V4-CH05 Relief Devices Scenario Sheets All

PETRONAS RAPID Project Nov 2012
Johor, Malaysia
350 KTA LLDPE PLANT Vol. : 4
Project n° 61070F
Process Design Package Page 1/4
CHAPTER 5
RELIEF DEVICES SCENARIO SHEETS
CONTENTS
SECTION ITEM
100 61070F-CN-3200-PSV-10002
61070F-CN-3200-PSV-10082 / 10083
61070F-CN-3200-PSV-10086 / 10087
61070F-CN-3200-PSV-10088 / 10089
61070F-CN-3200-PSV-10092 / 10093
61070F-CN-3200-PSV-10101
61070F-CN-3200-PSV-10182 / 10183
61070F-CN-3200-PSV-10204
61070F-CN-3200-PSV-10205 / 10206
61070F-CN-3200-PSV-10301
61070F-CN-3200-PSV-10582 / 10583
200 61070F-CN-3200-PSV-20001
61070F-CN-3200-PSV-20103/ 20113
61070F-CN-3200-PSV-20121
61070F-CN-3200-PSV-20122/ 20132
61070F-CN-3200-PSV-20125
61070F-CN-3200-PSV-20134
61070F-CN-3200-PSV-20139/ 20140
61070F-CN-3200-PSV-20203/ 20204
61070F-CN-3200-PSV-20208/ 20218
© INEOS Commercial Services UK Limited. All rights reserved. This document is the property of INEOS Commercial
Services UK Limited, and the information and images it contains are strictly confidential and may not be altered or
amended, copied, used or disclosed without the express permission of INEOS Commercial Services UK Limited.
Johor, Malaysia
Project n° 61070F
SECTION ITEM
200 61070F-CN-3200-PSV-20212
61070F-CN-3200-PSV-20251/ 20261
61070F-CN-3200-PSV-20311
61070F-CN-3200-PSV-20317
61070F-CN-3200-PSV-20406
61070F-CN-3200-PSV-20420/ 20430
61070F-CN-3200-PSV-20503/ 20513
61070F-CN-3200-PSV-20520/ 20530
61070F-CN-3200-PSV-20603
61070F-CN-3200-PSV-20814
300 61070F-CN-3200-PSE-30069/ 30169

61070F-CN-3200-PSV-30203
61070F-CN-3200-PSV-30269
400 61070F-CN-3200-PSV-40001
61070F-CN-3200-PSV-40006 / 40007
61070F-CN-3200-PSV-40050 / 40055
61070F-CN-3200-PSV-40065
61070F-CN-3200-PSV-40075
61070F-CN-3200-PSV-40204
61070F-CN-3200-PSV-40207
61070F-CN-3200-TSV-40303
61070F-CN-3200-PSV-40501 / 40511
61070F-CN-3200-PSV-40601 / 40602
600 61070F-CN-3200-PSV-60002 / 60003
Johor, Malaysia
Project n° 61070F
SECTION ITEM
600 61070F-CN-3200-PSV-60009 / 60032

61070F-CN-3200-PSV-60012
61070F-CN-3200-PSE / PSV-60074
61070F-CN-3200-PSV-60082
61070F-CN-3200- PSE / PSV-60086
61070F-CN-3200-PSV-60101 / 60103
61070F-CN-3200- PSE / PSV-60112
61070F-CN-3200-PSV-60501
61070F-CN-3200-PSV-60511
61070F-CN-3200- PSE / PSV-60521
61070F-CN-3200-PSV-60551
61070F-CN-3200-PSV-60601
61070F-CN-3200-PSV-60602
61070F-CN-3200-PSV-60801 / 60803
61070F-CN-3200-PSV-60802 / 60804
61070F-CN-3200-PSV-60821 / 60823
61070F-CN-3200- PSE / PSV-60851
61070F-CN-3200-PSV-60871
61070F-CN-3200-PSV-60891
700 61070F-CN-3200-PSV-70101
61070F-CN-3200-PSV-70111
61070F-CN-3200-PSV-70112 A/B
61070F-CN-3200-PSV-70116
61070F-CN-3200-PSV-70121
61070F-CN-3200-PSV-70402
61070F-CN-3200-PSV-70404
61070F-CN-3200-PSV-70412
61070F-CN-3200-PSV-70414
Johor, Malaysia
Project n° 61070F
SECTION ITEM
800 61070F-CN-3200-PSV-80801
Project unit Doc type Code Serial Nr Rev index
61070F CN 3200-PSV- 10002 0
CLIENT PETRONAS RAPID PAGE

PROJECT ________
LOCATION JOHOR, MALAYSIA PSV SCENARIO SHEET
1/ 1
UNIT 350 KTA LLDPE PLANT
PSV ITEM: 3200-PSV-10002 SET PRESSURE: 3.5 bar(g)

EQUIPMENT PROTECTED: 3200-V-151 DISCHARGE LOCATION: ATM
P&ID REFERENCE: PID0106
CASE ANALYSIS
Considered cases Yes No Comments
External fire X Tote bin is at grade. Fire case is applicable.
Liquid thermal expansion X N/A
Closed outlet X N/A
Valve inadvertently open or X LNP design pressure (2.8 barg) is lower than tote bin PSV
set pressure.
control valve failure
Accidental mixing X N/A
Overfilling X N/A
Flow through vent valve X N/A
Reflux failure X N/A
Blocked-in heat on X N/A
Tube rupture X N/A
Non-condensable built-up X N/A
Abnormal reboiler heat input X N/A
Abnormal vaporization in heat X N/A

exchanger
Loss of heat X N/A
Loss of cooling X N/A
Loss of steam X N/A
Loss of instrument air X N/A
Loss of electricity X N/A
Vacuum X N/A
Chemical reaction X N/A

Internal explosion
Backflow X N/A
Other X None identified.
SAFETY RELATED DEVICES:

AVAILABILITY FOR PSV MAINTENANCE :
Yes No Comments
VITAL X
TIED OR FREE X
61070F CN 3200-PSV 10082 / 10083 0

PROJECT ________
1/ 1
PSV ITEM : 3200-PSV-10082 / 10083 SET PRESSURE : 4.4 bar(g)

EQUIPMENT PROTECTED : LNS TO HEADER DISCHARGE LOCATION : ATM
(EXCEPT 3200-V-640
user)
P&ID REFERENCE : PID0102
CASE ANALYSIS
External fire X Not vessel.
Liquid thermal expansion X No liquid.
Closed outlet X Include in valve inadvertently open.
Valve inadvertently open or X 3200-PV-10081 wide open can pressurise the system with
LPN Pdesign = 12 bar(g).
Overfilling X N/A
Tube rupture X N/A

exchanger
Loss of heat X N/A
Loss of steam X N/A
Loss of instrument air X No pressure rise identified.
Loss of electricity X No pressure rise identified.
Vacuum X N/A

Internal explosion
Backflow X N/A
Other X N/A
SAFETY RELATED DEVICES: 3200-PV-10081

Yes No Comments
VITAL X Spare PSV installed.
TIED OR FREE X
61070F CN 3200-PSV 10086 / 10087 0

PROJECT ________
1/ 1

EQUIPMENT PROTECTED : LNP TO HEADER DISCHARGE LOCATION : ATM
CASE ANALYSIS
External fire X No vessel.
MNP Pdesign = 10.5 bar(g)
Overfilling X N/A
Tube rupture X N/A

exchanger
Loss of heat X N/A
Loss of steam X N/A
Vacuum X N/A

Internal explosion
Backflow X N/A
Other X N/A

Yes No Comments
TIED OR FREE X
61070F CN 3200-PSV 10088 / 10089 0

PROJECT ________
1/ 1

EQUIPMENT PROTECTED : LLN TO HEADER DISCHARGE LOCATION : ATM
CASE ANALYSIS
LNS Pdesign = 4.4 bar(g).
Overfilling X N/A
Tube rupture X N/A

exchanger
Loss of heat X N/A
Loss of steam X N/A
Vacuum X N/A

Internal explosion
Backflow X N/A
Other X N/A

Yes No Comments
TIED OR FREE X
61070F CN 3200-PSV 10092 / 10093 0

PROJECT ________
1/ 1

EQUIPMENT PROTECTED : LNS TO 3200-V-640 DISCHARGE LOCATION : ATM
CASE ANALYSIS
LPN Pdesign = 12 bar(g).
Overfilling X N/A
Tube rupture X N/A

exchanger
Loss of heat X N/A
Loss of steam X N/A
Vacuum X N/A

Internal explosion
Backflow X N/A
Other X N/A

Yes No Comments
TIED OR FREE X
61070F CN 3200-PSV 10101 0

PROJECT ________
1/ 1
PSV ITEM : 3200-PSV-10101 SET PRESSURE : 3.15 bar(g)

EQUIPMENT PROTECTED : 3200-S-151 DISCHARGE LOCATION : CRV
CASE ANALYSIS
External fire X No flammable source at concrete platform.
Liquid thermal expansion X
Closed outlet X In case of blockage of filter, the PSV must be able to

evacuate all catalyst vents (CV).
Valve inadvertently open or X Excess flow caused by control valve failure should be totally
evacuated by filter outlet to atmosphere.
Accidental mixing X
Overfilling X
Flow through vent valve X
Reflux failure X There is no reflux.
Blocked-in heat on X There is no source of heat.
Tube rupture X Not applicable.
Non-condensable built-up X
Abnormal reboiler heat input X Not applicable.
Abnormal vaporization in heat X Not applicable.

exchanger
Loss of heat X Not applicable.
Loss of cooling X Not applicable.
Loss of steam X Steam is not used.
Loss of instrument air X Not applicable.
Loss of electricity X
Vacuum X
Chemical reaction X
Internal explosion
Backflow X
Other X
SAFETY RELATED DEVICES: 3200-FO-30014 / 30070 / 30074 / 30170 / 30214 / 30270 / 30274

Yes No Comments
VITAL X
TIED OR FREE X
61070F CN 3200-PSV 10182 / 10183 0

PROJECT ________
1/ 1
PSV ITEM : 3200-PSV-10182/ 10183 SET PRESSURE : 4.4 bar(g)

EQUIPMENT PROTECTED : LN TO HEADER DISCHARGE LOCATION : ATM
CASE ANALYSIS
Closed outlet X Included in valve inadvertently open.
MN Pdesign = 10.5 bar(g).
Overfilling X N/A
Tube rupture X N/A

exchanger
Loss of heat X N/A
Loss of steam X N/A
Vacuum X N/A

Internal explosion
Backflow X N/A

Yes No Comments
TIED OR FREE X
61070F CN 3200-PSV 10204 0

PROJECT ________
1/ 1
PSV ITEM: 3200-PSV-10204 SET PRESSURE: 40 bar(g)

EQUIPMENT PROTECTED: 3200-V-175 DISCHARGE LOCATION: ATM
CASE ANALYSIS
External fire X To be confirmed after final plant layout.
Closed outlet X N/A
Valve inadvertently open or X N/A

Overfilling X N/A
Tube rupture X N/A

exchanger
Loss of heat X N/A
Loss of steam X N/A
Vacuum X
Chemical reaction X
Internal explosion
Backflow X N/A

Yes No Comments
VITAL X
TIED OR FREE X
61070F CN 3200-PSV 10205 / 10206 0

PROJECT ________
1/ 1

EQUIPMENT PROTECTED : MN NETWORK – LINE FROM DISCHARGE LOCATION : ATM
3200-R275 A/B
CASE ANALYSIS
Valve inadvertently open or X 3200-PV-10201 wide open can pressurise the system, with
HNP Pdesign = 40 bar(g).
Overfilling X N/A
Tube rupture X N/A

exchanger
Loss of heat X N/A
Loss of steam X N/A
Vacuum X N/A

Internal explosion
Backflow X N/A
Other X N/A

Yes No Comments
TIED OR FREE X
61070F CN 3200-PSV 10301 0

PROJECT ________
1/ 1

EQUIPMENT PROTECTED : 3200-V-153 DISCHARGE LOCATION : RFH via 3200-V-152
CASE ANALYSIS
External fire X To be confirmed after plant final layout.
Closed outlet X N/A

