This case study focuses on a HAZOP analysis conducted for a pigging facility of SPM pipelines in Hazira Manufacturing Division at Reliance Industries Limited, Gujarat. The Facility consists of SPM subsea & Cross country pipelines used for transporting Naphtha, refined products, and intermediate streams. Pig launching and receiving stations are located at strategic points along the pipelines to facilitate the pigging operations.
Pigging is a common pipeline cleaning technique used in various Industries, including oil and gas, chemical, and refining. Pigs are essentially cleaning devices propelled through pipelines by the product flow or a separate fluid. However, pigging operations involve inherent hazards that require thorough safety assessments.
Hazard and Operability (HAZOP) analysis is a valuable tool for identifying potential deviations from normal operation and their consequences, thereby allowing for the implementation of effective preventive measures. Typically, a multi-skilled team that examines instrument and pipe schematics conducts HAZOPs. Every pipeline and vessel is assessed for specific restrictions and variations in flow, temperature, pressure, and other variables.
The HAZOP team comprised representatives from iFluids Engineering and Various disciplines of Reliance industries limited, including Process Engineers, Operations Personnel, Maintenance Technicians, and Safety Specialists. Session was facilitated by iFluids Chairman and Supported by the Scribe
The scope of the analysis covered the entire pigging cycle, including:
- Pre-Pigging preparation
- Pig launching and operation
- Pig receiving and handling
HAZOP session was held online for pigging facility based on as-built P&IDs. The entire installation was divided into 3 nodes which corresponds to 100% of facility. For this brainstorming session, the BS IEC 61882:2016 Standard HAZOP approach was followed. Every node runs through the standard set of applicable deviations in order to determine the applicable causes based on P&ID and the corresponding consequences of the same; appropriate precautions (barriers) that stop the consequence will then be specified. Through the HAZOP analysis, several potential deviations and their consequences were identified. Examples include:
- No flow during pigging: Could lead to pig entrapment and pipeline damage.
- Higher pressure than expected: Could indicate a stuck pig or pipeline blockage.
- Leak during pigging: Could release hazardous fluids and endanger personnel.
- Pig malfunction: Could damage the pipeline or cause operational disruptions.
The HAZOP analysis provided valuable insights into the potential hazards associated with pigging operations at the facility. With an active brainstorming session, the study team identified all possible hazards as per standard and their suitable barriers. Being an HSE consultant, iFluids recommended the required safeguards to prevent the ultimate consequence and ensure the safer operation of pigging facility.
The HAZOP analysis conducted for the pigging facility of SPM pipelines in Hazira Manufacturing Division at RIL, Gujarat demonstrates the effectiveness of this technique in identifying and mitigating potential hazards. By proactively addressing safety concerns, the Facility can minimize risks, prevent accidents, and ensure the safe and efficient operation of its pigging system.