Introduction
Quantitative Risk Assessment (QRA) and Hazard and Operability Study (HAZOP) are critical methodologies for ensuring the safety and efficiency of industrial pipelines. At the IOCL Karwar Terminal in Karnataka, a comprehensive QRA and HAZOP study was conducted for the 8-inch pipeline to assess potential risks and enhance operational safety. This study plays a vital role in mitigating hazards and ensuring compliance with safety regulations.
Overview of the Facility
Karwar Bunkering Terminal of IOCL is situated near Sea Bird, Baithkol, Karwar, Uttara Kannada District in Karnataka. The Terminal was commissioned in the year 1991 and it is near Karwar Port. The terminal is at a distance of approximately 90 km from Goa Airport and 10 km from Karwar Railway Station. The terminal receives High Flash High-Speed Diesel (HFHSD), a Class C product having a flashpoint greater than or equal to 65oC but below 93oC, through Coastal Tankers loaded from different port locations of India. Karwar Bunkering Terminal is a fully Automated Terminal and all the operations are controlled from the control room of the Terminal. The system is divided into two working aspects: –
- Receipt of HFHSD through Coastal Tankers by 8-inch dia. 1.1 km underground Pipeline
- Pipeline Bunkering of HFHSD through 10-inch dia. 7.2 Km Naval jetty line to Naval Ships & Barges at Naval Jetty.
The Tanker is berthed in Karwar Port and from the port jetty product is pumped to the terminal through an 8-inch diameter. 1.1 Km long Jetty Pipeline. In case of extreme emergency or shortage of Coastal Tanker, the product is received through Road Tank Trucks to maintain the Navy’s MSL (Minimum Stock Level). A Mass Flow Meter (MFM) has been provided in the HFHSD receipt line inside the terminal premises.
Quantitative Risk Assessment (QRA)
QRA involves a systematic approach to evaluate risk levels associated with the pipeline operation. The methodology includes:
- Hazard Identification (HAZID): Recognizing potential risks such as leaks, corrosion, and external interferences.
- Consequence Modeling: Analyzing possible outcomes of hazardous events using advanced simulation tools.
- Risk Estimation: Quantifying risk levels using statistical models and past incident data.
- Risk Mitigation Strategies: Recommending measures like enhanced monitoring, emergency response planning, and structural reinforcements.
The scope of the project was to carry out a Quantitative Risk Assessment (QRA) study for an 8” MS Pipeline from Karwar port to IOCL. The assessment was based on the hazards that may occur during the operations of the project according to the information available.
The primary goal of this study is to assess the potential risk levels for personnel due to unintentional release of hazardous materials from loss of containment scenarios and to demonstrate that individual risks are within broadly acceptable ranges.
QRA’s objectives are as follows:
- Hazard detection and major loss of containment (LOC) incidents
- Calculation of physical impacts of failure case scenarios, including estimation of jet fire, flammable gas dispersion distances, and overpressure explosion distances
- Evaluation of failure frequency
- Estimation of potential loss of life and quantification of societal risk
- Conduct a risk assessment to check that risk can be reduced by the ALARP principle and the UK HSE risk acceptance criteria.
- Recommend risk-reduction actions to ensure that all risks are mitigated.
As part of the QRA study, hazard scenarios were identified for the project facility and consequence analysis was carried out using DNV PHAST software version 8.4. The risk analysis was carried out using DNV SAFETI software version 8.4 to obtain risk results in the form of Location Specific Individual Risk (LSIR) contours. These risk results were assessed based on the HSE UK Risk Acceptance Criteria and The Individual and Societal Risk for the risk ranking location was found to lie in the Acceptable region.
Hazard and Operability Study (HAZOP)
HAZOP is a systematic approach to identifying design and operational issues that may lead to hazardous situations. Key steps include:
- Node Identification: Breaking the pipeline system into manageable sections.
- Deviation Analysis: Assessing operational deviations such as pressure fluctuations, flow rate changes, and temperature variations.
- Cause and Consequence Evaluation: Identifying sources of deviations and their potential impact.
- Control and Safeguard Recommendations: Implementing corrective actions like automated monitoring systems, safety alarms, and procedural improvements.
The scope of the project was to carry out a HAZOP (Hazard & Operability) study for the 8” IOCL Pipeline at Karwar Terminal, Karnataka. The study aims to manage project risk through the early identification of hazards and operability problems and to reduce the probability and consequences of an incident that would have a detrimental impact on the personnel, plant, properties, and environment.
- The entire facility was taken as a single node.
- The team examines each system, or operation node, assesses potential deviations from intended operation, and studies their effects.
- Each cause-consequence combinations are identified and their effects are examined. Risks and challenges are then evaluated.
- Additional safety measures or operational procedures are recommended for reducing the likelihood of a hazardous event occurring or reducing the severity of the consequence.
- The entire study was conducted in PHA Pro software.
HAZOP study benefits in identifying Hazards and Operating problems due to equipment failure, Instrument malfunction, etc., and recommend changes in existing design or procedures to improve safety. The study team raised 5 recommendations to improve the safety and operability of the facility which includes
- P&ID to be developed for 8″ HFHSD pipeline from Karwar port to Karwar terminal
- Process Safety Information training is to be provided to the concerned operators.
- SOP to be developed to ensure TRV upstream and downstream isolation valves are kept locked open and training to be provided to concerned operators
- Consider developing a preventive maintenance inspection program to monitor pipeline thickness
- Ensure effective oil spill response plan /procedure is in place
Key Findings and Safety Recommendations
- Pipeline Integrity Enhancement: Regular inspections and corrosion prevention techniques to maintain structural integrity.
- Leak Detection System Implementation: Installing real-time monitoring sensors to detect leaks promptly.
- Emergency Response Planning: Developing an effective emergency response strategy to handle potential hazards.
- Operator Training Programs: Conducting safety training sessions to ensure staff preparedness for emergencies.
- Regulatory Compliance Adherence: Aligning operational procedures with national and international safety regulations.
Incorporation of all these recommendations will result in managing risks to tolerable levels.
Conclusion
The QRA and HAZOP analysis of the 8-inch IOCL pipeline at Karwar Terminal, Karnataka, is crucial for ensuring safe and efficient operations. By identifying risks and implementing strategic safety measures, IOCL enhances pipeline security, reduces operational risks, and ensures compliance with regulatory frameworks. These proactive safety assessments contribute to sustainable pipeline management and industry best practices. For detailed insights into the QRA and HAZOP study, contact iFluids Engineering, a trusted leader in industrial safety analysis and risk assessment.