2.

3 Systematic Safety Analysis (HAZOP) on Distillation Process in

Acetone Manufacturing Process
One of the commonly used safety analysis systems in process design is HAZOP. HAZOP
stands for Hazard and Operability Study. In typical scenarios, a HAZOP study is conducted by
a team comprising of specialists in different fields (varying from process engineers to plant
manager). The team uses a series of guide words to identify possible deviations from the
intended design or operation of a given process. After identifying such deviations, there then
comes about the discussion on how the deviations occur, consequences of these deviations,
reliability of existing safeguards in preventing or mitigating the issue and possibly
recommending additional safeguards into the system. In this report, the HAZOP study will be
conducted on the second distillation column (IPA Column, C-101).

2.3.1 PFD of Distillation

Before performing HAZOP on the distillation itself, a draft Process Flow Diagram (PFD) with
complete control loops are to be drawn. Following heuristics, there are to be these main control
loops in a distillation column set-up (with other considerations of the usage of cascade loops
and safety relief valves):

x Flowrate of feed
x Flowrate of reflux
x Level in distillation column
x Level in overhead accumulator
x Temperature of boil up return
x Pressure in distillation column
x Differential pressure across distillation column
The following is assumed:

x All control valves have a by-pass valve as well as isolation valves present but not drawn
into the PFD
x No proper level alarms for the process transmitter has been determined yet
x The pressure control systems are done separately through the use control valves PCV-101
and PCV-102
The preliminary PFD is shown in the following page.

40
 PC
PC 102 PCV-102 To Flare
101
PT
102
PRV-101
PT PCV-101
101
LT
V-102
102

TT TC LC
101 101 102

TT
E-106 102

TC
TCV-102 102
FC FT FT FC
101 101 102 102
CWR CWS
Bottoms
from C-100 C-101
FCV-101

P-102
PD
FCV-102
101

P-103 IPA for

Recycle
TC
103 LCV-102

TT
103 FT FC
103 103
LT
101
Steam
Inlet
FCV-103
E-107
LC
101 Steam
Outlet
LCV-101 Water for
Discharge

Figure 2.3.1.1: PFD of Distillation Column C-101 with control loops

2.3.2 HAZOP of Distillation

In this HAZOP analysis, there will be three parameters evaluated; (1) Level, (2) Temperature
and (3) Pressure. These parameters have been associated with a series of guidewords, forming
a deviation. These deviations are as such and a HAZOP will be done for each of them (in the
following order):

1. High level in C-101 7. High temperature in V-102

2. Low level in C-101 8. Low temperature in V-102
3. No level in C-101 9. High pressure in C-101
4. High level in V-102 10. Low pressure in C-101
5. High temperature in C-101 11. High pressure in V-102
6. Low temperature in C-101 12. Low pressure in V-102
The HAZOP analysis made for the 12 deviations are presented in a table format per deviation
in the following pages.

