PRODUCTION OF 2-ETHYLHEXANOL FROM PROPYLENE AND SYNTHESIS

GAS
HAZARD AND OPERABILITY STUDY (HAZOP)

NO GUIDE Element Deviation Possible Consequences Safeguards Comments Actions required Actions
. WORD Causes Assigned to

1 Tank 1 Pressure Above the Operating Explosion of the Relief valve If the pressure is too Always check the Operations
and 2 inside set point pressure of storage tank due 1 high for the capacity pressure inside Manager /
the turbine to overpressure of the tank, make the tank and also Supervisor
necessary actions its physical
condition
2 Flow from Flow rate of Above or Opening of Operating Valve 1 and Valve are designed Always check the Operations
tank 1 the stream below the the valve conditions of the manual to adjust the flow valve and the Manager/
set point compressor 1 valve 1 rate within the control devices Supervisor
stream

3 Heat Temperatur Higher or Unregulated Operating Valve 3 and Valves are Always check the Operations
Exchanger e of the lower than cold water conditions of the valve 9 programmed to valves in the cold Manager/
1 and 2 working fluid the entry separator address this events water stream Supervisor
entering the standard then immediately
heat temperatur sending it to the
exchanger e level control room.
4 Boiler Level inside Above or Opening of The boiler cannot Manual Valves are Maintenance of the Operations
the Boiler below the the valve handle the level Valve 5 programmed to valve Manager/Super
set point inside address this events visor
then immediately
sending it to the
control room.

5 Flow from Flow rate of Above or Defective Operating Valve 4 and Valves are Observe routinely Operations
heat the stream below the inlet or conditions of the manual programmed to maintenance of the Manager/Super
exchange set point outlet valve reactor 1 valve 3 address this events valves visor
1 and 2 then immediately
sending it to the
control room.

6 Reactor 1- Pressure Above or Unregulated Operating Relief valve Valves are Maintenance of the Operations
4 inside the below the pressure conditions of the 5 programmed to valve Manager/Super
storage tank set inside the Reactor 1 address this events
pressure reactor then immediately
sending it to the
control room.

7 Reactor 1- Temperatur Above or Unregulated Operating Manual Valves are Maintenance of the Operations
4 e inside the below the temperature conditions of the valve 3, 8, programmed to valve Manager/Super
storage tank set inside the reactor 1 and 23.1 address this events visor
temperature reactor then immediately
sending it to the
control room.
8 Reactor 1- Quality inside Above or Unregulated Operating Manual Valves are Maintenance of the Operations
4 the storage below the ratio inside conditions of the valve 3, 8, programmed to valve Manager/Super
tank set ratio the reactor reactor 1 and 23.1 address this events visor
then immediately
sending it to the
control room.

9 Reactor 1- Level inside Above or Unregulated Operating Control Valves are Maintenance of the Operations
4 the storage below the level inside conditions of the valve 4 programmed to valve Manager/Super
tank set level the reactor reactor 1 address this events visor
then immediately
sending it to the
control room.

10 Stripping Level of fluid Above the Defective The stripping Valve 13 Valves are Observe routinely Operations
column 1 inside the fluid limit inlet or column cannot and programmed to maintenance of the Manager/
stripping the outlet valve handle the manual address this events valves Supervisor
column 1 Stripping amount of fluid valve 11 then immediately
column 1 inside sending it to the
can handle control room.

11 Stripping Pressure Above or Fluctuations The stripping Relief valve Valves are Maintenance of the Operations
column 1 inside the below the of pressure column cannot 3 programmed to valve Manager/Super
stripping set point within the handle address this events visor
column 1 process of the pressure then immediately
the inside sending it to the
separator control room.

12 Stripping Temperature Above or Temperatur Operability of the Valve 17.1 Valves are Maintenance of the Operations
column 1 of the below the e of the hot filter press will be programmed to valve Manager/Super
Outlet set point fluid affected address this events visor
stream of the entering the then immediately
 stripping stripping sending it to the
column column control room

13 Flow of Flow rate of Above or Opening of Operability of the Valve 14 Valves are Maintenance of the Operations
fluid to the fluid below the the valve filter press will be and programmed to valve Manager/Super
the filter set point affected manual address this events visor
press valve 12 then immediately
sending it to the
control room.

14 Storage Level of fluid Above the Opening of Capacity of the Valve 15 Valves are Maintenance of the Operations
Tank 4 inside the level set the valve to storage tank and and programmed to valve Manager/Super
storage tank point the storage it might cause Manual address this events visor
tank overflow valve 13 then immediately
sending it to the
control room.

1 Distillation Pressure Higher/Lower Malfunction Malfunction in Relief Relief Valves are PI installation, Operations
Column 1 inside than the set of safety the process, Valve 6 programmed to regular examine, Manager
&2 point and control boiler column address this events PM program
Supervisor
valve, and its function, then immediately
malfunction inadequate sending it to the
of FRC (flow steam for the control room.
record process, delay to
control) reach desired
time, waste of
time and energy,
coil steam
damages

1 Distillation Temperature Higher/Lower Malfunction Disorder in the Control Valve is Always check the Operations
Column 1 inside in the process of Valve 22 programmed to valves in the steam Manager
 &2 columns distillation address this events pipeline
columns then immediately Supervisor
sending it to the
control room.

1 Distillation Fluid Flow Reverse Failure of Product off set Control Valve is Check the valve in Operations
Column process fluid process Valve 18 programmed to the pipeline Manager
1&2 flow fluid inlet address this events
Supervisor
valve then immediately
sending it to the
control room.

1 Distillation Contamination Contamination Leakage of Contamination of Manual Repair of the Proper Operations
Column of tube and process fluid Valve 17 pipeline maintenance and Manager
1&2 process cooling operator alert Supervisor
fluid line water goes
in

1 Reflux Cooling Water More/Less Failure of Output of Control Valve is Install Operations
Drum Flow cooling water inlet cooling Process fluid Valve 24 programmed to Temperature Manager
flow water valve temperature too address this events indicator before
to close and after process Supervisor
low then immediately
sending it to the fluid line
control room. Install TAL

1 Reboiler Heating Water More/Less Failure of Temperature of Control Valve is Low Temperature Operations
Flow heating flow valve process fluid Valve 22 programmed to Alarm Manager
decrease address this events
then immediately Supervisor
sending it to the
control room.

1 Reflux Fluid Flow Reverse Failure of Product off set Control Valve is Check the state of Operations
 drum process fluid process Valves 25 programmed to the valve in the manager
fluid inlet address this events pipeline
valve then immediately Supervisor
sending it to the
control room.

1 Reboiler Fluid Flow Reverse Failure of Product off set Control Valve is Check the state of Operations
process process fluid Valves 19 programmed to the valve in the Manager
fluid flow inlet valve & 20 address this events pipeline
Supervisor
then immediately
sending it to the
control room.

2 Mixer Level inside Above or Unregulated Operating Valve 37.1 Valves are Always check the Operations
below the pressure conditions of the programmed to valve and the Manager /
set level inside the mixer address this events control devices Supervisor
reactor then immediately
sending it to the
control room.

References
Guest (2021). HAZOP - PDFCOFFEE.COM. [online] pdfcoffee.com. Available at:
https://pdfcoffee.com/hazop-44-pdf-free.html [Accessed 30 Mar. 2022].
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