SPEEDBIRD HDPE PLANT SAFETY

<3D> basell REPORT

22 TEcnimonT
Y V MATTwr-SsvaGru^
Pply-ofefins

Identification Code

3443-SZ-RT-101
Plant: 320KT/Y HDPE Client _ ?a*el! Location: MÜNCHSMÜNSTER
Polyoleflns Sheet 1/94 Issue 04

ATTACHMENT 2

HAZOP WORKSHEET NPP PACKAGE AND

EXTRUSION

This document is Tecnimont's property and cannot be used by others for any purpose without prior written consent
1
 Package List

-Extrusion

-2PK2205 AND 2PK2401 PNEUMATIC HAULAGE PACKAGE UNITS

-2PK2301 MEMBRANE SEPARATION

-2PK3201 RECYCLE GAS COMPRESSOR PACKAGE UNIT

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

-2PK6101 REFRIGERATION UNIT PACKAGE

-5PK 6801 FLARE SYSTEM AND COLD FLARE

EXTRUSION HAZOP Additive feeding, Extruder & sampling points, Mixer, Pelletizer & powder
scales

CLIENT: BASELL ORLEN POLYOLEFINS

PROJECT NO: 3164

PROJECT: HDPE

DETAILS: This file contains HAZOP sheets of the following P&Id's:

-519: Vacuum system (common)
-521A: Pelletizing additive feeding
-521 B: Pelletizing additive feeding II
-521 C: Pelletizing additive feeding III
-514: Extruder (process connections). Oxygen injection -514H: Hot
oil unit
-514A: Extruder interconnections -514B: Continuous mixer
-514C: Pelletizer
-514G: PCW system
-511 A: Pelletizing powder bin and powder discharging scale
-242: Powder storage

-51 IB: Mixing screw and degassing filter

MEETING DATES: 23/24/25 June 2004 CHAIRMAN: G. GIOACCHINI -

AESSEQ SECRETARY: M. RIGOLIO - TCM

TEAM MEMBERS: Т. SCHERR - BASELL
G. MILLIGAN - BASELL M. BUCZEK. -
BOP M. WILMANOWICZ - BOP S.
SCHIFANO - BOP S. BONALDI - TCM
P. PEREGO - TCM S. BELSITO - TCM S.
GADOMSKI - BASELL L.
 SCHOONACKER - BASELL M.
SEBASTIANI - TCM

ACTION RESPONSES TO: TCM, BOP, VENDOR

3
 DOCUMENTS STUDIED P&I Diagrams Layout drawings
Technical specsOTHER DETAILS 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 condition (where applicable).

4)HAZOP has been performed assuming no random piping rupture.

5)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
PRESSURE TEMPERATURE FLOW LEVEL COMPOSITION
AGITATION
2M5101 CONCENTR
ROTATIO
ATION
N

SECONDARY KEYWORDS

MOREREVERSE
NO OTHERTHAN
LESS
 CORROSION MAINTENANCE
AS WELL AS PART OF

5
TABLE NO: 01 DOCUMENT REF: 519 REVISION: 3 DOCUMENT TITLE: 3PK5103 VACUUM
SYSTEM PACKAGE

ITEM: 3C5105; 3F5104; 3F5105; 3RF5105

The floors of extrusion building are provided with a number of hose station connected to a central
vacuum system: once the operator connects the portable hose, operating a local push button will start
the vacuum blower C5105.
The pellets and/or powder entrained is retained in the bag filter F5104, provided with automatic
cleaning system and a rotary cell discharging to a portable container.
The purpose of the system is to remove any spills of polymer in the Extrusion building.

Table 1 refers to the hose piping/filter/blower ensemble. Table 2 refers to the rotary cell & container
only.

TEAM MEMBERS: G.GIOACCHINI; M.RIGOLIO; T.SCHERR; M.BUCZEK;

M.WILMANOWICZ; S.SCHIFANO; S.BONALDI; P.PEREGO; S.GADOMSKI; G.MILLIGAN
DEVIATION CAUSE CONSEQUENCE SAFEGUARDS ACTION

PRESSURE Filters plugged. Possible 3C5105 3PSV51901 No action required,

LESS damage. (vacuum breather existing safeguards
valve) provided by considered
Vendor. adequate.