Overfilling X N/A
Blocked-in heat on X There is no source of heat.
Tube rupture X N/A

exchanger
Loss of heat X N/A
Vacuum X N/A

Internal explosion
Backflow X N/A
Other X N/A

Yes No Comments
VITAL X
TIED OR FREE X Fire scenario only
61070F CN 3200-PSV 10582 / 10583 0

PROJECT ________
1/ 1

EQUIPMENT PROTECTED : MNP NETWORK DISCHARGE LOCATION : ATM
CASE ANALYSIS
Valve inadvertently open or X 3200-PV-10584 wide open can pressurise the system, with
HNP Pdesign = 40 bar(g).
Overfilling X N/A
Tube rupture X N/A

exchanger
Loss of heat X N/A
Loss of steam X N/A
Vacuum X N/A

Internal explosion
Backflow X N/A
Other X N/A

Yes No Comments
TIED OR FREE X
61070F CN 3200-PSV 20001 0
PETRONAS RAPID PAGE

CLIENT ________
PROJECT
PSV SCENARIO SHEET
LOCATION JOHOR, MALAYSIA 1/1

EQUIPMENT PROTECTED : 3200-K-230 DISCHARGE LOCATION : RFH
CASE ANALYSIS
External fire X N/A
Closed outlet X 3200-K-230 discharge should be protected against

this scenario (3200-K-230 full capacity)
Accidental mixing X No mixing of streams.
Overfilling X N/A
Tube rupture X N/A. No heat exchanger in the system.

exchanger
Loss of heat X N/A
Loss of steam X N/A
Loss of instrument air X Leading to 3200-XV-20001 closing. This is covered by closed

outlet case.
Loss of electricity X 3200-K-230 stopped. No pressure rise will occur. This is not
an issue.
Vacuum X N/A
Chemical reaction X No chemical reaction takes place.

Internal explosion
Backflow X N/A
Other X N/A

Yes No Comments
VITAL X 3200-K-230 on intermittent service (only running at low
capacity)
TIED OR FREE X
61070F CN 3200-PSV 20103 / 20113 0
PETRONAS RAPID PAGE

CLIENT PROJECT ________
PSV SCENARIO SHEET

EQUIPMENT PROTECTED : 3200-K-271A/B DISCHARGE LOCATION : RFH
CASE ANALYSIS
External fire X N/A
Closed outlet X Discharge line can be blocked or plugged. PSV design is

based on closed outlet case with hydrogen discharging
through PSV to flare. Discharging flowrate is rated capacity
of hydrogen compressor, to be confirmed by Vendor.
Valve inadvertently open or X Pressure design of H2 network is equal to PSV Pressure
design. No overpressure risk.
Overfilling X N/A
Blocked-in heat on X No heat is present in the system.
Tube rupture X Not heat exchanger in system. N/A
Non-condensable built-up X No possibility of non-condensable accumulation.

exchanger
Loss of heat X N/A (this scenario is a PSV sizing issue for fractionation
systems only).
Loss of cooling X No cooling.
Loss of steam X N/A
Vacuum X Designed for vacuum

Internal explosion
Backflow X Ethylene design pressure is equal to hydrogen compressor
discharge pressure. No overpressure risk.
Other X

Yes No Comments
VITAL X Spare compressors.
TIED OR FREE X
61070F CN 3200-PSV 20121 0
PETRONAS RAPID PAGE

CLIENT ________
PROJECT
PSV SCENARIO SHEET

EQUIPMENT PROTECTED : NITROGEN & DISCHARGE LOCATION : RFH
HYDROGEN NETWORK
CASE ANALYSIS
External fire X N/A
Closed outlet X Manual valve closed, and H2 coming from OSBL (Pdes = 30 barg)
through 3200-FV-20120 can pressurize the system.
Valve inadvertently open or control X 3200-FV-20120 sudden erratic wide opening following flow control
failure.
valve failure
Overfilling X N/A
Reflux failure X There is no reflux
Tube rupture X N/A
Non-condensable built-up X No possibility of non condensable accumulation

exchanger
Loss of heat X N/A
Loss of steam X N/A
Vacuum X N/A
Chemical reaction X Regeneration with H2 is exothermic but does not lead to

overpressure.
Internal explosion
Backflow X Two check valves of different type protect H2 network from
backflow from ethylene treaters.
Other X N/A
SAFETY RELATED DEVICES: 3200-RO-20124

Yes No Comments
VITAL X
TIED OR FREE X H2 is only used during regeneration (reduction) of

3200-R-231 A/B catalysts.
61070F CN 3200-PSV 20122 / 20132 0
PETRONAS RAPID PAGE

CLIENT ________
PROJECT
PSV SCENARIO SHEET

EQUIPMENT PROTECTED : 3200-R-231 A/B DISCHARGE LOCATION : RFH
CASE ANALYSIS
External fire X 3200-R-231 A/B is at grade. Fire case is applicable.

X Design pressure of ethylene network is identical to 3200-R-231 A/B design pressure.
Closed outlet No overpressure risk.
Valve inadvertently open or X Not an issue. Ethylene system design pressure is higher than other systems design
control valve failure pressure.
Accidental mixing X Refer to chemical reaction scenario.
Overfilling X N/A.
Flow through vent valve X N/A.
Blocked-in heat on X Refer to chemical reaction scenario.
Tube rupture X Not heat exchanger with fluid or higher pressure than ethylene in the system. N/A.
Abnormal reboiler heat input X N/A.
Abnormal vaporization in heat X N/A.

exchanger
Loss of heat X N/A (this scenario is a PSV sizing issue for fractionation systems only).
Loss of steam X N/A.
Vacuum X N/A.
H2/O2 is added in regeneration nitrogen upstream 3200-R-231 A/B during
Chemical reaction X
3200-R-231 A/B regeneration. An exothermic chemical reaction occurs in
Internal explosion 3200-R-231 A/B. A temperature runaway is therefore possible but :
- temperature is mostly a local phenomenon, and is not strictly related to a pressure
rise,
- interlock I-2302-S stops the H2/O2 injection in case of high temperature detected in
3200-R-231 A/B,
- in case of high temperature, H2/O2 flow is stopped, nitrogen heater is stopped.
Cuprene formation in Cu based treater is a slow reaction. Reaction runaway is unlikely
to occur.
Backflow X During regeneration of 3200-R-231 A/B, a backflow from another treater, through
the regeneration N2 network can occur. But due to PSV set pressure, no relief can
happen.
Other X N/A

Yes No Comments
VITAL X Relieving scenario is a non-operational case (external fire)
TIED OR FREE X Treater not in continuous operation.
61070F CN 3200-PSV 20125 0
PETRONAS RAPID PAGE

CLIENT ________
PROJECT
PSV SCENARIO SHEET

EQUIPMENT PROTECTED : AIR TO 3200-R-231 A/B DISCHARGE LOCATION : RFH
REGENERATION
CASE ANALYSIS
External fire X N/A
Closed outlet X 3200-PSV-20125 at same pressure as plant air design pressure

and regeneration nitrogen. No risk of overpressure
Valve inadvertently open or control X No risk of overpressure.
valve failure
Overfilling X N/A
Tube rupture X N/A
Non-condensable built-up X No possibility of non condensable accumulation

exchanger
Loss of heat X N/A
Loss of steam X N/A
Loss of instrument air X This is not an issue
Loss of electricity X 3200-FV-20122 is fail close. Not an issue.
Vacuum X N/A
Chemical reaction X Regeneration with Air is exothermic but does not lead to
overpressure.
Internal explosion
Backflow X Two check valves of different type protect instrument air network
from backflow from ethylene treaters.
Other X N/A

Yes No Comments
VITAL X
TIED OR FREE X Air is only used during regeneration (oxidation) of

3200-R-231 A/B catalyst.
61070F CN 3200-PSV 20134 0
PETRONAS RAPID PAGE

CLIENT
PROJECT ________
PSV SCENARIO SHEET

EQUIPMENT PROTECTED : COMONOMER DISCHARGE LOCATION : RFH
MINI FLOW LINE
CASE ANALYSIS
External fire X Not considered on lines.
Liquid thermal expansion X Line is full of liquid.

3200-P-241 A/B discharge design pressure is much higher
Closed outlet than 12 bar g. In case of recirculation with closed outlet, it
X
can pressurize the line.
3200-FV-20601 sudden erratic wide opening. Pdesign of
Valve inadvertently open or injection pump can pressurize the system. Refer to closed
X
control valve failure outlet scenario.
Overfilling X N/A
Tube rupture X Not applicable for this PSV.
Abnormal vaporization in heat N/A

X
exchanger
Loss of heat X N/A
In case 3200-P-241 A/B is running in closed recirculation and
Loss of cooling 3200-E-241 cooling fails, comonomer is therefore heated.
X But time is long enough before lighter comonomer
vaporization to avoid considering such case.
Loss of steam X N/A
Loss of instrument air X Refer to control valve failure.
Vacuum X N/A
Chemical reaction N/A

X
Internal explosion
Backflow Back flow from loop through 3200-FO-40924 (PID 0403) and
X comonomer pumps mini flow line.
Other X N/A
SAFETY RELATED DEVICES: 3200-FV-20601 ; 3200-FO-40924

Yes No Comments
VITAL X Mini flow line is not in continuous operation
TIED OR FREE X
61070F CN 3200-PSV 20139 / 20140 0
PETRONAS RAPID PAGE

CLIENT ________
PROJECT
PSV SCENARIO SHEET

EQUIPMENT PROTECTED : 3200-S-271 A/B AND DISCHARGE LOCATION : RFH
HYDROGEN NETWORK
CASE ANALYSIS
External fire X Not considered on lines.
Closed outlet 3200-K-271 A/B discharge design pressure is much higher

X than 30 bar g. In case of recirculation with closed outlet, it
can pressurize the line. Covered by control valve failure.
Valve inadvertently open or 3200-PV-20108 sudden erratic wide opening. Pdesign of
X hydrogen compressor can pressurize the system.
Overfilling X N/A
Tube rupture X Not applicable for this PSV.

