Introduction
In Petrochemical industries, managing process safety is vital due to complex and hazardous operations.
HAZOP and SIL studies help identify deviations, assess risks, and define safety functions.
These studies ensure prevention of failures and enhance operational safety.
iFluids Engineering has completed a detailed HAZOP and SIL study for a Petrochemical facility.
The study ensured compliance with IEC 61508 and IEC 61511 standards.
Methodology
HAZOP Study:
A structured node-wise review of process design documents was carried out, applying guidewords to key operating parameters to identify deviations. Potential causes, consequences, existing safeguards, and recommendations were systematically recorded through multidisciplinary workshops.
SIL Study:
The SIL study was performed using the Layer of Protection Analysis (LOPA) technique. Each Safety Instrumented Function (SIF) was evaluated based on risk parameters, and SIL levels were assigned according to the likelihood and severity of potential hazards. Improvement recommendations were made where necessary to meet required safety performance.
Overall Outcomes
- Identification of operational risks and critical failure scenarios.
- Improvement recommendations for alarms, interlocks, and emergency shutdown systems.
- Assessment of Safety Instrumented Functions (SIFs) to verify their adequacy.
- Strengthening of process safety measures to ensure compliance with industry standards.
HAZOP & SIL Study for Slurry Bed Hydrocracking Pilot Plant – IOCL
Introduction
A Pilot-scale slurry bed hydrocracking plant was developed to demonstrate advanced technology for converting heavy hydrocarbon residues into lighter, high-value products. This initiative aimed to test operational efficiency, safety reliability, and process stability at demonstration scale before moving towards full commercial implementation.
Project Insights
iFluids Engineering performed a comprehensive safety study for the Slurry Bed Hydrocracking Demonstration Plant, covering the following key areas:
- Feed Preparation and Hydrogen Supply Systems
- Analyzed the handling and mixing of raw materials.
- Evaluated the hydrogen supply system for safe storage and transportation, ensuring no leaks or disruptions.
- Reactor and Distillation Sections
- Assessed the safe operation of the reactor and distillation units under high pressure and temperature
- Identified risks from equipment failure or pressure changes during product separation.
- Utility and Instrumentation Support Systems
- Reviewed utility systems, such as cooling and steam, to maintain safe operations.
- Ensured control systems are functional and emergency shutdowns can be triggered when necessary.
- Safety Function Verification and Risk Assessment
- Identified safety-critical functions to prevent major accidents.
- Determined the necessary safety levels and provided recommendations for system improvements.
- Operational and Maintenance Hazards
- Evaluated safety during start-up, shutdown, and normal operations.
- Reviewed maintenance procedures to reduce hazards and ensure safe equipment handling.
This study provided essential recommendations to improve plant safety and support for future commercial deployment.
Ensure Safe and Compliant Operations
iFluids Engineering’s HAZOP & SIL study for this petrochemical project helped identify critical risks, verify safety systems, and strengthen compliance with IEC standards.
Contact us to discuss your project requirements with our safety specialists.