HAZOP

CLIENT: BASELL ORLEN POLYOLEFINS

PROJECT NO: 3164

PROJECT: HDPE 320 KT/Y

DETAILS: HOSTALEN PLANT

- RECYCLE GAS COMPRESSOR PACKAGE UNIT (2PK3201)

MEETING DATES: 24 November 2003

*** Final issue, incorporating comments received from HAZOP Team ***

CHAIRMAN: G. GIOACCHINI - AESSEQ

SECRETARY: W. PRIOTTI - AESSEQ

TEAM MEMBERS: A. FUNK - BCA A.

KAUFMANN - BCA G. KUTSCHER - THYSSENKRUPP M. MACIUKIEWICZ -
BOP J. ROTOWSKI - BOP T. HORA - BASELL B.A. CAZZANIGA - TCM T.
SCHERR - BASELL S. BONALDI - TCM
p. PIOTROWSKI - BOP

ACTION RESPONSES TO: PROCS, JV

DOCUMENTS STUDIED P&I Diagrams

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

FLOW TEMPERATU PRESSURE LEVEL COMPOSITI

R ON
E
AGITATION

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

DEVIATIO CAUSE CONSEQUENCE SAFEGUARDS ACTION

FLOW NO See deviation

or LESS in "PRESSURE LESS".
1st stage
inlet

TABLE NO: 01 (continued) DOCUMENT REF: P&ID N. 021C ITEM: C3201 (1st stage) - D3206
- D3202 - E3201

DEVIAT CAUSE CONSEQUENCE SAFEGUARDS ACTION

ION

FLOW Compressor stops. Gas from delivery -Spring-loaded No action required,

REVER side @ 14 bar g valves on existing safeguards
SE could flow back to compressor considered
in 1st suction side @ 0.2 cylinders adequate.
stage bar g. (discharge side)
outlet to will close.
inle -Design pressure of
compressor body
=18 bar g, well
above the
compressor
delivery pressure
(14 bar g).
-Non return valve
NRV022 on
delivery side.
FLOW Corrosion, Shell side (@ 3.8 - LAH32113 only No action required,
OTHER mechanicai bar g) alarm on DCS. existing safeguards
THAN stress,... contaminated by -LAHH32114 trips considered
Tube cooling medium (@ the compressor. - adequate.
rupture 5.5 bar g). (LI32115, local
in E3201 Operational issue. gauge).
52
TEMPE 1)Hot gas from Temperature TI32133 only alarm MANDATORY
RATU reactors during exceeds the design (no shut down) both 1)Increase design
RE cooking phase value. local and on DCS. temperature of
MORE in (heating step) Design temperature equipment in
1st through D2101, due of all package is PK3201 from
stage to line 160 °C. interstage up to
inlet misalignment. delivery from 160
TABLE NO: 01 (continued) DOCUMENT REF: P&ID N. 021C ITEM: C3201 (1st stage) - D3206
- D3202 - E3201

DEVIAT CAUSE CONSEQUENCE SAFEGUARDS ACTION

ION

TEMPE Extremely low Operational issue. -Operating Manual No action required,

RATU ambient provides existing safeguards
RE LESS temperature. instructions. considered
-Design adequate.
temperature of all
package
equipment = -29
°C.
PRESSU 1)Hot (high 1)Possible Outside VENDOR MANDATORY
RE pressure) gas from Revise design
overpressure of
MORE reactors during pressure of
crank case and
in lst cooking phase -PSV32104 on Dernister (D3206)
ancillary
stage (heating step) suction line (sized on P&ID: shall be 6
equipment
inlet through D2101, due according to bar g, instead of 3
(Dernister).
to misalignment or API526) bar g.
to low level in -PAH32102.
reactor. 2)Slight pressure
increasing in
suction side. No Inside VENDOR BL:
2)PIC32102 failure -PI32124 on DCS
serious
or PV fails close. -PAHH32125
consequences.
-PAHH32109
-All suction side of
the package is
designed for 6 bar
g.
ACTION NO: 2 ASSIGNED TO: BURCKHARDT

53
TABLE NO: Ol (continued) DOCUMENT REF: P&ID N. 021C

ITEM: C3201 (1st stage) - - D3202 - E3201

D3206

DEVIAT CAUSE CONSEQUENCE SAFEGUARDS ACTION

ION

PRESSU 1) Manual valve on Possible vacuum in -PAL32124 on DCS MANDATORY

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

stage system. compressor. design pressure of

0.8

inlet 2) Demister bar a.

plugged.

