Reactor R-801, Reactor Outlet (Stream 9)
Parameter Deviation Causes
Temperature High 1) Air (Stream 1) temperature
2) Methanol (Stream 2) temperature
3) Recycle Methanol (Stream 14)
temperature
4) Temperature/Flow rate of mps in E-
801
5) Temperature/Flow rate of hps in E-
802
6) Decrease in pumping power of P-801
7) Valve on bfw and mps outlet fail
closed
Low 1) Air (Stream 1) temperature
2) Methanol (Stream 2) temperature
3) Recycle Methanol (Stream 11)
temperature
4) Temperature/Flow rate of mps/hps in
E-801/E-802
Consequences
1) Damage to Tubes in R-801/E-
801/E-802
2) Damage to Catalysts in R-801
3) Damage to pipe
4) Altered Conversion
5) Pressure Build up in R-801
6) Cavitation in P-801 A/B
7) Shivering in E-801/E-802
8) Damage to Impellers in C-801
1) Product quality will reduce
2) Increase in shell side level may
lead to leakage into tubes
Action
1) Sensors and Alarms
2) Control Heat Duty in E-801/E-
802 by valves on mps and hps
stream respectively.
3) Change power input to
Compressor
4) Install redundancies
1) Sensors and Alarm on streams 6
and 7
2) Control Heat Duty of Exchangers
by their respective utility stream
3) Change power input to
compressor
 Distillation Column T-801, Reflux
Parameter Deviation Causes Consequences Action
Flow Low 1) Pipe Blockage 1) Column Dry Out 1) Bypass
2) Leakage 2) Change in Product Quality 2) Pressure Sensor and Low Pressure Alarm
3) Pump Failure 3) Damage to pipe following P-802 A/B
4) Decreased Efficiency of 4) Toxic 3) Temperature Sensor on cw outlet
E-805 5) Increase in pressure in reflux 4) Control Heat Duty by valve on cw inlet
-High Overhead Vapour drum and column
Rate
-Low flow rate of cw or
higher
5) Temperature of cw
6) Faulty LIC of V-801
7) Faulty FIC following P-
802A/B
High 1) Valve fully open 1) Flooding 1) High Level Alarm at Bottom
2) Increased Pumping 2) Change in Product Quality 2) Bypass on stream 14 with independent
Capacity 3) Rise in Bottom flow measuring element on Reflux line and
3) Faulty LIC of V-801 4) Leakage control flow of methanol to maintain stream
4) Faulty FIC following P- 3 amount
802 A/B