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SPEEDBIRD HDPE PLANT SAFETY REPORT

ATTACHMENT 3 IDENTIFICATION CODE

SIL CLASSIFICATION NPP PROJECT 3443-SZ-RT-101 Att.3


Location MUNCHSMUNSTER
Plants HDPE 320 KT/Y Spedbird Project Sheet 2 of 71 Issue 04
GERMANY

SIL CLASSIFICATION SHEET <04>

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

Zone THS conditioning and metering Unit 1100


P&ID No. 111A Interlock desc. Pag: 6 of 79
Initiator Tag 2PAHH11102/03 High pressure in 2D1101A (1oo2) (2PAHH11107/08 for 2S11104)
Logic Solver Tag 2S11102 High pressure in 2D1101A (2S11104 High pressure in 2D1101B
Final Element Tag Permissive to open 2HV11102 (Permissive to open 2HV11103 for 2S11104)

Design Intent
To prevent pressurization of 2Z1101A and consequent damage of catalyst drum (2Z1101B for 2S11104)

Hazardous Scenario (Demand Scenario)


Two different human error opening valve in line to 2T2201 and opening 2HV11104A (2HV11104B for 2S11104)

Consequence Scenario
LOC of catalyst drum because PSV is not designed for this case

Frequency of Unwanted Occurrence (W) W1


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

Consequence Parameter for Personnel (C) C2


Comment:
C2 is selected for safety, for economical point of view minor consequence, C1 is selected, minor consequence in term of environment impact.

Exposure Parameter (F) F2


Comment:
Frequent to permanent exposure in the hazardous zone

Avoidance Parameter (P) P2


Comment:
Almost impossible

SIL for Personnel Protection 1

Loss SIL --

Environmental SIL -
Availability of Other Safety Related System
SPEEDBIRD HDPE PLANT SAFETY REPORT
ATTACHMENT 3 IDENTIFICATION CODE

SIL CLASSIFICATION NPP PROJECT 3443-SZ-RT-101 Att.3


Location MUNCHSMUNSTER
Plants HDPE 320 KT/Y Spedbird Project Sheet 3 of 71 Issue 04
GERMANY

SIL CLASSIFICATION SHEET

Function No. 1100-2LAHH11101-2I11101-2HV11108

Zone THS conditioning and metering Unit 1100


P&ID No. 111A Interlock desc. Pag: 6 of 79
Initiator Tag 2LAHH11101 High level in 2D1102A
Logic Solver Tag 2I11101 Level on 2D1102A
Final Element Tag Closes 2HV11108 distillated hexane

Design Intent
To prevent overfilling of catalyst suspension vessel 2D1102A

Hazardous Scenario (Demand Scenario)


Possible malfunction of FIC11105 or FV11105 blocked open or possible human error setting mass flow meter

Consequence Scenario
The overfilling gives higher pressure (less than the set point of PSV) the system react managing the pressure by PV11119A (sending hexane and catalyst to
2T2201).

Frequency of Unwanted Occurrence (W) W2


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

Consequence Parameter for Personnel (C) C1


Comment:
No safety consequence, in terms of economical loss minor consequence, C1 is selected.

Exposure Parameter (F) N/A


Comment:
not applicable

Avoidance Parameter (P) N/A


Comment:
not applicable

SIL for Personnel Protection nc

Loss SIL --

Environmental SIL nc

Availability of Other Safety Related System


SPEEDBIRD HDPE PLANT SAFETY REPORT
ATTACHMENT 3 IDENTIFICATION CODE

SIL CLASSIFICATION NPP PROJECT 3443-SZ-RT-101 Att.3


Location MUNCHSMUNSTER
Plants HDPE 320 KT/Y Spedbird Project Sheet 4 of 71 Issue 04
GERMANY

SIL CLASSIFICATION SHEET

Function No. 1100-2LAHH11104-2S11105-2XV11103/4

Zone Activator metering Unit 1100


P&ID No. 111B Interlock desc. Pag: 6 of 79
Initiator Tag 2LAHH11104 High level in 2D1103
Logic Solver Tag 2S11105 2D1103 level
Final Element Tag Closes 2XV11103/4 Distilled hexane

Design Intent
To prevent overfilling of the vessel and consequent TEAL 10% to other unit

Hazardous Scenario (Demand Scenario)


Possible malfunction of LI11103 or LV11103 blocked open, higher pressure in 2D4103

Consequence Scenario
TEAL 10% in hexane to 2D3402 and by manual operation to 2D3303

Frequency of Unwanted Occurrence (W) W1


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

Consequence Parameter for Personnel (C) C1


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

Exposure Parameter (F) N/A


Comment:
not applicable

Avoidance Parameter (P) N/A


Comment:
not applicable

SIL for Personnel Protection nc

Loss SIL --

Environmental SIL nc
Availability of Other Safety Related System
SPEEDBIRD HDPE PLANT SAFETY REPORT
ATTACHMENT 3 IDENTIFICATION CODE

SIL CLASSIFICATION NPP PROJECT 3443-SZ-RT-101 Att.3


Location MUNCHSMUNSTER
Plants HDPE 320 KT/Y Spedbird Project Sheet 5 of 71 Issue 04
GERMANY

SIL CLASSIFICATION SHEET

Function No. 1200-2PAHH12101\03B-2S12101-2HV12104

Zone Polymerization reactor I Unit 1200


P&ID No. 121A Interlock desc. Pag: 10 of 79
Initiator Tag 2PAHH12101\03B Very high pressure in 2R1201
Logic Solver Tag 2S12101 2R1201 Emergency
Final Element Tag 2HV12104 monomer inlet to reactor

Design Intent
To prevent very high pressure in the reactor

Hazardous Scenario (Demand Scenario)


Possible malfunction of FIC12104 or FV12104 blocked open

Consequence Scenario
Discharge of large quantity of ethylene and other monomer to flare.

Frequency of Unwanted Occurrence (W) W1


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

Consequence Parameter for Personnel (C) C1


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

Exposure Parameter (F) N/A


Comment:
not applicable

Avoidance Parameter (P) N/A


Comment:
not applicable

SIL for Personnel Protection nc

Loss SIL --

Environmental SIL ---


Availability of Other Safety Related System
SPEEDBIRD HDPE PLANT SAFETY REPORT
ATTACHMENT 3 IDENTIFICATION CODE

SIL CLASSIFICATION NPP PROJECT 3443-SZ-RT-101 Att.3


Location MUNCHSMUNSTER
Plants HDPE 320 KT/Y Spedbird Project Sheet 6 of 71 Issue 04
GERMANY

SIL CLASSIFICATION SHEET <04>

Function No. 1200-2TAHH12101D-2S12101-2HV12104

Zone Polymerization reactor I Unit 1200


P&ID No. 121A Interlock desc. Pag: 10 of 79
Initiator Tag 2TAHH12101D Very high T in 2R1201; (2PAHH12101\03B Very high P in 2R1201 (1oo2)) (1oo2)
Logic Solver Tag 2S12101 2R1201 Emergency
Final Element Tag 2HV12104 closed monomer feed to reactor

Design Intent
To preventy very high temperature and pressure in the reactor

Hazardous Scenario (Demand Scenario)


Cooling water failure due to pump failure or malfunction of TIC on the reactor (power failure for the three reactors deviation)

Consequence Scenario
Possible Loss of containment and damage of the reactor. PSV12101 is not designed for this case.

Frequency of Unwanted Occurrence (W) W2


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

Consequence Parameter for Personnel (C) C3


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

Exposure Parameter (F) F2


Comment:
Frequent to permanent exposure in the hazardous zone

Avoidance Parameter (P) P1


Comment:
Possible under certain conditions

SIL for Personnel Protection 1

Loss SIL 22

Environmental SIL -
Availability of Other Safety Related System
SPEEDBIRD HDPE PLANT SAFETY REPORT
ATTACHMENT 3 IDENTIFICATION CODE

SIL CLASSIFICATION NPP PROJECT 3443-SZ-RT-101 Att.3


Location MUNCHSMUNSTER
Plants HDPE 320 KT/Y Spedbird Project Sheet 7 of 71 Issue 04
GERMANY

SIL CLASSIFICATION SHEET

Function No. 1200-2LAHH12106-2S12101-2FV12105/06/12/13/20

Zone Polymerization reactor I Unit 1200


P&ID No. 121A Interlock desc. Pag: 10 of 79
Initiator Tag 2LAHH12106 Very high level in 2R1201, 2PAHH12101\03B Very high pressure in 2R1201
Logic Solver Tag 2S12101 2R1201 Emergency
Final Element Tag Close mother liquor line and Hexane line 2FV12112, 2FV12113, 2FV12105, 2FV12106, 2FV12120

Design Intent
To prevent overfilling in 2R1201 and consequent higher pressure

Hazardous Scenario (Demand Scenario)


LIC12101 failure or LV12101A\B blocked closed

Consequence Scenario
Possible increase of pressure up to set point of PSV of reactor (18barg designed for this case) consequent discharge of fresh hexane to Blow down.

Frequency of Unwanted Occurrence (W) W2


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

Consequence Parameter for Personnel (C) C1


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

Exposure Parameter (F) N/A


Comment:
not applicable

Avoidance Parameter (P) N/A


Comment:
not applicable

SIL for Personnel Protection nc

Loss SIL --

Environmental SIL nc
Availability of Other Safety Related System
SPEEDBIRD HDPE PLANT SAFETY REPORT
ATTACHMENT 3 IDENTIFICATION CODE

SIL CLASSIFICATION NPP PROJECT 3443-SZ-RT-101 Att.3


Location MUNCHSMUNSTER
Plants HDPE 320 KT/Y Spedbird Project Sheet 8 of 71 Issue 04
GERMANY

SIL CLASSIFICATION SHEET

Function No. 1200-2A1201-2S12101-2HV12104

Zone Polymerization reactor I Unit 1200


P&ID No. 121A Interlock desc. Pag: 10 of 79
Initiator Tag 2A1201 stop of agitator
Logic Solver Tag 2S12101 2R1201 Emergency
Final Element Tag Closed 2HV12104 monomer inlet to 2R1201

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

Hazardous Scenario (Demand Scenario)


Failure of agitator

Consequence Scenario
Undesired agglomeration of polymer and production of chunks.

Frequency of Unwanted Occurrence (W) W2


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

Consequence Parameter for Personnel (C) C1


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

Exposure Parameter (F) N/A


Comment:
not applicable

Avoidance Parameter (P) N/A


Comment:
not applicable

SIL for Personnel Protection nc

Loss SIL --

Environmental SIL nc
Availability of Other Safety Related System
SPEEDBIRD HDPE PLANT SAFETY REPORT
ATTACHMENT 3 IDENTIFICATION CODE

SIL CLASSIFICATION NPP PROJECT 3443-SZ-RT-101 Att.3


Location MUNCHSMUNSTER
Plants HDPE 320 KT/Y Spedbird Project Sheet 9 of 71 Issue 04
GERMANY

SIL CLASSIFICATION SHEET

Function No. 1200-2PDALL12116-2S12101-2HV12104

Zone Polymerization reactor I Unit 1200


P&ID No. 121A Interlock desc. Pag: 10 of 79
Initiator Tag 2PDALL12116 Low differential pressure ethylene/2R1201
Logic Solver Tag 2S12101 2R1201 Emergency
Final Element Tag Shuts 2HV12104 monomer inlet to 2R1201

Design Intent
To prevent back flow to ethylene line

Hazardous Scenario (Demand Scenario)


No ethylene at battery limit

Consequence Scenario
Back flow in the ethylene line could give plugging of the ethylene line

Frequency of Unwanted Occurrence (W) W1


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

Consequence Parameter for Personnel (C) C1


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

Exposure Parameter (F) N/A


Comment:
not applicable

Avoidance Parameter (P) N/A


Comment:
not applicable

SIL for Personnel Protection nc

Loss SIL --

Environmental SIL nc
Availability of Other Safety Related System
SPEEDBIRD HDPE PLANT SAFETY REPORT
ATTACHMENT 3 IDENTIFICATION CODE

SIL CLASSIFICATION NPP PROJECT 3443-SZ-RT-101 Att.3


Location MUNCHSMUNSTER
Plants HDPE 320 KT/Y Spedbird Project Sheet 10 of 71 Issue 04
GERMANY

SIL CLASSIFICATION SHEET

Function No. 1200-2PALL11136-2S12101-2HV12104

Zone Polymerization reactor I Unit 1200


P&ID No. 121A Interlock desc. Pag: 10 of 79
Initiator Tag 2PALL11136
Logic Solver Tag 2S12101 2R1201 Emergency
Final Element Tag 2HV12104 closed