PRESSURE Explosion risk in Catastrophic failure Explosion panel Confirm that

MORE 3F5104. of the filter. provided by Vendor package 3PK5103 is
on 3F5104 shell. adequately
The panel is located protected against
at 3.5 m height from electrostatic
grade and discharges charges.
to an open area.

1 ASSIGNED TO:
ACTION VENDOR / TCM
NO:
FLOW LESS 1)Electric motor Automatic floor 1)3EA 51901. No action required,
OR ZERO failure. cleaning existing safeguards
impossible: considered
operators have to adequate.
2)Filters plugged. 2)3PDAH 51912.
perform cleaning
operations
manually.
3)Line plugged. Operational issue.
FLOW No significant
MORE consequences
identified.

LEVEL 3RF5105 working Air entrainment in None. See LEVEL MORE

LESS continuously. 3F5104 through deviation.
IN3F5104 seals.
Operational issue.

7
 TABLE NO: 01 (continued) DOCUMENT REF: 519
ITEM: 3C5105; 3F5104; 3F5105; 3RF5105
DEVIATIO CAUSE CONSEQUENCE SAFEGUARDS ACTION
N
LEVEL 1)3RF5105 failure. Filter not working 3LSH51901. HAZOP team
MORE IN properly. recommends to
3F5104 provide batchwise
3F5104 emptying
2)Start sequence
instead of continuos
failure.
operation, as
indicated in the
3)Manual slide P&ID.
valve at 3F5104 Provide in the
bottom left Operating Manual
inadvertently close. detailed instruction
for emptying the
system.

2 ASSIGNED TO:
further discussed
with

ACTION
NO: NOTE: VENDOR / TCM
To be package vendor

TABLE NO: 02 DOCUMENT REF: 519 REVISION: 3 DOCUMENT TITLE: VACUUM SYSTEM

ITEM: MOBILE DUST CONTAINER

See previous table for system description.

This table refers to the rotary cell & container only.

TEAM MEMBERS: G.GIOACCHINI; M.RIGOLIO; T.SCHERR; M.BUCZEK;

M.WILMANOWICZ; S.SCHIFANO; S.BONALDI; P.PEREGO; S.GADOMSKI; G.MILLIGAN
DEVIATIO CAUSE CONSEQUENCE SAFEGUARDS ACTION
N
LEVEL Higher flow rates Dust released None. See LEVEL MORE
MORE than expected: outside the in 3F5104.
operator hasn't container.
replaced container Environmental
in time. issue.

further discussed package vendor

witt

NOTE: To
be
TABLE NO: 03 DOCUMENT REF: 521A REVISION: 3
DOCUMENT TITLE: HDPE PELLETIZING ADDITIVE FEEDING I

ITEM: 2RF5202; 2SF5201A/B; 2F5251; 2W5201; 2Z5201A/B; 2SF5206; 2F5201 HDPE Plant:
Pelletizing & additive feeding I.

The HDPE plant is fitted with 5 metering stations for solid additives, each provided with 100 %
spare: the stations are similar to each other, although it is recommended to use the same additive
in the same station. All streams are conveyed to the feeder 2SF5206 and then the mixture is then
sent to extrusion through the rotaiy feeder 2RF5202.
Solid additives come in 1 m3 big-bags, which are lifted to the discharge feeder, each provided
with scale: a metering system conveys either of the two big bags in a scale to a screw conveyor,
discharging to 2SF5206: a continuos Nitrogen feed is injected in 2SF5206 and S201A to E shafts,
to avoid powder release in the ambient. Nitrogen is then removed by the system via local bag
filters, each vented locally to atmosphere in hoods connected to a blower continuously running, to
avoid Nitrogen buildup in the work environment.

Table 3 refers to the first two additive stations:

-2Z5201 A/B
-2Z5202 A/B

Table 4 refers to the screw feeder 2SF5206, supplying all additives to HDPE extrusion.

TEAM MEMBERS: G.GIOACCHINI; M.RIGOLIO; T.SCHERR; M.BUCZEK;

9
 M.WILMANOWICZ; S.SCHIFANO; S.BONALDI; P.PEREGO; S.GADOMSKI; G.MILLIGAN

CAUSE
DEVIATION CONSEQUENCE

1)Empty bag. Plugging/bridging of The package comes with abnormal delivery

additives upstream its own DCS system, rate.
2)Mechanical failure
2SF5201A/B. which has been declared No action required,
of 2SF5201A/B.
Off-spec product. to provide some sort of existing safeguards
Operational issue. alarm in case of considered adequate.
3)

4) Mechanical failure of 2W5201.

