Node 1: Reformer, R-01

HAZOP Study Methanol Production Plant

Study Node Feed inlet into Reformer, R-01
Design Intention Supply heat to feed
PARAMETER GUIDE WORD DEVIATION

None No flow to reformer

Flow
Less Less flow to reformer

More More flow to reformer

Low Low temperature to reformer

Temperature
High High temperature to reformer

Low Low pressure to reformer

Pressure

High High pressure to reformer

 CAUSES CONSEQUENCES
Pipe blockage Pressure build up in reformer
Pump faulty Tube or vessel rupture
Failure of control valve Possible explosion
Fouling of heat exchanger Incomplete reaction
Low pump capacity
Valve not fully open
Increased pumping capacity Accumulation of feed causing spillage
Control valve malfunction
Fouled exchanger tubes Insufficient heat
Faulty instrumentation and control Incomplete reaction
Heat exchanger malfunction Possible explosion

Flange leakage Reverse flow

Control valve failure
Pump failure
Pipe blockage Pressure build up in reformer
High temperature in feed inlet to reformer Pipe or tube rupture
Possible explosion
 SAFEGUARDS
Install flow indicator and controller
Install emergency shutdown device (ESD)
Install pressure relief valve for emergency venting
Install flow indicator and controller
Install bypass valve

Install flow indicator and controller

Install emergency shutdown device (ESD)
Install temperature indicator and controller

Install temperature indicator and controller

Install alarm connected to emergency shutdown device (ESD)
Install pressure indicator and controller

Install pressure indicator and controller

Install emergency shutdown device (ESD)
Install Pressure Relief Valve for emergency venting
 ACTION REQUIRED ACTION BY
Regular inspection and maintenance Operator
Check and monitor reliability of control valve

Regular inspection and maintenance on heat exchanger Operator

Regular inspection on pump and valve

Regular inspection on pump and valve Operator

Regular inspection and maintenance on heat exchanger Operator

Regular inspection and maintenance on heat exchanger Operator

Regular inspection and maintenance on pipeline Operator

Regular inspection and maintenance on pipeline Operator

Node 2: Plug Flow Reactor, R-02
HAZOP Study Methanol Production Plant
Study Node Feed into Plug Flow Reactor, R-02
Design Intention Synthesis of methanol
PARAMETER GUIDE WORD DEVIATION

None No flow to reactor

Less Less flow to reactor

Flow

More More flow to reactor

Reverse Reverse flow from reactor

Low Low temperature to reactor

Temperature
High High temperature to reactor

Low Low pressure to reactor

Pressure

High High pressure to reactor

 CAUSES
Pipe blockage
Pump faulty
Failure of control valve
Low pump capacity
Fouling of heat exchanger
Valve not fully open
Increasing pump capacity
Control valve malfunction
Defective one way (check) valve
Incorrect pressure differential
High pressure in reactor
Fouled exchanger tubes
Faulty instrumentation and control
Heat exchanger malfunction
Reactor cooling system fail
Loss of cooling water
Flange leakage
Control valve failure
Pump failure
Pipe blockage
High temperature in feed inlet to reactor
CONSEQUENCES
Product halted
Pressure drop in reactor
Decrease in product yield
Reactants build up
Deviation in temperature and pressure
Accumulation of product causes spillage
Product halted
Runaway reaction
Potential for explosion to occur due to high pressure
Lower product conversion
Decrease rate of production
Rate of reaction increase
Runaway reaction
Possible explosion
Rate of reaction decrease
Reverse flow
Pressure build up in reactor
Possible explosion
Pipe or tube rupture
 SAFEGUARDS
Install flow indicator and controller at reactor inlet
Install additional pump
Install new control valve
Install flow indicator and controller at reactor inlet
Install bypass valve

Install flow indicator and controller at reactor inlet

Install emergency shutdown device (ESD)

Install flow indicator and controller at reactor inlet

Install pressure controller
Install pressure relief valve for emergency venting
Install temperature indicator and controller at reactor

