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HAZARD AND OPERABILITY (HAZOP)STUDY FOR MANGALORE REFINERY AND PETRO- CHEMICALS LIMITED MRPL & AROMATIC COMPLEX

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 DescriptionNo of P&ID's
CDU-1/VDU-1/NSU-143
VBU-137
ATU-1/SWS-115
 SRU -112
LPGI9
LPG/KERO  MEROX-119
HYDROGEN-1/PSA17
NHT-1/CCR-1/PSA47
HCU-171
BBU05
RSU11
CPP-116
Offsite-138
PHASE 1 utilities33
WWTP-1/214
Jetty facilities20
CDU-2/ VDU-2/ NSU-245
MIXED XYLENE20
VBU-237
SRU-2/SPU14
ISOMERIZATION UNIT 57
SEPU System04
Naphtha Hydro treating unit 25
PHASE 2 utilities50
PFCC/PRU50
CDU/VDU-390
Offsite-220
SRU-4/SPU52
HGU-3/RPSA52
POLYPROPYLENE UNIT64
N2 Plant32
CPP-379
GOHDS33
MEROX-22
PHASE 3 Offsites & Utilities137
Bitumen Drum filling unit01
Black Oil Truck Loading Facilities04
SPU Phase-201
White Oil Truck Loading Facilities04
CCR Regeneration (CCRG)05
Naphtha Hydro treating unit25
CCR Platformer unit (CCRP)38
Shell Sulfolane unit (SSU)21
Tatoray  unit15
Block-2 Utility31
Xylene  fractionation  unit  (XFU)31
OSBL andISBL Tank farm area68
Effluent treatment plant (ETP)27
Solid waste disposal & handling facility47
Laboratory draining system facility2
Effluent pre-treatment plant(EPTP)6
Cooling tower Blow down reverse osmosis plant (CTRO)6
Fire water system1
Nitrogen Plant2
Instrument air & Plant air system(IA & PA)2
ISOMERIZATION UNIT57
HYDROGEN-2/PSA16
LPG/KERO MEROX-225
HYDROGEN-2/PSA16
LNHT16
PHASE 2 utilities27
CDU/VDU-390
DCU205
PFCC/PRU194
CPP-379
Bitumen Drum filling uni01
Black Oil Truck Loading Facilities04
Block-1 Utility47
OSBL andISBL Tank farm area68
Shell Sulfolane unit (SSU)28
N2 Plant35
CHT89

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]

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