3547-SZ-RT-B300011-ISH
Short Description
Hazard...
Description
TECNIMONT IDENTIFICATION CODE
HSE DESIGN CONFERENCE BOROUGE 3 PROJECT
FEED SERVICES FOR PO,LDPE AND U&O INSTALLATIONS
Abu Dhabi Polymers Company Limited (Borouge)
3547-SZ-RT-B300011 Sheet 2 of 110
Rev H
BOROUGE IDENTIFICATION CODE
B3-PH-471-00011
TABLE OF CONTENTS 1
INTRODUCTION ....................................................................................................................... 3
2
SCOPE...................................................................................................................................... 3
3
PROJECT REFERENCE DOCUMENTATION .......................................................................... 3
4
ATTENDEES............................................................................................................................. 4
5
POLICY - HSE STUDIES .......................................................................................................... 5
6
HSE DESIGN CONFERENCE REQUIREMENTS ..................................................................... 6
ATTACHMENTS Attachment 1 – COMPANY Policy Attachment 2 - TECNIMONT Policy Attachment 3a - HSE Design Conference Requirements Status PO and U&O Attachment 3b - HSE Design Conference Requirements Status LDPE
THIS DOCUMENT IS BOROUGE’S PROPERTY AND CANNOT BE USED BY OTHERS FOR ANY PURPOSE WITHOUT PRIOR WRITTEN CONSENT
B3-PH-471-00011 Rev H
TECNIMONT IDENTIFICATION CODE
HSE DESIGN CONFERENCE BOROUGE 3 PROJECT
FEED SERVICES FOR PO,LDPE AND U&O INSTALLATIONS
Abu Dhabi Polymers Company Limited (Borouge)
3547-SZ-RT-B300011 Sheet 3 of 110
Rev H
BOROUGE IDENTIFICATION CODE
B3-PH-471-00011
1
INTRODUCTION
This document reports the main results of the HSE Design Conference for Polyolefins, Utilities and Offsite and LDPE plant that has been held from August 26th to 17th September in TCM Offices in Milan with the attendance of the representatives of each Discipline Leader. Only for LDPE Plant the meeting was held with COMPANY partecipation. This report will be updated with the results of periodical meetings with the Project Discipline Leaders, on the basis of the development of the Project. The meeting has been carried out with an introductive session in which HSE Manager has presented the HSE Management System with its organization, main objectives and activities and the Project HSE Policy to all attendees. Several dedicated sessions have been carried out for the specific Disciplines.
2
SCOPE
The aim of the HSE Design Conference was to review the available HSE basis of design, to identify general and specific HSE issues that need to be further addressed, to orient the process and engineering solutions and to define any possible modifications to the HSE Plans, such as additional HSE reviews on specific design activities.
3
PROJECT REFERENCE DOCUMENTATION
HSE Design is developed in compliance with the Project Reference Documentation which includes: United Arab Emirates Laws, HSEIA Report, Contract Requirements, Feed Specifications, International Codes and Standards and the following main COMPANY specifications: BPM-PH-03-007 BPM-PH-03-003 BDP-PP-03-001 BPD-PP-03-002 BDP-PH-03-003 BGS-IU-001 BGS-AU-034 BGS-AU-063 BGS-CU-012 BGS-EE-003 BGS-EU-001 BGS-MD-001
HSE Philosophy (EPC) (*) HSE Regulations, Guidelines & Requirements (*) Process Engineering Philosophies (*) Emergency SD & Block-In Depressuring Philosophy (*) Environmental Philosophy (*) Instrument & Control Outline Building Specification HVAC System Fireproofing Requirements Vessels & Structures Power Transformers Electrical Design Guidelines Vessel Design Basis
THIS DOCUMENT IS BOROUGE’S PROPERTY AND CANNOT BE USED BY OTHERS FOR ANY PURPOSE WITHOUT PRIOR WRITTEN CONSENT
B3-PH-471-00011 Rev H
TECNIMONT IDENTIFICATION CODE
HSE DESIGN CONFERENCE BOROUGE 3 PROJECT
FEED SERVICES FOR PO,LDPE AND U&O INSTALLATIONS
Abu Dhabi Polymers Company Limited (Borouge)
3547-SZ-RT-B300011 Sheet 4 of 110
Rev H
BOROUGE IDENTIFICATION CODE
B3-PH-471-00011
BGS-MD-003 BGS-MA-004 BGS-MN-002 BGS-MN-004 BGS-MN-100 BGS-MU-200 BGS-MU-201 BGS-MU-203 BGS-MU-204 BGS-MU-008 BGS-MU-009 HSE 009B-003 BER-CO-08-001-04
Field Fabricated – Spheres Emergency Generator Fireproofing Of Cable Trays Cold Insulation for Piping and Equipment Thermal Hot Service Insulation Fire Protection Design Philosophy Water Spray Fire Protection Systems Portable & Mobile Fire Fighting Equipment Fire Protection Clean Agent Systems Plant Noise Control Equipment Noise Control HSE Design Criteria for Basell – LDPE Process – June 2008 Rev 0 Borstar PE & PP HSE Design Requirements
(*) Documents number refers to Borouge 2 project. Documents reissued for Borouge 3 project with a different reference numbers.
4
ATTENDEES The attendees consisted of representatives for each involved Discipline: G. Franzoni Design HSE Manager and Design Conference Chairman C. Chiusolo Design HSE L. Di Clemente * Project Engineer P. Martignago Layout and Piping G. Blasizza Layout and Piping R. Sebastiani Machinery E. Bacchi Civil P. Caldarella Civil P. Perego Civil A. Colzani Civil G. Gilardi HVAC system D. Restelli Electrical S. Colleoni Electrical M. Vergallo Automation N. Desai Automation D. Volonte’ Instrumentation R. Santangelo Instrumentation
THIS DOCUMENT IS BOROUGE’S PROPERTY AND CANNOT BE USED BY OTHERS FOR ANY PURPOSE WITHOUT PRIOR WRITTEN CONSENT
B3-PH-471-00011 Rev H
TECNIMONT IDENTIFICATION CODE
HSE DESIGN CONFERENCE BOROUGE 3 PROJECT
FEED SERVICES FOR PO,LDPE AND U&O INSTALLATIONS
Abu Dhabi Polymers Company Limited (Borouge)
3547-SZ-RT-B300011 Sheet 5 of 110
Rev H
BOROUGE IDENTIFICATION CODE
B3-PH-471-00011
B. Goetz A. Brambilla F. Cavazzi L. Cartocci B. Terwelp A. Verma T. Adisa J. Ter Doest Y. Brendan B. Woo R. Anderson G. Moore K. Jedrzejczak R. Herve
Instrumentation Process Process Process Process Senior Project Manager Company Machinery Company Machinery Company Instrumentation Company HSE Company Process Company Civil Company Civil Company Electrical
( * partial attendance)
5
POLICY - HSE STUDIES Attachment 1 and Attachment 2 contain the COMPANY Policy and Tecnimont Policy, indicating the HSE objectives to be achieved. In order to achieve the above mentioned goals, a series of HSE studies, as detailed in the project HSE Plan (3547-SZ-PL-B300001), have been planned for the Project. These documents include, among others, the following:
Hazard study 2 (HAZID - only for U&O) Hazard study 3a (FEED HAZOP) HSE Reviews Quantitative Risk Assessment (QRA) COMAH report OHRA report HSE critical equipment and systems HSE decisions dossier Emission Inventory Noise preliminary study.
THIS DOCUMENT IS BOROUGE’S PROPERTY AND CANNOT BE USED BY OTHERS FOR ANY PURPOSE WITHOUT PRIOR WRITTEN CONSENT
B3-PH-471-00011 Rev H
TECNIMONT IDENTIFICATION CODE
HSE DESIGN CONFERENCE BOROUGE 3 PROJECT
FEED SERVICES FOR PO,LDPE AND U&O INSTALLATIONS
Abu Dhabi Polymers Company Limited (Borouge)
3547-SZ-RT-B300011 Sheet 6 of 110
Rev H
BOROUGE IDENTIFICATION CODE
B3-PH-471-00011
6
HSE DESIGN CONFERENCE REQUIREMENTS HSE Requirements, raised from the COMPANY specifications, Borstar Design Requirements and Basell HSE Design Criteria LDPE Process listed in section 3, have been collected into the tables shown in ATTACHMENT 3a (for PO and U&O) and 3b (for LDPE). PO and U&O tables show Borouge requirements and Borstar Design Requirements to be followed during design. In LDPE table it’s been collected an extract from HSE requirements of Basell HSE Design Criteria - LDPE Process that shall have higher order of precedence over Borouge Standards as per Letter ref. n. B3/EPO/TCM/0002. For each HSE requirement the relevant status of implementation inside the Project has been recorded. It must be highlighted that design philosophy is aimed to minimize emissions from Borouge 3 plants. In particular, secondary or fugitive emissions (emissions emanate from a variety of non-point sources in process operations in the form of leakage) are avoided or minimized where practicable. In Borouge 3 plant all vent from pressure relief valves venting hydrocarbons are collected to the flare during normal operation. Best available techniques for polyolefin production technology are used to minimize fugitive emissions and their effects and to achieving zero-flaring. These general aspects are considered in the design of PO, U&O and LDPE plant where practicable.
ATTACHMENT 1
THIS DOCUMENT IS BOROUGE’S PROPERTY AND CANNOT BE USED BY OTHERS FOR ANY PURPOSE WITHOUT PRIOR WRITTEN CONSENT
B3-PH-471-00011 Rev H
TECNIMONT IDENTIFICATION CODE
HSE DESIGN CONFERENCE BOROUGE 3 PROJECT
FEED SERVICES FOR PO,LDPE AND U&O INSTALLATIONS
Abu Dhabi Polymers Company Limited (Borouge)
3547-SZ-RT-B300011 Sheet 7 of 110
Rev H
BOROUGE IDENTIFICATION CODE
B3-PH-471-00011
ATTACHMENT 2
THIS DOCUMENT IS BOROUGE’S PROPERTY AND CANNOT BE USED BY OTHERS FOR ANY PURPOSE WITHOUT PRIOR WRITTEN CONSENT
B3-PH-471-00011 Rev H
TECNIMONT IDENTIFICATION CODE
HSE DESIGN CONFERENCE BOROUGE 3 PROJECT
FEED SERVICES FOR PO,LDPE AND U&O INSTALLATIONS
Abu Dhabi Polymers Company Limited (Borouge)
3547-SZ-RT-B300011 Sheet 8 of 110
Rev H
BOROUGE IDENTIFICATION CODE
B3-PH-471-00011
THIS DOCUMENT IS BOROUGE’S PROPERTY AND CANNOT BE USED BY OTHERS FOR ANY PURPOSE WITHOUT PRIOR WRITTEN CONSENT
B3-PH-471-00011 Rev H
TECNIMONT IDENTIFICATION CODE
HSE DESIGN CONFERENCE BOROUGE 3 PROJECT
FEED SERVICES FOR PO,LDPE AND U&O INSTALLATIONS
Abu Dhabi Polymers Company Limited (Borouge)
3547-SZ-RT-B300011 Sheet 9 of 110
Rev H
BOROUGE IDENTIFICATION CODE
B3-PH-471-00011
ATTACHMENT 3a - HSE Design Conference Requirements Status PO and U&O
THIS DOCUMENT IS BOROUGE’S PROPERTY AND CANNOT BE USED BY OTHERS FOR ANY PURPOSE WITHOUT PRIOR WRITTEN CONSENT
B3-PH-471-00011 Rev H
TECNIMONT IDENTIFICATION CODE
HSE DESIGN CONFERENCE BOROUGE 3 PROJECT
3547-SZ-RT-B300011
FEED SERVICES FOR PO,LDPE AND U&O INSTALLATIONS
Sheet 10 of 110
Abu Dhabi Polymers Company Limited (Borouge)
Rev H
BOROUGE IDENTIFICATION CODE
B3-PH-471-00011
No
General Topics
Application field
Discipline
1
NOISE
BUILDINGS
EDILE / HSE NOISE
2
PLANT LAYOUT
BUILDINGS
EDILE
3
BUILDINGS
BLAST RESISTANCE
EDILE
4
NOISE
BUILDINGS
EDILE / HSE NOISE
5
NOISE
BUILDINGS
EDILE / HSE NOISE
Requirement
Noise level limits in buildings and offices as defined in Table in 10.3.2 Offices: travel distance to a stairway or exit lower than 15 m; stairways and corridors width designed for 2 person's frontal crossing
Refer to BGS-AU-034 and BGS-CU-033
Sound pressure levels according to limits defined in BGS-AU-063 Background noise levels in occupied buildings during normal operation not exceeding limits contained in CISBE guide
Borealis BERCO- 08-001-04 Requirement
Study/Ref
Subchapter
BGSMU-008
10.3.2
Developed in compliance with the Document.
Closed
8-Sep-09
BPM-PH03-007
14.3
Developed in compliance with the Document.
Closed
8-Sep-09
BPM-PH03-007
20
Refer to Letter B3/EPO/TCM/L/0053
Closed
16Nov-09
BGS-AU034
15.4
Developed in compliance with the Document.
Closed
8-Sep-09
BGS-AU034
15.4
Developed in compliance with the Document.
Closed
8-Sep-09
THIS DOCUMENT IS BOROUGE’S PROPERTY AND CANNOT BE USED BY OTHERS FOR ANY PURPOSE WITHOUT PRIOR WRITTEN CONSENT
B3-PH-471-00011 Rev H
Ref
Answer
Remark
Action Status
Date
TECNIMONT IDENTIFICATION CODE
HSE DESIGN CONFERENCE BOROUGE 3 PROJECT
3547-SZ-RT-B300011
FEED SERVICES FOR PO,LDPE AND U&O INSTALLATIONS
Sheet 11 of 110
Abu Dhabi Polymers Company Limited (Borouge)
Rev H
BOROUGE IDENTIFICATION CODE
B3-PH-471-00011
No
General Topics
6
FIRE RESISTAN CE
BUILDINGS
EDILE
7
NOISE
BUILDINGS
EDILE/MAC CH HVAC
8
FIRE RESISTAN CE
Application field
POWER TRANSFORM ER
Discipline
EDILE
Requirement
Fire ratings on the basis of Table in Attachment 2 Noise caused by HVAC equipment shall be 10 db(A) below the noise level acceptable limits stated for the applicable buildings. In electrical equipment and rack equipment room the limit is 70 dB(A), in HVAC equipment room the limit is 85 dB(A)
Power transformers to be separated by fire resistant walls
Borealis BERCO- 08-001-04 Requirement
Study/Ref
Subchapter
BGS-AU034
Attachment 2
Developed in compliance with the Document.
Closed
8-Sep-09
BGS-AU063
14.6
Developed in compliance with the Document.
Closed
8-Sep-09
Closed
8-Sep-09
BGS-EU001
THIS DOCUMENT IS BOROUGE’S PROPERTY AND CANNOT BE USED BY OTHERS FOR ANY PURPOSE WITHOUT PRIOR WRITTEN CONSENT
18.2
High voltage transformers for outdooor service shall be located at least 50 m far from any flammable storage. Transformers containing insulation oil at least at 15 m distamce from other dfacilities or to be separated by 2 hours fire resistant walls B3-PH-471-00011 Rev H
Ref
Par a 12.6 pag 45
Answer
Trasformers will be separated by 2 hours fire resistant walls
Remark
Already applied
Action Status
Date
TECNIMONT IDENTIFICATION CODE
HSE DESIGN CONFERENCE BOROUGE 3 PROJECT
3547-SZ-RT-B300011
FEED SERVICES FOR PO,LDPE AND U&O INSTALLATIONS
Sheet 12 of 110
Abu Dhabi Polymers Company Limited (Borouge)
Rev H
BOROUGE IDENTIFICATION CODE
B3-PH-471-00011
No
General Topics
Application field
Discipline
9
FIREPRO OFING
GENERAL
EDILE
10
FIREPRO OFING
VESSELS
EDILE
Requirement
Minimum requirement shall be 3 hours protection from hydrocarbon fire. Fireproofing details in accordance with BTDCU-00104 (50 mm minimum thickness) and BTD-MD-00011. Standard material for fireproofing is concrete (see BGS-CU-010, BGS-CU-014). Fireprrofing of cable trays detailed in BGSMN-002 Skirts of vessels located in process areas or skirts of vessels containing hydrocarbons outside of a process area shall be externally fireproofed with 50 mm thick concrete. Internal fireprrofing is not required
Borealis BERCO- 08-001-04 Requirement
Study/Ref
Subchapter
BGS-CU012
1
Developed in compliance with the Document.
Closed
8-Sep-09
BGSMD-001
10.12
Developed in compliance with the Document.
Closed
8-Sep-09
THIS DOCUMENT IS BOROUGE’S PROPERTY AND CANNOT BE USED BY OTHERS FOR ANY PURPOSE WITHOUT PRIOR WRITTEN CONSENT
B3-PH-471-00011 Rev H
Ref
Answer
Remark
Action Status
Date
TECNIMONT IDENTIFICATION CODE
HSE DESIGN CONFERENCE BOROUGE 3 PROJECT
3547-SZ-RT-B300011
FEED SERVICES FOR PO,LDPE AND U&O INSTALLATIONS
Sheet 13 of 110
Abu Dhabi Polymers Company Limited (Borouge)
Rev H
BOROUGE IDENTIFICATION CODE
B3-PH-471-00011
No
General Topics
Application field
Discipline
Requirement
Interior of control room and of electrical power equipment building to be classified as non hazardous. Buildings to be located in non hazardous areas with positive pressure ventilation and air locks Noise limits at 0.3 m not exceeding results of formula given in 17.1.11 Working clearances between electrical equipment as per 18.2
11
PLANT LAYOUT
BUILDINGS
EDILE ELETT
12
NOISE
POWER TRANSFORM ER
ELETT
13
SPACING
ELECTRICAL EQUIPMENT
ELETT
14
HAZARDO US AREA CLASS
BATTERY ROOMS
ELETT
All electrical equipment suitable for Zone 1, II C
ELETT
The instrumented systems in each SIS and CCR shall be protected from loss of power by an uninterruptible power supply (UPS) capable of maintaining these systems in operation long enough to achieve a controlled shutdown of the whole plant.
15
SAFE SHUTDO WN
UPS
Borealis BERCO- 08-001-04 Requirement
Study/Ref
Subchapter
BPM-PH03-007
14.2
Developed in compliance with the Document.
Closed
8-Sep-09
BGS-EE003
17.1.11
Developed in compliance with the Document.
Closed
8-Sep-09
BGS-EU001
18.2
Developed in compliance with the Document.
Closed
8-Sep-09
BGS-EU001
18.4
Developed in compliance with the Document.
Closed
8-Sep-09
Developed in compliance with the Document.
Closed
8-Sep-09
BDP-PP03-003
THIS DOCUMENT IS BOROUGE’S PROPERTY AND CANNOT BE USED BY OTHERS FOR ANY PURPOSE WITHOUT PRIOR WRITTEN CONSENT
15
Minimum time of supply 30 minutes
B3-PH-471-00011 Rev H
Ref
Par a 12.7 pag 45
Answer
Remark
Action Status
Date
TECNIMONT IDENTIFICATION CODE
HSE DESIGN CONFERENCE BOROUGE 3 PROJECT
3547-SZ-RT-B300011
FEED SERVICES FOR PO,LDPE AND U&O INSTALLATIONS
Sheet 14 of 110
Abu Dhabi Polymers Company Limited (Borouge)
Rev H
BOROUGE IDENTIFICATION CODE
B3-PH-471-00011
No
General Topics
Application field
Discipline
62
AREA CLASSIFI CATION
RESTRICTED ZONES
ELETT
16
PLANT LAYOUT
GENERAL
IMPGE
17
PLANT LAYOUT
GENERAL
IMPGE
18
PLANT LAYOUT
BUILDINGS
IMPGE
19
PLANT LAYOUT
ROADS
IMPGE
Requirement
Restricted zones to be established by flammable gas dispersion studies. Control system shall have the capability to shutdown electrical equipment located in a restricted zone Fired units with flames exposed to atmosphere and sections with high tem to be locate upwind units forming vapour clouds in case of release Units processing toxic gases to be located at plant periphery in a part allowing the prevailing wind to carry vapours away Substations, IES, plant roads, maintenance shops, operator shelters to be located in non hazardous areas Roads to be located in such a way that personnel have to paths to safe areas from any point in the plant
Study/Ref
Subchapter
Borealis BERCO- 08-001-04 Requirement
Ref
Answer
Remark
Action Status
Date
BPM-PH03-007
16.3
The shutdown can be performed from dedicated substation or from relevant upstream main substation
BPM-PH03-007
14.2
Developed in compliance with the Document.
Closed
8-Sep-09
BPM-PH03-007
14.2
Developed in compliance with the Document.
Closed
8-Sep-09
BPM-PH03-007
14.2
Developed in compliance with the Document.
Closed
8-Sep-09
BPM-PH03-007
14.3
Developed in compliance with the Document.
