S.K. Nandy

Dy. General Manager (H,S&E),

Pipelines Head Office, Noida

Industry- Academia Workshop

“HAZOP - Pipeline Transportation”

18.4.2015

Presentation Outline

1. Hazard and Risk

2. Hazards at Pipeline Installation

3. Incident

4. Process Hazard Analysis

5. HAZOP

6. Examples

7. OISD Standard - 206

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Hazard

Anything with potential for

occurrence an accident

resulting in ill health,

injury, damage to property,

plant, products or the

environment, production

losses or increased

liabilities. Risk

Probability of Hazard resulting an Accident.

Risk = Probability of occurrence of hazard X Severity of hazard.

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A hazard is any chemical, mechanical, biological,

environmental or physical agent that is reasonably

likely to cause harm or damage to humans, other

organisms, or the environment in the absence of its

control.

This can include, but is not limited to: Electricity,

motor vehicles, Heavy Equipment, and X-rays etc.

Identification of hazards is the first step in performing

a risk assessment.

Hazard & Risk

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1. Mechanical

2. Physical

Physical hazards include, but are not limited to, earthquakes,

floods, and tornadoes.

Physical hazards often have both human and natural

elements. Flood problems can be affected by climate

fluctuations and storm frequency

3. Natural hazards

People and its surroundings are at risk from geophysical

hazards such as earthquakes, floods and tsunami

According to the Red Cross each year 130,000 people are

killed, 90,000 are injured and 140 million are affected by

unique events known as disaster

Hazard & Risk

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4. Chemical

A chemical can be considered a hazard if by virtue of its intrinsic properties it can cause harm or danger to humans, property, or the environment.

Corrosive chemicals like sulphuric acid, which is found in batteries and laboratories can cause severe skin burns.

The effects of other chemicals, such as alcohol and nicotine, have been well documented.

Hazards associated with chemicals are dependent on the dose or amount of the chemical. For example, iodine in the form of potassium iodate is used to produce iodised salt. When applied at a rate of 20 mg of potassium iodate per 1000 mg of table salt, the chemical is beneficial in preventing goitre, while iodine intakes of 1200–9500 mg in one dose have been known to cause death.

Hazard & Risk Hazard & Risk

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Workplace hazards can come from a wide range of sources. General

Examples include any substance, material, process, practice, etc that has

the ability to cause harm or adverse health effect to a person under certain

conditions.

Work place Hazard Example of Hazard Example of harm caused

Substance/chemical Hydrocarbon Fire, explosion, exposure

Material Asbestos Mesothelioma

Source of energy Electricity Shock, electrocution

Condition Wet floor Slips, falls

Process Welding Metal fume

Practice Hard rock mining Silicosis

Thing Knife Cut

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Length (km)

Capacity (MMTPA)

Product 6633 40.1

Crude Oil 4448 40.4

Total 11081 80.5

Gas 140 9.5 MMSCMD

11221

Legend

Crude Oil Pipeline

Product Pipeline

Gas Pipeline

Refinery

SPM

Vadinar

Chaksu

Mundra

Guwahati

Bongaigaon

Siliguri

Digboi

Tinsukia

Jalandhar

Delhi

Meerut

Tundla

Najibabad Roorkee

Ambala

Mathura

Kot

Jodhpur

Sanganer

Ajmer

Dahej

Chittaurgarh

Koyali

Bhatinda

Sangrur

Panipat

Rewari

Haldia

Barauni Kanpur

Lucknow

Mourigram

Rajbandh

Chennai

Sankari Asanur

Trichy

Madurai

CBR

Bangalore Bangalore AFS

Paradip

Ratlam

Chennai AFS

Hazira

Bharatpur

Ahmedabad Sidhpur

Viramgam Kandla

As on 31.3.2015

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Storage 6 crude oil storage tank farms

68 tanks

4.5 million KL storage capacity

Pipeline Network

11,221 km long, 80.5 MMTPA capacity, 80 Installations

Crude oil 4448 km 40.4 MMTPA

Product 6633 km 40.1 MMTPA

Gas 140 km 9.5 MMSCMD

Human Resource Total No. of employees – 2590

Single Point Mooring (SPM) Systems - 5

Location Year of

Commissioning Tankers handled

Crude handled (MMT)