3) PIC32102 failure

or PV fails open.

ACTION NO: 3 ASSIGNED TO: BURCKHARDT

COMPO 1) Liquid Hexane in 1), 2) Possible 1) 2) MANDATORY

SITI suction line, due to compressor - LAH32112 on BASELL process

damage.

ON overfill of upstream 54 demister. design shall

indicate

OTHER equipment in 2) Possible - LAHH32111 trips the maximum

TABLE NO: 02 DOCUMENT REF: P&ID N. 021C DOCUMENT TITLE: RECYCLE GAS
COMPRESSOR

ITEM: C3201 (2nd stage) - D3203 - D3204

This node concerns the equipment of second stage (compressor and upstream and
downstream dampers).

TEAM MEMBERS: FUNK, KAUFMANN, KUTSCHER, MACIUKIEWICZ, ROTOWSKI, HORA,

CAZZANIGA, SCHERR, BONALDI, PIOTROWSKI
DEVIA CAUSE CONSEQUENCE SAFEGUARDS ACTION
T ION

FLOW See deviation

NO "PRESSURE LESS".

or LESS
in 2nd
stage
inlet

FLOW 1)PCV32177 fails Accumulation of None. No actions

NO close. dirty particles in required.
distance piece
compartment. No
2)SV031 left
significant
or inadvertently close
consequences.
LESS or passing.
in

Ethyle
ne
purge

FLOW See deviation

MORE "PRESSURE MORE".
in 2nd
stage
inlet

55
TABLE NO: 02 (continued) DOCUMENT REF: P&ID N. 021C ITEM: C3201 (2nd stage) - D3203
- D3204

DEVIAT CAUSE CONSEQUENCE SAFEGUARDS ACTION

ION

FLOW PCV32177 fails Potential pressure None. MANDATORY

MORE in open or passing. increase of
1)VENDOR shall
compressor
verify the design
chambers where
pressure of
Ethylene is fed, up
Ethylene compressor
to the design
line components and
pressure of
shall confirm if
Ethylene from BL
they can withstand
supply line (25 bar
the design
g).
pressure of
Ethylene purge line
(25 bar g).

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

DEVIAT CAUSE CONSEQUENCE SAFEGUARDS ACTION

ION

TEMPE CW failure in Temperature at -TAH32104 on No action required,

E3201. 2nd stage inlet E3201 gas outlet. existing safeguards
increase up to 80 considered
°C and recycle gas adequate.
RATU hotter. More
Butene escaping -TAH32136 on 2nd
from top of T3201, stage outlet.
located
RE
downstream
compressor.
-TAHH32137 on
Operational issue. 2nd stage outlet
MORE in trips compressor.
2nd
stage
inlet

TEMPE See deviation

RATU "Temperature
Less" for 1st stage
compressor (Table
LESS
N. 1).

PRESSU See deviation See consequences -PSV32127 @ 6 bar No action required,

RE "Pressure more" for "Pressure g- existing safeguards
for 1st stage more" for 1st stage considered
compressor (Table compressor (Table adequate.
n. 1) n. 1).
MORE in -PAH32127.
2nd
stage
inlet
-PAHH32125 trips
compressor.

PRESSU 1)Manual valve at 1)Pressure rise up. GENERAL No action required,

RE T3201 inlet existing safeguards
-PSV32108, set@
(located considered
18 bar g.
downstream 2)Pressure adequate.
-PAH32108.
compressor) left increase.
MORE in inadvertently -PAHH32109 trips
57
2nd compressor.
closed.
stage
outlet 2) PSV32101 on
2)Manual valve on
T3201 top, set @
Hexane bottom
18 bar g.
discharge of T3201
left inadvertently
closed.
TABLE NO: 02 (continued) DOCUMENT REF: P&ID N. 021C ITEM: C3201 (2nd stage) - D3203
- D3204

DEVIAT CAUSE CONSEQUENCE SAFEGUARDS ACTION

ION

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;

3)Cross head guides;

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

CLIENT: BASELL ORLEN POLYOLEFINS

PROJECT NO: 3164 PROJECT: HDPE 320 KT/Y

DETAILS: HOSTALEN PLANT:

