567

R-102
E -102
V-103
D-101
V-103
Myristic acid
10

Figure 10.1 Study nodes for distillation column V-103




Table 10.20 HAZOP for distillation column V-103
Project Title: Production of high purity of stearic acid
Project Number: 1
Process: Vapour-liquid separation Section: Distillation column V-103
Reference drawing: Piping and Instrumentation Diagram
Study Node Parameter Guide Words Deviations Causes Consequences Action Required
10 Flow High High flow 1. Valve at the stream
failed opened.

1. Flooding in the
distillation column.
1. Install manual valve.
2. Scheduled inspection and
maintenance.




Low



Low flow 1. Low pressure from
source.
2. Pipe blockage.
1. Level decreased in
the column.
2. Not achieved the
desired product.

1. Scheduled inspection and
maintenance.
2. Install manual valve.





No No flow 1. Valve at the stream
failed closed.
2. Pipe blockage.


1. Loss of feed in the
column and not
achieved the desired
product.
2. Level decreased in
1. Scheduled inspection and
maintenance.
2. Install low level alarm.
5
6
8


the column.

V-103 Level



High High level 1. Failure of the
reflux.
2. Failure of the
control valve.

1. Flooding in the
column.

1. Install high level alarm.
2. Scheduled inspection and
maintenance.
Low


Low level

Failure of the pump. 1. Overheating in
reboiler.

1. Install low level alarm.
2. Scheduled inspection and
maintenance.

Pressure

High


High level

1. High rate in
reboiler
2. Failure of control
valve.

1. Explosion of the
column.

1. Install pressure indicator
to monitor the reading.
2. Scheduled inspection and
maintenance.

Low

Low
pressure

1. Low flow from the
source.
2. Failure of the
control valve.
1. The implosion of
the column.
2. Off specification of
the product.
1. None of PIC handled.
2. Schedule inspection and
maintenance.

Temperature High High 1. Failure of the TRC. 1. Wall rupture. 1. Install the temperature
5
6
9


temperature

2. Air leaked.
3. Product is off
specification.
4. Entrainment in the
column.

alarm high.

Low Low
temperature
1. Failure of the
LRC.
2. Malfunction of the
reboiler.

1. Separation failure.
2. Product off
specification.
1. Install temperature alarm
low.

Composition Low Low purity 1. The reaction is not
happened under the
desired condition.
1. Product off
Specification.
1. Proper maintenance.
2. Install low composition
alarm.



5
7
0

571

V-102
R-101
Palm
stearin
P-101
Steam
Water
V-101
P-102
1
5
6

Figure 10.2 Study nodes for centrifugal contactor separator R-101

4
1
5


Table 10.21 HAZOP for centrifugal contactor separator R-101
Project Title: Production of high purity of stearic acid
Project Number: 1
Process: Reaction Section: Centrifugal contactor separator R-101
Reference drawing: Piping and Instrumentation Diagram
Study Node Parameter Guide Words Deviations Causes Consequences Action Required
1


Flow High



High flow 1. Valve at the stream
failed opened.
1. Rupture at pipeline. 1. Install manual control
valve.
2. Scheduled inspection
and maintenance.




Low



Low flow 1. Leakage of
pipelines.
1. Incomplete reaction.
2. Backflow of fluid
3. Product off
specification.

1. Use check valves.
2. Scheduled inspection
and maintenance.

No No flow 1. Valve at the stream
failed closed.
2. Blockage at
pipelines.
1. No fluid flow into
reactor.
2. No reaction in the
reactor.
1. Scheduled inspection
and maintenance.


5
7
2


5



Flow High



High flow 1. Valve at the stream
failed opened.
1. Rupture at pipeline. 1. Install manual control
valve.
2. Scheduled inspection and
maintenance.




Low Low flow 1. Leakage of
pipelines.
1. Incomplete reaction.
2. Backflow of fluid
3. Product off
specification

1. Use non-return valves.
2. Scheduled inspection and
maintenance.





No No flow 1. Valve at the stream
failed closed.
2. Blockage at
pipelines.

1. No fluid flow into
reactor.
2. No reaction in the
reactor.
1. Scheduled inspection and
maintenance.


6 Flow High



High flow 1. Valve at the stream
failed opened.
1. Rupture at pipeline. 1. Install manual control
valve.
2. Scheduled inspection and
maintenance.


5
7
3


Low Low flow 1. Leakage of
pipelines.
1. Incomplete reaction.
2. Backflow of fluid
3. Product off
specification.

1. Use non-return valves.
2. Scheduled inspection and
maintenance.




No No flow 1. Valve at the stream
failed closed.
2. Blockage at
pipelines.

