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*** Final issue, incorporating comments received from HAZOP Team ***
OTHER DETAILS
The actions have been indicated as follows:
-RECOMMENDED means that JV will decide if the action will be performed
-MANDATORY means that the action shall be done (Safety issue)
If no particular indication is given, the relevant action will be implemented. GENERAL REMARK
1)Freezing: verify that all the tubing for instrumentation containing hydrocarbon or substances that may
be condensate/solidify are also adequately and fully traced according to the contract.
2)Spectacle blind: all spectacle blinds and manual valves upstream and/or downstream PSV shall be
tagged, recorded in a log and a special procedure is to be provided in the Operating Manual.
3)HAZOP has been performed assuming that all PSVs have been designed taking into account the external
fire
50
4)condition (where applicable).
5)HAZOP has been performed assuming no random piping rupture.
6)Operating Manual shall provide a procedure for prolonged shut-down of hot plant sections normally
working at near atmospheric pressure, in order to avoid possible Oxygen inlet because of vacuum
conditions inside equipment.
PRIMARY KEYWORDS
SECONDARY KEYWORDS
XESS
MORE
REVERSE
OTHER THAN
PART OF
CORROSION MAINTENAN CE
AS WELL
AS
51
TABLE NO: 01 DOCUMENT REF: P&ID N. 021C DOCUMENT TITLE: RECYCLE GAS COMPRESSOR
ITEM: C3201 (1st stage) - D3206 - D3202 - E3201 The
compressor package comprises the following items:
1)suction damper/demister, first stage (D3206);
2)1st stage compressor (C3201);
3)discharge damper, first stage (D3202);
4)Intercooler first stage (E3201);
5)suction damper/separator, second stage (D3203);
6)2nd compressor (C3201);
7)discharge damper, second stage (D3204).
This node concerns the equipment of first stage and the Intercooler.
TEAM MEMBERS: FUNK, KAUFMANN, KUTSCHER, MACIUKIEWICZ, ROTOWSKI, HORA, CAZZANIGA, SCHERR,
BONALDI, PIOTROWSKI
TABLE NO: 01 (continued) DOCUMENT REF: P&ID N. 021C ITEM: C3201 (1st stage) - D3206
- D3202 - E3201
53
TABLE NO: Ol (continued) DOCUMENT REF: P&ID N. 021C
ION
RE suction line suction side and (set @ 0.9 bar a). Demister D3203
(outside and
LESS package BL) left consequent entiy - PALL32123 (set @ connected piping
of
in 1st inadvertently Oxygen in the 0.8 bar a) trips shall be verified for
closed. a
3) PIC32102 failure
or PV fails open.
This node concerns the equipment of second stage (compressor and upstream and
downstream dampers).
or LESS
in 2nd
stage
inlet
Ethyle
ne
purge
55
TABLE NO: 02 (continued) DOCUMENT REF: P&ID N. 021C ITEM: C3201 (2nd stage) - D3203
- D3204
2)VENDOR shall
verify if, when
compressor stops,
Ethylene could flow
through the
stuffing box back
to equipment
upstream 1st
compressor stage.
): BURCKHARDT
ACTION
N0:5 ASSIGNED TC
FLOW See deviation "Flow
reverse" for 1st
stage compressor.
REVER
SE
56
in 2nd
stage
outlet to
inle
TABLE NO: 02 (continued) DOCUMENT REF: P&ID N. 021C ITEM: C3201 (2nd stage) - D3203
- D3204
PRES SUNO:
TABLE 1)See deviation REF:
03 DOCUMENT 1)See
P&1D N.321E DOCUMENT GENERAL No action
TITLE: COOLANT SYSTEMrequired,
"PRESSURE LESS" consequences for -PAL32126. existing safeguards
for 1st stage "PRESSURE LESS" considered
LESS in compressor (Table for 1st stage adequate.
ITEM: COOLING
N. 1) WATER SUPPLYcompressor
& RETURN LINES
(Table
2nd
N. 1)- Cause 2)
stage
2)Gas cooler -PAH32127.
inlet
E3201
Cooling water plugged.
circuit 2)Low
supply and returnpressure on
lines, feeding the following package equipment:
1st stage delivery.
-PAHH32125 trips
compressor.
1)Intercooler;
2)Oil cooler;
4)Cylinder block.
The system includes also a facility for re-circulation of return water from Intercooler back to
Cylinder block, to be used for start up at low ambient temperature.
DEVIAT CAUSE CONSEQUENCE SAFEGUARDS ACTION
See deviation
ION
"PRESSURE
MORE"
PRESSU Design pressure of Possible PK3201 None (PSV32123 TCM and VENDOR
RE cooling water overpressure. set @ 6 bar g as will decide
system is 10 bar g, indicated in the appropriate
while the design P&ID is not actions.
pressure of PK3201 acceptable, since
is 6 bar g. such PSV will lower
the CW network
rating, set at 10
bar g).
MORE
FLO
W
58
MOR N0:6 ASSIGNED TC
E in
1st
): TCM/VENDOR
stag
ACTION
e
inlet
HAZOP
*** Final issue, incorporating comments received from HAZOP Team ***
OTHER DETAILS
The actions have been indicated as follows:
-RECOMMENDED means that JV will decide if the action will be performed
-MANDATORY means that the action shall be done (Safety issue)
If no particular indication is given, TMC will implement relevant action.
GENERAL REMARKS:
1)Freezing: verify that all the tubing for instrumentation containing hydrocarbon or substances that may
be condensate/solidify are also adequately and fully traced according to the contract.
2)Spectacle blind: all spectacle blinds and manual valves upstream and/or downstream PSV shall be
tagged, recorded in a log and a special procedure is to be provided in the Operating Manual.
