Indian Oil Corporation Limited has awarded iFluids Engineering to carry out HAZOP Study for Panipat Refinery & Purified Terepthalic Acid unit .The Panipat Refinery is Indian Oil’s seventh and most technologically advanced public sector refinery complex in India. Covering approximately 4222 acres of vast land, located in Panipat. The Refinery’s capacity was increased to 12 MMTPA in June 2006, and then to 15 MMTPA in December 2010. In addition, there is a plan in the works to increase capacity to 25 MMTPA in the near future to satisfy prospective demand.
The Refinery’s major secondary processing units include the Catalytic Reforming Unit, Once Through Hydrocracker Unit, the Resid Fluidised Catalytic Cracking Unit, the Visbreaker Unit, the Bitumen Blowing Unit, the Sulphur Block, and the associated Auxiliary Facilities. A Diesel Hydro Desulphurisation Unit (DHDS) was later commissioned in 1999 to improve diesel quality.
Facilities to be covered under the Study includes:
PR (Panipat Refinery) Unit
| Unit Name | No Of P&ID’s |
| PR:CDU, VDU – 03, 04, 19 | 46 |
| PR:NSU-1 Revamp – 4 | 22 |
| PR : OHCU – 5 | 42 |
| PR : HGU – 6 | 20 |
| PR : RFCCU – 7 | 41 |
| PR : PSU – 33 | 20 |
| PR : CRU – 8 | 30 |
| PR : DHDS – 52 | 21 |
| PR : VBU – 9 | 16 |
| PR : BBU – 10 | 7 |
| PR : Gasoline Merox – 12 | 5 |
| PR : LPG Merox – 13 | 5 |
| PR : ATF/SKO Merox – 15 | 4 |
| Name: PR : SRU – 22 | 9 |
| PR : SSRU – 44 | 18 |
| PR : ARU – 21 | 10 |
| PR : SWS-I (Refinery)17 | 10 |
| PR : SWS-II(Hydro processing) – 18 | 10 |
| OMS : OM&S + Offsites-LPG/Tank farm | 250 |
| ETP : ETP-I – 61 | 15 |
| ETP : ETP-II – 62 | 12 |
| ETP : ETP-III – 257 | 8 |
| CPP : CPP | 65 |
| CPP : Utilities | 54 |
| PRE : AVU-II – 73 | 58 |
| PRE : VDU-II – 74 | 10 |
| Unit Name: PRE : NSU-2 – 59 | 3 |
| PRE : HCU – 75 | 92 |
| PRE : HGU – 76,77 | 87 |
| PRE : DCU Revamp – 78 | 87 |
| PRE : Cracked (DCU) LPG Merox – 79 | 5 |
| PRE : DHDT Revamp – 72 | 49 |
| PRE : SRU-I – 55 | 14 |
| PRE : SRU-II – 56 | 7 |
| PRE : TGU – 57 | 14 |
| PRE : ARU – 51 | 29 |
| PRE : SWS-I – 53 | 5 |
| PRE : SWS-II – 54 | 4 |
| PRE : SW Stripper (Hydroprocessing) – 20 | 5 |
| PRE : SRU – 25 | 31 |
| PRE : TGU – 26 | 14 |
| MSQ : NHT – 301 | 25 |
| MSQ : PENEX – 301 | 48 |
| MSQ : RSU – 302 | 12 |
| MSQ : FCC GDU – 303 | 46 |
| MSQ : MSQU (offsites) – 304 | 45 |
Total Nos. of P&ID’s for HAZOP in the PR units are 1430
PTA (Purified Terepthalic Acid) Unit
| Unit Name | No of P&ID’s |
| PX-PTA : NHT, CCR with REGTR – 201, 202 | 103 |
| PX-PTA : Shell Sulfolane – 204 | 36 |
| PX-PTA : Parex – 205 | 39 |
| Unit Name: PX-PTA : XFU – 206 | 39 |
| PX-PTA : Isomer – 207 | 30 |
| PX-PTA : Tatoray – 208 | 29 |
| PX-PTA : BTF – 209 | 19 |
| PX-PTA : PTA-Oxidation/ Purification – 2 | 122 |
| PX-PTA : PTA N2 plant – 37 | 5 |
Total Nos. of P&ID’s for HAZOP in the PTA units are 422
Total Nos. of P&ID’s for HAZOP in PR & PTA units are 1852
Scope of Study
- The Scope of study is to identify the Hazard and Operability problems and to reduce the probability and consequences of an incident in the process facilities which would have a detrimental impact on the personnel plant properties and environment.
- The HAZOP study will cover every piece Of Equipment capable of producing an event that could lead to serious injuries or equipment damage. Scope of study will include all Process and utility P&IDs.
The HAZOP will be conducted to examine the overall Process design searching for operating deviations and procedures that can lead to hazardous situations or operability problems which include:
- Review of the design and operation of process facility
- Safety and Occupational health hazards to personnel
- Damage to equipment / assets / environment
- Operability / maintainability Problems
- Plant non-availability/limitation and lack of product quality
- Environmental emissions
- Construction and commissioning hazards
- Identification of all possible causes of deviations from normal operation that could lead to any safety hazard, environmental risk or operability Problem.
- Identification of hazards, possible causes and consequences and suggest recommendations for necessary changes / alterations
Objective of the HAZOP Study
- To identify hazards associated with the facilities under the scope of work using the HAZOP study as the hazard evaluation technique.
- To identify all deviations from the way the design is expected to work, their causes and all the hazards and operability problems associated with these deviations.
- To decide whether action is required to control the hazard or the operability problem and if so to identify ways in which the problems can be solved.
- To identify cases where a decision cannot be made immediately and to decide what information or action is required.
- To document the Study in the Cause by Cause (CBC) format.
Deliverables
- Shall Submit the preliminary reports (observations)
- Shall Submit the HAZOP report
- Shall Submit the final recommendation