Vadinar SPM - I / II 1978 / 1997 4708 535.51

Paradip SPM - I / II / III 2008 / 2012 /

2013 382 73.25

Large inventory of Petroleum products-Highly

inflammable

Processing at high Pressure, Temperature

Using Hazardous chemicals

High Complexity & Process Integration

Loss of containment results in Fire/ Explosion

History of Major incidents in India & Ab

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INCIDENT - at Delivery / Terminal

•Incident : Product delivery from cross country was in progress to Tank no. A during the

day shift

Due to mal-operation, ROSOV of tank no. A got closed and line between PCV

and ROSOV got pressurized resulting in Pipe fittings on the low pressure side

SRV and TRVs were operated

Product spray from two flanges of gate valves

About 1.2KL product collected in surge tank

ESD of station was operated

TANK ROSOV ROSOV COMPRESSOR UNIT

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Restoration :

All the on-line flange gaskets on low pressure side has been replaced

with new gaskets

P/L integrity test has been conducted at higher pressure and

operation of SRV has been checked

Product delivery resumed next day

Recommendations

Carrying out Surge analysis of low pressure piping

Integration of ROSOV related signals with pipeline PLC system and

interlocking of safety protection measures.

GASKET LEAKS GASKET LEAKS

INCIDENT - at Delivery / Terminal contd…

14

Broad categories of hazard

To help with the process of identifying hazards it is

useful to categorise hazards in different ways, for

example by topic, e.g.:

Mechanical

Electrical

Radiation

Substances

Fire and explosion

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Hazards -list

During work activities could the following hazards exist? Slips/falls on the level.

Falls of persons from heights.

Falls of tools, materials, etc., from heights.

Inadequate headroom.

Hazards associated with manual lifting/handling of tools, materials, etc..

Hazards from plant and machinery associated with assembly, commissioning, operation, maintenance, modification, repair and dismantling.

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Hazards-list Fire and explosion.

Substances that may be inhaled or may cause harm by being ingested .

Substances that may cause harm by coming into contact with, or being absorbed through, the skin.

Harmful energies (e.g., electricity, radiation, noise,

vibration).

Inadequate thermal environment, e.g. too hot.

Lighting levels.

Slippery, uneven ground/surfaces.

Inadequate guard rails or hand rails on stairs.

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The system is divided into sub systems that

can be handled effectively.

It involves:

Identification of the component and parent

system.

Failure mode and cause of failure.

Effect of the failure on the subsystem or

system.

Method of detection and diagnostic aids

available.

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For each component’s functions, every conceivable mode of failure is identified and recorded.

It is also common to rate the failure rate for each failure mode identified.

The potential consequences for each failure must be identified along with its effects on other equipment, components within the rest of the system.

It is then necessary to record preventative measures that are in place or may be introduced to correct the failure, reduce its failure rate or provide some adequate form of detection.

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HAZOP is a team approach, involving a team of people representing all different functions in a plant.

Team should include one member who has the knowledge and experience specific to the process

They identify all the deviations by ‘brain-storming’ to a set of guide words which are applied to all parts of the system.

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Example

Consider the simple process diagram below. It

represents a plant where substances A and B react

with each other to form a new substance C. If there is

more B than A there may be an explosion.

AB

V1V2

V3

V4

V5

A < B = Explosion C

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The HAZOP sheet for the section of the plant from A to C will be as follows:

Guide Word

Deviation

Possible Causes

Consequences

Proposed Measures

NO, NOT

No A

Tank containing A is empty. V1 or V2 closed. Pump does not work. Pipe broken

Not enough A = Explosion

Indicator for low level. Monitoring of flow

MORE

Too much A

Pump too high capacity Opening of V1 or V2 is too large.

C contaminated by A. Tank overfilled.

Indicator for high level. Monitoring of flow LESS

Not enough A

V1,V2 or pipe are partially blocked. Pump gives low flow or runs for too short a time.

Not enough A = Explosion

See above

AS WELL AS

Other substance

V3 open – air sucked in

Not enough A = Explosion

Flow monitoring based on weight

REVERSE

Liquid pumped backwards

Wrong connector to motor

Not enough A = Explosion A is contaminated

Flow monitoring

OTHER THAN

A boils in pump

Temperature too high

Not enough A = Explosion

Temperature (and flow) monitoring.

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OISD-GDN-206

Frequency The process hazard analysis should be updated and

revalidated by a team, having requisite back ground, at

least every 5 years after the completion of initial

process hazard analysis.

The PHA for a new process or facility or modification in

existing facility and recommendations resulting from

the PHA should be completed before start-up.

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THANKS

Thanks

IndianOil The Energy of India

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