3443-sz-rt-101_04 attachment 13

HDPE SPEEDBIRD PLANT SAFETY REPORT

ATTACHMENT 13 - HAZOP & SIL RECOMMENDATIONS FOLLOW UP

PROCESS HAZOP 3443-SZ-RT-101 Attachment 13

Plant: 320 KT/Y HDPE Client: Basell Polyolefins Location: Münchsmünster Sheet 2 of 9 Issue 04

No. Action Ref. Node Reference Deviation Follow Up Notes P&ID Status Date

1 3 YES P&Id Updated Accordingly closed 26/10/2007

2 4 4.1 No/ Less Flow YES 121B closed 26/10/2007


4 7 YES Instruction for labeling provided to site 111A closed 9/8/2008

5 7 YES Operating manual updated accordingly 111A closed 9/8/2008

6 7 7.2 Others YES P&Id Updated Accordingly from process part. 111A closed 26/11/2007

7 10 10.1 No/ Less Flow YES 131 closed 26/10/2007

8 8 8.1 No/ Less Flow YES closed 26/10/2007

9 Verify 2PSV-12303-S is sized for 2PIC-12315 failure case. 8 9.4 High Pressure YES 123B closed 26/10/2007



12 20 YES Interlock Description updated accordingly closed 30/11/2007

13 20 YES Operating manual updated accordingly closed 9/8/2008

Provide double check valves instead of a single check valve at 1" TEAL start-up line

3.2 Reverse/ Misdirected Flow

122A 121A 123A

Provide interlock to trip 2P1204 on loss of open condition for 2HV-12110

P&Id & Interlock Description Updated Accordingly

Provide interlock to trip 2P1205 on loss of open condition for 2HV-12210


Ensure correct labelling on site of the alignment valves and reactor catalyst lines in order to avoid mis-alignment during changeover.


Operating procedure should highlight the consequence of mis-direction of catalyst feeds.


P&ID to include note indicating the requirement of elevating the alignment valves relative to the upstream/downstream piping in order to avoid sedimentation inside the valves.

Provide interlock to trip 2P1302A/B on loss of open condition for 2HV-13103


Provide interlock to close each reactor outlet feed to 3rd flash vessel on closed condition of 2HV-12310B depending on the mode of operation. This can be implemented through feedback from manual bypass valves at flash vessel inlet.


121B 122B 123B

In case of 2PIC-12315 malfunctions to close 2PV-12315, the scenario is the same as defined by Basell in the data sheet for 2PSV-12303: "Discharge of 3000 kg/h of Ethylene and 2500 kg/h of hexane in case of feeding C2 saturated hexane (12 barg, 85°C) to an isolated vessel D1203 at safety valve set pressure of 6 barg". 2PSV-12303 discharge capacity of 28145 kg/hr covers this relief case.





Interlock 2S-33303A is indicated on P&ID but this cause is not included in the interlock description for 2S-33303A. Interlock description to be revised.


331 333B 333D

Operating procedure to mention the requirement of repeating the distillation step in case of accidental opening of 2H/Y-33101/ 33102


331 333B 333D






14 20 YES closed 26/10/2007

15 20 20.11 High Level YES P&Id Updated Accordingly 333B 333D closed 26/10/2007

16 20 20.17 Others YES P&Id Updated Accordingly 333B 333D closed 26/10/2007

17 9 9.1 High Level YES 123B 321A closed 26/10/2007

18 15 15.1 High Pressure YES 222 221A-C closed 15/06/2008

19 P&ID to be updated to indicate the sight glass. 16 16.1 No/ Less Flow YES P&Id Updated Accordingly 223 closed 30/10/2007

20 Provide check valve downstream of 2FV-22304 16 YES P&Id Updated Accordingly 223 closed 30/10/2007

21 Locate pump start panel at a safe location from the pit. 22 21.1 Others YES P&Id Updated Accordingly 333C closed 26/10/2007

22 Provide hydrocarbon detectors inside the pump pit. 22 22.1 Others YES P&Id Updated Accordingly 333C closed 26/10/2007

23 23 YES 001 341A 341B closed 08/02/2008

24 24 24.1 High Pressure YES 411 413 Sep-2009

Interlock 2S-33302 will prevent operational flexibilty of draining the reactor when one of the distillation vessel is under discharge mode (though other distillation vessel is available to accept the reactor drain contents). To facilitate the above operational flexibility, provide open/ close limit switch for manual diversion valves in the reactor drain line (or isolation valves at the reactor) to distillation vessels 2D3303A/B. Interlock can then be modified such that loss of closed position of reactor drain line isolation or diversion valve will prevent opening of the bottom discharge valve of corresponding distillation vessel.