-OFF-GAS COMPRESSOR PACKAGE UNIT (2PK3402)
-CRACKER GAS COMPRESSOR PACKAGE (2PK3401)

MEETING DATES: 26 November 2003

*** Final issue, incorporating comments received from HAZOP Team ***

CHAIRMAN: G. GIOACCHINI - AESSEQ

SECRETARY: W. PRIOTTI - AESSEQ

TEAM MEMBERS: M. MACIUKIEWICZ -

BOP P.
PIOTROWSKY - BOP
J. ROSTOWSKI -
BOP T. HORA -
BASELL T. SCHERR
- BASELL S.
BONALDI - TCM A.R.
PATHAK - TCM P.
PEREGO - TCM

ACTION RESPONSES TO: PROCS, VENDOR, JV (BOP)

DOCUMENTS STUDIED P&I Diagrams

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

AS WELL PART OF CORROSION MAINTENAN

AS CE
1)

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

DEVIATIO CAUSE CONSEQUENCE SAFEGUARDS ACTION

FLOW NO 1)Manual valves on line Delivery pressure of 1)FSLL34104, No action required,

or LESS in from D3402 left compressor decreases compressor trip. existing safeguards
E3402 inadvertently close or and delivery considered adequate.
passing. temperature
increases. Compressor 2)
could run dry, leading -LAL34105 on DCS
2)Level less on the left to mechanical -LALL34105,
side of D3402. damage. compressor trip.

3) FAL34102 on DCS .
TABLE NO: 01 (continued) DOCUMENT REF: P&ID N. 341D and 341B

ITEM: C3402 - E3402 - E3412 - D3404

DEVIAT CAUSE CONSEQUENCE SAFEGUARDS ACTION
ION
FLOW FV34102 fails close Seal failure. 1) FALL34112 No action required,
Possible and/or
NO or FIC34102 gas leakage in the FALL34113 will trip existing safeguards
failure.
or LESS noise enclosure. compressor. considered
adequate.
in Potential formation 2) Two HC detector
mech. of
seal explosive available inside the
atmosphere
flush inside the noise noise hood.
enclosure.
FLOW 1)PV34107 fails 1) 1) No action required,
NO close or PIC34107 - See consequence - See safeguard for existing safeguards
for
or LESS failure. deviation deviation considered
adequate.
in gas "PRESSURE MORE "PRESSURE MORE
disch. 2) Compressor in suction side". in suction side".
to shut
KO down. - Compressor - Against
compressor
overload. 61
overload:
* TAH34114 and
2) Potential back TAH34115
flow (bearings)
from flare system on DCS
(see
Flare system * VT34102A/B/C/D,
HAZOP), vibration
transmitter
TABLE NO: 01 (continued) DOCUMENT REF: P&1D N. 341D and 341B ITEM: C3402 - E3402 -
E3412 - D3404

DEVIA CAUSE CONSEQUENCE SAFEGUARDS ACTION

T ION

FLOW PV34107 fails open Low pressure in None. None.

MORE in or PIC34107 D3404.
gas failure. No significant
disch. to consequences
KO identified.

FLOW XV on drain line Possible drain pot 1)LAL34122 on MANDATORY Verify

MORE in fails open or emptying and DCS. the feasibility of
pot relevant controller consequent gas 2)HSZH34108, on providing a new
drain failure. blow by through the DCS. interlock in order to
line drain line to the isolate the drain
drain collecting collecting system in
system. case of low low
level in the drain
pot.

ACTION ): PROCS

NO: 1 ASSIGNED
TC
FLOW No significant
LESS in causes/consequenc
C3402 es
suction identified.
line

FLOW Wearing. No serious None. No action required.

OTHER consequences,
THAN since the two fluids
gasket are compatible.
failure
in E3402

62
TABLE NO: 01 (continued) DOCUMENT REF: P&1D N. 341D and 341B ITEM: C3402 - E3402 -
E3412 - D3404

DEVIA CAUSE CONSEQUENCE SAFEGUARDS ACTION

T ION

TEMPE 1)Cooling water 1)Temperature 1) No action required,

failure (E3402). increase in existing safeguards
compressor and considered
possible adequate.
RATU 2)Cooling water - TAHH34192 on
cavitation.
failure (E3412). DCS.

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.

