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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
18.4.2015 PLHO,HSE 2
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.
18.4.2015 PLHO,HSE 3
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
18.4.2015 PLHO,HSE 4
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
18.4.2015 PLHO,HSE 5
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
18.4.2015 PLHO,HSE 7
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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
18.4.2015 PLHO,HSE 9
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
18.4.2015 PLHO,HSE 11
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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
18.4.2015 PLHO,HSE 15
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.
18.4.2015 PLHO,HSE 16
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.
18.4.2015 PLHO,HSE 18
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.
18.4.2015 PLHO,HSE 20
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.
18.4.2015 PLHO,HSE 22
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.
18.4.2015 PLHO,HSE 23
THANKS
Thanks
IndianOil The Energy of India
18.4.2015
24 PLHO,HSE