333B 333D 336

Provide independent level switch with interlock to close the reactor drain line isolation valves 2HV-33601A/B and trip pump 2P3301A/B on high high level in distillation vessel.

Push button 2HS-33301A should be located at a safe distance from big bag filling point.

In case an interlock is provided inside the recycle gas compressor package to trip the compresor on high level in suction damper 2D3206, the interlock 2I-12312 can be deleted and a DCS alarm can be retained.


Confirm this safeguard (High Pressure Safeguard 2.1.1) with decanter vendor.

The decanters 2S2101A/B/C have been provided with relief valves 2PSV-21117/18/19 set at 0.4 barg as a safeguard against overpressurisation.P&Id Updated Accordingly


Waste offgas compressor 2C3402 discharge design pressure is 6 barg and offgas header design pressure is 5 barg. Design parameters to be reviewed to address this discrepancy

23.1 No/ Less Flow 23.2 High Pressure

Off-Gas header design pressure has been increased in the revised stream list

Confirm 2PSV-41102-B is sized for 2PV-41301A full open case.

Confirmed.Highest flow rate possible through 2PV-41301A from Al-Alkyl Storage Tank 2D4103 entering into Motherliquor Tank 2D4102 is fire case discharge of 11750kg/hr . (Same sizing case is also for relief valve 2PSV41301-S on 2D4103). 2PSV41002_B on Motherliquor Tank 2D4102 is designed for this case.

re-closed after PSI

PSSR <04>

25 25 25.1 High Pressure YES P&Id Updated Accordingly 413 closed 26/10/2007

26 28 28.1 No/ Less Flow YES P&Id Updated Accordingly 341A closed 26/10/2007

27 Provide high pressure alarm with 2PI-62106. 31 31.1 High Pressure YES P&Id Updated Accordingly 621 closed 26/10/2007

Note to be included in the P&ID to highlight the requirement of locating check valve as close as possible to the tank 2D4103 nozzle.

Delete check valve in the waste offgas inlet to flare knockout drum 2D3402.






28 32 YES P&Id Updated Accordingly 622 closed 26/10/2007


30 32 YES P&Id Updated Accordingly 333B closed 26/10/2007


32 32 32.8 High Pressure YES P&Id Updated Accordingly 622 closed 26/10/2007

33 32 32.11 Low temperature YES 622 Sep-2009

34 32 YES 622 closed 26/10/2007

35 32 32.18 Others YES P&Id Updated Accordingly 622 closed 26/10/2007

36 34 34.1 No/ Less Flow YES 311A 331 closed 26/10/2007

37 35 35.1 No/ Less Flow YES 311A closed 26/10/2007

38 16 16.2 More Flow NO 223 closed 15/06/2008


Delete check valve in pump 2P6211 suction line as it will not provide protection in case 2PSV-62203-R actuates (will restrict relief of pressure since PSV is routed to pump suction and joins the section between check valve and pump)

32.1 No/ Less Flow of soda from IBCs to soda process tank

Provide overflow line for soda process tank 2D6210 routed to safe location.

32.6 More Flow of DM water

Provide check valve in the caustic dosing line to distillation vessel 2D3303A.


Check the possibility of reverse flow from membrane unit 2PK2301 and provide protection measures if required.


Provide high pressure alarm at pump 2P6210A/B discharge independent from 2PIC-62201.

Provide a local temperature gauge in the caustic circulation line upstream of 2PV-62201.

Temperature Gauge 2TI-62251 provided. Installation at the selected location downstream jacketed pipe was the envisaged solution during HAZOP meeting. Control valve 2PV-62201 was relocated later on due to layout restrictions. For this reason the description "upstream 2PV-62201" is misleading.

re-closed after PSI

PSSR <04>

Interlock 2I-62202 should also close DM water inlet to soda process tank 2D6210.

32.6 More Flow of DM water


Provide suction strainer for pump 2P6211. Consider relocating strainer provided upstream of 2HV-62201 to 2P6211 suction.Provide interlock to trip 2P3301A/B on loss of open condition for 2HV-31101




Consider control of 2PIC-22305 through pressure transmitter located downstream of take-off point for 2FV-22304. To be confirmed with conveying system vendor.