1. No fluid flow into
reactor.
2. No reaction in the
reactor.
1. Scheduled inspection and
maintenance.
R-101 Pressure High High
pressure
1. Failure of the
pressure controller.
2. High fluid flow
from the stream.
3. Sudden surge of the
pressure.

1. Rupture of the wall
of the reactor.
2. Explosion of reactor
that can cause
damage in the plant.

1. Install high pressure
alarm.
2. Scheduled inspection and
maintenance.
3. Install control valve.







Low



Low
pressure


1. Low flow of the
fluid.
2. Low pressure from
the source.
1. Implosion of reactor.
2. Product off
specification.

1. Install low pressure
alarm.
2. Scheduled inspection and
maintenance.
5
7
4


Temperature

High High
Temperature
1. Failure of the
control valve.
1. Flooding in the
reactor.
1. Install high temperature
alarm.
Low Low
temperature
1. Failure of the
control valve
1. Off specification of
product.
1. Install low temperature
alarm.

5
7
5

576

R-102
CW
Hydrogen
Fatty
acid
20
21

Figure 10.3 Study nodes for jacketed trickle bed reactor R-102


Table 10.22 HAZOP for jacketed trickle bed reactor R-102
Project Title: Production of high purity of stearic acid
Project Number: 1
Process: Liquid transfer Section: Jacketed trickle bed reactor, R-102
Reference drawing: Piping and Instrumentation Diagram
Study Node Parameter Guide Words Deviations Causes Consequences Action Required
20 Flow High High flow 1. Due to high
pressure.
2. Problem with the
valve.
1. Damage to
pipelines.
2. Damage to the
components.

1. Install manual control
valve.
2. Scheduled inspection
and maintenance.






Low

Low flow 1. Leakage of the
pipe.
2. Valve at the stream
partially closed.
3. Pipe partially
closed

1. Product off
specification.

1. Use non return valve.
2. Schedule inspection and
maintenance.



No

No flow 1. Valve failed
closed.
1. No flow of liquid in
the reactor.
1. Schedule inspection and
maintenance. 5
7
7








2. Pipe block.
3. No stearic acid.
2. No reaction between
Hydrogen and
Stearic Acid.

Pressure High High
pressure
1. High flow rate of
liquid
1. Damage to
pipelines.
2. Leakage in pipe
joints.

1. Scheduled inspection and
maintenance.
21 Flow High High flow 1. Due to high
pressure.
2. Problem with the
valve.
1. Damage to
pipelines.
2. Damage to the
components.
1. Install manual control
valve.
2. Scheduled inspection
and maintenance.

Low

Low flow 1. Leakage of the
pipe.
2. Valve partially
closed.
3. Pipe partially
closed.

1. Product off
specification.

1. Use non return valve.
2. Schedule inspection and
maintenance.

No No flow 1. Valve failed closed. 1. No flow of the 1. Schedule inspection and
5
7
8











2. Pipe block.
3. No stearic acid.

hydrogen gas in the
reactor.
2. No reaction between
Hydrogen and
Stearic Acid.

maintenance.

Pressure High High
pressure
1. High flow rate of
liquid.
1. Damage to
pipelines.
2. Leakage in pipe
joints.

1. Scheduled inspection
and maintenance.
2. Install pressure control
valve.
Low Low
pressure
1. Low flow rate of
liquid.
1. Backflow of liquid. 1. Install non-return valve.
2. Scheduled inspection
and maintenance.




R-102



Temperature High High
temperature

1. Faulty of the
temperature
controller.

1. Product off-
specification.
2. Rupture of the pipe
which can lead to
1. Scheduled inspection
and maintenance.
2. Implement standard
working procedure.
5
7
9





leakage.
3. Occurrence of the
runaway reaction.

3. Install high temperature
alarm.

Low Low
temperature
1. Faulty of the
temperature
controller.
1. Product off
specification.
1. Scheduled inspection and
maintenance.
2. Install low temperature
alarm.












Pressure










High










High
pressure









1. Faulty of the
pressure controller
due to the failure of
pressure control.
2. Sudden surge of
the pressure.
3. High flow of the
fluid.
4. The valve from
stream failed to
open.
1. Damage/Failure of
pump.
2. Lead to the
explosion of reactor
due to over pressure.
3. Hydrogen gas will
be emitted to the
surrounding.

1. Install high pressure
alarm and relief valve.
2. Schedule maintenance
and inspection.






5
8
0


Low Low
pressure
1. Low flow of the
fluid.
2. Low pressure from
the source.
1. Impulsion of the
reactor.
2. Emission of
hazardous gas
1. Install low pressure
alarm.
2. Schedule maintenance
and inspection.

5
8
1