Speedbird Hdpe Plant Safety Report Attachment 3 SIL Classification NPP Project

SPEEDBIRD HDPE PLANT SAFETY
REPORT ATTACHMENT 3
SIL IDENTIFICATION CODE
3443-SZ-RT-101
CLASSIFICATION NPP PROJECT Att.3
Location
Spedbird Sheet 2 of
Plants HDPE 320 KT/Y MUNCHSMUNSTER Issue 04
Project 71
GERMANY
SIL CLASSIFICATION SHEET <04>
Function No 1100-2PAH11102/3-2S11102-2HV11102 Applicable also to 2S11104
Zone THS conditioning and metering Unit 1100

P&ID No. 111A Interlock desc. Pag: 6 of 79
Initiator Tag 2PAHH11102/03 High pressure in 2D1101A (1oo2) (2PAHH11107/08 for 2S11104)
Logic Solver Tag 2S11102 High pressure in 2D1101A (2S11104 High pressure in 2D1101B
Final Element Tag Permissive to open 2HV11102 (Permissive to open 2HV11103 for 2S11104)
Design Intent
To prevent pressurization of 2Z1101A and consequent damage of catalyst drum (2Z1101B for 2S11104)
Hazardous Scenario (Demand Scenario)

Two different human error opening valve in line to 2T2201 and opening 2HV11104A (2HV11104B for 2S11104)
Consequence Scenario
LOC of catalyst drum because PSV is not designed for this case
Frequency of Unwanted Occurrence (W) W1

Comment:
A very slight probability that the unwanted scenario will come to pass.
Consequence Parameter for Personnel (C) C2

Comment:
C2 is selected for safety, for economical point of view minor consequence, C1 is selected, minor consequence in term of
environment impact.
Exposure Parameter (F) F2

Comment:
Frequent to permanent exposure in the hazardous zone
Avoidance Parameter (P) P2

Comment:
Almost impossible
SIL for Personnel Protection 1
Loss SIL
--
Environmental SIL -
Availability of Other Safety Related System
REPORT ATTACHMENT 3
3443-SZ-RT-101
Location
Spedbird Sheet 3 of
Project 71
GERMANY
SIL CLASSIFICATION SHEET
Function No 1100-2LAHH11101-2I11101-2HV11108
Zone THS conditioning and metering Unit 1100

Initiator Tag 2LAHH11101 High level in 2D1102A
Logic Solver Tag 2I11101 Level on 2D1102A
Final Element Tag Closes 2HV11108 distillated hexane
Design Intent
To prevent overfilling of catalyst suspension vessel 2D1102A

Possible malfunction of FIC11105 or FV11105 blocked open or possible human error setting mass flow meter
The overfilling gives higher pressure (less than the set point of PSV) the system react managing the pressure by
PV11119A (sending hexane and catalyst to 2T2201).

Comment:
A slight probability that the hazardous scenario will come to pass

Comment:
No safety consequence, in terms of economical loss minor consequence, C1 is selected.
Exposure Parameter (F) N/A

Comment:
not applicable
Avoidance Parameter (P) N/A

Comment:
not applicable
SIL for Personnel Protection nc
Loss SIL -
Environmental SIL nc

REPORT ATTACHMENT 3
3443-SZ-RT-101
Location
Spedbird Sheet 4 of
Project 71
GERMANY
Function No 1100-2LAHH11104-2S11105-2XV11103/4
Zone Activator metering Unit 1100

P&ID No. 111B Interlock desc. Pag: 6 of 79
Initiator Tag 2LAHH11104 High level in 2D1103
Logic Solver Tag 2S11105 2D1103 level
Final Element Tag Closes 2XV11103/4 Distilled hexane
Design Intent
To prevent overfilling of the vessel and consequent TEAL 10% to other unit

Possible malfunction of LI11103 or LV11103 blocked open, higher pressure in 2D4103
TEAL 10% in hexane to 2D3402 and by manual operation to 2D3303

Comment:
A very slight probability that the unwanted scenario will come to pass, because two different and not linked deviation.

Comment:
TEAL will ract with steam in the vessel 2D3303, possible increase of temperature over the design temperature of the
vessel (check the consistency of this scenario). Team doesn't consider a possible LOC of the equipment. No significant
consequence in terms of economical impact.

Comment:
not applicable

Comment:
not applicable
Loss SIL -
REPORT ATTACHMENT 3
3443-SZ-RT-101
Location
Spedbird Sheet 5 of
Project 71
GERMANY
Function No 1200-2PAHH12101\03B-2S12101-2HV12104
Zone Polymerization reactor I Unit 1200

Initiator Tag 2PAHH12101\03B Very high pressure in 2R1201
Logic Solver Tag 2S12101 2R1201 Emergency
Final Element Tag 2HV12104 monomer inlet to reactor
Design Intent
To prevent very high pressure in the reactor

Possible malfunction of FIC12104 or FV12104 blocked open
Discharge of large quantity of ethylene and other monomer to flare.

Comment:
A very slight probability that the unwanted scenario will come to pass, due to malfunction of PCV at battery limit and
FV12104 completely open

Comment:
In terms of economical loss possible stop of production up to 3 days, C1 is selected, from environmental point of view
emergency flaring gives C1. No safety consequence PSV is designed for this case.

Comment:
not applicable

Comment:
not applicable
Loss SIL -
Environmental SIL --
REPORT ATTACHMENT 3
3443-SZ-RT-101
Location
Spedbird Sheet 6 of
Project 71
GERMANY
Function No1200-2TAHH12101D-2S12101-2HV12104

Initiator Tag 2TAHH12101D Very high T in 2R1201; (2PAHH12101\03B Very high P in 2R1201 (1oo2)) (1oo2)
Final Element Tag 2HV12104 closed monomer feed to reactor
Design Intent
To preventy very high temperature and pressure in the reactor

Cooling water failure due to pump failure or malfunction of TIC on the reactor (power failure for the three reactors deviation)
Possible Loss of containment and damage of the reactor. PSV12101 is not designed for this case.

Comment:
A slight probability that the unwanted scenario will come to pass. Cooling water failure is considered very unlikely because
spare pump is available, the weak point could be TIC control or valve blocked closed, W2 is selected

Comment:
From economical point of view C3 is selected taking into account major damage of the equipment, possible fire and flash
fire is taken into account C2 is selected for safety. C1 in terms of environment impact.

Comment:

Comment:
Possible under certain conditions
Loss SIL 22
Environmental SIL -
REPORT ATTACHMENT 3
3443-SZ-RT-101
CLASSIFICATION NPP PROJECT
Location
Att.3
Spedbird Sheet 7 of
Project 71
GERMANY
Function No1200-2LAHH12106-2S12101-2FV12105/06/12/13/20

Initiator Tag 2LAHH12106 Very high level in 2R1201, 2PAHH12101\03B Very high pressure in 2R1201
Final Element Tag Close mother liquor line and Hexane line 2FV12112, 2FV12113, 2FV12105, 2FV12106,
2FV12120
Design Intent
To prevent overfilling in 2R1201 and consequent higher pressure

LIC12101 failure or LV12101A\B blocked closed
Possible increase of pressure up to set point of PSV of reactor (18barg designed for this case) consequent discharge of
fresh hexane to Blow down.

