University of Nottingham Rev:03

Department of Chemical and Environmental Engineering Date: September 2017

HAZOP RECORD SHEET

Project Title: H84ADT: Bioethanol Plant P&ID Title/Description DC-101/102 P&ID No. Rev No.: 6

Group No.: Delta Meeting Attendees HAZOP Meet Date 10/04/2019

Design Intent/Process Outline: Converting wheat to bioethanol

Node Action Required Status
Parameter Guideword Cause Consequence Current Safeguards Recommendations/Action Action Assigned To: Action Outcome
No No. Completion Date Open/Closed
- Fouling in the pipe
- Faulty level control loop from - Can cause entrainment,
- Damage the pumps
reactor, reduce tray efficiency
surrounding the column
DC- Low liquid column causing feed flow to decrease Pressure indicator and flow - Can eventually lead to
Flow - Poor separation quality 1.1 Ibrahim N., Yi Cao 10/04/2019 N/A
101/102 flow - Reboiler duty too high indicator flooding in the column
- Not meeting production
- Condenser duty too low - Significant decrease in
requirements
- Pump breakdown on reflux separation efficiency
loop

- Reflux flow too high due to Control loop within reboiler

temperature controlling
control loop, or condenser vessel - Can lead to weeping and utility flow in ratio to the feed
Low vapour column level even dumping of the trays Pressure indicator and flow flow
1.2 Yash B., Sohulli M. 10/04/2019 N/A
flow control loop - Reduces separation indicator Reboiler flow also in ratio
- Reboiler duty too low, or boiler efficiency control with
feed bottoms flow to minimum vapour
water flow/temperature too low flow met
Column level alarms
- Faulty level control on
Reflux flow control loop
fermenter, feeding - Reduce separation quality Flow indicator and pressure
If feed flow too much for
High liquid column excess liquid from reactor - Can lead to flooding of indicator
1.3 column to handle, Ibrahim N., Yi Cao 10/04/2019 N/A
flow - Reflux too high from condenser vessel Flow indicator and isolation
send feed to storage tanks (done
temperature control - Can damage pumps valve
using
or condenser level control
control loop)
Can knock trays out of
- Reboiler flow too high from place
Level alarms placed on the
column level Can cause flooding within Flow indicator and pressure
column
High vapour column control the column indicator
1.4 Reflux control loop as Guo S., Wan C., 10/04/2019 N/A
flow - Reflux too low Leads to entrainment Flow indicator and isolation
preliminary control
- Condenser duty too low or Tray efficiency reduced valve
to prevent rising vapour flow
cooling water Increase pressure within
column
Feed sent to storage tanks until
distillation
column is back and running
- Breakdown of pumps
- Broken valve/piping properly
No liquid column surrounding column Flow indicator and isolation
- Reactor failure/shutdown 1.5 Parallel pumps used around Ibrahim N., Yi Cao 10/04/2019 N/A
flow - Column will not operate, valve
- Fermenter flash vessel rupture column with
no separation
alternate motors in case one
pump runs dry
or gets damaged

- Reboiler broken or fouled

- Broken pipe in reboiler loop
- Poor separation, reduced Control loop placed on the
- Boiler water issues
product quality, poor column reboiler loop
No vapour column (temperature too low, Emergency shut down and flow
performance 1.6 controlling utility flow in ratio to Yash B. Sohulli M. 10/04/2019 N/A
flow or control causes low flow) indicator
- Can lead to weeping or the feed
- Reboiler ratio error causing no
dumping of trays flow entering the column
flow to go
to reboiler

Page 1 of 4
 University of Nottingham Rev:03
Department of Chemical and Environmental Engineering Date: September 2017
HAZOP RECORD SHEET
Project Title: H84ADT: Bioethanol Plant P&ID Title/Description DC-101/102 P&ID No. Rev No.: 6