Design Intent
To prevent high concentration of polymer in the slurry

Hazardous Scenario (Demand Scenario)


Failure of pump 2P1104A\B or possible human error on manual valve on the delivery of the pump

Consequence Scenario
Possible obstruction in the slurry line, possible agglomeration in the reactor and production of chunks

Frequency of Unwanted Occurrence (W) W1


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

Consequence Parameter for Personnel (C) C1


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

Exposure Parameter (F) N/A


Comment:
not applicable

Avoidance Parameter (P) N/A


Comment:
not applicable

SIL for Personnel Protection nc

Loss SIL --

Environmental SIL nc
Availability of Other Safety Related System
SPEEDBIRD HDPE PLANT SAFETY REPORT
ATTACHMENT 3 IDENTIFICATION CODE

SIL CLASSIFICATION NPP PROJECT 3443-SZ-RT-101 Att.3


Location MUNCHSMUNSTER
Plants HDPE 320 KT/Y Spedbird Project Sheet 11 of 71 Issue 04
GERMANY

SIL CLASSIFICATION SHEET

Function No. 1200-2LAHH12103-2I12102-2LV12101A\B

Zone Flash and cooling slurry Reactor I Unit 1200


P&ID No. 121B Interlock desc. Pag: 11 of 79
Initiator Tag 2LAHH12103 Very high level in 2D1201
Logic Solver Tag 2I12102 2D1201 high level
Final Element Tag Shuts 2LV12101A\B 2R1202 discharge valves

Design Intent
To prevent overfilling of the flash vessel

Hazardous Scenario (Demand Scenario)


Possible malfunction of LIC12104 or LV12104 blocked closed or 2P1204 shut off

Consequence Scenario
Overfilling of the flash vessel and consequent slurry up to liquid separator of 2PK3201 and to liquid ring compressor PK3401

Frequency of Unwanted Occurrence (W) W2


Comment:
A slight probability that the unwanted occurrence will come to pass and a few unwanted occurrences are likely.

Consequence Parameter for Personnel (C) C1


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

Exposure Parameter (F) N/A


Comment:
not applicable

Avoidance Parameter (P) N/A


Comment:
not applicable

SIL for Personnel Protection nc

Loss SIL --

Environmental SIL nc
Availability of Other Safety Related System
SPEEDBIRD HDPE PLANT SAFETY REPORT
ATTACHMENT 3 IDENTIFICATION CODE

SIL CLASSIFICATION NPP PROJECT 3443-SZ-RT-101 Att.3


Location MUNCHSMUNSTER
Plants HDPE 320 KT/Y Spedbird Project Sheet 12 of 71 Issue 04
GERMANY

SIL CLASSIFICATION SHEET

Function No. 1200-2PAHH12106-2I12103-2XV12106

Zone Flash and cooling slurry Reactor I Unit 1200


P&ID No. 121B Interlock desc. Pag: 11 of 79
Initiator Tag 2PAHH12106 Very high pressure in 2E1204 tube side
Logic Solver Tag 2I12103 2E1204 tube rupture
Final Element Tag Closes 2XV12106

Design Intent
To prevent monomer blow by to the CWR system

Hazardous Scenario (Demand Scenario)


Catastrophic failure of cooler tubes

Consequence Scenario
Monomer release to atmosphere through the vent of expansion drum.

Frequency of Unwanted Occurrence (W) W1


Comment:
A very slight probability that the unwanted occurrence will came to pass. The parameter is selected according to experience, taking into account the the SIS
is able to detect the hazardous situation only in case of catastrophic tube failure.

Consequence Parameter for Personnel (C) C1


Comment:
No significant effects on Environment. Fire and\or flammable vapor cloud may occur at the release point. C1 for economical loss for repairing on site
instrumentation is expected.

Exposure Parameter (F) F2


Comment:
Frequent to permanent exposure in the hazardous zone.

Avoidance Parameter (P) P1


Comment:
Possible under certain conditions

SIL for Personnel Protection -

Loss SIL --

Environmental SIL nc
Availability of Other Safety Related System
SPEEDBIRD HDPE PLANT SAFETY REPORT
ATTACHMENT 3 IDENTIFICATION CODE
SIL CLASSIFICATION NPP PROJECT 3443-SZ-RT-101 Att.3
Location MUNCHSMUNSTER
Plants HDPE 320 KT/Y Spedbird Project Sheet 13 of 71 Issue 04
GERMANY

SIL CLASSIFICATION SHEET

Function No. 1200-ESA12104-2I12105-2LV12103

Zone Polymerization reactor I Unit 1200


P&ID No. 121A Interlock desc. Pag: 11 of 79
Initiator Tag ESA12104 stop of pump 2P1204
Logic Solver Tag 2I12105 stop of pump
Final Element Tag Shuts 2LV12103 2D1201 discharge valve

Design Intent
To prevent back flow from second reactor

Hazardous Scenario (Demand Scenario)


Possible failure of the pump 2P1204

Consequence Scenario
Back flow of slurry from reactor 2R1202, major damage of the pump 2P1204

Frequency of Unwanted Occurrence (W) W2


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

Consequence Parameter for Personnel (C) C1


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

Exposure Parameter (F) N/A


Comment:
not applicable

Avoidance Parameter (P) N/A


Comment:
not applicable

SIL for Personnel Protection nc

Loss SIL --

Environmental SIL nc
Availability of Other Safety Related System
SPEEDBIRD HDPE PLANT SAFETY REPORT
ATTACHMENT 3 IDENTIFICATION CODE
SIL CLASSIFICATION NPP PROJECT 3443-SZ-RT-101 Att.3
Location MUNCHSMUNSTER
Plants HDPE 320 KT/Y Spedbird Project Sheet 14 of 71 Issue 04
GERMANY

SIL CLASSIFICATION SHEET

Function No. 1200-2LALL12102-2I12106-2P1201A/B

Zone Polymerization reactor I Unit 1200


P&ID No. 121A Interlock desc. Pag: 12 of 79
Initiator Tag 2LALL12102 Very low level in 2R1201
Logic Solver Tag 2I12106 2R1201 very low level
Final Element Tag Stops 2P1201A/B

Design Intent
Pump protection

Hazardous Scenario (Demand Scenario)


Possible LV12101A or LV12101B completely open

Consequence Scenario
Possible damage of the pump

Frequency of Unwanted Occurrence (W) W2


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

Consequence Parameter for Personnel (C) C1


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

Exposure Parameter (F) N/A


Comment:
not applicable

Avoidance Parameter (P) N/A


Comment:
not applicable

SIL for Personnel Protection nc

Loss SIL --

Environmental SIL nc
Availability of Other Safety Related System
SPEEDBIRD HDPE PLANT SAFETY REPORT
ATTACHMENT 3 IDENTIFICATION CODE
SIL CLASSIFICATION NPP PROJECT
3443-SZ-RT-101 Att.3
Location MUNCHSMUNSTER
Plants HDPE 320 KT/Y Spedbird Project Sheet 15 of 71 Issue 04
GERMANY

SIL CLASSIFICATION SHEET

Function No. 1200-2LALL12103-2I12108-2P1204

Zone Flash and cooling slurry Reactor I Unit 1200


P&ID No. 121B Interlock desc. Pag: 12 of 79
Initiator Tag 2LALL12103 Very low level in 2D1201
Logic Solver Tag 2I12108 2D1201 very low level
Final Element Tag 2P1204 stop

Design Intent
Pump protection

Hazardous Scenario (Demand Scenario)


LV12103 completely open or LIC12103 malfunction to signal

Consequence Scenario
Possible damage of the pump

Frequency of Unwanted Occurrence (W) W2


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

Consequence Parameter for Personnel (C) C1


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

Exposure Parameter (F) N/A


Comment:
not applicable

Avoidance Parameter (P) N/A


Comment:
not applicable

SIL for Personnel Protection nc

Loss SIL --
--
Environmental SIL nc
Availability of Other Safety Related System
SPEEDBIRD HDPE PLANT SAFETY REPORT
ATTACHMENT 3 IDENTIFICATION CODE
SIL CLASSIFICATION NPP PROJECT 3443-SZ-RT-101 Att.3
Location MUNCHSMUNSTER
Plants HDPE 320 KT/Y Spedbird Project Sheet 16 of 71 Issue 04
GERMANY

SIL CLASSIFICATION SHEET

Function No. 1200-2PAHH12201-2S12201-2HV12204

Zone Polymerization reactor II Unit 1200


P&ID No. 122A Interlock desc. Pag: 14 of 79
Initiator Tag 2PAHH12201-3 Very high pressure in 2R1202
Logic Solver Tag 2S12201 2R1202 Emergency
Final Element Tag 2HV12204 monomer inlet to reactor

Design Intent
To prevent very high pressure in the reactor

Hazardous Scenario (Demand Scenario)


Possible malfunction of FIC12203 or FV12203 blocked open

Consequence Scenario
Discharge of large quantity of ethylene and other monomer to flare

Frequency of Unwanted Occurrence (W) W1


Comment:
A very slight probability that the unwanted scenario will come to pass, due to malfunction of PCV at battery limit and FV12204 completely open

Consequence Parameter for Personnel (C) C1


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

Exposure Parameter (F) N/A


Comment:
not applicable

Avoidance Parameter (P) N/A


Comment:
not applicable

SIL for Personnel Protection nc

Loss SIL --

Environmental SIL -
Availability of Other Safety Related System
SPEEDBIRD HDPE PLANT SAFETY REPORT
ATTACHMENT 3 IDENTIFICATION CODE
SIL CLASSIFICATION NPP PROJECT
3443-SZ-RT-101 Att.3
Location MUNCHSMUNSTER
Plants HDPE 320 KT/Y Spedbird Project Sheet 17 of 71 Issue 04
GERMANY

SIL CLASSIFICATION SHEET <04>

Function No. 1200-2TAHH12201D-2S12201-2HV12204

Zone Polymerization reactor II Unit 1200


P&ID No. 122A Interlock desc. Pag: 14 of 79
Initiator Tag 2TAHH12201D Very high T in 2R1202; (2PAHH12201-3 Very high P in 2R1202 (1oo2)) (1oo2)
Logic Solver Tag 2S12201 2R1202 Emergency
Final Element Tag 2HV12204 closed monomer feed to reactor

Design Intent
To preventy very high temperature and pressure in the reactor

Hazardous Scenario (Demand Scenario)


Cooling water failure due to pump failure or malfunction of TIC on the reactor (power failure for the three reactors deviation)

Consequence Scenario
Possible Loss of containment and damage of the reactor. PSV12201 is not designed for this case.

Frequency of Unwanted Occurrence (W) W2


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

Consequence Parameter for Personnel (C) C3


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

Exposure Parameter (F) F2


Comment:
Frequent to permanent exposure in the hazardous zone

Avoidance Parameter (P) P1


Comment:
Possible under certain condition

SIL for Personnel Protection 1

Loss SIL 22

Environmental SIL -
Availability of Other Safety Related System
SPEEDBIRD HDPE PLANT SAFETY REPORT
ATTACHMENT 3 IDENTIFICATION CODE
SIL CLASSIFICATION NPP PROJECT
3443-SZ-RT-101 Att.3
Location MUNCHSMUNSTER
Plants HDPE 320 KT/Y Spedbird Project Sheet 18 of 71 Issue 04
GERMANY

SIL CLASSIFICATION SHEET

Function No. 1200-2LAHH12201-2S12201-2FV12205/06/12/13/20

Zone Polymerization reactor II Unit 1200


P&ID No. 122A Interlock desc. Pag: 14 of 79
Initiator Tag 2LAHH12201 Very high level in 2R1202
Logic Solver Tag 2S12201 2R1202 Emergency
Final Element Tag Close mother liquor line and Hexane line 2FV12212, 2FV12213, 2FV12205, 2FV12206, 2FV12220

Design Intent
To prevent overfilling in 2R1201 and consequent higher pressure

Hazardous Scenario (Demand Scenario)


LIC12201 failure or LV12201A\B blocked closed

Consequence Scenario
Possible increase of pressure up to set point of PSV of reactor (18barg designed for this case) consequent discharge of fresh hexane to Blow down.