Comment:
A slight probability that the unwanted scenario will come to pass.

Comment:
Shut down of the plant in order to perform maintanance on PSV. 3 days of no production are expected. C1 is selected for
economical loss.

Comment:
not applicable

Comment:
not applicable
Loss SIL --
REPORT ATTACHMENT 3
3443-SZ-RT-101
Location
Att.3
Spedbird Sheet 8 of
Project 71
GERMANY
Function No1200-2A1201-2S12101-2HV12104

Initiator Tag 2A1201 stop of agitator
Final Element Tag Closed 2HV12104 monomer inlet to 2R1201
Design Intent
To prevent possible agglomeration inside the reactor due to no agitation.

Failure of agitator
Undesired agglomeration of polymer and production of chunks.

Comment:

Comment:
Economical loss due to stop of production up to 3 days C1 is selected

Comment:
not applicable

Comment:
not applicable
Loss SIL -
REPORT ATTACHMENT 3
3443-SZ-RT-101
Location
Spedbird Sheet 9 of
Project 71
GERMANY
Function No1200-2PDALL12116-2S12101-2HV12104

Initiator Tag 2PDALL12116 Low differential pressure ethylene/2R1201
Final Element Tag Shuts 2HV12104 monomer inlet to 2R1201
Design Intent
To prevent back flow to ethylene line

No ethylene at battery limit
Back flow in the ethylene line could give plugging of the ethylene line

Comment:
A very slight probability that the unwanted scenario will come to pass. The probability of no ethylene at battery limit is
considered very unlikely by experience.

Comment:
Stop of the production up to 3 days, in case of plugging of the deep pipe. C1 for economical loss is selected.

Comment:
not applicable

Comment:
not applicable
Loss SIL -
REPORT ATTACHMENT 3
3443-SZ-RT-101
Location
Att.3
Spedbird Sheet 10 of
Project 71
GERMANY
Function No1200-2PALL11136-2S12101-2HV12

Initiator Tag 2PALL11136
Final Element Tag 2HV12104 closed
Design Intent
To prevent high concentration of polymer in the slurry

Failure of pump 2P1104A\B or possible human error on manual valve on the delivery of the pump
Possible obstruction in the slurry line, possible agglomeration in the reactor and production of chunks

Comment:
A very slight probability that the unwanted scenario will come to pass, taking into account that both pump are not running

Comment:
The safety time is estimated more than one hour, by experience the scenario is not considered critical.

Comment:
not applicable

Comment:
not applicable
Loss SIL --
REPORT ATTACHMENT 3
3443-SZ-RT-101
Location
Project 71
GERMANY
Function No1200-2LAHH12103-2I12102-2LV12101A\B
Zone Flash and cooling slurry Reactor I Unit 1200

Initiator Tag 2LAHH12103 Very high level in 2D1201
Logic Solver Tag 2I12102 2D1201 high level
Final Element Tag Shuts 2LV12101A\B 2R1202 discharge valves
Design Intent
To prevent overfilling of the flash vessel

Possible malfunction of LIC12104 or LV12104 blocked closed or 2P1204 shut off
Overfilling of the flash vessel and consequent slurry up to liquid separator of 2PK3201 and to liquid ring compressor
PK3401
Comment:
A slight probability that the unwanted occurrence will come to pass and a few unwanted occurrences are likely.

Comment:
Stop of production up to 2 days, C1 is selected for economical loss.

Comment:
not applicable

Comment:
not applicable
Loss SIL -
REPORT ATTACHMENT 3
3443-SZ-RT-101
Location
Project 71
GERMANY
Function No 1200-2PAHH12106-2I12103-2XV12106

Initiator Tag 2PAHH12106 Very high pressure in 2E1204 tube side
Logic Solver Tag 2I12103 2E1204 tube rupture
Final Element Tag Closes 2XV12106
Design Intent
To prevent monomer blow by to the CWR system

Catastrophic failure of cooler tubes
Monomer release to atmosphere through the vent of expansion drum.

Comment:
A very slight probability that the unwanted occurrence will came to pass. The parameter is selected according to
experience, taking into account the the SIS is able to detect the hazardous situation only in case of catastrophic tube
failure.
Comment:
No significant effects on Environment. Fire and\or flammable vapor cloud may occur at the release point. C1 for
economical loss for repairing on site instrumentation is expected.

Comment:
Frequent to permanent exposure in the hazardous zone.

Comment:
SIL for Personnel Protection -
Loss SIL -
REPORT ATTACHMENT 3
3443-SZ-RT-101
Location
Project 71
GERMANY
Function No1200-ESA12104-2I12105-2LV12103

Initiator Tag ESA12104 stop of pump 2P1204
Logic Solver Tag 2I12105 stop of pump
Final Element Tag Shuts 2LV12103 2D1201 discharge valve
Design Intent
To prevent back flow from second reactor

Possible failure of the pump 2P1204
Back flow of slurry from reactor 2R1202, major damage of the pump 2P1204

Comment:
A slight probability that the unwanted occurrence will came to pass.

Comment:
No stop of production are expected only pump damage in terms of economical loss. No significant consequence in terms of
safety and environment.

Comment:
not applicable

Comment:
not applicable
Loss SIL -
REPORT ATTACHMENT 3
3443-SZ-RT-101
Location
Project 71
GERMANY
Function No1200-2LALL12102-2I12106-2P1201A/B

Initiator Tag 2LALL12102 Very low level in 2R1201
Logic Solver Tag 2I12106 2R1201 very low level
Final Element Tag Stops 2P1201A/B
Design Intent
Pump protection

Possible LV12101A or LV12101B completely open
Possible damage of the pump

Comment:

Comment:
Pump damage could happen only after several minuts, in this case less production.

Comment:
not applicable

Comment:
not applicable
Loss SIL -
REPORT ATTACHMENT 3
3443-SZ-RT-101
Location
Project 71
GERMANY
Function No1200-2LALL12103-2I12108-2P1204

Initiator Tag 2LALL12103 Very low level in 2D1201
Logic Solver Tag 2I12108 2D1201 very low level
Final Element Tag 2P1204 stop
Design Intent
Pump protection

LV12103 completely open or LIC12103 malfunction to signal

Comment:

Comment:
Pump damage could happen only after several minuts, in this case minor consequence, it is possible to continue the
production with other product by passing the pump.

