QRA & HAZOP Study for Facilities at NRPL (Northern Region Pipelines), IOCL Rewari 

 IOCL has awarded iFluids Engineering to conduct HAZOP (Hazard and Operability) study and QRA (Quantitative Risk Assessment) study for the Facilities at NRPL (Northern Region Pipelines) Rewari.NRPL, Rewari installation has four pipelines in which two are crude oil carrier pipelines (Mundra – Panipat Pipeline & Salaya – Mathura Pipeline) and two are multiproduct pipelines (Panipat Rewari Product Pipeline and Jaipur-Panipat Naphtha Pipeline).


  • Basket strainers.
  • UFM and TFM are available.
  • Sump tank with sump tank motor.
  • Surge relief tank with motor.
  • Oil Water Separator (OWS).
  • Compressed Air System.
  • Fuel System.
  • Pig/Scrapper Receiving and Launching Barrel.
  • Fire Detection and Alarm & Firefighting System.
  • Cathodic Protection System.
  • Power System.


The HAZOP research focuses on risk management, identifies hazards, calculates the likelihood that an incident will occur in the plant, and assesses the safety measures that may be put in place to protect people, the plant, the environment, and property.

The Objective of HAZOP are as follows,

  • Identify the Hazards in the facility
  • Determine the cause that will probably result in consequences or an accident at the site.
  • To provide required Recommendations to prevent the occurrence of  hazards in the facility.
  • HAZOP occasionally identifies items that could enhance facility efficiency and unit operations.


The major goal of this study is to assess the potential risk levels for workers resulting from the unintentional discharge of hazardous materials from the Facilities under loss of containment scenarios and to show that individual risks fall within the generally acceptable ranges. The goals of QRA are listed below:

  • Identifying hazards and major loss of containment (LOC) events
  • Estimation of Jet Fire, Pool Fire heat radiation distances, Flammable Gas Dispersion distances, and Overpressure Explosion distances for physical consequences of failure case scenarios
  • Evaluation of Failure Frequency
  • Quantify social risks and estimate potential loss of life.
  • Conduct a risk assessment to ensure that the risk can be mitigated according to ALARP principle, in accordance with the UK HSE risk acceptance criteria
  • To make sure that all hazards are in ALARP or in the Acceptable area, suggest risk-reducing actions.

Facility Description

Mundra-Panipat Pipeline (MPPL)

Mundra-Panipat Pipeline, erstwhile KBPL was converted into a Crude pipeline to meet the requirements of Panipat Refinery under PREXPL project. The Pipeline is designed to meet the required throughput of Client. The Pipeline traverses the states of Gujarat, Rajasthan and Haryana. Intermediate pump stations are located at Sidhpur, Abu Road, Kot, Beawar, Sanganer and Rewari. Delivery station is located at Panipat. MPPL Rewari is an intermediate pumping station for Mundra- Panipat crude pipeline and upstream of Panipat delivery station. It was converted into crude pipeline from product pipeline KBPL in back in 2005, with 3 engine driven pumps as MLPUs. But in recent times the motors have been used as prime movers in MPPL in place of engines.

Salaya-Mathura Pipeline (SMPL)

Salaya-Mathura Pipeline is a crude oil pipeline transporting crude from Salaya to meet the requirements of Gujarat Refinery, Mathura Refinery and Panipat Refinery. The SMPL Rewari (Karnawas) is an intermediate pump station of Chaksu –Panipat section of SMPL. There are 3 Motor driven pumping units with 2+1 Configuration.

Panipat – Rewari Pipeline (PRPL)

Panipat – Rewari Pipeline (PRPL) is a multi-product pipeline System which transports finished products like Motor Spirit (MS) and High-Speed Diesel (HSD) from Panipat refinery to Rewari delivery station through a dedicated pipeline. The pipeline traverses through the state of Haryana.

Jaipur-Panipat Naphtha Pipeline (JPNPL)

JPNPL is a multiproduct pipeline with provision of pumping Naphtha as well as other products from Mohanpura (Jaipur) as well as Ex-KSPL to Panipat. In JPNPL an existing 20 km pipeline section  from Mohanpura to Sanganer (Jaipur) in Jaipur has been added to the newly constructed pipeline from Sanganer (Jaipur) to Panipat. Using JPNPL multiproduct can be delivered to Marketing TOP, Rewari using the existing PRPL station piping. Presently, existing delivery facilities (metering, filtering, manifold etc.) at NRPL Rewari are shared between PRPL and JPNPL.

Now, IOCL intends to provide separate dedicated delivery station facilities (Metering, Filtration, manifold etc.) for JPNPL at NRPL Rewari.

  • New facilities shall involve pressure control, surge control, filtering, metering facilities and manifold.
  • Auxiliary facilities include LT PMCC and RIO panels.
  • Fire and gas detection system shall include Point type Gas detectors.


One of HAZOP’s major challenges is the time and resource needs, especially for large, complicated, or dynamic systems or processes. For HAZOP, a broad group of experts is required, and they must devote a lot of time and effort towards collecting and analyzing data, creating scenarios, determining risks, and offering recommendations. HAZOP also calls for a lot of paperwork and communication, which can add to the effort and complexity. Depending on the scale and complexity of the system or process, a HAZOP may take a few weeks, months, or even years to complete.

Recommendations should be assigned to specific task groups and conveyed using action-based phrases (such as check, provide, consider, ensure, and review, etc.). When the HAZOP team felt that the current safeguards were sufficient to manage the possible risks detected to acceptable levels, recommendations were not made.


Location Specific Individual Risk

LSIR gives the average risk across each Area (as defined in the risk model) to a person continuously present independent of the population. The LSIR for the people at all the risk ranking locations considered for the study lies in the ALARP region.

Individual Risk for the people

The Individual Risk (IR), which is independent of population, provides a measurement of the risk that will be applicable to each location (in this example, each area, typically).

The Individual Risk Per Annum for the People at all the risk ranking locations considered for the study comes under the ALARP region.

Societal Risk A relationship between frequency and the number of people experiencing a specific level of harm in a given population as a result of the manifestation of a specific hazard is provided by societal risk. The study’s findings lead to the conclusion that the societal risk for the study’s entire population is within the Acceptable range.