Ema Chemical Systems Industry and Trade Inc.

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Established in 2005, the company commenced operations in June 2006.

As a subsidiary of Huntsman, EMA Chemical Systems Industry and Trade Inc. serves Turkey and neighbouring countries with a production capacity of 75,000 tonnes, supplying PU systems such as rigid, footwear, automotive, flex and elastomer to key sectors including construction, refrigeration, footwear, furniture, automotive, healthcare, paint and adhesives. EMA Kimya, which serves the market with innovative, sustainable and cost-effective solutions using Huntsman technologies, operates on the principles of being cost-effective, flexible, dynamic and customer-focused.

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Özlem Academy Education and Consultancy Inc. Project:

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1️⃣ HAZOP – Process Hazard Analysis (Hazard and Operability Study)

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A HAZOP (Hazard and Operability Study) was conducted to ensure the safe operation of process systems across the facility.

Within this scope:

• Node points were identified using process flow diagrams (PFD) and piping and instrumentation diagrams (P&ID).

• Potential deviation scenarios were identified for each node, and cause-and-effect relationships were analysed.

• Failures, operational errors and process abnormalities that could lead to hazardous incidents were systematically assessed.

• The HAZOP outputs formed the basis for determining the layers of protection (LOPA) and developing risk mitigation strategies.

 

2️⃣ LOPA – Layer of Protection Analysis

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Based on the HAZOP outputs, a LOPA (Layer of Protection Analysis) study was conducted to determine the risk levels of critical process events.

Within the scope of this analysis:

• Independent protection layers (IPL) were defined for each hazardous scenario.

• The reliability (PFDavg) values of the protection layers were calculated and target risk reduction ratios were determined.

• SIL requirements were established for scenarios where protection was found to be insufficient.

• The results obtained provided direct input to the SIL determination and verification analyses.

 

3️⃣ SIL – Safety Integrity Level Analyses (Safety Integrity Level Assessment)

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SIL determination, validation and verification studies were carried out for the plant’s safety instrumented systems (SIS).

Within this scope:

• Safety Requirement Specification (SRS) documents were created for each safety function.

• During the SIL determination phase, target safety integrity levels (SIL 1–SIL 3) were defined.

• During the SIL verification phase, an assessment was made as to whether the system delivers the required safety performance.

• As part of the SIL validation process, the consistency between the system’s design and its field implementation was verified.

• Consequently, the design integrity and functional reliability of each SIS function have been documented in accordance with international standards (IEC 61511, IEC 61508).

 

4️⃣ EPD – Explosion Protection Document

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An Explosion Protection Document (EPD) has been prepared for the facility in accordance with ATEX 2014/34/EU and the Regulation on Health and Safety Requirements for the Use of Work Equipment.

Within this scope:

• A hazardous substance inventory has been compiled, and zone classifications have been carried out in accordance with EN 60079-10-1 / EN 60079-10-2 standards.

• Potential ignition sources, ventilation levels, leakage scenarios and environmental conditions have been assessed.

• The protection types (Ex d, Ex e, Ex i, Ex t, Ex n) of the electrical and mechanical equipment located in the zones have been verified.

• Based on the results obtained, organisational and technical measures, operating instructions and periodic inspection plans have been drawn up.

 

5️⃣ Ex-proof Equipment Conformity Assessment

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The ATEX conformity of equipment used in explosive atmospheres throughout the facility has been inspected and a conformity assessment carried out in accordance with the EN 60079 series of standards.

Within this scope:

• Equipment identification labels, certificate numbers, category and group information were examined.

• Installation points were assessed in terms of zone compliance, mechanical damage, corrosion, connection safety and label legibility.

• A corrective action list was prepared for non-compliant equipment.

 

6️⃣ EN 60079-17 – Visual and Close Inspection Activities

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Under the EN 60079-17 standard, visual inspection (Visual Inspection) and close inspection (Close Inspection) activities were carried out on equipment for explosive atmospheres.

Within this scope:

• Equipment was classified according to category, zone and protection type.

• Sealing, connections, insulation, cable entries and enclosure integrity were checked.

• Inspection results were recorded on inspection forms and checklists.

• Findings were reported by establishing an Ex equipment maintenance plan and monitoring intervals.