HDPE SPEEDBIRD PLANT - SAFETY RELEVANT LOOPS

3443-SK-LE-001

Plant: 320 KT/Y HDPE Client: Basell Polyolefins Location: Münchsmünster Sheet 1 of 1

AD A6 Comments after SIL calculation considering

No. P&ID Loop Dossier N. Initiator Logic Solver Final Element SIL Safety Comments after internal Process, HSE and Instrumentation assessment Notes Reference Doc. and SIF
Check Vendor reliability data.

2PAHH11102; 2PAHH11103
1A 111A 3443-SK-FP-001 2S11102 Permissive to open 2HV11102 SIL 1 YES OK No comment SIL Class Poland 3443-SZ-RT-101 Att.3 Sheet 2
(1oo2)
2PAHH11107; 2PAHH11108
1B 111A 3443-SK-FP-018 2S11104 Permissive to open 2HV11107 SIL 1 YES OK No comment SIL Class Poland 3443-SZ-RT-101 Att.3 Sheet 2
(1oo2)
2TAHH12101D;
2 121A 3443-SK-FP-002 (2PAHH12101\03B (1oo2)) 2S12101 2HV12104 SIL 1 YES OK No comment SIL Class Poland 3443-SZ-RT-101 Att.3 Sheet 6
(1oo2)

A test Interval for the on-off valve of 1 year is acceptable from process point of
view considering that the complete full stroke test of valve can be done in less
than 10" (pipe of 6"). An appropriate procedure for the test, involving also the
control of 2FV12103 valve, in order to avoid overfilling once the test 2HV12106 is
complete, is proposed as below:

Valve Test Procedure activated by 2HS12106T:

- Put in MAN mode 2FIC12103 and freeze the output of controller (PID) to the
2FV12103 assumed malfunctioning in Demand Scenario, control valve 2FV12103,
so that can not be considered as final element of SIF. - Closing on-off valve 2HV12106,
3 121A 3443-SK-FP-002 2PAHH12101 2S12101 2FV12103; 2HV12106 (1oo2) SIL 2 YES In order to achieve SIL 2 Test Interval for the valve - Once 2HZSL12106 is active or 20" time has passed from the close command to SIL Class MG of Changes MuMu 3443-SZ-RT-101 Att.8.4c SIF 1
should be reduced to 1 year. 2HV12106, opening on-off valve 2HV12106
- Once 2HZSH12106 is active, release PID output of 2FV12103
- Operator to switch back to AUTO mode 2FIC12103 once process conditions will
be normalized.

2HS12106T is on dedicated graphic page (under password). The time available

after activation of graphic page with password is 30min.
Following above procedure the temporary closure of the valve (about 10 sec) will
not cause a significant process upset. According to SICIM, test interval of 1 year
for 2PT12101 is considered acceptable.

2TAHH12201D;
4 122A 3443-SK-FP-003 2S12201 2HV12204 SIL 1 YES OK No comment SIL Class Poland 3443-SZ-RT-101 Att.3 Sheet 17
(2PAHH12201\03 (1oo2)) (1oo2)

5 122A 3443-SK-FP-003 2PAHH12201 2S12201 2FV12203; 2HV12206 (1oo2) SIL 2 YES See No.3 See No.3 SIL Class MG of Changes MuMu 3443-SZ-RT-101 Att.8.4c SIF 1

2TAHH12301D;
6 123A 3443-SK-FP-004 (2PAHH12301\03B (1oo2)) 2S12301 2HV12304 SIL 1 YES OK No comment SIL Class Poland 3443-SZ-RT-101 Att.3 Sheet 28
(1oo2)

7 123A 3443-SK-FP-004 2PAHH12301 2S12301 2FV12303; 2HV12306 (1oo2) SIL 2 YES See No.3 See No.3 SIL Class MG of Changes MuMu 3443-SZ-RT-101 Att.8.4c SIF 1

Real configuration for final elements is: 2HV12310B;

(2LV12301A; 2LV12310B (2oo2)) (1oo2)
Hazardous Demand Scenario is generated by
malfunctioning of 2LC12301 and related control valves.
2PAHH12304; 2LAHH12304;
8 123B 3443-SK-FP-005 2S12302 2LV12301A; (2LV12301B; 2HV12310B (1oo2)) (2oo2) SIL 1 YES For this reason 2LV12301A and 2LV12301B can not be No comment SIL Class Poland 3443-SZ-RT-101 Att.3 Sheet 33
2LAHH12307 (1oo3)
considered as final elements of SIF.

