Abstract: Safety assessment becomes an important activity in chemical industries since the need to comply with general legal requirements in addition to meet safer plant and profit. This paper reviews some most frequently causes of distillation column malfunction. First, analysis of case histories will be discussed for providing guidelines in identifying potential trouble spots in distillation column. A dynamic simulation for operational failure is simulated as the basis for assessing the consequences. A case study will be used from a side stream distillation column to show the implementation of the concept. A framework for assessing safety in the column is proposed using Fault Mode and Effect Analysis (FMEA). Further, trouble-free operation in order to reduce the risk associated with column malfunction is described.