P RefStd - 4043 - 004 - v091130 - EN - LOPA

Short Name: OMV Petrom
4043_004_v091130 Refining Standard

(Recommended)
Sub-Document
Description:
Appendix D: Worked examples of typical risk
solutions for OMV Refining
User Instruction & Disclaimer

The examples given here are risk evaluation of typical systems of refinery process plants. They intend to
provide guidance on the practical use of LOPA. They may serve as support for actual, practical situations.
However, they shall not be understood as a standard solution. They do no replace evaluation and analysis
of the real situation and do not state minimum or maximum requirements for risk reduction. Unseen take
over of the assessment as part or as a whole is not allowed and does not ensure that the risk target is
achieved for the real situation.
Table: List of Examples
Description Comment
Pressurized tank - Overfilling protection Overfilling protection by a combination of a SIL2 high level
cut off and SIL1 high pressure cut off
(see also Refining Standard 2301 - Tank Equipment)
Stabilizing Column - Overpressure protection High pressure protection with safety valve and additional
pressures cut-off (not SIL rated)
Knock-out drum at piston compressor Protection of a piston compressor against liquid entry; shut
off compressor at high level in the knock-out drum
LPG transfer pipe - High pressure protection Protection of transfer pipe against overpressure of transfer
pump by high pressure cut-off
P RefStd_4043_004_v091130_EN_LOPA.doc
Appendix D: Worked examples of typical risk solutions Page Valid as of: 111110
for OMV Refining 1 of 9 Version: v091130
OMV Petrom Refining &Petrochemicals – all rights reserved
1. Pressurized Tank - Overfilling protection
System description:
A spherical tank T-01 with large volume is used for storage/buffering of LPG. The maximum service
operating pressure of the tank is 6 bar(g), the tank is equipped with a level measurement device LI-02 which
incorporates a High-Level-AlarmLI/AH-02 at a set-point of 80% via the DCS (this is also the maximum
allowed level in the tank). The overpressure protection of the tank is given by a safety valve SV-03, which
opens at a set-pressure of 8 bar(g) to the atmosphere. Additionally, the tank is equipped with a pressure
measurement device PI-04 which incorporates a High-Pressure-Alarm PI/AH-04 via the DCS at a set-point
of 6 bar(g).
Sketch Process Flow Diagram
SV-03
to atmosphere
LHHCO LI-AH
05 02
PHHCO PI-AH
06 04
PES
T-01
filling discharge
LOPA Assessment:
2. Stabilizing Column - Overpressure protection
System description:
A stabilizing column (D-01) is designed for a may operating pressure of 15bar which is also the set-pressure
of the safety valve (SV-02) at the top of the column opening to flare. The pressure is controlled by the flow of
top product from the reflux vessel (PC-03). The reboiler is operated with steam. If the pressure increases up
to 14bar a 2oo3 high pressure cut-off (PHHCO-04) which closes a shut-off valve in the steam pipe to the
reboiler.

SV-02 A/B to flare
2oo3
XV-04
TI-AL/AH PHHCO PHHCO PHHCO

09 04.1 04.2 04.3
MP-steam
Reflux
PC-AH
PI
03
08
G-06 A/B
PV-03
F-07
D-01
E-05
reactor product
C5/C6 fraction
FV-09
LOPA Assessment:
3. Knock-out drum at piston compressor
System description:
Upstream of a piston compressor C-01 a knock-out drum V-02 is installed to separate any liquid from the
gas flow and prevent liquid entry to the compressor. Liquid entry to the compressor may cause severe
damage to the machine and probably damage to the compressor casing and piping. This may result into
release of hydrocarbons,
The separation is controlled by a level controller LC-03 which opens a valve at the bottom of the knock-out
drum. At the level gauge of the LC-03 an additional level measurement LI-04 is installed which alarms high
level in the drum. Independently of these two measurements a high-level switch LHHCO-05 is installed
which stops the compressor at level high-high and closes the valve in the gas inlet to the drum.

to flare
SV-06
to compressor C-01
stop C-01
LHHCO LT
05 05
gas LT LI-AH
(with liquid) 04 04
V-02
LT LC
LV-05 03 03
to slop
LV-03
LOPA Assessment:
4. LPG transfer pipe - High pressure protection
System description:
From storage T-01 LPG is pumped by G-02A/B to a process unit. The operating pressure inside T-01 ranges
from 8bar to 12bar. For constant supply pressure to the process unit the pressure in the supply pipe is
controlled at 35bar by PC-03 which controls the frequency (SC-02A/B) of the pumps G-02A/B. The shut-off
head of the pumps is 35bar. The design pressure of the transfer pipe is maximum 40bar.
At malfunction of the pressure controller PC-03 the pumps may operate at maximum speed which will
increase the pressure in the transfer pipe up to shut off head plus suction pressure of the pumps (pressure
in T-01). In order to protect the transfer pipe a high pressure cut-off PHHCO-04 is installed which stops the
pumps.
T-01
SC PHHCO
02A 04
PC
G-02A 03
to process unit
G-02B
SC
02B
LOPA Assessment:
Note: the PHHCO-04 is no sufficient safeguard for other overpressure scenarios like thermal expansion.

P RefStd - 4043 - 004 - v091130 - EN - LOPA

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P RefStd - 4043 - 004 - v091130 - EN - LOPA

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Short Name: OMV Petrom

4043_004_v091130 Refining Standard

User Instruction & Disclaimer

Table: List of Examples

Sketch Process Flow Diagram

Sketch Process Flow Diagram

TI-AL/AH PHHCO PHHCO PHHCO

Sketch Process Flow Diagram

Sketch Process Flow Diagram

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