Abnormal vaporization in heat

X N/A
exchanger
Loss of heat X
N/A (this scenario is a PSV sizing issue for fractionation
systems only).
Loss of cooling In case hydrogen is running in close recirculation and
3200-E-272 cooling fails, hydrogen will be heated. But time is
X long enough before lighter pressurization to avoid
considering such case.
Loss of steam X No cooling.
Loss of instrument air X Refer to control valve failure.
Loss of electricity X Refer to closed outlet.
Vacuum X N/A
Chemical reaction
X N/A
Internal explosion
Backflow Back flow from loop is not a sizing case. Design pressure of
loop (28 bar g) is lower than PSV set pressure.
Backflow from ethylene treaters is not a sizing case since
X flowrate is limited by two check valves in series and ethylene
design pressure is equal to 3200-K-271A/B discharge design
pressure.
Other X N/A

Yes No Comments
VITAL X In normal operation, Hydrogen is always recycled.
TIED OR FREE X
61070F CN 3200-PSV 20203 / 20204 0
PETRONAS RAPID PAGE

CLIENT ________
PROJECT
PSV SCENARIO SHEET

EQUIPMENT PROTECTED : 3200-V-242 DISCHARGE LOCATION : RFH
CASE ANALYSIS
X 3200-V-242 is at grade. Fire case is applicable;
External fire
X 3200-V-242 is not full of liquid.
Liquid thermal expansion
X PIC failure: design pressure of MN network is lower than
Closed outlet 3200-V-242 design pressure.
X Pentane inlet is at the same design pressure. No risk of
Valve inadvertently open or control overpressure.
valve failure
X N/A
Accidental mixing
X Operator can overfill 3200-V-242 with pentane at
Overfilling Pdes = 12 bar g. No risk of overpressure.
X N/A
Flow through vent valve
X There is no reflux
Reflux failure
X No heat is present in the system
Blocked-in heat on
X No heat exchanger in the system. N/A
Tube rupture
X No possibility of non-condensable accumulation
Non-condensable built-up
X N/A
Abnormal reboiler heat input
X N/A
exchanger
X N/A
Loss of heat
X N/A
Loss of cooling
X N/A
Loss of steam
X No pressure rise identified
Loss of instrument air
X No pressure rise identified
Loss of electricity
X N/A
Vacuum
X N/A
Chemical reaction
Internal explosion
X Backflow from loop (through 3200-FO-40925, 3200-FO-40904 on
Backflow PID0403 and 3200-FO-20204 on PID 0209)
Other X
SAFETY RELATED DEVICES: 3200-FO-40925; 3200-FO-40904; 3200-FO-20204

Yes No Comments
VITAL X Pentane is vital for production. Two PSVs are required: one
in operation, one in spare.
TIED OR FREE X
61070F CN 3200-PSV 20208 / 20218 0
PETRONAS RAPID PAGE

CLIENT
PROJECT ________
PSV SCENARIO SHEET

CASE ANALYSIS
External fire 3200-R-232 A/B are at grade. Fire case is applicable.
X
Liquid thermal expansion 3200-R-232 A/B is not full of liquid

X
Closed outlet Design pressure of ethylene network is identical to

X 3200-R-232 A/B design pressure. No overpressure risk.
Valve inadvertently open or Not an issue. Ethylene system design pressure is higher than
X other systems design pressure.
Accidental mixing N/A
X
Overfilling N/A
X
Flow through vent valve N/A

X
Reflux failure There is no reflux

X
Blocked-in heat on No heat is present in the system

X
Tube rupture No heat exchanger in system. N/A

X
Non-condensable built-up No possibility of non condensable accumulation

X
Abnormal reboiler heat input N/A

X

X
exchanger
Loss of heat N/A
X
Loss of cooling N/A

X
Loss of steam N/A

X
Loss of instrument air No pressure rise identified

X
Loss of electricity No pressure rise identified

X
Vacuum N/A
X
Chemical reaction Treaters are filled with adsorbents. No chemical reaction

X occurs, only sieving and physical adsorption are relevant. No
Internal explosion risk.
Backflow Backflow from another treater can occur through N2
X regeneration network. However, due to PSV set pressure,
it is not a relief case.
Other N/A
X

Yes No Comments
TIED OR FREE X Treater is not in continuous operation.
61070F CN 3200-PSV 20212 0
PETRONAS RAPID PAGE

CLIENT ________
PROJECT
PSV SCENARIO SHEET

EQUIPMENT PROTECTED : 3200-P-242A DISCHARGE LOCATION : 3200-P-242A suction
DICHARGE LINE
CASE ANALYSIS
External fire X No vessel
Closed outlet Discharge valve can be closed or discharge line can be

plugged. PSV design is based on closed outlet case with
X pentane discharging through PSV to pump inlet. Discharging
flowrate is rated capacity of pentane injection pump, to be
confirmed by vendor
Valve inadvertently open or control Pdesign of pentane network is equal to PSV Pdesign. No
X overpressure risk
valve failure
Overfilling X N/A
Tube rupture X No heat exchanger in system. N/A.

X
exchanger
systems only)
Loss of steam X N/A
Vacuum X Design for vacuum.
Chemical reaction Internal N/A

X
explosion
Backflow X
Other X

Yes No Comments
VITAL X Pump 3200-P-242A may be used..
TIED OR FREE X
61070F CN 3200-PSV 20251 / 20261 0
PETRONAS RAPID PAGE

CLIENT ________
PROJECT
PSV SCENARIO SHEET 1/1
LOCATION JOHOR, MALAYSIA

CASE ANALYSIS
X
Liquid thermal expansion Design pressure of Pentane network (12 bar g) is equal to
X 3200-R-242 A/B design pressure.
Treater 3200-R-242 A/B full of liquid is not a risk.
Closed outlet Design pressure of Pentane network (12 bar g) is equal to
X 3200-R-242 A/B design pressure.
No overpressure risk.
Valve inadvertently open or control Nitrogen for regeneration and pentane network have
X the same design pressure. No overpressure risk.
valve failure
X
Overfilling N/A
X

X

X

X
Tube rupture No heat exchanger in the system. N/A

X
Non-condensable built-up No possibility of non-condensable accumulation

X

X

X
exchanger
Loss of heat N/A
X
Loss of cooling N/A

X
Loss of steam N/A

X

X

X
Vacuum N/A
X
Chemical reaction Internal Treater is filled with adsorbents. No chemical reaction

X occurs, only physical adsorption is relevant. No risk
explosion
Backflow During regeneration of 3200-R-242 A/B, a backflow from
X another treater, through the regeneration N2 network can
occur. But due to PSV set pressure, no relief can happen.
Other N/A
X

Yes No Comments
61070F CN 3200-PSV 20311 0
PETRONAS RAPID PAGE

CLIENT ________
PROJECT
PSV SCENARIO SHEET

EQUIPMENT PROTECTED : 3200-R-273 DISCHARGE LOCATION : RFH
CASE ANALYSIS
External fire X 3200-R-273 is at grade. Fire case applicable.
Closed outlet X Design pressure of H2 network is equal to PSV set pressure.

Valve inadvertently open or X Design pressure of H2 network is equal to PSV set pressure.
Overfilling X N/A
Tube rupture X No heat exchanger in system. N/A.

exchanger
systems only).
Loss of steam X N/A
Vacuum X Designed for vacuum.

Internal explosion
Backflow X Possible backflow from ethylene treaters. Design pressure of
ethylene network is equal to H2 design pressure.
Other X N/A

Yes No Comments
VITAL X
TIED OR FREE X Treater can be by-passed
61070F CN 3200-PSV 20317 0

PROJECT ________
LOCATION JOHOR - MALAYSIA PSV SCENARIO SHEET
1/ 1
UNIT 350 Kta LLDPE

EQUIPMENT PROTECTED : SCL HEADER DISCHARGE LOCATION : ATM
CASE ANALYSIS
Closed outlet X Included in valve inadvertently open.
Valve inadvertently open or X 3200-TZV-20316 wide open can pressurise the system with
SH Pdesign = 62 bar(g).
Overfilling X N/A
Tube rupture X N/A

exchanger
Loss of heat X N/A
Loss of steam X N/A
Vacuum X N/A

Internal explosion
Backflow X N/A
SAFETY RELATED DEVICES: 3200-TZV-20316

Yes No Comments
VITAL X
TIED OR FREE X Heater usage is not continuous.
61070F CN 3200-PSV 20406 0

PROJECT ________
LOCATION JOHOR – MALAYSIA PSV SCENARIO SHEET
1/1
UNIT 350 Kta LLDPE

EQUIPMENT PROTECTED: H2 LINE TO DISCHARGE LOCATION: RFH
3200-R-274 A/B
CASE ANALYSIS
Valve inadvertently open or 3200-FV-20422 wide open can pressurize the system with
X Hydrogen Pdesign = 30 bar(g).
Overfilling X N/A
Tube rupture X N/A

X N/A
exchanger
Loss of heat X N/A
Loss of steam X N/A
Loss of instrument air X Not an issue.
Loss of electricity X 3200-FV-20422 is fail close. Not an issue.
Vacuum X N/A
Chemical reaction Regeneration with H2 is exothermic but doesn’t lead to

X overpressure.
Internal explosion
Backflow from MPN not possible: Pdesign MPN = Pset PSV =
Backflow X 12 bar(g). Backflow from ethylene at 30 bar(g) (Pset PSV
ethylene) : same as control valve failure.
Other X N/A
SAFETY RELATED DEVICES: 3200-FV-20422

Yes No Comments
VITAL X
TIED OR FREE X H2 only using during regeneration.
61070F CN 3200-PSV 20420 / 20430 0

PROJECT ________
1/2
UNIT 350 Kta LLDPE
PSV ITEM: 3200-PSV-20420 / 20430 SET PRESSURE: 40.0 bar(g)

EQUIPMENT PROTECTED: 3200-R-274 A/B DISCHARGE LOCATION: ATM
CASE ANALYSIS
Closed outlet X Same design pressure than upstream HN network.
Valve inadvertently open or

X
Excess H2 during regeneration will increase temperature, but
Accidental mixing X not the pressure.
Overfilling X N/A
3200-H-201 is not able to warm up sufficiently the blocked

Blocked-in heat on X gas to reach the PSV set pressure.
Tube rupture X N/A

X N/A
exchanger
Loss of heat X N/A
Loss of steam X N/A
Vacuum X N/A
H2/O2 are added in regeneration nitrogen upstream
3200-R-274 A/B during 3200-R-274 A/B regeneration.
An exothermic chemical reaction occurs in 3200-R-274 A/B.
A temperature runaway is therefore possible but:
Chemical reaction - temperature is mostly a local phenomenon, and is not
X strictly related to a pressure rise,
Internal explosion
- interlock I-2760-S stops the H2/O2 injection in case of high
temperature detected in 3200-R-274 A/B,
- in case of high temperature, H2/O2 flow is stopped, nitrogen
heater is stopped.
Upstream and downstream systems have the same design
Backflow X pressure. Backflow from other treaters is not possible
because regeneration is not simultaneous.
61070F CN 3200-PSV 20420 / 20430 0

PROJECT ________
2/2
UNIT 350 Kta LLDPE

Yes No Comments
VITAL X
61070F CN 3200-PSV 20503 / 20513 0
PETRONAS RAPID PAGE

CLIENT ________
PROJECT
PSV SCENARIO SHEET

CASE ANALYSIS
X
Liquid thermal expansion Design pressure of Comonomer network (12 bar g) is equal
X to 3200-R-243 A/B design pressure.
Treater 3200-R-243 A/B full of liquid is not a risk.
Closed outlet Design pressure of Comonomer network (12 bar g) is equal
X to 3200-R-243 A/B design pressure.
Valve inadvertently open or control Nitrogen for regeneration and pentane network is at lower (or
X equal) design pressure
valve failure
X
Overfilling N/A
X

X

X
X
Tube rupture No heat exchanger in the system. N/A

X
Non-condensable built-up No possibility of non-condensable accumulation

X
X

X
exchanger
Loss of heat N/A
X
Loss of cooling N/A

X
Loss of steam N/A

X
X

X
Vacuum N/A
X
Chemical reaction Internal Treater is filled with adsorbents. No chemical reaction
X occurs, only physical adsorption is relevant. No risk
explosion
Backflow During regeneration of 3200-R-243 A/B, a backflow from
X another treater, through the regeneration N2 network can
occur. But due to PSV set pressure, no relief can happen.
Other N/A
X

Yes No Comments
61070F CN 3200-PSV 20520 / 20530 0

PROJECT ________
1/1
UNIT 350 Kta LLDPE

EQUIPMENT PROTECTED: 3200-R-275 A/B DISCHARGE LOCATION: ATM
CASE ANALYSIS
Closed outlet X Same design pressure than HN upstream network.