Without considering LV, the final element is constituted

only by 2HV12310B (1oo1). SIL 1 can be reached.

2FV31203 assumed malfunctioning in Demand Scenario,

9 312 3443-SK-FP-006 2TAHH31201/02/03 (1oo3) 2S31201 2FV31203; 2XV31201 (1oo2) SIL 1 NO so that can not be considered as final element of SIF. No comment SIL Class Poland 3443-SZ-RT-101 Att.3 Sheet 51
Without considering FV SIL 1 can be reached.

10 312 3443-SK-FP-006 2TAHH31204/05/06 (1oo3) 2S31201 2FV31203; 2XV31201 (1oo2) SIL 1 NO See No.9 See No.9 SIL Class Poland 3443-SZ-RT-101 Att.3 Sheet 51

11 321B 3443-SK-FP-006 2TAHH32108A/09A/10A (1oo3) 2S31201 2FV31203; 2XV31201 (1oo2) SIL 1 NO See No.9 See No.9 SIL Class Poland 3443-SZ-RT-101 Att.3 Sheet 51
12 321B 3443-SK-FP-006 2TAHH32108B/09B/10B (1oo3) 2S31201 2FV31203; 2XV31201 (1oo2) SIL 1 NO See No.9 See No.9 SIL Class Poland 3443-SZ-RT-101 Att.3 Sheet 51
13 312 3443-SK-FP-007 2TAHH31209A/B (1oo2) 2S31205 Stop 2E3107 SIL 1 NO OK No comment SIL Class Poland 3443-SZ-RT-101 Att.3 Sheet 55

2PAH-33103A; 2PAHH-33103B In order to achieve SIL 2 Test Interval for the pumps The pumps do not run in the same time (the second pump is a spare pump), so
14 331 3443-SK-FP-008 2S33104 2P3301A stop; 2P3301B stop (2oo2) SIL 2 NO SIL Class Main Changes MuMu 3443-SZ-RT-101 Att.6.4 SIF 21
(1oo2) should be reduced to 6 months. that they can be tested every 6 months without any process upset.

2PAHH33305A; 2PAHH33307A
15 333B 3443-SK-FP-009 2S33302A 2HV33601A/B (1oo2) SIL 1 NO OK No comment SIL Class Main Changes MuMu 3443-SZ-RT-101 Att.6.4 SIF 6
(1oo2)
2PAHH33305; 2PAHH33307
16 333D 3443-SK-FP-010 2S33302B 2HV33601A/B (1oo2) SIL 1 NO OK No comment SIL Class Main Changes MuMu 3443-SZ-RT-101 Att.6.4 SIF 10
(1oo2)
 AD A6 Comments after SIL calculation considering
No. P&ID Loop Dossier N. Initiator Logic Solver Final Element SIL Safety Comments after internal Process, HSE and Instrumentation assessment Notes Reference Doc. and SIF
Check Vendor reliability data.

In order to achieve SIL 2 Test Interval for the valves The valve is operated more than once every six months as normal operation for
2PAHH33305A; 2PAHH33307A
17 333B 3443-SK-FP-011 2S33303A 2HV33301A; 2HV33302 (2oo2) SIL 2 NO should be reduced to 6 months. wax discharge, therefore the test interval of 6 months should be acceptable in SIL Class Main Changes MuMu 3443-SZ-RT-101 Att.6.4 SIF 13
(1oo2)
this case.