41
Unit/Node
Process Variable
Deviation
Cause(s) of Deviation
High feed flow rate. More feed
entering distillation column
LCV-101 fail close. Hence, result
in no flow of bottom out.
IPA distillation column, C-101
Level
High level in C-101
Possible Consequences
a) With constant heating from
reboiler, the excess feed will not
be sufficiently heated so the
purity of the product will be low.
a) Accumulation liquid inside C-
101.
b) Continuous heating of same
column liquid causing the purity
of the product to remain low.
Table 2.3.2.1: High level in C-101 HAZOP analysis
Guide Word
Existing Safeguards Available
a) Level transmitter (LT-101) and b) Install composition analyser
controller (LC-101).
a) Flow transmitter (FC-102) and product composition.
controller (FC-102)
More of
Additional Safeguards
Recommended
a) Install level transmitter with
level alarm high (LAH) to alert
operator when levels increase
pass the optimum settings.
(AI-101) to measure the top
product composition.
c) Scheduled trips by field staff to
double check control panel values
with onsite instruments
a) Install composition analyser
(AI-101) to measure the top
b) Scheduled trips by field staff
to double check control panel
values with onsite instruments
42
Unit/Node
Process Variable
Deviation
Cause(s) of Deviation
Low feed flow rate. Lesser feed
entering distillation column.
FCV-102 fail closed, hence
resulting in no reflux entering C-
101, causing lesser level.
IPA distillation column, C-101
Level
Low level in C-101
Possible Consequences
a) Top and bottom product
collected will be lowered that
will cause the demands of client
to not be met.
a) Temperature of top product
will increase, as there is no reflux
to cool down the vapour. More
cooling of top product is
required.
b) Separation efficiency in the
column and top and bottom
products stream composition will
be affected
Table 2.3.2.2: Low level in C-101 HAZOP analysis
Guide Word
Existing Safeguards Available
a) Level transmitter (LT-101) and to double check control panel
controller (LC-101)
a) Temperature transmitter (TT-
101) and controller (TC-101).
b) Flow transmitter (FC-102) and (AI-101) to measure the
controller (FC-102)
Less of
Additional Safeguards
Recommended
a) Install level transmitter with
level alarm low (LAL) to alert
operator when levels decreases
pass the optimum settings.
b) Scheduled trips by field staff
values with onsite instruments
c) Install a safety interlock
system which will cause a
solenoid block valve to activate
when column level is past the
low-low limit
a) Install temperature indicator
with temperature alarm high
(TAH) to indicate high alarm of
top product.
b) Install composition analyser
composition of the top product.
c) Scheduled trips by field staff to
double check control panel values
with onsite instruments
43
Unit/Node
Process Variable
Deviation
Cause(s) of Deviation
P-102 pump fail. No feed will
enter the distillation column.
FCV-101 fail closed, line
blockage due to presence of
impurities (like corrosion
product). No feed will enter the
distillation column.
IPA distillation column, C-101
Level Guide Word No
No level in C-101
Additional Safeguards
Possible Consequences Existing Safeguards Available
Recommended
a) Steam continues to flow to
reboiler so heating continues.
a) Flow transmitter (FT-101) and a) Install parallel pump along P-
With no feed to heat, the vapour
controller (FC-101) 102 in case one fails.
inside the column will be heated
b) Pressure differential indicator b) Pressure relief valve (PRV) to
causing the pressure to increase
(PD-101) relief excess pressure.
overheating the reboiler at the
same time.
a) Steam continues to flow to
reboiler so heating continues.
With no feed to heat, the vapour
inside the column will be heated
a) Pressure relief valve (PRV) to
causing the pressure to increase.
relief excess pressure.
b) Feed in the pipeline between
b) Install minimum flowrate line
P-102 and FCV-101 will a) Flow transmitter (FT-101) and
for P-102.
accumulate and increase the controller (FC-101).
c) Addition of pump strainers for
pressure causing the pipeline to
P-102 to remove any addition
eventually burst and release
impurities.
chemicals into the atmosphere.
c) Pump will continue to pump
feed and do work that will cause
the pump to overheat.
Table 2.3.2.3: No level in C-101 HAZOP analysis
44
Unit/Node
Process Variable
Deviation
Cause(s) of Deviation
TCV-102 fail open. Increased
cooling water into E-106
LCV-102 fail closed. Result
lesser flow out of V-102, hence
level increase.
Reflux drum, V-102
Level
High level in V-102
Possible Consequences
a) More cooling of distillate
product entering E-106 so more
condensate will be formed. As
such greater increase of flow rate
of condensate into V-102.
b) Higher flow rate of condensate
will cause the temperature to be
lower in the outlet stream of E-
106.
c) Pressure in V-102 will
decrease due to lesser vapour
flow into the reflux drum
a) Pressure in V-102 build-up due
to high level inside, hence result
in vessel from bursting.
b) Releasing of top product to
environment, which can cause
fire when there ignition
Table 2.3.2.4: High level in V-102 HAZOP analysis
Guide Word
Existing Safeguards Available
a) Temperature transmitter (TT-
102) and controller (TC-102) to
measure the temperature of outlet
stream of E-106.
b) Pressure transmitter (PT-102)
and controller (PC-102)
a) Pressure transmitter (PT-102)
and controller (PC-102)
b) Pressure relief valve (PRV-
101)
More of
Additional Safeguards
Recommended
a) Install temperature indicator
with temperature low alarm
(TAL) to alert operator of low
temperature in discharge stream.
b) Scheduled trips by field staff
to double check control panel
values with onsite instruments
a) Install Pressure indicator with
pressure high alarm (PAH) to
alert the operator of the high
pressure in V-102.
b) Regular inspection and
patrolling of the area.
45
Unit/Node
Process Variable
Deviation
Cause(s) of Deviation
Faulty control valve (FCV-103)
resulting in an excess heating of
stripping section using reboiler E-
107.
Little or no rectifying reflux
stream to provide cooling of the
vapour stream. This could be due b) This will result in a higher
to pump failure (P-103) or/and
faulty control valve (FCV-102).
IPA distillation column, C-101
Temperature
High temperature in C-101
Possible Consequences
a) With a faulty control valve
(FCV-103), there could be an
increase in steam flow rate into
the reboiler (E-107) which will
then result in higher vapour
production.
b) Higher vapour production will
result in an increase in overall
pressure, and may over pressurise
condenser E-106 and reflux drum
V-102.
c) The over pressurisation will
consequently cause E-106 and V-
102 to rupture and burst,
releasing flammable content.
a) Faulty control valve (FCV-
102) or/and P-103 failure may
cause little or no reflux flow into
C-101.
yield of vapour product due to
absence of rectifying reflux
stream to cool the vapour stream
sufficiently.
Guide Word
Existing Safeguards Available
a) Cascade control, TC-103, to
control the steam flow rate
entering the reboiler.
b) PC-101 located at the top of
the distillation column, C-101, to
control the pressure entering the
reflux drum, V-102.
a) PC-101 located at the top of
the distillation column, C-101, to
control the pressure entering the
reflux drum, V-102.
b) Cascade control, TC-101, to
control the reflux flow rate into
C-101.
More of
Additional Safeguards
Recommended
a) Install another control valve
that works independently and can
be used as a backup control valve
in case FCV-103 fails.
b) Separate TAH and TAHH to
trip the steam entering the
reboiler in the case of excess
heating in stripping section.
c) Install pressure relief valve at
the top of the distillation column,
C-101, to appropriately relieve
excess pressure before entering
condenser and reflux drum to
prevent over pressurisation.
a) Install another pump (parallel
configuration) that is used as a
backup pump in case P-103 fails.
b) Install another control valve
that works independently and can
be used as backup control valve
in case FCV-102 fails.
46
 c) Higher vapour production will c) Install pressure relief valve at
result in an increase in overall the top of the distillation column,
pressure, and may over pressurise C-101 to appropriately relieve
the E-106 and V-102. excess pressure before entering
d) The over pressurisation will condenser and reflux drum to
consequently cause E-106 and V- prevent from over pressurisation.
102 to rupture and burst,
releasing flammable content.
a) Higher temperature resulted
from the reboiler E-104 (located
at the bottom of C-100) will
a) Install temperature transmitter
cause the temperature of the feed
(TT) with TAH at the inlet of C-
entering to be high, which may
101 to detect and alert the high
consequently lead to higher
temperature flow that is entering
pressure and temperature in
High intermediate temperature C-101.
transfer line and eventually in
from bottoms of C-100 (due to None. b) Install pressure relief valve at
column C-101.
reboiler E-104). the top of the distillation column,
b) This increases the likelihood
C-101 to appropriately relieve
of C-101 to rupture and burst due
excess pressure so as to protect
to the high inlet pressure entering
the column from being over
the column.
pressurised and rupture.
c) Isopropyl alcohol, being
flammable, may cause fire or
explosion when ignited.
Table 2.3.2.5: High temperature in C-101 HAZOP analysis

