Situated in Bina, Madhya Pradesh, Bina Refinery (BR) of Bharat Petroleum Corporation Limited (BPCL) runs a 7.8 MMTPA refinery. The refinery was commissioned in 2011 with crude oil processing capacity of 6.0 MMTPA, which was subsequently debottlenecked to 7.8 MMTPA in year 2018-19. To source crude up to refinery, there is a Single Point Mooring (SPM) system, Crude Oil Terminal (COT) and a cross country 937 kms pipeline from Vadinar, Gujarat to Bina, Madhya Pradesh. Oil is sourced mainly from the Middle East in tankers and is unloaded at the SPM, stored in COT and then transported to Bina via pipeline. Very large crude carriers can be received by the SPM (VLCCs).
The refinery complex at Bina produces various petroleum fuels such as LPG, Naphtha, Kerosene, Aviation Turbine Fuel/Jet Fuel, Motor Spirit (BS VI), Diesel (BS VI), Pet coke and Sulphur.
SCOPE
Scope of Work (SOW) is to carry out HAZOP study of –HGU, Utilities, Offsite, BDT & COT-SPM units at BPCL -Bina Refinery in accordance with applicable regulations and standards to identify hazards, design deficiencies, and operability issues within the specified units.
OBJECTIVE
Hazard and Operability (HAZOP) study is a design review technique used for identification of hazards, design deficiencies which may lead to operability problems. HAZOP is most frequently used in systems that handle, transmit, or process hazardous materials or activities where there are risks associated and there could be serious repercussions for not controlling those risks in terms of harm to people, property, or the environment.
The main objective of HAZOP study is to identify hazard scenarios that would eliminate or reduce the Risk in Operation.
- To identify deviations from the design intent & applicable standards.
- To recognize possible risks and problems with operation
- To make suggestions for mitigating the issues found.
Author Summary about this study:
NODE STUDIED:
- BINA DISPATCH TERMINAL-10 NODES
- OFFSITES-25 NODE
- CRUDE OIL TERMINAL-7 NODES
- HYDROGEN GENERATION UNIT- 21 NODES
- Utilities-
- CONDENSATE POLISHING UNIT-6 NODES
- EMERGENCY DIESEL GENERATOR- 6 NODES
- EFFLUENT TREATMENT PLANT – 22 NODES
- NITROGEN UNIT- 6 NODES
- RO-DM PLANT -15 NODES
- RWTP – 8 NODES
METHODOLOGY:
The study analysed possible deviations for all nodes, their respective causes, and consequences. Safeguards were identified to reduce the likelihood of hazardous events occurring or to minimize their severity. In cases where existing safeguards were deemed inadequate, recommendations were provided to mitigate risks. The HAZOP study was conducted using PHA Pro software, ensuring a comprehensive analysis of the units.
RECOMENDATIONS:
- SOP to be developed for ensuring Following.
- Proper Decontamination of unloading hose.
- Material of construction (MOC) and cleanliness of unloading hose.
- SOP to be developed to Decontaminate or to eliminate dead legs on a H2O2 pipelines.
- Install H2S detector near sour water storage tank
- Tank top emergency pressure release hatch provision should be taken into consideration.
- Explore the possibility of N2 blanket system on Tank
- Install H2S and HC gas detector near OWS/CRWS sump
- Study and provide additional piping arrangement from the HV-2951 downstream to EE-1035 for eliminating stagnant cold liquid and to maintain the normal operating temp.
- Provide PT and remote operated on valve for emergency closure to eliminate LOC
- Check for alternate dosing point on low pressure and temp site in consultation with vendor
CONCLUSION:
The HAZOP study of HGU, Utilities, Offsite, BDT & COT-SPM units at BPCL – Bina Refinery identified potential hazards, deviations, and operability issues, and provided actionable recommendations to mitigate risks and enhance operational safety. By implementing these recommendations, BPCL can further strengthen its commitment to process safety and ensure the smooth and secure functioning of its refinery operations.