Install temperature indicator and controller at reactor

Install alarm connected to emergency shutdown valve

Install pressure indicator and controller at reactor

Install new control valve
Install new pump
Install pressure indicator and controller at reactor
Install pressure relief valve for emergency venting
Install emergency shutdown device (ESD)
 RECOMMENDATION ACTION BY
Regular inspection of pipeline Operator
Regular inspection of pump
Regular inspection of control valve
Check and monitor reliability of control valve Operator
Regular maintenance check on heat exchanger

Regular maintenance Operator

Check and monitor reliability of control valve

Regular inspection of check valve Operator

Regular check on pressure indicator connected to tra

Regular maintenance on heat exchanger Operator

Install quench system Engineer

Install cooling jacket on reactor

Regular maintenance Operator

Regular inspection on pump
Regular inspection on control valve
Operator
Regular check on pressure indicator connected to tra
Check and monitor reliability of relief valve
Check and monitor reliability of control valve
Node 3: Distillation Column, C-05
HAZOP Study Methanol Production Plant
Study Node Feed inlet into Distillation Column, C-05
Design Intention To separate methanol from by-products
PARAMETER GUIDE WORD DEVIATION

None No flow to distillation column

Flow
Less Less flow to distillation column

More More flow to distillation column

Low Low temperature in distillation column

Temperature

High High temperature in distillation column

Low Low pressure in distillation column

Pressure
High High pressure in distillation column

Low Low level in distillation column

Level

High High level in distillation column

 CAUSES CONSEQUENCES
Failure of control valve Failure of separation process
Blockage in the pipeline No yield of distillate and bottom product
Feed shortage
Pump faulty
Flange leakage Less yield of distillate and bottom product
Valve not fully open Overheating
Low pump capacity Less yield of distillate and bottom product
Increasing pump capacity Rise in liquid level causing spillage
Control valve malfunction Flooding
Heat exchanger malfunction Reduce separation efficiency
Fouled or failed exchanger tubes Decrease rate of production
Faulty instrumentation and control
Cooler malfunction Overheating
Faulty instrumentation and control Poor separation
Reboiler control failure Flooding
Pump failure Reduce separation efficiency
Pipeline leakage
High feed rate Pressure build up
Insufficient cooling water from condenser Flooding
Control valve malfunction
Inlet flow stops Reduce separation efficiency
Outflow greater than inflow Temperature increase
Faulty level measurement
Control failure
Outlet pipeline blocked Pressure build up
Level control failure Possible spillage
Low pressure drop across column Reduce separation efficiency
 SAFEGUARDS
Install flow indicator and controller at distillation column
Install standby pump

Install flow indicator and controller at distillation column

Install emergency shutdown device (ESD)
Install flow indicator and controller at distillation column
Install flow indicator and controller at distillation column
Install bypass valve
Install temperature indicator and controller at distillation column
Install temperature indicator and controller at reactor

Install temperature indicator and controller at distillation column

Install emergency shutdown device (ESD)

Install pressure indicator and controller at distillation column

Install pressure indicator and controller at distillation column

Install Pressure Relief Valve at distillation column
Install bypass valve
Install level indicator and controller at distillation column
Install emergency shutdown device (ESD)

Install level indicator and controller at distillation column

Install emergency shutdown device (ESD)
 RECOMMENDATION ACTION BY
Regular maintenance / inspection Operator
Check and monitor reliability of control valve

Regular maintenance / inspection Operator

Regular maintenance / inspection Operator

Regular maintenance on heat exchanger Operator

Regular maintenance / inspection Operator/Engineer

Install cooling jacket

Regular inspection on pipeline Operator

Regular inspection on pump
Monitor the flow indicator Operator/Engineer
Manually add cooling water into condenser
Regular maintenance / inspection
Regular maintenance and inspection on level indicator and controller Operator
Check and monitor reliability of control valve

Regular maintenance and inspection on level indicator and controller Operator

Check and monitor reliability of control valve