47
Unit/Node
Process Variable
Deviation
Cause(s) of Deviation
Faulty control valve (FCV-103)
resulting in little or no heating of
stripping section using reboiler E-
107.
Excess cooling provided by
rectifying reflux stream. This
could be due to pump failure (P-
103) or/and faulty control valve
(FCV-102).
IPA distillation column, C-101
Temperature Guide Word Less of
Low temperature in C-101
Additional Safeguards
Possible Consequences Existing Safeguards Available
Recommended
a) With a faulty control valve
(FCV-103), there could be a
decrease in steam flow rate into
a) Install another control valve
the reboiler (E-107) which will
that works independently and can
then result in lesser vapour
a) Cascade control, TC-103, to be used as a backup control valve
production.
control the steam flow rate in case FCV-103 fails.
b) Lesser vapour product will
entering the reboiler. b) Ensure regular checks and
lead to reduced separation
b) LT-102 to indicate the low maintenance of the control valve.
efficiency in C-101, hence
level in V-102 due to lesser c) Separate LAL and LALL to
resulting in a lower amount of
product present in V-102. trip LCV-102 in order to stop
IPA available to recycle.
c) Minimum flow line on pump outflow of IPA for recycle and
c) Lesser vapour product will
P-103 to prevent cavitation. prevent the level in V-102 from
also mean that the level in V-102
dropping even further which may
drops. This may consequently
cause pump P-103 to cavitate.
cause pump P-103 to damage or
cavitate due to insufficient level
in reflux drum V-102.
a) Faulty control valve (FCV-
a) Cascade control, TC-101, to a) Install another control valve
102) or/and pump failure could
control the amount of reflux that works independently and can
result in large amount of reflux
stream entering the column C- be used as a backup control valve
stream entering C-101.
101. in case FCV-102 fails.
b) The excess cooling provided
b) LT-102 to indicate the low b) Ensure regular checks and
by the large amount of reflux
level in V-102 due to lower maintenance of the control valve.
stream will result in lower yield
product present in V-102.
of vapour product.
48
 c) Lesser vapour production will
lead to reduced separation
efficiency which consequently
results in a lower amount of IPA
available for recycle.
d) Low level in V-102 may also
cause pump to damage due to
insufficient level in reflux drum
V-102.
a) Lower temperature of liquid
feed would result to a lower
generation of vapour from
reboiler E-107.
Low intermediate temperature
b) The lower feed temperature
from bottoms of C-100 (due to
entering will lead to reduced
reboiler E-104).
separation efficiency in C-101.
c) Lesser vapour generated would
result to a lower liquid level in V-
102.
Table 2.3.2.6: Low temperature in C-101 HAZOP analysis
c) Minimum flow line on pump
P-103 to prevent cavitation.
a) TC-103 to control steam
heating into reboiler E-107
b) TC-101 to control the flowrate
of cool reflux into column
c) Separate LAL and LALL to
trip LCV-102 in order to stop
outflow for IPA recycle and
prevent the level in V-102 from
dropping even further which may
cause pump P-103 to cavitate.
a) Install temperature transmitter
(TT) with TAL at the inlet of C-
101 to detect and alert the low
temperature feed flow that is
entering C-101.
b) Separate LAL and LALL to
trip LCV-102 in order to stop
outflow of IPA for recycle and
prevent the level in V-102 from
dropping even further which may
cause pump P-103 to cavitate.
49
Unit/Node
Process Variable
Deviation
Cause(s) of Deviation
Faulty control valve (TCV-102)
resulting in little or no
condensation in E-106.
Faulty control valve (FCV-103)
resulting in an excess heating of
stripping section using reboiler E- the reboiler (E-107) which will
107.
Reflux drum, V-102
Temperature Guide Word More of
High temperature in V-102
Additional Safeguards
Possible Consequences Existing Safeguards Available
Recommended
a) With a faulty control valve
(TCV-102), there could be little
or no condensation in E-106 due
to lesser or no flow of cooling
water into the condenser E-106,
this will consequently result in
greater vapour product in reflux a) PC-102 located at the top of
a) Install another control valve
drum V-102. the reflux drum, V-102, to
that works independently and can
b) There could be a possibility of control the pressure in V-102 by
be used as a backup control valve
over pressurisation in V-102 due sending the excess pressure to
in case TCV-102 fails.
to the reduced condensation at flare.
b) Ensure regular checks and
the top of the distillation column, b) PRV-101 to relieve excess
maintenance of the control valve.
C-101. This may eventually pressure in V-102.
cause V-102 to rupture and burst,
releasing flammable isopropyl
alcohol into the atmosphere.
c) The release of isopropyl
alcohol may cause fire or
explosion if ignited.
a) With a faulty control valve
a) Cascade control, TC-103, to a) Install another control valve
(FCV-103), there could be an
control the steam flow rate that works independently and can
increase in steam flow rate into
entering the reboiler. be used as a backup control valve
in case FCV-103 fails.
then result in higher vapour
production.
50
 b) Higher vapour production will b) PC-101 located at the top of b) Separate TAH and TAHH to
result in more vapour present in the distillation column, C-101, to trip the steam entering the
V-102 which may result in an control the pressure entering the reboiler in the case of excess
increase in overall pressure and reflux drum, V-102. heating in stripping section.
eventually lead to V-102 over
pressurisation.
c) The over pressurisation may
cause V-102 to rupture and burst,
releasing flammable isopropyl
alcohol into the atmosphere.
a) Higher temperature resulted
from the reboiler E-104 (located
at the bottom of C-100) will lead
to higher pressure and a) Install temperature transmitter
temperature in transfer line and (TT) with TAH at the inlet of C-
eventually in column C-101. 101 to detect and alert the high
b) With a higher temperature of temperature flow that is entering
feed inlet, more vapour is likely C-101.
to be produced and hence a) PC-101 located at the top of b) Install pressure relief valve at
High intermediate temperature
collected in V-102. the distillation column, C-101, to the top of C-101 to appropriately
from bottoms of C-100 (due to
c) This will then result in an control the pressure entering the relieve pressure so as to protect
reboiler E-104).
increase in vapour product reflux drum, V-102. the column from being over
entering the condenser E-106 and pressurised and rupture.
reflux drum V-102, causing these c) Install temperature transmitter
equipment to over pressurise. with TAH to indicate and alert
d) Over pressurisation of E-106 the high temperature stream
and V-102 will cause equipment entering V-102.
to rupture and burst. Flammable
isopropyl alcohol may cause fire
or explosion.
Table 2.3.2.7: High temperature in V-102 HAZOP analysis