SAFEGUARDS ACTIO
N

FLOW
LESS
TO
2SF5206
 TABLE NO: 03 (continued) DOCUMENT REF: 521A
ITEM: 2RF5202; 2SF5201A/B; 2F5251; 2W5201; 2Z5201A/B; 2SF5206; 2F5201
DEVIATION CAUSE CONSEQUENCE SAFEGUARDS ACTION

LEVEL LESS Container empties at Off-spec product. 1)2WAL5201A/B. No action required,

OR ZERO IN a higher rate than Operational issue. existing safeguards
BIG BAG expected. considered
adequate.
2)2LSL52101/2.

3)Operator has to
switch containers
manually. This
information is
included in the
Operating Manual.

TABLE NO: 04 DOCUMENT REF: 521A REVISION: 3 DOCUMENT TITLE: HDPE

PELLETIZING ADDITIVE FEEDING I
ITEM: 2SF5202A/B; 2F5252; 2W5202; 2Z5202A/B; 2SF5206; 2RF5202; 2F5201 HDPE Plant:
Pelletizing & additive feeding I (continued).

See previous table for system description.

This table refers to the screw feeder 2SF5206, supplying all additives to HDPE extrusion.

TEAM MEMBERS: G.GIOACCHINI; M.RIGOLIO; T.SCHERR; M.BUCZEK;

M.WILMANOWICZ; S.SCHIFANO; S.BONALDI; P.PEREGO; S.GADOMSKI; G.MILLIGAN
DEVIATION CAUSE CONSEQUENCE SAFEGUARDS ACTION

FLOW 1)Empty bag. Off-spec product. The package comes No action required,
LESS Operational issue. with its own DCS existing safeguards
TO system, which has considered
2SF5206 2)Mechanical been declared to adequate.
failure of provide some sort of
2SF5202A/B. alarm in case of
abnormal delivery
rate.
3)
Plugging/bridging
of additives adding
upstream
2SF5202A/B.

4)Mechanical
failure of 2W5202.
TABLE NO: 04 (continued) DOCUMENT REF: 521A
ITEM: 2SF5202A/B; 2F5252; 2W5202; 2Z5202A/B; 2SF5206; 2RF5202; 2F5201
DEVIATION CAUSE CONSEQUENCE SAFEGUARDS ACTION

FLOW Control system not Off-spec product. The package comes No action required,
MORE TO working properly. Operational issue. with its own DCS existing safeguards
11
2SF5206 system, which has considered
been declared by adequate.
Vendor to provide
some sort of alarm
in case of abnormal
delivery rate.
TABLE NO: 05 DOCUMENT REF: 521B REVISION: 3 DOCUMENT TITLE: HDPE
PELLETIZING ADDITIVE FEEDING II

ITEM: 2SF5203A/B; 2F5253; 2W5203; 2Z5203A/B; 2SF5206; 2RF5202; 2F5201 HDPE Plant:
TABLE NO:
Pelletizing & 06 DOCUMENT
additive REF: 521B REVISION: 3 DOCUMENT TITLE: HDPE
feeding II.
PELLETIZING ADDITIVE FEEDING II
See previous
ITEM: table for 2F5254;
2SF5204A/B; system description.
2W5204; 2Z5204A/B; 2SF5206; 2RF5202; 2F5201 HDPE Plant:
Pelletizing & additive feeding II (continued).

This table refers

See previous to for
table thesystem
following additive station: - 2Z5203 A/B
description.