Frequency of Unwanted Occurrence (W) W2


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

Consequence Parameter for Personnel (C) C1


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

Exposure Parameter (F) N/A


Comment:
not applicable

Avoidance Parameter (P) N/A


Comment:
not applicable

SIL for Personnel Protection nc

Loss SIL --

Environmental SIL nc
Availability of Other Safety Related System
SPEEDBIRD HDPE PLANT SAFETY REPORT
ATTACHMENT 3 IDENTIFICATION CODE
SIL CLASSIFICATION NPP PROJECT
3443-SZ-RT-101 Att.3
Location MUNCHSMUNSTER
Plants HDPE 320 KT/Y Spedbird Project Sheet 19 of 71 Issue 04
GERMANY

SIL CLASSIFICATION SHEET

Function No. 1200-2A1202-2S12201-2HV12204

Zone Polymerization reactor I Unit 1200


P&ID No. 121A Interlock desc. Pag: 14 of 79
Initiator Tag 2A1202 stop of agitator
Logic Solver Tag 2S12201 2R1202 Emergency
Final Element Tag Closed 2HV12204 monomer inlet to 2R1202

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

Hazardous Scenario (Demand Scenario)


Failure of agitator

Consequence Scenario
Undesired agglomeration of polymer and production of chunks.

Frequency of Unwanted Occurrence (W) W2


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

Consequence Parameter for Personnel (C) C1


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

Exposure Parameter (F) N/A


Comment:
not applicable

Avoidance Parameter (P) N/A


Comment:
not applicable

SIL for Personnel Protection nc

Loss SIL --

Environmental SIL nc
Availability of Other Safety Related System
SPEEDBIRD HDPE PLANT SAFETY REPORT
ATTACHMENT 3 IDENTIFICATION CODE
SIL CLASSIFICATION NPP PROJECT
3443-SZ-RT-101 Att.3
Location MUNCHSMUNSTER
Plants HDPE 320 KT/Y Spedbird Project Sheet 20 of 71 Issue 04
GERMANY

SIL CLASSIFICATION SHEET

Function No. 1200-2PDALL12216-2S12201-2HV12104

Zone Polymerization reactor II Unit 1200


P&ID No. 122A Interlock desc. Pag: 14 of 79
Initiator Tag 2PDALL12216 Low differential pressure ethylene/2R1202
Logic Solver Tag 2S12201 2R1202 Emergency
Final Element Tag Shuts 2HV12204 monomer inlet to 2R1202

Design Intent
To prevent back flow to ethylene line

Hazardous Scenario (Demand Scenario)


No ethylene at battery limit

Consequence Scenario
Back flow in the ethylene line could give plugging of the ethylene line

Frequency of Unwanted Occurrence (W) W1


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

Consequence Parameter for Personnel (C) C1


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

Exposure Parameter (F) N/A


Comment:
not applicable

Avoidance Parameter (P) N/A


Comment:
not applicable

SIL for Personnel Protection nc

Loss SIL --

Environmental SIL nc
Availability of Other Safety Related System
SPEEDBIRD HDPE PLANT SAFETY REPORT
ATTACHMENT 3 IDENTIFICATION CODE
SIL CLASSIFICATION NPP PROJECT 3443-SZ-RT-101 Att.3
Location MUNCHSMUNSTER
Plants HDPE 320 KT/Y Spedbird Project Sheet 21 of 71 Issue 04
GERMANY

SIL CLASSIFICATION SHEET

Function No. 1200-2PALL11136-2S12201-2HV12204

Zone Polymerization reactor II Unit 1200


P&ID No. 122A Interlock desc. Pag: 14 of 79
Initiator Tag 2PALL11136
Logic Solver Tag 2S12201 2R1202 Emergency
Final Element Tag 2HV12204 closed

Design Intent
To prevent high concentration of polymer in the slurry

Hazardous Scenario (Demand Scenario)


Failure of pump 2P1104A\B or possible human error on manual valve on the delivery of the pump

Consequence Scenario
Possible obstruction in the slurry line, possible agglomeration in the reactor and production of chunks

Frequency of Unwanted Occurrence (W) W1


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

Consequence Parameter for Personnel (C) C1


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

Exposure Parameter (F) N/A


Comment:
not applicable

Avoidance Parameter (P) N/A


Comment:
not applicable

SIL for Personnel Protection nc

Loss SIL --

Environmental SIL nc
Availability of Other Safety Related System
SPEEDBIRD HDPE PLANT SAFETY REPORT
ATTACHMENT 3 IDENTIFICATION CODE
SIL CLASSIFICATION NPP PROJECT
3443-SZ-RT-101 Att.3
Location MUNCHSMUNSTER
Plants HDPE 320 KT/Y Spedbird Project Sheet 22 of 71 Issue 04
GERMANY

SIL CLASSIFICATION SHEET

Function No. 1200-2LAHH12203-2I12202-2LV12201A\B

Zone Flash and cooling slurry Reactor II Unit 1200


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

Design Intent
To prevent overfilling of the flash vessel

Hazardous Scenario (Demand Scenario)


Possible malfunction of LIC12204 or LV12204 blocked closed or 2P1205 shut off

Consequence Scenario
Overfilling of the flash vessel and consequent slurry up to liquid separator of 2PK3201 and to liquid ring compressor PK3401

Frequency of Unwanted Occurrence (W) W2


Comment:
A slight probability that the unwanted occurrence will come to pass and a few unwanted occurrences are likely.

Consequence Parameter for Personnel (C) C1


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

Exposure Parameter (F) N/A


Comment:
not applicable

Avoidance Parameter (P) N/A


Comment:
not applicable

SIL for Personnel Protection nc

Loss SIL -

Environmental SIL nc
Availability of Other Safety Related System
SPEEDBIRD HDPE PLANT SAFETY REPORT
ATTACHMENT 3 IDENTIFICATION CODE
SIL CLASSIFICATION NPP PROJECT 3443-SZ-RT-101 Att.3
Location MUNCHSMUNSTER
Plants HDPE 320 KT/Y Spedbird Project Sheet 23 of 71 Issue 04
GERMANY

SIL CLASSIFICATION SHEET

Function No. 1200-2PAHH12206-2I12203-2XV12206

Zone Flash and cooling slurry Reactor II Unit 1200


P&ID No. 126 Interlock desc. Pag: 15 of 79
Initiator Tag 2PAHH12206 Very high pressure in 2E1206 tube side
Logic Solver Tag 2I12203 2E1206 tube rupture
Final Element Tag Closes 2XV12206

Design Intent
To prevent monomer blow by to the CWR system

Hazardous Scenario (Demand Scenario)


Catastrophic failure of cooler tubes

Consequence Scenario
Monomer release to atmosphere through the vent of expansion drum.

Frequency of Unwanted Occurrence (W) W1


Comment:
A very slight probability that the unwanted occurrence will came to pass. The parameter is selected according to experience, taking into account the the SIS
is able to detect the hazardous situation only in case of catastrophic tube failure.

Consequence Parameter for Personnel (C) C1


Comment:
No significative effects on Environment. Fire and\or flammable vapor cloud may occur at the release point. C1 for economical loss for repairing on site
instrumentation is expected.

Exposure Parameter (F) F2


Comment:
Frequent to permanent exposure in the hazardous zone.

Avoidance Parameter (P) P1


Comment:
Possible under certain conditions

SIL for Personnel Protection -

Loss SIL --

Environmental SIL nc
Availability of Other Safety Related System
SPEEDBIRD HDPE PLANT SAFETY REPORT
ATTACHMENT 3 IDENTIFICATION CODE
SIL CLASSIFICATION NPP PROJECT 3443-SZ-RT-101 Att.3
Location MUNCHSMUNSTER
Plants HDPE 320 KT/Y Spedbird Project Sheet 24 of 71 Issue 04
GERMANY

SIL CLASSIFICATION SHEET

Function No. 1200-2ESA12204-2I12205-2LV12203

Zone Polymerization reactor I Unit 1200


P&ID No. 121 Interlock desc. Pag: 15 of 79
Initiator Tag 2ESA12204 stop of pump 2P1205
Logic Solver Tag 2I12205 stop of pump
Final Element Tag 2LV12203 closed

Design Intent
To prevent back flow from second reactor

Hazardous Scenario (Demand Scenario)


Possible failure of the pump 2P1205

Consequence Scenario
Back flow of slurry from reactor 2R1202, major damage of the pump 2P1205

Frequency of Unwanted Occurrence (W) W2


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

Consequence Parameter for Personnel (C) C1


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

Exposure Parameter (F) N/A


Comment:
not applicable

Avoidance Parameter (P) N/A


Comment:
not applicable

SIL for Personnel Protection nc

Loss SIL --

Environmental SIL nc
Availability of Other Safety Related System
SPEEDBIRD HDPE PLANT SAFETY REPORT
ATTACHMENT 3 IDENTIFICATION CODE
SIL CLASSIFICATION NPP PROJECT
3443-SZ-RT-101 Att.3
Location MUNCHSMUNSTER
Plants HDPE 320 KT/Y Spedbird Project Sheet 25 of 71 Issue 04
GERMANY

SIL CLASSIFICATION SHEET

Function No. 1200-2LALL12202-2I12206-2P1202A/B

Zone Polymerization reactor II Unit 1200


P&ID No. 122 Interlock desc. Pag: 16 of 79
Initiator Tag 2LALL12202 Very low level in 2R1202
Logic Solver Tag 2I12206 2R1201 very low level
Final Element Tag Stops 2P1202A/B

Design Intent
Pump protection

Hazardous Scenario (Demand Scenario)


LV12201A or LV12201B completely open

Consequence Scenario
Possible damage of the pump

Frequency of Unwanted Occurrence (W) W2


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

Consequence Parameter for Personnel (C) C1


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

Exposure Parameter (F) N/A


Comment:
not applicable

Avoidance Parameter (P) N/A


Comment:
not applicable

SIL for Personnel Protection nc

Loss SIL --

Environmental SIL nc
Availability of Other Safety Related System
SPEEDBIRD HDPE PLANT SAFETY REPORT
ATTACHMENT 3 IDENTIFICATION CODE
SIL CLASSIFICATION NPP PROJECT
3443-SZ-RT-101 Att.3
Location MUNCHSMUNSTER
Plants HDPE 320 KT/Y Spedbird Project Sheet 26 of 71 Issue 04
GERMANY

SIL CLASSIFICATION SHEET

Function No. 1200-2LALL12203-2I12208-2P1205

Zone Flash and cooling slurry Reactor II Unit 1200


P&ID No. 126 Interlock desc. Pag: 16 of 79
Initiator Tag 2LALL12203 Very low level in 2D1202
Logic Solver Tag 2I12208 2D1202 very low level
Final Element Tag 2P1205 stop

Design Intent
Pump protection

Hazardous Scenario (Demand Scenario)


LV12203 completely open or LIC12203 malfunction to signal

Consequence Scenario
Possible damage of the pump

Frequency of Unwanted Occurrence (W) W2


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

Consequence Parameter for Personnel (C) C1


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

Exposure Parameter (F) N/A


Comment:
not applicable

Avoidance Parameter (P) N/A


Comment:
not applicable

SIL for Personnel Protection nc

Loss SIL --
--
Environmental SIL --
nc
Availability of Other Safety Related System
SPEEDBIRD HDPE PLANT SAFETY REPORT
ATTACHMENT 3 IDENTIFICATION CODE
SIL CLASSIFICATION NPP PROJECT
3443-SZ-RT-101 Att.3
Location MUNCHSMUNSTER
Plants HDPE 320 KT/Y Spedbird Project Sheet 27 of 71 Issue 04
GERMANY

SIL CLASSIFICATION SHEET

Function No. 1200-2PAHH12301/3B-2S12301-2HV12304

Zone Polymerization reactor III Unit 1200


P&ID No. 123 Interlock desc. Pag: 18 of 79
Initiator Tag 2PAHH12301/3B Very high pressure in 2R1203
Logic Solver Tag 2S12301 2R1203 Emergency
Final Element Tag 2HV12304 closed

Design Intent
To prevent very high pressure in the reactor

Hazardous Scenario (Demand Scenario)


Possible malfunction of FIC12303 or FV12303 blocked open

Consequence Scenario
Discharge of large quantity of ethylene and other monomer to flare

Frequency of Unwanted Occurrence (W) W1


Comment:
A very slight probability that the unwanted scenario will come to pass, due to malfunction of PCV at battery limit and FV12303 completely open

Consequence Parameter for Personnel (C) C1


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

Exposure Parameter (F) N/A


Comment:
not applicable

Avoidance Parameter (P) N/A


Comment:
not applicable

SIL for Personnel Protection nc

Loss SIL --

Environmental SIL -
Availability of Other Safety Related System
SPEEDBIRD HDPE PLANT SAFETY REPORT
ATTACHMENT 3 IDENTIFICATION CODE
SIL CLASSIFICATION NPP PROJECT
3443-SZ-RT-101 Att.3
Location MUNCHSMUNSTER
Plants HDPE 320 KT/Y Spedbird Project Sheet 28 of 71 Issue 04
GERMANY

SIL CLASSIFICATION SHEET <04>

Function No. 1200-2TAHH12301D-2S12301-2HV12304

Zone Polymerization reactor III Unit 1200


P&ID No. 123 Interlock desc. Pag: 18 of 79
Initiator Tag 2TAHH12301D Very high T in 2R1203; (2PAHH12301/03B Very high P in 2R1203 (1oo2)) (1oo2)
Logic Solver Tag 2S12301 2R1203 Emergency
Final Element Tag 2HV12304 closed monomer feed to reactor

Design Intent
To preventy very high temperature and pressure in the reactor

Hazardous Scenario (Demand Scenario)


Cooling water failure due to pump failure or malfunction of TIC on the reactor (power failure for the three reactors deviation)

Consequence Scenario
Possible Loss of containment and damage of the reactor. PSV12301 is not designed for this case.