In order to achieve SIL 2 Test Interval for all elements

18 333B 3443-SK-FP-011 2TAHH33304A 2S33303A 2HV33301A SIL 2 NO should be reduced to 1 year. Test Interval acceptable, see No.17 SIL Class Main Changes MuMu 3443-SZ-RT-101 Att.6.4 SIF 14

In order to achieve SIL 2 Test Interval for the valve

2PAHH33305; 2PAHH33307
19 333D 3443-SK-FP-012 2S33303B 2HV33301 SIL 2 NO 2HV33301 should be reduced to 1.5 years. Test Interval acceptable, see No.17 SIL Class Main Changes MuMu 3443-SZ-RT-101 Att.6.4 SIF 17
(1oo2)

In order to achieve SIL 2 Test Interval for all elements

20 333D 3443-SK-FP-012 2TAHH33304 2S33303B 2HV33301 SIL 2 NO should be reduced to 1 year. Test Interval acceptable, see No.17 SIL Class Main Changes MuMu 3443-SZ-RT-101 Att.6.4 SIF 18

21 413 3443-SK-FP-013 2LAHH41301 2S41301 2XV41401;2HV41404 (1oo2) SIL 1 NO OK No comment SIL Class Poland 3443-SZ-RT-101 Att.3 Sheet 65

Considering the phisycal location of the initiators the

22 414 3443-SK-FP-014 2BAH41401\02\03\04 (2oo4) 2S41401 2PV41401; 2HV41403 (2oo2) SIL 1 NO actual configuration is 2BAH41401\02\03\04 (2oo4) test No comment SIL Class Poland 3443-SZ-RT-101 Att.3 Sheet 66
interval of 5 years is achieved

23 414 3443-SK-FP-015 2HZLL41405A/B (1oo2) 2S41402 Permissive to open 2HV41404 SIL 1 NO OK No comment SIL Class Poland 3443-SZ-RT-101 Att.3 Sheet 67

In order to achieve SIL 1 Test Interval for oxygen

24 581 3443-SK-FP-016 2AIAHH58101 2S58104 Stop 2RF5801; 2RF5803 (1oo2) SIL 1 NO Test Interval acceptable, > 2 years SIL Class Packages (Deo) MuMu 3443-SZ-RT-101 Att.8.4b SIF 7
analyzer 2AIAHH58101 should be reduced to 3 years.

25 621 3443-SK-FP-017 2TAHH62107/08 (1oo2) 2S62102 2PV62103; 2XV62107 (1oo2) SIL 1 NO OK No comment SIL Class Poland 3443-SZ-RT-101 Att.3 Sheet 69

In order to achieve SIL 2 Test Interval for the valve Test Interval acceptable, valves can be tested while plant is running without
26 212 3443-SK-FP-019 2PAHH21201 2S21201 2HV21201 SIL 2 YES SIL Class Poland - Revised 3443-SZ-RT-101 Att.3 Sheet 37
2HV21201 should be reduced to 1 year. major operational problems

In order to achieve SIL 2 Test Interval for the valve Test Interval acceptable, valves can be tested while plant is running without
27 212 3443-SK-FP-019 2PAHH21201 2S21201 2HV21202 SIL 2 YES SIL Class Poland - Revised 3443-SZ-RT-101 Att.3 Sheet 37
2HV21202 should be reduced to 1 year. major operational problems
In order to achieve SIL 2 Test Interval for the valve Test Interval acceptable, valves can be tested while plant is running without
28 212 3443-SK-FP-019 2PAHH21201 2S21201 2HV21203 SIL 2 YES SIL Class Poland - Revised 3443-SZ-RT-101 Att.3 Sheet 37
2HV21203 should be reduced to 1 year. major operational problems
2PAHH13101/02; 2LAHH13101A
29 131 3443-SK-FP-020 2S13101 2LV12303; 2HV13102 (1oo2) SIL 1 YES OK SIL 1 applied to comply with AD Merkblatt A6 Requirements SIL Class Poland - Revised 3443-SZ-RT-101 Att.3 Sheet 36
(1oo3)

NOTES:

1) For the SIL calculation the only SIL Levels for safety consequences have been considered.
2) The mentioned test intervals have been already checked with Licensor (Basell Process Design) and considered acceptable from Process point of view.