Abstract
A process simulation involving pressure, energy and mass balancing, prior plant layout and detailed models for all process units, piping, valves, pumps and blowers has been used to explore the effect of various disturbances caused by partial failure of a component part on the total system. Analysis shows that maintenance of product specifications within acceptable limits is significantly sensitive to faults occuring upstream of, or within, the system reactors but much less sensitive to faults arising downstream of reactors. Simulation involves approximations (steady-state, pseudo-ideal reactions and phase separations assumed) to the real system but results obtained are considered representative. Implications regarding importance of local unit malfunctions to overall system performance and which measurements need be routinely recorded are discussed.
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