Node 1: Distillation column T-3022

Description: This column takes the bottoms from the debutaniser containing propane and propene, it is the first half of the column that is used to separate
these two products and it represents the enrichment section of a standard column
Item
Parameter
Cause
Consequence
Current Safeguards
Actions
number
1.1
No flow
Blockage upstream
Build up of pressure upstream - V-30213 fails open
1.1.1 - Put flow indicator after PV-30213 failure
potential explosion risk (BLEVE) V-3022 relief valve on previous
3021
P-3021 failure
P-3022 runs dry
column in case of overpressure 1.1.2 - Regular maintenance of
Not producing product
up stream
pumps and valves.
1.1.3 - In case of no flow operate
column at 100% reflux until feed
can be started again
1.2
More feed
Pump operating out of
Flooding of column
LT-30220 and related control
See 1.1.1
flow from
operating range
Less efficient separation
loop
1.2.1 - High level alarm at base of
upstream
Increased bottoms flow
Required product purity not
TT-30212 and related control
T-3022 to be connected to pump
from previous column
met
scheme (composition control
to be installed after V-30223 in
If goes unnoticed potential for
loop)
case of high level alarm being
liquid to build up to top of
V-30214 relief valve
indicated pump will increase flow
column and increase pressure
from base of column
of column
1.2.2 - Put intermediate storage
Damage to P3022 due to
tank between T-3023 and recycle
overrunning
to ATR
1.3

More
vapour flow
from second
column

Increased boil up
High pressure in second
column

Increased pressure in column

Potential change in product
composition
Higher condenser duty

1.4

Less feed
flow from
upstream

Blockage
Leaks
P-3021 failure
V-30231 failure

Entrainment
Less product
Potential if very low flow to
damage P3022

PT-30210 and associated

control scheme
TT-30212 and related control
scheme (composition control
loop)
V-30214 relief valve
The fact that the column
operates at high reflux makes
entrainment highly unlikely
TT-30212 and related control

1.3.1 - Put pressure indicator at

top of T-3023
1.3.2 - Low and high pressure
alarms on T-3023

See 1.1.1
See 1.1.2

1.5

Less flow
from second
column

1.6

More
temperature

1.7

Less
temperature

1.8

More
pressure

Reduction in bottoms
outlet from T-3021

Reduction in column pressure

Blockage
Leaks
Less boil up
Low pressure in second
column
E-3023 failure
Leak of steam into
process streams within E3023
Change in steam quality
supplied to E-3023
Higher ambient
temperature
Reduced cooling water
flow in E-3024
Fouling on E-3024
E-3023 failure
Change in steam quality
supplied to E-3023
Lower ambient
temperature
Reduced steam flow to E3023
Fouling on E-3023
Blockages downstream
(in propane recycle line)
Tray blockages
Build up of liquid level in
column

Potential compositions changes

Entrainment

scheme can maintain a high

reflux
PT-30210 and related control
scheme
See safeguards in section 1.4

See 1.3.1
See 1.3.2

Changes in product composition

Extreme excess temperature
can result in corrosion
Hot column and equipment
present safety risks to operators
Strain on materials of
construction

TT-30212 to TT-30219
Column is insulated
Column is designed so material
can withstand excess
temperatures

1.6.1 Regular maintenance and

inspection of E-302
1.6.2 - Regular maintenance and
inspection of E-3024

Change of product compositions

TT-30212 and related control

scheme
TT-30213 to TT-30219
Insulation

See 1.6.1

Potential explosion
Vessel rupture resulting in leak
of propane and propene
potentially creating a flammable
atmosphere

PT-30210 and associated

control scheme
Relief valves V-30214, V-30219
and V-30221
Column designed to withstand

See 1.3.1
See 1.3.2

Increased vapour flow

from T-3023
High temperatures
P-3022 failure

Change of product compositions

excess pressure
See more flow

Change of product composition

Potential that top product dew
point decreases meaning
cooling water is not able to
condense
Higher product purity
More propene in bottom
stream meaning propene is
recycled through the system
reducing propene selectivity in
DTP reactor
Lower product purity

See 1.4

No Actions

TT-30212 and related

composition control scheme
TT-30213-TT-30219 provide
composition indications

No Actions

See safeguards for 1.10

1.11.1 - Periodically sample

distillate throughout the day to
directly analyse composition

Change of product composition

Thermal inefficiency in column
Increase in utility requirements

TT-3029 and associated control

scheme
See safeguards for 1.10

See 1.6.1

1.9

Low pressure

Less flow
Leaks

1.10

More
composition
(propene)

Higher selectivity in DTP

reaction upstream

1.11

Less
composition
(propene)

