HAZOP Study for BDEP of Middle Distillate Hydrotreater of HPCL R&D Bangalore

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:

  1. Select the node (line, equipment or a system) on the Piping & Instrumentation Diagram;
  2. List all the intention & process parameters, guidewords for the node;
  3. List all deviations
  4. Brainstorm and list various causes for that deviation and ignore causes that are not credible;
  5. Determine the consequences of the deviation due to each listed credible cause;
  6. Identify Safeguards that are already provided in the system
  7. Suggest recommendations/actions, if the safeguards are inadequate;
  8. Repeat steps 3 to 7 for each deviation
  9. 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