Group No.: Delta Meeting Attendees HAZOP Meet Date 10/04/2019

Design Intent/Process Outline: Converting wheat to bioethanol

Node Action Required Status
Parameter Guideword Cause Consequence Current Safeguards Recommendations/Action Action Assigned To: Action Outcome
No No. Completion Date Open/Closed
Temperature control loop added
using
- Can cause entrainment,
reflux
reduceflow
tray rate to control
efficiency
- High liquid flow through the column
- Can eventually lead to
column temperature andcolumn
flooding in the distillate flow
- Poor column operation
- Low vapour flow through the rate
- Significant decrease in
Low column and product purity directly
Temperature column Isolation valve 1.7 Two alternate
separation temperature
efficiency Ibrahim N., Yi Cao 10/04/2019 N/A
temperature influenced by column
- Feed flow is too large sensors were
temperature
- Reboiler duty too low used sending the average value to
- Reflux flow too high the
controller
Temperature indicators were
placed at the

Temperature control loop added

using
reflux flow rate to control
column
temperature and distillate flow
rate
- High vapour flow within the
- Can lead to unsafe Two alternate temperature
column, or Emergency shutdown and
High column conditions and poor column sensors were
low liquid flow isolation valve, emergency 1.8 Guo S., Wan C., 10/04/2019 N/A
temperature operation causing product used sending the average value to
- Vapour condenser not working services.
purity to suffer the
properly
controller
Temperature indicators were
placed at the
top and bottom of the column, as
well as
near the feed tray.

Pressure within column is

controlled via
utility flow into the condenser
Two alternate pressure sensors
- Can lead to weeping or
used to
dumping of trays
- Reboiler duty is too low increase reliability, where the
- Column needs to be
Pressure Low column pressure - Feed flow is too low Emergency shutdown. 1.9 average Ibrahim N., Yi Cao 10/04/2019 N/A
restarted if dumping occurs
- Reflux flow too high reading between the two sensors
- Decrease in separation
is sent to
efficiency
the controller
Low pressure alarm placed near
top of
column

Page 2 of 4
 University of Nottingham Rev:03
Department of Chemical and Environmental Engineering Date: September 2017
HAZOP RECORD SHEET
Project Title: H84ADT: Bioethanol Plant P&ID Title/Description DC-101/102 P&ID No. Rev No.: 6

Group No.: Delta Meeting Attendees HAZOP Meet Date 10/04/2019

Design Intent/Process Outline: Converting wheat to bioethanol

Node Action Required Status
Parameter Guideword Cause Consequence Current Safeguards Recommendations/Action Action Assigned To: Action Outcome
No No. Completion Date Open/Closed

-Pressure
Can causerelief is achieved via a
entrainment,
safety
reduce tray efficiency
relief
- Can valve near the
eventually leadtop
to of the
- Can cause entrainment,
column
floodinginin the column
reduce tray efficiency
- Reboiler duty is too low case of pressure
- Significant buildup
decrease in
- Can eventually lead to Back-up valve with isolation
High column pressure - Feed flow is too low 1.1 High pressure alarm
separation efficiency placed near Guo S., Wan C., 10/04/2019 N/A
flooding in the column syaytem.
- Reflux flow too high the top of
- Significant decrease in
the column
separation efficiency
Pressure indicators placed
throughout the
column

Page 3 of 4
 University of Nottingham Rev:03
Department of Chemical and Environmental Engineering Date: September 2017
HAZOP RECORD SHEET
Project Title: H84ADT: Bioethanol Plant P&ID Title/Description DC-101/102 P&ID No. Rev No.: 6

Group No.: Delta Meeting Attendees HAZOP Meet Date 10/04/2019

Design Intent/Process Outline: Converting wheat to bioethanol

Node Action Required Status
Parameter Guideword Cause Consequence Current Safeguards Recommendations/Action Action Assigned To: Action Outcome
No No. Completion Date Open/Closed

- Can cause entrainment,

reduce tray efficiency
- Can eventually lead to
flooding in the column
- Significant decrease in
separation efficiency

Page 4 of 4