The function of control unit 2FV22304 is to keep a constant discharge flow and is controlled by 2FT22304; hence 2FV22304 cannot be controlled by a PIC. Low-pressure alarm will be provided with 2PI22307





PROCESS SIL CLASSIFICATION 3443-SZ-RT-101 Attachment 13


No. Action Ref. SIF Reference Scenario Follow Up Notes P&ID Status Date

1 1 NO 621 CLOSED Jan-09

2 3 YES 621 CLOSED Jan-09

3 5 YES 123B CLOSED Jan-09

4 3 YES 621 CLOSED Jan-09

Check for protections inside the extruder package. In case independent protections are provided inside the package, W2 can be reduced to W1 for extruder damage. However, W2 can still be considered for piping damage.

To prevent very high temperature in HP steam header;

No additional protections are present in extruder package. W2 has been considered for both piping and extruder damage in the SIL assignment of SIF N.1 (SIL 1)

Check if there is any other independent safeguards for plate heat exchanger for dryer 2D2201 inside the package and if present, W2 can be reduced to W1. However, for piping damage W2 is still valid.

To prevent very high temperature in LP steam header (2TIC-62103 malfunctions to close 2TV-62103)

Independent safeguard has been provided with 2TAHH22113 closing steam supply valve 2XV22106 on high steam temperature (P&ID sheet 221A). W1 has been considered therefore for dryer damage and W2 for piping damage in the SIL assignment for SIF 3 (SIL 1)

As per HAZOP Recommendation 17, in case an interlock is provided inside the recycle gas compressor package to trip the compressor on high level in suction damper 2D3206, the interlock 2I-12312 can be deleted and a DCS alarm can be retained.

To prevent damage to compressor 2C3201 due to liquid carry over

Interlock 2IS32102 stops recycle gas compressor on high level in suction dampner 2D3206. Interlock 2I-12312 has been therefore deleted

Check if there is any other independent safeguards for plate heat exchanger for dryer 2D2201 inside the package and if present, W2 can be reduced to W1 for plate type heat exchanger damage. However, for piping damage W2 is still valid.

To prevent very high temperature in LP steam header (DM water supply failure due to condensate pump 2P6201A/B trip)

Independent safeguard has been provided with 2TAHH22113 closing steam supply valve 2XV22106 on high steam temperature (P&ID sheet 221A). W1 has been considered therefore for dryer damage and W2 for piping damage in the SIL assignment for SIF 3 (SIL 1)



PACKAGES HAZOP 3443-SZ-RT-101 Attachment 13


Package Action Ref. Node Notes P&ID Status Date

Dryer 1 4. High Pressure YES 221,221A Dec-2009

Dryer 1 4. High Pressure YES 221,221A Sep-2009

Dryer 1 4. High Pressure YES 221,221A Dec-2009

1 1. High Pressure YES 341A,341B Sep-2009

1 2. High Level YES 341A,341B Dec-2009

1 1. No/Less Flow YES 581,582,513 closed Apr-08

1 1. No/Less Flow YES 581,582,513 closed Apr-08

1 1. No/Less Flow YES P&ID Updated Accordingly - RPI RV-069 581,582,513 closed Apr-08

1 1. No/Less Flow YES 581,582,513 closed Jun-08

1 YES P&ID Updated Accordingly - RPI RV-069 581,582,513 closed Apr-08

6. Provide a low flow alarm on 2FIC-58103 1 9. Low Level YES P&ID Updated Accordingly - RPI RV-069 581,582,513 closed Apr-08

2 1. No/Less Flow YES P&ID Updated Accordingly - RPI RV-069 582 closed Apr-08

Reference Deviation

Follow Up

1.Provide a relief valve on each expansion vessel 2D2207A/B sized for N2 fully open case.

2PSV22114 and 2PSV22115 on expansion vessel 2D2207A/B are sized adequately for inadvertant opening of 2PCV22126 or 2PCV22127 (N2 fully open case is 50 kg/hr). PSV datasheets for 2PSV22114 and 2PSV22115 are showing also Cv of 2PCV22126 or 2PCV22127.

re-closed after PSI

PSSR <04>

2.Provide a relief valve at the hot water inlet of each set of dryer panel sized for pump flow case and set at 6barg.