Closed
8-Sep-09
THIS DOCUMENT IS BOROUGE’S PROPERTY AND CANNOT BE USED BY OTHERS FOR ANY PURPOSE WITHOUT PRIOR WRITTEN CONSENT
B3-PH-471-00011 Rev H
Closed
8-Sep-09
TECNIMONT IDENTIFICATION CODE
HSE DESIGN CONFERENCE BOROUGE 3 PROJECT
3547-SZ-RT-B300011
FEED SERVICES FOR PO,LDPE AND U&O INSTALLATIONS
Sheet 15 of 110
Abu Dhabi Polymers Company Limited (Borouge)
Rev H
BOROUGE IDENTIFICATION CODE
B3-PH-471-00011
No
General Topics
Application field
20
PLANT LAYOUT
GENERAL
IMPGE
21
PLANT LAYOUT
GENERAL
IMPGE
22
PLANT LAYOUT
FENCE
IMPGE
23
FIREPRO OFING
GENERAL
IMPGE
24
PURGING FLUSHING
PIPING
IMPGE
25
INSULATI ON
PIPING
IMPGE
26
HAZARDO US MATERIAL S
MANAGEMEN T
IMPGE
Discipline
Requirement
Firefighting equipment to be located away from units with potential for large fires Units with large volumes of flammable liquids to be separated, bunded and drained Security fence with gates for fire equipment access on all four sides Refer to BGS-CU-012 for fireprofing requirements Connections for purging and flushing to be provided for equipment contatining toxic gases to be periodically maintained (e.g. filters) Insulation for personnel protection to be installed in accessible areas where operating temperature exceeds 70 C. Refer to 22.12 for details Provide storage facilities for hazardous wastes and materials
Borealis BERCO- 08-001-04 Requirement
Study/Ref
Subchapter
BPM-PH03-007
14.3
Developed in compliance with the Document.
Closed
8-Sep-09
BPM-PH03-007
14.4
Developed in compliance with the Document.
Closed
8-Sep-09
BPM-PH03-007
14.4
Developed in compliance with the Document.
Closed
8-Sep-09
BPM-PH03-007
14.5
Developed in compliance with the Document.
Closed
8-Sep-09
BPM-PH03-007
22.9
Developed in compliance with the Document.
Closed
8-Sep-09
BPM-PH03-007
22.12
Developed in compliance with the Document.
Closed
8-Sep-09
BPM-PH03-007
24.5
Developed in compliance with the Document.
Closed
8-Sep-09
THIS DOCUMENT IS BOROUGE’S PROPERTY AND CANNOT BE USED BY OTHERS FOR ANY PURPOSE WITHOUT PRIOR WRITTEN CONSENT
B3-PH-471-00011 Rev H
Ref
Answer
Remark
Action Status
Date
TECNIMONT IDENTIFICATION CODE
HSE DESIGN CONFERENCE BOROUGE 3 PROJECT
3547-SZ-RT-B300011
FEED SERVICES FOR PO,LDPE AND U&O INSTALLATIONS
Sheet 16 of 110
Abu Dhabi Polymers Company Limited (Borouge)
Rev H
BOROUGE IDENTIFICATION CODE
B3-PH-471-00011
No
General Topics
Application field
Discipline
27
PIPING
FLANGE PROTECTOR S
IMPGE
28
LIQUID EFFLUEN TS
PAVED AREAS
IMPGE
29
LIQUID EFFLUEN TS
NON PAVED AREAS
IMPGE
30
PLANT LAYOUT
GENERAL
IMPGE
Requirement
Flange protectors to be provided for piping containing caustic solutions where leakage is dangerous to exposed skin Potential accidentaly oil contaminated waters from process paved areas to be sent to a first flush interceptor . When the interceptor is full, water shall overflow to an evaporation pond Storm water run off from road and non paved areas to be discharged into sea via storm water culverts provide they meet the quality standard for water discharged into the sea (Table 7) Onsite - The equipment shall be installed to keep a minimum safety distance indicated in 'Oil and Chemical Plant Layout Spacing' GAP 252 -2001 - Refer also to Appendix 1
Borealis BERCO- 08-001-04 Requirement
Study/Ref
Subchapter
BPM-PH03-007
24.7
Developed in compliance with the Document.
Closed
8-Sep-09
BDP-PH03-003
10
Developed in compliance with the Document.
Closed
8-Sep-09
BDP-PH03-003
10
Developed in compliance with the Document.
Closed
8-Sep-09
BGS-LU001
8.1.1 and Appendix 1
Developed in compliance with the Document.
Closed
8-Sep-09
THIS DOCUMENT IS BOROUGE’S PROPERTY AND CANNOT BE USED BY OTHERS FOR ANY PURPOSE WITHOUT PRIOR WRITTEN CONSENT
B3-PH-471-00011 Rev H
Ref
Answer
Remark
Action Status
Date
TECNIMONT IDENTIFICATION CODE
HSE DESIGN CONFERENCE BOROUGE 3 PROJECT
3547-SZ-RT-B300011
FEED SERVICES FOR PO,LDPE AND U&O INSTALLATIONS
Sheet 17 of 110
Abu Dhabi Polymers Company Limited (Borouge)
Rev H
BOROUGE IDENTIFICATION CODE
B3-PH-471-00011
No
General Topics
31
PLANT LAYOUT
32
PLANT LAYOUT
Application field
EQUIPMENT
GENERAL
Discipline
Requirement
IMPGE
Equipment which is a potential source of fire shall not be installed under pipe racks
IMPGE
A minimum of two entry points shall be provided for each unit and these shall be barrier controlled
33
PLANT LAYOUT
GENERAL
IMPGE
34
PLANT LAYOUT
PUMPS
IMPGE
Minimum clearance for equipment, structures, platforms and supports on the basis of table in 8.3.1 Pumps shall be located close to the equipment from which they take suction. Pumps that are a potential source of fire shall not be located under pipe racks or air coolers; a minimum of 1 m clear space shall be maintained between the edge of the pipe rack and or the edge of an air cooler to the pump coupling
Study/Ref
Subchapter
BGS-LU001
8.1.4
Borealis BERCO- 08-001-04 Requirement
The site layout shall include at least two fire fighting access roads to each unit
Ref
Par a 7.4 pag 16
Answer
Remark
Action Status
Date
Developed in compliance with the Document.
Closed
8-Sep-09
Developed in compliance with the Document.
Closed
8-Sep-09
BGS-LU001
8.1.10
BGS-LU001
8.3.1
Developed in compliance with the Document.
Closed
8-Sep-09
BGS-LU001
8.5.1
Developed in compliance with the Document.
Closed
8-Sep-09
THIS DOCUMENT IS BOROUGE’S PROPERTY AND CANNOT BE USED BY OTHERS FOR ANY PURPOSE WITHOUT PRIOR WRITTEN CONSENT
B3-PH-471-00011 Rev H
TECNIMONT IDENTIFICATION CODE
HSE DESIGN CONFERENCE BOROUGE 3 PROJECT
3547-SZ-RT-B300011
FEED SERVICES FOR PO,LDPE AND U&O INSTALLATIONS
Sheet 18 of 110
Abu Dhabi Polymers Company Limited (Borouge)
Rev H
BOROUGE IDENTIFICATION CODE
B3-PH-471-00011
No
General Topics
Application field
Discipline
35
PLANT LAYOUT
ESD VALVES
IMPGE
36
PLANT LAYOUT
FIRED EQUIPMENT
IMPGE
37
PLANT LAYOUT
HEATER STACKS
IMPGE
Requirement
ESD valves at liquid outlets shall be installed directly onto the vessel flange. No spool piece is allowed between the vessel flange and the ESD valve. Fired equipment shall, if practical, be located so that flammable gases from hydrocarbon or other processing areas cannot be blown into the open flames by prevailing winds Heater stacks shall terminate a minimum of 4.6 m above any platform within a radius of 12.5 m
Borealis BERCO- 08-001-04 Requirement
Study/Ref
Subchapter
BGS-LU001
8.7.18
As indicated in P&IDs
Closed
8-Sep-09
BGS-LU001
8.8.1
Developed in compliance with the Document.
Closed
8-Sep-09
BGS-LU001
8.8.4
Developed in compliance with the Document.
Closed
8-Sep-09
THIS DOCUMENT IS BOROUGE’S PROPERTY AND CANNOT BE USED BY OTHERS FOR ANY PURPOSE WITHOUT PRIOR WRITTEN CONSENT
B3-PH-471-00011 Rev H
Ref
Answer
Remark
Action Status
Date
TECNIMONT IDENTIFICATION CODE
HSE DESIGN CONFERENCE BOROUGE 3 PROJECT
3547-SZ-RT-B300011
FEED SERVICES FOR PO,LDPE AND U&O INSTALLATIONS
Sheet 19 of 110
Abu Dhabi Polymers Company Limited (Borouge)
Rev H
BOROUGE IDENTIFICATION CODE
B3-PH-471-00011
No
General Topics
Application field
Discipline
38
PLANT LAYOUT
ESD VALVES
IMPGE
39
PLANT LAYOUT
RELIEF VALVES
IMPGE
Requirement
ESD and major isolation valves are to be preferably located at ground level or shall be provided with good and safe access and be located a minimum of 15 m horizontally from the equipment protected; if additional protection is provided (such as a fireproof protection wall) a distance of 7.5 m is acceptable upon company approval When indicated on P&ID's, relief valves dischargng to atmosphere shall comply with requirements a) -f) point 8.13.4 to protect personnel and equipment
Borealis BERCO- 08-001-04 Requirement
Study/Ref
Subchapter
BGS-LU001
8.10.6
Developed in compliance with the Document.
Closed
8-Sep-09
BGS-LU001
8.13.4
Developed in compliance with the Document.
Closed
8-Sep-09
THIS DOCUMENT IS BOROUGE’S PROPERTY AND CANNOT BE USED BY OTHERS FOR ANY PURPOSE WITHOUT PRIOR WRITTEN CONSENT
B3-PH-471-00011 Rev H
Ref
Answer
Remark
Action Status
Date
TECNIMONT IDENTIFICATION CODE
HSE DESIGN CONFERENCE BOROUGE 3 PROJECT
3547-SZ-RT-B300011
FEED SERVICES FOR PO,LDPE AND U&O INSTALLATIONS
Sheet 20 of 110
Abu Dhabi Polymers Company Limited (Borouge)
Rev H
BOROUGE IDENTIFICATION CODE
B3-PH-471-00011
No
40
41
General Topics
PLANT LAYOUT
PLANT LAYOUT
Application field
EYEWASH EM SHOWERS
GENERAL
Discipline
Requirement
IMPGE
Emergency safety showers / eye washes shall be provided with an appropriate arrangement for continuous flushing to ensure a constant supply of clean water. An arrangement to ensure normal water temperature shall be provided. Water supply piping to emergency showers eye washes shall be arranged so free access is ensured from all directions
IMPGE
Minimum safety distances between plant units and equipment as per GAP 2.5.2 'Oil and Chemical plant layout and spacing'
Study/Ref
BGS-LU001
BGS-LU001
THIS DOCUMENT IS BOROUGE’S PROPERTY AND CANNOT BE USED BY OTHERS FOR ANY PURPOSE WITHOUT PRIOR WRITTEN CONSENT
Subchapter
Borealis BERCO- 08-001-04 Requirement
Ref
Answer
8.23.1
Refer to para 8.6 for criteria for location, minimum water flow, water temperature, material
Par a 8.6 pag 24
Developed in compliance with the Document.
Closed
8-Sep-09
Appendix 1 - 1.0
Minimum safety distances between units as per Table 2
Par a 7.2 pag 15
Refer to Concession request B3-CR-TCMENV-001 approved by Client.
Closed
23-Oct09
B3-PH-471-00011 Rev H
Remark
Action Status
Date
TECNIMONT IDENTIFICATION CODE
HSE DESIGN CONFERENCE BOROUGE 3 PROJECT
3547-SZ-RT-B300011
FEED SERVICES FOR PO,LDPE AND U&O INSTALLATIONS
Sheet 21 of 110
Abu Dhabi Polymers Company Limited (Borouge)
Rev H
BOROUGE IDENTIFICATION CODE
B3-PH-471-00011
No
42
General Topics
PLANT LAYOUT
Application field
FIXED SOURCES OF IGNITION
Discipline
IMPGE
49
ENVIRON MENT
EMISSIONS
IMPGE
43
FIREPRO OFING
BLOCK IN VALVES
IMPGE/STR UM
44
EMISSION S
PUMPS
MACCH
Borealis BERCO- 08-001-04 Requirement
Requirement
Study/Ref
Subchapter
Minimum distances between fixed sources of ignition (furnaces, boilers, offices, laboratories, fixed engines) and LPG handlimg facilities as per requirements given in Appendix 1 - Par 2.5
BGS-LU001
Appendix 1 - 2.5
In PO there is no LPG
Not applicable
BDP-PH03-003
9.2
Developed in compliance with the Document.
Closed
8-Sep-09
BDP-PP03-002
10.4
Developed in compliance with the Document.
Closed
8-Sep-09
Developed in compliance with the Document.
Closed
8-Sep-09
Permanent type sampling arrangement with proper platforms etc., shall be provided to all continuous emission sources as per internationally accepted standards (e.g. US EPA Methods) Block in valves and accessories, when located in a fire protection zones, must be 30 minutes fire resistant Pumps handling materials with high vapour pressure to be seal less or equipped with double seals
BDP-PH03-003
THIS DOCUMENT IS BOROUGE’S PROPERTY AND CANNOT BE USED BY OTHERS FOR ANY PURPOSE WITHOUT PRIOR WRITTEN CONSENT
9.3
Pumps in light hydrocarbon service (> 1.3 kPa@20degC) shall be canned or double/tandem sealed B3-PH-471-00011 Rev H
Ref
Answer
Remark
Action Status
Date
TECNIMONT IDENTIFICATION CODE
HSE DESIGN CONFERENCE BOROUGE 3 PROJECT
3547-SZ-RT-B300011
FEED SERVICES FOR PO,LDPE AND U&O INSTALLATIONS
Sheet 22 of 110
Abu Dhabi Polymers Company Limited (Borouge)
Rev H
BOROUGE IDENTIFICATION CODE
B3-PH-471-00011
No
45
46
General Topics
NOISE
NOISE
Application field
EQUIPMENT
EMERGENCY GENERATOR
Discipline
Requirement
Study/Ref
Subchapter
Borealis BERCO- 08-001-04 Requirement
Ref
Answer
Maximum SPL at 1 m: 80 dBA under operating condition
Par a 10.1 pag 35
MACCH
Maximum spl at 1 m: 85 dB(A), otherwise acoustic attenuation has to be provided
BDP-PH03-003
12
MACCH / ELETTR
The noise limit of the total skid (diesel engine and alternator) shall be less or equal to 85 dB(A) at 1 metre distance
BGS-MA004
13.8
THIS DOCUMENT IS BOROUGE’S PROPERTY AND CANNOT BE USED BY OTHERS FOR ANY PURPOSE WITHOUT PRIOR WRITTEN CONSENT
B3-PH-471-00011 Rev H
Remark
Action Status
Date
Refer to Concession Request B3-CRTCM-ENV-004, Borealis criteria NOT to be applied
Agreed according to BDP-PH-03003
8-Sep-09
Developed in compliance with the Document.
Closed
8-Sep-09
TECNIMONT IDENTIFICATION CODE
HSE DESIGN CONFERENCE BOROUGE 3 PROJECT
3547-SZ-RT-B300011
FEED SERVICES FOR PO,LDPE AND U&O INSTALLATIONS
Sheet 23 of 110
Abu Dhabi Polymers Company Limited (Borouge)
Rev H
BOROUGE IDENTIFICATION CODE
B3-PH-471-00011
No
General Topics
Application field
Discipline
47
NOISE
EQUIPMENT
MACCH
48
NOISE
EQUIPMENT
MACCH
Requirement
For general equipment continuously operating the noise limit is 85 dB(A) at 1 meter distance. If equipment consist of components, the limit shall apply to the equipment (for the single components limits are lower). Further reductions have to be considered for equipment mounted close together or near reverberant areas. For equipment emitting intermittent or fluctuating noise the maximum level shall not exceed of 10 dB(A) the limit for continuous use For equipment outside work area, at position inaccessible to personnel, an increse to the limits is allowed, according to the formulas given in 11.4
Borealis BERCO- 08-001-04 Requirement
Study/Ref
Subchapter
BGSMU-008
11.2, 11.3
Developed in compliance with the Document.
Closed
8-Sep-09
BGSMU-008
11.4
Developed in compliance with the Document.
Closed
8-Sep-09
THIS DOCUMENT IS BOROUGE’S PROPERTY AND CANNOT BE USED BY OTHERS FOR ANY PURPOSE WITHOUT PRIOR WRITTEN CONSENT
B3-PH-471-00011 Rev H
Ref
Answer
Remark
Action Status
Date
TECNIMONT IDENTIFICATION CODE
HSE DESIGN CONFERENCE BOROUGE 3 PROJECT
3547-SZ-RT-B300011
FEED SERVICES FOR PO,LDPE AND U&O INSTALLATIONS
Sheet 24 of 110
Abu Dhabi Polymers Company Limited (Borouge)
Rev H
BOROUGE IDENTIFICATION CODE
B3-PH-471-00011
No
50
51
General Topics
ENVIRON MENT
ENVIRON MENT
Application field
LIQUID EFFLUENT
LIQUID EFFLUENT
Discipline
Borealis BERCO- 08-001-04 Requirement
Requirement
Study/Ref
Subchapter
PROCS
Potentially accidentally oil contaminated waste water which is derived from process paved areas and includes wash-down water, storm water and fire water, shall be sent to a ‘first flush’ interceptor for capture and treatment in the waste water treatment plant. When the ‘first flush’ interceptor is full, water shall overflow to an evaporation pond.
BDP-PH03-003
10
Developed in compliance with the Document.
Closed
8-Sep-09
PROCS
Storm water run-off from roads and nonpaved areas, designated as non oily areas, can be discharged into the sea via storm water culverts if they meet the quality standards for water discharged into the sea as given in Table 7.
10
Table 7 shall be applied for the water treatment of ETP. Storm water run-off from roads and nonpaved areas and overflow from AOC basins will be collected in the Storm water retention lagoon / evaporation pond.
