Quantitative Risk Assessment And HAZard OPerability Study For IOCL

IOCL Small Can Filling Plant – Tadepalli is located near Vijayawada. IOCL has awarded iFluids Engineering to carry out Hazard and Operability (HAZOP) study for small can filling plant at Tadepalli area. The plant receives base oil through tank trucks (TT) from LBP/CPCL. Additives are received in packed condition (barrels) and also in bulk through tanker Lorries. Major portion of additives are received from M/s Lubrizol (l) Ltd, Mumbai, Indian Additives, Chennai and LBP Chennai.

The base oils are stored in above ground tankers. Packed additives are stored in go down /open yard. Lube oil are produced by suitable blending of base oils and additives of various grades (about 17 grades). Blending is carried out in kettles of various capacities. Heat for the purpose of blending is obtained from the hot water generator. Finished products are filled in 210 liters barrels and also in cans varying from ½ lit to 50 liter. The barrels and small containers are dispatched to IOCL depot located adjacent to the premises.

The objective of the HAZOP (Hazard & Operability) study is to aid in managing project risk through early identification of hazards and operability problems and to reduce the probability and consequences of an incident that would have a detrimental impact to the personnel, plant, properties and environment.

The main objective of this study is to evaluate the potential risk levels for personnel due to accidental release of hazardous materials from loss of containment scenarios from the facilities and to demonstrate that individual risks are within the broadly acceptable regions. The Objectives of QRA are as follows:

  • Hazard identification and selection of failure case scenarios
  • Calculation of physical effects of failure case scenarios which include Estimation of Jet Fire, Pool Fire heat radiation distances, Flammable gas dispersion distances, and overpressure explosion distances
  • Failure Frequency evaluation
  • Societal risk quantification and Potential Loss of Life estimation
  • Perform a risk assessment to confirm that risk can be reduced consistent with the ALARP principle according to the UK HSE risk acceptance criteria

Recommend risk reducing measures to ensure that all risks are in ALARP or in Acceptable region