51
Unit/Node
Process Variable
Deviation
Cause(s) of Deviation
Faulty control valve (TCV-102)
resulting in an excess
condensation in E-106.
Reflux drum, V-102
Temperature
Low temperature in V-102
Possible Consequences
a) With a faulty control valve
(TCV-102), there could an
excessive condensation in E-106
due to more flow of cooling
water into the condenser E-106.
This will result in lesser vapour
product entering the reflux drum
V-102.
b) Lesser vapour production will
lead to reduced separation
efficiency, hence resulting in a
lower amount of IPA available to
recycle.
c) Low level in V-102 may also
result in pump damage due to
insufficient level in reflux drum
V-102.
Guide Word
Existing Safeguards Available
a) LT-102 to indicate the low
level in V-102 due to lower
product present.
b) Minimum flow line on pump
P-103 to prevent cavitation.
Less of
Additional Safeguards
Recommended
a) Install another control valve
that works independently and can
be used as a backup control valve
in case TCV-102 fails.
b) Ensure regular checks and
maintenance of the control valve.
c) Separate LAL and LALL to
trip LCV-102 in order to stop
outflow for IPA recycle and
prevent the level in V-102 from
dropping even further which may
cause pump P-103 to cavitate.
52
 a) With a faulty control valve
(FCV-103), there could be a
a) Install another control valve
decrease in steam flow rate into
that works independently and can
the reboiler (E-107) which will
a) Cascade control, TC-103, to be used as a backup control valve
then result in lesser vapour
control the steam flow rate in case FCV-103 fails.
production.
Faulty control valve (FCV-103) entering the reboiler. b) Ensure regular checks and
b) Lesser vapour production will
resulting in little or no heating of b) LT-102 to indicate the low maintenance of the control valve.
lead to reduced separation
stripping section using reboiler E- level in V-102 due to lower c) Separate LAL and LALL to
efficiency, hence resulting in a
107. product present in V-102. trip LCV-102 in order to stop
lower amount of IPA available
c) Minimum flow line on pump outflow for IPA recycle and
for recycle.
P-103 to prevent cavitation. prevent the level in V-102 from
c) Low level in V-102 may also
dropping even further which may
cause pump P-103 to damage due
cause pump P-103 to cavitate.
to insufficient level in reflux
drum V-102.
Table 2.3.2.8: Low temperature in V-102 HAZOP analysis