All injections valves (for regeneration) are at lower pressure
X or are protected with a pressure safety valve dedicated to
control valve failure this scenario.
Overfilling X N/A
3200-H-201 is not able to warm up sufficiently the blocked

Blocked-in heat on X gas to reach the PSV set pressure.
Tube rupture X N/A

X N/A
exchanger
Loss of heat X N/A
Loss of steam X N/A
Vacuum X
Treaters are filled with adsorbents. No chemical reactions
Chemical reaction
X occur, only sieving and physical adsorption are relevant. No
Internal explosion risks.
Upstream and downstream systems have the same design
Backflow X pressure. Backflow from other treaters is not possible
because regeneration is not simultaneous.
Other X N/A

Yes No Comments
VITAL X
TIED OR FREE X Parallel treater 3200-R-275 A/B
61070F CN 3200-PSV 20603 0
PETRONAS RAPID PAGE

CLIENT
PROJECT ________
PSV SCENARIO SHEET

CASE ANALYSIS
External fire X 3200-V-243 is at grade. Fire case is applicable.
Liquid thermal expansion X 3200-V-243 is not full of liquid.
PIC failure: design pressure of MN network is equal to

Closed outlet X 3200-V-243 design pressure.
Valve inadvertently open or Design pressure of MN is equal to PSV set pressure. No risk
X of overpressure.
Operator can overfill 3200-V-243 with comonomer at
Overfilling X Pdes = 12 bar g. No risk of overpressure.
Tube rupture X 3200-E-241 is double pipe.

X
exchanger
Not applicable (this scenario is a PSV sizing issue for
Loss of heat X fractionation systems only).
In case 3200-P-241 A/B is running in close recirculation, and
Loss of cooling 3200-E-241 cooling fails, comonomer is therefore heated,
X which increases the temperature/pressure. Covered by
3200-PSV-20134
Loss of steam X N/A
Vacuum X N/A
Chemical reaction N/A

X
Internal explosion
Backflow Back flow from loop through 3200-FO-40924 (PID 0403) is
X covered by 3200-PSV-20134.
Other X
SAFETY RELATED DEVICES: 3200-FO-40924

Yes No Comments
TIED OR FREE X
61070F CN 3200-PSV 20814 0

PROJECT ________
1/ 1
UNIT 350 Kta LLDPE

EQUIPMENT PROTECTED : RN NETWORK DISCHARGE LOCATION : RFH
CASE ANALYSIS
External fire X 3200-H-201 is at grade.
Closed outlet X N/A
Valve inadvertently open or X Same design pressure than upstream MPN network.
Overfilling X N/A
Blocked-in heat on X Thermal expansion of heater.
Tube rupture X 3200-E-206 SH side (Pdesign = 62 bar(g)) is higher than

network design pressure (12 bar(g)).
Non-condensable built-up X No possibility of non condensable accumulation.

exchanger
Loss of heat X May lead to vacuum in case of hot gas blocked in. Design for
FV.
Loss of steam X N/A
Loss of instrument air X 3200-FV-20311 in upstream position and manual valve in

downstream position will close, leading to blocked in, heat on
scenario.
Vacuum X Warm N2 blocked in. Heater off. N2 cool down. Design for
FV.
Internal explosion
Backflow X Backflow all treaters protection with 2 NRV of different type.
Worst case: ethylene.

Yes No Comments
VITAL X
TIED OR FREE X Used only for treater regeneration, not continuous.
61070F CN 3200-PSE 30069 / 30169 0

PROJECT ________
LOCATION JOHOR – MALAYSIA PSE SCENARIO SHEET 1/1
UNIT 350 Kta LLDPE
PSE ITEM : 3200-PSE-30069 / SET PRESSURE : 3.15 bar(g)

3200-PSE-30169
EQUIPMENT PROTECTED : ZG CATALYST TOTE BIN DISCHARGE LOCATION : CRV
P&ID REFERENCE : PID0301 / 0302
CASE ANALYSIS
External fire X No source of fire 20m below stock pipe.
Closed outlet X N/A
Valve inadvertently open or X 3200-XZV-30070 / 30071 / 30170 / 30171 fail open during
stock pipe pressurization. HP side at 31.4 bar(g) normal
control valve failure (40 bar(g) design)
Overfilling X N/A
Tube rupture X N/A

exchanger
Loss of heat X N/A
Loss of steam X N/A
Vacuum X N/A

Internal explosion
Backflow X Backflow from reactor through 3200-X-380 A/B is not
retained because 3200-X-380 A/B leakage is very small
compared to sizing case. And because 2 on/off valves would
need to be inadvertently opened.
Other X N/A

AVAILABILITY FOR PSE MAINTENANCE :
Yes No Comments
VITAL X LP stock pipe is not required when the other catalyst (NCT or
SDX) is used for production.
TIED OR FREE X
61070F CN 3200-PSE 30203 0

PROJECT ________
UNIT 350 Kta LLDPE
PSE ITEM : 3200-PSE-30203 SET PRESSURE : 3.15 bar(g)

EQUIPMENT PROTECTED : CATALYST WASTE DISCHARGE LOCATION : CRV
DRUM
CASE ANALYSIS
External fire X Exterior fire on waste catalyst tote bin can lead to a gas
expansion in tote bin. Not a sizing case.
Closed outlet X Vent line to catalyst vent plugged.
Valve inadvertently open or X Manual valve on DN50 diameter lines connected with hose to
spool pieces below 3200-X-380 A/B and 3200-X-386 A/B/C
control valve failure for maintenance purpose with an upstream normal pressure
of 31.4 bar(g) during catalyst injection (lines emptying in
catalyst tote bin). HNP design pressure is 40 bar(g).
Overfilling X N/A
Tube rupture X N/A

exchanger
Loss of heat X N/A
Loss of steam X N/A
Vacuum X N/A

Internal explosion
Backflow X N/A
Other X N/A

Yes No Comments
VITAL X System is non-continuous and can be isolated sometimes
without interrupting the production.
TIED OR FREE X
61070F CN 3200-PSE 30269 0

PROJECT ________
UNIT 350 Kta LLDPE
PSE ITEM : 3200-PSE-30269 SET PRESSURE : 3.15 bar(g)

EQUIPMENT PROTECTED : MT CATALYST TOTE BIN DISCHARGE LOCATION : CRV
CASE ANALYSIS
External fire X No source of fire 20m below stock pipe.
Closed outlet X N/A
Valve inadvertently open or X 3200-XZV-30270 / 30271 fail open during stock pipe
pressurization. HP side at 31.4 bar(g) normal (40 bar(g)
control valve failure design)
Overfilling X N/A
Tube rupture X N/A

exchanger
Loss of heat X N/A
Loss of steam X N/A
Vacuum X N/A

Internal explosion
Backflow X Backflow from reactor through 3200-X-386 A/B/C is not
retained because 3200-X-386 A/B/C leakage is very small
compared to sizing case. And because 2 on/off valves would
need to be inadvertently opened.
Other X N/A

Yes No Comments
VITAL X N/A
TIED OR FREE X
61070F CN 3200-PSV 40001 0

PROJECT ________
LOCATION JOHOR – MALAYSIA PSV SCENARIO SHEET 1/1
UNIT 350 Kta LLDPE
PSV ITEM : 3200-PSV-40001 SET PRESSURE: 12.0 bar(g)

EQUIPMENT PROTECTED : MPN LINE TO DISCHARGE LOCATION : ATM
3200-R-400
CASE ANALYSIS
External fire X N/A for piping protection.
Liquid thermal expansion X There is no liquid in this part.
Closed outlet X Spectacle blind in closed position. Refer to Backflow

scenario.
Accidental mixing X There is no mixing.
Overfilling X There is no filling.
Tube rupture X N/A

exchanger
Loss of heat X N/A
Loss of steam X N/A
Vacuum X N/A
Chemical reaction X There is no chemical reaction.

Internal explosion
Backflow X This line is used for maintenance purpose only. For normal
operation, this line is closed by spectacle blind. Therefore
Reactor Backflow is not the design case. HN backflow can
occur during maintenance.
Other X

Yes No Comments
VITAL X
TIED OR FREE X Only for maintenance.
61070F CN 3200-PSV 40006 / 007 0

PROJECT ________
LOCATION JOHOR, MALAYSIA PSV SCENARIO SHEET 1/1
PSV ITEM : 3200-PSV-40006 / SET PRESSURE: 28 bar(g) Rupture disk set

pressure 27.3 bar(g) at
3200-PSV-40007 operating temperature.
EQUIPMENT PROTECTED : 3200-R-400 DISCHARGE LOCATION : RFH

CASE ANALYSIS
External fire X Fire under 3200-R-400. 3200-S-409 is above 7.7m.
Liquid thermal expansion X 3200-R-400 is not liquid full.
Closed outlet X N/A, this is a loop.
Valve inadvertently open or Ethylene feed valve 3200-FV-40063 fully open. Other feed
X valves are also a scenario but flow is much smaller.
Overfilling X Loop volume is huge compared to liquid feed.
Tube rupture X N/A

X N/A
exchanger
Loss of heat X N/A
Loss of cooling X No reaction runaway in case of CW loop failure, as PE melts

and stops reaction.
Loss of instrument air X All feed valves fail closed. No closed outlet as it is a loop so no
overpressure.
Vacuum X N/A
Chemical reaction No possible reaction runaway, see comment on Loss of

X cooling.
Internal explosion
Backflow X Possible backflow from PHN grid to reactor through 3200-J-
380 A/B and 3200-J-386 A/B/C.
Other X

Yes No Comments
VITAL X 2 PSVs required (one PSV on line, one spare off-line).
TIED OR FREE X
61070F CN 3200-PSV 40050 / 40055 0

PROJECT ________
UNIT 350 Kta LLDPE
PSV ITEM : 3200-PSV-40050 / SET PRESSURE: 13.0 bar(g)

3200-PSV-40055
EQUIPMENT PROTECTED : 3200-E-400 (shell side) DISCHARGE LOCATION : ATM
CASE ANALYSIS
External fire X 3200-E-400 is located at ground level. If a fire occurs, water
will boil and pressurize 3200-E-400 (shell side).
Liquid thermal expansion X Liquid thermal expansion in case exchanger is blocked in.
Closed outlet X Similar to liquid thermal expansion.
Valve inadvertently open or 3200-FV-40070 A/B failing open does not pressurize
control valve failure X the system since the whole loop is designed at CW design
pressure.
Overfilling X 3200-E-400 is always filled with water.
Reflux failure X N/A.
Blocked-in heat on X In case of exchanger blocked in, cooling water may be

heated up to the reactor offgas temperature.
At this temperature, the water will expand. Similar to liquid
thermal expansion.
Tube rupture X The design pressure of the shell side 13 bar(g) is lower than
the design pressure of the high pressure side
(28 bar(g))
Non-condensable built-up X No possibility of non condensable accumulation.
Abnormal vaporization in heat In case of exchanger blocked in, the water will expand but
X will not vaporise.
exchanger
Loss of heat X N/A (This scenario is a PSV sizing issue for fractionation
systems only).
Loss of cooling X Loss of cooling is similar to closed outlet scenario and
blocked in heat on scenario: liquid thermal expansion.
Loss of instrument air X 3200-FV-40070 A/B will fail open and CW will continue
circulating. This is not an issue.
Loss of electricity X Cooling water pumps 3200-P-405 A/B will shutdown but
water will still circulate through pumps.
Vacuum X N/A
Chemical reaction
X No chemical reaction takes place.
Internal explosion
Backflow X N/A
Other X N/A
SAFETY RELATED DEVICES: -

Yes No Comments
VITAL X
TIED OR FREE X Relieving cases are a non-operational case (fire, tube

rupture, thermal expansion).
61070F CN 3200-PSV 40065 0

PROJECT ________
1/1
UNIT 350 Kta LLDPE

EQUIPMENT PROTECTED : PHN network DISCHARGE LOCATION : RFH
CASE ANALYSIS
External fire X N/A
Closed outlet X N/A