Closed
8-Sep-09
BDP-PH03-003
THIS DOCUMENT IS BOROUGE’S PROPERTY AND CANNOT BE USED BY OTHERS FOR ANY PURPOSE WITHOUT PRIOR WRITTEN CONSENT
B3-PH-471-00011 Rev H
Ref
Answer
Remark
Action Status
Date
TECNIMONT IDENTIFICATION CODE
HSE DESIGN CONFERENCE BOROUGE 3 PROJECT
3547-SZ-RT-B300011
FEED SERVICES FOR PO,LDPE AND U&O INSTALLATIONS
Sheet 25 of 110
Abu Dhabi Polymers Company Limited (Borouge)
Rev H
BOROUGE IDENTIFICATION CODE
B3-PH-471-00011
No
General Topics
Application field
Discipline
52
LIQUID EFFLUEN TS
COOLING WATER
PROCS
53
ISOLATIO N
GENERAL
PROCS
54
ISOLATIO N
EQUIPMENT
PROCS
55
ESD
ESD VALVES
PROCS
Requirement
Maximum delta T for seawater as cooling water is 10 C Positive isolation to be applied to all severe services as defined in 6.2, general isolation to non severe services. Details on positive and general isolation defined in 6.32, 6.3.3 Isolation requirements for different equipment as defined in 6.3.4, 6.3.5, 6.36, 6.3.7, 6.3.8, 6.3.9
Isolation with ESD valves required for vessel containg flammable liquids in excess of 10 m3, suction lines to hydrocarbon punps pumping C4 and lighter, export pipelines
Borealis BERCO- 08-001-04 Requirement
Study/Ref
Subchapter
BDP-PH03-003
10
Developed in compliance with the Document
Closed
8-Sep-09
BDP-PP03-001
6.2
Developed in compliance with the Document
Closed
8-Sep-09
BDP-PP03-001
6.3
Developed in compliance with the Document
Closed
8-Sep-09
Developed in compliance with the Document
Closed
8-Sep-09
BDP-PP03-002
THIS DOCUMENT IS BOROUGE’S PROPERTY AND CANNOT BE USED BY OTHERS FOR ANY PURPOSE WITHOUT PRIOR WRITTEN CONSENT
9.1
Tanks containing more than 10 m3 of hydrocarbons to be equipped with a remotely actuated, fire safe, thermally (melting fuse) activated shutoff valve located at the first bottom flange of the tank / equipment
B3-PH-471-00011 Rev H
Ref
Par a 9.2, pag 25
Answer
Remark
Action Status
Date
TECNIMONT IDENTIFICATION CODE
HSE DESIGN CONFERENCE BOROUGE 3 PROJECT
3547-SZ-RT-B300011
FEED SERVICES FOR PO,LDPE AND U&O INSTALLATIONS
Sheet 26 of 110
Abu Dhabi Polymers Company Limited (Borouge)
Rev H
BOROUGE IDENTIFICATION CODE
B3-PH-471-00011
No
56
General Topics
INSULATI ON
Application field
PIPING
Discipline
PROCS
Requirement
Uninsulated process piping and equipment having an operating temperature of minus 10 C and below must be provided with cold insulation limited within the confines of a working area. Cold insulation is used for personnel protection whenever other alternative protective measures are not suitable
Study/Ref
BGSMN-004
THIS DOCUMENT IS BOROUGE’S PROPERTY AND CANNOT BE USED BY OTHERS FOR ANY PURPOSE WITHOUT PRIOR WRITTEN CONSENT
Subchapter
10.4.5
Borealis BERCO- 08-001-04 Requirement
Ref
Answer
Refer for details to Para 10.10
Par a 10.1 0, pag 40
Developed in compliance with the Document
B3-PH-471-00011 Rev H
Remark
Action Status
Closed
Date
8-Sep-09
TECNIMONT IDENTIFICATION CODE
HSE DESIGN CONFERENCE BOROUGE 3 PROJECT
3547-SZ-RT-B300011
FEED SERVICES FOR PO,LDPE AND U&O INSTALLATIONS
Sheet 27 of 110
Abu Dhabi Polymers Company Limited (Borouge)
Rev H
BOROUGE IDENTIFICATION CODE
B3-PH-471-00011
No
57
General Topics
INSULATI ON
Application field
PIPING
Discipline
PROCS
Requirement
For peronnel protection consideration shall be given first to alternative measures. Insulation for personnel protection is required for continuous operating temperatures greater than 70 C where hot surfaces are in accessible location and will present a safety hazard. When the insulation is required, the extent shall not exceed 2 m above or more than 1 meter away accessible areas. For piping and equipment operating at temperatures below 150 C, personnel protection by means of insulation is not preferred
Study/Ref
Subchapter
BGSMN-100
10.3
THIS DOCUMENT IS BOROUGE’S PROPERTY AND CANNOT BE USED BY OTHERS FOR ANY PURPOSE WITHOUT PRIOR WRITTEN CONSENT
Borealis BERCO- 08-001-04 Requirement
Ref
Answer
Developed in compliance with the Document
B3-PH-471-00011 Rev H
Remark
Action Status
Closed
Date
8-Sep-09
TECNIMONT IDENTIFICATION CODE
HSE DESIGN CONFERENCE BOROUGE 3 PROJECT
3547-SZ-RT-B300011
FEED SERVICES FOR PO,LDPE AND U&O INSTALLATIONS
Sheet 28 of 110
Abu Dhabi Polymers Company Limited (Borouge)
Rev H
BOROUGE IDENTIFICATION CODE
B3-PH-471-00011
No
General Topics
Application field
Discipline
58
PLANT LAYOUT
PUMPS
PROCS
59
ENVIRON MENT
LIQUID EFFLUENT
PROCS
60
HAZARDO US SERVICE
INSTRUMENT
PROCS/IMP GE/STRUM
Requirement
The discharge line shall also have a block valve. A non return valve shall be installed in the discharge line upstream the block valve. Highly corrosive, hazardous or hydrocarbon fluids shall have a drain valve in the discharge line between the non return valve and the block valve All process and process contaminated effluents shall be treated within the site Waste Water Treatment Plant Instrument drain connections in acid/caustic/lethal services to be permanently piped to nearst process sewer, area drain or other drain point. Hazardous services include acid custic toxic fluids and blow downs for fluid at operating temp greater than 260 C
Borealis BERCO- 08-001-04 Requirement
Study/Ref
Subchapter
BGS-LU001
8.5.6
Developed in compliance with the Document
Closed
8-Sep-09
BDP-PH03-003
10
Developed in compliance with the Document
Closed
8-Sep-09
BGS-IU001
20.7
THIS DOCUMENT IS BOROUGE’S PROPERTY AND CANNOT BE USED BY OTHERS FOR ANY PURPOSE WITHOUT PRIOR WRITTEN CONSENT
Ref
Answer
Remark
Action Status
PROCS: Not applicable
B3-PH-471-00011 Rev H
Date
TECNIMONT IDENTIFICATION CODE
HSE DESIGN CONFERENCE BOROUGE 3 PROJECT
3547-SZ-RT-B300011
FEED SERVICES FOR PO,LDPE AND U&O INSTALLATIONS
Sheet 29 of 110
Abu Dhabi Polymers Company Limited (Borouge)
Rev H
BOROUGE IDENTIFICATION CODE
B3-PH-471-00011
No
General Topics
Application field
Discipline
61
HAZARDO US SERVICE
INSTRUMENT
PROCS/IMP GE/STRUM
63
PLANT LAYOUT
CAMPS
SICIM
64
PERSONN EL SAFETY
FIRST AID BOX
SICIM
65
PERSONN EL SAFETY
NOISE LIMITS
SICIM
66
PERSONN EL SAFETY
PORTABLE FIRE EXTINGUISH ERS
SICIM
Requirement
Instrument vent connections in sour/lethal service to be permanently piped to the nearest process vento Areas for temporary facilities to be located such that risks to workers are minimised to ALARP through studies (QRA) One first aid box to be installed in each operator shelter, fire point shelter, electrical substation and IES. FAB suitable for electrical shock injuries to be provided for electrical substation Noise limits to comply with BGS-MU-008, BGS-MU-009. Ambient noise levels to be within limits detailed in BDPPH-003 To be in accordance with BGS-MU-203
Borealis BERCO- 08-001-04 Requirement
Study/Ref
Subchapter
BGS-IU001
20.7
BPM-PH03-007
14.8
Developed in compliance with the Document
Closed
8-Sep-09
BPM-PH03-007
22.2
Developed in compliance with the Document
Closed
8-Sep-09
BPM-PH03-007
22.3
Developed in compliance with the Document
Closed
8-Sep-09
BPM-PH03-007
22.4
Developed in compliance with the Document
Closed
8-Sep-09
THIS DOCUMENT IS BOROUGE’S PROPERTY AND CANNOT BE USED BY OTHERS FOR ANY PURPOSE WITHOUT PRIOR WRITTEN CONSENT
Ref
Answer
Remark
Action Status
Date
PROCS: Not applicable
B3-PH-471-00011 Rev H
TECNIMONT IDENTIFICATION CODE
HSE DESIGN CONFERENCE BOROUGE 3 PROJECT
3547-SZ-RT-B300011
FEED SERVICES FOR PO,LDPE AND U&O INSTALLATIONS
Sheet 30 of 110
Abu Dhabi Polymers Company Limited (Borouge)
Rev H
BOROUGE IDENTIFICATION CODE
B3-PH-471-00011
No
General Topics
Application field
Discipline
67
PERSONN EL SAFETY
SAFETY SHOWERS
SICIM
68
PERSONN EL SAFETY
SAFETY POINTS
SICIM
69
PERSONN EL SAFETY
BRATHING APPARATUS
SICIM
70
PERSONN EL SAFETY
BREATHING AIR
SICIM
71
NOISE
GENERAL
SICIM
72
NOISE
GENERAL
SICIM
Requirement
Wall mounted eyewash fountains for battery rooms. Lighting and emergency lighting to be provided at safety shower locations. Water supply maximum temp below 40 C Refer to 22.6 for the content of safety points (provisions for 2 operators) Refer to 22.7 for breathing apparatuses characteristics Breathing air supply system to be provided for maintenace operations on equipments containing toxic gases SPL lower than 90 dB(A) where the presence of personnel is required for only a short period of time Overall noise limit for units supeimposed on background level: lower than 60 dB(A) in areas outside and 600 m from the process plant fence line (Total noise limit for the project: 57 dB(A))
Borealis BERCO- 08-001-04 Requirement
Study/Ref
Subchapter
BPM-PH03-007
22.5
Developed in compliance with the Document
Closed
8-Sep-09
BPM-PH03-007
22.6
Developed in compliance with the Document
Closed
8-Sep-09
BPM-PH03-007
22.7
Developed in compliance with the Document
Closed
8-Sep-09
BPM-PH03-007
22.9
Developed in compliance with the Document
Closed
8-Sep-09
BDP-PH03-003
12
Developed in compliance with the Document
Closed
8-Sep-09
BDP-PH03-003
12
Developed in compliance with the Document
Closed
8-Sep-09
THIS DOCUMENT IS BOROUGE’S PROPERTY AND CANNOT BE USED BY OTHERS FOR ANY PURPOSE WITHOUT PRIOR WRITTEN CONSENT
B3-PH-471-00011 Rev H
Ref
Answer
Remark
Action Status
Date
TECNIMONT IDENTIFICATION CODE
HSE DESIGN CONFERENCE BOROUGE 3 PROJECT
3547-SZ-RT-B300011
FEED SERVICES FOR PO,LDPE AND U&O INSTALLATIONS
Sheet 31 of 110
Abu Dhabi Polymers Company Limited (Borouge)
Rev H
BOROUGE IDENTIFICATION CODE
B3-PH-471-00011
No
General Topics
Application field
Discipline
Requirement
73
BUILDING S
BLAST RESISTANCE
SICIM
Perform a building risk assessment for each of the EU2, PO, OCU, U&O areas to determine the building classification (Blast resistant, blast resilient, normal). Buildings anticipated to withstand an external overpressure are substations in PO, EU2, OCU, U&O, Satellite instrument shelters in PO, EU2, OCU, U&O, ETP, Operator shelters / satellite mechanical shops in PO and U&O
74
ESD
GENERAL
STRUM
Refer to BDP-PP-002
STRUM
Instrumentation cables as defined in 15.1.1.1 to be fire resistant and in compliance with IEC 60331
75
FIREPRO OFING
CABLES
Study/Ref
Subchapter
Borealis BERCO- 08-001-04 Requirement
Ref
Answer
Control room to be located outside 0.2 bar range of the pressure wave. Service buildings to be located outside 0.04 bar range, or appropriate alternative measures to be considered
Par a 7.3, pag 16
Developed in compliance with the Document
Closed
8-Sep-09
Remark
Action Status
Date
BGS-AU034
15.3
BPM-PH03-007
21
Developed in compliance with the Document
Closed
8-Sep-09
15.1
Cables for ESD,PA and F&G are designed in compliance with IEC 60331 std.
Closed
8-Sep-09
BGS-IU001
THIS DOCUMENT IS BOROUGE’S PROPERTY AND CANNOT BE USED BY OTHERS FOR ANY PURPOSE WITHOUT PRIOR WRITTEN CONSENT
B3-PH-471-00011 Rev H
TECNIMONT IDENTIFICATION CODE
HSE DESIGN CONFERENCE BOROUGE 3 PROJECT
3547-SZ-RT-B300011
FEED SERVICES FOR PO,LDPE AND U&O INSTALLATIONS
Sheet 32 of 110
Abu Dhabi Polymers Company Limited (Borouge)
Rev H
BOROUGE IDENTIFICATION CODE
B3-PH-471-00011
No
76
General Topics
FIREPRO OFING
Application field
ESD VALVES
Discipline
Requirement
Study/Ref
STRUM
Accessories for ESD valves and actuators and remote operated valves to be protected from fire by installation in fire resistant local boxes, rated at least 30 minutes
BGS-IU001
Subchapter
Borealis BERCO- 08-001-04 Requirement
Ref
Answer
Remark
Action Status
15.1.1.2
Accessories for sectionalization ESD valves and actuators and remote operated valves are fire resistant.
Closed
BGSMN-002
1.0, 10.0
The cable trays are not in flammable zones
To be finalized during EPC phase
Date
8-Sep-09
77
FIREPRO OFING
CABLE TRAYS
STRUM / ELETTR
Electrical, instrumentation, control cable trays in flammable zones to be protected in order to allow equipment to operate during the first 30 minutes of fire . The fireproofing system shall prevent the temperature within a cable tray enclosure to exceed 177 C when exposed to an ASTM E119 fire for a nominal period of 60 minutes)
78
NOISE
SAFETY RELIEF
STRUM
Noise limit is 115 dB(A) at 1 meter distance
BGSMU-008
11.6
Developed in compliance with the Document
Closed
8-Sep-09
79
FIRE AND GAS DETECTIO N
F&G DETECTORS
STRUM
All gas detectors are wired to the DCS which carries out the display and alarming.
BDP-PP03-003
11.2
Developed in compliance with the Document
Closed
8-Sep-09
THIS DOCUMENT IS BOROUGE’S PROPERTY AND CANNOT BE USED BY OTHERS FOR ANY PURPOSE WITHOUT PRIOR WRITTEN CONSENT
B3-PH-471-00011 Rev H
TECNIMONT IDENTIFICATION CODE
HSE DESIGN CONFERENCE BOROUGE 3 PROJECT
3547-SZ-RT-B300011
FEED SERVICES FOR PO,LDPE AND U&O INSTALLATIONS
Sheet 33 of 110
Abu Dhabi Polymers Company Limited (Borouge)
Rev H
BOROUGE IDENTIFICATION CODE
B3-PH-471-00011
No
General Topics
Application field
Discipline
80
FIRE AND GAS DETECTIO N
F&G DETECTORS
81
FIRE AND GAS DETECTIO N
F&G DETECTORS
STRUM
82
FIRE AND GAS
GENERAL
STRUM
83
ENVIRON MENT
EMISSIONS
84
ENVIRON MENT
EMISSIONS
87
SPACING
TRANSFORM ERS
STRUM
Requirement
Selected gas detectors are also wired to the Process Fire and Gas Detection System (FGD). These are required for trip actions carried out by the FGD. All fire detection devices shall be wired to the FGD, which will generate alarms in the DCS and in the field.
Study/Ref
Subchapter
BDP-PP03-003
11.2
BDP-PP03-003
11.2
Refer to BGS-IS-003
BPM-PH03-007
17
TECN
Emission limits form point sources
BDP-PH03-003
Table 3
TECN
Emission limits from combustion sources
BDP-PH03-003
Table 2
ELETT
Power transformers shall be located along outside walls (side not facing Process unit) of substation building under sunshade. Fire wall shall be provided between adjcent transformers and both ends. Access to transformers shall be through a lockable mesh gate.
BGS-EU001
18.2
THIS DOCUMENT IS BOROUGE’S PROPERTY AND CANNOT BE USED BY OTHERS FOR ANY PURPOSE WITHOUT PRIOR WRITTEN CONSENT
Borealis BERCO- 08-001-04 Requirement
Ref
Answer
Developed in compliance with the Document
Refer to general criteria provided in Chapter 8.3
Para 8.3, pag 17-18
Action Status
Closed
Date
8-Sep-09
To be done during EPC phase Developed in compliance with the Document Developed in compliance with the Document Developed in compliance with the Document
Developed in compliance with the Document
B3-PH-471-00011 Rev H
Remark
Closed
8-Sep-09
Closed
8-Sep-09
Closed
8-Sep-09
Closed
8-Sep-09
TECNIMONT IDENTIFICATION CODE
HSE DESIGN CONFERENCE BOROUGE 3 PROJECT
3547-SZ-RT-B300011
FEED SERVICES FOR PO,LDPE AND U&O INSTALLATIONS
Sheet 34 of 110
Abu Dhabi Polymers Company Limited (Borouge)
Rev H
BOROUGE IDENTIFICATION CODE
B3-PH-471-00011
No
88
89
General Topics
EXTRUDE R BUILDING S
FIREFIGH TING
Application field
FIRE RESISTANCE OF STAIRCASES
FIREWATER DISTRIBUTIO N SYSTEM
Borealis BERCO- 08-001-04 Requirement
Ref
Answer
IMPGE/EDIL E
The staircase of an extruder building shall be kept separate from the different production floors and shall be as a different fire compartment with a fire rating of 1 hour. Doors accessing different floors, including ground floor, shall be closing fire doors
Para 13.4. 6 pag 49
Developed in compliance with the Document
Closed
8-Sep-09
SICIM
The distribution system shall be divided into different sections to achieve that maximum 5 systems are supplied by each section
Para 8.5.2 pag 20
Borouge criteria shall be used , each system supplied by automatic valve and manual valve located at the opposite corners of the firewater ring around the unit
Closed
8-Sep-09
Discipline
Requirement
Study/Ref
THIS DOCUMENT IS BOROUGE’S PROPERTY AND CANNOT BE USED BY OTHERS FOR ANY PURPOSE WITHOUT PRIOR WRITTEN CONSENT
Subchapter
B3-PH-471-00011 Rev H
Remark
Action Status
Date
TECNIMONT IDENTIFICATION CODE
HSE DESIGN CONFERENCE BOROUGE 3 PROJECT
3547-SZ-RT-B300011
FEED SERVICES FOR PO,LDPE AND U&O INSTALLATIONS
Sheet 35 of 110
Abu Dhabi Polymers Company Limited (Borouge)
Rev H
BOROUGE IDENTIFICATION CODE
B3-PH-471-00011
No
90
90
91
General Topics
Application field
FIREFIGH TING
PROTECTION PHILOSOPHY
FLARE
DESIGN CRITERIA
PLANT LAYOUT
STORAGE TANKS / BUNDS
Borealis BERCO- 08-001-04 Requirement
Ref
Answer
SICIM
In process areas all process equipment containing more than 1 m3 of liquefied hydrocarbons shall be protected with an automatic deluge sprinkler system. Refer to Para 8.5.3 also for other details
Para 8.5.3 pag 21
Refer to Concession request B3-CR-TCM-ENV0002-Rev.1 approved by Client.
Closed
6-Aug-09
AUSI
Refer to para 9.6 for details
Para 9.6 pag 28-29
Developed in compliance with the Document
Closed
8-Sep-09
IMPGE
For bunds, volume capacity equal to 110% of the capacity of the largest tank, maximum bund height 1.5 m
Para 13.4. 2 pag 48
This requirement shall be applied to U&O
Closed
16-Sep09
Discipline
Requirement
Study/Ref
THIS DOCUMENT IS BOROUGE’S PROPERTY AND CANNOT BE USED BY OTHERS FOR ANY PURPOSE WITHOUT PRIOR WRITTEN CONSENT
Subchapter
B3-PH-471-00011 Rev H
Remark
Action Status
Date
TECNIMONT IDENTIFICATION CODE
HSE DESIGN CONFERENCE BOROUGE 3 PROJECT
3547-SZ-RT-B300011
FEED SERVICES FOR PO,LDPE AND U&O INSTALLATIONS
Sheet 36 of 110
Abu Dhabi Polymers Company Limited (Borouge)
Rev H
BOROUGE IDENTIFICATION CODE
B3-PH-471-00011
No
92
General Topics
HAZARDO US AREA CLASSIFI CATION
Application field
GENERAL
Discipline
ELETT
Requirement
Area classification and selection of apparatus for use in areas where there is a flammable dust hazard shall be in accordance with IEC 61241. Equipment enclosure IP ratings to BS EN 60529 shall be applied.
Study/Ref
BGS-EU001
THIS DOCUMENT IS BOROUGE’S PROPERTY AND CANNOT BE USED BY OTHERS FOR ANY PURPOSE WITHOUT PRIOR WRITTEN CONSENT
Subchapter
Borealis BERCO- 08-001-04 Requirement
Ref
16
An electrical area classification shall be done for the whole plant based on the base chemicals and additives used. This classification shall be in accordance with IEC 60079-10 or other equivalent national regulations. Typical drawings from API RP 500 and NFPA 69 should be used to define the magnitude of the classified zones around the potential leak sources.
Para 12.2 pag 44
B3-PH-471-00011 Rev H
Answer
Area classification will be done in accordance with IP15 as per BGSEU-001
Remark
Action Status
Closed
Date
8-Sep-09
TECNIMONT IDENTIFICATION CODE
HSE DESIGN CONFERENCE BOROUGE 3 PROJECT
3547-SZ-RT-B300011
FEED SERVICES FOR PO,LDPE AND U&O INSTALLATIONS
Sheet 37 of 110
Abu Dhabi Polymers Company Limited (Borouge)
Rev H
BOROUGE IDENTIFICATION CODE
B3-PH-471-00011
No
93
General Topics
LIGHTING AND EMERGEN CY LIGHTING
Application field
GENERAL
Discipline
ELETTR / HVAC
Requirement
Half of the 20% of generator fed luminaries in substations and 10% of the generator fed luminaries in control buildings shall be provided with integral 30 minutes battery back-up. Lighting/receptacle distribution Panels shall be located in the area being served. All outgoing circuits in Panels located in plant area shall be controlled by double pole miniature circuit breakers. At least 20% spare outlets shall be provided in each lighting and receptacle distribution Panel.
Study/Ref
BGS-EU001
THIS DOCUMENT IS BOROUGE’S PROPERTY AND CANNOT BE USED BY OTHERS FOR ANY PURPOSE WITHOUT PRIOR WRITTEN CONSENT
Subchapter
Borealis BERCO- 08-001-04 Requirement
15.1.2, 29.0
Regular lighting design should take into account the need for adequate level lumen at those places where regular operating and maintenance actions are expected (e.g. sampling points, catalyst injection, etc.). Emergency lighting shall be provided to illuminate areas where actions might be required during an emergency (control room, motor control centres, rack rooms, etc.), and shall identify exits and illuminate the way to exits and escape routes, as per NFPA 101 or equivalent. Emergency lighting in buildings should be based on independent systems with a capacity of at least 30 minutes, e.g. dry battery, instant restart type, charged by the standard electrical supply. The lighting system shall include testing facilities.
B3-PH-471-00011 Rev H
Ref
Para 12.3 pag 44
Answer
BGS-EU-001 and Borealis Std. will be followed together. Emergency lighting will be fed from emergency diesel generator and provided with 30 minutes battery back up.