Frequency of Unwanted Occurrence (W) W2


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

Consequence Parameter for Personnel (C) C3


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

Exposure Parameter (F) F2


Comment:
Frequent to permanent exposure in the hazardous zone

Avoidance Parameter (P) P1


Comment:
Possible under certain condition

SIL for Personnel Protection 1

Loss SIL 22

Environmental SIL -
Availability of Other Safety Related System
SPEEDBIRD HDPE PLANT SAFETY REPORT
ATTACHMENT 3 IDENTIFICATION CODE
SIL CLASSIFICATION NPP PROJECT
3443-SZ-RT-101 Att.3
Location MUNCHSMUNSTER
Plants HDPE 320 KT/Y Spedbird Project Sheet 29 of 71 Issue 04
GERMANY

SIL CLASSIFICATION SHEET

Function No. 1200-2LAHH12301-2S12301-2FV12312/13

Zone Polymerization reactor III Unit 1200


P&ID No. 123 Interlock desc. Pag: 18 of 79
Initiator Tag 2LAHH12301 Very high level in 2R1203
Logic Solver Tag 2S12301 2R1203 Emergency
Final Element Tag Close mother liquor line 2FV12312, 2FV12313

Design Intent
To prevent overfilling in 2R1201 and consequent higher pressure

Hazardous Scenario (Demand Scenario)


LIC12301 failure or LV12301A\B blocked closed

Consequence Scenario
Possible increase of pressure up to set point of PSV of reactor (18barg designed for this case) consequent discharge of fresh hexane to Blow down.

Frequency of Unwanted Occurrence (W) W2


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

Consequence Parameter for Personnel (C) C1


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

Exposure Parameter (F) N/A


Comment:
not applicable

Avoidance Parameter (P) N/A


Comment:
not applicable

SIL for Personnel Protection nc

Loss SIL --

Environmental SIL nc
Availability of Other Safety Related System
SPEEDBIRD HDPE PLANT SAFETY REPORT
ATTACHMENT 3 IDENTIFICATION CODE
SIL CLASSIFICATION NPP PROJECT
3443-SZ-RT-101 Att.3
Location MUNCHSMUNSTER
Plants HDPE 320 KT/Y Spedbird Project Sheet 30 of 71 Issue 04
GERMANY

SIL CLASSIFICATION SHEET

Function No. 1200-2A1203-2S12301-2HV12304

Zone Polymerization reactor III Unit 1200


P&ID No. 123 Interlock desc. Pag: 18 of 79
Initiator Tag 2A1203 stop of agitator
Logic Solver Tag 2S12301 2R1203 Emergency
Final Element Tag Closed 2HV12304 monomer inlet to 2R1203

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

Hazardous Scenario (Demand Scenario)


Failure of agitator

Consequence Scenario
Undesired agglomeration of polymer and production of chunks.

Frequency of Unwanted Occurrence (W) W2


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

Consequence Parameter for Personnel (C) C1


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

Exposure Parameter (F) N/A


Comment:
not applicable

Avoidance Parameter (P) N/A


Comment:
not applicable

SIL for Personnel Protection nc

Loss SIL --

Environmental SIL nc
Availability of Other Safety Related System
SPEEDBIRD HDPE PLANT SAFETY REPORT
ATTACHMENT 3 IDENTIFICATION CODE
SIL CLASSIFICATION NPP PROJECT
3443-SZ-RT-101 Att.3
Location MUNCHSMUNSTER
Plants HDPE 320 KT/Y Spedbird Project Sheet 31 of 71 Issue 04
GERMANY

SIL CLASSIFICATION SHEET

Function No. 1200-2PDALL12316-2S12301-2HV12304

Zone Polymerization reactor III Unit 1200


P&ID No. 123A Interlock desc. Pag: 18 of 79
Initiator Tag 2PDALL12316 Low differential pressure ethylene/2R1203
Logic Solver Tag 2S12301 2R1203 Emergency
Final Element Tag Shuts 2HV12304 monomer inlet to 2R1203

Design Intent
To prevent back flow to ethylene line

Hazardous Scenario (Demand Scenario)


No ethylene at battery limit

Consequence Scenario
Back flow in the ethylene line could give plugging of the ethylene line

Frequency of Unwanted Occurrence (W) W1


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

Consequence Parameter for Personnel (C) C1


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

Exposure Parameter (F) N/A


Comment:
not applicable

Avoidance Parameter (P) N/A


Comment:
not applicable

SIL for Personnel Protection nc

Loss SIL --

Environmental SIL nc
Availability of Other Safety Related System
SPEEDBIRD HDPE PLANT SAFETY REPORT
ATTACHMENT 3 IDENTIFICATION CODE
SIL CLASSIFICATION NPP PROJECT
3443-SZ-RT-101 Att.3
Location MUNCHSMUNSTER
Plants HDPE 320 KT/Y Spedbird Project Sheet 32 of 71 Issue 04
GERMANY

SIL CLASSIFICATION SHEET

Function No. 1200-2PALL11136-2S12101-2HV12304

Zone Polymerization reactor I Unit 1200


P&ID No. 121A Interlock desc. Pag: 18 of 79
Initiator Tag 2PALL11136
Logic Solver Tag 2S12101 2R1201 Emergency
Final Element Tag 2HV12304 closed

Design Intent
To prevent high concentration of polymer in the slurry

Hazardous Scenario (Demand Scenario)


Failure of pump 2P1104A\B or possible human error on manual valve on the delivery of the pump

Consequence Scenario
Possible obstruction in the slurry line, possible agglomeration in the reactor and production of chunks

Frequency of Unwanted Occurrence (W) W1


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

Consequence Parameter for Personnel (C) C1


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

Exposure Parameter (F) N/A


Comment:
not applicable

Avoidance Parameter (P) N/A


Comment:
not applicable

SIL for Personnel Protection nc

Loss SIL --

Environmental SIL nc
Availability of Other Safety Related System
SPEEDBIRD HDPE PLANT SAFETY REPORT
ATTACHMENT 3 IDENTIFICATION CODE

SIL CLASSIFICATION NPP PROJECT 3443-SZ-RT-101 Att.3


Location MUNCHSMUNSTER
Plants HDPE 320 KT/Y Spedbird Project Sheet 33 of 71 Issue 04
GERMANY

SIL CLASSIFICATION SHEET <04>

Function No. 1200-2PAHH12304-2S12302-2HV12310A\B,2LV12301A\B

Zone Flash and cooling slurry Reactor III Unit 1200


P&ID No. 127 Interlock desc. Pag: 19 of 79
Initiator Tag 2PAHH12304 Very high P in 2D1203, 2LAHH12304\07 very high level in flash vessel (1oo3)
Logic Solver Tag 2S12302 2D1203 high pressure
Final Element Tag Shuts 2LV12301A; (2LV12301B; 2HV12310B (1oo2)) (2oo2)

Design Intent
To prevent overpressure of equipment due to overfilling

Hazardous Scenario (Demand Scenario)


Possible malfunction of LIC12301

Consequence Scenario
Overfilling of flash vessel and consequent overpressure of the vessel (PSV is not designed for this case).

Frequency of Unwanted Occurrence (W) W2


Comment:
A slight probability that the unwanted occurrence will come to pass and a few unwanted occurrences are likely.

Consequence Parameter for Personnel (C) C3


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

Exposure Parameter (F) F2


Comment:
Frequent to permanent exposure in the hazardous zone

Avoidance Parameter (P) P1


Comment:
Possible under certain condition

SIL for Personnel Protection 1

Loss SIL 22

Environmental SIL -
Availability of Other Safety Related System
SPEEDBIRD HDPE PLANT SAFETY REPORT
ATTACHMENT 3 IDENTIFICATION CODE
SIL CLASSIFICATION NPP PROJECT
3443-SZ-RT-101 Att.3
Location MUNCHSMUNSTER
Plants HDPE 320 KT/Y Spedbird Project Sheet 34 of 71 Issue 04
GERMANY

SIL CLASSIFICATION SHEET

Function No. 1200-2LALL12302-2I12306-2P1203A/B

Zone Polymerization reactor III Unit 1200


P&ID No. 123 Interlock desc. Pag: 19 of 79
Initiator Tag 2LALL12302 Very low level in 2R1203
Logic Solver Tag 2I12306 2R1203 very low level
Final Element Tag Stops 2P1203A/B

Design Intent
Pump protection

Hazardous Scenario (Demand Scenario)


LV12301A or LV12301B completely open

Consequence Scenario
Possible damage of the pump

Frequency of Unwanted Occurrence (W) W2


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

Consequence Parameter for Personnel (C) C1


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

Exposure Parameter (F) N/A


Comment:
not applicable

Avoidance Parameter (P) N/A


Comment:
not applicable

SIL for Personnel Protection nc

Loss SIL --

Environmental SIL nc
Availability of Other Safety Related System
SPEEDBIRD HDPE PLANT SAFETY REPORT
ATTACHMENT 3 IDENTIFICATION CODE
SIL CLASSIFICATION NPP PROJECT 3443-SZ-RT-101 Att.3
Location MUNCHSMUNSTER
Plants HDPE 320 KT/Y Spedbird Project Sheet 35 of 71 Issue 04
GERMANY

SIL CLASSIFICATION SHEET

Function No. 1200-2LALL12303-2I12308-2P1301 A/B

Zone Flash and cooling slurry Reactor III Unit 1200


P&ID No. 127 Interlock desc. Pag: 19 of 79
Initiator Tag 2LALL12303 Very low level in 2D1203
Logic Solver Tag 2I12308 2D1203 very low level
Final Element Tag Stops 2P1301 A/B

Design Intent
Pump protection

Hazardous Scenario (Demand Scenario)


LV12303 completely open or LIC12303 malfunction to signal

Consequence Scenario
Possible damage of the pump

Frequency of Unwanted Occurrence (W) W2


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

Consequence Parameter for Personnel (C) C1


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

Exposure Parameter (F) N/A


Comment:
not applicable

Avoidance Parameter (P) N/A


Comment:
not applicable

SIL for Personnel Protection nc

Loss SIL --

Environmental SIL nc
Availability of Other Safety Related System
SPEEDBIRD HDPE PLANT SAFETY REPORT
ATTACHMENT 3 IDENTIFICATION CODE
SIL CLASSIFICATION NPP PROJECT
3443-SZ-RT-101 Att.3
Location MUNCHSMUNSTER
Plants HDPE 320 KT/Y Spedbird Project Sheet 36 of 71 Issue 04
GERMANY

SIL CLASSIFICATION SHEET <04>

Function No. 1300-2PAHH13101/02-2S13101-2LV12303

Zone Decanter feed vessel Unit 1300


P&ID No. 131 Interlock desc. Pag: 24 of 79
Initiator Tag 2PAHH13101/02 Very high pressure in 2D1301, 2LAHH13101A very high level in 2D1301 (1oo3)
Logic Solver Tag 2S13101 2D1301 High pressure \ high level
Final Element Tag 2LV12303; 2HV13102 (1oo2)

Design Intent
To prevent overpressure due to overfilling of the vessel

Hazardous Scenario (Demand Scenario)


Human error during the reactor bottom discharge to decanter feed vessel

Consequence Scenario
Overfilling of decanter feed vessel and consequent overpressure (PSV is not designed for this case).

