CASE STUDY

HAZOP Study for Uran–Chakan–Shikrapur LPG Pipeline

Introduction

Hindustan Petroleum Corporation Limited (HPCL) has developed an underground cross-country LPG pipeline connecting the LPG Bottling Plant of Bharat Petroleum Corporation Limited (BPCL) at Uran to BPCL’s LPG Plant at Shikrapur. This extensive pipeline includes dispatch terminals, receiving terminals, and sectionalizing valve stations to ensure the seamless transportation of LPG.

Scope of the HAZOP Study

The Hazard and Operability (HAZOP) study for the Uran–Chakan–Shikrapur LPG pipeline aimed to:

  • Evaluate the safety and operability of dispatch terminals, receiving terminals, and sectionalizing valve stations.
  • Identify potential hazards, deviations, and operational inefficiencies.
  • Propose actionable recommendations to mitigate risks and enhance operational safety.

This study adhered to a systematic, structured approach involving cross-disciplinary expertise to analyze and improve the safety and reliability of HPCL’s pipeline operations.

Objectives of the HAZOP Study

The primary goals of the HAZOP study were to:

The image visually represents the objectives of a HAZOP (Hazard and Operability) study in a structured design. It features three key objectives displayed in rounded frames: "Identify Hazards," symbolized by a magnifying glass and an exclamation mark, "Enhance Safety Measures," illustrated with a shield and a medical cross, and "Improve Operational Efficiency," represented by a gear with an arrow. The design uses a clean and professional layout with blue and beige tones, emphasizing clarity and focus on safety, hazard identification, and operational improvements in industrial processes.
Objectives of the HAZOP Study
  • Identify Hazards: Detect potential risks, such as equipment malfunctions or human errors, that could lead to operational issues or accidents.
  • Enhance Safety Measures: Evaluate existing safeguards and propose enhancements where necessary.
  • Improve Operational Efficiency: Address deviations from normal operating conditions to ensure seamless performance.

By employing PHA Pro software, the study ensured comprehensive coverage and robust analysis of potential deviations.

Methodology

The HAZOP study followed a structured methodology comprising the following steps:

The image depicts a structured flowchart titled Methodology of HAZOP Study, presented in a step-by-step format. It consists of two parallel vertical columns connected by arrows, showing the sequence of steps involved. The left column includes Team Formation, Defining Scope, Gathering Process Information, and Node Identification. Each step is linked via an arrow to corresponding actions in the right column: Defining Guidewords, Deviation Identification, Safeguard Evaluation, and Recommendations. The design uses purple-colored rectangular boxes and connecting arrows, emphasizing a systematic approach to conducting a HAZOP (Hazard and Operability) study.
HAZOP Methodology
  • Team Formation:
    • Assemble a multidisciplinary team of experts.
  • Defining Scope:
    • Clearly outline the study’s objectives and boundaries.
  • Process Information Gathering:
    • Collect detailed data about the pipeline and associated systems.
  • Node Identification:
    • Break down the pipeline into manageable sections (nodes) for analysis.
  • Guidewords Definition:
    • Use specific terms like “Flow,” “Pressure,” and “Temperature” to identify deviations.
  • Deviation Analysis:
    • Evaluate deviations, their causes, and potential consequences.
  • Safeguard Assessment:
    • Assess existing measures to mitigate risks.
  • Recommendation Development:
    • Propose actionable steps to address identified hazards.

Key Guidewords in the Study

The following guidewords were critical in identifying potential deviations:

  • Flow
  • Pressure
  • Temperature
  • Level
  • Others: Leakage and corrosion risk

Outcomes and Recommendations

The HAZOP study conducted for the Uran–Chakan–Shikrapur LPG pipelines of HPCL has effectively pinpointed various potential hazards, deviations from standard operations, and issues affecting operability. Through a detailed analysis, the study outlined specific, actionable recommendations designed to mitigate identified risks and bolster operational safety. By adopting the recommendations, HPCL not only addresses immediate safety concerns but also reinforces its overarching commitment to maintaining a safe and efficient operational environment. This proactive approach to risk management is crucial for ensuring the seamless and secure functioning of its refinery operations, thereby protecting both personnel and infrastructure. Ultimately, the implementation of these measures will contribute to the long-term sustainability and reliability of HPCL’s UCSPL operations, fostering a culture of safety and continuous improvement.

Why Choose HAZOP for Pipeline Safety?

HAZOP studies are a proactive tool to enhance the safety and reliability of critical infrastructure like LPG pipelines. By systematically identifying and addressing risks, businesses can prevent accidents, protect personnel, and ensure uninterrupted operations. Contact us today to learn more about how HAZOP studies can safeguard your infrastructure and foster a culture of safety and innovation.