Comment:
not applicable

Comment:
not applicable
Loss SIL -
-
REPORT ATTACHMENT 3
3443-SZ-RT-101
Location
Project 71
GERMANY
Function No 1200-2PAHH12201-2S12201-2HV12204
Zone Polymerization reactor II Unit 1200

Initiator Tag 2PAHH12201-3 Very high pressure in 2R1202
Final Element Tag 2HV12204 monomer inlet to reactor
Design Intent

Discharge of large quantity of ethylene and other monomer to flare

Comment:

Comment:

Comment:
not applicable

Comment:
not applicable
Loss SIL -
Environmental SIL -
REPORT ATTACHMENT 3
3443-SZ-RT-101
Location
Project 71
GERMANY

Initiator Tag 2TAHH12201D Very high T in 2R1202; (2PAHH12201-3 Very high P in 2R1202 (1oo2)) (1oo2)
Design Intent


Comment:

Comment:

Comment:

Comment:
Possible under certain condition
Loss SIL 22
Environmental SIL -
REPORT ATTACHMENT 3
3443-SZ-RT-101
Location
Project 71
GERMANY
Function No1200-2LAHH12201-2S12201-2FV12205/06/12/13/20

Initiator Tag 2LAHH12201 Very high level in 2R1202
Final Element Tag Close mother liquor line and Hexane line 2FV12212, 2FV12213, 2FV12205, 2FV12206,
2FV12220
Design Intent

Comment:

Comment:
economical loss.

Comment:
not applicable

Comment:
not applicable
Loss SIL --
REPORT ATTACHMENT 3
3443-SZ-RT-101
Location
Project 71
GERMANY
Function No1200-2A1202-2S12201-2HV12204

Design Intent
To prevent possible agglomeration inside the reactor due to no agitation

Failure of agitator

Comment:

Comment:

Comment:
not applicable

Comment:
not applicable
Loss SIL -
REPORT ATTACHMENT 3
3443-SZ-RT-101
Location
Project 71
GERMANY

Design Intent


Comment:

Comment:

Comment:
not applicable

Comment:
not applicable
Loss SIL -
REPORT ATTACHMENT 3
3443-SZ-RT-101
Location
Project 71
GERMANY
Function No 1200-2PALL11136-2S12201-2HV12204

Design Intent


Comment:

Comment:

Comment:
not applicable

Comment:
not applicable
Loss SIL -
REPORT ATTACHMENT 3
3443-SZ-RT-101
Location
Project 71
GERMANY
Function No1200-2LAHH12203-2I12202-2LV12201A\B
Zone Flash and cooling slurry Reactor II Unit 1200

P&ID No. 126 Interlock desc. Pag: 15 of 79
Initiator Tag 2LAHH12203 Very high level in 2D1202
Logic Solver Tag 2I12202 2D1202 high level
Final Element Tag Shuts 2LV12201A\B 2R1202 discharge valves
Design Intent
To prevent overfilling of the flash vessel

Possible malfunction of LIC12204 or LV12204 blocked closed or 2P1205 shut off
Overfilling of the flash vessel and consequent slurry up to liquid separator of 2PK3201 and to liquid ring compressor
PK3401

Comment:

Comment:
Stop of production up to 2 days, C1 is selected for economical loss.

Comment:
not applicable

Comment:
not applicable
Loss SIL -
REPORT ATTACHMENT 3
3443-SZ-RT-101
Location
Project 71
GERMANY
Function No 1200-2PAHH12206-2I12203-2XV12206

Initiator Tag 2PAHH12206 Very high pressure in 2E1206 tube side
Logic Solver Tag 2I12203 2E1206 tube rupture
Final Element Tag Closes 2XV12206
Design Intent
To prevent monomer blow by to the CWR system

Catastrophic failure of cooler tubes
Monomer release to atmosphere through the vent of expansion drum.

Comment:
A very slight probability that the unwanted occurrence will came to pass. The parameter is selected according to
experience, taking into account the the SIS is able to detect the hazardous situation only in case of catastrophic tube
failure.
Comment:
No significative effects on Environment. Fire and\or flammable vapor cloud may occur at the release point. C1 for
economical loss for repairing on site instrumentation is expected.

Comment:
Frequent to permanent exposure in the hazardous zone.

Comment:
Loss SIL -
REPORT ATTACHMENT 3
3443-SZ-RT-101
Location
Project 71
GERMANY
Function No1200-2ESA12204-2I12205-2LV12203

Initiator Tag 2ESA12204 stop of pump 2P1205
Logic Solver Tag 2I12205 stop of pump
Final Element Tag 2LV12203 closed
Design Intent
To prevent back flow from second reactor

Possible failure of the pump 2P1205
Back flow of slurry from reactor 2R1202, major damage of the pump 2P1205

Comment:

Comment:
No stop of production are expected only pump damage in terms of economical loss. No significant consequence in terms of
saferty and environment.

Comment:
not applicable

Comment:
not applicable
Loss SIL -
REPORT ATTACHMENT 3
3443-SZ-RT-101
Location
Project 71
GERMANY

Design Intent
Pump protection

LV12201A or LV12201B completely open

Comment:

Comment:

Comment:
not applicable

Comment:
not applicable
Loss SIL -
REPORT ATTACHMENT 3
3443-SZ-RT-101
Location
Project 71
GERMANY
Function No1200-2LALL12203-2I12208-2P1205

Final Element Tag 2P1205 stop
Design Intent
Pump protection


Comment:

Comment:

Comment:
not applicable

Comment:
not applicable
Loss SIL -
-
Environmental SIL -
nc
REPORT ATTACHMENT 3
3443-SZ-RT-101
Location
Project 71
GERMANY
Function No1200-2PAHH12301/3B-2S12301-2HV12304
Zone Polymerization reactor III Unit 1200

Initiator Tag 2PAHH12301/3B Very high pressure in 2R1203
Design Intent

Discharge of large quantity of ethylene and other monomer to flare

Comment:

Comment:

Comment:
not applicable

Comment:
not applicable
Loss SIL -
Environmental SIL -
REPORT ATTACHMENT 3
3443-SZ-RT-101
Location
Project 71
GERMANY

Initiator Tag 2TAHH12301D Very high T in 2R1203; (2PAHH12301/03B Very high P in 2R1203 (1oo2)) (1oo2)
Design Intent


Comment:

Comment:

Comment:

Comment:
Loss SIL 22
Environmental SIL -
REPORT ATTACHMENT 3
3443-SZ-RT-101
Location
Project 71
GERMANY
Function No1200-2LAHH12301-2S12301-2FV12312/13

Initiator Tag 2LAHH12301 Very high level in 2R1203
Final Element Tag Close mother liquor line 2FV12312, 2FV12313
Design Intent


Comment:

Comment:
economical loss.

Comment:
not applicable

Comment:
not applicable
Loss SIL -
REPORT ATTACHMENT 3
3443-SZ-RT-101
Location
Project 71
GERMANY
Function No1200-2A1203-2S12301-2HV12304

Design Intent
To prevent possible agglomeration inside the reactor due to no agitation

Failure of agitator

Comment:

Comment:

Comment:
not applicable

Comment:
not applicable
Loss SIL -
REPORT ATTACHMENT 3
3443-SZ-RT-101
Location
Project 71
GERMANY

Design Intent


Comment:

Comment:

Comment:
not applicable

Comment:
not applicable
Loss SIL -
REPORT ATTACHMENT 3
3443-SZ-RT-101
Location
Project 71
GERMANY
Function No 1200-2PALL11136-2S12101-2HV12304

Design Intent


Comment:

Comment:

Comment:
not applicable

Comment:
not applicable
Loss SIL -
REPORT ATTACHMENT 3
3443-SZ-RT-101
Location
Project 71
GERMANY
Function No 1200-2PAHH12304-2S12302-2HV12310A\B,2LV12301A\B
Zone Flash and cooling slurry Reactor III Unit 1200

Initiator Tag 2PAHH12304 Very high P in 2D1203, 2LAHH12304\07 very high level in flash vessel (1oo3)
Logic Solver Tag 2S12302 2D1203 high pressure
Final Element Tag Shuts 2LV12301A; (2LV12301B; 2HV12310B (1oo2)) (2oo2)
Design Intent
To prevent overpressure of equipment due to overfilling

Possible malfunction of LIC12301
Overfilling of flash vessel and consequent overpressure of the vessel (PSV is not designed for this case).

