Industry- Academia Workshop HAZOP - Pipeline Transportation S.K. Nandy Dy. General Manager (H,S&E), Pipelines Head Office, Noida

Transcription

1 Industry- Academia Workshop HAZOP - Pipeline Transportation S.K. Nandy Dy. General Manager (H,S&E), Pipelines Head Office, Noida

2 Presentation Outline 1. Hazard and Risk 2. Hazards at Pipeline Installation 3. Incident 4. Process Hazard Analysis 5. HAZOP 6. Examples 7. OISD Standard PLHO,HSE 2

3 Hazard Anything with potential for occurrence an accident resulting in ill health, injury, damage to property, plant, products or the environment, production losses or Risk increased liabilities. Probability of Hazard resulting an Accident. Risk = Probability of occurrence of hazard X Severity of hazard. PLHO,HSE 3

4 Hazard & Risk 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. PLHO,HSE 4

5 Hazard & Risk 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 PLHO,HSE 5

6 Hazard Hazard & Risk Risk 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 mg in one dose have been known to cause death. PLHO,HSE 6

7 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 PLHO,HSE 7

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9 As on Length (km) Capacity (MMTPA) Mundra Kandla Vadinar Jodhpur Sanganer Ajmer Kot Sidhpur Ahmedabad Viramgam Dahej Jalandhar Bhatinda Ambala Koyali Sangrur Panipat Rewari Chaksu Chittaurgarh Ratlam Roorkee Bharatpur Najibabad Meerut Delhi Mathura Kanpur Tundla Lucknow Barauni Bongaigaon Siliguri Guwahati Rajbandh Mourigram Haldia Product Crude Oil Tinsukia Total Gas MMSCMD Digboi Hazira Paradip Legend Crude Oil Pipeline Bangalore Bangalore AFS Sankari Madurai Chennai Chennai AFS Asanur CBR Trichy Product Pipeline Gas Pipeline Refinery SPM PLHO,HSE 9

10 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 Storage 6 crude oil storage tank farms 68 tanks 4.5 million KL storage capacity Single Point Mooring (SPM) Systems - 5 Location Year of Commissioning Tankers handled Crude handled (MMT) Vadinar SPM - I / II 1978 / Paradip SPM - I / II / III 2008 / 2012 / Human Resource Total No. of employees 2590

11 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 PLHO,HSE 11

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13 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 PLHO,HSE 13

14 INCIDENT - at Delivery / Terminal contd 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 14

15 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 PLHO,HSE 15

16 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. PLHO,HSE 16

17 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. PLHO,HSE 17

18 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. PLHO,HSE 18

19 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. PLHO,HSE 19

20 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. PLHO,HSE 20

21 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. V3 V4 A V1 V2 V5 B A < B = Explosion C PLHO,HSE 21

22 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 MORE LESS AS WELL AS Too much A Not enough A Other substance Pump too high capacity Opening of V1 or V2 is too large. V1,V2 or pipe are partially blocked. Pump gives low flow or runs for too short a time. Not enough A = Explosion C contaminated by A. Tank overfilled. Not enough A = Explosion V3 open air sucked in Not enough A = Explosion Indicator for low level. Monitoring of flow Indicator for high level. Monitoring of flow See above Flow monitoring based on weight REVERSE OTHER THAN Liquid pumped backwards A boils in pump Wrong connector to motor Not enough A = Explosion A is contaminated Temperature too high Not enough A = Explosion Flow monitoring Temperature (and flow) monitoring. PLHO,HSE 22

23 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. PLHO,HSE 23

24 Thanks PLHO,HSE IndianOil THANKS The Energy of India