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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

Opening of nitrogen line


Possible overpressurization of
when slide valve Slide valve 2HY58104 is kept
4 High Pressure 4.1 4.1.1 rotary feeder 2RF5801 and 4.1.1.1
2HY58104 below 2D5802 locked open.
2RF5803
is kept closed

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


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 8 of 20 Issue 04

Node: 2. Updating of piping and instrumentation on deodorized pellet dryer system 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

Deviation Causes Consequences Safeguards Recommendations By


Loss of Blanketing in 2D5804
Check with Coperion if it is
leading to possible carryover of
correct to vent directly from
No flow of Nitrogen to Oxygen in deodorizer and Off-
2D5804 or if the vent shall be TCM /
1 No/ Less Flow 1.1 2D5804 due to malfunction 1.1.1 Gas system. Actually the 1.1.1.1 2FAL58201 1
relocated to the seal pot, in Coperion
2FIC58201. blanketing seems to be
order to maintain the
prevented by a vent line from
blanketing function.
2D5804 to safe location

2 More Flow 2.1 No new issue

3 Reverse Flow 3.1 No new issue

4 High Pressure 4.1 No new issue

5 Low Pressure 5.1 No new issue

Malfunction of 2TIC58202, Troubles in palletizing section 2TAH58202 in case of loss of


6 High Temperature 6.1 6.1.1 6.1.1.1
loss of cooling due to too hot pellets cooling
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 9 of 20 Issue 04

Node: 2. Updating of piping and instrumentation on deodorized pellet dryer system 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

Deviation Causes Consequences Safeguards Recommendations By


Wet pellets in the deodorizer
Install an independent low
7 Low Temperature 7.1 Malfunction of 2TIC58202 7.1.1 pellet receiver and in 7.1.1.1 None 2 TCM
temperature alarm on 2D5804
downstream section
Loss of Blanketing in 2D5804
leading to possible carryover of
Low level in water seal due Oxygen in deodorizer and Off-
8 Low Level 8.1 to drain valve left 8.1.1 Gas system. Actually the 8.1.1.1 2LAL58210.1
inadvertently open blanketing seems to be
prevented by a vent line from
2D5804 to safe location

9 High Level 9.1 No new issue


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 10 of 20 Issue 04

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

Deviation Causes Consequences Safeguards Recommendations By


2FAL-51112 provided on the
1.1.1.1
weighing station
No flow of polybutene / recycle
Limit Switch 2HZLL-51101
1 No/ Less Flow 1.1 pellets due to 2XV51101 1.1.1 Offspec product 1.1.1.2
provided on DCS
malfunction / close
Downstream product quality
1.1.1.3
checking provided
2 More Flow 2.1 No new issue

3 Reverse Flow 3.1 No new issue

4 High Pressure 4.1 No new issue

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


Operating procedure to open
Inadvertent opening of 2HV- 10.1.1.1 first 2HV-51101 and then slide
10.1 51101 when loading truck is 10.1.1 Spillage of pellets valve 2H/Y51101C Consider to provide
not in position Limit Switch 2HZLH-51101 Grounding on the bottom of
10 Hazard requirements 10.1.1.2 TCM
provided on DCS discharge pipe to be
Inadvertent opening of 2HV- connected to the truck.
Limit Switch 2HZLH-51101
10.2 51101 when loading truck is 10.1.2 Static discharge 10.1.2.1
provided on DCS
not connected to earth
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 11 of 20 Issue 04

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

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

Possible increase of pressure


2PAH 41303 activating
Malfunction of the blanketing in 2D4103 exceeding the
4 High Pressure 4.1 4.1.1 4.1.1.1 2S410301 closing TEAL and
system design pressure of TEAL
Hexane from TEAL Container
Container

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


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 12 of 20 Issue 04

3443-XZ-DM-333B,681,681A; 3443-T-MF-
Node: 5. Addition of flare dip pot discharge 5D 6802 and pumps 5P 6801 A/B Drawings:
0122

Items: 5D 6802 Flare Dip Pot Discharge


5P 6801A/B Flare Discharge Pumps

Deviation Causes Consequences Safeguards Recommendations By


Connection between flare water Deep pipe connection in waste
1.1 Low level in flare water seal 1.1.1 seal and waste water tank 1.1.1.1 water and goose neck provision
1 No/ Less Flow D3304 on the line to waste water tank
Manual valve on 2D56802 left Pump running dry. No major
1.2 1.1.2 1.1.1.2 5LAL68102 tripping the pump
inadvertently close issue
2 More Flow 2.1 No new issue

