Académique Documents
Professionnel Documents
Culture Documents
Identification Code
3443-SZ-RT-101
Plant: 320KT/Y HDPE Client _ ?a*el! Location: MÜNCHSMÜNSTER
Polyoleflns Sheet 1/94 Issue 04
ATTACHMENT 2
This document is Tecnimont's property and cannot be used by others for any purpose without prior written consent
1
Package List
-Extrusion
PROJECT: HDPE
3
DOCUMENTS STUDIED P&I Diagrams Layout drawings
Technical specsOTHER DETAILS GENERAL REMARK
1)Freezing: verify that all the tubing for instrumentation containing hydrocarbon or substances that
may be condensate/solidify are also adequately and fully traced according to the contract.
2)Spectacle blind: all spectacle blinds and manual valves upstream and/or downstream PSV shall
be tagged, recorded in a log and a special procedure is to be provided in the Operating Manual,
3)HAZOP has been performed assuming that all PSVs have been designed taking into account the
external fire condition (where applicable).
PRIMARY KEYWORDS
PRESSURE TEMPERATURE FLOW LEVEL COMPOSITION
AGITATION
2M5101 CONCENTR
ROTATIO
ATION
N
SECONDARY KEYWORDS
MOREREVERSE
NO OTHERTHAN
LESS
CORROSION MAINTENANCE
AS WELL AS PART OF
5
TABLE NO: 01 DOCUMENT REF: 519 REVISION: 3 DOCUMENT TITLE: 3PK5103 VACUUM
SYSTEM PACKAGE
The floors of extrusion building are provided with a number of hose station connected to a central
vacuum system: once the operator connects the portable hose, operating a local push button will start
the vacuum blower C5105.
The pellets and/or powder entrained is retained in the bag filter F5104, provided with automatic
cleaning system and a rotary cell discharging to a portable container.
The purpose of the system is to remove any spills of polymer in the Extrusion building.
Table 1 refers to the hose piping/filter/blower ensemble. Table 2 refers to the rotary cell & container
only.
1 ASSIGNED TO:
ACTION VENDOR / TCM
NO:
FLOW LESS 1)Electric motor Automatic floor 1)3EA 51901. No action required,
OR ZERO failure. cleaning existing safeguards
impossible: considered
operators have to adequate.
2)Filters plugged. 2)3PDAH 51912.
perform cleaning
operations
manually.
3)Line plugged. Operational issue.
FLOW No significant
MORE consequences
identified.
7
TABLE NO: 01 (continued) DOCUMENT REF: 519
ITEM: 3C5105; 3F5104; 3F5105; 3RF5105
DEVIATIO CAUSE CONSEQUENCE SAFEGUARDS ACTION
N
LEVEL 1)3RF5105 failure. Filter not working 3LSH51901. HAZOP team
MORE IN properly. recommends to
3F5104 provide batchwise
3F5104 emptying
2)Start sequence
instead of continuos
failure.
operation, as
indicated in the
3)Manual slide P&ID.
valve at 3F5104 Provide in the
bottom left Operating Manual
inadvertently close. detailed instruction
for emptying the
system.
2 ASSIGNED TO:
further discussed
with
ACTION
NO: NOTE: VENDOR / TCM
To be package vendor
TABLE NO: 02 DOCUMENT REF: 519 REVISION: 3 DOCUMENT TITLE: VACUUM SYSTEM
NOTE: To
be
TABLE NO: 03 DOCUMENT REF: 521A REVISION: 3
DOCUMENT TITLE: HDPE PELLETIZING ADDITIVE FEEDING I
ITEM: 2RF5202; 2SF5201A/B; 2F5251; 2W5201; 2Z5201A/B; 2SF5206; 2F5201 HDPE Plant:
Pelletizing & additive feeding I.
The HDPE plant is fitted with 5 metering stations for solid additives, each provided with 100 %
spare: the stations are similar to each other, although it is recommended to use the same additive
in the same station. All streams are conveyed to the feeder 2SF5206 and then the mixture is then
sent to extrusion through the rotaiy feeder 2RF5202.
Solid additives come in 1 m3 big-bags, which are lifted to the discharge feeder, each provided
with scale: a metering system conveys either of the two big bags in a scale to a screw conveyor,
discharging to 2SF5206: a continuos Nitrogen feed is injected in 2SF5206 and S201A to E shafts,
to avoid powder release in the ambient. Nitrogen is then removed by the system via local bag
filters, each vented locally to atmosphere in hoods connected to a blower continuously running, to
avoid Nitrogen buildup in the work environment.
Table 4 refers to the screw feeder 2SF5206, supplying all additives to HDPE extrusion.
9
M.WILMANOWICZ; S.SCHIFANO; S.BONALDI; P.PEREGO; S.GADOMSKI; G.MILLIGAN
CAUSE
DEVIATION CONSEQUENCE
SAFEGUARDS ACTIO
N
FLOW
LESS
TO
2SF5206
TABLE NO: 03 (continued) DOCUMENT REF: 521A
ITEM: 2RF5202; 2SF5201A/B; 2F5251; 2W5201; 2Z5201A/B; 2SF5206; 2F5201
DEVIATION CAUSE CONSEQUENCE SAFEGUARDS ACTION
3)Operator has to
switch containers
manually. This
information is
included in the
Operating Manual.
