M/s. Indian Oil Corporation Ltd. (IOCL) has entrusted iFluids Engineering to conduct the Hazard and Operability Study (HAZOP) for the Digboi Refinery in Assam in line with OISD guideline. The scope of the project is to conduct HAZOP study of all the process units and utility & offsite facilities in the complex of Digboi Refinery. Digboi Refinery has a crude processing capacity of 0.65 MMTPA. It processes waxy crude extracted from oil fields operating in an area near Digboi.

HAZOP Study

The objective of the HAZOP study was to identify hazard and operability problems and to reduce the probability and consequences of an incident in the process units and utility & offsite facilities in the Indian Oil Corporation Ltd. (IOCL) that would have a detrimental impact to the personnel, plant, properties and environment.

Methodology of HAZOP

• Node Marking  based on (Stream, equipment or a Package) on the P&ID
• List the intention & process parameters, guidewords for the node
• List all deviations and ignore deviations that are not meaningful and Apply the deviation
• Brainstorm and list various causes of the deviation and ignore causes that are not credible
• Determine the consequences of the deviation due to each listed credible cause
• Identify Safeguards already provided in the system
• Identify Risk Matrix based on severity & likelihood
• Suggest recommendations/actions, should the safeguards be inadequate

HAZOP Study of Process Units at Digboi Refinery.

S.No.	Process Unit	No. of P&ID
1	CPP	34
2	AVU-CDU-VDU	56
3	CRU	23
4	DCU	47
5	HDT	105
6	HGU	45
7	SDU	84
8	SRU	27
9	SWS	5
10	DM PLANT	2
11	HDT offsite HPNU	8
12	LDU	1
13	MSQ	53
14	NTF	7
15	WHF	20
16	WPU	4

Project Duration: 04 Months

Software Used: The HAZOP software used was PHA-Pro/PHA

Asian Paints Limited has an existing installation at Visakhapatnam district, Andhra Pradesh for the purpose of producing two main types of paint, namely industrial and decorative paints. While industrial paints are used for protection against corrosion and rust on steel structures, vehicles, white goods and appliances, decorative paints are used for protecting valuable assets like buildings.

Asian Paints Limited being keen on increasing the safety culture of the plant, has entrusted iFluids Engineering to perform the Hazard and Operability (HAZOP) study of the plant, located in Visakhapatnam, Andhra Pradesh.

A HAZOP study systematically reviews potential hazards and operability problems which could potentially lead to asset damage, business interruption, environmental damage, and/or personnel injury. The study helps identify problems or needs that the operator should consider and solve. It also helps classify the existing safeguards provided as prevention or mitigation. Recommendations and/or operating procedures are provided as prevention or mitigation measures against potential hazards and operability problems identified during HAZOP Study Workshop.

The HAZOP study was initiated with a Kick off meeting by a team of experts from iFluids Engineering along with the Asian Paints Limited multi-disciplinary team. The HAZOP study methodology and how the workshop would be performed was explained and the inputs required for the study were proposed. During the HAZOP Workshop, the multi-disciplinary team reviewed the relevant documents and discussed potential hazard and operability scenarios through a brainstorming session. The outcomes of the session were systematically recorded.

The recorded discussion were then reviewed by the experts of iFluids engineering and the report was produced to Asian Paints Limited. The methodology and results proposed by the iFluids team were accepted by Asian Paints for the identification and minimization of risk, which paved way for the successful completion of the project.

Bharat Petroleum Corporation Limited awarded iFluids Engineering to conduct the Hazard and operability study (HAZOP) for the following Process Plants: CDU/VDU3, DHDT, VGO HDT, PFCC, DCU, SRU3, NHT-ISOM and related Utilities.