Comment:

Comment:

Comment:

Comment:
Loss SIL 22
Environmental SIL -
REPORT ATTACHMENT 3
3443-SZ-RT-101
Location
Project 71
GERMANY

Design Intent
Pump protection

LV12301A or LV12301B completely open

Comment:

Comment:

Comment:
not applicable

Comment:
not applicable
Loss SIL -
REPORT ATTACHMENT 3
3443-SZ-RT-101
Location
Project 71
GERMANY
Function No1200-2LALL12303-2I12308-2P1301 A/B
Zone Flash and cooling slurry Reactor III Unit 1200

Final Element Tag Stops 2P1301 A/B
Design Intent
Pump protection


Comment:

Comment:

Comment:
not applicable

Comment:
not applicable
Loss SIL -
REPORT ATTACHMENT 3
3443-SZ-RT-101
Location
Project 71
GERMANY
Function No1300-2PAHH13101/02-2S13101-2LV12303
Zone Decanter feed vessel Unit 1300

Initiator Tag 2PAHH13101/02 Very high pressure in 2D1301, 2LAHH13101A very high level in 2D1301 (1oo3)
Logic Solver Tag 2S13101 2D1301 High pressure \ high level
Final Element Tag 2LV12303; 2HV13102 (1oo2)
Design Intent
To prevent overpressure due to overfilling of the vessel

Human error during the reactor bottom discharge to decanter feed vessel
Overfilling of decanter feed vessel and consequent overpressure (PSV is not designed for this case).

Comment:
A very slight probability that the unwanted occurrence will come to pass, selected by experience

Comment:

Comment:

Comment:
SIL for Personnel Protection a (Note 1)
Loss SIL 11
Environmental SIL -
Note 1: SIL 1 to be considered in SIL Verification in order to comply with AD MerkBlatt A6 Requirements
REPORT ATTACHMENT 3
CLASSIFICATION NPP PROJECT 3443-SZ-RT-101

Location
Att.3
Project 71
GERMANY
Function No2100-2PAHH21201-2S21201-2HV21201 Applicable also to 2HV21202 and 2HV21203
Zone Mother liquor system Unit 2100

Initiator Tag 2PAHH21201 Very high pressure in 2D2101
Logic Solver Tag 2S21201 2D2101 high pressure / high level
Final Element Tag 2HV21201 closed (same as 2HV21202 and 2HV21203)
Design Intent
To prevent very high pressure in centrifuges

Possible malfunction of PIC32102 and failure of compressor 2PK3201 or External fire
Possible damage to the centrifuges due to overpressure in the equipments

Comment:

Comment:
Possible exceeding of design pressure values could lead to release of hexane into atmoshpere with consequent potential
fire/explosion. In terms of economical loss stop of production due to damage of seal centrifuges.

Comment:
In case of vapor cloud formation, presence of personnel in hazardous area shall be considered

Comment:
Independent safeguards alarming about the scenario are present, gas and fire detection system can mitigate the
consequences
Loss SIL aa
REPORT ATTACHMENT 3
3443-SZ-RT-101
Location
Project 71
GERMANY
Function No 2100-2HZLH21201-2S21204-2HV21107 (applicable also for 2S2101B & C)
Zone Powder separation I Unit 2100

Initiator Tag 2HZLH21201 limit switch
Logic Solver Tag 2S21204 2S2101A overfilling prevention
Final Element Tag Closes 2HV21107 or doesn't allow to open the valve
Design Intent
To prevent overpressure of centrifuges

Human error closing liquid discharge line to mother liquor collecting vessel
Possible damage to the centrifuges due to overpressure in the equipments

Comment:
A very slight probability that the unwanted occurrence will come to pass.

Comment:
In terms of economical loss stop of production due to damage of seal centrifuges. Minor consequence are expected in this
case.

Comment:
not applicable

Comment:
not applicable
Loss SIL aa
REPORT ATTACHMENT 3
3443-SZ-RT-101
Location
Project 71
GERMANY
Function No2200-2TAHH22102A-2I22102-TV22102/06 XV22106
Zone Powder drying I Unit 2200

Initiator Tag 2TAHH22102A and 2TAHH22106A very high temperature 1st and 2nd stage of 2D2201
Logic Solver Tag 2I22102 very high temperature in 2D2201
Final Element Tag Cut LLP steam inlet in the dryer TV22102/06; XV22106
Design Intent
To prevent very high temperature of polymer in 2D2201

TIC22102D malfunction to signal or LV22102D blocked open (1st stage) or TIC22103D malfunction to signal or LV22103D
blocked open (2nd stage)
Possible melting of polymer consequent possible obstruction and less efficiency of drying system.

Comment:
A slight probability that the unwanted occurrence will come to pass.

Comment:
No safety consequence. Stop of production up to 3 days in order to clean 2D2201.

Comment:
not applicable

Comment:
not applicable
Loss SIL -
REPORT ATTACHMENT 3
3443-SZ-RT-101
Location
Project 71
GERMANY
Function No 2200-ESA22103-IS22103-RF2204
Zone Pneumatic haulge to powder Unit 2200

P&ID No. purification
223\224 I and II Interlock desc. Pag:
Initiator Tag ESA22103 \ ESA22301\2 C2204 and C2203A\B stop
Logic Solver Tag IS22103 dryer discharge stop
Final Element Tag Stop RF2205 and RF2204
Design Intent
To prevent plugging of pneumatic transport system

Possible failure of C2204 or C2203A\B
In case of no stop of rotary feeder possible plugging in the pneumatic transport system.

Comment:

Comment:
Stop of production up to 3 days due to maintanance in the pneumatic transport system.

Comment:
not applicable

Comment:
not applicable
Loss SIL --
INTERLOCK DELETED IN HDPE SPEEDBIRD PLANT

REPORT ATTACHMENT 3
3443-SZ-RT-101
Location
Project 71
GERMANY
Function No 2200-ESA22101/2-IS22202-TV22102/06 HV2210
Zone Powder drying I Unit 2200

P&ID No. 221 Interlock desc. Pag:
Initiator Tag ESA22101\2 C2201\2 stop
Logic Solver Tag IS22203 stop of nitrogen cycle
Final Element Tag Cut LLP steam inlet in the dryer TV22102/06 HV22106
Design Intent
To prevent very high temperature of polymer in 2D2201

Failure of 2C2201 or 2C2202
Possible melting of polymer consequent possible obstruction and less efficiency of drying system.

