Mangalore Refinery and Petrochemicals Limited (MRPL) has awarded iFluids Engineering to carry out HAZOP study for the entire refinery complex and other facilities covering jetty, cross country pipelines, SPM, Aromatic Complex (around 2650 no of P&ID’s) of MRPL located in Karnataka.The refinery has got a versatile design with high flexibility to process Crudes of various API and with high degree of automation & a design capacity to process 15 million metric tons per annum (MMTPA).
MRPL owns and operates cross country pipelines to receive crude oil and transport finished products from and to Jetty facilities of New Mangalore Port respectively. Further, MRPL owns and operates Single Point Mooring (SPM) facilities off the coast of Mangalore to receive large to very large crude oil carriers
Facilities to be covered
HAZOP study to be carried out on all latest updated Piping and Instrumentation Diagrams (P&IDs) of Process and Utility plants.
| Unit Description | No of P&ID’s |
| CDU-1/VDU-1/NSU-1 | 43 |
| VBU-1 | 37 |
| ATU-1/SWS-1 | 15 |
| SRU -1 | 12 |
| LPG | I9 |
| LPG/KERO MEROX-1 | 19 |
| HYDROGEN-1/PSA | 17 |
| NHT-1/CCR-1/PSA | 47 |
| HCU-1 | 71 |
| BBU | 05 |
| RSU | 11 |
| CPP-1 | 16 |
| Offsite-1 | 38 |
| PHASE 1 utilities | 33 |
| WWTP-1/2 | 14 |
| Jetty facilities | 20 |
| CDU-2/ VDU-2/ NSU-2 | 45 |
| MIXED XYLENE | 20 |
| VBU-2 | 37 |
| SRU-2/SPU | 14 |
| ISOMERIZATION UNIT | 57 |
| SEPU System | 04 |
| Naphtha Hydro treating unit | 25 |
| PHASE 2 utilities | 50 |
| PFCC/PRU | 50 |
| CDU/VDU-3 | 90 |
| Offsite-2 | 20 |
| SRU-4/SPU | 52 |
| HGU-3/RPSA | 52 |
| POLYPROPYLENE UNIT | 64 |
| N2 Plant | 32 |
| CPP-3 | 79 |
| GOHDS | 33 |
| MEROX- | 22 |
| PHASE 3 Offsites & Utilities | 137 |
| Bitumen Drum filling unit | 01 |
| Black Oil Truck Loading Facilities | 04 |
| SPU Phase-2 | 01 |
| White Oil Truck Loading Facilities | 04 |
| CCR Regeneration (CCRG) | 05 |
| Naphtha Hydro treating unit | 25 |
| CCR Platformer unit (CCRP) | 38 |
| Shell Sulfolane unit (SSU) | 21 |
| Tatoray unit | 15 |
| Block-2 Utility | 31 |
| Xylene fractionation unit (XFU) | 31 |
| OSBL andISBL Tank farm area | 68 |
| Effluent treatment plant (ETP) | 27 |
| Solid waste disposal & handling facility | 47 |
| Laboratory draining system facility | 2 |
| Effluent pre-treatment plant(EPTP) | 6 |
| Cooling tower Blow down reverse osmosis plant (CTRO) | 6 |
| Fire water system | 1 |
| Nitrogen Plant | 2 |
| Instrument air & Plant air system(IA & PA) | 2 |
| ISOMERIZATION UNIT | 57 |
| HYDROGEN-2/PSA | 16 |
| LPG/KERO MEROX-2 | 25 |
| HYDROGEN-2/PSA | 16 |
| LNHT | 16 |
| PHASE 2 utilities | 27 |
| CDU/VDU-3 | 90 |
| DCU | 205 |
| PFCC/PRU | 194 |
| CPP-3 | 79 |
| Bitumen Drum filling uni | 01 |
| Black Oil Truck Loading Facilities | 04 |
| Block-1 Utility | 47 |
| OSBL andISBL Tank farm area | 68 |
| Shell Sulfolane unit (SSU) | 28 |
| N2 Plant | 35 |
| CHT | 89 |
Approximate no of P&ID’s for HAZOP study in the refinery is 2650.
Scope of work
- To carry out Hazard & Operability (HAZOP) study for all the units mentioned above.
- Review of Consequence of failure of measuring instrument/devices, final control element (control valve), safety system (PLC) and control system (DCS).
- Review of existing safety controls and interlocks and trip alarm set value
- Review of standards/statutory requirements
- Study report shall consider operational controls, safeguard evaluation, Hazard recognition, recommendations, etc HAZOP study shall be comprehensive.
HAZOP Methodology
- The technique for Hazard and Operability Study was developed to assess the safety and operability of a process system in a systematic manner
- The examination procedure takes a full description of the process, the intention of the design and decides whether these deviations can give rise to hazards. Process unit interconnections shall be considered where ever necessary
- Necessary action plan to mitigate/reduce the hazard is suggested based on available safety provision
- HAZOP should be done to meet the OISD requirement as minimum for each unit operation.
Completion Period
The project will be Completed within 18 months from the date of issue of LOA
Deliverables
- Kick off Meeting (KOM) as per scope/Road map schedule.
- Shall submit HAZOP Study Methodology Procedures
- Shall draft HAZOP Reports for each unit
- Final HAZOP Reports for each unit [Four (4) hard copies and soft editable copy]