PRES SU 1)See deviation 1)See deviation 2) No action required,

RE "FLOW MORE". "FLOW MORE". existing safeguards
considered
adequate.
2)PV34107 fails 2)Delivery -PAH34107 on DCS
MORE in close or PIC34107 pressure will (not working in
C3402 failure. increase. case of PIC34107
suction failure).
line

-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

DEVIAT CAUSE CONSEQUENCE SAFEGUARDS ACTION

ION

PRESSU 1)PV34110 fails Possible GENERAL No action required,

close or PIC34110 compressor existing safeguards
failure. cavitation. Possible considered
vacuum in suction adequate.
RE side, with -compressor
2)Manual valve on designed for foil
consequent danger
suction line left vacuum.
of Oxygen entry in
inadvertently
the system. ,
LESS closed.

-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.

LEVEL XV on drain line Possible overfill -LAHH34123, No action required,

MORE in fails close or and discharge of compressor trip. existing safeguards
left side relevant controller water in HDPE KO considered
of failure. drum (D3402). adequate.
D3404
-(LI34152, local
gauge).

LEVEL See deviation

LESS in "FLOW MORE in
left side E3402".
of
D3404
64
TABLE NO: 01 (continued) DOCUMENT REF: P&ID N. 34ID and 34IB

ITEM: C3402 - E3402 - E3412 - D3404

DEVIAT CAUSE CONSEQUENCE SAFEGUARDS ACTION

ION

COMPO 1) More Hexane GENERAL Cause 1) No action required,

than

SITI expected (see No significant - maximum existing safeguards

ON deviation consequences temperature inside considered

the adequate.

OTHER "TEMPERATURE identified. compressor seal

THAN MORE" in Table 44 system is 30/40 °C,

in and Table 30, therefore no

C3402 HDPE Hexane

suction plant HAZOP, as evaporation can

line discussed in occur.

deviation "FLOW - seal system
MORE"). arranged to
prevent any
2)More fines than leakage to
expected, due to atmosphere.
high pressure in
powder conveying Causes 2), 3)
systems. Special powder
drain mechanism
65
downstream the
3)More fines than
expected coming separator D3404.
from diying section.
TABLE NO: 02 DOCUMENT REF: P&ID N. 341C and 341B DOCUMENT TITLE: PK3401 -
RECYCLE GAS COMPRESSOR (UNIT 300)

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.

DEVIAT CAUSE CONSEQUENCE SAFEGUARDS ACTION

ION

FLOW 1)Manual valves on Delivery pressure 1)FSLL34103 trips No action required,

NO line from D3403 left of compressor compressor. existing safeguards
inadvertently close. decreases and considered
delivery adequate.
2)
temperature -LAL34109 on DCS.
or LESS 2)Level less on the increases.
in E3401 leftside ofD3401.

-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

DEVIA CAUSE CONSEQUENCE SAFEGUARDS ACTION

T ION

FLOW FV34101 fails close Seal failure. 1)FALL34110 No action required,

NO or FIC34101 Possible gas existing safeguards
failure. leakage in the and/or FALL34111 considered
noise enclosure. will trip adequate.
Potential formation compressor.
or LESS of explosive
in atmosphere inside
mech. the noise
seal 2)Two HC detector
enclosure.
flush available inside the
noise hood.

FLOW 1)No gas demand 1) 1) No action required,

NO from BL OR existing safeguards
isolation valve left considered
adequate.
-See consequence -See safeguard for
or LESS for deviation deviation
in gas inadvertently
disch. closed.
to BL
"PRESSURE MORE "PRESSURE MORE
2)Compressor shut in suction side". in suction side".
down.

-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

DEVIAT CAUSE CONSEQUENCE SAFEGUARDS ACTION

ION

FLOW 1)Higher 1), 2), 3), 4), 5) GENERAL No action required,

MORE production of Suction pressure existing safeguards
in waste gas caused could increase over considered
C3402 by vessel(s) normal value (0.1 adequate.
suction blanketing. bar g) if the -Design pressure
line compressor cannot for C3401 = 10 bar
displace the g.
2)Nitrogen valve(s)
required flowrate.
in blanketing
Operational issue.
system failing open
or passing. -(PI34150, local
3), 4) Higher gauge).
amount of Hexane
3)High
vapour in suction
temperature in
line (see deviation
D3302 (see
"COMPOSITION
deviation
OTHER THAN").
"TEMPERATURE
MORE" in Table 44,
HDPE plant 5) Possible fines
HAZOP). entrainment (see
deviation
"COMPOSITION
4)High temperature
OTHER THAN").
in E3108/D3104
(see deviation
"TEMPERATURE
MORE" in Table 30,
HDPE plant
HAZOP).