1.12

Other state
(Upstream
feed)

Higher selectivity in DTP

reaction upstream Lower
recovery of propene in
upstream separation
processes
Reduced steam flow to E3023
Fouling on E-3023
Change in steam quality
to E-3023
V-3028 failure
Change in feed
composition (feed will
have a different
saturation temperature

Node 2: E-3024 top product condenser

Description: Totally condenses the vapour from the top of T-3022 some of the condensed vapour is returned to the column for reflux and some is taken to final
product storage
Item
Parameter
Cause
Consequence
Current Safeguards
Actions
number
2.1
No flow (of vapour
Blockage in lines
No product
See 1.8
2.1.1 If both low level alarm on
out of T-3022)
No vapour flow in No level in reflux drum
LIC-30211 and associated high reflux drum and high pressure
column
Build up of pressure (if
and low level alarms on reflux alarm at top of column are
blockage)
drum
enunciated it indicates a blockage
- a trip will be set to initiate
emergency shutdown in this
instance
2.2
No flow (of cooling
Blockage in lines
No condensation of distillate LIC-30211 low level alarm
See 2.1.1
water)
V-30217 failure
and hence pressure build up PIC-30210 high pressure alarm
in column
PT-30210 and associate
No product
control scheme
V-30214
2.3
More flow of (of
See 1.3
Total condensing of stream
Pressure relief valves V-30214 No Actions
vapour out of Tis not achieved
and V-30219
3022)
High pressure in V-3022
PT-30213 and associated
control scheme
2.4
More flow (of
V-30217 failure
Lower pressure in column
Low pressure alarm indicates
2.4.1 Regular maintenance and
cooling water)
Failure of pump
Increased utility cost
failure in pressure control loop inspection of V-30217
upstream in
2.4.2 Flow indicator after Vutility system
30217
2.5
Less flow of (of
See 1.5
Less product
PT-30210 and associated
No Actions
vapour out of TLow pressure in column Low control scheme
3022)
pressure in E-3024 and VLT-30211 and associated
3022
control scheme
Low level in V-3022

Commented [EB1]: What???

2.6

Less flow (of cooling

water)

See 2.4

2.7

More temperature
(of vapour out of T3022)

Higher pressure
in column
Higher ambient
temperature
Change in
composition

2.8

More Temperature
(of cooling water)

2.9

Lower temperature
(of vapour out of T3022)

2.10

Less temperature (of

cooling water)

Higher ambient
temperature
External Fire
Changes to
upstream utility
system
Lower ambient
temperature
Lower pressure in
column
Changes in
composition
Lower ambient
temperature
Faults in utility
system upstream

No level
More level
Less level
More composition
(propene)
Less composition

Higher pressure in column

Total condensing of stream
is not achieved
See 2.6

See 2.4

See 2.4.1
See 2.4.2

See 2.4

No Actions

Less efficient heat transfer

Potential that total
condensing of stream is not
achieved

See 2.3
TT-30222 gives indicator

See 2.4.2

See 2.4

No Actions

Less efficient heat transfer

See 2.6

(Propene)
Other state
(Upstream feed)

Node 3: V-3022 Reflux Drum

Description:
Item number
Parameter
3.1
No Flow
More Flow
Less Flow
More Temperature
Less Temperature
More Pressure
Less Pressure
More Level
Less Level
No Level
More composition
(propene)
Less composition
(Propene)
Other state (Upstream
feed)

Node 4: P-3022 Pump between columns

Cause

Consequence

Current Safeguards

Actions

Description:
Item number
4.1

Node 5: T-3023
Description:
Item number
4.1

Parameter
No Flow
More Flow
Less Flow
More Temperature
Less Temperature
More Pressure
Less Pressure
More Level
Less Level
No Level
More composition
(propene)
Less composition
(Propene)
Other state (Upstream
feed)

Cause

Consequence

Current Safeguards

Actions

Parameter
No Flow
More Flow
Less Flow
More Temperature
Less Temperature
More Pressure
Less Pressure

Cause

Consequence

Current Safeguards

Actions

More Level
Less Level
No Level
More composition
(propene)
Less composition
(Propene)
Other state (Upstream
feed)

Node 6: E-3025 - Reboiler

Description:
Item number
Parameter
6.1
No Flow
More Flow
Less Flow
More Temperature
Less Temperature
More Pressure
Less Pressure
More Level
Less Level
No Level
More composition
(propene)
Less composition
(Propene)
Other state (Upstream
feed)

Commented [EB2]: Combine with first coumn?

Cause

Consequence

Current Safeguards

Actions

Notes: Pressure control loop - less cooling water, increases pressure in condenser which is the pressure in top of column