Frequency of Unwanted Occurrence (W) W1


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

Consequence Parameter for Personnel (C) C3


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

Exposure Parameter (F) F2


Comment:
Frequent to permanent exposure in the hazardous zone

Avoidance Parameter (P) P1


Comment:
Possible under certain condition

SIL for Personnel Protection a (Note 1)

Loss SIL 11

Environmental SIL -
Availability of Other Safety Related System

Note 1: SIL 1 to be considered in SIL Verification in order to comply with AD MerkBlatt A6 Requirements
SPEEDBIRD HDPE PLANT SAFETY REPORT
ATTACHMENT 3 IDENTIFICATION CODE
SIL CLASSIFICATION NPP PROJECT
3443-SZ-RT-101 Att.3
Location MUNCHSMUNSTER
Plants HDPE 320 KT/Y Spedbird Project Sheet 37 of 71 Issue 04
GERMANY

SIL CLASSIFICATION SHEET <04>

Function No. 2100-2PAHH21201-2S21201-2HV21201 Applicable also to 2HV21202 and 2HV21203

Zone Mother liquor system Unit 2100


P&ID No. 212 Interlock desc. Pag: 33 of 79
Initiator Tag 2PAHH21201 Very high pressure in 2D2101
Logic Solver Tag 2S21201 2D2101 high pressure / high level
Final Element Tag 2HV21201 closed (same as 2HV21202 and 2HV21203)

Design Intent
To prevent very high pressure in centrifuges

Hazardous Scenario (Demand Scenario)


Possible malfunction of PIC32102 and failure of compressor 2PK3201 or External fire

Consequence Scenario
Possible damage to the centrifuges due to overpressure in the equipments

Frequency of Unwanted Occurrence (W) W2


Comment:
A slight probability that the unwanted occurrence will come to pass and a few unwanted occurrences are likely.

Consequence Parameter for Personnel (C) C3


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

Exposure Parameter (F) F2


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

Avoidance Parameter (P) P1


Comment:
Independent safeguards alarming about the scenario are present, gas and fire detection system can mitigate the consequences

SIL for Personnel Protection 2

Loss SIL aa

Environmental SIL nc
Availability of Other Safety Related System
SPEEDBIRD HDPE PLANT SAFETY REPORT
ATTACHMENT 3 IDENTIFICATION CODE
SIL CLASSIFICATION NPP PROJECT
3443-SZ-RT-101 Att.3
Location MUNCHSMUNSTER
Plants HDPE 320 KT/Y Spedbird Project Sheet 38 of 71 Issue 04
GERMANY

SIL CLASSIFICATION SHEET

Function No. 2100-2HZLH21201-2S21204-2HV21107 (applicable also for 2S2101B & C)

Zone Powder separation I Unit 2100


P&ID No. 211A Interlock desc. Pag: 33 of 79
Initiator Tag 2HZLH21201 limit switch
Logic Solver Tag 2S21204 2S2101A overfilling prevention
Final Element Tag Closes 2HV21107 or doesn't allow to open the valve

Design Intent
To prevent overpressure of centrifuges

Hazardous Scenario (Demand Scenario)


Human error closing liquid discharge line to mother liquor collecting vessel

Consequence Scenario
Possible damage to the centrifuges due to overpressure in the equipments

Frequency of Unwanted Occurrence (W) W1


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

Consequence Parameter for Personnel (C) C2


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

Exposure Parameter (F) N/A


Comment:
not applicable

Avoidance Parameter (P) N/A


Comment:
not applicable

SIL for Personnel Protection nc

Loss SIL aa

Environmental SIL nc
Availability of Other Safety Related System
SPEEDBIRD HDPE PLANT SAFETY REPORT
ATTACHMENT 3 IDENTIFICATION CODE
SIL CLASSIFICATION NPP PROJECT 3443-SZ-RT-101 Att.3
Location MUNCHSMUNSTER
Plants HDPE 320 KT/Y Spedbird Project Sheet 39 of 71 Issue 04
GERMANY

SIL CLASSIFICATION SHEET

Function No. 2200-2TAHH22102A-2I22102-TV22102/06 XV22106

Zone Powder drying I Unit 2200


P&ID No. 221 Interlock desc. Pag: 35 of 79
Initiator Tag 2TAHH22102A and 2TAHH22106A very high temperature 1st and 2nd stage of 2D2201
Logic Solver Tag 2I22102 very high temperature in 2D2201
Final Element Tag Cut LLP steam inlet in the dryer TV22102/06; XV22106

Design Intent
To prevent very high temperature of polymer in 2D2201

Hazardous Scenario (Demand Scenario)


TIC22102D malfunction to signal or LV22102D blocked open (1st stage) or TIC22103D malfunction to signal or LV22103D blocked open (2nd stage)

Consequence Scenario
Possible melting of polymer consequent possible obstruction and less efficiency of drying system.

Frequency of Unwanted Occurrence (W) W2


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

Consequence Parameter for Personnel (C) C1


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

Exposure Parameter (F) N/A


Comment:
not applicable

Avoidance Parameter (P) N/A


Comment:
not applicable

SIL for Personnel Protection nc

Loss SIL --

Environmental SIL nc
Availability of Other Safety Related System
SPEEDBIRD HDPE PLANT SAFETY REPORT
ATTACHMENT 3 IDENTIFICATION CODE
SIL CLASSIFICATION NPP PROJECT
3443-SZ-RT-101 Att.3
Location MUNCHSMUNSTER
Plants HDPE 320 KT/Y Spedbird Project Sheet 40 of 71 Issue 04
GERMANY

SIL CLASSIFICATION SHEET

Function No. 2200-ESA22103-IS22103-RF2204

Zone Pneumatic haulge to powder purification I and Unit 2200


P&ID No. II
223\224 Interlock desc. Pag:
Initiator Tag ESA22103 \ ESA22301\2 C2204 and C2203A\B stop
Logic Solver Tag IS22103 dryer discharge stop
Final Element Tag Stop RF2205 and RF2204

Design Intent
To prevent plugging of pneumatic transport system

Hazardous Scenario (Demand Scenario)


Possible failure of C2204 or C2203A\B

Consequence Scenario
In case of no stop of rotary feeder possible plugging in the pneumatic transport system.

Frequency of Unwanted Occurrence (W) W2


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

Consequence Parameter for Personnel (C) C1


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

Exposure Parameter (F) N/A


Comment:
not applicable

Avoidance Parameter (P) N/A


Comment:
not applicable

SIL for Personnel Protection nc

Loss SIL --

Environmental SIL nc
Availability of Other Safety Related System

INTERLOCK DELETED IN HDPE SPEEDBIRD PLANT


SPEEDBIRD HDPE PLANT SAFETY REPORT
ATTACHMENT 3 IDENTIFICATION CODE
SIL CLASSIFICATION NPP PROJECT
3443-SZ-RT-101 Att.3
Location MUNCHSMUNSTER
Plants HDPE 320 KT/Y Spedbird Project Sheet 41 of 71 Issue 04
GERMANY

SIL CLASSIFICATION SHEET

Function No. 2200-ESA22101/2-IS22202-TV22102/06 HV22106

Zone Powder drying I Unit 2200


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

Design Intent
To prevent very high temperature of polymer in 2D2201

Hazardous Scenario (Demand Scenario)


Failure of 2C2201 or 2C2202

Consequence Scenario
Possible melting of polymer consequent possible obstruction and less efficiency of drying system.

Frequency of Unwanted Occurrence (W) W2


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

Consequence Parameter for Personnel (C) C1


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

Exposure Parameter (F) N/A


Comment:
not applicable

Avoidance Parameter (P) N/A


Comment:
not applicable

SIL for Personnel Protection nc

Loss SIL --

Environmental SIL nc
Availability of Other Safety Related System

INTERLOCK DELETED IN HDPE SPEEDBIRD PLANT


SPEEDBIRD HDPE PLANT SAFETY REPORT
ATTACHMENT 3 IDENTIFICATION CODE
SIL CLASSIFICATION NPP PROJECT
3443-SZ-RT-101 Att.3
Location MUNCHSMUNSTER
Plants HDPE 320 KT/Y Spedbird Project Sheet 42 of 71 Issue 04
GERMANY

SIL CLASSIFICATION SHEET

Function No. 2200-2LALL22101-2I22204-2P2201A/B

Zone Powder drying II Unit 2200


P&ID No. 222 Interlock desc. Pag: 41 of 79
Initiator Tag 2LALL22101 Very low level in 2T2201
Logic Solver Tag 2I22204 Very low level in 2T2201
Final Element Tag Stop of 2P2201 A/B

Design Intent
Pump protection

Hazardous Scenario (Demand Scenario)


Possible malfunction of LIC 22201 or LV22201 completely open or no cold hexane to scrubbing tower.

Consequence Scenario
Possible damage of the pump 2P2201A

Frequency of Unwanted Occurrence (W) W2


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

Consequence Parameter for Personnel (C) C1


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

Exposure Parameter (F) N/A


Comment:
not applicable

Avoidance Parameter (P) N/A


Comment:
not applicable

SIL for Personnel Protection nc

Loss SIL --

Environmental SIL nc
Availability of Other Safety Related System
SPEEDBIRD HDPE PLANT SAFETY REPORT
ATTACHMENT 3 IDENTIFICATION CODE
SIL CLASSIFICATION NPP PROJECT
3443-SZ-RT-101 Att.3
Location MUNCHSMUNSTER
Plants HDPE 320 KT/Y Spedbird Project Sheet 43 of 71 Issue 04
GERMANY

SIL CLASSIFICATION SHEET

Function No. 2200-LAHH22202-2I22205-2LV22201

Zone Powder drying II Unit 2200


P&ID No. 222 Interlock desc. Pag: 41 of 79
Initiator Tag LAHH22202 Very high level in 2D2203
Logic Solver Tag 2I22205 very high level in 2D2203
Final Element Tag Close 2LV22201

Design Intent
To prevent the overfilling of hexane flash vessel

Hazardous Scenario (Demand Scenario)


LV22101 completely open or LV22203 completely closed.

Consequence Scenario
Overfilling of vessel and consequent "hot hexane" to 2T2201 no significant consequence

Frequency of Unwanted Occurrence (W) W2


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

Consequence Parameter for Personnel (C) C1


Comment:
No significant consequence.

Exposure Parameter (F) N/A


Comment:
not applicable

Avoidance Parameter (P) N/A


Comment:
not applicable

SIL for Personnel Protection nc

Loss SIL --

Environmental SIL nc
Availability of Other Safety Related System
SPEEDBIRD HDPE PLANT SAFETY REPORT
ATTACHMENT 3 IDENTIFICATION CODE
SIL CLASSIFICATION NPP PROJECT
3443-SZ-RT-101 Att.3
Location MUNCHSMUNSTER
Plants HDPE 320 KT/Y Spedbird Project Sheet 44 of 71 Issue 04
GERMANY

SIL CLASSIFICATION SHEET

Function No. 2200-LSAHH23103-IS23101-stop of RF2205

Zone Pneumatic haulage Unit 2200


P&ID No. 224 Interlock desc. Pag:
Initiator Tag LSAHH23103 Very high level in 2F2302
Logic Solver Tag IS23101 very high level in 2F2301
Final Element Tag Stop RF2205

Design Intent
To prevent the overfilling of 2F2302

Hazardous Scenario (Demand Scenario)


Possible failure of RF2301

Consequence Scenario
Overfilling of filter and consequent plugging

Frequency of Unwanted Occurrence (W) W2


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

Consequence Parameter for Personnel (C) C1


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

Exposure Parameter (F) N/A


Comment:
not applicable

Avoidance Parameter (P) N/A


Comment:
not applicable

SIL for Personnel Protection nc

Loss SIL --

Environmental SIL nc
Availability of Other Safety Related System

INTERLOCK DELETED IN HDPE SPEEDBIRD PLANT


SPEEDBIRD HDPE PLANT SAFETY REPORT
ATTACHMENT 3 IDENTIFICATION CODE
SIL CLASSIFICATION NPP PROJECT 3443-SZ-RT-101 Att.3
Location MUNCHSMUNSTER
Plants HDPE 320 KT/Y Spedbird Project Sheet 45 of 71 Issue 04
GERMANY

SIL CLASSIFICATION SHEET

Function No. 2200-LRCSAHH23101-IS23102-stop of RF2301

Zone Powder purification Unit 2300


P&ID No. 231 Interlock desc. Pag:
Initiator Tag LRSAHH23101 Very high level in 2D2301
Logic Solver Tag IS23102 very high level in 2D2301
Final Element Tag Stop RF2301

Design Intent
To prevent the overfilling of 2D2301

Hazardous Scenario (Demand Scenario)


