Case Study

HAZOP Analysis for Thriveni Earthmovers’ LNG Storage and Filling Station in Keonjhar, Odisha

Introduction

Thriveni Earthmovers Private Limited plans to install an LNG Filling Station in Keonjhar District, Odisha. The Facility shall have 2 storage tanks for LNG storage from transport tankers via unloading Pump. This LNG Filling Station shall have a Facility to fill cylinders via a filling pump. BOG generated from the Storage Tank and Unloading Pump is routed to the Gas Generator which is used to produce power in addition to that Degasified Natural Gas shall be used from nearby sites for power generation. This document provides the methodology and results carried out and accepted by Thriveni Earthmovers Private Limited for the completion of the HAZOP study.

Key Objectives of the HAZOP Study

Infographic depicting the objectives of a HAZOP study, highlighting five key aspects: hazard identification, risk assessment, operability analysis, risk mitigation, and documentation
Key Objectives of the HAZOP Study
  • Hazard Identification: Recognizing inherent dangers within the LNG storage and filling processes.
  • Risk Assessment: Evaluating the severity and likelihood of identified hazards.
  • Operability Analysis: Ensuring the system functions as intended under various conditions.
  • Risk Mitigation: Developing strategies to minimize or eliminate identified risks.
  • Documentation: Recording all findings and recommendations for future reference and compliance purposes.

Key Steps Involved in a HAZOP Study

Infographic illustrating the key steps involved in a HAZOP study, including defining objectives, assembling the team, selecting guide words, node identification, applying guide words, evaluating deviations, developing recommendations, documentation, and follow-up implementation
Key Steps Involved in a HAZOP Study
  • Define the Study Objectives: Establish the goals and scope of the HAZOP study. Define the process or system to be analyzed and determine the specific objectives, such as identifying hazards, assessing risks, and improving operability.
  • Assemble the Study Team: Form a multidisciplinary team comprising individuals with relevant expertise and knowledge of the process or system being studied. This may include Process Engineers, Safety Specialists, Operators, Maintenance Personnel, and other relevant Stakeholders.
  • Select Guide Words: Guide words are used to systematically and creatively explore potential deviations from the design intent of the process or system. Commonly used guide words include “more,” “less,” “no,” “part of,” “reverse,” and “other than.” These guidewords are applied to various process parameters (e.g., Pressure, Temperature, Flow rate) to stimulate brainstorming and identify possible deviations.
  • Conduct Node Identification: Break down the process or system into manageable sections called “Nodes.” Each Node represents a specific part or equipment within the process or system. Nodes are systematically examined one by one to identify potential deviations and associated hazards.
  • Apply Guide Words: For each Node, apply the selected guide words to the process parameters to generate potential deviations. The team members brainstorm and discuss the consequences of each deviation, considering possible hazards, risks, and operability issues that may arise.
  • Evaluate Deviations: Evaluate the consequences of each deviation in terms of safety, operability, and potential risks. Assess the severity, likelihood, and potential consequences of each identified hazard or deviation.
  • Develop Recommendations: Based on the identified hazards and operability issues, develop recommendations for risk mitigation and operational improvements. These recommendations may include design changes, procedural modifications, safety measures, or other necessary actions to address the identified risks.
  • Document the Study: Document all findings, identified hazards, consequences, and recommendations resulting from the HAZOP study.  This documentation serves as a record for future reference, as well as for regulatory compliance and audit purposes.
  • Follow‐up and Implementation: Ensure that the recommendations from the HAZOP study are appropriately communicated and implemented. Monitor the progress of recommended actions and verify that the necessary changes and improvements are made to address the identified hazards and operability issues.

HAZOP studies often serve the purpose of ensuring compliance with regulatory requirements and Industry standards. By systematically examining the process or system, HAZOP helps in identifying any deviations or non‐compliance with applicable regulations.  This enables organizations to take corrective actions and ensure that their operations meet the required safety and operational standards.

HAZOP Study conducted for LNG Filling Station Thriveni Earthmovers Private Limited reveals that the recommendations identified were not proposed as the HAZOP team believed that the existing safeguards were adequate to manage the potential risks to acceptable levels. In total, the HAZOP study identified 7 recommended actions for LNG Filling Station Keonjhar district, Odisha Thriveni Earthmovers Private Limited, for reducing the likelihood of a hazardous event occurring or reducing the severity of the consequence. Given that recommendations were made to lower risks believed to be outside tolerable limits to an acceptable (or tolerable level). Incorporation and close out of all HAZOP recommendations results in a Facility where all risks identified have been managed to tolerable levels.

Conclusion

The HAZOP study for the LNG filling station identified seven recommended actions. However, the team determined that existing safeguards were sufficient to manage potential risks, and no additional measures were proposed. Conducting such HAZOP studies is crucial for compliance with regulatory standards and industry best practices. They play a vital role in proactively identifying and addressing potential issues, thereby safeguarding both personnel and infrastructure.