3443-SZ-RT-101_04 Attachment 9-3 HAZOP Worksheet Close Out Session

HDPE SPEEDBIRD PLANT SAFETY REPORT

ATTACHMENT 9.3 - HAZOP WORKSHEET CLOSE OUT SESSION

3443-SZ-RT-101 Attachment 9

Plant: 320 KT/Y HDPE Client: Basell Polyolefins Location: Münchsmünster Sheet 7 of 20 Issue 04

Node: 1. Updating of piping and instrumentation on pellet deodorizing unit Drawings: 3443-XZ-DM- 581, 582; 3443-T-MF-0081 & 0100

Items: 2D-5801 Pellet Deodorizer

2D-5802 Feding Hopper

2RF-5801 Deodorizer Rotary Feeder

2RF-5803 Deodorizer Inlet Rotary Feeder

2E-5801 Deodorizer Condenser

Deviation Causes Consequences Safeguards Recommendations By

1 No/ Less Flow 1.1 No new issue

2 More Flow 2.1 No new issue

3 Reverse Flow 3.1 No new issue

4 High Pressure 4.1 4.1.1 4.1.1.1

5 Low Pressure 5.1 No new issue

6 High Temperature 6.1 No new issue

7 Low Temperature 7.1 No new issue

8 Low Level 8.1 No new issue

9 High Level 9.1 No new issue

Opening of nitrogen line when slide valve 2HY58104 below 2D5802 is kept closed

Possible overpressurization of rotary feeder 2RF5801 and 2RF5803

Slide valve 2HY58104 is kept locked open.





Node: 2. Drawings: 3443-XZ-DM-582; 3443-T-MF-0081 & 0100

Items: 2D-5804 Pellet Conveying Pick-up Vessel

2D-5805 Conveying Water Buffer Vessel

2D-5806 Pellet Receiver

2RF-5802 Deodorizer Outlet Rotary Feeder

2P-5802 A/B Conveying Water Pump

2C-5802 Pellet Dryer Fan

2S-5801 Pellet Dryer

2E-5802 Conveying Water Cooler


1 No/ Less Flow 1.1 1.1.1 1.1.1.1 2FAL58201 1



4 High Pressure 4.1 No new issue


6 High Temperature 6.1 6.1.1 6.1.1.1

Updating of piping and instrumentation on deodorized pellet dryer system

No flow of Nitrogen to 2D5804 due to malfunction 2FIC58201.

Loss of Blanketing in 2D5804 leading to possible carryover of Oxygen in deodorizer and Off-Gas system. Actually the blanketing seems to be prevented by a vent line from 2D5804 to safe location

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.

TCM / Coperion

Malfunction of 2TIC58202, loss of cooling

Troubles in palletizing section due to too hot pellets

2TAH58202 in case of loss of cooling





Node: 2. Drawings: 3443-XZ-DM-582; 3443-T-MF-0081 & 0100

Items: 2D-5804 Pellet Conveying Pick-up Vessel

2D-5805 Conveying Water Buffer Vessel

2D-5806 Pellet Receiver

2RF-5802 Deodorizer Outlet Rotary Feeder

2P-5802 A/B Conveying Water Pump

2C-5802 Pellet Dryer Fan

2S-5801 Pellet Dryer

2E-5802 Conveying Water Cooler


7 Low Temperature 7.1 Malfunction of 2TIC58202 7.1.1 7.1.1.1 None 2 TCM

8 Low Level 8.1 8.1.1 8.1.1.1 2LAL58210.1


Updating of piping and instrumentation on deodorized pellet dryer system

Wet pellets in the deodorizer pellet receiver and in downstream section

Install an independent low temperature alarm on 2D5804

Low level in water seal due to drain valve left inadvertently open

Loss of Blanketing in 2D5804 leading to possible carryover of Oxygen in deodorizer and Off-Gas system. Actually the blanketing seems to be prevented by a vent line from 2D5804 to safe location





Node: 3. Addition of knife valve and modification of logic downstream 2D 5102 Drawings: 3443-XZ-DM-511C; 3443-T-MF-0088

Items: 2D 5102 Intermediate HDPE and Polybutene Pellet Bin


1 No/ Less Flow 1.1 1.1.1 Offspec product

1.1.1.1

1.1.1.2

1.1.1.3









10 Hazard requirements

10.1 10.1.1 Spillage of pellets10.1.1.1

TCM10.1.1.2

10.2 10.1.2 Static discharge 10.1.2.1

No flow of polybutene / recycle pellets due to 2XV51101 malfunction / close

2FAL-51112 provided on the weighing stationLimit Switch 2HZLL-51101 provided on DCSDownstream product quality checking provided

Inadvertent opening of 2HV-51101 when loading truck is not in position

Operating procedure to open first 2HV-51101 and then slide valve 2H/Y51101C Consider to provide

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

Limit Switch 2HZLH-51101 provided on DCS

Inadvertent opening of 2HV-51101 when loading truck is not connected to earth

Limit Switch 2HZLH-51101 provided on DCS





Node: 4. Addition of pressure transmitter and interlock on waste gas line of D4103 Drawings: 3443-XZ-DM-413; 3443-T-MF-0108