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

DEVIAT CAUSE CONSEQUENCE SAFEGUARDS ACTION

ION

FLOW 1)PV34107 fails Low pressure in None. None.

MORE in open or PIC34107 D3403. No
gas failure. significant
disch. to consequences
BL identified.

FLOW LV34102 on drain Possible vessel (LI34151, local MANDATORY

MORE in line fails open (or emptying and gauge). Provide a low low
D3403 passing) OR consequent gas level alarm, whose
drain LIC34102 failure. blown by through signal is to be
line the drain line to derived from an
the drain collecting additional level
system. transmitter on
D3403 standpipe.

ACTION NO: 2 ASSIGNED TO: PROCS

FLOW No significant
LESS in
C3401
suction
line causes/consequenc
es

identified.

FLOW Wearing. No serious None. No action required.

consequences,
since the two fluids
are compatible.
OTHER

THAN

gasket

69
failure

in E3401
TABLE NO: 02 (continued) DOCUMENT REF: P&ID N. 341C and 341B ITEM: C3401 - E3401 -
E3411 - D3403

DEVIA CAUSE CONSEQUENCE SAFEGUARDS ACTION

T ION

TEMPE 1)Cooling water 1)Temperature 1) No action required,

failure (E3401). increase in existing safeguards
compressor and considered
possible cavitation. adequate.
RATU 2)Cooling water - TAHH34191 on
failure (E3411). DCS.
2)Increase of the
wearing rate for
RE the mechanical
seals. -(TI34194, local
gauge).

MORE in
2) None.
C3401

TEMPE Extremely low For prolonged For the No action required,

RATU RE ambient compressor shut compressor: existing safeguards
LESS in temperature. down, possible -winterisation has considered
C3401 water freezing been provided. adequate.
inside the
compressor, plate
heat exchangers, For the heat
etc. exchangers:
-uninterrupted
cooling water flow
prevents freezing.

PRESSU 1)See deviation 1)See deviation 2) No action required,

RE "FLOW MORE". "FLOW MORE". existing safeguards
considered
adequate.
2)PV34109 fails 2)Delivery -PAH34109 on DCS
MORE in open ORPIC34109 pressure increase. (not working in
C3401 failure. case of PIC34109
suction failure)
line

-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

DEVIAT CAUSE CONSEQUENCE SAFEGUARDS ACTION

ION

PRESSU 1)PV34109 fails Cause 1), 2) Causes 1), 2) No action required,

close or PIC34109 Possible existing safeguards
failure. compressor considered
cavitation. Possible adequate.
RE vacuum in suction -compressor
2)Manual valve on
side with designed for full
suction line left
consequent danger vacuum.
inadvertently
of Oxygen entry in
LESS closed.
the system.
-mechanical seal
permanently
in C3401 flushed with water.

suction -PAL34112 on local

panel.

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).

LEVEL See deviation

LESS in "FLOW MORE in
left side E3402".
of
D3403
71
TABLE NO: 02 (continued) DOCUMENT REF: P&ID N. 341C and 341B

ITEM: C3401 - E3401 - E3411 - D3403

DEVIAT CAUSE CONSEQUENCE SAFEGUARDS ACTION

ION

COMPO 1) More Hexane 1),2), 3) 1) No action required,

than

SITI expected (see No significant - maximum existing safeguards

ON deviation consequences temperature inside considered

the adequate.

OTHER "TEMPERATURE identified. compressor seal

THAN MORE" in Table 44 system is 30/40 °C,

in and Table 30, therefore no

C3401 HDPE Hexane

suction plant HAZOP as evaporation can

line discussed in occur.

deviation

"FLOW MORE"). - seal system

arranged

to prevent any

2) More fines than leakage to

expected, due to atmosphere.

high
72

pressure in powder

conveying 2), 3) Special

systems. powder drain
FLOW FV34102 fails close or Level decrease in See safeguard for No action required,
D3404

NO FIC34102 failure. (see deviation "FLOW "FLOW NO or LESS in existing safeguards

or LESS NO or LESS in E3402"). E3402". considered adequate.

in Change of ratio of the

make-up two phases in D3404.

water Operational issue.

73