X N/A
Overfilling X N/A
Tube rupture X N/A

X N/A
exchanger
Loss of heat X N/A
Loss of steam X N/A
Vacuum X N/A
Chemical reaction
X N/A
Internal explosion
Backflow X Backflow of ethylene through 2 check valves of different
types and 3200-XV-40065. Ethylene design pressure =
42 bar(g).
Other X

Yes No Comments
VITAL X
TIED OR FREE X Normal Buffer gas is Ethylene. Back up can be isolated for
PSV servicing.
61070F CN 3200-PSV 40075 0

PROJECT ________
UNIT 350 Kta LLDPE

EQUIPMENT PROTECTED : Condensate system at DISCHARGE LOCATION : ATM
3200-E-405 outlet
CASE ANALYSIS
External fire X N/A for piping protection.
Closed outlet X System design pressure is equal to steam design pressure:

9.0 bar(g)
Overfilling X There is no filling.
Tube rupture X 3200-E-405 shell side design pressure is 13 bar(g) and

condensate system design pressure is 9.0 bar(g).

exchanger
Loss of heat X N/A
Loss of steam X N/A
Vacuum X N/A

Internal explosion
Backflow X N/A
Other X N/A

Yes No Comments
VITAL X
TIED OR FREE X Only for start-up.
61070F CN 3200-PSV 40204 0

PROJECT ________
UNIT 350 Kta LLDPE
PSV ITEM : 3200-PSV-40204 SET PRESSURE : 40 bar(g)

CASE ANALYSIS
External fire X 3200-V-443 is located at minimum distance from the ground
Closed outlet X HN design pressure is 40 bar(g)
Valve inadvertently open or X HN Pdes = 40 bar(g)

Accidental mixing X
Overfilling X Not sizing case. S1 flowrate is very low (defined by DE)
Blocked-in heat on X There is no source of heat
Tube rupture X N/A

exchanger
Loss of heat X N/A
Loss of steam X Steam is not used
Loss of instrument air X 3200-XZV-40206 / 40209 will close.
Vacuum X
Chemical reaction X In case of wrong additive transfer. Already covered by fire

case.
Internal explosion
Backflow X - Backflow from reactor PD = 28 bar(g) < PSV set pressure
(not to be considered)
- Backflow from pentane PDPentane = 48 bar(g).
Other X

Yes No Comments
VITAL X
TIED OR FREE X
61070F CN 3200-PSV 40207 0

PROJECT ________
UNIT 350 Kta LLDPE

CASE ANALYSIS
External fire X 3200-V-442 is located at minimum distance from the ground
Closed outlet X HN design pressure is 40 bar(g)
Valve inadvertently open or X HN Pdes = 40 bar(g)

Accidental mixing X
Overfilling X Not sizing case. B1 flowrate is very low (defined by DE)
Tube rupture X N/A

exchanger
Loss of heat X N/A
Loss of steam X Steam is not used
Loss of instrument air X 3200-XZV-40204 / 40207 will close.
Vacuum X
Chemical reaction X In case of wrong additive transfer. Already covered by fire

case.
Internal explosion
Backflow X - Backflow from reactor PD = 28 bar(g) < PSV set pressure
(not to be considered)
- Backflow from pentane PDPentane = 48 bar(g).
Other X

Yes No Comments
VITAL X
TIED OR FREE X
61070F CN 3200-PSV 40501 / 40511 0

PROJECT ________
UNIT 350 Kta LLDPE
PSV ITEM : 3200-PSV-40501 / 40511 SET PRESSURE : 50 bar(g)

EQUIPMENT PROTECTED : 3200-P-455 A/B DISCHARGE LOCATION : 3200-P-455 A/B
DISCHARGE LINE SUCTION LINE
CASE ANALYSIS
External fire X Not applicable to pumps.
Liquid thermal expansion X Not a design case.
Closed outlet X 3200-P-455 A/B are protected by their own PSV. But
volumetric pumps, so downstream process must be
protected. Set pressure is piping design pressure.
Overfilling X N/A
Tube rupture X N/A

exchanger
Loss of heat X Not applicable (this scenario is a PSV sizing issue for
fractionation systems only)
Loss of instrument air X 3200-XZV-40521 / 40522 will fail closed. Refer to closed
outlet scenario.
Vacuum X N/A

Internal explosion
Backflow X N/A
Other X N/A

Yes No Comments
VITAL X
TIED OR FREE X
61070F CN 3200-PSV 40601 / 40602 0

PROJECT ________
UNIT 350 Kta LLDPE
PSV ITEM : 3200-PSV-40601 / 40602 SET PRESSURE : 47 bar(g)

CASE ANALYSIS
External fire X 3200-V-456 is located at minimum distance from the ground.
Liquid thermal expansion X 3200-V-456 is not fulfilled with liquid.
Closed outlet X Closed outlet + 3200-PCV-40608 leaking. 3200-FO-40605 is

installed to limit flow.
Valve inadvertently open or X 3200-PCV-40608 failure: flowrate through PCV wide open
(upstream pressure = CO bottles design pressure).
control valve failure 3200-FO-40605 is intalled to limit flow.
Overfilling X There is no liquid filling in this system.
Tube rupture X N/A. No heat exchanger in the system.

exchanger
Loss of heat X Not applicable (this scenario is a PSV sizing issue for
fractionation systems only)
Loss of instrument air X 3200-XZV-40601 at drum outlet will fail closed. Similar to
closed outlet scenario.
Vacuum X N/A

Internal explosion
Backflow X 3200-V-456 design pressure is higher than discharge open
pressure of 3200-K-400. This is not the relieving case.
Other X N/A

Yes No Comments
VITAL X Safety system
TIED OR FREE X
61070F CN 3200-TSV 40303 0

PROJECT ________
1/1
UNIT 350 Kta LLDPE
PSV ITEM : 3200-TSV-40303 SET PRESSURE: 25.9 bar(g)

EQUIPMENT PROTECTED : 3200-E-403 (shell side) DISCHARGE LOCATION : CWR
CASE ANALYSIS
External fire X N/A
Liquid thermal expansion X Liquid thermal expansion in case exchanger is blocked in.
Closed outlet X N/A

X N/A
Overfilling X N/A
Tube rupture X N/A

X N/A
exchanger
Loss of heat X N/A
Loss of steam X N/A
Vacuum X N/A
Chemical reaction
X N/A
Internal explosion
Backflow X N/A
Other X

Yes No Comments
VITAL X
TIED OR FREE X 3200-E-403 only used at start-up.
61070F CN 3200-PSV 60002 / 60003 0
CLIENT PETRONAS PAGE

RAPID PROJECT ________
LOCATION Johor, Malaysia PSV SCENARIO SHEET 1/1
UNIT 350 KTA LLDPE
PLANT
PSV ITEM: 3200-PSV-60002 / 60003 SET PRESSURE: 10 (1) bar(g)

EQUIPMENT PROTECTED: 3200-E-672 AND DISCHARGE LOCATION: RFH
3200-V-672
CASE ANALYSIS
Vessel located at 6 m from ground. (as minimum process
External fire X
requirement).
Liquid thermal expansion X Drum not full of liquid.
Closed outlet X Pre-commissioning error with spade in.
Valve inadvertently open or 3200-PV-60002 full open: no risk of pressurisation.

X 3200-LZV-60001C / 3200-XZV-60008 full open: refer to
control valve failure overfilling case.

-Overfilling from 3200-LZV-60001C / 3200-XZV-60008 full open.
Overfilling X -Pump stops.
Tube rupture X Cooling water design pressure 13 bar(g).

X N/A
exchanger
Loss of heat X N/A
Loss of cooling in 3200-E-672 will create an extra vapor flow.
Loss of cooling X This case is covered by closed outlet.
Loss of steam X N/A
Loss of electricity X 3200-K-675 will stop. There is a risk of backflow (see below).
Vacuum X 3200-V-672 and 3200-E-672 are designed for full vacuum.
Chemical reaction
X N/A
Internal explosion
Backflow from PU loop (Pdes = 28 bar(g) through 2 different
Backflow X
check valves.
Other X
SAFETY RELATED DEVICES: 3200-LZV-60001C, 3200-FO-60009

Yes No Comments
VITAL X 1 operating + 1 spare
TIED OR FREE X
Note: (1) To be confirmed by 3200-K-675 Vendor.
61070F CN 3200-PSV 60009 / 60032 0

PROJECT ________
1/2
UNIT 350 Kta LLDPE
PSV ITEM: 3200-PSV-60009 / 60032 SET PRESSURE: 4.4 Bar(g)

EQUIPMENT PROTECTED: 3200-V-640 DISCHARGE LOCATION: PRV
CASE ANALYSIS
3200-V-640 bottom is assumed to be located at same level
External fire X as a concrete platform where powder can accumulate.
Closed outlet X Refer to note 1.

X Refer to note 2.
Overfilling X N/A
Flow through vent valve X Vent network design pressure is 3.5 bar(g).
Tube rupture X 3200-E-645 is designed for 10/13.

X N/A
exchanger
Loss of heat X No overpressure case. Degassing less efficient.
Loss of steam X See loss of heat.
Loss of instrument air X 3200-FZV-60015 will fail open. Refer to note 2.
Loss of electricity X 3200-K-640 stops. The system remains open to RFH.
3200-V-640 is designed for -0.25 bar(g) which is

Vacuum X the maximum vacuum achievable in the drum.
Chemical reaction
X N/A
Internal explosion
Backflow X Refer to note 4.
Other X Refer to note 3.

Yes No Comments
VITAL X One operating + one spare PSV.
TIED OR FREE X
61070F CN 3200-PSV 60009 / 60032 0

PROJECT ________
2/2
UNIT 350 Kta LLDPE
REMARKS AND NOTES
1. Closed outled
3200-S-642 backflushing system does not provide scenario because filter supplier will
manage overpressure scenario.
Flow coming from SL valve is leading to a relieving scenario when 3200-V-640 outlet is
closed. See control valve failure.
2. Valve inadvertently open or control valve failure

3200-FZV-60014 full open (with 3200-FO-60017 to limit the flow).
3200-FZV-60013 full open doesn’t need to be considered as design pressure of LNS
and 3200-V-640 is 4.4 bar(g)
Same for 3200-XZV-60012 and 3200-FZV-60015 full open or DN25 manual valve at
bottom full open or 3200-FV-60007 full open, all connected to LNS network.
3. Other
HP / LP interface:
Flow through 3200-X-641 from upstream equipment 3200-S-641 to 3200-V-640 is not
considered, as design pressure of 3200-S-641 is the same as 3200-V-640 design pressure.
This has to be confirmed during detailed engineering according to conveying system
3200-A-660 vendor selection.
4. Backflow
Backflow from reactor through 3200-X-667 and 3200-X-666 is already covered by
3200-PSV-60074.
61070F CN 3200-PSV 60012 0

LOCATION Johor, Malaysia PSV SCENARIO SHEET 1/ 1
UNIT 350 KTA LLDPE
PLANT
PSV ITEM: 3200-PSV-60012 SET PRESSURE: 28 bar(g)

EQUIPMENT PROTECTED: 3200-K-675 discharge DISCHARGE LOCATION: RFH
system
CASE ANALYSIS
External fire X N/A
Closed outlet X 3200-K-675 full flow through 3200-PSV-60012.