TEAM MEMBERS: G.GIOACCHINI; M.RIGOLIO; T.SCHERR; M.BUCZEK;

M.WILMANOWICZ;
This table refers to the S.SCHIFANO; S.BONALDI;
following additive P.PEREGO;
station: - 2Z5204 A/B S.GADOMSKI; G.MILLIGAN
DEVIATION CAUSE CONSEQUENCE SAFEGUARDS ACTION
TEAM MEMBERS:
FLOW 1)EmptyG.GIOACCfflNI;
bag. M.RIGOLIO;
Off-spec product.T.SCHERR; M.BUCZEK;
The package comes No action required,
M.WILMANOWICZ; S.SCHIFANO;Operational
LESS S.BONALDI; P.PEREGO;
issue. with itsS.GADOMSKI;
own DCS G.MILLIGAN
existing safeguards
DEVIATION
TO CAUSE CONSEQUENCE system, SAFEGUARDS
which has considered ACTION
2SF5206 2)Mechanical been declared to adequate.
FLOW 1)Empty
failure of bag. Off-spec product. The package
provide some comes
sort No action required,
LESS 2SF5203A/B. Operational issue. with its in
of alarm owncaseDCS
of existing safeguards
TO system,
abnormalwhich
rate of has considered
2SF5206 been declared by adequate.
delivery.
2)Mechanical
3) Vendor to provide
failure of
Plugging/bridging some sort of alarm
2SF5204A/B.
of additives in case of abnormal
upstream delivery rate.
3)Plugging
2SF5203A/B. /
bridging of additive
upstream
2SF5204A/B.
4)Mechanical
failure of 2W5203.
FLOW Control system not Off-spec product. The package comes No action required,
4)Mechanical
MORE TO working 2W5204. Operational issue. with its own DCS existing safeguards
failure ofproperly.
2SF5206
FLOW Control system not Off-spec product. The system, whichcomes
package has No
considered
action required,
MORE TO working properly. been declared by
Operational issue. with its own DCS existing adequate.safeguards
2SF5206 Vendor to
system, whichprovide
has considered
been declaredalarm
some sort of by adequate.
in case ofto abnormal
Vendor provide
delivery
some rate.of alarm
sort
in case of abnormal
delivery rate.

LEVEL LESS Container empties Off-spec product. 1)2WAL5204A/B. No action required,

OR ZERO IN faster than Operational issue. existing safeguards
BIG BAG expected. considered
adequate.
2)2LSL52107/8.

3)Operator has to
switch containers
manually. This
information is
included in the
Operating Manual.
TABLE NO: 07 DOCUMENT REF: 521C REVISION: 3 DOCUMENT TITLE: HDPE
PELLETIZING ADDITIVE FEEDING III

ITEM: 2SF5205A/B; 2F5255; 2W5205; 2Z5205A/B; 2SF5206; 2RF5202; 2F5201 HDPE Plant:
Pelletizing & additive feeding EL

See previous table for system description.

This table refers to following additive station: - 2Z5205 A/B

TEAM MEMBERS: G.GIOACCHINI; M.RIGOLIO; T.SCHERR; M.BUCZEK;

M.WILMANOWICZ; S.SCHIFANO; S.BONALDI; P.PEREGO; S.GADOMSKI; G.MILLIGAN
DEVIATION CAUSE CONSEQUENCE SAFEGUARDS ACTION

FLOW 1)Empty bag Off-spec product. The package comes No action required,
LESS Operational issue. with a DCS system, existing safeguards
TO which has been considered
2SF5206 2)Mechanical declared by Vendor adequate.
failure of to provide some sort
2SF5205A/B. of alarm in case of
abnormal delivery
rate.
3)
Plugging/bridging of
additive upstream
2SF5205A/B.

4)Mechanical
failure of 2W5205.
FLOW Control system not Off-spec product. The package comes No action required,
MORE TO working properly. Operational issue. with its own DCS existing safeguards
2SF5206 system, which has considered
been declared by adequate.
Vendor to provide
some sort of alarm
in case of abnormal
delivery rate.

LEVEL LESS Container empties at Off-spec product. 1)2WAL5205A/B. No action required,

OR ZERO IN a higher rate than Operational issue. existing safeguards
BIG BAG expected. considered
adequate.
2)2LSL52109/10.

3)Operator has to
switch containers
13 manually. This
information is
included in the
Operating Manual.
TABLE NO: 08 DOCUMENT REF: 521A REVISION: 3 DOCUMENT TITLE: HDPE
PELLETIZING ADDITIVE FEEDING I

ITEM: 2SF5206; S202; 2F5201

HDPE Plant: Pelletizing & additive feeding I (continued).

