HAZOP

Node: put a feed pt.

Guide
Deviation Cause Consequences Action
Word
No No flow  Line blockage.  Methanol conversion is zero.  Conduct regular maintenance
 Empty methanol storage  Decrease in production rate. of pipes.
tank.  Spillage from ruptured pipe can  Install a level control system.
 Ruptured inlet pipe to harm employees if they come into (flow meters and indicators).
reactor. contact with it.  Install automatic valves and
 Valve in closed position.  Possible ignition of methanol of pumps.
 Pump closed. pipe is ruptured.  Improve on fire protection
 Control valve failure. services and mechanisms (fire
extinguishers).
 Install a secondary emergency
relief valve.

More of Higher inlet  Low conversion in  Increase in quantity of recycle  Install automatic valve.
flow at reactor previous cycle. feed of methanol.  Install flow meters.
entrance and  Greater valve opening.  Lower quality of production.  Ensure sensors are placed.
feed.  Control valve failed to  Thermal runaway effect (Reactor  Check reactor conditions
close. Temperature Increase) and (catalyst, efficiency,
possible explosion. temperature and pressure).
Less of Lower inlet  Smaller degree of valve  Lower production rate.  Install automatic valves.
flow at reactor opening.  Higher temperature of feed to  Proper temperature control for
entrance and  Close of feed valve and reactor. reactor feed preparation.
feed. failure.  Conversion is too low.  Install flow meters.
 Plugging of pipelines.  Damage of pumps  Conduct regular inspections.
 Lower methanol
recovery at binary
column.
 Control valve failed to
open.

More of Higher  Incoming methanol feed  Higher conversion of methanol as  Install a high temperature
temperature at can be entering at a the rate of reaction increases. alarm.
the inlet and higher temperature due  Lower selectivity.  Install temperature sensors at
outlet. to adverse weather  Decrease in yield of DME. the methanol storage.
conditions.  Any sudden temperature rise can  Before the recycle is
 Recycled methanol from cause a thermal runaway effect. introduced, ensure the
binary column could be  Catalyst deactivation can occur temperature limits are within
leaving at a higher sooner. proper operating range.
temperature.  Can cause hot spots on reactor
 Temperature controller surface.
failure.
Less of Lower  Temperature controller  Higher selectivity.  Install a low temperature
temperature at failure.  Lower reaction rate and thus a alarm.
the inlet and  Incoming methanol feed lower conversion of methanol.  Install temperature sensors.
outlet. is at a lower  See the effect on pressure.
temperature.
 Recycled methanol
entering at a lower
temperature.
More of Higher reactor  Relief valve fails closed.  Vessel rupture due to over  Install pressure indicators.
pressure.  Incoming methanol feed pressurization.  Install high pressure alarm for
enters at a higher  Can result in a smaller pressure dangerous build-ups and
pressure. drop. initiate emergency shutdown
 Can lower conversion and procedures.
therefore, yield.
 Can affect the catalyst bed.
Less of Lower reactor  Relief valve fails open.  Can cause a significant pressure- 
pressure  Incoming methanol feed drop to occur.
enters at a lower  Increases outlet temperature.
pressure.