Comment:

Comment:
No consequence in terms of safety. Stop of production up to 3 days in order to clean 2D2201

Comment:
not applicable

Comment:
not applicable
Loss SIL --

REPORT ATTACHMENT 3
3443-SZ-RT-101
Location
Project 71
GERMANY
Zone Powder drying II Unit 2200

Initiator Tag 2LALL22101 Very low level in 2T2201
Logic Solver Tag 2I22204 Very low level in 2T2201
Final Element Tag Stop of 2P2201 A/B
Design Intent
Pump protection

Possible malfunction of LIC 22201 or LV22201 completely open or no cold hexane to scrubbing tower.
Possible damage of the pump 2P2201A

Comment:

Comment:
Pump damage could happen only after several minuts, spare pump is available.

Comment:
not applicable

Comment:
not applicable
Loss SIL -
REPORT ATTACHMENT 3
3443-SZ-RT-101
Location
Project 71
GERMANY
Function No2200-LAHH22202-2I22205-2LV22201
Zone Powder drying II Unit 2200

Initiator Tag LAHH22202 Very high level in 2D2203
Logic Solver Tag 2I22205 very high level in 2D2203
Final Element Tag Close 2LV22201
Design Intent
To prevent the overfilling of hexane flash vessel

LV22101 completely open or LV22203 completely closed.
Overfilling of vessel and consequent "hot hexane" to 2T2201 no significant consequence

Comment:

Comment:
No significant consequence.

Comment:
not applicable

Comment:
not applicable
Loss SIL -
REPORT ATTACHMENT 3
3443-SZ-RT-101
Location
Project 71
GERMANY
Function No 2200-LSAHH23103-IS23101-stop of RF2205
Zone Pneumatic haulage Unit 2200

Initiator Tag LSAHH23103 Very high level in 2F2302
Logic Solver Tag IS23101 very high level in 2F2301
Final Element Tag Stop RF2205
Design Intent
To prevent the overfilling of 2F2302

Possible failure of RF2301
Overfilling of filter and consequent plugging

Comment:

Comment:
Possible stop of production up to 1 day in order to empty and clean the filter.

Comment:
not applicable

Comment:
not applicable
Loss SIL --

REPORT ATTACHMENT 3
3443-SZ-RT-101
Location
Project 71
GERMANY
Function No 2200-LRCSAHH23101-IS23102-stop of RF2301
Zone Powder purification Unit 2300

Initiator Tag LRSAHH23101 Very high level in 2D2301
Logic Solver Tag IS23102 very high level in 2D2301
Final Element Tag Stop RF2301
Design Intent
To prevent the overfilling of 2D2301

Possible failure of RF2303
Overfilling of filter and consequent plugging

Comment:

Comment:
Possible stop of production up to 1 day in order to empty and clean the filter.

Comment:
not applicable

Comment:
not applicable
Loss SIL --

REPORT ATTACHMENT 3
3443-SZ-RT-101
Location
Project 71
GERMANY
Function No 2400-PALL24106-IS24106-stop C2401A\B
Zone Powder pneumatic II Unit 2400

Initiator Tag PALL24106 very low pressure at C2401 A\B suction
Logic Solver Tag IS24106pneumatic transport PK2401 shut down
Final Element Tag Stops of blowers
Design Intent
To prevent air entry in the system

Human error closing nitrogen make up in the system
To be verified later with Vendor information

Comment:

Comment:

Comment:

Comment:
Loss SIL --

REPORT ATTACHMENT 3
3443-SZ-RT-101
Location
Project 71
GERMANY
Function No3100-2LAHH31102-2I31101-2XV31102A close 2XV31102B o
Zone Hexane distillation Unit 3100

Initiator Tag 2LAHH31102 very high level in 2D3101
Logic Solver Tag 2I31101 D3101 very high level
Final Element Tag 2XV31102A close and 2XV31102B opens
Design Intent
To prevent overfilling of the vessel

Possible no MP steam to 2E3102 or LIC31101 malfunction to signal
Mother liquor with Waxes to 2T3101 and to 2E2201 and 2E2205

Comment:

Comment:
Possible fouling of heat exchanger and other equipment, consequent stop of production up to 3 days.

Comment:
not applicable

Comment:
not applicable
Loss SIL -
REPORT ATTACHMENT 3
3443-SZ-RT-101
Location
Project 71
GERMANY
Function No3100-2PAHH31101-2I31103-2LV31101

Initiator Tag 2PAHH31101 very high pressure in D3101
Logic Solver Tag 2I31103 D3101 very high pressure
Final Element Tag 2LV31101 closes
Design Intent
To prevent very high pressure in 2D3101

Possible LV31101 completely open or PIC31102 malfunction or PV31102A and B blocked closed
Mother liquor with Waxes to 2T3101 and to 2E2201 and 2E2205

Comment:

Comment:
Possible increase of pressure up to set point of PSV, consequent possible stop of production to restore the PSV. Minor
consequences are expected.

Comment:
not applicable

Comment:
not applicable
Loss SIL -
REPORT ATTACHMENT 3
3443-SZ-RT-101
Location
Project 71
GERMANY
Function No3100-2LAHH31106-7-2I31102-2LV31103

Initiator Tag 2LAHH31106-7 very high level in T3101
Logic Solver Tag 2I31102 Very high level in 2T3101
Final Element Tag 2LV31103 closes
Design Intent
To prevent very high level in 2T3101

Malfunction of LIC31103 or LV31103 blocked closed
Possible less efficiency of the column

Comment:

Comment:
No significant consequences.

Comment:
not applicable

Comment:
not applicable
Loss SIL -
REPORT ATTACHMENT 3
3443-SZ-RT-101
Location
Project 71
GERMANY
Function No3100-2PAHH31103-2I31108-2LV31105

Initiator Tag 2PAHH31103 very high pressure in 2T3101
Logic Solver Tag 2I31108 Very high pressure in 2T3101
Final Element Tag 2LV31105 closes hexane vapor to 2E3104
Design Intent
To prevent very high pressure in 2T3101

No cooling water to condenser
Higher pressure than the operating, the maximum pressure achieved will be lower of the set point of the PSV (designed for
fire)

Comment:

Comment:
No significant consequences.

