Beruflich Dokumente
Kultur Dokumente
Faculty of Engineering
2
1. Question
The process shown in the figure below consists of a fired heater, which raises the
temperature of a hydrocarbon stream via convective and radiative heat transfer, and
a packed bed chemical reactor. The process has been working well for over one year.
Recently, the market demand for the product has been decreasing, and in response the
plant is reducing production rate. This week the operating orders specify another 5%
decrease in production rate, to 80% of the design rate. While sipping your first cup of
coffee in your office, you receive a message from the plant production supervisor.
When the operators reduced the plant feed rate by the 5% specified, the flows and
temperatures began to oscillate wildly. The operators immediately returned to the
original feed rate, and the oscillations stopped. We are producing more than we are
selling, and as a result, the product tank is filling up fast. You better solve the problem!
You are not expected to completely solve this problem. Your answer must address the
following issues.
No other parts of the troubleshooting procedure are required for this assignment.
a) Give at least four hypotheses for the cause of the trouble.
b) Give at least four actions that would be useful in eliminating incorrect hypotheses
and reducing to one correct hypothesis. (You will not be able to determine the correct
hypothesis in this problem, because you cannot obtain the feedback from your proposed
actions.) Your actions should be clearly stated and numbered in the order you would
request them in the plant.
c) If you believe you have enough information, suggest a short-term and a longer-term
corrective action.
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2. Node selection
NODE 2
NODE 1
NODE 3
4
3. HAZOP study for node 1
NODE 1 Feed tank & Heat process fluid
NO. PARAMETER GUIDE DEVIATION CAUSES CONSEQUENCES EXISTING ACTION TO
WORDS SAFEGAURDS BE TAKEN
1. FLOW NO No flow into heating fluid Blockage at Heat exchanger
process the pump. temperature
Pump failed to build up and may
operate. cause pressure
Feed tank is build up.
empty. Pump will
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4. HAZOP study for node 2
Node 2 Heat transfer, Air intake & Fuel oil.
PARAMETE GUIDE
NO DEVIATION CAUSES CONSEQUENCES EXISTING SAFEGAURDS ACTION TO BE TAKEN
R WORD
6
To Install Flow Indicator
To Install Low Level Alarm
Blockage at the valve Conduct regular inspection
Low level of fuel oil in Off spec product and maintenance of valve
Less fuel oil Temperature
the oil tank delay in product line and pipeline. (Predictive and
3 Flow Less flow into heat Controller
Valve failed to open economic loss Preventive Maintenance)
transfer Auto valve control
completely Flush the pipeline. (blockage)
Emergency shutdown (ESD)
arrangements
7
More flow of fuel oil
into the heater Pressure builds up and
may exceed the To Install temperature alarm
No flow of
Maximum allowable To install high level alarm
hydrocarbon
The working pressure Flow rate controller Conduct regular inspection
Control Valve failure
temperature MAWP from high Auto valve control and maintenance of valve
Temperatur Controller fail (valve
5 High in fired heater temperature. Temperature and pipeline. (Predictive and
e open)
increased Cracks in fired heat Controller Preventive Maintenance)
Runaway reaction
above usual due to high Emergency shutdown (ESD)
Heater control failure
temperature arrangements
Reaction control
failures Economic
More flow
hydrocarbon
Less flow of fuel oil
To Install temperature alarm
into the heater
The To install low level alarm
Control Valve failure Flow rate controller
temperature Ineffective heating Conduct regular inspection
Temperatur (valve failed to open Auto valve control
6 Low in fired heater process and maintenance of valve
e completely) Temperature
lower than the Off spec product and pipeline. (Predictive and
Temperature Controller
usual Preventive Maintenance)
controller fail
Contamination in the
fuel oil
8
No flow of
hydrocarbon into
fired heater due to To Install temperature alarm
failure of FC 1 valve to To install low level alarm
open Conduct regular inspection
More flow of fuel oil delay in product line and maintenance of valve
Flow rate controller and pipeline. (Predictive and
which leads to economic loss
High pressure Auto valve control Preventive Maintenance)
7 Pressure High increase the Cracks in fired heat
in fired heater Temperature Fire and gas detection and
temperature due to due to high
Controller alarms
TC 2 failed to stop the temperature
process Emergency shutdown (ESD)
Relief valves isolated arrangements
Eternal fire due to
leakage of
hydrocarbon
Undetected leakage
Vessel drainage
Fire conditions
Weather conditions
Less pressure
8 Pressure Low Low level of fuel oil
in fired heater
which leads to
decrease the
temperature inside
the fired heater
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5. HAZOP study for node 3
Node 2 Packed Bed Reactor (PBR) & Product tank
N GUIDE
PARAMETER DEVIATION CAUSES CONSEQUENCES EXISTING SAFEGAURDS ACTION TO BE TAKEN
O WORD
10
To Install Flow Indicator
To Install Low Level Alarm
Blockage at the valve Conduct regular inspection
Less fuel oil Low level of fuel oil in Off spec product and maintenance of valve
Temperature
flow into the oil tank delay in product line and pipeline. (Predictive and
3 Flow Less Controller
Packed Bed Valve failed to open economic loss Preventive Maintenance)
Auto valve control
Reactor completely Flush the pipeline. (blockage)
Emergency shutdown (ESD)
arrangements
11
More flow of fuel oil
into the heater Pressure builds up and
may exceed the To Install temperature alarm
No flow of
Maximum allowable To install high level alarm
hydrocarbon
The working pressure Flow rate controller Conduct regular inspection
Control Valve failure
temperature MAWP from high Auto valve control and maintenance of valve
Temperatur Controller fail (valve
5 High in PBR temperature. Temperature and pipeline. (Predictive and
e open)
increased Cracks in fired heat Controller Preventive Maintenance)
Runaway reaction
above usual due to high Emergency shutdown (ESD)
Heater control failure
temperature arrangements
Reaction control
failures Economic
More flow
hydrocarbon
Less flow of fuel oil
To Install temperature alarm
into the heater
To install low level alarm
The Control Valve failure Flow rate controller
Ineffective heating Conduct regular inspection
Temperatur temperature (valve failed to open Auto valve control
6 Low process and maintenance of valve
e in PBR lower completely) Temperature
Off spec product and pipeline. (Predictive and
than the usual Temperature Controller Preventive Maintenance)
controller fail
Contamination in the
fuel oil
12
No flow of
hydrocarbon into
fired heater due to To Install temperature alarm
failure of FC 1 valve to To install low level alarm
open Conduct regular inspection
More flow of fuel oil delay in product line and maintenance of valve
Flow rate controller and pipeline. (Predictive and
High pressure which leads to economic loss
Auto valve control Preventive Maintenance)
7 Pressure High in Packed Bed increase the Cracks in fired heat
Temperature Fire and gas detection and
Reactor temperature due to due to high
Controller alarms
TC 2 failed to stop the temperature
process Emergency shutdown (ESD)
Relief valves isolated arrangements
Eternal fire due to
leakage of
hydrocarbon
Undetected leakage
Vessel drainage
Fire conditions
Less pressure Weather conditions
8 Pressure Low in Packed Bed Low level of fuel oil
Reactor which leads to
decrease the
temperature inside
the fired heater
13
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