Remark
Action Status
Closed
Date
8-Sep-09
TECNIMONT IDENTIFICATION CODE
HSE DESIGN CONFERENCE BOROUGE 3 PROJECT
3547-SZ-RT-B300011
FEED SERVICES FOR PO,LDPE AND U&O INSTALLATIONS
Sheet 38 of 110
Abu Dhabi Polymers Company Limited (Borouge)
Rev H
BOROUGE IDENTIFICATION CODE
B3-PH-471-00011
No
94
General Topics
LIGHTNIN G PROTECTI ON
Application field
GENERAL
Discipline
ELETTR
Requirement
Separate lightning protection systems shall be provided for tall masonry or concrete structures based on the concept of acceptable risk in accordance with BS6651, Code of Practice for Protection of Structures against Lightning. Down conductors of other parts of the lightning protection systems shall not be used for earthing electrical equipment. The system shall be electrically and mechanically bonded directly to the general earthing system. The lightning protection system shall be a maximum of 10 ohms to the main body of earth.
Study/Ref
BGS-EU001
THIS DOCUMENT IS BOROUGE’S PROPERTY AND CANNOT BE USED BY OTHERS FOR ANY PURPOSE WITHOUT PRIOR WRITTEN CONSENT
Subchapter
Borealis BERCO- 08-001-04 Requirement
Ref
32
The need for lightning protection of buildings and structure shall be evaluated. Lightning protection design shall be in accordance with IEC 61024.
Para 12.4 pag 45
B3-PH-471-00011 Rev H
Answer
Lightining protection will be designed in accordance with IEC61024.
Remark
Action Status
Closed
Date
8-Sep-09
TECNIMONT IDENTIFICATION CODE
HSE DESIGN CONFERENCE BOROUGE 3 PROJECT
3547-SZ-RT-B300011
FEED SERVICES FOR PO,LDPE AND U&O INSTALLATIONS
Sheet 39 of 110
Abu Dhabi Polymers Company Limited (Borouge)
Rev H
BOROUGE IDENTIFICATION CODE
B3-PH-471-00011
No
95
General Topics
GROUNDI NG
Application field
GENERAL
Discipline
Requirement
Study/Ref
ELETTR / PROCS
THIS DOCUMENT IS BOROUGE’S PROPERTY AND CANNOT BE USED BY OTHERS FOR ANY PURPOSE WITHOUT PRIOR WRITTEN CONSENT
Subchapter
Borealis BER-CO08-001-04 Requirement
Ref
Buildings and equipment shall be grounded according to National Electric Code or equivalent, ensuring a complete equipotential bonding system in the plant. All flange connections with improper conductivity shall be bounded. For combustible powders and dusts (e.g. polymer) the following shall be fulfilled: · Where couplings without metal contact are used to connect transfer piping for, a noninsulated jumper wire shall be installed across the coupling to maintain electrical continuity and avoid the build-up of static charge. · Flexible hoses shall be conductive. · Equipotential bonding and grounding shall be done between all equipment handling combustible powders and dust. Grounding connections shall be provided for the following: · All sampling points · All loading / unloading points for road tankers
Para 12.5 pag 45
B3-PH-471-00011 Rev H
Answer
Developed in compliance with the Document
Remark
Action Status
Closed
Date
8-Sep-09
TECNIMONT IDENTIFICATION CODE
HSE DESIGN CONFERENCE BOROUGE 3 PROJECT
3547-SZ-RT-B300011
FEED SERVICES FOR PO,LDPE AND U&O INSTALLATIONS
Sheet 40 of 110
Abu Dhabi Polymers Company Limited (Borouge)
Rev H
BOROUGE IDENTIFICATION CODE
B3-PH-471-00011
No
96
97
General Topics
TRANSFO RMERS
EXTRUDE R BUILDING
Application field
GENERAL
FORCED VENTILATION
Discipline
Requirement
Study/Ref
Subchapter
Borealis BERCO- 08-001-04 Requirement
ELETTR / EDILE
High voltage transformers for outdoor service shall be located at least 50 m from any flammable storage. Transformers containing insulation oil (which should be of the less flammable type) shall be at least 15 m distance from other facilities. As an alternative fire resistant barriers (2 hours) shall be erected between each transformer and between transformer(s) and adjacent facilities. The transformer oil shall not contain any PCB. Drainage of leaking oil to a safe catch basin shall be provided.
HVAC
A general and local ventilation system shall be installed. The system shall be capable of removing the produced heat, extruder vapour, vapours from from melted polymer and the dust from polymer and solid additives.
THIS DOCUMENT IS BOROUGE’S PROPERTY AND CANNOT BE USED BY OTHERS FOR ANY PURPOSE WITHOUT PRIOR WRITTEN CONSENT
B3-PH-471-00011 Rev H
Ref
Answer
Remark
Action Status
Para 12.6 pag 45
CIVIL: the leaking oil of the transformers shall be collected in the safe catch basin of transformers pit. The storm water should be collected in the clean water net. To be defined during EPC phase.
To be defined during EPC phase
Para 13.4. 6
Developed in compliance with the Document
Closed
Date
17-Sep09
TECNIMONT IDENTIFICATION CODE
HSE DESIGN CONFERENCE BOROUGE 3 PROJECT
FEED SERVICES FOR PO,LDPE AND U&O INSTALLATIONS
3547-SZ-RT-B300011 Sheet 41 of 110
Abu Dhabi Polymers Company Limited (Borouge)
Rev H
BOROUGE IDENTIFICATION CODE
B3-PH-471-00011
ATTACHMENT 3b - HSE Design Conference Requirements Status LDPE
THIS DOCUMENT IS BOROUGE’S PROPERTY AND CANNOT BE USED BY OTHERS FOR ANY PURPOSE WITHOUT PRIOR WRITTEN CONSENT
B3-PH-471-00011 Rev H
TECNIMONT IDENTIFICATION CODE
HSE DESIGN CONFERENCE BOROUGE 3 PROJECT
3547-SZ-RT-B300011
FEED SERVICES FOR PO,LDPE AND U&O INSTALLATIONS
Sheet 42 of 110
Rev H
BOROUGE IDENTIFICATION CODE
Abu Dhabi Polymers Company Limited (Borouge)
B3-PH-471-00011
No
General Topics
Application field
Discipline
BOROUGE Requirement
Study/ Ref
Subchapter
BASELL Requirements
Subchapter
Answer
Remarks
Action Status
Date
Closed
14-Sep-09
Noise level in building and offices as per Table 10.3.2 of BGS-MU-008
1
NOISE
BUILDINGS
EDILE
Noise level limits in buildings and offices as defined in Table in 10.3.2
BGSMU008
10.3.2
No specific requirements by BASELL
THIS DOCUMENT IS BOROUGE’S PROPERTY AND CANNOT BE USED BY OTHERS FOR ANY PURPOSE WITHOUT PRIOR WRITTEN CONSENT
B3-PH-471-00011 Rev H
Noise Specialists will do a study of acoustic impact and a study for vibration reduction for Hyper and Booster Compressors shelter to evaluate panel type.
Hyper and Booster Compressor buildings will be a completely Open type Structure.
TECNIMONT IDENTIFICATION CODE
HSE DESIGN CONFERENCE BOROUGE 3 PROJECT
3547-SZ-RT-B300011
FEED SERVICES FOR PO,LDPE AND U&O INSTALLATIONS
Sheet 43 of 110
Rev H
BOROUGE IDENTIFICATION CODE
Abu Dhabi Polymers Company Limited (Borouge)
B3-PH-471-00011
No
3
General Topics
BUILDIN GS
Application field
BLAST RESISTANC E
Discipline
EDILE
BOROUGE Requirement
Study/ Ref
Subchapter
BASELL Requirements
The control room shall be designed for “low response” (ASCE definition) to the predicted dynamic overpressure from a Vapour Cloud Explosion in the adjacent process area. The predicted pressures shall be determined from a VCE explosion risk assessment study. See figure 1 and section F4.4 and F4.5 (indicates that duratiuon of overpressure wave is 40 milliseconds) that indicates overpressures from an explosion in the reactor cell, which could result in higher overpressures . Note3 For Service Buildings less than 200 m, the windows shall be tempered or laminated safety glass, approved plastic glazing or be protected with plastic film, and the building must be built to be resilient to the actual predicted overpressure (damage but no collapse) based on the “Service Building Overpressure Design” curve (Table 2).
THIS DOCUMENT IS BOROUGE’S PROPERTY AND CANNOT BE USED BY OTHERS FOR ANY PURPOSE WITHOUT PRIOR WRITTEN CONSENT
Subchapter
Answer
B2.2.1.1, B2.2.1.4, B2.2.1.5, B2.2.1.6, B2.2.1.7, B2.2.1.8, Note 3 Table 2 (table of distance)
Point B2.2.1.2 The MCC, instrument rack room and the battery room shall be separated from the main control room with two hour fire resistant walls (more conservative than Basell req.) Point B2.2 LDPE Plant in Borouge 3 Project has NOT a dedicated control room, the LDPE control room is in the Main Control Room.
B3-PH-471-00011 Rev H
Remarks
Applied
Action Status
Date
Closed
2-Sep-09
TECNIMONT IDENTIFICATION CODE
HSE DESIGN CONFERENCE BOROUGE 3 PROJECT
3547-SZ-RT-B300011
FEED SERVICES FOR PO,LDPE AND U&O INSTALLATIONS
Sheet 44 of 110
Rev H
BOROUGE IDENTIFICATION CODE
Abu Dhabi Polymers Company Limited (Borouge)
B3-PH-471-00011
No
General Topics
Application field
Discipline
4
NOISE
BUILDINGS
EDILE
5
NOISE
BUILDINGS
EDILE
6
FIRE RESISTA NCE
BUILDINGS
EDILE
BOROUGE Requirement
Sound pressure levels according to limits defined in BGS-AU-063 Background noise levels in occupied buildings during normal operation not exceeding limits contained in CISBE guide
Fire ratings on the basis of Table in Attachment 2
Study/ Ref
Subchapter
BASELL Requirements
BGSAU034
15.4
No specific requirements by BASELL
BGSAU034
15.4
No specific requirements by BASELL
Attachmen t2
A11.1.12 All walls specified as fireresistant walls shall be two-hour fire rated walls. All openings in fire walls, such as doors and ducts, shall have the same rating as the wall. A10.1.13 Where cables, conduit, or piping penetrate fire resistant walls, the opening shall be sealed with an approved sealant having the required fire rating.
BGSAU034
THIS DOCUMENT IS BOROUGE’S PROPERTY AND CANNOT BE USED BY OTHERS FOR ANY PURPOSE WITHOUT PRIOR WRITTEN CONSENT
Subchapter
A.11.1.12
B3-PH-471-00011 Rev H
Answer
Remarks
Action Status
Date
BGS-AU-034 shall be followed.
Closed
2-Sep-09
BGS-AU-034 shall be followed.
Closed
2-Sep-09
Already applied
Closed
2-Sep-09
TECNIMONT IDENTIFICATION CODE
HSE DESIGN CONFERENCE BOROUGE 3 PROJECT
3547-SZ-RT-B300011
FEED SERVICES FOR PO,LDPE AND U&O INSTALLATIONS
Sheet 45 of 110
Rev H
BOROUGE IDENTIFICATION CODE
Abu Dhabi Polymers Company Limited (Borouge)
B3-PH-471-00011
No
7
8
General Topics
NOISE
FIRE RESISTA NCE
Application field
BUILDINGS
POWER TRANSFOR MER
Discipline
BOROUGE Requirement
Study/ Ref
Subchapter
BASELL Requirements
EDILE/ HVAC
Noise caused by HVAC equipment shall be 10 db(A) below the noise level acceptable limits stated for the applicable buildings. In electrical equipment and rack equipment room the limit is 70 dB(A), in HVAC equipment room the limit is 85 dB(A)
BGSAU063
14.6
No specific requirements by BASELL
18.2
Where oil filled transformers are used, the separation distance between the building and the transformer and between transformers is dependent on the volume of oil in the transformer and the flammability of the oil. Separation distances shall be per Table 3A and 3B in Table 3. Where it is not practical to safeguard with separation distances, fire resistant barriers shall be erected between adjacent transformers and other facilities, or sprinkler protection shall be provided over the transformers.
EDILE
Power transformers to be separated by fire resistant walls
BGSEU001
THIS DOCUMENT IS BOROUGE’S PROPERTY AND CANNOT BE USED BY OTHERS FOR ANY PURPOSE WITHOUT PRIOR WRITTEN CONSENT
Subchapter
A13.12.2
B3-PH-471-00011 Rev H
Answer
Remarks
Action Status
Date
BGS-AU-063 shall be followed.
Closed
2-Sep-09
Already applied
Closed
2-Sep-09
TECNIMONT IDENTIFICATION CODE
HSE DESIGN CONFERENCE BOROUGE 3 PROJECT
3547-SZ-RT-B300011
FEED SERVICES FOR PO,LDPE AND U&O INSTALLATIONS
Sheet 46 of 110
Rev H
BOROUGE IDENTIFICATION CODE
Abu Dhabi Polymers Company Limited (Borouge)
B3-PH-471-00011
No
9
General Topics
FIREPRO OFING
Application field
GENERAL
Discipline
EDILE
BOROUGE Requirement
Minimum requirement shall be 3 hours protection from hydrocarbon fire. Fireproofing details in accordance with BTDCU-00104 (50 mm minimum thickness) and BTD-MD-00011. Standard material for fireproofing is concrete (see BGS-CU-010, BGS-CU-014). Fireprrofing of cable trays detailed in BGSMN-002
Study/ Ref
BGSCU012
Subchapter
BASELL Requirements
Subchapter
Answer
1
Steel building columns, beams and vessel skirts supporting major equipment containing LPG or flammables shall be fire protected with automatic sprinklers directed into the column web, or with a 1 1/2 hour fire resistant insulation (See NFPA 251). Columns with skirts shall be fire proofed to 7.5m or to the height of the skirtif lower than 7.5m with fire resistant insulation.
A11.1.5 General
As per Basell fireproofing shall last 1 1/2 hours as minimum requirement.
THIS DOCUMENT IS BOROUGE’S PROPERTY AND CANNOT BE USED BY OTHERS FOR ANY PURPOSE WITHOUT PRIOR WRITTEN CONSENT
B3-PH-471-00011 Rev H
Remarks
This Basell minimum requirement’s been applied.
Action Status
Date
Closed
2-Sep-09
TECNIMONT IDENTIFICATION CODE
HSE DESIGN CONFERENCE BOROUGE 3 PROJECT
3547-SZ-RT-B300011
FEED SERVICES FOR PO,LDPE AND U&O INSTALLATIONS
Sheet 47 of 110
Rev H
BOROUGE IDENTIFICATION CODE
Abu Dhabi Polymers Company Limited (Borouge)
B3-PH-471-00011
No
10
12
General Topics
Application field
FIREPRO OFING
VESSELS
NOISE
POWER TRANSFOR MER
Discipline
BOROUGE Requirement
Study/ Ref
Subchapter
BASELL Requirements
EDILE
Skirts of vessels located in process areas or skirts of vessels containing hydrocarbons outside of a process area shall be externally fireproofed with 50 mm thick concrete. Internal fireprrofing is not required
BGSMD001
10.12
Steel building columns, beams and vessel skirts supporting major equipment containing LPG or flammables shall be fire protected with automatic sprinklers directed into the column web, or with a 1 1/2 hour fire resistant insulation (See NFPA 251). Columns with skirts shall be fire proofed to 7.5m or to the height of the skirt (which ever is greater) with fire resistant insulation. Additionally, structures within 7.5m horizontal distance that support equipment that has potential to add fuel or escalate the fire shall be fireproofed. Fire protection on columns shall extend to a height of 7.5m (25ft) above ground level, and 7.5m (25ft) above a solid floor. Intumescent paint shall only be used for fire proofing where approved by Basell Corporate HSE.
ELETT
Noise limits at 0.3 m not exceeding results of formula given in 17.1.11
BGSEE003
17.1.11
No specific requirements from BASELL
THIS DOCUMENT IS BOROUGE’S PROPERTY AND CANNOT BE USED BY OTHERS FOR ANY PURPOSE WITHOUT PRIOR WRITTEN CONSENT
Subchapter
Answer
B2.1.2 Process Area
As per Basell fireproofing shall last 1 1/2 hours as minimum requirement.
B3-PH-471-00011 Rev H
Developed in compliance with the Document
Remarks
This Basell minimum requirement’s been applied.
Action Status
Date
Closed
2-Sep-09
Closed
2-Sep-09
TECNIMONT IDENTIFICATION CODE
HSE DESIGN CONFERENCE BOROUGE 3 PROJECT
3547-SZ-RT-B300011
FEED SERVICES FOR PO,LDPE AND U&O INSTALLATIONS
Sheet 48 of 110
Rev H
BOROUGE IDENTIFICATION CODE
Abu Dhabi Polymers Company Limited (Borouge)
B3-PH-471-00011
No
General Topics
Application field
Discipline
BOROUGE Requirement
Study/ Ref
Subchapter
BASELL Requirements
BGSEU001
18.2
No specific requirements from BASELL
BGSEU001
18.4
No specific requirements from BASELL
13
SPACING
ELECTRICAL EQUIPMENT
ELETT
Working clearances between electrical equipment as per 18.2
14
HAZARD OUS AREA CLASS
BATTERY ROOMS
ELETT
All electrical equipment suitable for Zone 1, II C
150
HAZARD OUS AREA CLASS
GENERAL
ELETT
Where hydrogen is used or can be formed (battery charging), and can exceed 30% by volume, a Zone 2, Group C, or equivalent classification shall extend to a height of 7.5m (25 ft) above and 5m (15 ft) below (or to ground level) a potential leak source for a radius of 5 m (15 ft).
THIS DOCUMENT IS BOROUGE’S PROPERTY AND CANNOT BE USED BY OTHERS FOR ANY PURPOSE WITHOUT PRIOR WRITTEN CONSENT
Subchapter
A13.5
B3-PH-471-00011 Rev H
Answer
Remarks
Action Status
Date
Developed in compliance with the Document
Closed
2-Sep-09
Developed in compliance with the Document
Closed
2-Sep-09
Developed in compliance with the Document
Closed
2-Sep-09
TECNIMONT IDENTIFICATION CODE
HSE DESIGN CONFERENCE BOROUGE 3 PROJECT
3547-SZ-RT-B300011
FEED SERVICES FOR PO,LDPE AND U&O INSTALLATIONS
Sheet 49 of 110
Rev H
BOROUGE IDENTIFICATION CODE
Abu Dhabi Polymers Company Limited (Borouge)
B3-PH-471-00011
No
General Topics
15
SAFE SHUTDO WN
19
PLANT LAYOUT
25
INSULATI ON
Application field
Discipline
BOROUGE Requirement
The instrumented systems in each SIS and CCR shall be protected from loss of power by an uninterruptible power supply (UPS) capable of maintaining these systems in operation long enough to achieve a controlled shutdown of the whole plant.
Study/ Ref
BDPPP03003
Subchapter
BASELL Requirements
Subchapter
Answer
15
An Uninterruptible Power Supply (UPS) designed to provide a minimum of 30 minutes supply shall be installed in case of power failure to allow the plant to be shut down in a safe orderly manner. An alarm shall be provided to indicate when the UPS is off line (UPS failure or in manual bypass). The alarm shall continue until the UPS is back in the primary source condition, and the DCS shall be designed to re-alarm every 10 minutes. Another alarm shall be provided to alarm when the DCS is under battery power. This alarm shall be repeated every 10 minutes.
A13.22
UPS
ELETT
ROADS
IMPGE/SI CIM
Escape access ways should be as straight and obstruction free as possible.
IMPGE/P ROCS
Hot surfaces shall be insulated for personnel protection as required. Maximum allowed surface temperature without protection is 60oC (140oF).
PIPING
THIS DOCUMENT IS BOROUGE’S PROPERTY AND CANNOT BE USED BY OTHERS FOR ANY PURPOSE WITHOUT PRIOR WRITTEN CONSENT
Action Status
Date
Developed in compliance with the Document
Closed
2-Sep-09
A8.1 point 11
Developed in compliance with the Document
Closed
26-Aug-09
A14.2
Insulation for hot surfaces is excluded if they are caused by solar radiation.
Closed
26-Aug-09
B3-PH-471-00011 Rev H
Remarks
TECNIMONT IDENTIFICATION CODE
HSE DESIGN CONFERENCE BOROUGE 3 PROJECT
3547-SZ-RT-B300011
FEED SERVICES FOR PO,LDPE AND U&O INSTALLATIONS
Sheet 50 of 110
Rev H
BOROUGE IDENTIFICATION CODE
Abu Dhabi Polymers Company Limited (Borouge)
B3-PH-471-00011
No
General Topics
Application field
Discipline
26
HAZARD OUS MATERIA LS
MANAGEM ENT
IMPGE/P ROCS
27
PIPING
FLANGE PROTECTO RS
IMPGE
BOROUGE Requirement
Study/ Ref
Subchapter
BASELL Requirements
G2.3 Solid Waste Waste waxes are a normal unavoidable by-product of the high pressure LDPE process. These are collected for disposal OSBL (e.g. incineration). Other solid wastes are from spillages or packaging of raw materials which have to be managed locally to minimise such wastes and recycle where possible. G2.4 Liquid Waste Waste oil and ethylene oligomers are a normal unavoidable by-product of the high pressure LDPE process. These are collected in a closed system to allow disposal OSBL (e.g. incineration). Waste peroxide / solvent should be minimised by good operating practices. All waste material from draining and flushing equipment is collected in the slops vessel for disposal OSBL (e.g. incineration). Flanges in lines containing hot oil, acids and caustic shall be protected with flange covers.