53
Unit/Node
Process Variable
Deviation
Cause(s) of Deviation
Malfunctioning of FCV-103,
leaving the control valve at full
open position. With an increased
flow of hot steam, the reboiler E-
107 duty increases. As such,
there will be more vapourisation
of the liquid in the column,
resulting in a pressure increase in
the IPA Column C-101.
The inlet stream from P-102
contains the bottoms from C-100.
It may overheat and enter column
C-101 as hot vapour instead of
hot liquid. Hence, the influx of
hot vapour in C-101 will build up
in the column, resulting in a
pressure increase in IPA column
C-101.
IPA distillation column, C-101
Pressure
High Pressure in C-101
Possible Consequences
a) Reboiler E-107 may overheat
and get damaged due to the
suddenly increase in steam
flowrate.
b) Over-pressurization in column
C-101 is unsafe and may rupture
if pressure continues to build-up.
c) Increased pressure may affect
the separation in the column and
hence, reduce C-101s efficiency.
a) Over-pressurization in column
C-101 is unsafe and may rupture
if pressure continues to build-up.
b) Increased pressure may affect
the separation in the column and
hence, reduce C-101s efficiency.
c) High pressure may also
damage condenser E-106 as hot
vapour will enter at pressure
much higher than operating
levels.
Guide Word
Existing Safeguards Available
a) Basic Process Control System:
PCV-101 will open to relieve
pressure in the column C-101
when PT-101 reads a high
pressure in the column.
a) Basic Process Control System:
PCV-101 will open to relieve
pressure in the column C-101
when PT-101 reads a high
pressure in the column.
More of
Additional Safeguards
Recommended
a) Install a high pressure alarm
(PAH) that is independent of PC-
101 and its control loop. Hence,
operator can intervene during
high pressure situations.
b) Incorporate a safety interlock
system to cut off steam flow into
the reboiler E-107 if the pressure
in column C-101 increases past
the high-high limit set.
a) Install a high pressure alarm
(PAH) that is independent of PT-
101. Hence, operator can
intervene during high pressure
situations.
b) Incorporate a heat exchanger
after column C-100 and before
column C-101 to cool the
incoming bottoms from C-100.
Hence, inlet stream of C-101 will
not enter as vapour.
54

