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HAZOP study for Pata Petrochemical Complex (PC-I & PC-II Units) - GAIL India Limited

GAIL (India) Limited is the country’s premier Natural Gas Marketer & Transporter, diversified into the manufacturing and marketing of downstream HDPE & LLDPE from natural gas cracking at its Pata (Uttar Pradesh state, India) unit since 19th March 1999.

This complex recovers ethane-propane (C2/C3) from natural gas received through the HVJ pipeline for producing polymers. GAIL, Pata Petrochemical Complex (PC) has a capacity to produce 8,10,000 TPA (PC-I capacity:4,10,000 TPA & PC-II capacity: 4,00,000 TPA) of Polymers HDPE and LLDPE. PC-II was commissioned in March 2015.

GAIL India has awarded iFluids Engineering to carry out HAZOP Study of Pata Petrochemical Complex (PC-I & PC-II) Units. The objective of HAZOP Study is to highlight the process hazards, deviation, causes, consequences and safeguards against them. Corrective actions and recommendations shall be proposed in order to improve the operability and safety of the plant.

As per the OISD Guideline 206 (GDN-206), it is necessary to revalidate the HAZOP study, once in 5 years in order to identify & mitigate the Process Hazards which may have developed since last HAZOP study.

Scope Of Work

  • HAZOP study to be carried out as per standards prevailing in the industry & acceptable to OISD, for identifying hazards and problems associated with the operating & safety procedures
  • HAZOP study shall be carried out on all piping and instrumentation diagrams (P&IDs) including modifications in plant and cover all the lines and equipment's of units such as
  Sl.No      Name of Process Unit          No. of As Built P&IDs
1GPU-I62
2GPU-II55
3LPG33
4GCU-I152
5GCU-II327
6HDPE-I50
7HDPE-II52
8LLDPE-I70
9BUTENE-118
10LLDPE-II150
11NEW BUTENE-159
12PP-I17
13PP-II30
14IOP&S PC-I111
15IOP&S PC-II73
16ANALYSER SHELTER35
 Total1294
  • Study shall cover all modifications i.e MOCs (Management of Changes)

Methodology

The HAZOP study will be carried out on all Piping and Instrumentation Diagrams (P&IDs) and will cover all the Lines and equipment’s of various Unit. Based on this study, recommendations for mitigating/reducing the hazards and ease of operability shall be arrived at and a report, incorporating the same will be submitted

The procedure will consider a full description of the process, & systematically investigate every part of it to discover how deviations from the intention of the design could occur and decide whether these deviations can give rise to hazards.

Software Used

The HAZOP software PHA-Pro/PHA to be used

Completion Period

The Completion period of the project is 10 months.

Deliverables

HAZOP Study report for all the Units will be submitted.

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