X No open valve can pressurise the system
Overfilling X N/A
Tube rupture X N/A

X N/A
exchanger
Loss of heat X N/A
Loss of steam X N/A
3200-K-675 is stopped. No risk of pressurisation. This is not

Loss of electricity X an issue.
Vacuum X N/A
Chemical reaction
X N/A
Internal explosion
Backflow from PU loop is not an issue since loop design
Backflow X pressure is 28 bar(g).
Other X
SAFETY RELATED DEVICES: -

Yes No Comments
VITAL X
3200-K-675 outlet valve can be locked open during PSV
TIED OR FREE X maintenance.
61070F CN 3200-PSE / PSV 60074 0

PROJECT ________
1/ 2
UNIT 350 Kta LLDPE
PSE / PSV ITEM: 3200-PSE / PSV-60074 SET PRESSURE: 4.4 Bar(g)

EQUIPMENT PROTECTED: 3200-S-666 DISCHARGE LOCATION: PRV
CASE ANALYSIS
External fire X Note 1
Closed outlet X Refer to Backflow. Backflushing system is self protected.
Valve inadvertently open or PCV and FV (by Vendor) full open: HN design pressure =
X 40 bar(g)
Overfilling X N/A
Flow through vent valve X LN design pressure is equal to PSV set pressure.
Tube rupture X N/A

X N/A
exchanger
Loss of heat X N/A
Loss of steam X N/A
Vacuum X N/A
Chemical reaction
X N/A
Internal explosion
Backflow from reactor 3200-R-400 to 3200-S-666 through
Backflow X 3200-X-667.
Other X N/A
SAFETY RELATED DEVICES: By Vendor

Yes No Comments
VITAL X
61070F CN 3200-PSE / PSV 60074 0

PROJECT ________
2/ 2
UNIT 350 Kta LLDPE
REMARKS AND NOTES
1. Hypothesis of 19 m² of filter surface exposed to fire. Discharge flowrate to be confirmed

after 3200-S-666 selection.
61070F CN 3200-PSV 60082 0

PROJECT ________
1/1
UNIT 350 Kta LLDPE
PSV ITEM: 3200-PSV-60082 SET PRESSURE: 28.0 Bar(g)

EQUIPMENT PROTECTED: HN NETWORK DISCHARGE LOCATION: RFH
CASE ANALYSIS
External fire X N/A
Closed outlet X N/A

Overfilling X N/A
Tube rupture X N/A

exchanger
Loss of heat X N/A
Loss of steam X N/A
Vacuum X N/A

Internal explosion
Backflow Backflow from reactor 3200-R-400 through two check valves
X of different types and control valve 3200-FV-60081.
Other X N/A

Yes No Comments
VITAL X

61070F CN 3200-PSE / PSV 60086 0

PROJECT ________
1/1
UNIT 350 Kta LLDPE

CASE ANALYSIS
External fire X
Closed outlet X LNS design pressure is 4.4 bar(g). Not a scenario.
Valve inadvertently open or X Similary to closed outlet case.

Overfilling X N/A
If 3200-K-640 fails, flow going to its suction will be sent to its
Flow through vent valve X discharge thanks to its bypass. Moreover, other equipments
connected to its suction have their own PSV set to 4.4 bar(g).
Tube rupture X N/A

exchanger
Loss of heat X N/A
Loss of steam X N/A
Loss of instrument air X 3200-PV-60084 will fail open.
Vacuum X N/A

Internal explosion
Backflow X N/A
Other X Backflush failure is not a sizing case. Backflushing system is

self protected.

Yes No Comments
VITAL X

61070F CN 3200-PSV 60101 / 60103 0

UNIT 350 KTA LLDPE
PLANT

EQUIPMENT PROTECTED: 3200-V-671 DISCHARGE LOCATION: RFH
3200-E-670
CASE ANALYSIS
Vessel located at 6 m from ground. (minimum process
External fire X requirement)

Not a case for this PSV. Upstream equipment (3200-V-628)
Closed outlet X has the same design pressure.
Refer also to overfilling scenario
Valve inadvertently open or Refer to Note 1.

X
control valve failure Refer also to overfilling scenario
Accidental mixing X
Overfilling X Refer to Note 2

Reflux failure X
Blocked-in heat on X
Tube rupture X Cooling water design pressure= 13 bar(g)
Abnormal reboiler heat input X
X
exchanger
Loss of heat X
Loss of cooling X No overpressure foreseen for this PSV.
Loss of steam X
Loss of instrument air X
3200-K-675 stops; estimated settle out pressure is lower
Loss of electricity X than PSV set pressure so it is not an overpressure scenario.
Refer to Backflow.
Vacuum X 3200-V-671 is designed for full vacuum.
Chemical reaction Reaction between TEAL and Water in case of 3200-E-670

X tube rupture.
Internal explosion
Backflow from PU through 2 check valves and
3200-PV-60013 or 3200-PV-60101.
Backflow X Backflow from PU loop through 3200-P-671A/B covered by 3
NRV and backflow protection on PID0403
Other X
SAFETY RELATED DEVICES: 3200-LV-60501B / 3200-LV-60001A

Yes No Comments
VITAL X 1 operating PSV+ 1 spare PSV
TIED OR FREE X
61070F CN 3200-PSV 60101 / 60103 0

UNIT 350 KTA LLDPE
PLANT
REMARKS AND NOTES
1. Control valve failure:
- 3200-PV-60101, 3200-PV-60013 or 3200-LV-60006 can be full open but will not

pressurise because it is a closed loop with an estimated settle out pressure of less
than 4.4 bar(g) (To be confirmed by detailed engineering).
2. Overfilling:
- 3200-LV-60501B full open: design pressure upstream = 36.7 bar(g).
- 3200-LV-60001A full open: design pressure upstream = 35 bar(g).
- 3200-FV-60103 or 3200-LV-60101 full closed / 3200-P-671A/B stops: design
pressure upstream = 36.9 bar(g). It is not a relieving case because time for overfilling
exceeds 20 minutes.
61070F CN 3200-PSE / PSV 60112 0

PROJECT ________
1/2
UNIT 350 Kta LLDPE
PSE / PSV ITEM : 3200-PSE / PSV-60112 SET PRESSURE: 4.4 Bar(g)

EQUIPMENT PROTECTED : 3200-S-641 DISCHARGE LOCATION : PRV
CASE ANALYSIS
External fire X Note 1.
Covered by blower PSV. To be confirmed during detailed

Closed outlet X engineering after selection of blower vendor. Refer to Note 2.
- LN design pressure is equal to 3200-S-641 design
pressure; not relieving case.
X - MN through backflushing system is not a relieving case
control valve failure because backflushing system will include protection (to be
confirmed by DEC).
Overfilling X N/A
Flow through vent valve X PSV set pressure is equal to 4.4 bar(g). LN design pressure.
Tube rupture X N/A

X N/A
exchanger
Loss of heat X N/A
Loss of steam X N/A
Loss of electricity X Refer to Closed outlet.
Vacuum X 3200-S-641 is designed for full vacuum.
Chemical reaction
X N/A
Internal explosion
LN from PID0607 has a design pressure of 4.4 bar(g), equal
Backflow X to PSV set pressure; not a relieving case.
Other X N/A

Yes No Comments
VITAL X Only for fire case.
TIED OR FREE X
61070F CN 3200-PSE / PSV 60112 0

PROJECT ________
2/2
UNIT 350 Kta LLDPE
REMARKS AND NOTES
1. Hypothesis of 32 m² for filter surface exposed to fire.

Discharge flowrate to be confirmed after 3200-S-641 selection.
2. If 3200-K-660 A/B inlet pressure increases, compressor outlet pressure will also increase. So
as long as 3200-PSV-60043 / 60053 set pressure is below 4.4 bar(g), the blower PSV will
relieve before 3200-PSV-60112.
61070F CN 3200-PSV 60501 0

UNIT 350 KTA LLDPE
PLANT

CASE ANALYSIS
External fire X 3200-V-675 is located at 6 m from ground
3200-K-675 will pressurize the system, but scenario has

Closed outlet X already been considered in 3200-PSV-60012, which is
upstream and has same set pressure. This is not an issue.
Valve inadvertently open or control

X No open valve can pressurize the system.
valve failure
In case of bottom level control failure, liquid condensed in

Overfilling X 3200-E-677 can overfill the drum. But it cannot pressurize
above 3200-V-675 design pressure.
Cold liquid (-35°C) may vaporize under atmospheric

Blocked-in heat on X temperature. Covered by fire case.
- Cooling water design pressure: 13 bar(g). No risk of
Tube rupture X pressurisation.
- 3200-E-676 designed for 10/13 rule.

X N/A
exchanger
Loss of heat X N/A
Loss of cooling in 3200-E-677 will create an extra vapour

flow through 3200-V-675. The downstream equipment may
Loss of cooling X not be able to handle this flow increase, but in any case, it
will not be more than 3200-K-675 flow. This is similar case to
closed outlet.
Loss of steam X N/A

3200-K-675 will be stopped. No risk of pressurization. This is
Loss of electricity X not an issue.
Vacuum X 3200-V-675 is designed for -78°C / 0 bar(g).
Chemical reaction
X N/A
Internal explosion
Backflow X N/A
Other X N/A
61070F CN 3200-PSV 60501 0

UNIT 350 KTA LLDPE
PLANT

Yes No Comments
VITAL X
TIED OR FREE X 320-PSV-60012 takes a larger flow.
61070F CN 3200-PSV 60511 0

PROJECT ________
1/ 1
UNIT 350 Kta LLDPE
PSV ITEM : 3200-PSV-60511 SET PRESSURE : 3.9 Bar(g)

EQUIPMENT PROTECTED : 3200-V-628 / 3200-S-628 DISCHARGE LOCATION : RFH
CASE ANALYSIS
3200-V-628 elevation assumed to be above 7.6 m. To be
External fire X confirmed by detailed engineering.
Closed outlet X Relief flow is equal to 3200-V-628 design flow.
- Gas breakthrough from reactor through withdrawal hopper

Valve inadvertently open or (1 line).
X
control valve failure - Assist gas full open, restricted by orifices can pressurize
3200-V-628.
No over filling of powder (more than 20 min operator

Overfilling X response.)
Tube rupture X N/A

X N/A
exchanger
Loss of heat X N/A
Loss of steam X N/A
Loss of electricity X 3200-K-675 stops – refer to closed outlet.
Chemical reaction
X N/A
Internal explosion
Backflow X Considered by 3200-PSV-60101.
Other X N/A
SAFETY RELATED DEVICES: 3200-FO-60304 / 60313 / 60323 / 60333 / 60051 / 60001

Yes No Comments
VITAL X 3200-PSV-60521 is used as spare PSV.
TIED OR FREE X
61070F CN 3200-PSE / PSV 60521 0

PROJECT ________
1/ 1
UNIT 350 Kta LLDPE
PSE / PSV ITEM : 3200-PSE / PSV-60521 SET PRESSURE : 4.4 Bar(g)

CASE ANALYSIS
3200-V-628 elevation assumed to be above 7.6 m. To be
External fire X confirmed by detailed engineering.
Closed outlet X Relief flow is equal to 3200-V-628 design flow.
- Gas breakthrough from reactor through withdrawal hopper

Valve inadvertently open or (1 line).
X
control valve failure - Assist gas full open, restricted by orifices can pressurize
3200-V-628.
No over filling of powder (more than 20 min operator

Overfilling X response.)
Tube rupture X N/A

X N/A
exchanger
Loss of heat X N/A
Loss of steam X N/A
Loss of electricity X 3200-K-675 stops – refer to closed outlet.
Chemical reaction
X N/A
Internal explosion
Backflow X Considered by 3200-PSV-60101.
Other X N/A
SAFETY RELATED DEVICES: 3200-FO-60304 / 60313 / 60323 / 60333 / 60051 / 60001

Yes No Comments
VITAL X 3200-PSV-60511 is used as spare PSV.
TIED OR FREE X
61070F CN 3200-PSE / PSV 60551 0

PROJECT ________
1/ 2
UNIT 350 Kta LLDPE-

CASE ANALYSIS
External fire X See note 2.
Closed outlet X See note 1.
Valve inadvertently open or X - LN design pressure is equal to 3200-S-665 design

pressure, not relieving case.
- MN through backflushing system is not relieving case
because backflushing system will include protection (To be
confirmed by DEC).
Overfilling X N/A
Tube rupture X N/A

exchanger
Loss of heat X N/A
Loss of steam X N/A

Internal explosion
Backflow X N/A
Other X N/A

Yes No Comments
TIED OR FREE X
61070F CN 3200-PSE / PSV 60551 0

PROJECT ________
2/ 2
UNIT 350 Kta LLDPE-
REMARKS AND NOTES
1. Closed outlet
PSV set pressure is set at such a pressure that 3200-S-665 can not be pressurised by any
system (upstream or downstream):
- LN design pressure = 4.4 bar(g)
- Conveying system 3200-A-660 design pressure by vendor but lower than
4.4 bar(g).
2. Fire case
Hypothesis of 15m² for surface exposed to fire.
61070F CN 3200-PSV 60601 0

UNIT 350 KTA LLDPE
PLANT

EQUIPMENT PROTECTED: 3200-E-678 AND LINE DISCHARGE LOCATION: RFH
CASE ANALYSIS
3200-E-678 assumed to be at grade level.
External fire X To be confirmed by detail engineering.
Closed outlet X Gas from 3200-K-675 will pressurise the system.
Valve inadvertently open or 3200-FV-60603 full open does not pressurise the system (LN
X PD= 4.4 bar(g)). 3200-FV-60602 full open.
Overfilling X N/A
SL design pressure 9.0 bar(g), but 3200-E-678 is designed

Tube rupture X for 10/13 rule.