Malfunctioning of FCV-102,
leaving the control valve at full
close position. Hence, there will
be no reflux flow from reflux
drum V-102. With no reflux
flow, there is no liquid to
condense the rising vapours. As
such, the accumulation of vapour
will result in high pressure in C-
101.
a) Install a high pressure alarm
(PAH) that is independent of PT-
a) Over-pressurization in column
101. Hence, operator can
C-101 is unsafe and may rupture
a) Basic Process Control System: intervene during high pressure
if pressure continues to build-up.
PCV-101 will open to relieve situations.
b) With no reflux, the purity of
pressure in the column C-101 b) Incorporate a safety interlock
the distillate will be affected.
when PT-101 reads a high system to cut off steam supply to
Hence, the column C-101
pressure in the column. reboiler E-107 to stop
efficiency in separating IPA from
vapourisation. Interlock activates
water will be reduced.
when pressure pass the high-high
limit set.
Table 2.3.2.9: High Pressure in C-101 HAZOP analysis
55
Unit/Node
Process Variable
Deviation
Cause(s) of Deviation
Malfunctioning of PCV-101,
leaving the control valve at full
close position. Hence, with the
control valve fully closed, vapour
will all condense as it passes
through condenser E-106. As
such, vapour is unable to build up
in IPA column C-101. This will
result in a low pressure scenario
in column C-101.
Malfunctioning of FCV-103,
leaving the control valve at full
close position. With no flow of
hot steam, the reboiler E-107
duty decreases. As such, there be
no vapourisation of the liquid in
the column, resulting in low
pressure in IPA Column C-101.
IPA distillation column, C-101
Pressure
Low Pressure in C-101
Possible Consequences
a) Reduced pressure may affect
the separation in the column and
hence, reduce C-101s efficiency.
b) With all the vapour top
product being condensed, level in
reflux drum, V-102, will increase
drastically and continue to build-
up.
a) Reduced pressure may affect
the separation in the column and
hence, reduce C-101s efficiency.
b) With no vapourisation, there
will be no top product being
formed. The liquid level in
column C-101 will start to build-
up. Hence, resulting in high level
in column.
Table 2.3.2.10: Low Pressure in C-101 HAZOP analysis
Guide Word Less of
Additional Safeguards
Existing Safeguards Available
Recommended
a) Install a low pressure alarm
(PAL) that is independent of PT-
101. Hence, operator can
a) Basic Process Control System: intervene during low pressure
LCV-102 will open in an attempt situations.
to reduce the level in reflux drum b) BPCS: Control valve to
V-102 when LT-102 reads a high increase steam flowrate to
level in the reflux drum. reboiler E-107 when pressure is
low. It can be set to work
alongside FC-103 using a selector
control scheme.
a) Basic Process Control System:
PCV-101 will open in an attempt
to prevent hot vapour from being
condensed in E-106. As such, a) Install a low pressure alarm
vapour should accumulate to try (PAL) that is independent of PT-
to increase the pressure. 101. Hence, operator can
b) Basic Process Control System: intervene during low pressure
LVC-101 will open in an attempt situations.
to reduce the level in column C-
101 when LT-101 reads a high
level in the column.
56
Unit/Node
Process Variable
Deviation
Cause(s) of Deviation
Malfunctioning of PCV-101,
leaving the control valve at full
open position. Hence, with the
control valve fully opened,
vapour will by-pass the
condenser E-106 and begin to
accumulate in V-102. As such,
vapour is builds up in reflux
drum and result in a high pressure
scenario in reflux drum V-102.
Malfunctioning of FCV-103,
leaving the control valve at full
open position. With an increased
flow of hot steam, the reboiler E-
107 duty increases. As such,
there will be more vapourisation
of the liquid in the column,
resulting in more vapour
accumulated in V-102. Hence,
the high pressure V-102.
Reflux Drum, V-102
Pressure
High Pressure in V-102
Possible Consequences
a) Over-pressurization in reflux
drum V-102 is dangerous and
may rupture if pressure continues
to build-up.
a) Over-pressurization in reflux
drum V-102 is dangerous and
may rupture if pressure continues
to build-up.
b) Reboiler E-107 may overheat
and get damaged due to the
suddenly increase in steam
flowrate.
Guide Word
Existing Safeguards Available
a) Pressure Relief Valve (PRV-
101) is installed to relief excess
pressure in reflux drum V-101.
2) Basic Process Control System:
PCV-102 will open in an attempt
to reduce pressure in V-102 when
PT-102 reads a high pressure in
the reflux drum.
a) Pressure Relief Valve (PRV-
101) is installed to relief excess
pressure in reflux drum V-101.
b) Basic Process Control System:
PCV-102 will open in an attempt
to reduce pressure in V-102 when
PT-102 reads a high pressure in
the reflux drum.
Less of
Additional Safeguards
Recommended
a) Install a high pressure alarm
(PAH) that is independent of PT-
102. Hence, operator can
intervene during high pressure
situations.
b) Install a rupture disc for reflux
drum V-102 that is in parallel
with PRV-101. This rupture disc
will rupture only at a higher
pressure when the PRV-101
cannot relief the pressure
sufficiently.
a) Install a high pressure alarm
(PAH) that is independent of PT-
102. Hence, operator can
intervene during high pressure
situations.
b) Install a rupture disc for reflux
drum V-102 that is in parallel
with PRV-101. This rupture disc
will rupture only at a higher
pressure when the PRV-101
cannot relief the pressure
sufficiently.
57
 a) Install a high pressure alarm
Malfunctioning of PCV-102,
(PAH) that is independent of PT-
leaving the control valve at full
102. Hence, operator can
close position. Hence, vapour is
a) Over-pressurization in reflux intervene during high pressure
trapped in V-102. This results in a) Pressure Relief Valve (PRV-
drum V-102 is dangerous and situations.
an accumulation of hot vapour in 101) is installed to relief excess
may rupture if pressure continues b) Install a rupture disc for reflux
V-102 that will build-up pressure pressure in reflux drum V-101.
to build-up. drum V-102 that is in parallel
over time such that there will be
with PRV-101. This rupture disc
high pressure in reflux drum V-
will rupture only at a higher
102.
pressure.
Table 2.3.2.11: High Pressure in V-102 HAZOP analysis