This table refers to the screw feeder 2SF5206, supplying all additives to HDPE extrusion.
FLOW 1)Empty bag. Off-spec product. The package comes No action required,
LESS Operational issue. with its own DCS existing safeguards
TO system, which has considered
2SF5206 2)Mechanical been declared to adequate.
failure of provide some sort of
2SF5202A/B. alarm in case of
abnormal delivery
rate.
3)
Plugging/bridging
of additives adding
upstream
2SF5202A/B.
4)Mechanical
failure of 2W5202.
TABLE NO: 04 (continued) DOCUMENT REF: 521A
ITEM: 2SF5202A/B; 2F5252; 2W5202; 2Z5202A/B; 2SF5206; 2RF5202; 2F5201
DEVIATION CAUSE CONSEQUENCE SAFEGUARDS ACTION
FLOW Control system not Off-spec product. The package comes No action required,
MORE TO working properly. Operational issue. with its own DCS existing safeguards
11
2SF5206 system, which has considered
been declared by adequate.
Vendor to provide
some sort of alarm
in case of abnormal
delivery rate.
TABLE NO: 05 DOCUMENT REF: 521B REVISION: 3 DOCUMENT TITLE: HDPE
PELLETIZING ADDITIVE FEEDING II
ITEM: 2SF5203A/B; 2F5253; 2W5203; 2Z5203A/B; 2SF5206; 2RF5202; 2F5201 HDPE Plant:
TABLE NO:
Pelletizing & 06 DOCUMENT
additive REF: 521B REVISION: 3 DOCUMENT TITLE: HDPE
feeding II.
PELLETIZING ADDITIVE FEEDING II
See previous
ITEM: table for 2F5254;
2SF5204A/B; system description.
2W5204; 2Z5204A/B; 2SF5206; 2RF5202; 2F5201 HDPE Plant:
Pelletizing & additive feeding II (continued).
3)Operator has to
switch containers
manually. This
information is
included in the
Operating Manual.
TABLE NO: 07 DOCUMENT REF: 521C REVISION: 3 DOCUMENT TITLE: HDPE
PELLETIZING ADDITIVE FEEDING III
ITEM: 2SF5205A/B; 2F5255; 2W5205; 2Z5205A/B; 2SF5206; 2RF5202; 2F5201 HDPE Plant:
Pelletizing & additive feeding EL
FLOW 1)Empty bag Off-spec product. The package comes No action required,
LESS Operational issue. with a DCS system, existing safeguards
TO which has been considered
2SF5206 2)Mechanical declared by Vendor adequate.
failure of to provide some sort
2SF5205A/B. of alarm in case of
abnormal delivery
rate.
3)
Plugging/bridging of
additive upstream
2SF5205A/B.
4)Mechanical
failure of 2W5205.
FLOW Control system not Off-spec product. The package comes No action required,
MORE TO working properly. Operational issue. with its own DCS existing safeguards
2SF5206 system, which has considered
been declared by adequate.
Vendor to provide
some sort of alarm
in case of abnormal
delivery rate.
3)Operator has to
switch containers
13 manually. This
information is
included in the
Operating Manual.
TABLE NO: 08 DOCUMENT REF: 521A REVISION: 3 DOCUMENT TITLE: HDPE
PELLETIZING ADDITIVE FEEDING I
The 5 metering stations convey the appropriate quantities of additives to a common screw conveyor
(2SF5206) feeding in turn the mixing screw 2M5101 (see P&ID 51 IB).
The conveyor shaft is continuously purged with low-pressure Nitrogen, to avoid powder release to
the work environment: the powder entrained retained in the bag filter 2F5201, provided with
automatic cleaning system, while the Nitrogen is released
REMARK
This P&ID does not follow the numbering sequence as the equipment represented provide common
service to all the five additive feeding stations of P&ID's 521 A, 52 IB and 521C.
The mixture of polymer and additives coming from the feeder 2W5201 (see P&ID 511 A) is
homogenized in the mixing screw supplying the extruder (see P&ID 514).
A continuous Nitrogen feed is injected in the shaft seals: Nitrogen is dedusted in the bag filter
2F5201 and discharged to a safe location outdoors via the fan 2C5102 that keeps the screw under
slow
TABLE Nitrogen
NO: 10pressure through
(continued) a pressure controller
DOCUMENT REF: 51 IBvalve, with2D5102;
ITEM: the purpose to avoid
2M5101; Oxygen
2F5101
entering the extruder that could possibly spoil the final product.
The intermediate pellet bin 2D5102 is provided to recycle off spec polymer.