X N/A
exchanger
Loss of heat X N/A
Loss of steam X N/A
Loss of instrument air X 3200-XZV-60602 is fail close. This is not an issue.

Vacuum X 3200-E-678 is designed for full vacuum.
Chemical reaction
X N/A
Internal explosion
Backflow X N/A
Other X

Yes No Comments
VITAL X
3200-XZV-60602 and 3200-FZV-60602 can be lock closed
TIED OR FREE X and LN will be used as stripping gas during PSV
maintenance.
61070F CN 3200-PSV 60602 0

UNIT 350 KTA LLDPE
PLANT

EQUIPMENT PROTECTED: LINE FROM 3200-E-675 TO DISCHARGE LOCATION: RFH
3200-S-628 BACKFLUSH

CASE ANALYSIS
External fire X N/A
Gas from 3200-K-675 will pressurise the system.

Closed outlet X Covered by control valve failure.
X 3200-XV-60607 open and 3200-PCV-60609 full open.
Overfilling X N/A
Tube rupture X N/A

X N/A
exchanger
Loss of heat X N/A
Loss of steam X N/A
Loss of instrument air X 3200-XV-60607 is fail close. This is not an issue.

Vacuum X System is designed for full vacuum,.
Chemical reaction
X N/A
Internal explosion
Backflow X MN design pressure : 10.5 bar(g). No risk of pressurisation.
Other X
SAFETY RELATED DEVICES: 3200-PCV-60609

Yes No Comments
If flushing gas is not available, MN can be used as back-up,
VITAL X ensuring that block valve downstream 3200-PCV-60609 is
closed.
TIED OR FREE X
61070F CN 3200-PSV 60801 / 60803 0

UNIT 350 KTA LLDPE
PLANT

3200-E-681
CASE ANALYSIS
Vessel located at 6 m from ground. (minimum process
External fire X requirement)
Not a case for this PSV. Upstream equipment (3200-V-638)

Closed outlet X has the same design pressure.
Refer also to overfilling scenario
Valve inadvertently open or Refer to Note 1.

X
control valve failure Refer also to overfilling scenario
Accidental mixing X
Overfilling X Refer to Note 2
Reflux failure X
Blocked-in heat on X
Tube rupture X Cooling water design pressure= 13 bar(g)
Abnormal reboiler heat input X

X
exchanger
Loss of heat X
Loss of cooling X No overpressure foreseen for this PSV.
Loss of steam X

3200-K-685 stops; estimated settle out pressure is lower
Loss of electricity X than PSV set pressure so it is not an overpressure scenario.
Refer to Backflow.
Chemical reaction
X
Internal explosion
Backflow X No connection with PU Loop.
Other X
SAFETY RELATED DEVICES: 3200-LV-60871B ; 3200-FO-60802

Yes No Comments
VITAL X 1 operating PSV+ 1 spare PSV
TIED OR FREE X
61070F CN 3200-PSV 60801 / 60803 0

UNIT 350 KTA LLDPE
PLANT
REMARKS AND NOTES
1. Control valve failure:
- 3200-PV-60801 can be full open but will not pressurise because it is a closed loop
with an estimated settle out pressure of less than 4.4 bar(g) (To be confirmed by
detailed engineering).
2. Overfilling:
- 3200-LV-60871B full open: design pressure upstream = 43.6 bar(g).
- 3200-FV-60803 full closed/3200-P681A/B stops: design pressure upstream = 9.6
bar(g). It is not a relieving case because time for overfilling exceeds 20 minutes.
- 3200-XZV-60803 full open.
61070F CN 3200-PSV 60802 / 60804 0

UNIT 350 KTA LLDPE
PLANT
PSV ITEM: 3200-PSV-60802 / 60804 SET PRESSURE: 4.4 (1) bar(g)

EQUIPMENT PROTECTED: 3200-K-685 DISCHARGE DISCHARGE LOCATION: RFH
SYSTEM
CASE ANALYSIS
External fire X N/A
Pre-commissioning error with spade in. 3200-K-685 full flow

Closed outlet X through 3200-PSV-60802 / 60804.
X No open valve can pressurise the system.
Overfilling X N/A
Tube rupture X Cooling water design pressure 13 bar(g).

X N/A
exchanger
Loss of heat X N/A
Loss of cooling in 3200-E-682 will create an extra vapor flow.

Loss of cooling X This case is covered by closed outlet.
Loss of steam X N/A
3200-K-685 will stop. Risk of backflow covered by

Loss of electricity X 3200-PSV-60871.
Vacuum X 3200-E-682 is designed for full vacuum.
Chemical reaction
X N/A
Internal explosion
Backflow X See 3200-PSV-60871.
Other X

Yes No Comments
VITAL X 1 operating + 1 spare
TIED OR FREE X
Note: (1) To be confirmed by 3200-K-685 vendor.

61070F CN 3200-PSV 60821 / 60823 0

PROJECT ________
1/2
UNIT 350 Kta LLDPE
PSV ITEM: 3200-PSV-60821 / 60823 SET PRESSURE: 4.4 Bar(g)

CASE ANALYSIS
3200-V-638 bottom is assumed to be located at same level
External fire X as a concrete platform where powder can accumulate.
Closed outlet X N/A

X N/A
Overfilling X N/A
Flow through vent valve X Vent network design pressure is 3.5 bar(g).
Tube rupture X N/A

X N/A
exchanger
Loss of heat X No overpressure case. Degassing less efficient.
Loss of steam X See loss of heat.
3200-V-638 is designed for -0.75 bar(g) which is

Vacuum X the maximum vacuum achievable in the drum.
Chemical reaction
X N/A
Internal explosion
Backflow X N/A
Other X Refer to note 2.

Yes No Comments
VITAL X One operating + one spare PSV.
TIED OR FREE X
61070F CN 3200-PSV 60821 / 60823 0

PROJECT ________
2/2
UNIT 350 Kta LLDPE
REMARKS AND NOTES
1. Closed outled
3200-S-638 backflushing system does not provide scenario because filter supplier will
manage overpressure scenario.
Flow coming from SL valve is leading to a relieving scenario when 3200-V-638 outlet is
closed. See control valve failure.
2. Other
HP / LP interface:
Flow through 3200-X-639 from upstream equipment 3200-S-639 to 3200-V-638 is not
considered, as design pressure of 3200-S-639 is the same as 3200-V-638 design pressure.
This has to be confirmed during detailed engineering according to conveying system
3200-A-660 vendor selection.
61070F CN 3200-PSE / PSV 60851 0

PROJECT ________
1/ 2
UNIT 350 Kta LLDPE-

CASE ANALYSIS
External fire X See note 2.
Closed outlet X See note 1.
Valve inadvertently open or X LN design pressure is equal to 3200-S-662 design pressure,

not relieving case.
Overfilling X N/A
Tube rupture X N/A

exchanger
Loss of heat X N/A
Loss of steam X N/A

Internal explosion
Backflow X N/A
Other X N/A

Yes No Comments
TIED OR FREE X
61070F CN 3200-PSE / PSV 60851 0

PROJECT ________
2/ 2
UNIT 350 Kta LLDPE-
REMARKS AND NOTES
1. Closed outlet
PSV set pressure is set at such a pressure that 3200-S-662 can not be pressurised by any
system (upstream or downstream):
- LN design pressure = 4.4 bar(g)
- Conveying system 3200-A-660 design pressure by vendor but lower than
4.4 bar(g).
2. Fire case
Hypothesis of 15m² for surface exposed to fire.
61070F CN 3200-PSV 60871 0

UNIT 350 KTA LLDPE
PLANT

CASE ANALYSIS
External fire X 3200-V-684 is located at 6 m from ground
3200-K-685 will pressurize the system, but scenario has

Closed outlet X already been considered in 3200-PSV-60802 / 60804, which
is upstream and has same set pressure. This is not an issue.
Valve inadvertently open or control

X No open valve can pressurize the system.
valve failure
In case of bottom level control failure, liquid condensed in

Overfilling X 3200-E-684 can overfill the drum. But it cannot pressurize
above 3200-V-684 design pressure.
Cold liquid (-35°C) may vaporize under atmospheric

Blocked-in heat on X temperature. Covered by fire case.
Cooling water design pressure: 13 bar(g). Risk of
Tube rupture X pressurisation.

X N/A
exchanger
Loss of heat X N/A
Loss of cooling in 3200-E-684 will create an extra vapour

flow through 3200-V-684. The downstream equipment may
Loss of cooling X not be able to handle this flow increase, but in any case, it
will not be more than 3200-K-685 flow. This is similar case to
closed outlet.
Loss of steam X N/A

3200-K-685 will be stopped. No risk of pressurization. This is
Loss of electricity X not an issue.
Vacuum X 3200-V-684 is designed for -45°C.
Chemical reaction
X N/A
Internal explosion
Backflow from Reactor through 3200-P-684A/B. 3 NRV and
Backflow X backflow protection on PID0403.
Other X N/A
61070F CN 3200-PSV 60871 0

UNIT 350 KTA LLDPE
PLANT

Yes No Comments
VITAL X
TIED OR FREE X 3200-PSV-60802 / 60804 take a larger flow.
61070F CN 3200-PSV 60891 0

PROJECT ________
1/2
UNIT 350 Kta LLDPE
PSV ITEM : 3200-PSV-60891 SET PRESSURE: 4.4 Bar(g)

EQUIPMENT PROTECTED : 3200-S-639 DISCHARGE LOCATION : PRV
CASE ANALYSIS
External fire X Note 1.
Covered by blower PSV. To be confirmed during detailed

Closed outlet X engineering after selection of blower vendor. Refer to Note 2.
- LN design pressure is equal to 3200-S-639 design
pressure; not relieving case.
X - MN through backflushing system is not a relieving case
control valve failure because backflushing system will include protection (to be
confirmed by DEC).
Overfilling X N/A
Flow through vent valve X PSV set pressure is equal to 4.4 bar(g). LN design pressure.
Tube rupture X N/A

X N/A
exchanger
Loss of heat X N/A
Loss of steam X N/A
Loss of electricity X Refer to Closed outlet.
Chemical reaction
X N/A
Internal explosion
LN from PID0607 has a design pressure of 4.4 bar(g), equal
Backflow X to PSV set pressure; not a relieving case.
Other X N/A

Yes No Comments
TIED OR FREE X
61070F CN 3200-PSV 60891 0

PROJECT ________
2/2
UNIT 350 Kta LLDPE
REMARKS AND NOTES
1. Hypothesis of 32 m² for filter surface exposed to fire.