THIS DOCUMENT IS BOROUGE’S PROPERTY AND CANNOT BE USED BY OTHERS FOR ANY PURPOSE WITHOUT PRIOR WRITTEN CONSENT
Subchapter
Answer
G2.3 G2.4
Solid waste and solid waxes will be collected in a drum located in an accessible area. Waste peroxide / solvent will be collected in a slop tank located near Peroxide Dosing. Due to changes in the Layout, Peroxide storage and Peroxide Dosing are connected by means of pipe of about 50m.
A12.29
Developed in compliance with the Document
B3-PH-471-00011 Rev H
Remarks
Pipe between Peroxide Storage and Peroxide Dosing is designed as per Basell PDP philosophy.
Action Status
Date
Closed
12-Oct-09
Closed
26-Aug-09
TECNIMONT IDENTIFICATION CODE
HSE DESIGN CONFERENCE BOROUGE 3 PROJECT
3547-SZ-RT-B300011
FEED SERVICES FOR PO,LDPE AND U&O INSTALLATIONS
Sheet 51 of 110
Rev H
BOROUGE IDENTIFICATION CODE
Abu Dhabi Polymers Company Limited (Borouge)
B3-PH-471-00011
No
28
29
General Topics
LIQUID EFFLUEN TS
LIQUID EFFLUEN TS
Application field
PAVED AREAS
NON PAVED AREAS
Discipline
BOROUGE Requirement
Study/ Ref
Subchapter
BASELL Requirements
Subchapter
Answer
G3 Soil and groundwater protection
Effluent coming from LDPE Plant will be treated by U&O. Inform U&O Dep.
IMPGE / PROCS
Potential accidentaly oil contaminated waters from process paved areas to be sent to a first flush interceptor . When the interceptor is full, water shall overflow to an evaporation pond
BDPPH03003
10
Relatively little liquid is handled within the main process units. Those areas where liquid ispresent or there is a chance of spillage due to handling and / or maintenance work (peroxidedosing, Propionaldehyde dosing, Vinyl Acetate (if applicable) dosing, compressors, extruder lube & hydraulic oil system, hydraulic oil system, media loading/unloading station) are equipped with impermeable flooring and liquid is collected and directed to the continuously contaminated sewer.The bulk storage areas should be treated similarly.
IMPGE
Storm water run off from road and non paved areas to be discharged into sea via storm water culverts provide they meet the quality standard for water discharged into the sea (Table 7)
BDPPH03003
10
No specific requirements by Basell
THIS DOCUMENT IS BOROUGE’S PROPERTY AND CANNOT BE USED BY OTHERS FOR ANY PURPOSE WITHOUT PRIOR WRITTEN CONSENT
B3-PH-471-00011 Rev H
Same philosophy applied to all Borouge 3 Complex
Remarks
Action Status
Closed
Closed
Date
12-Oct-09
26-Aug-09
TECNIMONT IDENTIFICATION CODE
HSE DESIGN CONFERENCE BOROUGE 3 PROJECT
3547-SZ-RT-B300011
FEED SERVICES FOR PO,LDPE AND U&O INSTALLATIONS
Sheet 52 of 110
Rev H
BOROUGE IDENTIFICATION CODE
Abu Dhabi Polymers Company Limited (Borouge)
B3-PH-471-00011
No
30
31
General Topics
PLANT LAYOUT
PLANT LAYOUT
32
PLANT LAYOUT
33
PLANT LAYOUT
Application field
GENERAL
EQUIPMEN T
GENERAL
GENERAL
BOROUGE Requirement
Study/ Ref
Subchapter
BASELL Requirements
Subchapter
Answer
IMPGE / EDILE
Onsite - The equipment shall be installed to keep a minimum safety distance indicated in 'Oil and Chemical Plant Layout Spacing' GAP 252 -2001 Refer also to Appendix 1
BGSLU001
8.1.1 and Appendix 1
Table 2 of Safety Distance
Table 2
IMPGE
Equipment which is a potential source of fire shall not be installed under pipe racks
8.1.4
Equipment or vessels containing flammable or combustible materials shall not be located under exit stairs or piperacks.
Discipline
BGSLU001
IMPGE/SI CIM / EDILE
A minimum of two entry points shall be provided for each unit and these shall be barrier controlled
BGSLU001
8.1.10
At least two means of egress, 75 cm minimum width, shall be provided from all process areas handling flammable materials larger than 20m2 (200ft2) or where direct egress is hampered by equipment containing flammable materials. Exits shall be remote from each other.
IMPGE
Minimum clearance for equipment, structures, platforms and supports on the basis of table in 8.3.1
BGSLU001
8.3.1
No specific requirements by Basell
THIS DOCUMENT IS BOROUGE’S PROPERTY AND CANNOT BE USED BY OTHERS FOR ANY PURPOSE WITHOUT PRIOR WRITTEN CONSENT
Action Status
Date
Developed in compliance with the Document 3547XX-DG-L300001
Closed
18-Sep-09
A11.1.6
Developed in compliance with the document.
Closed
26-Aug-09
A11.1.17
Agreed for all areas of LDPE. Major topics: Openings in the Reactor Cell
Closed
27-Aug-09
Closed
26-Aug-09
B3-PH-471-00011 Rev H
Developed in compliance with the document.
Remarks
As per Basell PDP, reactor cell on the side of blow down vessel & HP separator doesn't need any door.
TECNIMONT IDENTIFICATION CODE
HSE DESIGN CONFERENCE BOROUGE 3 PROJECT
3547-SZ-RT-B300011
FEED SERVICES FOR PO,LDPE AND U&O INSTALLATIONS
Sheet 53 of 110
Rev H
BOROUGE IDENTIFICATION CODE
Abu Dhabi Polymers Company Limited (Borouge)
B3-PH-471-00011
No
General Topics
Application field
Discipline
34
PLANT LAYOUT
PUMPS
IMPGE
35
PLANT LAYOUT
ESD VALVES
IMPGE/P ROCS
36
PLANT LAYOUT
FIRED EQUIPMEN T
IMPGE
37
PLANT LAYOUT
HEATER STACKS
IMPGE
BOROUGE Requirement
Pumps shall be located close to the equipment from which they take suction. Pumps that are a potential source of fire shall not be located under pipe racks or air coolers; a minimum of 1 m clear space shall be maintained between the edge of the pipe rack and or the edge of an air cooler to the pump coupling ESD valves at liquid outlets shall be installed directly onto the vessel flange. No spool piece is allowed between the vessel falnge and the ESD valve. Fired equipment shall, if practical, be located so that flammable gases from hydrocarbon or other processing areas cannot be blown into the open flames by prevailing winds Heater stacks shall terminate a minimum of 4.6 m above any platform within a radius of 12.5 m
Study/ Ref
Subchapter
BASELL Requirements
Subchapter
Answer
BGSLU001
8.5.1
Flammable liquid pumps shall not be located under piperacks (at least 3m away) and should be located on the outside of the process where they are easily accessible for firefighting.
A12.33
BGSLU001
8.7.18
No specific requirements by BASELL
BGSLU001
8.8.1
No specific requirements by BASELL
BGSLU001
8.8.4
No specific requirements by BASELL
THIS DOCUMENT IS BOROUGE’S PROPERTY AND CANNOT BE USED BY OTHERS FOR ANY PURPOSE WITHOUT PRIOR WRITTEN CONSENT
B3-PH-471-00011 Rev H
Remarks
Action Status
Date
Developed in compliance with the document.
Closed
26-Aug-09
As per P&IDs
Closed
26-Aug-09
Not Applicable
To be applied to RTO
Closed
26-Aug-09
TECNIMONT IDENTIFICATION CODE
HSE DESIGN CONFERENCE BOROUGE 3 PROJECT
3547-SZ-RT-B300011
FEED SERVICES FOR PO,LDPE AND U&O INSTALLATIONS
Sheet 54 of 110
Rev H
BOROUGE IDENTIFICATION CODE
Abu Dhabi Polymers Company Limited (Borouge)
B3-PH-471-00011
No
38
General Topics
PLANT LAYOUT
Application field
ESD VALVES
Discipline
IMPGE
BOROUGE Requirement
ESD and major isolation valves are to be preferably located at ground level or shall be provided with good and safe access and be located a minimum of 15 m horizontally from the equipment protected; if additional protection is provided (such as a fireproof protection wall) a distance of 7.5 m is acceptable upon company approval
Study/ Ref
BGSLU001
Subchapter
8.10.6
BASELL Requirements
Subchapter
No specific requirements by BASELL
THIS DOCUMENT IS BOROUGE’S PROPERTY AND CANNOT BE USED BY OTHERS FOR ANY PURPOSE WITHOUT PRIOR WRITTEN CONSENT
B3-PH-471-00011 Rev H
Answer
P&ID shall mark requirement for ESD valves. At Battery limit, in case of space constraints and when the accessibility can be granted with platform and stairs, ESD valves can be located also in elevation.
Remarks
Action Status
To verify in 3D Model during EPC phase
Date
TECNIMONT IDENTIFICATION CODE
HSE DESIGN CONFERENCE BOROUGE 3 PROJECT
3547-SZ-RT-B300011
FEED SERVICES FOR PO,LDPE AND U&O INSTALLATIONS
Sheet 55 of 110
Rev H
BOROUGE IDENTIFICATION CODE
Abu Dhabi Polymers Company Limited (Borouge)
B3-PH-471-00011
No
39
General Topics
PLANT LAYOUT
Application field
RELIEF VALVES
Discipline
PIPING / PROCS / STRUM
BOROUGE Requirement
When indicated on P&ID's, relief valves dischargng to atmosphere shall comply with requirements a) -f) point 8.13.4 to protect personnel and equipment
Study/ Ref
BGSLU001
Subchapter
BASELL Requirements
8.13.4
A12.23 Where pressure or vacuum can exceed the design of a vessel, emergency relief shall be provided as per API 520 for pressure vessels or API 2000 for atmospheric/low pressure storage tanks, or applicable design code. All relief devices shall discharge to a safe location. Discharge piping from safety relief devices shall be adequately supported to avoid movement during releases. Nitrogen, steam or other hazardous materials shall be vented outside the building. For high pressure equipment with a design pressure of 325 bar or greater, emergency relief shall be provided as per ADMerkblatt A1 and A2.
THIS DOCUMENT IS BOROUGE’S PROPERTY AND CANNOT BE USED BY OTHERS FOR ANY PURPOSE WITHOUT PRIOR WRITTEN CONSENT
Subchapter
A12.23
B3-PH-471-00011 Rev H
Answer
PIPING: HP vent line discharge vertically.
Remarks
Normal relief devices are designed as per API std. API std are NOT applicable for high pressure devices, so high pressure devices will be designd as per ADMerkblatt std that is a consolidate std (as per PDP too).
Action Status
Closed
Date
9-Sep-09
TECNIMONT IDENTIFICATION CODE
HSE DESIGN CONFERENCE BOROUGE 3 PROJECT
3547-SZ-RT-B300011
FEED SERVICES FOR PO,LDPE AND U&O INSTALLATIONS
Sheet 56 of 110
Rev H
BOROUGE IDENTIFICATION CODE
Abu Dhabi Polymers Company Limited (Borouge)
B3-PH-471-00011
No
40
General Topics
PLANT LAYOUT
Application field
EYEWASH EM SHOWERS
Discipline
IMPGE/SI CIM/AUSI
BOROUGE Requirement
Emergency safety showers / eye washes shall be provided with an appropriate arrangement for continuous flushing to ensure a constant supply of clean water. An arrangement to ensure normal water temperature shall be provided. Water supply piping to emergency showers eye washes shall be arranged so free access is ensured from all directions
Study/ Ref
BGSLU001
Subchapter
BASELL Requirements
Subchapter
Answer
8.23.1
The water should be circulated to prevent stagnation. The minimum flow rate shall be 75 lit/m (20 gpm) for showers and 1.5 lit/min. (0.4 gpm) for eyewashes . A14.1.2 In the ISBL the water supply system shall be designed to deliver water to two safety showers simultaneously. A14.1.3 Safety showers and eyewashes shall have good access and shall be clearly identified. A14.1.4 The maximum travel distance to a shower should be 15m (50ft) from the point of exposure. Design should not require travel between floors to access a safety shower or eyewash station. A14.1.5 Activation of a Safety Showers/eyewash shall sound an alarm in the control room, and shall identify the location of the shower/eyewash. A14.1.6 Safety showers and eye wash stations shall be protected from overheating from solar radiation in hot climates.
A14.1 (from A14.1.1 to A14.1.6)
Developed in compliance with the document.
THIS DOCUMENT IS BOROUGE’S PROPERTY AND CANNOT BE USED BY OTHERS FOR ANY PURPOSE WITHOUT PRIOR WRITTEN CONSENT
B3-PH-471-00011 Rev H
Remarks
Action Status
Date
Closed
26-Aug-09
TECNIMONT IDENTIFICATION CODE
HSE DESIGN CONFERENCE BOROUGE 3 PROJECT
3547-SZ-RT-B300011
FEED SERVICES FOR PO,LDPE AND U&O INSTALLATIONS
Sheet 57 of 110
Rev H
BOROUGE IDENTIFICATION CODE
Abu Dhabi Polymers Company Limited (Borouge)
B3-PH-471-00011
No
General Topics
Application field
Discipline
41
PLANT LAYOUT
GENERAL
IMPGE
42
PLANT LAYOUT
FIXED SOURCES OF IGNITION
IMPGE
49
ENVIRON MENT
EMISSIONS
IMPGE/P ROCS
BOROUGE Requirement
Minimum safety distances between equipment as per GAP 2.5.2 'Oil and Chemical plant layout and spacing' Minimum distances between fixed sources of ignition (furnaces, boilers, offices, laboratories, fixed engines) and LPG handlimg facilities as per requirements given in Appendix 1 Par 2.5 Permanent type sampling arrangement with proper platforms etc., shall be provided to all continuous emission sources as per internationally accepted standards (e.g. US EPA Methods)
Study/ Ref
Subchapter
BASELL Requirements
Subchapter
Answer
BGSLU001
Appendix 1 - 1.0
Table 2 of Safety Distance
Table 2
BGSLU001
Appendix 1 - 2.5
Table 2 of Safety Distance
Table 2
BDPPH03003
9.2
No specific requirements by Basell
THIS DOCUMENT IS BOROUGE’S PROPERTY AND CANNOT BE USED BY OTHERS FOR ANY PURPOSE WITHOUT PRIOR WRITTEN CONSENT
B3-PH-471-00011 Rev H
Remarks
Action Status
Date
Developed in compliance with the document.
Closed
26-Aug-09
Developed in compliance with the document.
Closed
26-Aug-09
The only continuous emission source for LDPE Plant is the stack on RTO, which is provided of a permanent platform for manual sampling.
Closed
9-Sep-09
TECNIMONT IDENTIFICATION CODE
HSE DESIGN CONFERENCE BOROUGE 3 PROJECT
3547-SZ-RT-B300011
FEED SERVICES FOR PO,LDPE AND U&O INSTALLATIONS
Sheet 58 of 110
Rev H
BOROUGE IDENTIFICATION CODE
Abu Dhabi Polymers Company Limited (Borouge)
B3-PH-471-00011
No
43
General Topics
ESD VALVES FIREPRO OFING
Application field
BLOCK IN VALVES
Discipline
PIPING /STRUM / PROCS
BOROUGE Requirement
Block in valves and accessories, when located in a fire protection zones, must be 30 minutes fire resistent
Study/ Ref
BDPPP03002
Subchapter
BASELL Requirements
10.4
A manual valve (upstream of the remote actuated ESD valve) and a remote operated, firesafe ESD valves (30 minutes fire-safe design; see API 598, ISO 10497, BS EN ISO 10497 or UNI EN ISO) shall be installed in the supply piping of all flammable materials (e.g., propylene, ethylene, hydrogen, etc.) coming into the ISBL to shut off the flow in the event of a process emergency. A bleed to the flare shall be installed between the two valves. The valves shall fail in the closed position. Remote operation from the control room is required. The valves shall be located a minimum of 15m (50ft) from the ISBL. A trunnion mounted ball valve with double seat and internal bleed can be used as an alternative.
THIS DOCUMENT IS BOROUGE’S PROPERTY AND CANNOT BE USED BY OTHERS FOR ANY PURPOSE WITHOUT PRIOR WRITTEN CONSENT
Subchapter
Answer
A12.34
STRUM: As per previous plant, only Battery Limits Valves (ON-OFF Valves) are firesafe and remoted controlled.
B3-PH-471-00011 Rev H
Remarks
Action Status
Date
Closed
9-Sep-09
TECNIMONT IDENTIFICATION CODE
HSE DESIGN CONFERENCE BOROUGE 3 PROJECT
3547-SZ-RT-B300011
FEED SERVICES FOR PO,LDPE AND U&O INSTALLATIONS
Sheet 59 of 110
Rev H
BOROUGE IDENTIFICATION CODE
Abu Dhabi Polymers Company Limited (Borouge)
B3-PH-471-00011
No
44
General Topics
EMISSIO NS
Application field
PUMPS
Discipline
MACCH
BOROUGE Requirement
Pumps handling materials with high vapour pressure to be seal less or equipped with double seals
Study/ Ref
BDPPH03003
Subchapter
9.3
BASELL Requirements
Subchapter
Answer
Remarks
Normally: pumps handling flammables are equipped with double seals or seal less (magnetic drive coupling)
No specific requirements by Basell
Action Status
Date
Closed
27-Aug-09
Closed
27-Aug-09
Noise levels measured at a
45
NOISE
EQUIPMEN T
MACCH
Maximum spl at 1 m: 85 dB(A), otherwise acoustic attenuation has to be provided
BDPPH03003
12
point 1m (3 ft.) from the machine or equipment shall not exceed 85 dBA when operating under normal operating conditions. Noise levels to which employees will be exposed during an 8 hour exposure period must be demonstrated to be 85 dBA or less. If measurements with all equipment operating indicate noise levels above 85 dBA, engineering controls shall be implemented where it is safe and practical to do so. An exception shall be the compressor area where people must wear hear protection. Noise levels measured at a point 1m (3 ft.) from the machine or equipment shall not exceed 85 dBA when operating under normal operating conditions. Noise levels to which employees will be exposed during an 8 hour exposure period must be demonstrated to be 85 dBA or less. If measurements with all equipment operating indicate noise levels above 85 dBA, engineering controls shall be implemented where it is safe and practical to do so. An exception shall be the compressor area where people must wear hear protection.
THIS DOCUMENT IS BOROUGE’S PROPERTY AND CANNOT BE USED BY OTHERS FOR ANY PURPOSE WITHOUT PRIOR WRITTEN CONSENT
A14.3
B3-PH-471-00011 Rev H
Developed in compliance with the document.
TECNIMONT IDENTIFICATION CODE
HSE DESIGN CONFERENCE BOROUGE 3 PROJECT
3547-SZ-RT-B300011
FEED SERVICES FOR PO,LDPE AND U&O INSTALLATIONS
Sheet 60 of 110
Rev H
BOROUGE IDENTIFICATION CODE
Abu Dhabi Polymers Company Limited (Borouge)
B3-PH-471-00011
No
46
47
General Topics
NOISE
NOISE
Application field
EMERGEN CY GENERATO R
EQUIPMEN T
Discipline
ELETTR
MACCH
BOROUGE Requirement
The noise limit of the total skid (diesel engine and alternator) shall be less or equal to 85 dB(A) at 1 metre distance For general equipment continuously operating the noise limit is 85 dB(A) at 1 meter distance. If equipment consist of components, the limit shall apply to the equipment (for the single components limits are lower). Further reductions have to be considered for equipment mounted close together or near reverberant areas. For equipment emitting intermittent or fluctuating noise the maximum level shall not exceed of 10 dB(A) the limit for continuous use
Study/ Ref
Subchapter
BASELL Requirements
BGSMA004
13.8
No specific requirements by BASELL
11.2, 11.3
No specific requirements by Basell relating to Equipment emitting continuos or intermittent or fluctuating noise.
BGSMU008
THIS DOCUMENT IS BOROUGE’S PROPERTY AND CANNOT BE USED BY OTHERS FOR ANY PURPOSE WITHOUT PRIOR WRITTEN CONSENT
Subchapter
B3-PH-471-00011 Rev H
Answer
Remarks
Action Status
Date
Developed in compliance with the document.
Closed
2-Sep-09
Developed in compliance with the document.
Closed
27-Aug-09
TECNIMONT IDENTIFICATION CODE
HSE DESIGN CONFERENCE BOROUGE 3 PROJECT
3547-SZ-RT-B300011
FEED SERVICES FOR PO,LDPE AND U&O INSTALLATIONS
Sheet 61 of 110
Rev H
BOROUGE IDENTIFICATION CODE
Abu Dhabi Polymers Company Limited (Borouge)
B3-PH-471-00011
No
48
General Topics
NOISE
Application field
EQUIPMEN T
Discipline
MACCH
BOROUGE Requirement
For equipment outside work area, at position inaccessible to personnel, an increse to the limits is allowed, according to the formulas given in 11.4
Study/ Ref
BGSMU008
Subchapter
BASELL Requirements
Subchapter
Answer
11.4
LDPE plants use a large number of items of rotating equipment (large compressors, extruder, air blowers, pumps etc.). The size and nature of the preand hyper-compressors are such that noise levels from the machine and pipework may be higher than local site requirements, however it is impracticable and undesirable from a safety point of view to install noise hoods. Therefore these machines should be located away from the site boundary to avoid high off-site noise levels. Noise levels can also be reduced by strategic location of other buildings. This is considered in the current plot plan. Clearly, any areas where noise is above the required levels should be appropriately marked and the use of hearing protection should be mandatory.
