
1.1 Batch Columns ................................................................................................................. 3
1.2 Continuous Columns ........................................................................................................ 3
2 Main Components of Distillation Column .............................................................................. 3
3 HAZOP Studies on Distillation Column ................................................................................. 5

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1 Distillation column
There are many types of distillation columns, each designed to perform specific types of
separations, and each design differs in terms of complexity.

1.1 Batch Columns


In batch operation, the feed to the column is introduced batch-wise. That is, the column is charged
with a 'batch' and then the distillation process is carried out. When the desired task is achieved, a
next batch of feed is introduced.

1.2 Continuous Columns


In contrast, continuous columns process a continuous feed stream. No interruptions occur unless
there is a problem with the column or surrounding process units. They are capable of handling
high throughputs and are the more common of the two types. We shall concentrate only on this
class of columns.

The studies on distillation column suggest the following objectives:

1. Product quality control to maintain either the overhead or bottom composition at a specified
value
2. Material balances control to maintain its column hold-up and overhead and bottom
inventories between maximum and minimum limits.
3. Constraints. The column should not flood. Pressure should be high enough to maintain
effective column operation and the temperature difference in the reboiler should not
exceeded critical temperature difference.

2 Main Components of Distillation Column


Distillation columns are made up of several components, each of which is used either to tranfer
heat energy or enhance material transfer.

A typical distillation contains several major components:

 A vertical shell where the separation of liquid components is carried out


 column internals such as trays/plates and/or packings which are used to enhance
component separations

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 A reboiler to provide the necessary vaporization for the distillation process
 A condenser to cool and condense the vapour leaving the top of the column
 A reflux drum to hold the condensed vapour from the top of the column so that liquid
(reflux) can be recycled back to the column

The vertical shell houses the column internals and together with the condenser and reboiler,
constitute a distillation column. A schematic of a typical distillation unit with a single feed and
two product streams is shown below:

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3 HAZOP Studies on Distillation Column
Guide Possible Action
Deviation Consequences
word causes required
NO No flow  Pipe blockage  Column dry out  Install low level
 Control valve shut  Possible alarm
 Valves fail dangerous  Check
 Tube leakage and concentration maintenance
blocking  No operation procedure and
 Pump failure schedule
 Make bypass
 Emergency plant
shut down
LESS Less Flow  Pipe blockage  Column dry out  Install low level
 Control valve shut  Changes in alarm
 Valves fail product quality  Check
 Tube leakage and maintenance
blocking procedure
 Pump failure  Make bypass
 Emergency plant
shut down
MORE More flow  Control valve is  Flooding in the  Install high level
fully opened column alarm
 Increase pumping  Changes in  Check
capacity product quality maintenance
 Control valves  Temperature procedure and
failure decrease schedule
 Rise in bottom  Install control
liquid level valves
 Install flow
indicator
 Make bypass
HIGH High  Vapor pressure high  Low efficiency  Install high
pressure  Pressure indicator of separation pressure alarm
controller fail  Rupture of  Install pressure
column or other relief valve
related
equipment
 Product loss

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High  Instrumentation  Separation  Install temperature
Temperature failure cannot be done indicator
 More steam flow  Changes in controller
 Exchanger tube product quality  Instruct operator
failure  Column on procedure
 High steam pressure flooding  Attention to heat
 Cooling water in  Film boiling in input and output
condenser failure. column and control
 Reboiler control reboiler
failure  Phase effect
 Heating medium  Pressure
leak into process changes
LOW Low  Vapour line leakage  Low efficiency  Install pressure
pressure of separation indicator
 Loss of products
Low  Instrumentation  Pressure change  Install temperature
temperature failure  Product loss indicator
 Less steam flow  Changes in  Instruct operator
 Loss of heating product quality on procedure
(steam leakage)  Ineffective  Upgrade isolation
 Low steam pressure separating  Attention to heat
and temperature process input and out
 Ineffective isolation  Phase effect control

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