The 5 metering stations convey the appropriate quantities of additives to a common screw conveyor
(2SF5206) feeding in turn the mixing screw 2M5101 (see P&ID 51 IB).
The conveyor shaft is continuously purged with low-pressure Nitrogen, to avoid powder release to
the work environment: the powder entrained retained in the bag filter 2F5201, provided with
automatic cleaning system, while the Nitrogen is released

REMARK
This P&ID does not follow the numbering sequence as the equipment represented provide common
service to all the five additive feeding stations of P&ID's 521 A, 52 IB and 521C.

TEAM MEMBERS: G.GIOACCHINI; M.RIGOLIO; T.SCHERR; M.BUCZEK;

M.WILMANOWICZ; S.SCHIFANO; S.BONALDI; P.PEREGO; S.GADOMSKI; G.MILLIGAN
DEVIATION CAUSE CONSEQUENCE SAFEGUARDS ACTION
TABLE NO: 09 DOCUMENT REF: 521C DOCUMENT TITLE: HDPE REVISION: 3
COMPOSITI
PELLETIZING1)Valve ADDITIVEpassing or Off-spec
FEEDING III product. The package comes No action required,
ON left inadvertently Operational issue. with its own DCS existing safeguards
OTHER
ITEM: 2C5201opened permits system, which has considered
THAN cross contamination been declared by adequate.
HDPE Plant: Pelletizing
EXPECTED to occur. & additive feeding III (continued).
Vendor to provide
See previous table for system description. some sort of alarm
in case of abnormal
2)Control system
This table refersnot
to working delivery
the local Nitrogen suction system, common rate.
to the 5 additive metering and
feeding stations.properly.
Each feeder has a
REMARK list of
This P&ID does not follow the numbering sequence as the recommended
equipment represented provide common
service to all the five additive feeding stations of P&ID's 521A, 521Band
additives and 521C.
operators shall
TEAM MEMBERS: G.GIOACCHINI; M.RIGOLIO; T.SCHERR; M.BUCZEK;
follow design
M.WILMANOWICZ; S.SCHIFANO; S.BONALDI; P.PEREGO; S.GADOMSKI; G.MILL1GAN
guidelines.
DEVIATION CAUSE CONSEQUENCE SAFEGUARDS ACTION

FLOW LESS 1)Mechanical failure 80 m3/h of 1)2EA52113 Provide in the

OR ZERO of fan 2C5201. Nitrogen consumed electrical failure Operating Manual
by the package are alarm. proper instruction
released in the for the operator in
2)Electrical failure
building. Possible case of fan stop.
of fan motor. 2)Forced ventilation
hazard for operators
system in the
due to Oxygen-
building.
depleted
atmosphere
buildup. 3)Oxygen detectors
provided at selected
locations in
building.
ACTION 3 ASSIGNED TO: TCM
NO:
TABLE NO: 10 DOCUMENT REF: 511B REVISION: 3 DOCUMENT TITLE: MIXING SCREW
AND DEGASSING FILTER

ITEM: 2D5102; 2M5101; 2F5101

HDPE Plant: HDPE polymer and additives mixing screw and degassing system.

The mixture of polymer and additives coming from the feeder 2W5201 (see P&ID 511 A) is
homogenized in the mixing screw supplying the extruder (see P&ID 514).
A continuous Nitrogen feed is injected in the shaft seals: Nitrogen is dedusted in the bag filter
2F5201 and discharged to a safe location outdoors via the fan 2C5102 that keeps the screw under
slow
TABLE Nitrogen
NO: 10pressure through
(continued) a pressure controller
DOCUMENT REF: 51 IBvalve, with2D5102;
ITEM: the purpose to avoid
2M5101; Oxygen
2F5101
entering the extruder that could possibly spoil the final product.
The intermediate pellet bin 2D5102 is provided to recycle off spec polymer.
DEVIATION CAUSE CONSEQUENCE SAFEGUARDS ACTION
TEAM
FLOW MEMBERS: G.GIOACCHINI;
Nitrogen purge AirM.RIGOLIO;
entering the T.SCHERR;
1+2) M.BUCZEK;No action required,
M.WILMANOWICZ;
LESS S.SCHIFANO;system:
flow stops. S.BONALDI; P.PEREGO; G.MILLIGANexisting safeguards
DEVIATION
OF CAUSE CONSEQUENCE 2PAL51103 SAFEGUARDS low ACTION
considered
pressure alarm.
NITROGEN adequate.
PRESSURE 1)Nitrogen purge 1)Off-spec
Air enteringproduct
the 1+2) No action required,
TO 2M5101
LESS IN flow stops. Operational
system: issue. existing safeguards
2FAL51106,
2PAL51103 low
2M5I01 considered
2FAL51107,
pressure alarm.
adequate.
2)2PV51103 fails 2)Possible
1)Off-spec product. 2FAL51108,
open or instrument explosion
Operational hazard
issue.in 2FAL51109 low
2FAL51106,
loop failure. filter 2F5101. flow alarms on
2FAL51107,
Safety issue. DCS.
2)Possible 2FAL51108,
explosion hazard in 2FAL51109 low
filter 2F5101. 2)
flowThe
alarmssystem
on is
Safety issue. depressurized
DCS. but
there is still Nitrogen
excess, because of
2) The system is
the high flow
depressurized but
coming from feeding
there is still
line 16"-2- PE016.
Nitrogen excess,
LEVEL No more pellets Off-spec pellets to 2LI51103. because of the high No action required,
LESS IN arriving from the 2M5101. flow coming from existing safeguards
2D5102 BIN feed lines. Operational issue. feeding line 16"-2- considered
PE016. adequate.