Possible failure of RF2303

Consequence Scenario
Overfilling of filter and consequent plugging

Frequency of Unwanted Occurrence (W) W2


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

Consequence Parameter for Personnel (C) C1


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

Exposure Parameter (F) N/A


Comment:
not applicable

Avoidance Parameter (P) N/A


Comment:
not applicable

SIL for Personnel Protection nc

Loss SIL --

Environmental SIL nc
Availability of Other Safety Related System

INTERLOCK DELETED IN HDPE SPEEDBIRD PLANT


SPEEDBIRD HDPE PLANT SAFETY REPORT
ATTACHMENT 3 IDENTIFICATION CODE
SIL CLASSIFICATION NPP PROJECT
3443-SZ-RT-101 Att.3
Location MUNCHSMUNSTER
Plants HDPE 320 KT/Y Spedbird Project Sheet 46 of 71 Issue 04
GERMANY

SIL CLASSIFICATION SHEET

Function No. 2400-PALL24106-IS24106-stop C2401A\B

Zone Powder pneumatic II Unit 2400


P&ID No. 241 Interlock desc. Pag:
Initiator Tag PALL24106 very low pressure at C2401 A\B suction
Logic Solver Tag IS24106pneumatic transport PK2401 shut down
Final Element Tag Stops of blowers

Design Intent
To prevent air entry in the system

Hazardous Scenario (Demand Scenario)


Human error closing nitrogen make up in the system

Consequence Scenario
To be verified later with Vendor information

Frequency of Unwanted Occurrence (W) W2


Comment:

Consequence Parameter for Personnel (C) C1


Comment:

Exposure Parameter (F) N/A


Comment:

Avoidance Parameter (P) N/A


Comment:

SIL for Personnel Protection nc

Loss SIL --

Environmental SIL nc
Availability of Other Safety Related System

INTERLOCK DELETED IN HDPE SPEEDBIRD PLANT


SPEEDBIRD HDPE PLANT SAFETY REPORT
ATTACHMENT 3 IDENTIFICATION CODE
SIL CLASSIFICATION NPP PROJECT
3443-SZ-RT-101 Att.3
Location MUNCHSMUNSTER
Plants HDPE 320 KT/Y Spedbird Project Sheet 47 of 71 Issue 04
GERMANY

SIL CLASSIFICATION SHEET

Function No. 3100-2LAHH31102-2I31101-2XV31102A close 2XV31102B open

Zone Hexane distillation Unit 3100


P&ID No. 311A Interlock desc. Pag: 48 of 79
Initiator Tag 2LAHH31102 very high level in 2D3101
Logic Solver Tag 2I31101 D3101 very high level
Final Element Tag 2XV31102A close and 2XV31102B opens

Design Intent
To prevent overfilling of the vessel

Hazardous Scenario (Demand Scenario)


Possible no MP steam to 2E3102 or LIC31101 malfunction to signal

Consequence Scenario
Mother liquor with Waxes to 2T3101 and to 2E2201 and 2E2205

Frequency of Unwanted Occurrence (W) W2


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

Consequence Parameter for Personnel (C) C1


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

Exposure Parameter (F) N/A


Comment:
not applicable

Avoidance Parameter (P) N/A


Comment:
not applicable

SIL for Personnel Protection nc

Loss SIL --

Environmental SIL nc
Availability of Other Safety Related System
SPEEDBIRD HDPE PLANT SAFETY REPORT
ATTACHMENT 3 IDENTIFICATION CODE
SIL CLASSIFICATION NPP PROJECT
3443-SZ-RT-101 Att.3
Location MUNCHSMUNSTER
Plants HDPE 320 KT/Y Spedbird Project Sheet 48 of 71 Issue 04
GERMANY

SIL CLASSIFICATION SHEET

Function No. 3100-2PAHH31101-2I31103-2LV31101

Zone Hexane distillation Unit 3100


P&ID No. 311A Interlock desc. Pag: 48 of 79
Initiator Tag 2PAHH31101 very high pressure in D3101
Logic Solver Tag 2I31103 D3101 very high pressure
Final Element Tag 2LV31101 closes

Design Intent
To prevent very high pressure in 2D3101

Hazardous Scenario (Demand Scenario)


Possible LV31101 completely open or PIC31102 malfunction or PV31102A and B blocked closed

Consequence Scenario
Mother liquor with Waxes to 2T3101 and to 2E2201 and 2E2205

Frequency of Unwanted Occurrence (W) W2


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

Consequence Parameter for Personnel (C) C1


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

Exposure Parameter (F) N/A


Comment:
not applicable

Avoidance Parameter (P) N/A


Comment:
not applicable

SIL for Personnel Protection nc

Loss SIL --

Environmental SIL nc
Availability of Other Safety Related System
SPEEDBIRD HDPE PLANT SAFETY REPORT
ATTACHMENT 3 IDENTIFICATION CODE
SIL CLASSIFICATION NPP PROJECT
3443-SZ-RT-101 Att.3
Location MUNCHSMUNSTER
Plants HDPE 320 KT/Y Spedbird Project Sheet 49 of 71 Issue 04
GERMANY

SIL CLASSIFICATION SHEET

Function No. 3100-2LAHH31106-7-2I31102-2LV31103

Zone Hexane distillation Unit 3100


P&ID No. 311B Interlock desc. Pag: 48 of 79
Initiator Tag 2LAHH31106-7 very high level in T3101
Logic Solver Tag 2I31102 Very high level in 2T3101
Final Element Tag 2LV31103 closes

Design Intent
To prevent very high level in 2T3101

Hazardous Scenario (Demand Scenario)


Malfunction of LIC31103 or LV31103 blocked closed

Consequence Scenario
Possible less efficiency of the column

Frequency of Unwanted Occurrence (W) W2


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

Consequence Parameter for Personnel (C) C1


Comment:
No significant consequences.

Exposure Parameter (F) N/A


Comment:
not applicable

Avoidance Parameter (P) N/A


Comment:
not applicable

SIL for Personnel Protection nc

Loss SIL --

Environmental SIL nc
Availability of Other Safety Related System
SPEEDBIRD HDPE PLANT SAFETY REPORT
ATTACHMENT 3 IDENTIFICATION CODE
SIL CLASSIFICATION NPP PROJECT
3443-SZ-RT-101 Att.3
Location MUNCHSMUNSTER
Plants HDPE 320 KT/Y Spedbird Project Sheet 50 of 71 Issue 04
GERMANY

SIL CLASSIFICATION SHEET

Function No. 3100-2PAHH31103-2I31108-2LV31105

Zone Hexane distillation Unit 3100


P&ID No. 311B Interlock desc. Pag: 49 of 79
Initiator Tag 2PAHH31103 very high pressure in 2T3101
Logic Solver Tag 2I31108 Very high pressure in 2T3101
Final Element Tag 2LV31105 closes hexane vapor to 2E3104

Design Intent
To prevent very high pressure in 2T3101

Hazardous Scenario (Demand Scenario)


No cooling water to condenser

Consequence Scenario
Higher pressure than the operating, the maximum pressure achieved will be lower of the set point of the PSV (designed for fire)

Frequency of Unwanted Occurrence (W) W2


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

Consequence Parameter for Personnel (C) C1


Comment:
No significant consequences.

Exposure Parameter (F) N/A


Comment:
not applicable

Avoidance Parameter (P) N/A


Comment:
not applicable

SIL for Personnel Protection nc

Loss SIL --

Environmental SIL nc
Availability of Other Safety Related System
SPEEDBIRD HDPE PLANT SAFETY REPORT
ATTACHMENT 3 IDENTIFICATION CODE
SIL CLASSIFICATION NPP PROJECT 3443-SZ-RT-101 Att.3
Location MUNCHSMUNSTER
Plants HDPE 320 KT/Y Spedbird Project Sheet 51 of 71 Issue 04
GERMANY

SIL CLASSIFICATION SHEET <04>

Function No. 3100-2TAHH31201/02/03-2S31201-1FV31203 Applicable also to 2T3102B and 2T3202A/B

Zone Hexane purification Unit 3100


P&ID No. 312 Interlock desc. Pag: 51 of 79
Initiator Tag 2TAHH31201/02/03 very high temperature in 2T3102A (1oo3)
Logic Solver Tag 2S31201 Very high temperature in 2T3102A/B and 2T3202A/B
Final Element Tag 2FV31203 close; 2XV31201 close (1oo2)

Design Intent
To prevent very high temperature in 2T3102 A\B (2T3202A/B) during the regeneration phase

Hazardous Scenario (Demand Scenario)


Possible different ratio of oxygen and nitrogen due to malfunction of FIC31203 or FV31203 completely open or FV31202 closed

Consequence Scenario
Possible temperature in 2T3102 A\B (2T3202A/B) higher than design temperature and possible damage of KC pearl

Frequency of Unwanted Occurrence (W) W2


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

Consequence Parameter for Personnel (C) C2


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

Exposure Parameter (F) F1


Comment:
Rare to more often exposure in the hazardous zone

Avoidance Parameter (P) P2


Comment:
Almost impossible

SIL for Personnel Protection 1

Loss SIL --

Environmental SIL nc
Availability of Other Safety Related System
SPEEDBIRD HDPE PLANT SAFETY REPORT
ATTACHMENT 3 IDENTIFICATION CODE
SIL CLASSIFICATION NPP PROJECT 3443-SZ-RT-101 Att.3
Location MUNCHSMUNSTER
Plants HDPE 320 KT/Y Spedbird Project Sheet 52 of 71 Issue 04
GERMANY

SIL CLASSIFICATION SHEET

Function No. 3100-2AAHH31204-2S31202-2HV31201

Zone Hexane purification Unit 3100


P&ID No. 312 Interlock desc. Pag: 51 of 79
Initiator Tag 2AAHH31204 high concentration of HC and CO
Logic Solver Tag 2S31202 High HC concentration in the vent
Final Element Tag Closes 2HV31201

Design Intent
To avoide to discharge hydrocarbon to atmosphere

Hazardous Scenario (Demand Scenario)


Human error applyng the procedure

Consequence Scenario
Possible undesired vent of Hydrocarbon to atmosphere

Frequency of Unwanted Occurrence (W) W1


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

Consequence Parameter for Personnel (C) C1


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

Exposure Parameter (F) N/A


Comment:
not applicable

Avoidance Parameter (P) N/A


Comment:
not applicable

SIL for Personnel Protection nc

Loss SIL nc
nc
nc
nc
Environmental SIL -
Availability of Other Safety Related System
SPEEDBIRD HDPE PLANT SAFETY REPORT
ATTACHMENT 3 IDENTIFICATION CODE
SIL CLASSIFICATION NPP PROJECT 3443-SZ-RT-101 Att.3
Location MUNCHSMUNSTER
Plants HDPE 320 KT/Y Spedbird Project Sheet 53 of 71 Issue 04
GERMANY

SIL CLASSIFICATION SHEET

Function No. 3100-2HZLL31201-2S31203-2HV31202

Zone Hexane purification Unit 3100


P&ID No. 312 Interlock desc. Pag: 51 of 79
Initiator Tag 2HZLL31201
Logic Solver Tag 2S31203 regeneration system to atmosphere
Final Element Tag Doesn't allow to open 2HV31202

Design Intent
To prevent air entry in system with hydrocarbon

Hazardous Scenario (Demand Scenario)


Human error follwing the procedure

Consequence Scenario
Possible flammable mixture in the regeneration circuit.

Frequency of Unwanted Occurrence (W) W1


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

Consequence Parameter for Personnel (C) C2


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

Exposure Parameter (F) F1


Comment:
Rare to more often exposure in the hazardous zone

Avoidance Parameter (P) P2


Comment:
Almost impossible

SIL for Personnel Protection a

Loss SIL aa
nc
nc
Environmental SIL -
Availability of Other Safety Related System
This interlock will be implemented on ESD
SPEEDBIRD HDPE PLANT SAFETY REPORT
ATTACHMENT 3 IDENTIFICATION CODE
SIL CLASSIFICATION NPP PROJECT 3443-SZ-RT-101 Att.3
Location MUNCHSMUNSTER
Plants HDPE 320 KT/Y Spedbird Project Sheet 54 of 71 Issue 04
GERMANY

SIL CLASSIFICATION SHEET

Function No. 3100-2TAHH31210-2S31204-2FV31202

Zone Hexane purification Unit 3100


P&ID No. 312 Interlock desc. Pag: 52 of 79
Initiator Tag 2TAHH31210 very high temperature in D3104
Logic Solver Tag 2S31204 Very high temperature in 2D3104
Final Element Tag 2FV31202 closed

Design Intent
To prevent very high temperature in 2D3104 during the regeneration phase

Hazardous Scenario (Demand Scenario)


No cooling water to 2E3108

Consequence Scenario
Possible temperature inside the equipment over than the design temprature of the equipment.