G4
Developed in compliance with the document.
THIS DOCUMENT IS BOROUGE’S PROPERTY AND CANNOT BE USED BY OTHERS FOR ANY PURPOSE WITHOUT PRIOR WRITTEN CONSENT
B3-PH-471-00011 Rev H
Remarks
Action Status
Date
Closed
27-Aug-09
TECNIMONT IDENTIFICATION CODE
HSE DESIGN CONFERENCE BOROUGE 3 PROJECT
3547-SZ-RT-B300011
FEED SERVICES FOR PO,LDPE AND U&O INSTALLATIONS
Sheet 62 of 110
Rev H
BOROUGE IDENTIFICATION CODE
Abu Dhabi Polymers Company Limited (Borouge)
B3-PH-471-00011
No
General Topics
Application field
Discipline
50
ENVIRON MENT
LIQUID EFFLUENT
51
ENVIRON MENT
LIQUID EFFLUENT
PROCS
52
LIQUID EFFLUEN TS
COOLING WATER
PROCS
PROCS
BOROUGE Requirement
Potentially accidentally oil contaminated waste water which is derived from process paved areas and includes wash-down water, storm water and fire water, shall be sent to a ‘first flush’ interceptor for capture and treatment in the waste water treatment plant. When the ‘first flush’ interceptor is full, water shall overflow to an evaporation pond. Storm water run-off from roads and nonpaved areas, designated as non oily areas, can be discharged into the sea via storm water culverts if they meet the quality standards for water discharged into the sea as given in Table 7. Maximum delta T for seawater as cooling water is 10 C
Study/ Ref
Subchapter
BASELL Requirements
BDPPH03003
10
(for OSBL) A separation/skimmer system shall be installed to separate polymer from storm water discharges at polymer storage silos, loading stations, degassing silo’s, etc.
BDPPH03003
10
BDPPH03003
10
Action Status
Date
In P&IDs will be indicated a dedicated area to collect storm water discharge.
Closed
9-Sep-09
No specific requirements by Basell
Everything is collected in the storm water basin
Closed
No specific requirements by Basell
Developed in compliance with the Document.
Closed
THIS DOCUMENT IS BOROUGE’S PROPERTY AND CANNOT BE USED BY OTHERS FOR ANY PURPOSE WITHOUT PRIOR WRITTEN CONSENT
Subchapter
Answer
A8.5.2
B3-PH-471-00011 Rev H
Remarks
9-Sep-09
9-Sep-09
TECNIMONT IDENTIFICATION CODE
HSE DESIGN CONFERENCE BOROUGE 3 PROJECT
3547-SZ-RT-B300011
FEED SERVICES FOR PO,LDPE AND U&O INSTALLATIONS
Sheet 63 of 110
Rev H
BOROUGE IDENTIFICATION CODE
Abu Dhabi Polymers Company Limited (Borouge)
B3-PH-471-00011
No
53
54
General Topics
ISOLATI ON
ISOLATI ON
Application field
GENERAL
Discipline
PROCS
EQUIPMEN T
PROCS
BOROUGE Requirement
Study/ Ref
Subchapter
BASELL Requirements
Positive isolation to be applied to all severe services as defined in 6.2, general isolation to non severe services. Details on positive and general isolation defined in 6.32, 6.3.3
BDPPP03001
6.2
No specific list of Severe services
6.3
A12.37 Where equipment will be isolated for maintenance or removal while the remainder of the process remains under pressure, double block valves with a bleed to the flare (or safe location) between the two valves (for clean service only) or a trunion mounted ball valve with double activated seat and internal bleed located on side of the body, shall be installed to isolate equipment that contains flammable liquid, flammable gas, LPG, Aluminum alkyls, or flammable slurry. This requirement applies to all except for piping below 1” in pressure services below 3 barg. On services where the bleed cannot be sent to flare and consequently cannot be kept open during all the maintenance operation, additional spectacle blinds or provision for a blind flanges shall be provided. Generally this will include process filters, treatment columns, pumps or compressors with installed spares, and similar equipment. Additionally, relief valves shall not be relied on as isolation valves.
Isolation requirements for different equipment as defined in 6.3.4, 6.3.5, 6.36, 6.3.7, 6.3.8, 6.3.9
BDPPP03001
THIS DOCUMENT IS BOROUGE’S PROPERTY AND CANNOT BE USED BY OTHERS FOR ANY PURPOSE WITHOUT PRIOR WRITTEN CONSENT
Subchapter
A12.37 A12.26
B3-PH-471-00011 Rev H
Answer
Remarks
Action Status
Date
Developed in compliance with the Document.
Closed
9-Sep-09
Developed in compliance with the Document.
Closed
9-Sep-09
TECNIMONT IDENTIFICATION CODE
HSE DESIGN CONFERENCE BOROUGE 3 PROJECT
3547-SZ-RT-B300011
FEED SERVICES FOR PO,LDPE AND U&O INSTALLATIONS
Sheet 64 of 110
Rev H
BOROUGE IDENTIFICATION CODE
Abu Dhabi Polymers Company Limited (Borouge)
B3-PH-471-00011
No
55
56
General Topics
ESD
INSULATI ON
Application field
ESD VALVES
PIPING
Discipline
PROCS
PROCS
BOROUGE Requirement
Isolation with ESD valves required for vessel containg flammable liquids in excess of 10 m3, suction lines to hydrocarbon punps pumping C4 and lighter, export pipelines Uninsulated process piping and equipment having an operating temperature of minus 10 C and below must be provided with cold insulation limited within the confines of a working area. Cold insulation is used for personnel protection whenever other alternative protective measures are not suitable
Study/ Ref
BDPPP03002
BGSMN004
Subchapter
BASELL Requirements
9.1
No specific requirement
10.4.5
(…) It is therefore important that equipment is either designed to withstand such cold temperatures, or equipment not designed to withstand such temperatures is protected against them occurring.
THIS DOCUMENT IS BOROUGE’S PROPERTY AND CANNOT BE USED BY OTHERS FOR ANY PURPOSE WITHOUT PRIOR WRITTEN CONSENT
Subchapter
Answer
To be checked if Borouge requirement refers to vessel or tanks
B8
B3-PH-471-00011 Rev H
Developed in compliance with the Document.
Remarks
BASELL ESD Isolation philosophy shall be followed.
Action Status
Closed
Closed
Date
9-Sep-09
9-Sep-09
TECNIMONT IDENTIFICATION CODE
HSE DESIGN CONFERENCE BOROUGE 3 PROJECT
3547-SZ-RT-B300011
FEED SERVICES FOR PO,LDPE AND U&O INSTALLATIONS
Sheet 65 of 110
Rev H
BOROUGE IDENTIFICATION CODE
Abu Dhabi Polymers Company Limited (Borouge)
B3-PH-471-00011
No
57
58
General Topics
INSULATI ON
PLANT LAYOUT
Application field
PIPING
PUMPS
BOROUGE Requirement
Study/ Ref
Subchapter
BASELL Requirements
Subchapter
PROCS
For peronnel protection consideration shall be given first to alternative measures. Insulation for personnel protection is required for continuous operating temperatures greater than 70 C where hot surfaces are in accessible location and will present a safety hazard. When the insulation is required, the extent shall not exceed 2 m above or more than 1 meter away accessible areas. For piping and equipment operating at temperatures below 150 C, personnel protection by means of insulation is not preferred
BGSMN100
10.3
See point 25
A14.2
PROCS
The discharge line shall also have a block valve. A non return valve shall be installed in the discharge line upstream the block valve. Highly corrosive, hazardous or hydrocarbon fluids shall have a drain valve in the discharge line between the non return valve and the block valve
BGSLU001
8.5.6
No specific requirements by BASELL
Discipline
THIS DOCUMENT IS BOROUGE’S PROPERTY AND CANNOT BE USED BY OTHERS FOR ANY PURPOSE WITHOUT PRIOR WRITTEN CONSENT
B3-PH-471-00011 Rev H
Answer
Developed in compliance with the Document.
Remarks
Action Status
Date
Closed
9-Sep-09
Closed
9-Sep-09
TECNIMONT IDENTIFICATION CODE
HSE DESIGN CONFERENCE BOROUGE 3 PROJECT
3547-SZ-RT-B300011
FEED SERVICES FOR PO,LDPE AND U&O INSTALLATIONS
Sheet 66 of 110
Rev H
BOROUGE IDENTIFICATION CODE
Abu Dhabi Polymers Company Limited (Borouge)
B3-PH-471-00011
No
59
General Topics
ENVIRON MENT
Application field
LIQUID EFFLUENT
Discipline
PROCS
60
HAZARD OUS SERVICE
INSTRUME NT
PROCS / STRUM
61
HAZARD OUS SERVICE
INSTRUME NT
PROCS/I MPGE/ST RUM
BOROUGE Requirement
All process and process contaminated effluents shall be treated within the site Waste Water Treatment Plant
Instrument drain connections in acid/caustic/lethal services to be permanently piped to nearst process sewer, area drain or other drain point. Hazardous services include acid custic toxic fluids and blow downs for fluid at operating temp greater than 260 C Instrument vent connections in sour/lethal service to be permanently piped to the nearest process vent
Study/ Ref
Subchapter
BASELL Requirements
Subchapter
BDPPH03003
10
Relatively little liquid is handled within the main process units. The only normal process releases into the aqueous sewers (such as pellet water tank overflow) have a relatively minor pollution loading, and are directed to theContinuously Contaminated water system.The ISBL surface drainage system shall be designed to ensure accidentally or continuously contaminated water is appropriately collected and treated.
G2.2 Aqueous Effluent
BGSIU-001
20.7
No specific requirements by Basell
Not Applicable
BGSIU-001
20.7
No specific requirements by Basell
Not applicable
THIS DOCUMENT IS BOROUGE’S PROPERTY AND CANNOT BE USED BY OTHERS FOR ANY PURPOSE WITHOUT PRIOR WRITTEN CONSENT
B3-PH-471-00011 Rev H
Answer
Remarks
Borouge has to decide how to manage the Liquid waste.
Action Status
Date
Closed
20-Nov-09
TECNIMONT IDENTIFICATION CODE
HSE DESIGN CONFERENCE BOROUGE 3 PROJECT
3547-SZ-RT-B300011
FEED SERVICES FOR PO,LDPE AND U&O INSTALLATIONS
Sheet 67 of 110
Rev H
BOROUGE IDENTIFICATION CODE
Abu Dhabi Polymers Company Limited (Borouge)
B3-PH-471-00011
No
64
66
General Topics
PERSON NEL SAFETY
PERSON NEL SAFETY
Application field
FIRST AID BOX
PORTABLE FIRE EXTINGUIS HERS
Discipline
BOROUGE Requirement
Study/ Ref
Subchapter
BASELL Requirements
Subchapter
Answer
SICIM
For all other personnel there are no specific health surveillance those of a normal petrochemical site. Typically operators are hearing loss due to the potentially higher levels of noise.
H6
SICIM
Hand-portable fire extinguishers shall be located at regular intervals throughout the facility. The total travel distance from a potential fire hazard to an extinguisher should not exceed 15 m (50 ft). The travel distance shall not require a person to change floors (elevation) to reach an extinguisher. Dry chemical extinguishers should be used in chemical processing and in flammable liquid loading and unloading areas. Carbon Dioxide extinguishers, HCFC123 or equivalent should be used in motor control centres and control rooms. ABC type extinguishers should be used where there are combustible solids, such as the Additivation/Extrusion Area.
A10.2.3
THIS DOCUMENT IS BOROUGE’S PROPERTY AND CANNOT BE USED BY OTHERS FOR ANY PURPOSE WITHOUT PRIOR WRITTEN CONSENT
B3-PH-471-00011 Rev H
Remarks
Action Status
Date
Developed in compliance with the Document.
Closed
27-Sep-09
Developed in compliance with the Document.
Closed
27-Sep-09
TECNIMONT IDENTIFICATION CODE
HSE DESIGN CONFERENCE BOROUGE 3 PROJECT
3547-SZ-RT-B300011
FEED SERVICES FOR PO,LDPE AND U&O INSTALLATIONS
Sheet 68 of 110
Rev H
BOROUGE IDENTIFICATION CODE
Abu Dhabi Polymers Company Limited (Borouge)
B3-PH-471-00011
No
71
72
73
General Topics
NOISE
NOISE
BUILDIN GS
Application field
GENERAL
Discipline
SICIM
GENERAL
SICIM
BLAST RESISTANC E
SICIM
BOROUGE Requirement
SPL lower than 90 dB(A) where the presence of personnel is required for only a short period of time Overall noise limit for units supeimposed on background level: lower than 60 dB(A) in areas outside and 600 m from the process plant fence line (Total noise limit for the project: 57 dB(A)) Perform a building risk assessment for each of the EU2, PO, OCU, U&O areas to determine the building classification (Blast resistant, blast resilient, normal). Buildings anticipated to withstand an external overpressure are substations in PO, EU2, OCU, U&O, Satellite instrument shelters in PO, EU2, OCU, U&O, ETP, Operator shelters / satellite mechanical shops in PO and U&O
Study/ Ref
Subchapter
BASELL Requirements
Subchapter
Answer
BDPPH03003
12
See point 45
A14.3
BDPPH03003
12
See point 45
15.3
Assure a Risk Assessment is conducted to identify and evaluate the consequences from potential releases, fires bleves or vapour cloud explosions including the effect on the workplace, occupied buildings, the adjacent community and the environment. The results of the risk assessment must be taken into account in the plant layout and building design.
BGSAU034
THIS DOCUMENT IS BOROUGE’S PROPERTY AND CANNOT BE USED BY OTHERS FOR ANY PURPOSE WITHOUT PRIOR WRITTEN CONSENT
Action Status
Date
Developed in compliance with the Document.
Closed
27-Sep-09
A14.3
Developed in compliance with the Document.
Closed
27-Sep-09
A6.2.3
Developed in compliance with the Document.
Closed
27-Sep-09
B3-PH-471-00011 Rev H
Remarks
TECNIMONT IDENTIFICATION CODE
HSE DESIGN CONFERENCE BOROUGE 3 PROJECT
3547-SZ-RT-B300011
FEED SERVICES FOR PO,LDPE AND U&O INSTALLATIONS
Sheet 69 of 110
Rev H
BOROUGE IDENTIFICATION CODE
Abu Dhabi Polymers Company Limited (Borouge)
B3-PH-471-00011
No
74
General Topics
ESD
Application field
GENERAL
Discipline
PIPING / STRUM /PROCS
BOROUGE Requirement
Study/ Ref
Subchapter
BASELL Requirements
A12.34 A manual valve (upstream of the remoted actuated ESD valve) and a remote operated, fire-safe ESD valves (30 minutes firesafe design; see API 598, ISO 10497, BS EN ISO 10497 or UNI EN ISO) shall be installed in the supply piping of all flammable materials (e.g., propylene, ethylene, hydrogen, etc.) coming into the ISBL to shut off the flow in the event of a process emergency. A bleed to the flare shall be installed between the two valves. The valves shall fail in the closed position. Remote operation from the control room is required. The valves shall be located a minimum of 15m (50ft) from the ISBL. A trunnion mounted ball valve with double seat and internal bleed can be used as an alternative.
THIS DOCUMENT IS BOROUGE’S PROPERTY AND CANNOT BE USED BY OTHERS FOR ANY PURPOSE WITHOUT PRIOR WRITTEN CONSENT
Subchapter
Answer
A12.34
STRUM: As per previous plant, only Batery Limits Valves (ON-OFF Valves) are firesafe and remoted controlled.
B3-PH-471-00011 Rev H
Remarks
Action Status
Date
Closed
9-Sep-09
TECNIMONT IDENTIFICATION CODE
HSE DESIGN CONFERENCE BOROUGE 3 PROJECT
3547-SZ-RT-B300011
FEED SERVICES FOR PO,LDPE AND U&O INSTALLATIONS
Sheet 70 of 110
Rev H
BOROUGE IDENTIFICATION CODE
Abu Dhabi Polymers Company Limited (Borouge)
B3-PH-471-00011
No
74
74
General Topics
ESD
ESD
Application field
GENERAL
GENERA L
Discipline
STRUM /PROCS / ELETTR
STRUM /PROCS / ELETTR
BOROUGE Requirement
Study/ Ref
Subchapter
BASELL Requirements
Where more than one process line are located adjacently, the hardware for the control systems for the fire detection and protection, gas detectors, ESD system, Emergency Depressurisation (EDP) system shall be located in a room (s) that is protected in the event of an explosion. However, emergency lighting systems (UPS and cabinets) shall always be protected in case of an explosion.
B5.2 The safety of high Pressure LDPE plant is dependent upon the ability of depressurising. B5.3 Safeguarding system of plant with (...) emergency program.
THIS DOCUMENT IS BOROUGE’S PROPERTY AND CANNOT BE USED BY OTHERS FOR ANY PURPOSE WITHOUT PRIOR WRITTEN CONSENT
Subchapter
Answer
B2.2.6
The hardware for the control systems for the fire detection and protection, gas detectors, ESD system, EDP system are located in the SIS in the LDPE Electtrical substation which is designed as Blast Resillient. Even emergency lighting systems are located in the SIS.
B5.2, B5.3
Chapters B5.2 and B5.3 of Basell HSEDC should be taken as REFERENCE only. Conceptual requirements are correct, but it shall be followed Specific requirements mentioned in a separated PDP documentation Interlock Description, P&IDs etc. - to design EP1 and EP2.
B3-PH-471-00011 Rev H
Remarks
ELETTR: The UPS room is located in LDPE Elettrical Substation
Action Status
Closed
Closed
Date
12-Oct-09
12-Oct-09
TECNIMONT IDENTIFICATION CODE
HSE DESIGN CONFERENCE BOROUGE 3 PROJECT
3547-SZ-RT-B300011
FEED SERVICES FOR PO,LDPE AND U&O INSTALLATIONS
Sheet 71 of 110
Rev H
BOROUGE IDENTIFICATION CODE
Abu Dhabi Polymers Company Limited (Borouge)
B3-PH-471-00011
No
74
74
74
General Topics
ESD
ESD
ESD
Application field
GENERAL
Discipline
STRUM /PROCS / ELETTR
GENERAL
STRUM /PROCS / ELETTR
GENERAL
STRUM /PROCS / ELETTR
BOROUGE Requirement
Study/ Ref
Subchapter
BASELL Requirements
B6 Design Criteria for Reactor blow down vessel, Emergency Expansion valves and thermocouples.
B10.1 A single push button Emergency Shutdown (ESD) shall be provided to shutdown the process. The PLC shall be Fail safe and Fault Tolerant to the degree specified in the Process Design Package (PDP). Bypass switches used to exclude the interlocks shall be limited to those specified in the Basell Interlock System Description. B10.2 An Emergency shutdown switch (ESD) shall be provided in the main control room to shutdown the Extruder. The ESD shall be designed to automatically actuate and shutoff all electrical supplies.
THIS DOCUMENT IS BOROUGE’S PROPERTY AND CANNOT BE USED BY OTHERS FOR ANY PURPOSE WITHOUT PRIOR WRITTEN CONSENT
Subchapter
Answer
B6, B6.1, B6.2, B6.3
EEV: are directly conncted to RDS. Point B6.3 It's valid only for LDPE Plant.
B10.1
B10.2
B3-PH-471-00011 Rev H
Remarks
Action Status
Date
Closed
9-Sep-09
Standard for LDPE Plant
Closed
9-Sep-09
In case of fire all power to MCC shall be electrically disconnected by a switch, excepting the vital equipment
Closed
13-Oct-09
PROCS: All B6 points are already followed and designed in basell PDP.
TECNIMONT IDENTIFICATION CODE
HSE DESIGN CONFERENCE BOROUGE 3 PROJECT
3547-SZ-RT-B300011
FEED SERVICES FOR PO,LDPE AND U&O INSTALLATIONS
Sheet 72 of 110
Rev H
BOROUGE IDENTIFICATION CODE
Abu Dhabi Polymers Company Limited (Borouge)
B3-PH-471-00011
No
74
74
75
General Topics
ESD
ESD
FIREPRO OFING
Application field
GENERAL
GENERAL
CABLES
Discipline
BOROUGE Requirement
Study/ Ref
BASELL Requirements
Subchapter
Answer
STRUM /PROCS / ELETTR
B4.20 A depressurization system shall be installed on the reactor. The system shall be sized to depressure the reactor to below 1000 Barg in less than 4.2 seconds. An auto log system should be used to monitor and record the efficiency of the emergency blow down system.
B4.20
Developed in compliance with the Document.
STRUM /PROCS / ELETTR
A12.41 (...) Design of EDP valve for process equipment contain greater than 2 tonnes of LPG or 2 tonnes of flammable liquids than can be heated above their atmospheric boiling point.