DEVIATION CAUSE CONSEQUENCE SAFEGUARDS ACTION
TEAM
FLOW MEMBERS: G.GIOACCHINI;
Nitrogen purge AirM.RIGOLIO;
entering the T.SCHERR;
1+2) M.BUCZEK;No action required,
M.WILMANOWICZ;
LESS S.SCHIFANO;system:
flow stops. S.BONALDI; P.PEREGO; G.MILLIGANexisting safeguards
DEVIATION
OF CAUSE CONSEQUENCE 2PAL51103 SAFEGUARDS low ACTION
considered
pressure alarm.
NITROGEN adequate.
PRESSURE 1)Nitrogen purge 1)Off-spec
Air enteringproduct
the 1+2) No action required,
TO 2M5101
LESS IN flow stops. Operational
system: issue. existing safeguards
2FAL51106,
2PAL51103 low
2M5I01 considered
2FAL51107,
pressure alarm.
adequate.
2)2PV51103 fails 2)Possible
1)Off-spec product. 2FAL51108,
open or instrument explosion
Operational hazard
issue.in 2FAL51109 low
2FAL51106,
loop failure. filter 2F5101. flow alarms on
2FAL51107,
Safety issue. DCS.
2)Possible 2FAL51108,
explosion hazard in 2FAL51109 low
filter 2F5101. 2)
flowThe
alarmssystem
on is
Safety issue. depressurized
DCS. but
there is still Nitrogen
excess, because of
2) The system is
the high flow
depressurized but
coming from feeding
there is still
line 16"-2- PE016.
Nitrogen excess,
LEVEL No more pellets Off-spec pellets to 2LI51103. because of the high No action required,
LESS IN arriving from the 2M5101. flow coming from existing safeguards
2D5102 BIN feed lines. Operational issue. feeding line 16"-2- considered
PE016. adequate.
See previous table for process description. This table refers to: -bag filter 2F5102 -Nitrogen fan
2C5102.
FLOW LESS 1)Pump failure. Operational issue. Spare pump No action required,
OR ZERO available. existing safeguards
IN considered
P810A/B adequate.
2)Line plugged. EA8408.
Operator has to
switch manually
containers. This
information is
included in the
,•rt
Operating Manual.
REMARK
P&ID diagram of hot oil unit is not clear.
BOP will require Vendor to provide an updated P&ID (with a clear explanation of the symbols)
together with the Operating Manual.
Project team will then perform a Safety Analysis on the updated documents.
During the Safety Analysis it will be decided whether or not to perform a full HAZOP for this
system.
17
DOCUMENT TITLE: EXTRUDER INTERCONNECTION
ITEM: 2EX5101
HDPE Plant: Extrusion system interconnections P&ID
After reviewing the P&ID, the team has concluded that no HAZOP is needed.
TEAM MEMBERS: G.GIOACCHINI; M.RIGOLIO; T.SCHERR; M.BUCZEK;
M.WILMANOWICZ; L.SCHOONACKER; S.BONALDI; P.PEREGO; S.GADOMSKI;
G.MILLIGAN
19
TABLE NO: 17 DOCUMENT REF: 511A REVISION: 3 DOCUMENT TITLE: HDPE
PELLETIZING POWDER BIN AND POWDER DOSING SCALE
ITEM: 2D5101; 2RF5101
HDPE Plant: Powder bin and dosing scale
This P&ID refers to the intermediate storage of HDPE powder before additive mixing and injection
in the Extruder. The bin is provided with a bag filter, vented to fan 2C2402 A/B/C (see P&ID 241).
The powder is fed to the scale by means of a rotary feeder (2RF5101): from the meter the powder is
then sent to the extruder 2M5101 (see P&ID 51 IB).
2PDAHH51101
across the filter.
2PAH51105 on the
vessel top.
3)2RF5101 stops.
2EA51101 motor
failure alarm
activating interlock
4)Flow into vessel 2IS51101.
greater than
capacity for
outflow.
LEVEL LESS 1)Level switch No polymer supply Interlock 2IS51101. No action required,
IN 2D5101 malfunction. to the extruder. existing safeguards
Operational issue. considered
adequate.
2)Weight transmitter 2LALL51102
malfunction. activating interlock
2IS51101.
3)Bottom gate valve
sticking open. 2WAL51101
excess weight
4)No powder alarm.
supplied from
2PK2401 pneumatic
haulage.
FLOW 2FIC51116 control Powder rate sent to The system No action required,
MORE loop failure. the mixer higher downstream is existing safeguards
than expected. designed to handle considered
Operational issue the maximum adequate.
21
capacity.
FLOW LESS Rotary feeder No powder fed to 2FIC51116. No action required,
OR ZERO 2RF5101 down. the extruder. existing safeguards
Operational issue. considered
adequate.
Bottom slide valve
left inadvertently
close.
TABLE NO: 18 DOCUMENT REF: 242 REVISION: 3 DOCUMENT TITLE: HDPE POWDER
STORAGE I
ITEM: 2D2401A/B; 2RF2401A/B; 2RF2402A/B HDPE Plant: Polymer powder storage.
2PDAH24201/2
across the filter(s).
2PAH24203/4 on
silo(s) top.