Frequency of Unwanted Occurrence (W) W1


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

Consequence Parameter for Personnel (C) C1


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

Exposure Parameter (F) N/A


Comment:
not applicable

Avoidance Parameter (P) N/A


Comment:
not applicable

SIL for Personnel Protection nc

Loss SIL --

Environmental SIL nc
Availability of Other Safety Related System
SPEEDBIRD HDPE PLANT SAFETY REPORT
ATTACHMENT 3 IDENTIFICATION CODE
SIL CLASSIFICATION NPP PROJECT
3443-SZ-RT-101 Att.3
Location MUNCHSMUNSTER
Plants HDPE 320 KT/Y Spedbird Project Sheet 55 of 71 Issue 04
GERMANY

SIL CLASSIFICATION SHEET <04>

Function No. 3100-2TAHH31209 A/B-2S31205-2E3107

Zone Hexane purification Unit 3100


P&ID No. 312 Interlock desc. Pag: 52 of 79
Initiator Tag 2TAHH31209 A/B very high temperature 2E3107 (1oo2)
Logic Solver Tag 2S31205 stop of regeneration heater
Final Element Tag Stop of 2E3107

Design Intent
To prevent very high temperature in 2T3102 A\B during the regeneration phase

Hazardous Scenario (Demand Scenario)


TIC31206 malfunction to signal.

Consequence Scenario
Possible temperature in 2T3102 higher than design temperature and possible damage of KC pearl.

Frequency of Unwanted Occurrence (W) W2


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

Consequence Parameter for Personnel (C) C2


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

Exposure Parameter (F) F1


Comment:
Rare to more often exposure in the hazardous zone

Avoidance Parameter (P) P2


Comment:
Almost impossible

SIL for Personnel Protection 1

Loss SIL --

Environmental SIL nc
Availability of Other Safety Related System
SPEEDBIRD HDPE PLANT SAFETY REPORT
ATTACHMENT 3 IDENTIFICATION CODE
SIL CLASSIFICATION NPP PROJECT
3443-SZ-RT-101 Att.3
Location MUNCHSMUNSTER
Plants HDPE 320 KT/Y Spedbird Project Sheet 56 of 71 Issue 04
GERMANY

SIL CLASSIFICATION SHEET

Function No. 3200-LSAHH32105-IS32101-C3201

Zone Recycle gas compressor Unit 3200


P&ID No. 321A Interlock desc. Pag: 52 of 79
Initiator Tag LSAHH32105 very high level in 2D3206
Logic Solver Tag 2IS32101 2C3201 shut down
Final Element Tag Shut down of 2C3201

Design Intent
Compressor 2C3201 protection

Hazardous Scenario (Demand Scenario)


Possible overfilling of equipment in unit Upstream and relevant safety function failure

Consequence Scenario
Possible damage of compressor 2C3201

Frequency of Unwanted Occurrence (W) W1


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

Consequence Parameter for Personnel (C) C3


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

Exposure Parameter (F) N/A


Comment:
not applicable

Avoidance Parameter (P) N/A


Comment:
not applicable

SIL for Personnel Protection nc

Loss SIL 11

Environmental SIL -
Availability of Other Safety Related System
SPEEDBIRD HDPE PLANT SAFETY REPORT
ATTACHMENT 3 IDENTIFICATION CODE
SIL CLASSIFICATION NPP PROJECT
3443-SZ-RT-101 Att.3
Location MUNCHSMUNSTER
Plants HDPE 320 KT/Y Spedbird Project Sheet 57 of 71 Issue 04
GERMANY

SIL CLASSIFICATION SHEET

Function No. 3200-2LAHH32101/02-2I32102-2FV32101

Zone Butene recovery & hexane column top Unit 3200


P&ID No. purification
321B Interlock desc. Pag: 53 of 79
Initiator Tag 2LAHH32101/02 very high level in 2T3201
Logic Solver Tag 2I32102 very high level in 2T3201 bottom
Final Element Tag Close 2FV32101 fresh hexane to 2T3201

Design Intent
To prevent the overfilling of 2T3201

Hazardous Scenario (Demand Scenario)


Possible malfunction of LIC32101 or FIC12222\3

Consequence Scenario
In case of high level less efficiency of the separetion of light ends and consequent quality problem in the production. It isn't considered the possibility of
pressure increasing over the PSV set point.

Frequency of Unwanted Occurrence (W) W2


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

Consequence Parameter for Personnel (C) C1


Comment:
Minor consequence.

Exposure Parameter (F) N/A


Comment:
not applicable

Avoidance Parameter (P) N/A


Comment:
not applicable

SIL for Personnel Protection nc

Loss SIL --

Environmental SIL nc
Availability of Other Safety Related System
SPEEDBIRD HDPE PLANT SAFETY REPORT
ATTACHMENT 3 IDENTIFICATION CODE
SIL CLASSIFICATION NPP PROJECT 3443-SZ-RT-101 Att.3
Location MUNCHSMUNSTER
Plants HDPE 320 KT/Y Spedbird Project Sheet 58 of 71 Issue 04
GERMANY

SIL CLASSIFICATION SHEET

Function No. 3200-LSAHH32102-IS33101-2P3301A/B

Zone WAX recovery Unit 3300


P&ID No. 331 Interlock desc. Pag: 53 of 79
Initiator Tag LSAHH33102 very high level in 2D3301, PSAHH33103
Logic Solver Tag IS33101 stop of pump 2P3301A/B
Final Element Tag Stop 2P3301A/B

Design Intent
To prevent the overfilling of 2D3301

Hazardous Scenario (Demand Scenario)


Possible obstruction in the bottom line of 2D3301 due to no LPS

Consequence Scenario
Overfilling of 2D3301 and consequent obstruction on the demister or on the outlet line to the condenser.

Frequency of Unwanted Occurrence (W) W1


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

Consequence Parameter for Personnel (C) C2


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

Exposure Parameter (F) F1


Comment:
Rare to more often exposure in the hazardous zone

Avoidance Parameter (P) P2


Comment:
Almost impossible

SIL for Personnel Protection a

Loss SIL aa

Environmental SIL nc
Availability of Other Safety Related System

REPLACED BY 2S33104 - SIF 21 ATTACHMENT 6.4


SPEEDBIRD HDPE PLANT SAFETY REPORT
ATTACHMENT 3 IDENTIFICATION CODE
SIL CLASSIFICATION NPP PROJECT 3443-SZ-RT-101 Att.3
Location MUNCHSMUNSTER
Plants HDPE 320 KT/Y Spedbird Project Sheet 59 of 71 Issue 04
GERMANY

SIL CLASSIFICATION SHEET

Function No. 3300-PISAHH33305/06-IS33302-PV13101A/B

Zone Waste water pretreatment Unit 3300


P&ID No. 333B Interlock desc. Pag: 54 of 79
Initiator Tag PISAHH33305/06 very high pressure in 2D3303
Logic Solver Tag IS33302 very high pressure in 2D3303
Final Element Tag PV13101A\B closed (Reactor discharge header)

Design Intent
To prevent very high pressure in the vessel

Hazardous Scenario (Demand Scenario)


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

Consequence Scenario
Possible overpressure of 2D3303

Frequency of Unwanted Occurrence (W) W1


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

Consequence Parameter for Personnel (C) C2


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

Exposure Parameter (F) F1


Comment:
Rare to more often exposure in the hazardous zone

Avoidance Parameter (P) P2


Comment:
Almost impossible

SIL for Personnel Protection a

Loss SIL aa

Environmental SIL nc
Availability of Other Safety Related System

REPLACED BY 2S33302A/B - SIF 6 & 10 ATTACHMENT 6.4


SPEEDBIRD HDPE PLANT SAFETY REPORT
ATTACHMENT 3 IDENTIFICATION CODE
SIL CLASSIFICATION NPP PROJECT
3443-SZ-RT-101 Att.3
Location MUNCHSMUNSTER
Plants HDPE 320 KT/Y Spedbird Project Sheet 60 of 71 Issue 04
GERMANY

SIL CLASSIFICATION SHEET

Function No. 3300-PSAH33305/06-IS33303-HV33301

Zone Waste water pretreatment Unit 3300


P&ID No. 333B Interlock desc. Pag: 54 of 79
Initiator Tag PISAH33305\06 high pressure in 2D3303
Logic Solver Tag IS33303 high Pressure and high temperature in 2D3303
Final Element Tag HV33301 closed discharge to container

Design Intent
To prevent high pressure in the vessel during the unloading to container

Hazardous Scenario (Demand Scenario)


Human error appling the procedures

Consequence Scenario
Possible injury to the operator that makes the unloading to the container

Frequency of Unwanted Occurrence (W) W2


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

Consequence Parameter for Personnel (C) C2


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

Exposure Parameter (F) F2


Comment:
Frequent to permanent exposure in the hazardous zone

Avoidance Parameter (P) P1


Comment:
Possible under certain condition

SIL for Personnel Protection 1

Loss SIL nc
nc

Environmental SIL nc
Availability of Other Safety Related System

REPLACED BY 2S33303A/B - SIF 13 & 17 ATTACHMENT 6.4


SPEEDBIRD HDPE PLANT SAFETY REPORT
ATTACHMENT 3 IDENTIFICATION CODE
SIL CLASSIFICATION NPP PROJECT
3443-SZ-RT-101 Att.3
Location MUNCHSMUNSTER
Plants HDPE 320 KT/Y Spedbird Project Sheet 61 of 71 Issue 04
GERMANY

SIL CLASSIFICATION SHEET

Function No. 3300-ZSL33302-IS33304-PV13101A/B

Zone Waste water pretreatment Unit 3300


P&ID No. 333B Interlock desc. Pag: 54 of 79
Initiator Tag ZSL33302 close not active
Logic Solver Tag IS33304 reactor drain cut off (This interlock will be added directly to IS33302)
Final Element Tag PV13101A\B closed

Design Intent
To prevent very high pressure in the vessel 2D3304

Hazardous Scenario (Demand Scenario)


Possible human error applying the procedure

Consequence Scenario
Possible overpressure of 2D3304

Frequency of Unwanted Occurrence (W) W2


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

Consequence Parameter for Personnel (C) C2


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

Exposure Parameter (F) F2


Comment:
Frequent to permanent exposure in the hazardous zone

Avoidance Parameter (P) P1


Comment:
Possible under certain condition

SIL for Personnel Protection 1

Loss SIL 11

Environmental SIL nc
Availability of Other Safety Related System

REPLACED BY 2S33303A/B - SIF 15 & 19 ATTACHMENT 6.4


SPEEDBIRD HDPE PLANT SAFETY REPORT
ATTACHMENT 3 IDENTIFICATION CODE
SIL CLASSIFICATION NPP PROJECT 3443-SZ-RT-101 Att.3
Location MUNCHSMUNSTER
Plants HDPE 320 KT/Y Spedbird Project Sheet 62 of 71 Issue 04
GERMANY

SIL CLASSIFICATION SHEET

Function No. 3300-2PDALL33310A-2I33308A-2FV33304A

Zone Waste water pretreatment Unit 3300


P&ID No. 333B Interlock desc. Pag: 56 of 79
Initiator Tag 2PDALL33310A low differential pressure steam/2D3303A
Logic Solver Tag 2I33308A low steam to 2D3303A cut off
Final Element Tag 2FV33304A steam to 2D3303A closed

Design Intent
To prevent back flow to LS line

Hazardous Scenario (Demand Scenario)


Possible higher pressure due to no cooling water during the distillation step

Consequence Scenario
Possible hydrocarbon in the low pressure steam line.

Frequency of Unwanted Occurrence (W) W2


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

Consequence Parameter for Personnel (C) C1


Comment:
Minor consequence for safety and environment.

Exposure Parameter (F) N/A


Comment:
not applicable

Avoidance Parameter (P) N/A


Comment:
not applicable

SIL for Personnel Protection -

Loss SIL nc
nc

Environmental SIL -
Availability of Other Safety Related System
Check valve provided
SPEEDBIRD HDPE PLANT SAFETY REPORT
ATTACHMENT 3 IDENTIFICATION CODE
SIL CLASSIFICATION NPP PROJECT 3443-SZ-RT-101 Att.3
Location MUNCHSMUNSTER
Plants HDPE 320 KT/Y Spedbird Project Sheet 63 of 71 Issue 04
GERMANY

SIL CLASSIFICATION SHEET

Function No. 3400-PSAHH34102/03-IS34104-PV34103A/B/C

Zone Off gas system I Unit 3400


P&ID No. 341A Interlock desc. Pag:
Initiator Tag PSAHH34102/03 very high pressure in flare header
Logic Solver Tag IS34104 Flare header high pressure
Final Element Tag PV34103 A\B close and PV34103C open

Design Intent
To prevent overpressure in the low pressure unit, during emergency in the high pressure unit, and massive hydrocarbon discharge to atmosphere throught
cold flare
Hazardous Scenario (Demand Scenario)
Two different emergency involving the waste gas header (LP unit) and flare header (HP unit)

Consequence Scenario
Possible damage of low pressure design equipment.