LEVEL 1)Tank overfilled Transfer lines 2LAH51108 high No action required,

MORE IN from polymer plugged. level alarm. existing safeguards
2D5102 recycle lines. Operational issue considered
adequate.
2LAHH51104 high
2)Tank overfilled high level alarm.
during truck
unloading (rare
2LI51103.
occurrence, since
the tank volume is 15
120 m3).
2M5101 Power outage or Extrusion stops. 2EA51103. No action required,
ROTATION mechanical failure. Operational issue. existing safeguards
NO considered
adequate.
TABLE NO: 11 DOCUMENT REF: 51 IB REVISION: 3 DOCUMENT TITLE: MIXING SCREW
AND DEGASSING FILTER

ITEM: 2F5101; 2C5102

HDPE Plant: HDPE polymer and additives mixing screw and degassing system (continued).

See previous table for process description. This table refers to: -bag filter 2F5102 -Nitrogen fan
2C5102.

TEAM MEMBERS: G.GIOACCHINI; M.RIGOLIO; T.SCHERR; M.BUCZEK;

M.WILMANOWICZ; S.SCHIFANO; S.BONALDI; P.PEREGO; G.MILLIGAN
DEVIATIO CAUSE CONSEQUENCE SAFEGUARDS ACTION
N
PRESSURE 2PCV51101 fails Pressure build up in 2PSV51104 set @ No action required,
MORE IN open. 2F5102. 0.15 bar. existing safeguards
2F5102 considered
adequate.

FLOW LESS 1)2C5102 Pressure build up 1+2) 2EA51107 No action required,

OR ZERO mechanical failure. upstream with motor failure alarm. existing safeguards
OF operational trouble considered
NITROGEN in additive feeding: adequate.
2)2PV51103 sticks (2PI51151, local
PURGE excess Nitrogen
close or PICS 1103 gauge).
will leave the
malfunction.
system from vent
connections 1) 2PAH51103.
available on loss-in-
weight metering
stations.

FLOW LESS 1)Pump failure. Operational issue. Spare pump No action required,
OR ZERO available. existing safeguards
IN considered
P810A/B adequate.
2)Line plugged. EA8408.

Mass flow meter

FT8302,providing
flow deviation alarm
to DCS.
LEVEL Container empties at Off-spec product. 1WAL802A/B. No action required,
LESS OR a higher rate than Operational issue. existing safeguards
ZERO IN expected. considered
BIG BAG adequate.
1LSL8103/4.

Operator has to
switch manually
containers. This
information is
included in the
,•rt
 Operating Manual.

TABLE NO: 12 DOCUMENT REF: 514 REVISION: 3

DOCUMENT TITLE: EXTRUSION (PROCESS CONNECTION)
ITEM: 2C5101; 2EX5101
HDPE Plant: Extrusion process connections.
After reviewing the P&ID, the team has concluded that no HAZOP is needed.
TEAM MEMBERS: G.GIOACCHINI; M.RIGOLIO; T.SCHERR; M.BUCZEK; M.WÏLMANOWICZ;
L.SCHOONACKER; S.BONALDI; P.PEREGO; S.GADOMSKI; G.MILLIGAN

No significant deviations identified for this Item

TABLE NO: 13 DOCUMENT REF: 514H REVISION: 2

DOCUMENT TITLE: HOT OIL UNIT
ITEM: 2D5113; 2E5108; 2E5109; 2P5107A/B HDPE Plant: Hot oil circuit in the extrusion system.

