Case Study

HAZOP Study at IOCL Manmad Terminal: Risk Assessment & Safety Improvements

Introduction

The Hazard and Operability (HAZOP) study for the Manmad Terminal has been awarded to iFluids Engineering by IOCL. The study identifies the methodology and results proposed by iFluids Engineering that IOCL has acknowledged for the completion of the HAZOP study.

M/s. IOCL, Terminal, Manmad intended to conduct a HAZOP study for their Receiving, storing, and dispatching MS & HSD to fulfill the requirement for domestic as well as commercial purposes. The Terminal has storage facilities for Ethanol and Bio-Diesel for blending purposes. The Terminal receives Petroleum, Oil, and Lubricant products through the Petroleum Product Pipeline coming from the BPCL terminal and also proposed to receive Petroleum, Oil, and Lubricant products from the IOCL pipeline division for storage.

Objective of HAZOP

Objective of HAZOP - A structured diagram illustrating four key objectives: Hazard Identification, Causes of Accidents, Risk Reduction Measures, and Efficiency Improvements, connected to a central node for better visualization
Objective of HAZOP

The principal objective of HAZOP research is risk management through hazard identification, likelihood estimation, and assessment of possible mitigation strategies for people, property, environment, and plants.

The Objective of HAZOP follows,

  • Identify the Hazards in the facility
  • Determine the cause that will probably result in consequences or an accident at the site.
  • If necessary, offer recommendations to reduce the risks present in the establishment.
  • Now and again, HAZOP finds things that could enhance facility efficiency and unit operations.

HAZOP Process for IOCL Manmad Terminal - A circular flowchart illustrating five key steps: Team Formation & Planning, Process Review & Data Collection, Risk Assessment & Hazard Identification, Recommendations & Mitigation Strategies, and Final Report Submission
HAZOP Process for IOCL Manmad Terminal

HAZOP Process for IOCL Manmad Terminal

  • Team Formation & Planning – Assembling industry experts to conduct the study.
  • Process Review & Data Collection – Analyzing critical process parameters, P&IDs, and operational workflows.
  • Risk Assessment & Hazard Identification – Using guidewords to systematically evaluate deviations.
  • Recommendations & Mitigation Strategies – Proposing actionable risk reduction measures.
  • Final Report Submission – Delivering a detailed report outlining findings, analysis, and compliance recommendations.

HAZOP Methodology

The image is a flowchart outlining the HAZOP (Hazard and Operability Study) methodology. It depicts a structured step-by-step process for identifying potential hazards and operability issues in a system. The flowchart starts with explaining the overall design, selecting a node, and examining the design intent. It proceeds through identifying elements, selecting guide words, applying interpretations, and assessing credible deviations. If deviations are credible, causes, consequences, and protections are investigated and documented. The process iterates until all guide words, elements, and parts have been examined, leading to the final stop. The structured approach ensures a systematic hazard analysis.
HAZOP Methodology

Key Challenges

Especially for large, complex, or dynamic systems or processes, HAZOP’s time and resource requirements provide a major challenge. Creating scenarios, gathering and analyzing data, assessing risks, and formulating recommendations all take a lot of time and work from a diverse team of professionals in HAZOP. To make matters more complicated and labor-intensive, HAZOP also requires a lot of documentation and communication. A HAZOP may take a few weeks, months, or even years to complete, depending on the size and complexity of the system or procedure.

Recommendations

It is recommended that specific task groups receive suggestions, which should be communicated using action-based language (e.g., check, deliver, consider, assure, and review). Recommendations were not proposed in instances where the HAZOP team believed that the existing safeguards were adequate to manage the potential risks identified to acceptable levels.

Why Choose iFluids Engineering for HAZOP Studies?

  • Expert-Led Analysis – Our team of seasoned process safety consultants ensures a detailed risk assessment tailored to the unique requirements of the Manmad Terminal (IOCL).
  • Regulatory Compliance – We align our HAZOP study with industry standards and API guidelines.
  • Risk Identification & Mitigation – Our structured methodology helps identify potential hazards, deviations, and operability issues, ensuring a proactive safety approach.
  • Detailed HAZOP Reports – We provide comprehensive documentation with actionable insights, recommendations, and risk control measures.

Key Benefits of Our HAZOP Study at IOCL Manmad Terminal

✔ Enhanced Safety – Minimize risks associated with hazardous processes.
✔ Improved Operational Efficiency – Identify inefficiencies and optimize processes.
✔ Regulatory Adherence – Ensure compliance with industry safety standards and regulations.
✔ Reduced Downtime & Costs – Prevent accidents and unplanned shutdowns, saving time and resources.

Conclusion

The Hazard and Operability (HAZOP) study conducted by iFluids Engineering for the Indian Oil Corporation Limited (IOCL) Manmad Terminal focused on identifying potential hazards associated with the terminal’s operations, which include receiving, storing, and dispatching petroleum products such as Motor Spirit (MS) and High-Speed Diesel (HSD), as well as handling Ethanol and Bio-Diesel for blending purposes. The study aimed to assess risks to personnel, property, the environment, and plant infrastructure, and to propose mitigation strategies to manage these risks effectively. Despite the challenges inherent in analyzing large and complex systems, the HAZOP study provided actionable recommendations to enhance safety and operational efficiency at the Manmad Terminal.