Distillation Column

Process Guide Available

Possible Cause Consequences Recommendation
Parameters Word Safeguards
• FCV-XXX Failure and • Backflow of methanol • LIA-XXX HH •
stuck close during normal liquid going to V-XX level alarm
operation (from vessel) causing carry over of (Vessel
liquid to V-XX overhead upstream)
• Overheating of C-XXX • Split range •
No/Less causing pressure build up controller
inside C-XXX

• FCV-XXX(from reboiler) • Pressure drop in C-XXX • LIA-XXX LL •

Flow Failure and stuck close causing C-XXX to XXXX level alarm
during normal operation (Dist column)
• FCV-XXX (from Vessel) • C-XXX flooding causing • PZA-XXXX will •
failure and stuck open tray collapse cut off feed
More
during normal operation supply to C-
XXX
• FCV-XXX Failure and • Backflow of methanol • LIA-XXX HH •
stuck close during liquid going to V-XX level alarm
Reverse
normal operation causing carry over of (Vessel
liquid to V-XX overhead upstream)
• FCV-XXX(from reboiler) • Pressure drop in C-XXX • LIA-XXX LL •
Less Failure and stuck close causing C-XXX to XXXX level alarm
during normal operation (Dist column)
• FCV-XXX(from reboiler) • Overheating of C-XXX • Split range •
Failure and stuck open causing pressure build up controller
Temperature
during normal operation inside C-XXX
More • E-XXX Motor failure • Insufficient cooling duty • Opening of •
by E-XXX causing flare valve
pressure build up at
downstream
 • FCV-XXX(from reboiler) • Pressure drop in C-XXX • LIA-XXX LL •
Less Failure and stuck close causing C-XXX to XXXX level alarm
during normal operation (Dist column)
Pressure
• FCV-XXX(from reboiler) • Pressure build up inside • Split range •
More Failure and stuck open C-XXX causing tray controller
during normal operation collapse
• Leakage of flowline from • Backflow of methanol • LIA-XXX HH •
upstream of C-XXX (dist liquid going to V-XX level alarm
column) causing carry over of (Vessel
Less liquid to V-XX overhead upstream)
• Overheating of C-XXX • Split range •
Level causing pressure build up controller
inside C-XXX
• FCV-XXX (from Vessel) • C-XXX flooding causing • PZA-XXXX will •
failure and stuck open tray collapse cut off feed
More
during normal operation supply to C-
XXX
 MeOH Reactor

Process Guide Available

Possible Cause Consequences Recommendation
Parameters Word Safeguards
• FCV-XXX Failure and • Backflow of vapour going • LIA-XXX HH •
stuck close during normal to V-XX causing gas blow level alarm
operation (from flash) by to V-XX overhead (flash)
No/Less • Surging of K-XXX causing • ASV •
compressor failure

Flow • FCV-XXX Failure and • Overloading (choke) of • FCV-XXX •

stuck open during compressor
More
normal operation (from
flash)
• KM-XXX failure causing • Backflow of vapour going • LIA-XXX HH •
Reverse low discharge pressure to V-XX causing gas blow level alarm
by to V-XX overhead (flash)
• FCV-XXX (LP steam) • Pressure drop in R-XXX • LIA-XXX LL •
Less failure and stuck close causing R-XXX to XXXX level alarm
(Reactor)
Temperature • FCV-XXX(from LP steam) • Overheating of R-XXX • TIA-XXX HH •
Failure and stuck open causing pressure build up level alarm
More
during normal operation inside R-XXX causing R- (from LP
XXX rupture steam)
• K-XXX motor failure • Pressure drop in R-XXX • PIA-XXX LL •
Less causing R-XXX to XXXX pressure alarm
(reactor)
Pressure
• PCV-XXX (compressor) • Pressure build up in R- • PIA-XXX HH •
More failure XXX causing R-XXX pressure alarm
explosion (reactor)
 CO2 Absorber

Process Guide Available

Possible Cause Consequences Action Required
Parameters Word Safeguards
• FCV-XXX Failure and • Backflow of flue gas • LIA-XXX HH •
stuck close during normal going to C-XXX causing level alarm
No/Less
operation (from flash) gas blow by to V-XX (Vessel
overhead upstream)
Flow • FCV-XXX failure and stuck • C-XXX flooding causing • LIA-XXX HH •
open during normal tray collapse level alarm
More operation (from lean (rich amine)
amine) triggering FCV-
XXX opening
• FCV-XXX failure • N/A • N/A •
and stuck open
Less during normal
operation (from
Temperature
cooler)
• FCV-XXX failure and stuck • C-XXX rupture due to • TC-XXX •
More close during normal thermal shock (cooler)
operation (from cooler)
Level • P-XXX blockage (lean • N/A • N/A •
Less
amine)
• FCV-XXX failure and stuck • C-XXX flooding causing • LIA-XXX HH •
open during normal tray collapse level alarm
More operation (from lean (rich amine)
amine) triggering FCV-
XXX opening
PDP References
[1]
Chapter 6
Bolton, W. (2015). Instrumentation and control systems. Newnes.
[1] “WHAT IS RATIO CONTROL ? | Instrumentation and Control Engineering.” [Online]. Available: https://automationforum.co/what-is-
ratio-control/. [Accessed: 23-Nov-2019].

Chapter 7

Calixto, E. (2016). Reliability and Safety Processes. Gas and Oil Reliability Engineering, 553–663.

Smith, D. J. (2017). Risk Assessment (QRA). Reliability, Maintainability and Risk, 159–181.