REMARK
P&ID diagram of hot oil unit is not clear.
BOP will require Vendor to provide an updated P&ID (with a clear explanation of the symbols)
together with the Operating Manual.
Project team will then perform a Safety Analysis on the updated documents.
During the Safety Analysis it will be decided whether or not to perform a full HAZOP for this
system.

TEAM MEMBERS: G.GIOACCHINI; M.RIGOLIO; T.SCHERR; M.BUCZEK; M.WILMANOWICZ;

L.SCHOONACKER; S.BONALDI; P.PEREGO; S.GADOMSKI; G.MILLIGAN

No significant deviations identified for this Item

TABLE NO: 14 DOCUMENT REF: 514A REVISION: 3

17
DOCUMENT TITLE: EXTRUDER INTERCONNECTION
ITEM: 2EX5101
HDPE Plant: Extrusion system interconnections P&ID
After reviewing the P&ID, the team has concluded that no HAZOP is needed.
TEAM MEMBERS: G.GIOACCHINI; M.RIGOLIO; T.SCHERR; M.BUCZEK;
M.WILMANOWICZ; L.SCHOONACKER; S.BONALDI; P.PEREGO; S.GADOMSKI;
G.MILLIGAN

No significant deviations identified for this Item

TABLE NO: 15 DOCUMENT REF: 514B REVISION: 3

DOCUMENT TITLE: HDPE EXTRUDER - CONTINUOS MIXER
ITEM: 2EX5101
HDPE Plant: Extruder continuous mixer.
BASELL HSE Corporate and TCM staff, after reviewing the P&ID, agreed that HAZOP review is not
required.
The Safety Review already performed has been deemed sufficient.

TEAM MEMBERS: G.GIOACCHINI; M.RIGOLIO; T.SCHERR; M.BUCZEK; S.BONALDI;

P.PEREGO; S.GADOMSKI; G.MILLIGAN; S.BELSITO;

No significant deviations identified for this Item

TABLE NO: 15 DOCUMENT REF: 514C REVISION: 3

DOCUMENT TITLE: HDPE EXTRUDER - PELLETIZER
ITEM: 2EX5101
HDPE Plant: Extruder pelletizer
BASELL HSE Corporate and TCM staff, after reviewing the P&ID, agreed that HAZOP review is not
required.
The Safety Review already performed has been deemed sufficient.

TEAM MEMBERS: G.GIOACCHINI; M.RIGOLIO; T.SCHERR; M.BUCZEK; S.BONALDI;

P.PEREGO; S.GADOMSKI; G.MILLIGAN; S.BELSITO;

No significant deviations identified for this Item

TABLE NO: 16 ' DOCUMENT REF: 514G REVISION: 3
DOCUMENT TITLE: HDPE EXTRUDER - PCW SYSTEM
ITEM: 2EX5101
HDPE Plant: Extruder PCW system
BASELL HSE Corporate and TCM staff, after reviewing the P&ID, agreed that HAZOP review is not
required.________________________________________________________________________
The Safety Review already performed has been deemed sufficient.
TEAM MEMBERS: G.GIOACCHINI; M.RIGOLIO; T.SCHERR; M.BUCZEK; S.BONALDI;
P.PEREGO; S.GADOMSKI; G.MILLIGAN; S.BELSITO;

No significant deviations identified for this Item

19
TABLE NO: 17 DOCUMENT REF: 511A REVISION: 3 DOCUMENT TITLE: HDPE
PELLETIZING POWDER BIN AND POWDER DOSING SCALE
ITEM: 2D5101; 2RF5101
HDPE Plant: Powder bin and dosing scale

This P&ID refers to the intermediate storage of HDPE powder before additive mixing and injection
in the Extruder. The bin is provided with a bag filter, vented to fan 2C2402 A/B/C (see P&ID 241).
The powder is fed to the scale by means of a rotary feeder (2RF5101): from the meter the powder is
then sent to the extruder 2M5101 (see P&ID 51 IB).