Comment:
not applicable

Comment:
not applicable
Loss SIL -
REPORT ATTACHMENT 3
3443-SZ-RT-101
Location
Project 71
GERMANY
Function No3100-2TAHH31201/02/03-2S31201-1FV31203 Applicable also to 2T3102B and 2T3202A/B
Zone Hexane purification Unit 3100

Initiator Tag 2TAHH31201/02/03 very high temperature in 2T3102A (1oo3)
Logic Solver Tag 2S31201 Very high temperature in 2T3102A/B and 2T3202A/B
Final Element Tag 2FV31203 close; 2XV31201 close (1oo2)
Design Intent
To prevent very high temperature in 2T3102 A\B (2T3202A/B) during the regeneration phase

Possible different ratio of oxygen and nitrogen due to malfunction of FIC31203 or FV31203 completely open or FV31202
closed
Possible temperature in 2T3102 A\B (2T3202A/B) higher than design temperature and possible damage of KC pearl

Comment:

Comment:
In terms of safety C2 is selected taking into account possible loss of containment in the column. In terms of economical
impact C1

Comment:
Rare to more often exposure in the hazardous zone

Comment:
Almost impossible
Loss SIL -
REPORT ATTACHMENT 3
3443-SZ-RT-101
Location
Project 71
GERMANY
Function No3100-2AAHH31204-2S31202-2HV31201

Initiator Tag 2AAHH31204 high concentration of HC and CO
Logic Solver Tag 2S31202 High HC concentration in the vent
Final Element Tag Closes 2HV31201
Design Intent
To avoide to discharge hydrocarbon to atmosphere

Human error applyng the procedure
Possible undesired vent of Hydrocarbon to atmosphere

Comment:

Comment:
It is not expected possible concentration of hydrocarbon and air within lower and upper flammable limits. C1 is selected
taking into account undesired release in atmosphere of dangerous gas.

Comment:
not applicable

Comment:
not applicable
Loss SIL nc
nc
nc
nc
Environmental SIL -
REPORT ATTACHMENT 3
3443-SZ-RT-101
Location
Project 71
GERMANY
Function No3100-2HZLL31201-2S31203-2HV31202

Initiator Tag 2HZLL31201
Logic Solver Tag 2S31203 regeneration system to atmosphere
Final Element Tag Doesn't allow to open 2HV31202
Design Intent
To prevent air entry in system with hydrocarbon

Human error follwing the procedure
Possible flammable mixture in the regeneration circuit.

Comment:

Comment:
It is expected possible concentration of hydrocarbon and air within lower and upper flammable limits, possible explosione
inside the equipment C2 is selected for safety. C2 is selected for economical loss taking into major damage of the
purification system.
Comment:

Comment:
Almost impossible
SIL for Personnel Protection a
Loss SIL aa
nc
nc
Environmental SIL -
This interlock will be implemented on ESD
REPORT ATTACHMENT 3
3443-SZ-RT-101
Location
Project 71
GERMANY
Function No3100-2TAHH31210-2S31204-2FV31202

Initiator Tag 2TAHH31210 very high temperature in D3104
Logic Solver Tag 2S31204 Very high temperature in 2D3104
Final Element Tag 2FV31202 closed
Design Intent
To prevent very high temperature in 2D3104 during the regeneration phase

No cooling water to 2E3108
Possible temperature inside the equipment over than the design temprature of the equipment.

Comment:

Comment:
Possible damage of the equipment and consequent loss of containment of hot gas are not considered because the vessel
is filled with water at ambient temperature. Minor consequence are expected.

Comment:
not applicable

Comment:
not applicable
Loss SIL --
REPORT ATTACHMENT 3
3443-SZ-RT-101
Location
Project 71
GERMANY
Function No3100-2TAHH31209 A/B-2S31205-2E3107

Initiator Tag 2TAHH31209 A/B very high temperature 2E3107 (1oo2)
Logic Solver Tag 2S31205 stop of regeneration heater
Final Element Tag Stop of 2E3107
Design Intent
To prevent very high temperature in 2T3102 A\B during the regeneration phase

TIC31206 malfunction to signal.
Possible temperature in 2T3102 higher than design temperature and possible damage of KC pearl.

Comment:

Comment:
In terms of safety C2 is selected taking into account possible loss of containment in the column. In terms of economical
impact C1

Comment:

Comment:
Almost impossible
Loss SIL -
REPORT ATTACHMENT 3
3443-SZ-RT-101
Location
Project 71
GERMANY
Function No 3200-LSAHH32105-IS32101-C3201
Zone Recycle gas compressor Unit 3200

Initiator Tag LSAHH32105 very high level in 2D3206
Logic Solver Tag 2IS32101 2C3201 shut down
Final Element Tag Shut down of 2C3201
Design Intent
Compressor 2C3201 protection

Possible overfilling of equipment in unit Upstream and relevant safety function failure
Possible damage of compressor 2C3201

Comment:

Comment:
Environmental impact C1 for continuos flaring, In terms of economical loss, in case of major damage, stop of production up
to 1 month. C3 is selected.

Comment:
not applicable

Comment:
not applicable
Loss SIL 11
Environmental SIL -
REPORT ATTACHMENT 3
3443-SZ-RT-101
Location
Project 71
GERMANY
Function No3200-2LAHH32101/02-2I32102-2FV32101
Zone Butene recovery & hexane column Unit 3200

P&ID No. top
321Bpurification Interlock desc. Pag: 53 of 79
Initiator Tag 2LAHH32101/02 very high level in 2T3201
Logic Solver Tag 2I32102 very high level in 2T3201 bottom
Final Element Tag Close 2FV32101 fresh hexane to 2T3201
Design Intent
To prevent the overfilling of 2T3201

Possible malfunction of LIC32101 or FIC12222\3
In case of high level less efficiency of the separetion of light ends and consequent quality problem in the production. It isn't
considered the possibility of pressure increasing over the PSV set point.

Comment:

Comment:
Minor consequence.

Comment:
not applicable

Comment:
not applicable
Loss SIL --
REPORT ATTACHMENT 3
3443-SZ-RT-101
Location
Project 71
GERMANY
Function No 3200-LSAHH32102-IS33101-2P3301A/B
Zone WAX recovery Unit 3300

Initiator Tag LSAHH33102 very high level in 2D3301, PSAHH33103
Logic Solver Tag IS33101 stop of pump 2P3301A/B
Final Element Tag Stop 2P3301A/B
Design Intent
To prevent the overfilling of 2D3301

Possible obstruction in the bottom line of 2D3301 due to no LPS
Overfilling of 2D3301 and consequent obstruction on the demister or on the outlet line to the condenser.

Comment:
A very slight probability that the unwanted occurrence will come to pass, selected according to experience.

Comment:
The process safety time for the overfilling of the vessel will be more or less 8 hours, in case of batch disposal of the wax
the Process safety time could be much lower. In this case the overfilling will give overpressure (PSV is a cold point of the
vessel). Consequent damage of the equipment and L.O.C. of hot WAX and hexane. C2 for safety and medium term shut
down of the production up to 1 week, consequently C2 is selected for economical loss.

Comment:

Comment:
Almost impossible
Loss SIL aa
REPLACED BY 2S33104 - SIF 21 ATTACHMENT 6.4

REPORT ATTACHMENT 3
3443-SZ-RT-101
Location
Project 71
GERMANY
Function No 3300-PISAHH33305/06-IS33302-PV13101A/B
Zone Waste water pretreatment Unit 3300

Initiator Tag PISAHH33305/06 very high pressure in 2D3303
Logic Solver Tag IS33302 very high pressure in 2D3303
Final Element Tag PV13101A\B closed (Reactor discharge header)
Design Intent
To prevent very high pressure in the vessel

Human error opening discharge line from reactor to 2D3303 when reactor is in normal operating pressure
Possible overpressure of 2D3303

Comment:

Comment:
Overpressure (PSV is not designed for this case). Consequent damage of the equipment and L.O.C. of hot hexane. C2 for
safety and medium term shut down of the production up to 3 week C2 is selected.