3)Analysis has been performed assuming that all PSVs have been designed taking into account the
external fire condition (where applicable).
4)Analysis has been performed assuming no random piping rupture.
59
Operating Manual shall provide a procedure for prolonged shut-down
of hot plant sections normally working at near atmospheric
pressure, to avoid possible Oxygen inlet because of vacuum COMPOSITI
conditions inside equipment.PRIMARY KEYWORDS
ON
FLOW TEMPERATU PRESSURE LEVEL
RE
AGITATION
OTHER
SECONDARY KEYWORDS
THAN
NO MORE LESS REVERSE
60
TABLE NO: 01 DOCUMENT REF: P&ID N. 341D and 341B DOCUMENT TITLE: PK3402 - OFF GAS COMPRESSOR
PACKAGE (UNIT 300)
ITEM: C3402 - E3402 - E3412 - D3404 Items included in
this node are: C3402 - Liquid ring compressor E3402 - Ring
liquid cooler E3412 - Cooler
This machine delivers low HC gas content coming from polymerisation area blanketing to the flare header.
TEAM MEMBERS: KUTSCHER, ROTOWSKI, MACIUKIEWICZ, PIOTROWSKY, HORA, SCHERR, PATHAK, BONALDI,
PEREGO
3) FAL34102 on DCS .
TABLE NO: 01 (continued) DOCUMENT REF: P&ID N. 341D and 341B
ACTION ): PROCS
NO: 1 ASSIGNED
TC
FLOW No significant
LESS in causes/consequenc
C3402 es
suction identified.
line
62
TABLE NO: 01 (continued) DOCUMENT REF: P&1D N. 341D and 341B ITEM: C3402 - E3402 -
E3412 - D3404
2)Increase of the
RE wearing rate for
the mechanical -(TI34193, local
seals. gauge).
MORE in
2) None.
C3402
TEMPE Extremely low For prolonged For the compressor: No action required,
RATU RE ambient compressor shut -winterisation has existing safeguards
LESS in temperature. down, possible considered
been provided.
C3402 water freezing adequate.
inside the
compressor, plate For the heat
heat exchangers, exchangers:
etc. -cooling water flow
prevents freezing.
-PAH34110 on DCS.
-PAH34117 on local
panel.
-PAHH34118 trips
compressor.
63
-PSV34104 on
D3404, set @ 6 bar
g.
TABLE NO: 01 (continued) DOCUMENT REF: P&ID N. 341D and 341B ITEM: C3402 - E3402 -
E3412 - D3404
-Mechanical seal
permanently
in C3402 flushed with water.
-PAL34116 on local
panel.
suction
-PALL34115 trips
line compressor.
Cause 2)
-PAL34107 on DCS
-PAL34110 on DCS.
ION
ITEM: C3401 - E3401 - E3411 - D3403 Items included in this node are: C3401 - Liquid ring
compressor E3401 - Ring liquid cooler E3411 - Cooler D3403 - Separator
This machine delivers high HC gas content coming from polymerisation area blanketing to
recovery OS BL.
-LALL34109 trips
Compressor could compressor.
run dry, leading to
mechanical
damage. 3) FAL34101 on
DCS
FLOW FV34101 fails close Level decrease in See safeguard for No action required,
NO or FIC34101 failure. D3404 (see "FLOW NO or LESS existing safeguards
deviation "FLOW in E3401", considered
NO or LESS in adequate.
E3401"). Change of
or LESS ratio of the two
in phases in D3403.
Operational issue.
make-up
water
66
TABLE NO: 02 (continued) DOCUMENT REF: P&ID N. 341C and 341B ITEM: C3401 - E340I -
E3411 - D3403
-Compressor -Against
overload. compressor
overload:
2) Potential back
flow from BL.
*TAH34110 and
TAH34111
(bearings) on DCS.
*VT34102A/B/C/D,
vibration
transmitter onMMS.
*EAL34102, high
power
consumption.
2) None.
FLOW 1)LV34102 on 1)Level rise in 3)(LI34151, local No action required,
NO or drain line fails D3403. gauge). existing safeguards
Less in close OR LIC34102 67
considered
D3403 failure. adequate.
2)See 2) See safeguards
drain
consequence for for deviation
2)Low level in left deviation "LEVEL "LEVEL LESS in left
separator side (see LESS in left separator side".
deviation "LEVEL separator side".
LESS in left
separator side").
TABLE NO: 02 (continued) DOCUMENT REF: P&1D N. 341C and 341B ITEM: C3401 - E3401 -
E3411 - D3403
5)High pressure in
powder conveying
systems.
FLOW No significant
MORE in
E3401
causes/consequenc
es
identified.
68
TABLE NO: 02 (continued) DOCUMENT REF: P&ID N. 341C and 341B ITEM: C3401 - E3401 -
E3411 - D3403
FLOW No significant
LESS in
C3401
suction
line causes/consequenc
es
identified.
THAN
gasket
69
failure
in E3401
TABLE NO: 02 (continued) DOCUMENT REF: P&ID N. 341C and 341B ITEM: C3401 - E3401 -
E3411 - D3403
MORE in
2) None.
C3401
-PAH34113 on local
panel.
-PAHH34114 alarm
on local panel and
compressor trip.
70
-PSV34102 on
D3403, set @ 6 bar
g.
TABLE NO: 02 (continued) DOCUMENT REF: P&ID N. 341C and 341B ITEM: C3401 - E3401 -
E3411 - D3403
line
-PALL3411 trips
compressor,
2)
-PAL34109 on DCS.
LEVEL LV34102 fails close Possible tank -LAH34102 on DCS No action required,
MORE in or LIC34102 overfill. (not working for LIC existing safeguards
left side failure. failure). considered
of adequate.
D3403
-(LI34151 local
gauge).
ION
to prevent any
pressure in powder
73