TEAM MEMBERS: G.GIOACCHINI; M.RIGOLIO; T.SCHERR; M.BUCZEK; S.BONALDI;

P.PEREGO; S.GADOMSKI; G.MILLIGAN; S.BELSITO;
DEVIATION CAUSE CONSEQUENCE SAFEGUARDS ACTION

PRESSURE Filter 2F5101 Possible pressure Design pressure of No action required,

MORE plugged. buildup in silo silo = 0.2 bar. existing safeguards
2D5101 until the considered
maximum line adequate.
2PSV51101 set @
pressure. Safety
0.15bar (sized to
issue.
discharge Nitrogen
flow rate entering
2D5101 bottom
through 2F051105).

2PDAHH51101
across the filter.

2PAH51105 on the
vessel top.

Bag filter automatic

cleaning system.
PRESSURE Sudden cooling due Vacuum condition 2PSV51101 set @ - No action required,
LESS to weather changes inside the silos 0.50 mm water existing safeguards
with silo isolation could lead to column. considered
devices close. Oxygen adequate.
entrainment or silos
implosion. Safety
issue.
TABLE NO: 17 (continued) ITEM: DOCUMENT REF: 511A
2D5101; 2RF5101

DEVIATIO CAUSE CONSEQUENCE SAFEGUARDS ACTION

N
LEVEL 1)Flow impeded Silo overflow. 2LAH51107. No action required,
MORE IN downstream (line Operational issue. existing safeguards
2D5101 blocked, conflict considered
with downstream adequate.
2LAHH51101
control system).
activating interlock
2IS24135.
2)Bottom slide
valve sticking shut
2WAH51101
or left inadvertently
excess weight
closed.
alarm.

3)2RF5101 stops.
2EA51101 motor
failure alarm
activating interlock
4)Flow into vessel 2IS51101.
greater than
capacity for
outflow.
LEVEL LESS 1)Level switch No polymer supply Interlock 2IS51101. No action required,
IN 2D5101 malfunction. to the extruder. existing safeguards
Operational issue. considered
adequate.
2)Weight transmitter 2LALL51102
malfunction. activating interlock
2IS51101.
3)Bottom gate valve
sticking open. 2WAL51101
excess weight
4)No powder alarm.
supplied from
2PK2401 pneumatic
haulage.
FLOW 2FIC51116 control Powder rate sent to The system No action required,
MORE loop failure. the mixer higher downstream is existing safeguards
than expected. designed to handle considered
Operational issue the maximum adequate.

21
 capacity.
FLOW LESS Rotary feeder No powder fed to 2FIC51116. No action required,
OR ZERO 2RF5101 down. the extruder. existing safeguards
Operational issue. considered
adequate.
Bottom slide valve
left inadvertently
close.

TABLE NO: 18 DOCUMENT REF: 242 REVISION: 3 DOCUMENT TITLE: HDPE POWDER
STORAGE I
ITEM: 2D2401A/B; 2RF2401A/B; 2RF2402A/B HDPE Plant: Polymer powder storage.

Intermediate powder storage upstream Pelletizing powder bin.

TEAM MEMBERS: G.GIOACCHINI; M.RIGOLIO; T.SCHERR; M.BUCZEK; S.BONALDI;

P.PEREGO; S.GADOMSKI; G.MILLIGAN; S.BELSITO;
DEVIATION CAUSE CONSEQUENCE SAFEGUARDS ACTION

PRESSURE Filter(s) Possible pressure Design pressure of No action required,

MORE 2F2401A/B buildup in silo(s) silos = 0.2 bar. existing safeguards
plugged. 2D2401A/B to the considered
maximum line adequate.
2PSV24201/2 on
pressure. Safety
silo(s) set @
issue.
0.15bar.

2PDAH24201/2
across the filter(s).

2PAH24203/4 on
silo(s) top.

Bag filter automatic

cleaning system.
PRESSURE Sudden cooling due Vacuum condition 1PSV24201/2 set @ No action required,
LESS to weather changes inside the silo(s) -0.50 mm water existing safeguards
with silo(s) isolation could lead to column. considered
devices close. Oxygen entrainment adequate.
or silos implosion.
Safety issue.