Frequency of Unwanted Occurrence (W) W1


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

Consequence Parameter for Personnel (C) C3


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

Exposure Parameter (F) F2


Comment:
Frequent to permanent exposure in the hazardous zone

Avoidance Parameter (P) P2


Comment:
Almost impossible

SIL for Personnel Protection 1

Loss SIL 11

Environmental SIL -
Availability of Other Safety Related System
Check valve provided

INTERLOCK DELETED IN HDPE SPEEDBIRD PLANT


SPEEDBIRD HDPE PLANT SAFETY REPORT
ATTACHMENT 3 IDENTIFICATION CODE
SIL CLASSIFICATION NPP PROJECT 3443-SZ-RT-101 Att.3
Location MUNCHSMUNSTER
Plants HDPE 320 KT/Y Spedbird Project Sheet 64 of 71 Issue 04
GERMANY

SIL CLASSIFICATION SHEET

Function No. 4100-2LAHH41102,2PAHH41104-2I41101-2XV41102

Zone Hexane \ Mother liquor Unit 4100


P&ID No. 411 Interlock desc. Pag: 59 of 79
Initiator Tag 2LAHH41102 very high level in 2D4101, 2PAHH41104 very high pressure in 2D4101
Logic Solver Tag 2I41101 distillated hexane cut off
Final Element Tag 2XV41102 closed distilled hexane feed

Design Intent
To prevent overfilling of the distilled hexane tank

Hazardous Scenario (Demand Scenario)


Human error appllying the procedure during filling of the tank or Manual valve blocked open

Consequence Scenario
Possible rain out of liquid hexane to a not confined area.

Frequency of Unwanted Occurrence (W) W1


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

Consequence Parameter for Personnel (C) C2


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

Exposure Parameter (F) F1


Comment:
Rare to more often exposure in the hazardous zone

Avoidance Parameter (P) P1


Comment:
Possible under certain conditions

SIL for Personnel Protection a

Loss SIL nc
nc

Environmental SIL nc
Availability of Other Safety Related System
SPEEDBIRD HDPE PLANT SAFETY REPORT
ATTACHMENT 3 IDENTIFICATION CODE
SIL CLASSIFICATION NPP PROJECT 3443-SZ-RT-101 Att.3
Location MUNCHSMUNSTER
Plants HDPE 320 KT/Y Spedbird Project Sheet 65 of 71 Issue 04
GERMANY

SIL CLASSIFICATION SHEET <04>

Function No. 4100-2LAHH41301-2S41301-2XV41401-2HV41404 (1oo2)

Zone Al-Alkyl receiver Unit 4100


P&ID No. 413 Interlock desc. Pag: 63 of 79
Initiator Tag 2LAHH41301 very high level in 2D4103
Logic Solver Tag 2S41301 very high level in 2D4103
Final Element Tag 2XV41401 close TEAL and hexane from cylinder 2HV41404 close hexane to TEAL unloading (1oo2)

Design Intent
To prevent overfilling of Al-Alkyl storage tank 2D4103

Hazardous Scenario (Demand Scenario)


Possible malfunction to signal of FQI41402

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

Frequency of Unwanted Occurrence (W) W2


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

Consequence Parameter for Personnel (C) C2


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

Exposure Parameter (F) F2


Comment:
Frequent to permanent exposure in the hazardous zone

Avoidance Parameter (P) P1


Comment:
Possible under certain condition

SIL for Personnel Protection 1

Loss SIL nc
nc

Environmental SIL nc
Availability of Other Safety Related System
SPEEDBIRD HDPE PLANT SAFETY REPORT
ATTACHMENT 3 IDENTIFICATION CODE
SIL CLASSIFICATION NPP PROJECT
3443-SZ-RT-101 Att.3
Location MUNCHSMUNSTER
Plants HDPE 320 KT/Y Spedbird Project Sheet 66 of 71 Issue 04
GERMANY

SIL CLASSIFICATION SHEET <04>

Function No. 4100-2BAH41401/02/03/04-2S41401-2PV41401-2HV41403

Zone Al-Alkyl unloading Unit 4100


P&ID No. 414 Interlock desc. Pag: 65 of 79
Initiator Tag 2BAH41401/02/03/04 Flame detector (2oo4)
Logic Solver Tag 2S41401 TEAL unloading cut off
Final Element Tag 2PV41401 nitrogen closed, 2HV41403 open vent to 2D4102 (2oo2)

Design Intent
To detect fire and stop leakage

Hazardous Scenario (Demand Scenario)


TEAL leakage from couplings and flanges

Consequence Scenario
Increased fire and related damages (on TEAL cylinder and pipe).

Frequency of Unwanted Occurrence (W) W2


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

Consequence Parameter for Personnel (C) C2


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

Exposure Parameter (F) F1


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

Avoidance Parameter (P) P2


Comment:
Almost impossible

SIL for Personnel Protection 1

Loss SIL 11

Environmental SIL nc
Availability of Other Safety Related System
SPEEDBIRD HDPE PLANT SAFETY REPORT
ATTACHMENT 3 IDENTIFICATION CODE
SIL CLASSIFICATION NPP PROJECT
3443-SZ-RT-101 Att.3
Location MUNCHSMUNSTER
Plants HDPE 320 KT/Y Spedbird Project Sheet 67 of 71 Issue 04
GERMANY

SIL CLASSIFICATION SHEET <04>

Function No. 4100-2HZLL41405 A / B -2S41402-2HV41404

Zone Al-Alkyl unloading Unit 4100


P&ID No. 414 Interlock desc. Pag: 65 of 79
Initiator Tag 2HZLL41405 A / B (1oo2)
Logic Solver Tag 2S41402 Hexane to TEAL dilution
Final Element Tag 2HV41404 not allowed to open

Design Intent
To prevent Hexane to teal cylinder

Hazardous Scenario (Demand Scenario)


Human error applying the procedure

Consequence Scenario
Overpressure of TEAL cylinder

Frequency of Unwanted Occurrence (W) W2


Comment:
A slight probability that the unwanted occurrence will come to pass and a few unwanted occurrences are likely.

Consequence Parameter for Personnel (C) C2


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

Exposure Parameter (F) F1


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

Avoidance Parameter (P) P2


Comment:
Almost impossible

SIL for Personnel Protection 1

Loss SIL 11

Environmental SIL nc
Availability of Other Safety Related System
SPEEDBIRD HDPE PLANT SAFETY REPORT
ATTACHMENT 3 IDENTIFICATION CODE
SIL CLASSIFICATION NPP PROJECT
3443-SZ-RT-101 Att.3
Location MUNCHSMUNSTER
Plants HDPE 320 KT/Y Spedbird Project Sheet 68 of 71 Issue 04
GERMANY

SIL CLASSIFICATION SHEET

Function No. 6200-TSHH62105/06-IS61201-PV62101-TV62105

Zone Steam supply and condensate system Unit 6200


P&ID No. 621 Interlock desc. Pag: 70 of 79
Initiator Tag TSAHH62105\06 very high temperature in high steam header
Logic Solver Tag IS62101 High pressure steam cut off
Final Element Tag PV62101 high steam to 2D6201, TV62105 closed high steam header (1 of 2)

Design Intent
To prevent temperature of steam higher than the design temperature of the downstream equipments

Hazardous Scenario (Demand Scenario)


TIC62104 malfunction or TV62104 closed

Consequence Scenario
Equipment downstream are not design for the design temperature of HP steam from battery limit

Frequency of Unwanted Occurrence (W) W2


Comment:
A slight probability that the unwanted occurrence will come to pass and a few unwanted occurrences are likely.

Consequence Parameter for Personnel (C) C2


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

Exposure Parameter (F) F1


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

Avoidance Parameter (P) P2


Comment:
Almost impossible

SIL for Personnel Protection 1

Loss SIL 11

Environmental SIL nc
Availability of Other Safety Related System

REPLACED BY 2S62101 - SIF 1 ATTACHMENT 6.4


SPEEDBIRD HDPE PLANT SAFETY REPORT
ATTACHMENT 3 IDENTIFICATION CODE
SIL CLASSIFICATION NPP PROJECT
3443-SZ-RT-101 Att.3
Location MUNCHSMUNSTER
Plants HDPE 320 KT/Y Spedbird Project Sheet 69 of 71 Issue 04
GERMANY

SIL CLASSIFICATION SHEET <04>

Function No. 6200-2TAHH62107\08-2S62102-PV62103-2XV62107

Zone Steam supply Unit 6200


P&ID No. 621 Interlock desc. Pag: 70 of 79
Initiator Tag 2TAHH62107\08 very high temperature in medium steam header (1oo2)
Logic Solver Tag 2S62102 Medium pressure steam cut off
Final Element Tag PV62103 closed medium steam to 2D6202, 2XV62107 closed medium steam header (1oo2)

Design Intent
To prevent temperature of steam higher than the design temperature of the downstream equipments

Hazardous Scenario (Demand Scenario)


TIC62105 malfunction or TV62105 closed

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

Frequency of Unwanted Occurrence (W) W2


Comment:
A slight probability that the unwanted occurrence will come to pass and a few unwanted occurrences are likely.

Consequence Parameter for Personnel (C) C2


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

Exposure Parameter (F) F1


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

Avoidance Parameter (P) P2


Comment:
Almost impossible

SIL for Personnel Protection 1

Loss SIL 11

Environmental SIL nc
Availability of Other Safety Related System
SPEEDBIRD HDPE PLANT SAFETY REPORT
ATTACHMENT 3 IDENTIFICATION CODE
SIL CLASSIFICATION NPP PROJECT 3443-SZ-RT-101 Att.3
Location MUNCHSMUNSTER
Plants HDPE 320 KT/Y Spedbird Project Sheet 70 of 71 Issue 04
GERMANY

SIL CLASSIFICATION SHEET

Function No. 6200-2TAHH62109\10-2S62103-2PV62105-2XV62109

Zone Steam supply Unit 6200


P&ID No. 621 Interlock desc. Pag: 70 of 79
Initiator Tag 2TAHH62109\10 very high temperature in low steam header
Logic Solver Tag 2S62103 Low pressure steam cut off
Final Element Tag 2PV62105 closed low steam to 2D6203, 2XV62109 closed low steam header

Design Intent
To prevent temperature of steam higher than the design temperature of the downstream equipments

Hazardous Scenario (Demand Scenario)


TIC62106 malfunction or TV62106 closed

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

Frequency of Unwanted Occurrence (W) W1


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

Consequence Parameter for Personnel (C) C2


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

Exposure Parameter (F) F1


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

Avoidance Parameter (P) P2


Comment:
Almost impossible

SIL for Personnel Protection a

Loss SIL --

Environmental SIL nc
Availability of Other Safety Related System

REPLACED BY 2S62101 - SIF 3 ATTACHMENT 6.4


SPEEDBIRD HDPE PLANT SAFETY REPORT
ATTACHMENT 3 IDENTIFICATION CODE
SIL CLASSIFICATION NPP PROJECT
3443-SZ-RT-101 Att.3
Location MUNCHSMUNSTER
Plants HDPE 320 KT/Y Spedbird Project Sheet 71 of 71 Issue 04
GERMANY

SIL CLASSIFICATION SHEET

Function No. 6200-TSHH62112-IS61204-TV62111

Zone Steam supply Unit 6200


P&ID No. 621 Interlock desc. Pag: 70 of 79
Initiator Tag TSAHH62111\12 very high temperature in low low steam header (TSAHH of dryer)
Logic Solver Tag IS62104 Low low pressure steam cut off
Final Element Tag All the final action (HV22101 common element)

Design Intent
To prevent melting of polymer in the dryer

Hazardous Scenario (Demand Scenario)


TIC62115 malfunction or TV62115 closed

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

Frequency of Unwanted Occurrence (W) W2


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

Consequence Parameter for Personnel (C) C1


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

Exposure Parameter (F) N/A


Comment:
not applicable

Avoidance Parameter (P) N/A


Comment:
not applicable

SIL for Personnel Protection nc

Loss SIL --

Environmental SIL nc
Availability of Other Safety Related System