A12.41
STRUM
Electrical and instrument cables shall be flame retardant, nonfire propagating meeting Institute of Electrical and Electronic Engineers (IEEE) Test 383, Factory Mutual Group II, or equivalent, for flame spread. For inside use the cable material shall be halogen-free.
A13.13
Instrumentation cables as defined in 15.1.1.1 to be fire resistant and in compliance with IEC 60331
BGSIU-001
Subchapter
15.1
THIS DOCUMENT IS BOROUGE’S PROPERTY AND CANNOT BE USED BY OTHERS FOR ANY PURPOSE WITHOUT PRIOR WRITTEN CONSENT
B3-PH-471-00011 Rev H
Remarks
Action Status
Date
Closed
9-Sep-09
Not Applicable
Cables in fire area are designed Fire Resistant as per BGS-IU-001
Developed in compliance with BGS-IU-001
Closed
9-Sep-09
TECNIMONT IDENTIFICATION CODE
HSE DESIGN CONFERENCE BOROUGE 3 PROJECT
3547-SZ-RT-B300011
FEED SERVICES FOR PO,LDPE AND U&O INSTALLATIONS
Sheet 73 of 110
Rev H
BOROUGE IDENTIFICATION CODE
Abu Dhabi Polymers Company Limited (Borouge)
B3-PH-471-00011
No
General Topics
Application field
Discipline
76
FIREPRO OFING
ESD VALVES
STRUM
77
FIREPRO OFING
CABLE TRAYS
STRUM
BOROUGE Requirement
Accessories for ESD valves and actuators and remote operated valves to be protected from fire by installation in fire resistant local boxes, rated at least 30 minutes Electrical, instrumentation, control cable trays in flammable zones to be protected in order to allow equipment to operate during the first 30 minutes of fire . The fireproofing system shall prevent the temperature within a cable tray enclosure to exceed 177 C when exposed to an ASTM E119 fire for a nominal period of 60 minutes)
Study/ Ref
Subchapter
BASELL Requirements
BGSIU-001
15.1
No specific requirements by Basell
BGSMN002
1.0, 10.0
No specific requirements by Basell
THIS DOCUMENT IS BOROUGE’S PROPERTY AND CANNOT BE USED BY OTHERS FOR ANY PURPOSE WITHOUT PRIOR WRITTEN CONSENT
Subchapter
B3-PH-471-00011 Rev H
Answer
Remarks
Action Status
Date
To be checked the ESD valves that are located within a Fire Zone.
Closed
9-Sep-09
Developed in compliance with the Document.
Closed
9-Sep-09
TECNIMONT IDENTIFICATION CODE
HSE DESIGN CONFERENCE BOROUGE 3 PROJECT
3547-SZ-RT-B300011
FEED SERVICES FOR PO,LDPE AND U&O INSTALLATIONS
Sheet 74 of 110
Rev H
BOROUGE IDENTIFICATION CODE
Abu Dhabi Polymers Company Limited (Borouge)
B3-PH-471-00011
No
General Topics
Application field
78
NOISE
SAFETY RELIEF
81
FIRE AND GAS DETECTI ON
F&G DETECTOR S
Discipline
BOROUGE Requirement
Study/ Ref
STRUM
Noise limit is 115 dB(A) at 1 meter distance
BGSMU008
STRUM
All fire detection devices shall be wired to the FGD, which will generate alarms in the DCS and in the field.
BDPPP03003
Subchapter
11.6
11.2
BASELL Requirements
(...) All equipment except the pre- and hypercompressors should be supplied by the manufacturer according to the local site noise requirements, with e.g. noise hoods as required. The size and nature of the pre- and hypercompressors are such that noise levels from the machine and pipework may be higher than local site requirements, however it is impracticable and undesirable from a safety point of view to install noise hoods. (...) A mosaic panel that indicates the layout of the combustible gas detectors, oxygen analyzers, fire detection and automatic extinguishing systems, wind speed and wind direction shall be installed in the Control Room. The alarm status of each device shall be indicated. Alternatively, a dedicated large LCD monitor can be installed depicting the items indicated above. This display shall be redundant on the DCS monitors.
THIS DOCUMENT IS BOROUGE’S PROPERTY AND CANNOT BE USED BY OTHERS FOR ANY PURPOSE WITHOUT PRIOR WRITTEN CONSENT
Subchapter
Answer
G4
Developed in compliance with the Document.
B2.2.7
One meteorological station is enough for entire CCR if located visible from each operator station.
B3-PH-471-00011 Rev H
Remarks
Each Plant have a dedicated mosaic panel
Action Status
Date
Closed
9-Sep-09
Closed
13-Oct-09
TECNIMONT IDENTIFICATION CODE
HSE DESIGN CONFERENCE BOROUGE 3 PROJECT
3547-SZ-RT-B300011
FEED SERVICES FOR PO,LDPE AND U&O INSTALLATIONS
Sheet 75 of 110
Rev H
BOROUGE IDENTIFICATION CODE
Abu Dhabi Polymers Company Limited (Borouge)
B3-PH-471-00011
No
General Topics
Application field
Discipline
BOROUGE Requirement
83
ENVIRON MENT
EMISSIONS
TECN
Emission limits form point sources
84
ENVIRON MENT
EMISSIONS
TECN
Emission limits from combustion sources
85
BUILDIN GS
BLAST RESISTANC E (Reactor Cell)
EDILE
Study/ Ref
BDPPH03003 BDPPH03003
Subchapter
BASELL Requirements
Table 3
No quality std by Basell.
Table 2
No quality std by Basell. The LDPE plant has an open-topped concrete cell. The Reactor Cell contains the reactor, preheater, product cooler and HPPS. The cell walls are intended to limit the effects of potential major equipment failures within the cell: these would include gas clouds, fires, or missiles. The LDPE cell is designed on this basis. The partially enclosed nature of the reactor cell can lead to higher explosion overpressures. The cell wall design may allow some damage in the event of an explosion but ensure the cell will not fragment or collapse.
THIS DOCUMENT IS BOROUGE’S PROPERTY AND CANNOT BE USED BY OTHERS FOR ANY PURPOSE WITHOUT PRIOR WRITTEN CONSENT
Subchapter
B2.3 (see B2.3.1, B2.3.2, B2.3.3)
B3-PH-471-00011 Rev H
Answer
Remarks
Action Status
Date
Developed in compliance with the Document.
Closed
9-Sep-09
Developed in compliance with the Document.
Closed
9-Sep-09
Developed in compliance with the Document.
Closed
2-Sep-09
TECNIMONT IDENTIFICATION CODE
HSE DESIGN CONFERENCE BOROUGE 3 PROJECT
3547-SZ-RT-B300011
FEED SERVICES FOR PO,LDPE AND U&O INSTALLATIONS
Sheet 76 of 110
Rev H
BOROUGE IDENTIFICATION CODE
Abu Dhabi Polymers Company Limited (Borouge)
B3-PH-471-00011
No
86
87
General Topics
PROCES S EQUIPM ENT
SPACING
Application field
SAMPLING STATION
TRANSFOR MERS
Discipline
BOROUGE Requirement
Study/ Ref
Subchapter
PROCS
ELETT
Power transformers shall be located along outside walls (side not facing Process unit) of substation building under sunshade. Fire wall shall be provided between adjcent transformers and both ends. Access to transformers shall be through a lockable mesh gate.
BGSEU001
18.2
BASELL Requirements
Sampling stations for flammable liquids or gasses shall be designed to prevent exposing personnel to flammable materials. A sampling device, such as DOPAK or equivalent shall be used. The terminal sampling valves for all flammable liquids or gasses shall be selfclosing. Where oil filled transformers are used, the separation distance between the building and the transformer and between transformers is dependent on the volume of oil in the transformer and the flammability of the oil.Separation distances shall be per Table 3A and 3B in Table 3. Where it is not practical to safeguard with separation distances, fireresistant barriers shall be erected between adjacent transformers and other facilities, or sprinkler protection shall be provided over the transformers.
THIS DOCUMENT IS BOROUGE’S PROPERTY AND CANNOT BE USED BY OTHERS FOR ANY PURPOSE WITHOUT PRIOR WRITTEN CONSENT
Subchapter
Answer
A12.9
A13.12 (Table 3A and 3 B)
B3-PH-471-00011 Rev H
Remarks
Action Status
Date
Developed in compliance with the Document.
Closed
9-Sep-09
Developed in compliance with the Document.
Closed
2-Sep-09
TECNIMONT IDENTIFICATION CODE
HSE DESIGN CONFERENCE BOROUGE 3 PROJECT
3547-SZ-RT-B300011
FEED SERVICES FOR PO,LDPE AND U&O INSTALLATIONS
Sheet 77 of 110
Rev H
BOROUGE IDENTIFICATION CODE
Abu Dhabi Polymers Company Limited (Borouge)
B3-PH-471-00011
No
88
89
General Topics
UPS
PLANT LAYOUT
Application field
UPS ROOM DESIGN
GENERAL
Discipline
HVAC / ELETTR / STRUM
IMPGE
BOROUGE Requirement
Study/ Ref
Subchapter
BASELL Requirements
At the UPS room provide: -Continuous mechanical ventilation over the battery charging area if the batteries are not sealed, sufficient to remove any flammable gasses.Ventilation shall be designed to extract gas from the top of the room. -Safety shower and eye wash station. If batteries are not sealed. - Where wet cell batteries are used the UPS controller shall be in a separate room from the batteries. - The UPS rooms should be located where they are protected in the event of a process explosion. The layout of the site and the process unit shall provide for easy access to fire hydrants, fire monitors and fire system valves. A minimum of two access roads shall be provided for fire trucks and emergency apparatus on opposite sides of the process unit and, where possible, perpendicular to prevailing wind direction.
THIS DOCUMENT IS BOROUGE’S PROPERTY AND CANNOT BE USED BY OTHERS FOR ANY PURPOSE WITHOUT PRIOR WRITTEN CONSENT
Subchapter
Answer
B2.2.5
HVAC: Battery charging area which is ventilated, is located in a different room of UPS room. HSE: It would been provided H2 detector in the battery room
A8.3 (see also A8.1)
Exception: Road between LDPE Compression and LDPE Polymerization is a closed road.
B3-PH-471-00011 Rev H
Remarks
ELETTR: The batteries of UPS are sealed. The UPS is located in the LDPE electrical substation which is Blast Resilient Building
Action Status
Date
Closed
27-Sep-09
Closed
26-Aug-09
TECNIMONT IDENTIFICATION CODE
HSE DESIGN CONFERENCE BOROUGE 3 PROJECT
3547-SZ-RT-B300011
FEED SERVICES FOR PO,LDPE AND U&O INSTALLATIONS
Sheet 78 of 110
Rev H
BOROUGE IDENTIFICATION CODE
Abu Dhabi Polymers Company Limited (Borouge)
B3-PH-471-00011
No
90
General Topics
DRAINAG E (ISBL)
Application field
GENERAL
Discipline
EDILE
BOROUGE Requirement
Study/ Ref
Subchapter
BASELL Requirements
Subchapter
Answer
A8.4.1 Drainage shall be provided to drain spills or leaks of materials that could harm the environment, including polymer to a separation/skimmer basin. A8.4.3 The drainage trenches shall be designed to drain 125% of the fire water system demand (including monitors) without pooling. A8.4.4 For new projects; the separation basin shall be designed such that it can easily be cleaned manually (...). A8.4.6 (...) The oily side shall be sized to contain a minimum of 110% of the volume of the largest vessel. A8.4.7 A retention basin / vessel (separate from the separation/skimmer) shall be located in a safe area, recognising that a flash fire can occur in this area for the adjacent equipment/people, and shall be sized to retain the water from the firefighting systems for a period of 1.5 hours.
A8.4 (see also par. from A8.4.1 to A8.4.8 and Drawing 1)
Already applied
THIS DOCUMENT IS BOROUGE’S PROPERTY AND CANNOT BE USED BY OTHERS FOR ANY PURPOSE WITHOUT PRIOR WRITTEN CONSENT
B3-PH-471-00011 Rev H
Remarks
Action Status
Date
Closed
2-Sep-09
TECNIMONT IDENTIFICATION CODE
HSE DESIGN CONFERENCE BOROUGE 3 PROJECT
3547-SZ-RT-B300011
FEED SERVICES FOR PO,LDPE AND U&O INSTALLATIONS
Sheet 79 of 110
Rev H
BOROUGE IDENTIFICATION CODE
Abu Dhabi Polymers Company Limited (Borouge)
B3-PH-471-00011
No
General Topics
Application field
Discipline
91
DRAINAG E (OSBL)
GENERAL
EDILE / PROCS / AUSI
92
FIXED LADDER S
GENERAL
EDILE
BOROUGE Requirement
Study/ Ref
Subchapter
BASELL Requirements
A8.5.1 Storage tanks for materials that could harm the environment located outside the Process Area shall have containment dikes sized to contain 110% of the largest storage tank. Fixed ladders shall be installed in accordance with Basell Std. 4ES3H1, or more restrictive local code. Where ladders are off-set at floor landings, the offset shall be not more than 5 m and have an unobstructed line of sight. Ladders higher than 3 m shall have a cage for fall protection, and ladders higher than 9 m shall have an off-set every 9 m. All ladders shall discharge to a solid landing (not on gravel, sand, etc). (...) For new projects, a double bar selfclosing gate shall be installed.
THIS DOCUMENT IS BOROUGE’S PROPERTY AND CANNOT BE USED BY OTHERS FOR ANY PURPOSE WITHOUT PRIOR WRITTEN CONSENT
Subchapter
Answer
A8.5
To be considered in the future (FEED) design 110% of storage tank.
A11.1.7
B3-PH-471-00011 Rev H
Remarks
To be finalized during EPC phase
Action Status
Date
Closed
9-Sep-09
Closed
12-Oct-09
TECNIMONT IDENTIFICATION CODE
HSE DESIGN CONFERENCE BOROUGE 3 PROJECT
3547-SZ-RT-B300011
FEED SERVICES FOR PO,LDPE AND U&O INSTALLATIONS
Sheet 80 of 110
Rev H
BOROUGE IDENTIFICATION CODE
Abu Dhabi Polymers Company Limited (Borouge)
B3-PH-471-00011
No
General Topics
Application field
93
EMERGE NCY EXIT
EMERGEN CY EXIT STAIRWAY S
94
THERMA L INSULATI ON
EQUIPMEN T, PIPING
Discipline
PIPING/E DILE/SICI M
PROCES S/ PIPING
BOROUGE Requirement
Study/ Ref
Subchapter
BASELL Requirements
For new projects only; Emergency exit stairways on the process structures handling flammable materials shall be remote from each other and installed at the outside of the structure. The stairways shall be protected with a 90 minute fire-resistant walls and doors. Alternately, the stairs can be separated with a 90 minute fire-resistant wall that extends laterally 3 m on each side of the door. Thermal insulation on vessels, tanks, and piping containing combustible liquids that may auto-oxidize and self-heat (...) shall be cellular glass such as foam glass. (...). For large equipment the entire vessel does not have to be insulated with foam glass, only the area where leaking oil could accumulate. For piping, foam glass shall be installed a minimum of 0.5 m (2 ft) to each side of each flange.
THIS DOCUMENT IS BOROUGE’S PROPERTY AND CANNOT BE USED BY OTHERS FOR ANY PURPOSE WITHOUT PRIOR WRITTEN CONSENT
Subchapter
Answer
A11.1.18
CIVIL Dep.: Already applied 120 minutes fire resistant walls and doors as per Bourouge requrements. As per Basell fireproofing shall last 90 minutes as minimum requirement.
A12.10
Developed in compliance with the Document
B3-PH-471-00011 Rev H
Remarks
PIPING Dep.: HP Recycle, Extrusion and PO dosing structure will have stairs protected with fireproof wall.
Action Status
Date
Closed
2-Sep-09
Closed
2-Sep-09
TECNIMONT IDENTIFICATION CODE
HSE DESIGN CONFERENCE BOROUGE 3 PROJECT
3547-SZ-RT-B300011
FEED SERVICES FOR PO,LDPE AND U&O INSTALLATIONS
Sheet 81 of 110
Rev H
BOROUGE IDENTIFICATION CODE
Abu Dhabi Polymers Company Limited (Borouge)
B3-PH-471-00011
No
95
General Topics
RADIOAC TIVE ISOTOPE S
Application field
GENERAL
Discipline
PIPING/P ROCS/SIC IM
BOROUGE Requirement
Study/ Ref
Subchapter
BASELL Requirements
Subchapter
Answer
All equipment and instrumentation using radioactive isotopes or that produce nuclear radiation shall have a “Radioactive” warning sign. (...). The source shall be guarded to prevent personnel/hand access in front of the beam. If access needs to be restricted due to the radiation from the source, then the layout should be such as to not obstruct walkways / ladders.
A12.18
Developed in compliance with the Document
THIS DOCUMENT IS BOROUGE’S PROPERTY AND CANNOT BE USED BY OTHERS FOR ANY PURPOSE WITHOUT PRIOR WRITTEN CONSENT
B3-PH-471-00011 Rev H
Remarks
Action Status
Date
Closed
9-Sep-09
TECNIMONT IDENTIFICATION CODE
HSE DESIGN CONFERENCE BOROUGE 3 PROJECT
3547-SZ-RT-B300011
FEED SERVICES FOR PO,LDPE AND U&O INSTALLATIONS
Sheet 82 of 110
Rev H
BOROUGE IDENTIFICATION CODE
Abu Dhabi Polymers Company Limited (Borouge)
B3-PH-471-00011
No
General Topics
Application field
Discipline
96
INERT GAS
GENERAL
MACCH / HVAC/SIC IM
97
NITROGE N
UTILITY STATION
PIPING/SI CIM
BOROUGE Requirement
Study/ Ref
Subchapter
BASELL Requirements
Subchapter
Vessels, enclosures or equipment that could contain nitrogen or other inert gases shall have a sign stating: "CAUTION, Contains Inert Gas, Permit Required For Entry". Also for such enclosures which also can be physically walked into, then additionally, they should have 12 air changes/hour with alarm on the fan or oxygen detectors/alarms. As a minimum, signs shall be installed on silica/master batch vessel, degassing bunkers, surge vessels, GC cabin, primary and hyper compressor casings & motors, peroxide storage cells, and any other equipment that is routinely opened for maintenance or inspection that could contain inert gas.
A12.19
Nitrogen utility stations shall not be installed in any enclosed area.
A12.21
THIS DOCUMENT IS BOROUGE’S PROPERTY AND CANNOT BE USED BY OTHERS FOR ANY PURPOSE WITHOUT PRIOR WRITTEN CONSENT
B3-PH-471-00011 Rev H
Answer
Remarks
To be informed supplier of the package of refrigeration unit for peroxide storage cell
Developed in compliance with the Document.
Action Status
Date
Closed
17-Sep-09
Closed
27-Sep-09
TECNIMONT IDENTIFICATION CODE
HSE DESIGN CONFERENCE BOROUGE 3 PROJECT
3547-SZ-RT-B300011
FEED SERVICES FOR PO,LDPE AND U&O INSTALLATIONS
Sheet 83 of 110
Rev H
BOROUGE IDENTIFICATION CODE
Abu Dhabi Polymers Company Limited (Borouge)
B3-PH-471-00011
No
General Topics
Application field
Discipline
98
FLANGE LEAK
GENERAL
PIPING/E DILE/SICI M
99
ISOLATI ON VALVES
EQUIPMEN T CONTAINIG FLAMMABL E
PROCS
BOROUGE Requirement
Study/ Ref
Subchapter
BASELL Requirements
On vessels containing flammables that can create a jet fire impinging on itself or adjacent equipment that cannot be reached with fire monitors, the flanges shall be located to prevent flange leak impingement on the vessel or nearby equipment, or shall be protected against flame impingement with fireresistant insulation. Alternatively, a deflector plate attached to the flange could be used. Process equipment (including refrigeration units) inside the ISBL containing greater than 4m3 of LPG and flammables (independent of whether there is a gas/vapour phase during normal operations) shall also be designed with a remote operated isolation valve in order to block in the equipment in case of a major leak.
THIS DOCUMENT IS BOROUGE’S PROPERTY AND CANNOT BE USED BY OTHERS FOR ANY PURPOSE WITHOUT PRIOR WRITTEN CONSENT
Subchapter
Answer
B3-PH-471-00011 Rev H
Action Status
Date
To be finalized during EPC phase
A12.35
A12.42
Remarks
Developed in compliance with the Document.
Closed
9-Sep-09
TECNIMONT IDENTIFICATION CODE
HSE DESIGN CONFERENCE BOROUGE 3 PROJECT
3547-SZ-RT-B300011
FEED SERVICES FOR PO,LDPE AND U&O INSTALLATIONS
Sheet 84 of 110
Rev H
BOROUGE IDENTIFICATION CODE
Abu Dhabi Polymers Company Limited (Borouge)
B3-PH-471-00011
No
General Topics
Application field
Discipline
100
ESD
STORAGE TANKS
AUTOCO/ STRUM / PROCS
101
HAZARD OUS AREA CLASS
GENERAL
ELETTR
102
HAZARD OUS AREA CLASS
GENERAL
ELETTR
BOROUGE Requirement
Study/ Ref
Subchapter
BASELL Requirements
Storage tanks for flammable materials shall have three level instruments that operate on different principals. High high level should trip the ESD system (close the inlet valve and shut off / protect the supply pumps). All processes containing flammable liquids, flammable gases or LPG’s installed in an open well ventilated structure shall be classified Zone 2 for a horizontal radius of 15m from the ISBL perimeter trench, and to a vertical radius of 7.5m above grade or above equipment whichever is greater. For processes with LPG in vessels or equipment larger than 1ton the Zone 2 electrical classification shall extend for a horizontal radius of 30 m around the equipment to a vertical radius of 7.5 m above grade or above equipment, whichever is greater. Areas below grade shall be Zone 1. Electrical equipment inside of vessels containing flammables shall be rated for Zone 0.
