The Middle Distillate Hydrotreater Unit at HPCL plays a critical role in refining process by improving the quality of middle distillate products such as Diesel. To ensure safe and efficient operations, L&T engaged iFluids Engineering, an industry-leading engineering consultancy firm, to conduct a comprehensive HAZOP study.
The Primary objective of HAZOP study are as follows:
- Identify potential hazards and operability issues in the Middle Distillate Hydrotreater Unit
- Assess the existing safety measures and safeguards in place
- Propose recommendations to mitigate identified risks and enhance operational safety
The HAZOP study followed a systematic approach involving the following steps:
- Select the node (line, equipment or a system) on the Piping & Instrumentation Diagram;
- List all the intention & process parameters, guidewords for the node;
- List all deviations
- Brainstorm and list various causes for that deviation and ignore causes that are not credible;
- Determine the consequences of the deviation due to each listed credible cause;
- Identify Safeguards that are already provided in the system
- Suggest recommendations/actions, if the safeguards are inadequate;
- Repeat steps 3 to 7 for each deviation
- Repeat steps from one (1) to eight (8) to next node until all the nodes are covered.
The HAZOP study, in collaboration with L&T, enabled HPCL to implement targeted safety measures and operational improvements, resulting in the following benefits:
- Enhanced safety levels by mitigating identified hazards and risks
- Improved process efficiency through the implementation of recommended control measures
- Compliance with regulatory requirements and Industry best practices
Strengthened emergency response capabilities and preparedness
The following are the standards used for HAZOP study
- IEC-61882 Hazard and Operability studies (HAZOP Studies) – Application guide
- IS 15656:2006 Hazard Identification and Risk Analysis – Code of Practice
- CCPS – Guidelines for Hazard Evaluation Procedures