58
Unit/Node
Process Variable
Deviation
Cause(s) of Deviation
Malfunctioning of PCV-102,
leaving the control valve at full
open position. Hence, vapour will
continuously leave the reflux
drum at a fast rate. With the loss
of vapour, vapour is unable to
build up in reflux drum V102.
This will result in a low pressure
scenario in reflux drum V-102.
Malfunctioning of FCV-103,
leaving the control valve at full
close position. With no flow of
hot steam, the reboiler E-107
duty decreases. As such, there be
no vapourisation of the liquid in
the column. Thus, no vapour will
build up in the reflux drum V-
102. This will result in a low
pressure scenario in reflux drum
V-102.
Reflux Drum, V-102
Pressure
Low Pressure in V-102
Possible Consequences
a) A large amount of product will
be lost. This is because the top
vapour product is continuously
sent to the flare to be burnt off.
a) With no vapourisation, there
will be no top product being
formed. The liquid level in
column C-101 will start to build-
up. Hence, resulting in high level
in column.
b) No top product being formed
means level in V-101 will drop.
Table 2.3.2.12: Low Pressure in V-102 HAZOP analysis
Guide Word
Existing Safeguards Available
No existing safeguard available.
a) Basic Process Control System:
LVC-101 will open in an attempt
to reduce the level in column C-
101 when LT-101 reads a high
level in the column.
b) Basic Process Control System:
LCV-102 will close in an
attempted to increase the level in
reflux drum when LT-102 reads a
low level in the reflux drum.
Less of
Additional Safeguards
Recommended
a) Install a low pressure alarm
(PAL) that is independent of PT-
102. Hence, operator can
intervene during low pressure
situations.
a) Install a low pressure alarm
(PAL) that is independent of PT-
102. Hence, operator can
intervene during low pressure
situations.
b) Install a low level alarm (LAL)
that is independent of LT-102.
Hence, operator can intervene
during low level in reflux drum
situations.
59
2.3.3 PFD of distillation process after HAZOP
From the HAZOP analysis performed on the 12 deviations, the required safeguards to be built
onto the current preliminary PFD is as such (with further considerations made through
observation and evaluation) with reference to the preliminary column PFD:

x Introduce a parallel pump configuration for feed pump P-102

x Introduce a parallel pump configuration for reflux pump P-103
x Install a minimum flowline for feed pump P-102
x Introduce a strainer each for all pumps
x Introduce a pressure relief valve (sized for two-phase flow) immediately at the top outlet
of the column C-101, venting off to flare
x Introduce a rupture disc parallel to the pressure relief valve at the reflux tank which will
lead to the flare
x Introduce a composition analyser for feed, top product (before the pipeline splits between
distillate and reflux lines) and bottom product
x Install separate transmitters to provide alarm signals (from their Basic Process Control
System, BPCS, counter parts) for the following process parameters
Pressure of column C-101 (For high and low)
Pressure in reflux tank V-102 (For high and low)
Level in column C-101 (For high and low)
Level in reflux tank V-102 (For high and low)
Temperature of vapour boil-up after reboiler E-107 (For high only)
Temperature of top vapour flow out from column C-101 (For high only)
Temperature of condensed fluid flow after condenser E-106 (For high and low)
x Install a temperature transmitter (and indicator) along the feed inlet line with alarms set
at high and low limits
x Installer safety interlock systems for the following process parameters
Low-low level switch for column C-101 which activates a solenoid valve that blocks
liquid flow out of reboiler
Low-low level switch for reflux tank V-102 which will switch off all reflux pumps
High-high pressure switch for column C-101 which activates a solenoid valve that
blocks steam flow into the reboiler
High-high temperature switch for vapour boil-up flow from reboiler E-107 which
activates a solenoid valve that blocks steam flow into the reboiler
x Ensure there are scheduled trips to ensure that all equipment are in proper operating
conditions, to confirm if reading transmitted is that on-site, and to perform regular control
valve stroke checks
x Employ a split range pressure controller scheme that controls PCV-101 and PCV-102
rather than to use two separate control schemes

60
Main discussion pointers
The main two recommendations from the HAZOP analysis that were not considered are the
employment of a heat exchanger to cool the feed stream and to introduce additional back-up
control valves parallel to their original ones. The former would be relatively unnecessary due
to the fact that heat is generally lost over flow distance. Implementation of a heat exchanger
would result to excessive energy and utility demands. If it is critically demanded that the stream
is to be cooled, an exposed section of the piping coiled up as a heating coil can be implemented
so as to exchange heat to the surroundings. For the latter idea, the idea of using extra control
valves may cause confusions during operations which can result to miscommunications and
process upsets. Also the idea of using a low selector switch between PC-101 (column pressure
regulator) and TC-103 (temperature control of vapour outlet from reboiler) to then act as the
master control for cascade controller FC-103 (steam inlet flow into reboiler) is not advisable.
This is because the pressure in the column has its own BPCS to operate thus providing two
conflicting signals may result to producing a vapour flowrate that is not desired; ultimately
affecting the purity of the outlet streams.
The edited overall IPA column PFD with all these considerations is presented as such:

PAH
PRV-101 PIT PIT PC To Flare
101 PAL
101 101

PCV-101B
PCV-101A PRV-102

PAH
TAH TAH PIT
TIT E-106 TIT 102
LAH
102 103 TAL LIT
PAL

102
TIT TIC V-102 LAL

102 102
TIT
PSHH
103 LIT
101
102
LSLL
TC 102
TCV-103 103 LC
102

CWR CWS
II
FC FIT FIT FC
101 101 102 102 P-103A

AIT
C-101 102
FCV-101 P-103B
Bottoms AIT TIT
TAH

from C-100 P-102A 101 101 TAL IPA for

FCV-102 HV-102
PDI Recycle
101

LCV-102
P-102B TSHH III
104
TC
TIT
TAH
TIT 104
104 104
LAH FIT FC
LIT
103 103
101 LAL

LIT Steam
101 Inlet
LSLL FCV-103 UZV-101
101
E-107

Steam
LC Outlet
101 HV-101 LCV-101
I

Water for
AIT Discharge
103

Figure 2.3.3.1: Edited PFD of C-101 with consideration of performed HAZOP analysis

61