Items: 2D-4103 Al-Alkyl Storage Tank


1 No/ Less Flow 1.1 No new issue



4 High Pressure 4.1 4.1.1 4.1.1.1






Malfunction of the blanketing system

Possible increase of pressure in 2D4103 exceeding the design pressure of TEAL Container

2PAH 41303 activating 2S410301 closing TEAL and Hexane from TEAL Container





Node: 5. Addition of flare dip pot discharge 5D 6802 and pumps 5P 6801 A/B Drawings:

Items: 5D 6802 Flare Dip Pot Discharge

5P 6801A/B Flare Discharge Pumps


1 No/ Less Flow 1.1 Low level in flare water seal 1.1.1 1.1.1.1

1.2 1.1.2 1.1.1.2 5LAL68102 tripping the pump





6 High Temperature 6.1 6.1.26.1.2.1 5TAH68136

6.1.2.2

7 Low Temperature

7.1 Failure of heat tracing

7.1.2

7.1.2.1 5TAL68136

7.2 7.1.2.2

3443-XZ-DM-333B,681,681A; 3443-T-MF-0122

Connection between flare water seal and waste water tank D3304

Deep pipe connection in waste water and goose neck provision on the line to waste water tank

Manual valve on 2D56802 left inadvertently close

Pump running dry. No major issue

High flow of steam to flare water seal

Low level in case temperature reaches 100degC Safeguards against low level in

5D6802

Increase of level in 5D6802 with possible overfilling leading to level and backpressure increase in flare system

Extreme low ambient temperature

Safeguards against high level in 5D6802





Node: 5. Addition of flare dip pot discharge 5D 6802 and pumps 5P 6801 A/B Drawings:

Items: 5D 6802 Flare Dip Pot Discharge

5P 6801A/B Flare Discharge Pumps


8 Low Level in 5D68028.1 Low level in flare water seal 8.1.1 8.1.1.1

8.2 8.1.2 8.1.1.2 5LAL68102 tripping the pump

9 High Level in 5D6802

9.1

9.1.1

9.1.1.1

9.2 Malfunction of 5LT68102 9.1.1.2

9.3 Failure of heat tracing 9.1.1.3

9.1.1.4 Spare pump provided

10 Contamination 10.1 10.1.110.1.1.1 Spare pump provided

10.1.1.2

11 Instrument air failure 11.1 11.1.1 11.1.1.1

3443-XZ-DM-333B,681,681A; 3443-T-MF-0122

Connection between flare water seal and waste water tank D3304

Deep pipe connection in waste water and goose neck provision on the line to waste water tank

Manual valve on 2D56802 left inadvertently close

Pump running dry. No major issue

Failure of the pump 5P6801A/B

Overfilling of 5D6802 leading to level and backpressure increase in flare system

5LAH68102 if the failure is not in the transmitter

5LAHH68101 independent high high level alarm

5LAH68177 and 5LAHH68176 in flare water seal

Failure of pumps 5P6801A/B in case of hydrocarbon presence in flare water seal

Accumulation of hydrocarbon in 5D6802 leading to possible accumulation of hydrocarbons in flare system

Safeguard against high level in 5D6802

Steam and water valve failing open

Continuous flow discharging in the water seal leading to high level and high temperature

Safeguard against high level and high temperature in 5D6802





Node: 6. Drawings: 3443-XZ-DM-611, 612, 612A, 614

Items: 2E-6101B 2nd Chiller Evaporator

2P-6101C 3rd Cold Hexane Pump

2Z-6101C 3rd Cold Hexane Pump Seal Pot


1

1.1 2P6101A/B/C Failure

1.1.1

1.1.1.1

1.2 1.1.1.2





6

6.1 2LV61262 fails open

6.1.1

6.1.1.1

6.2 6.1.1.2


Refrigeration Unit - Addition of 2nd Evaporator and 3rd Pump on cold hexane distribution system

No/ Less Flow to 2E6101B

No chilled hexane supplied to the plant leading to upset in downstream section

2 pumps are running and one spare. Flow will be interrupted only in case of contemporarily double failure of the pump

See causes of no flow in Cold Hexane Distribution Main HAZOP

Safeguards in the downstream section

High Temperature in 2E6101B

Chilled Hexane supply temperature higher leading to upset in the downstream section

TAH 61101 in cold hexane circuit

See causes of high temperature in Cold Hexane Distribution Main HAZOP

Safeguards in the downstream section





Node: 6. Drawings: 3443-XZ-DM-611, 612, 612A, 614

Items: 2E-6101B 2nd Chiller Evaporator

2P-6101C 3rd Cold Hexane Pump

2Z-6101C 3rd Cold Hexane Pump Seal Pot



9 High Level 9.1 9.1.1 9.1.1.1

10 Composition 10.1 Tube rupture in E6101B 10.1.110.1.1.1 LAH61261

10.1.1.2

Refrigeration Unit - Addition of 2nd Evaporator and 3rd Pump on cold hexane distribution system

High level in the liquid trap due to liquid propylene carryover in case of propylene condensation (long pipe between cooler and compressor suction)

Liquid propylene to the compressor suction leading to possible damage of C6101

2LAH61229 tripping the compressor

Hexane enters in propylene shell side and possible transfer to compressor C6101 LAHH 61260 tripping the

compressor

3443-SZ-RT-101_04 Attachment 9-3 HAZOP Worksheet Close Out Session

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