3 Reverse Flow 3.1 No new issue

4 High Pressure 4.1 No new issue

5 Low Pressure 5.1 No new issue

6.1.2.1 5TAH68136
High flow of steam to flare Low level in case temperature
6 High Temperature 6.1 6.1.2
water seal reaches 100degC Safeguards against low level in
6.1.2.2
5D6802

7.1 Failure of heat tracing Increase of level in 5D6802 with 7.1.2.1 5TAL68136
possible overfilling leading to
7 Low Temperature 7.1.2
Extreme low ambient level and backpressure increase Safeguards against high level in
7.2 in flare system 7.1.2.2
temperature 5D6802

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 13 of 20 Issue 04

3443-XZ-DM-333B,681,681A; 3443-T-MF-
Node: 5. Addition of flare dip pot discharge 5D 6802 and pumps 5P 6801 A/B Drawings:
0122

Items: 5D 6802 Flare Dip Pot Discharge


5P 6801A/B Flare Discharge Pumps

Deviation Causes Consequences Safeguards Recommendations By

Connection between flare water Deep pipe connection in waste


8.1 Low level in flare water seal 8.1.1 seal and waste water tank 8.1.1.1 water and goose neck provision
8 Low Level in 5D6802 D3304 on the line to waste water tank

Manual valve on 2D56802 left Pump running dry. No major


8.2 8.1.2 8.1.1.2 5LAL68102 tripping the pump
inadvertently close issue
Failure of the pump 5LAH68102 if the failure is not in
9.1 9.1.1.1
5P6801A/B the transmitter
5LAHH68101 independent high
9.2 Malfunction of 5LT68102 Overfilling of 5D6802 leading to 9.1.1.2 high level alarm
9 High Level in 5D6802 9.1.1 level and backpressure increase
in flare system 5LAH68177 and 5LAHH68176 in
9.3 Failure of heat tracing 9.1.1.3
flare water seal
9.1.1.4 Spare pump provided

Accumulation of hydrocarbon in 10.1.1.1 Spare pump provided


Failure of pumps 5P6801A/B
5D6802 leading to possible
10 Contamination 10.1 in case of hydrocarbon 10.1.1
accumulation of hydrocarbons Safeguard against high level in
presence in flare water seal 10.1.1.2
in flare system 5D6802

Continuous flow discharging in


Steam and water valve failing Safeguard against high level and
11 Instrument air failure 11.1 11.1.1 the water seal leading to high 11.1.1.1
open high temperature in 5D6802
level and high temperature
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 14 of 20 Issue 04

Refrigeration Unit - Addition of 2nd Evaporator and 3rd Pump on cold hexane
Node: 6. Drawings: 3443-XZ-DM-611, 612, 612A, 614
distribution system

Items: 2E-6101B 2nd Chiller Evaporator


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

Deviation Causes Consequences Safeguards Recommendations By


2 pumps are running and one
spare. Flow will be interrupted
1.1 2P6101A/B/C Failure 1.1.1.1
No chilled hexane supplied to only in case of contemporarily
No/ Less Flow to double failure of the pump
1 1.1.1 the plant leading to upset in
2E6101B
downstream section
See causes of no flow in Cold Safeguards in the downstream
1.2 1.1.1.2
Hexane Distribution Main HAZOP section

2 More Flow 2.1 No new issue

3 Reverse Flow 3.1 No new issue

4 High Pressure 4.1 No new issue

5 Low Pressure 5.1 No new issue

TAH 61101 in cold hexane


6.1 2LV61262 fails open Chilled Hexane supply 6.1.1.1
circuit
High Temperature in temperature higher leading to
6 6.1.1
2E6101B upset in the downstream
See causes of high temperature section Safeguards in the downstream
6.2 in Cold Hexane Distribution Main 6.1.1.2
section
HAZOP

7 Low Temperature 7.1 No new issue

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 15 of 20 Issue 04

Refrigeration Unit - Addition of 2nd Evaporator and 3rd Pump on cold hexane
Node: 6. Drawings: 3443-XZ-DM-611, 612, 612A, 614
distribution system

Items: 2E-6101B 2nd Chiller Evaporator


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

Deviation Causes Consequences Safeguards Recommendations By


8 Low Level 8.1 No new issue

High level in the liquid trap due to


liquid propylene carryover in case Liquid propylene to the
2LAH61229 tripping the
9 High Level 9.1 of propylene condensation (long 9.1.1 compressor suction leading to 9.1.1.1
compressor
pipe between cooler and possible damage of C6101
compressor suction)

Hexane enters in propylene 10.1.1.1 LAH61261


10 Composition 10.1 Tube rupture in E6101B 10.1.1 shell side and possible transfer
to compressor C6101 LAHH 61260 tripping the
10.1.1.2
compressor