P&ID Updated Accordingly - RPI RV-069. PSV areadequate for the sizing case: 100% closed panels with pump full flowrate of 325000kg/hr. PSV22122 and PSV 22123 sized is for 434321kg/hr.

re-closed after PSI

PSSR <04>

3.2PSV-22113S/ 22114S should be sized for DM water full open case.

Relief valves 2PSV -22113-S and 2PSV22114-S are adequately sized for Demineralized Water full open case. This can be demonstrated by a pressure drop calculation on the DM water supply lines to the Hot Water Expansion Vessels 2D 2207A/B. The maximum flow possible at PSV set pressure (17972 kg/hr) is well covered by the discharge capacity of the relief valves (27145 kg/hr).

re-closed after PSI

PSSR <04>

Off Gas Compresor

1. Consider sizing 2PSV-34104S on separator 2D-3404 for N2 valve full open case.

Nitrogen blanketing line is sized 1". Line length approx. 30 meters. For nitrogen at 8.8bar(g) and 10°C the critical flow at PSV set pressure (6 barg) is reached at approx. 850kg/hr. 2PSV-34104 on 2D3404 is sized for 860kg/hr and has a relief capacity of 1362 kg/hr. P&ID Updated Accordingly by Vendor

re-closed after PSI

PSSR <04>

Off Gas Compresor

2. Consider providing a PSV on the DM water make up line (inside package battery limit and downstream of isolation valve), sized for DM water valve full open case and set at 6barg.

DM water make-up flow to offgas compressor package 2PK3402 is controlled by 2FV34102 (Cv=0.32). In case of valve full opening the maximum flow is approx. 480kg/hr of water. The safety valve 2PSV34120-S (orifice diameter 10mm) is adequately sized for this case. The relief capacity at set pressure of 6 barg is 3600kg/hr of water.

re-closed after PSI

PSSR <04>

Deodorization

1. Consider tripping the pellet rotary feeder 2RF-5104 on very high level in deodorizer feeding hopper instead of tripping entire pneumatic transport package. This will give operator flexibility to take a decision whether divert it to homogenizer/ recycle bin or trip pneumatic transport.

P&ID and Interlock description Updated Accordingly - RPI RV-069

Deodorization

2. Consider only tripping rotary feeder 2RF-5801/ 5803 and not very low pressure steam on very high level in pellet deodorizer 2D-5801. However, tripping of steam on very high pressure is still to be retained


Deodorization

3. Provide a low temp alarm with 2TI-58102/ 58103 on pellet deodorizer

Deodorization

5. Consider relocating the check valve from present location i.e. on the 16" waste gas line from pellet deodorizer to the 4" waste gas line from deodorizer condenser

Check valve not relocated. Reverse flow prevented with another solution

Deodorization

4. Consider providing a temp indication with high temp alarm on the waste gas outlet of deodorizer condenser 2E-5801

8. High Level 14. Utility Failure

Deodorization

Deodorization

7. Consider tripping the pellet water conveying pumps 2P-5802A/B in case of loss of open condition of both bottom HVs of pellet conveying pick up vessel

Package Action Ref. Node Notes P&ID Status DateReference Deviation

Follow Up

2 1. No/Less Flow YES 582 closed Apr-08Deodorizatio

n

8. Verify there is an interlock to trip rotary feeder 2RF-5802 on very high level in deodorizer pellet receiver 2D-5806. The set point of very high level trip should be such that deodorizer pellet receiver can receive the pellet content of pellet conveying pick up vessel


Package Action Ref. Node Notes P&ID Status DateReference Deviation

Follow Up



PACKAGES HAZOP 3443-SZ-RT-101 Attachment 13


Package Action Ref. Node Notes P&ID Status Date

2 YES Vendor confirmation of system reliability 582 closed Aug-08

2 9. Low Level YES Vendor confirmation of system reliability 582 closed Aug-08

1 YES P&ID Updated Accordingly - RPI RV-069 511C closed Apr-08

Flare 1 2. More Flow YES 681 Dec-2009

Reference Deviation

Follow Up

Deodorization

9. Check the requirement of designing steam ejector downstream piping and pellet conveying pick up vessel for LP steam condition. Consideration may be given to fact that this operation is required only during startup and pellet conveying pick up vessel is open to atmosphere

6. High Temperature

Deodorization

10. Check the suitability of the type of level instrument used for tripping the conveying water pump considering there will be pellet level in the vessel which may affect the level measurement and thus intended purpose of interlock may not served.