Comment:

Comment:
Almost impossible
Loss SIL aa
REPLACED BY 2S33302A/B - SIF 6 & 10 ATTACHMENT 6.4

REPORT ATTACHMENT 3
3443-SZ-RT-101
Location
Project 71
GERMANY
Function No 3300-PSAH33305/06-IS33303-HV33301

Initiator Tag PISAH33305\06 high pressure in 2D3303
Logic Solver Tag IS33303 high Pressure and high temperature in 2D3303
Final Element Tag HV33301 closed discharge to container
Design Intent
To prevent high pressure in the vessel during the unloading to container

Human error appling the procedures
Possible injury to the operator that makes the unloading to the container

Comment:

Comment:
C2 for safety is selected taking into account possible release of vapour and flammable gas during the unloading.

Comment:

Comment:
Loss SIL nc
nc

REPORT ATTACHMENT 3
CLASSIFICATION NPP PROJECT 3443-SZ-RT-101

Location
Att.3
Project 71
GERMANY
Function No 3300-ZSL33302-IS33304-PV13101A/B

Initiator Tag ZSL33302 close not active
Logic Solver Tag IS33304 reactor drain cut off (This interlock will be added directly to IS33302)
Final Element Tag PV13101A\B closed
Design Intent
To prevent very high pressure in the vessel 2D3304

Possible human error applying the procedure
Possible overpressure of 2D3304

Comment:
A slight probability that the unwanted occurrence will come to pass, taking into account that the valve HV33303 is expected
to be operated by personnel of the plant

Comment:
Overpressure (PSV is not designed for this case). Consequent damage of the equipment and L.O.C. of hexane. C2 for
safety and short term shut down of the production up to 3 week C2 is selected.

Comment:

Comment:
Loss SIL 11

REPORT ATTACHMENT 3
3443-SZ-RT-101
Location
Project 71
GERMANY
Function No3300-2PDALL33310A-2I33308A-2FV33304A

Initiator Tag 2PDALL33310A low differential pressure steam/2D3303A
Logic Solver Tag 2I33308A low steam to 2D3303A cut off
Final Element Tag 2FV33304A steam to 2D3303A closed
Design Intent
To prevent back flow to LS line

Possible higher pressure due to no cooling water during the distillation step
Possible hydrocarbon in the low pressure steam line.

Comment:

Comment:
Minor consequence for safety and environment.

Comment:
not applicable

Comment:
not applicable
Loss SIL nc
nc
Environmental SIL -
Check valve provided
REPORT ATTACHMENT 3
3443-SZ-RT-101
Location
Project 71
GERMANY
Function No 3400-PSAHH34102/03-IS34104-PV34103A/B/C
Zone Off gas system I Unit 3400

P&ID No. 341A Interlock desc. Pag:
Initiator Tag PSAHH34102/03 very high pressure in flare header
Logic Solver Tag IS34104 Flare header high pressure
Final Element Tag PV34103 A\B close and PV34103C open
Design Intent
To prevent overpressure in the low pressure unit, during emergency in the high pressure unit, and massive hydrocarbon
discharge to atmosphere throught cold flare
Two different emergency involving the waste gas header (LP unit) and flare header (HP unit)
Possible damage of low pressure design equipment.

Comment:
A very slight probability that the unwanted occurrence will come to pass selecteed taking into account two different and
simultaneusly emergency.

Comment:
C2 is selected for safety, taking into account massive emission of hydrocarbon and consequent possible flash fire. C3 for
economical point of view, major damage to low pressure equipment. C1 for environment impact.

Comment:

Comment:
Almost impossible
Loss SIL 11
Environmental SIL -
Check valve provided

REPORT ATTACHMENT 3
3443-SZ-RT-101
Location
Project 71
GERMANY
Function No 4100-2LAHH41102,2PAHH41104-2I41101-2XV41102
Zone Hexane \ Mother liquor Unit 4100

Initiator Tag 2LAHH41102 very high level in 2D4101, 2PAHH41104 very high pressure in 2D4101
Logic Solver Tag 2I41101 distillated hexane cut off
Final Element Tag 2XV41102 closed distilled hexane feed
Design Intent
To prevent overfilling of the distilled hexane tank

Human error appllying the procedure during filling of the tank or Manual valve blocked open
Possible rain out of liquid hexane to a not confined area.

Comment:
A very slight probability that the unwanted occurrence will come to pass considering very unfrequent operation. It's
expected 1 filling \ year.

Comment:
The release of liquid hexane from PSV 41101/02 could give pool fire. C2 is selected for safety.

Comment:

Comment:
Loss SIL nc
nc
REPORT ATTACHMENT 3
3443-SZ-RT-101
Location
Project 71
GERMANY
Function No4100-2LAHH41301-2S41301-2XV41401-2HV41404 (1oo2)
Zone Al-Alkyl receiver Unit 4100

Initiator Tag 2LAHH41301 very high level in 2D4103
Logic Solver Tag 2S41301 very high level in 2D4103
Final Element Tag 2XV41401 close TEAL and hexane from cylinder 2HV41404 close hexane to TEAL unloading
(1oo2)
Design Intent
To prevent overfilling of Al-Alkyl storage tank 2D4103

Possible malfunction to signal of FQI41402
Overfilling of the vessel (cut off pressure of pump P4101A\B is lower than PSV set point) the system react managing the
pressure by PV41301A (sending hexane and TEAL to 2D4102).

Comment:

Comment:
The overfilling gives higher pressure (less than the set point of PSV) the system react managing the pressure by
PV41301A (sending hexane and catalyst to 2D4102). C2 is selected for safety taking into account that we have a big
quantity of TEAL in equipment where is not expected. During maintenance or batch operation possible injury to operator.

Comment:

Comment:
Loss SIL nc
nc
REPORT ATTACHMENT 3
3443-SZ-RT-101
Location
Project 71
GERMANY
Function No 4100-2BAH41401/02/03/04-2S41401-2PV41401-2HV41403
Zone Al-Alkyl unloading Unit 4100

Initiator Tag 2BAH41401/02/03/04 Flame detector (2oo4)
Logic Solver Tag 2S41401 TEAL unloading cut off
Final Element Tag 2PV41401 nitrogen closed, 2HV41403 open vent to 2D4102 (2oo2)
Design Intent
To detect fire and stop leakage

TEAL leakage from couplings and flanges
Increased fire and related damages (on TEAL cylinder and pipe).

Comment:
A slight probability that the unwanted occurrence will come to pass and a few unwanted occurrences are likely. This
parameter is selected by experience.

Comment:
C2 is selected for safety (Serius permanent injury to 1or 2 persons; death to 1 person), C2 parameter is selected for
Economical loss (restore line and start the production it is assumed four days of no production)

Comment:
Rare to more often exposure in the hazardous zone.