THIS DOCUMENT IS BOROUGE’S PROPERTY AND CANNOT BE USED BY OTHERS FOR ANY PURPOSE WITHOUT PRIOR WRITTEN CONSENT
Subchapter
Answer
A12.43
The applied design with one local indication and 2 level transmitters (different measuring principles) is sufficient.
A13.2
A13.3
B3-PH-471-00011 Rev H
Remarks
Action Status
Date
Closed
12-Oct-09
Developed in compliance with the Document.
Closed
2-Sep-09
Developed in compliance with the Document.
Closed
2-Sep-09
PROCS: Agreed. Storage tanks have 3 level instruments: 1 local indication, 1 pressure indication and 1 level indication.
TECNIMONT IDENTIFICATION CODE
HSE DESIGN CONFERENCE BOROUGE 3 PROJECT
3547-SZ-RT-B300011
FEED SERVICES FOR PO,LDPE AND U&O INSTALLATIONS
Sheet 85 of 110
Rev H
BOROUGE IDENTIFICATION CODE
Abu Dhabi Polymers Company Limited (Borouge)
B3-PH-471-00011
No
General Topics
Application field
Discipline
103
HAZARD OUS AREA CLASS
COMBUSTI BLE DUSTS
ELETTR
104
HAZARD OUS AREA CLASS
PIPE RACK WITH FLAMMABL E LIQUIDS
ELETTR
105
HAZARD OUS AREA CLASS
PIPE RACK WITH FLAKED POLYMER
ELETTR
BOROUGE Requirement
Study/ Ref
Subchapter
BASELL Requirements
The electrical classification for outside areas where combustible dusts are stored or handled in closed systems shall be Zone 22. The classification shall extend 3m (10ft) around the equipment or potential leak source. For all pipe racks containing flammable liquids or gasses with flanged piping, any arcing or heat producing devices within 5 m (15 ft) of a pipe flange shall be Zone 2. For all pipe racks containing flaked polymer or other combustible dusts, any arcing or heat producing devices within 3m (10 ft) of the pipe flange or coupling shall be Zone 22.
THIS DOCUMENT IS BOROUGE’S PROPERTY AND CANNOT BE USED BY OTHERS FOR ANY PURPOSE WITHOUT PRIOR WRITTEN CONSENT
Subchapter
Answer
A13.4
Action Status
Date
Developed in compliance with the Document.
Closed
2-Sep-09
A13.6
Developed in compliance with the Document.
Closed
2-Sep-09
A13.7
Developed in compliance with the Document.
Closed
2-Sep-09
B3-PH-471-00011 Rev H
Remarks
TECNIMONT IDENTIFICATION CODE
HSE DESIGN CONFERENCE BOROUGE 3 PROJECT
3547-SZ-RT-B300011
FEED SERVICES FOR PO,LDPE AND U&O INSTALLATIONS
Sheet 86 of 110
Rev H
BOROUGE IDENTIFICATION CODE
Abu Dhabi Polymers Company Limited (Borouge)
B3-PH-471-00011
No
106
General Topics
EMERGE NCY INSTRUM ENT AIR
Application field
GENERAL
Discipline
PROC
BOROUGE Requirement
Study/ Ref
Subchapter
BASELL Requirements
An emergency instrument air supply system shall be provided to allow a minimum of 1/2 hour of operation. Consideration should be given to providing an air compressor on emergency power as an additional backup air supply. Nitrogen, or other inert gas, shall never be used as a backup air supply. The air supply vessel shall be protected for fire exposure by either locating outside the fire zone (min 10m and outside drainage area) or insulating with fire resistant insulation. Even considering the above, air failure ISBL shall still be considered as a creditable scenario. Where the buffer vessel is outside of the ISBL, then secure air supplies shall be provided for the dry pilot system of the deluge valves and for the air actuators for the fire monitors.
THIS DOCUMENT IS BOROUGE’S PROPERTY AND CANNOT BE USED BY OTHERS FOR ANY PURPOSE WITHOUT PRIOR WRITTEN CONSENT
Subchapter
Answer
A13.10
In ISBL of LDPE Plant, there isn't an additional back up air supply, but it's in OSBL.
B3-PH-471-00011 Rev H
Remarks
Action Status
Date
Closed
12-Oct-09
TECNIMONT IDENTIFICATION CODE
HSE DESIGN CONFERENCE BOROUGE 3 PROJECT
3547-SZ-RT-B300011
FEED SERVICES FOR PO,LDPE AND U&O INSTALLATIONS
Sheet 87 of 110
Rev H
BOROUGE IDENTIFICATION CODE
Abu Dhabi Polymers Company Limited (Borouge)
B3-PH-471-00011
No
General Topics
107
EMERGE NCY LIGHTIN G
108
INSTRUM ENTED PROTEC TIVE FUNCTIO NS
Application field
Discipline
BOROUGE Requirement
Study/ Ref
Subchapter
BASELL Requirements
Subchapter
Answer
A13.11
A13.26
GENERAL
PIPING / SICIM / ELETTR
Emergency lighting (instant restart type) shall be provided to illuminate areas where actions may be required during an emergency and to identify exits and illuminate the way to the exits, per the Life Safety code (NFPA-101) or applicable local code. Emergency lighting shall be installed in the following areas: • Central Control Room, MCC, battery room and Rack Rooms • Process Areas - illuminate the exits and the way to the exits. • Tanktruck/tankcar/barge loading/unloading areas for flammable materials • All buildings including the warehouse • Fire Pump House • Over the ISBL process feed isolation valves • At wind socks • In all elevator cars • Local Flare Control Panel
GENERAL
AUTCO/S TRUM/PR OCS
Instrumented protective functions shall not be controlled by the DCS. It should be controlled by a SIL rated PLC.
THIS DOCUMENT IS BOROUGE’S PROPERTY AND CANNOT BE USED BY OTHERS FOR ANY PURPOSE WITHOUT PRIOR WRITTEN CONSENT
B3-PH-471-00011 Rev H
Remarks
Action Status
Date
Developed in compliance with the Document.
Closed
27-Sep-09
Developed in compliance with the Document.
Closed
2-Sep-09
TECNIMONT IDENTIFICATION CODE
HSE DESIGN CONFERENCE BOROUGE 3 PROJECT
3547-SZ-RT-B300011
FEED SERVICES FOR PO,LDPE AND U&O INSTALLATIONS
Sheet 88 of 110
Rev H
BOROUGE IDENTIFICATION CODE
Abu Dhabi Polymers Company Limited (Borouge)
B3-PH-471-00011
No
109
General Topics
UPS
Application field
FIRE&GAS SYSTEM
Discipline
AUTCO/S TRUM
110
GAS DETECT ORS
PERSONNE L HEALTH
SICIM / STRUM
111
PROCES S PIPING
GENERAL
PIPING
BOROUGE Requirement
Study/ Ref
Subchapter
BASELL Requirements
The controls for fire and gas detection system shall be backed up by 24 hours of UPS.
Oxygen and hydrocarbon monitoring shall be provided in all enclosed areas that personnel visit and where flammable vapours, nitrogen or other inert gases could be present e.g. analyzer houses. The oxygen monitors shall alarm at 19 %. The alarm shall sound locally and to an area that is continuously attended. The hydrocarbon detectors shall be set to alarm at 10% LFL. All piping (including weld material), bolting, vessels and equipment containing liquefied gases, shall be constructed of stainless steel or carbon steel suitable for the lowest temperature and highest pressure (at low temperature) that could be reached.
THIS DOCUMENT IS BOROUGE’S PROPERTY AND CANNOT BE USED BY OTHERS FOR ANY PURPOSE WITHOUT PRIOR WRITTEN CONSENT
Subchapter
Answer
Action Status
Date
A13.27
The control of fire & gas system is backed up by 8 hours of UPS batteries. In case of power failure, the UPS is fed by Borouge Diesel Generator.
Closed
13-Oct-09
A14.6
Developed in compliance with the Document.
Closed
27-Sep-09
B3.7
Developed in compliance with the Document.
Closed
26-Aug-09
B3-PH-471-00011 Rev H
Remarks
TECNIMONT IDENTIFICATION CODE
HSE DESIGN CONFERENCE BOROUGE 3 PROJECT
3547-SZ-RT-B300011
FEED SERVICES FOR PO,LDPE AND U&O INSTALLATIONS
Sheet 89 of 110
Rev H
BOROUGE IDENTIFICATION CODE
Abu Dhabi Polymers Company Limited (Borouge)
B3-PH-471-00011
No
112
General Topics
LIQUID METAL EMBRITT LEMENT
Application field
GENERAL
Discipline
PIPING
BOROUGE Requirement
Study/ Ref
Subchapter
BASELL Requirements
Subchapter
Answer
Austenitic SS equipment shall not be in contact with zinc. Care shall be taken to avoid zinc coated components on or above stainless steel vessel to avoid zinc embrittlement (also called Liquid Metal embrittlement (LME)) in the event of a fire. This does not apply to the structure. Specifically, to avoid LME on equipment in processes handling flammable materials, the following shall be avoided: • contact between stainless steel parts and zinc or zinc-containing parts (e.g. galvanised shackles, clamps and rollers) shall be prevented. If there is any doubt, the stainless steel shall be chemically cleaned before any further work is carried out. • trunking/trays: galvanized steel shall not be used for cable trunking/trays or other supporting materials in the vicinity of such installations. • wire and cladding used on insulation shall not be galvanized. • Relief Valve Design: The springs of relief valves shall be given a suitable coating to protect against general corrosion and/or sulphide stress corrosion cracking. Coatings of cadmium or zinc shall not be used due to the risk of liquid metal embrittlement during service and/or hydrogen embrittlement during the galvanising process. Suitable aluminium coatings may be used.
B3.8
Developed in compliance with the Document.
THIS DOCUMENT IS BOROUGE’S PROPERTY AND CANNOT BE USED BY OTHERS FOR ANY PURPOSE WITHOUT PRIOR WRITTEN CONSENT
B3-PH-471-00011 Rev H
Remarks
Action Status
Date
Closed
26-Aug-09
TECNIMONT IDENTIFICATION CODE
HSE DESIGN CONFERENCE BOROUGE 3 PROJECT
3547-SZ-RT-B300011
FEED SERVICES FOR PO,LDPE AND U&O INSTALLATIONS
Sheet 90 of 110
Rev H
BOROUGE IDENTIFICATION CODE
Abu Dhabi Polymers Company Limited (Borouge)
B3-PH-471-00011
No
113
114
General Topics
PULSATI ON STUDY
GAS DETECT ORS
Application field
COMPRESS OR HIGH PRESSURE PIPING
GENERAL
Discipline
BOROUGE Requirement
Study/ Ref
Subchapter
BASELL Requirements
PIPING/M ACCH
An integrated pulsation study should be considered for the compressor and high pressure piping system at an early stage of the design process.
SICIM/ST RUM
Combustible gas detectors: B3.14.1 A single ring of combustible, or line of sight gas detectors shall be provided around the process area’s containing flammable gasses or liquid B3.14.2 Gas detectors shall be installed at all high potential leak-points. B3.14.3 The detector's high level alarm shall be set at 10% of the LFL and the high high level alarm at 25% of the LFL. The high level alarm shall sound in the control room. The high high alarm shall sound locally and in the control room. B3.14.4 The gas detector layout shall be submitted to the Corporate HSE for comments and approval. B3.14.5 Infrared detectors are recommended over the catalytic bead detectors. B3.14.6 The gas detectors in the reactor cell shall be generate an automatic venting as soon as 2 out of 3 gas detectors in any group are activated.
THIS DOCUMENT IS BOROUGE’S PROPERTY AND CANNOT BE USED BY OTHERS FOR ANY PURPOSE WITHOUT PRIOR WRITTEN CONSENT
Subchapter
Answer
B3.13
The integrated pulsation study is provided by the vendor according to the API code
B3.14
B3-PH-471-00011 Rev H
Remarks
Consider also a LOCAL alarm for high level and not only in control room, as per Borouge requirement
Action Status
Date
Closed
27-Aug-09
Closed
9-Sep-09
TECNIMONT IDENTIFICATION CODE
HSE DESIGN CONFERENCE BOROUGE 3 PROJECT
3547-SZ-RT-B300011
FEED SERVICES FOR PO,LDPE AND U&O INSTALLATIONS
Sheet 91 of 110
Rev H
BOROUGE IDENTIFICATION CODE
Abu Dhabi Polymers Company Limited (Borouge)
B3-PH-471-00011
No
General Topics
Application field
Discipline
BOROUGE Requirement
Study/ Ref
Subchapter
BASELL Requirements
Subchapter
Answer
B4.1 (See ALL B4)
Equipment are already selected by Basell in PDP.
Remarks
Action Status
115
SAFETY RELIEF VALVES AND BLOWDO WN
GENERAL
PROCS
The LDPE plant is fitted with "conventional" mechanically operated relief devices to protect against over-pressure. The high pressure reaction and HP recycle sections also contain Emergency Expansion Valves to rapidly depressurise the plant in the event of abnormal operating conditions occurring, and these are activated via trip systems.
116
PLANT SAFETY
GENERAL
PROCS / AUTCO / STRUM
For Plant Emergency Program (EP1 and EP2) follow par. B5.
B5
See Point 74
PROCS
For design criteria follow par. B6.1, B6.2 and B6.3
B6
See Point 74
PROCS
For protection of waterside follow par B7
B7
117
DESIGN CRITERI A
118
DESIGN CRITERI A
REACTOR BLOW DOWN, EMERGEN CY ESPASION VALVES AND THERMOC OUPLES PROTECTI ON OF WATERSID E ON HP EQUIPMEN T
THIS DOCUMENT IS BOROUGE’S PROPERTY AND CANNOT BE USED BY OTHERS FOR ANY PURPOSE WITHOUT PRIOR WRITTEN CONSENT
B3-PH-471-00011 Rev H
Included in PDP
Closed
Closed
Date
9-Sep-09
9-Sep-09
TECNIMONT IDENTIFICATION CODE
HSE DESIGN CONFERENCE BOROUGE 3 PROJECT
3547-SZ-RT-B300011
FEED SERVICES FOR PO,LDPE AND U&O INSTALLATIONS
Sheet 92 of 110
Rev H
BOROUGE IDENTIFICATION CODE
Abu Dhabi Polymers Company Limited (Borouge)
B3-PH-471-00011
No
119
120
General Topics
VENT DISPERS ION
FIRE&GA S DETECTI ON
Application field
GENERAL
PROCESS AREA GAS DETECTIO N AND MONITORIN G
Discipline
BOROUGE Requirement
Study/ Ref
Subchapter
BASELL Requirements
Subchapter
Answer
PROCS / SICIM
Due to the large but short-term release from the reactor blowdown vessel vent stack, no ignition sources above the level of vent outlet (e.g. tip of flare flame with wind blowing towards the LDPE plant) are permitted within a radius of at least 120m of the vent.
B9.2 (See also B9.1 and B9.3)
SICIM
B11.1 There are a number of ethylene gas detectors located in the high pressure area of the plant like compressors; reactor cell and high pressure recycle treatment. The individual locations of the ethylene detectors are defined by considering the HP equipment and apparatus where a possible leak of ethylene gas may occur. B11.2 Any detection of ethylene will cause an ALARM in the control building. Certain groups of gas detectors will be linked in a voting system (e.g. in the reactor cell or enclosed buildings containing high pressure ethylene equipment and pipework) to automatically vent the plant if ethylene is detected, by initiating an EP2.
B11
THIS DOCUMENT IS BOROUGE’S PROPERTY AND CANNOT BE USED BY OTHERS FOR ANY PURPOSE WITHOUT PRIOR WRITTEN CONSENT
B3-PH-471-00011 Rev H
Remarks
Action Status
Date
Developed in compliance with the Document.
Closed
27-Sep-09
Developed in compliance with the Document.
Closed
27-Sep-09
TECNIMONT IDENTIFICATION CODE
HSE DESIGN CONFERENCE BOROUGE 3 PROJECT
3547-SZ-RT-B300011
FEED SERVICES FOR PO,LDPE AND U&O INSTALLATIONS
Sheet 93 of 110
Rev H
BOROUGE IDENTIFICATION CODE
Abu Dhabi Polymers Company Limited (Borouge)
B3-PH-471-00011
No
121
General Topics
FLARE RADIATI ON
Application field
GENERAL
Discipline
SICIM / PIPING
BOROUGE Requirement
Study/ Ref
Subchapter
BASELL Requirements
Subchapter
Answer
The area around the flare where the radiation may exceed 4.7 kW/m2(1500 BTU/hr./ft2) or for a radius of 50m (whichever is greater) shall be designated as a sterile area. No occupied buildings shall be located in this area. (see API RP 521-Table 3). The radiation for occupied buildings shall not exceed 3.2 kW/m2 (1000 BTU/hr/ft2). A barrier chain, or equal, shall be placed at the 4.7 kW/m2 (1500 BTU/hr/ft2) radius, or 50 m, whichever is greater.
D1.1
Flare sterile area in Layout is marked as a circle with 240m radius
THIS DOCUMENT IS BOROUGE’S PROPERTY AND CANNOT BE USED BY OTHERS FOR ANY PURPOSE WITHOUT PRIOR WRITTEN CONSENT
B3-PH-471-00011 Rev H
Remarks
Action Status
Date
Closed
26-Aug-09
TECNIMONT IDENTIFICATION CODE
HSE DESIGN CONFERENCE BOROUGE 3 PROJECT
3547-SZ-RT-B300011
FEED SERVICES FOR PO,LDPE AND U&O INSTALLATIONS
Sheet 94 of 110
Rev H
BOROUGE IDENTIFICATION CODE
Abu Dhabi Polymers Company Limited (Borouge)
B3-PH-471-00011
No
122
General Topics
FLARE DESIGN
Application field
GENERAL
Discipline
PROCS / SICIM
BOROUGE Requirement
Study/ Ref
Subchapter
BASELL Requirements
Subchapter
Answer
D1.2 A knock-out drum shall be installed prior to the flare. It shall be sized as per API 521. (...) D1.3 The flare shall be designed for the worst case flow as per API 521. (...) D1.4 The main flare line shall be provided with clean-out ports and inspection ports. (...) D1.5 The flare line shall be designed with a minimum number of bends, sloped to drain, and have no pockets (except inspection ports) where material can accumulate. D1.6 Flares shall be furnished with a minimum of three pilots. (...) D1.7 The pilot flames for the flare shall be supplied from two independent gas sources. (...) D1.8 The supply lines to the pilots shall have a strainer installed at ground level in between the carbon steel fuel supply line and the stainless steel lines to the pilots. (...) D1.9 The first 100m of the flare line shall be made from low temperature carbon steel where LPG could be present. (...) D1.10 The flare ignition panel shall be connected to the UPS system. D1.11 The local ignition panel shall have a steel roof to provide radiant heat protection for the operator. D1.12 Valves in the flare line shall be full port valves and the stem shall be in the horizontal or down position. D1.13 A water seal or\ molecular seal (Fluidic seal recommended) shall be installed on the flare to prevent backflow of air into the flare line. (...). D1.14 Hydrocarbons > C4 shall not enter the flare stack. (...)
Par. From D1.2 to D1.14
Developed in compliance with the Document.
THIS DOCUMENT IS BOROUGE’S PROPERTY AND CANNOT BE USED BY OTHERS FOR ANY PURPOSE WITHOUT PRIOR WRITTEN CONSENT
B3-PH-471-00011 Rev H
Remarks
Action Status
Date
Closed
27-Sep-09
TECNIMONT IDENTIFICATION CODE
HSE DESIGN CONFERENCE BOROUGE 3 PROJECT
3547-SZ-RT-B300011
FEED SERVICES FOR PO,LDPE AND U&O INSTALLATIONS
Sheet 95 of 110
Rev H
BOROUGE IDENTIFICATION CODE
Abu Dhabi Polymers Company Limited (Borouge)
B3-PH-471-00011
No
122
General Topics
HAZARD OUS SERVICE
Application field
GENERAL
Discipline
PROCS / STRUM / PIPING
BOROUGE Requirement
Study/ Ref
Subchapter
BASELL Requirements
Subchapter
Answer
All piping, valves, gaskets and flanges shall be designed in accordance with Basell Standards and the PDP requirements. Screwed fittings shall not be used in propylene, LPG and high pressure ethylene lines, including vendor packages. Note: Connections to instruments are an exception, but shall be provided with flanged block valves to isolate the instrument. Also that high pressure lines (> 325Barg) shall be designed to the Basell works norm or equivalent. Another exception is for small bore HP-tubes (
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