Polybutene feeding

1. Confirm that 2FICA-51112 provides alarm in case of high or low flow

2. No/Less Flow of polybutene pellets

1. Check maximum back pressure for all flaring scenarios to be within design pressure drop of 45mbar

Confirmed. 3443-VZ-SG-301-IS06 including pressure drop calculations for other flaring scenarios officially issued to Basell

re-closed after PSI

PSSR <04>



MANAGEMENT OF CHANGES HAZOP 3443-SZ-RT-101 Attachment 13


N Action Ref. Node Ref. MOC Form. Reference Deviation Follow Up Notes P&ID Status Date

1 1 3443-T-MF-0045 1. No/Less Flow YES closed Apr-08

2 2 3443-T-MF-0051 1. No/Less Flow YES 38,411,412 closed Apr-08

3 2 3443-T-MF-0051 4. High Pressure YES 38,411,412 closed Feb-09

4 2 3443-T-MF-0051 5. Low Pressure YES 38,411,412 closed May-08

5 3 3443-T-MF-0052 1. No Flow YES 111A closed Jun-08



8 4 3443-T-MF-0053 1. Others YES 241 closed Apr-08

1. Consider closing the 2HV-12104 on close condition of 2HV-12106 (through 2S-12107)

P&ID Updated Accordingly - RPI RV-069

121A,122A, 123A

2. Consider an interlock/ permissive to inhibit starting of hexane unloading pump 2P-4104 on loss of open condition of 2XV-41201


3. Check that design pressure of pump seal pot is equal or more than design pressure of N2 system (8.5barg). If not pressure protection system like a relief valve, need to be provided for pump seal pot

Design pressure of seal pot of existing unloading pump 2P4104 is

about 32 barg. No Further protection are necessary.

4. Confirm hexane truck tank is designed for full vacuum condition

P&ID Updated Accordingly - RPI RV-069 and letter E-BM-TM-01086

5. Provide a selector switch for selecting the 2HV-41103/ 41105 in line that will trip the mother liquid feed pump 2P-4102A/B on loss of open condition. This is required considering only one of the HVs will be in open condition at a time

P&ID Updated Accordingly with RPI RV-069 - Interlock description

updated accordingly with Issue 03 of 3443-VZ-SG-221

6. Provide a selector switch for selecting the 2HV-41102/ 41104 in line that will trip the distilled hexane feed pump 2P-4101A/B on loss of open condition. This is required considering only one of the HVs will be in open condition at a time



7. Consider tripping the hexane feed pumps and flushing hexane pump 2P-1104A/B and 2P-1105 also on loss of open condition of 2HV-41102/ 41104. Also provide a selector switch for selecting the 2HV-41102/ 41104 in line that will trip the pumps



8. Provide a note on P&ID (3443-XZ-DM-001_241) to route the outlet of 2PSV-24101 to safe location




CLOSE OUT HAZOP 3443-SZ-RT-101 Attachment 13


HDPE SPEEDBIRD - CLOSE OUT HAZOP ACTIONS FOLLOW-UP TRACKINGN Action Ref. Node Ref. MOC Form. Reference Deviation Follow Up Notes P&ID Status Date

1 2 3443-T-MF-0100 1. No/Less Flow YES 582 CLOSED Mar-09

2 2 3443-T-MF-0100 7. Low Temperature YES 582 CLOSED Mar-09

3 3 3443-T-MF-0088 10. Hazard Requirements YES 511C CLOSED Mar-09

Check with Coperion if it is correct to vent directly from 2D5804 or if the vent shall be relocated to the seal pot, in order to maintain the blanketing function.

Coperion confirmed that Vent Line shall be connected to the vessel and not to the seal pot, because connecting the vent line to the seal pot will cause bubbling of Nitrogen on the water seal surface. A self regulating valve has been provided on the vent line to preserve the blanketing function. P&ID updated accordingly

Install an independent low temperature alarm on 2D5804

Independent temperature transmitter with low level alarm has been added, providing a double thermocouple with redundant connection on the line from nozzle K3 of 2D5804; P&ID Updated accordingly

Consider to provide Grounding on the bottom of discharge pipe to be connected to the truck.

Note of P&ID to ensure provision of grounding on the bottom of discharge pipe to be connected to the Polybutene Truck has been added.

3443-sz-rt-101_04 attachment 13

Documents