Distillation column

The studies on distillation column suggest the following objectives:

1. Product quality control to maintain either the overhead or bottom composition at a
specified value
2. Material balances control to maintain its column hold-up and overhead and bottom
inventories between maximum and minimum limits.
3. Constraints. The column should not flood. Pressure should be high enough to maintain
effective column operation and the temperature difference in the reboiler should not
exceeded critical temperature difference.
HAZOP Studies on Distillation Column
Guide
word
NO

Deviation
No flow

Possible
causes
Pipe blockage
Control valve shut
Valves fail
Tube leakage and
blocking
Pump failure

Consequences

Column dry out

Possible
dangerous
concentration
No operation

LESS

Less Flow

MORE

More flow

Pipe blockage
Control valve shut
Valves fail
Tube leakage and
blocking
Pump failure

Control valve is
fully opened
Increase pumping
capacity
Control valves
failure

Column dry out

Changes in
product quality

Flooding in the
column
Changes in
product quality
Temperature
decrease
Rise in bottom

Action
required
Install low level
alarm
Check
maintenance
procedure and
schedule
Make bypass
Emergency plant
shut down
Install low level
alarm
Check
maintenance
procedure
Make bypass
Emergency plant
shut down
Install high level
alarm
Check
maintenance
procedure and
schedule
Install control

liquid level

HIGH

High
pressure

High
Temperature

LOW

Low
pressure

Vapor pressure high

Pressure indicator
controller fail

Instrumentation
failure
More steam flow
Exchanger tube
failure
High steam pressure
Cooling water in
condenser failure.
Reboiler control
failure
Heating medium
leak into process
Vapour line leakage

Low
temperature

Instrumentation
failure
Less steam flow
Loss of heating
(steam leakage)
Low steam pressure
and temperature
Ineffective isolation

Low efficiency
of separation
Rupture of
column or other
related
equipment
Product loss
Separation
cannot be done
Changes in
product quality
Column
flooding
Film boiling in
column and
reboiler
Phase effect
Pressure
changes
Low efficiency
of separation
Loss of
products
Pressure change
Product loss
Changes in
product quality
Ineffective
separating
process
Phase effect

valves
Install flow
indicator
Make bypass
Install high
pressure alarm
Install pressure
relief valve

Install temperature
indicator
controller
Instruct operator
on procedure
Attention to heat
input and output
control

Install pressure
indicator

Install temperature
indicator
Instruct operator
on procedure
Upgrade isolation
Attention to heat
input and out
control