Comment:
Almost impossible
Loss SIL 11
REPORT ATTACHMENT 3
3443-SZ-RT-101
Location
Project 71
GERMANY
Function No4100-2HZLL41405 A / B -2S41402-2HV41404
Zone Al-Alkyl unloading Unit 4100

Initiator Tag 2HZLL41405 A / B (1oo2)
Logic Solver Tag 2S41402 Hexane to TEAL dilution
Final Element Tag 2HV41404 not allowed to open
Design Intent
To prevent Hexane to teal cylinder

Human error applying the procedure
Overpressure of TEAL cylinder

Comment:

Comment:
C2 is selected for safety (Serius permanent injury to 1or 2 persons; death to 1 person), C2 parameter is selected for
Economical loss (restore line and start the production it is assumed four days of no production)

Comment:

Comment:
Almost impossible
Loss SIL 11
REPORT ATTACHMENT 3
3443-SZ-RT-101
Location
Project 71
GERMANY
Function No 6200-TSHH62105/06-IS61201-PV62101-TV6210
Zone Steam supply and condensate syste Unit 6200

Initiator Tag TSAHH62105\06 very high temperature in high steam header
Logic Solver Tag IS62101 High pressure steam cut off
Final Element Tag PV62101 high steam to 2D6201, TV62105 closed high steam header (1 of 2)
Design Intent
To prevent temperature of steam higher than the design temperature of the downstream equipments

TIC62104 malfunction or TV62104 closed
Equipment downstream are not design for the design temperature of HP steam from battery limit

Comment:

Comment:
C2 for safety is selected taking into account possible release from line and jacket of steam at temperature near to 450 C.
Possible major damage on the extruder. To be confirmed later with Vendor specialist

Comment:

Comment:
Almost impossible
Loss SIL 11

REPORT ATTACHMENT 3
3443-SZ-RT-101
Location
Project 71
GERMANY
Function No 6200-2TAHH62107\08-2S62102-PV62103-2XV62107
Zone Steam supply Unit 6200

Initiator Tag 2TAHH62107\08 very high temperature in medium steam header (1oo2)
Logic Solver Tag 2S62102 Medium pressure steam cut off
Final Element Tag PV62103 closed medium steam to 2D6202, 2XV62107 closed medium steam header (1oo2)
Design Intent

Equipment downstream are not design for the design temperature of MP steam from battery limit

Comment:

Comment:
C2 for safety is selected taking into account possible release from line and jacket of steam at very high temperature.
Possible major damage on several process users C2 is selected for economical loss.

Comment:

Comment:
Almost impossible
Loss SIL 11
REPORT ATTACHMENT 3
3443-SZ-RT-101
Location
Project 71
GERMANY
Function No 6200-2TAHH62109\10-2S62103-2PV62105-2XV62109

Initiator Tag 2TAHH62109\10 very high temperature in low steam header
Logic Solver Tag 2S62103 Low pressure steam cut off
Final Element Tag 2PV62105 closed low steam to 2D6203, 2XV62109 closed low steam header
Design Intent

Equipment downstream are not design for the design temperature of LP steam from battery limit

Comment:
A very slight probability that the unwanted occurrence will come to pass, taking into account instrument failure of TIC62106
and that only in case of temperature at battery limits close to design temperature it could be possible to reach the
consequence (normal operating temperature at battery limit from design basis is acceptable by the equipment down
stream).

Comment:
C2 for safety is selected taking into account possible release from line and jacket of steam at temperature near to 450 C.
Possible minor damage on several process users C1 is selected for economical loss.

Comment:

Comment:
Almost impossible
Loss SIL -

REPORT ATTACHMENT 3
3443-SZ-RT-101
Location
Project 71
GERMANY
Function No 6200-TSHH62112-IS61204-TV62111

Initiator Tag TSAHH62111\12 very high temperature in low low steam header (TSAHH of dryer)
Logic Solver Tag IS62104 Low low pressure steam cut off
Final Element Tag All the final action (HV22101 common element)
Design Intent
To prevent melting of polymer in the dryer

Very high temperature in the steam to dryer (up to 160 C) could give melting of polymer.

Comment:

Comment:
No consequence for safety are expected. Stop of production due to melting of polymer in the dryer and consequent
cleaning of the equipment. Shut down up to 3 days C1 is selected

Comment:
not applicable

Comment:
not applicable
Loss SIL --

Speedbird Hdpe Plant Safety Report Attachment 3 SIL Classification NPP Project

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Speedbird Hdpe Plant Safety Report Attachment 3 SIL Classification NPP Project

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SPEEDBIRD HDPE PLANT SAFETY

SIL CLASSIFICATION SHEET <04>

Function No 1100-2PAH11102/3-2S11102-2HV11102 Applicable also to 2S11104

Zone THS conditioning and metering Unit 1100

Hazardous Scenario (Demand Scenario)

Frequency of Unwanted Occurrence (W) W1

Consequence Parameter for Personnel (C) C2

Exposure Parameter (F) F2

Avoidance Parameter (P) P2

SIL for Personnel Protection 1

SIL CLASSIFICATION SHEET

Zone THS conditioning and metering Unit 1100

Hazardous Scenario (Demand Scenario)

Frequency of Unwanted Occurrence (W) W2

Consequence Parameter for Personnel (C) C1

Exposure Parameter (F) N/A

Avoidance Parameter (P) N/A

SIL for Personnel Protection nc

Availability of Other Safety Related System

SIL CLASSIFICATION SHEET

Zone Activator metering Unit 1100

Hazardous Scenario (Demand Scenario)

Frequency of Unwanted Occurrence (W) W1

Consequence Parameter for Personnel (C) C1

Exposure Parameter (F) N/A

Avoidance Parameter (P) N/A

SIL for Personnel Protection nc

SIL CLASSIFICATION SHEET

Zone Polymerization reactor I Unit 1200

Hazardous Scenario (Demand Scenario)

Frequency of Unwanted Occurrence (W) W1

Consequence Parameter for Personnel (C) C1

Exposure Parameter (F) N/A

Avoidance Parameter (P) N/A

SIL for Personnel Protection nc

SIL CLASSIFICATION SHEET <04>

Zone Polymerization reactor I Unit 1200

Hazardous Scenario (Demand Scenario)

Frequency of Unwanted Occurrence (W) W2

Consequence Parameter for Personnel (C) C3

Exposure Parameter (F) F2

Avoidance Parameter (P) P1

SIL for Personnel Protection 1

SIL CLASSIFICATION SHEET

Zone Polymerization reactor I Unit 1200

Hazardous Scenario (Demand Scenario)

Frequency of Unwanted Occurrence (W) W2

Consequence Parameter for Personnel (C) C1

Exposure Parameter (F) N/A

Avoidance Parameter (P) N/A

SIL for Personnel Protection nc

SIL CLASSIFICATION SHEET

Zone Polymerization reactor I Unit 1200

Hazardous Scenario (Demand Scenario)

Frequency of Unwanted Occurrence (W) W2

Consequence Parameter for Personnel (C) C1

Exposure Parameter (F) N/A

Avoidance Parameter (P) N/A

SIL for Personnel Protection nc

SIL CLASSIFICATION SHEET

Zone Polymerization reactor I Unit 1200

Hazardous Scenario (Demand Scenario)

Frequency of Unwanted Occurrence (W) W1