2. If 3200-K-660 A/B inlet pressure increases, compressor outlet pressure will also increase. So
as long as 3200-PSV-60043 / 60053 set pressure is below 4.4 bar(g), the blower PSV will
relieve before 3200-PSV-60891.
61070F CN 3200-PSV 70101 0

UNIT 350 KTA LLDPE
PLANT

CASE ANALYSIS
External fire X 3200-V-712 is exposed to fire.
Closed outlet X Consequence is Over filling for liquid closed outlet and loss
of cooling for gas closed outlet. See below.
Valve inadvertently open or X FV-70101 fails wide open: refer to loss of cooling and
abnormal reboiler heat input below.
FV-70102 fails wide open. MN design pressure (10.5 bar(g))
is higher than 3200-V-712 design pressure.
Accidental mixing X Refer to chemical reaction below.
Overfilling X 3200-P-711 has higher design Pressure.
Reflux failure X See loss of cooling below
Blocked-in heat on X See abnormal reboiler heat input below.
Tube rupture X Generates a chemical reaction. See below
Abnormal reboiler heat input X Steam control valve fully open.

exchanger
Loss of heat X N/A
Loss of cooling X Lack of reflux leading to overpressure.
Loss of steam X N/A
Loss of electricity X 3200-K-711 stops and overhead vapour cannot be

evacuated. Refer to gas closed outlet.
Vacuum X Designed for full vacuum.
Chemical reaction X Reaction with water or steam in case of tube rupture.

Reaction with air in case of air ingress. Not sizing.
Internal explosion
Backflow X N/A
Other

Yes No Comments
VITAL X Batch / intermittent operation.
TIED OR FREE X LRU in use for Ziegler grades only.
61070F CN 3200-PSV 70111 0

UNIT 350 KTA LLDPE
PLANT

EQUIPMENT PROTECTED: LRU FEED NETWORK DISCHARGE LOCATION: RFH
CASE ANALYSIS
External fire X N/A
Liquid thermal expansion X Covered by closed outlet.
Closed outlet X 3200-XZV-70111 fails closed and LRU feed streams can
pressurise the system.
Valve inadvertently open or X Covered by 3200-PSV-70112A/B.
Overfilling X N/A
Tube rupture X N/A

exchanger
Loss of heat X N/A
Loss of steam X N/A
Vacuum X N/A

Internal explosion
Backflow X N/A
Other X

Yes No Comments
VITAL X
TIED OR FREE X 3200-XZV-70111 can be lock open during PSV maintenance.
61070F CN 3200-PSV 70112 A/B 0

UNIT 350 KTA LLDPE
PLANT
PSV ITEM: 3200-PSV-70112 A/B SET PRESSURE: 4.4 bar(g)

CASE ANALYSIS
External fire X 3200-V-711 at grade.
Closed outlet X N/A
Valve inadvertently open or X Several sources at vessel inlet have higher design pressure
than the system.
Accidental mixing X Potential water ingress if LRU on recycle and there is a tube
rupture.
Overfilling X Possibility to be overfilled by 3200-P-684A/B,
3200-P-671A/B, 3200-P-675A/B, 3200-P-105A/B,
3200-P-618 A/B or 3200-P-455 A/B.
Tube rupture X N/A

exchanger
Loss of heat X N/A
Loss of steam X N/A
Vacuum X N/A
Chemical reaction X See accidental mixing above.

Internal explosion
Backflow X Backflow from 3200-S-408 via recycle line.
Other X HP/LP interface: gas break through from 3200-V-675.

Yes No Comments
VITAL X
TIED OR FREE X
61070F CN 3200-PSV 70116 0

UNIT 350 KTA LLDPE
PLANT

EQUIPMENT PROTECTED: 3200-V-711 DISCHARGE LOCATION: 3200-V-711
CASE ANALYSIS
External fire X N/A
Closed outlet X N/A

Overfilling X N/A
Tube rupture X N/A

exchanger
Loss of heat X N/A
Loss of steam X N/A
Vacuum X N/A

Internal explosion
Backflow X TEAL injection pump 3200-P-455A/B (Pdes = 50.0 bar(g))
can pressurize the system. Backflow from LRU column
bottom is also to be considered.
Other X N/A

Yes No Comments
VITAL X
TIED OR FREE X
61070F CN 3200-PSV 70121 0

UNIT 350 KTA LLDPE
PLANT

EQUIPMENT PROTECTED: 3200-P-711 DISCHARGE LOCATION: 3200-P-711 SUCTION
CASE ANALYSIS
External fire X Not applicable
Liquid thermal expansion X Not applicable
Closed outlet X Discharge valve manually closed.
Valve inadvertently open or X Not applicable

Accidental mixing X Not applicable
Overfilling X Not applicable
Flow through vent valve X Not applicable.
Reflux failure X Not applicable.
Blocked-in heat on X Not applicable.
Non-condensable built-up X Not applicable.

exchanger
Loss of steam X Not applicable.
Loss of electricity X Not applicable.
Vacuum X Not applicable.
Chemical reaction X Not applicable

Internal explosion
Backflow X Not applicable
Other

Yes No Comments
TIED OR FREE X LRU used for Ziegler operation only.
61070F CN 3200-PSV 70402 0

UNIT 350 KTA LLDPE
PLANT

CASE ANALYSIS


exchanger

Internal explosion
Other

Yes No Comments
61070F CN 3200-PSV 70404 0

UNIT 350 KTA LLDPE
PLANT

CASE ANALYSIS
Closed outlet X Not applicable
Valve inadvertently open or X Valve 3200-PV-70401 fully open. MN design pressure (10.5
bar(g)) is higher than 3200-V-713 design pressure.
Overfilling X In case of 3200-P-713 failure or XZV-70401 fails closed, LRU

column design pressure is equal to 3200-V-714 design
pressure. No overpressure risk.

exchanger
Chemical reaction X Not applicable.

Internal explosion
Backflow X Not applicable.
Other X HP/LP interface: gas breakthrough from 3200-S-409 (PU) via

2 NRVs.

Yes No Comments
TIED OR FREE X LRU used for Ziegler grades only.
61070F CN 3200-PSV 70412 0

UNIT 350 KTA LLDPE
PLANT

CASE ANALYSIS


exchanger

Internal explosion
Other

Yes No Comments
61070F CN 3200-PSV 70414 0

UNIT 350 KTA LLDPE
PLANT

CASE ANALYSIS
Closed outlet X Not applicable
Valve inadvertently open or X Valve PV-70411 fully open. MN design pressure (10.5 bar(g))
is higher than 3200-V-714 design pressure.
Overfilling X In case of 3200-P-714 failure or XZV-70411 fails closed, LRU

column design pressure is equal to 3200-V-714 design
pressure. No overpressure risk.

exchanger
Chemical reaction X Not applicable.

Internal explosion
Backflow X Not applicable.
Other X Not applicable.

Yes No Comments
TIED OR FREE X LRU used for Ziegler grades only.
61070F CN 3200-PSV 80801 A/B 0

PROJECT ________
LOCATION
PSV SCENARIO SHEET 1/1
JOHOR – MALAYSIA
UNIT 350 Kta LLDPE
PSV ITEM : 3200-PSV-80801 A/B SET PRESSURE : By extruder Vendor
EQUIPMENT PROTECTED : 3200-M-844 DISCHARGE LOCATION : Return line to
3200-T-848
CASE ANALYSIS
External fire X Exterior fire case in the extruder area which may lead to
a gas expansion but not a release case for PSV. Pelletizer
water circuit is open at suction and at discharge (3200-D-847
and 3200-M-844)
Liquid thermal expansion X Same as external fire
Closed outlet X Pelletizer chamber blocked
Valve inadvertently open or X Live steam valve and water make-up in 3200-T-848 which is
open to air. Pelletizer water flowrate 3200-FV-80801 is
control valve failure upstream PSV. If 3200-TV-80801 blocked closed, refer to
loss of cooling case.
Accidental mixing X Live steam in 3200-T-848 which is open to air.
Overfilling X Water make-up in 3200-T-848 which is open to air.
Tube rupture X Plate exchanger 3200-E-844 A/B Joint rupture – CW

pressure = Pelletizer water circuit open at discharge point.

exchanger
Loss of heat X N/A
Loss of cooling X 3200-TV-80801 blocked closed – Hot pelletizer water

(5.5 bar(g) Tvap = 166°C). Not a PSV release case.
Loss of steam X Not a PSV release case.
Loss of instrument air X Pelletizer water by-pass to 3200-T-848.
Loss of electricity X Pelletizer water by-pass to 3200-T-848.
Vacuum X N/A

Internal explosion
Backflow X N/A

Yes No Comments
VITAL X
TIED OR FREE X Extruder shall not be in operation during PSV maintenance –

Production storage in purge column (4 h) during PSV
maintenance or replacement.

V4-CH05 Relief Devices Scenario Sheets All

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PETRONAS RAPID Project Nov 2012

RELIEF DEVICES SCENARIO SHEETS

300 61070F-CN-3200-PSE-30069/ 30169

600 61070F-CN-3200-PSV-60002 / 60003

600 61070F-CN-3200-PSV-60009 / 60032

CLIENT PETRONAS RAPID PAGE

PSV ITEM: 3200-PSV-10002 SET PRESSURE: 3.5 bar(g)

Liquid thermal expansion X N/A

Closed outlet X N/A

Flow through vent valve X N/A

Reflux failure X N/A

Blocked-in heat on X N/A

Tube rupture X N/A

Non-condensable built-up X N/A

Abnormal reboiler heat input X N/A

Abnormal vaporization in heat X N/A

Loss of cooling X N/A

Loss of steam X N/A

Loss of instrument air X N/A

Loss of electricity X N/A

Chemical reaction X N/A

Other X None identified.

SAFETY RELATED DEVICES:

CLIENT PETRONAS RAPID PAGE

PSV ITEM : 3200-PSV-10082 / 10083 SET PRESSURE : 4.4 bar(g)

Liquid thermal expansion X No liquid.

Closed outlet X Include in valve inadvertently open.

Flow through vent valve X N/A

Reflux failure X N/A

Blocked-in heat on X N/A

Tube rupture X N/A

Non-condensable built-up X N/A

Abnormal reboiler heat input X N/A

Abnormal vaporization in heat X N/A

Loss of cooling X N/A

Loss of steam X N/A

Loss of instrument air X No pressure rise identified.

Loss of electricity X No pressure rise identified.

Chemical reaction X N/A

SAFETY RELATED DEVICES: 3200-PV-10081

AVAILABILITY FOR PSV MAINTENANCE :

CLIENT PETRONAS RAPID PAGE

PSV ITEM : 3200-PSV-10086 / 10087 SET PRESSURE : 2.8 bar(g)

Liquid thermal expansion X No liquid.

Closed outlet X Include in valve inadvertently open.

Flow through vent valve X N/A

Reflux failure X N/A

Blocked-in heat on X N/A

Tube rupture X N/A

Non-condensable built-up X N/A

Abnormal reboiler heat input X N/A

Abnormal vaporization in heat X N/A

Loss of cooling X N/A

Loss of steam X N/A

Loss of instrument air X No pressure rise identified.

Loss of electricity X No pressure rise identified.

Chemical reaction X N/A

SAFETY RELATED DEVICES: 3200-PV-10085

AVAILABILITY FOR PSV MAINTENANCE :

CLIENT PETRONAS RAPID PAGE

PSV ITEM : 3200-PSV-10088 / 10089 SET PRESSURE : 0.1 bar(g)

Liquid thermal expansion X No liquid.

Closed outlet X Include in valve inadvertently open.

Flow through vent valve X N/A

Reflux failure X N/A

Blocked-in heat on X N/A