HAZOP, the concise form of Hazard and Operability Study is a systematic way to identify the hazards associated in a process. Firstly, the study begins by breaking down the process into simple nodes and uses guidewords (No, Less, More) combined with the significant process parameters (Flow, Temperature, Pressure & Level) to form Deviations. Deviations helps us to brainstorm the causes for the particular deviation happens in the process. For Example: In a particular node, what are the causes for No flow. Then, it identifies the consequences and their safeguards present in the system for each cause. After that, it evaluates the sufficiency of the existing safeguards and access whether those safeguards are adequate enough to protect PEAR (People, Environment, Asset and Reputation) related to the system. Finally, if the safeguards are not enough to protect PEAR, feasible recommendation/s would be proposed. Thus, the same process is repeated step by step for all the nodes.

BPCL HAZOP had been successfully completed by brainstorming each unit with the multi-disciplinary team such as process engineers, DCS engineer, Process safety Engineer and Control & Instrumentation engineers led by the Chairman. Therefore, BPCL HAZOP quantitatively evaluated the severity and risk for each consequence and identified the gaps present in the process with the aid of above mentioned procedure.

Oil India Limited has awarded iFluids Engineering to carry out As-built P&ID and PFD drawings, HAZOP study, Quantitative Risk Analysis, Consequence Analysis, Preparation of SOPs & Manual of Heavy Crude oil and Natural Gas Production installations and Work over operations in Rajasthan Fields .Oil India Limited (OIL) is a premier national Oil Company engaged in the business of Exploration, Production & Transportation of Crude Oil & Natural Gas. It discovered commercially viable gas fields at Tanot, Dandewala and Bagitibba in Jaisalmer district of Rajasthan.

To operate the fields, OIL has two production installations such as Processing Centre (GPC) & Gas Gathering Station (GGS).12 wells were drilled in Tanot field out of which 4 wells are having pressure, which needs workover operation for revival. This resulted in setting up of a centralized Natural Gas Processing facilities named DND GPC (Dandewala Gas Processing Complex) with the capacity of handling 1 MMSCM of Natural Gas per Day.

The Baghewala field of OIL has very high viscosity in thousands of centipoise and is not producible by conventional production methods on a regular basis.OIL has implemented CSS (Cyclic Steam Stimulation) technique for extraction of heavy crude in some of its wells on pilot basis. Addition to above, Rig will be deployed for Workover operation. It is intended to carry out HAZOP, QRA Study and Consequence Analysis for all the three installations.

To access engineering information easily at the time of need OIL has planned to create As-built engineering information for the oil and gas productions/process units through latest software tools so as to get the relevant information thereby minimizing losses in the event of an incident

Scope of Work

• To create engineering information of the following type of installations in Jaisalmer District
  • Dandewala Gas Processing Complex (DND GPC)
  • Baghewala Field (Heavy Oil) & Workover Rig engaged for Workover operations

• To convert all as-built engineering information of above installations to digital format using appropriate software tools.

• To carry out Hazard and Operability (HAZOP) study based on the intelligent As-built Process & Instrumentation Diagram and Process Flow diagram (P& IDs and PFD) for the early identification of potential hazards and threat affecting people, the environment, assets or reputation.

Scope of HAZOP study shall include the following aspects in addition:

1. Process Hazards
2. Maintenance Hazards
3. Electrical Hazards.
4. Design Verification (Hazards)
5. Instrument Hazards
6. Fire & toxic Hazards etc

• To carry out Quantitative Risk Analysis
• To carry out Consequence Analysis
• End Users Training & Submission of reports

Creation of As-built P&ID and PFD Drawings using recommended software

Collection of input data through physical survey, input verification & creation of P&IDs and PFD's for each installation using recommended international standard practice & software.

HAZOP Study

During the HAZOP each P&ID, PFD, Operation Manuals will be considered in turn Section wise with defined nodes .Recommendation will be provided on Emergency Measures & statutory requirements

QRA studies

Quantitative Risk Analysis includes identification of Hazards, Selection of Scenarios, Risk contours, Effects & consequences, Likelihood Estimation & Risk Summation along with control measures conducted as per International accepted guidelines. Quantitative Risk Analysis (QRA) and Emergency Response and Disaster Management Plan are to be carried out as per the statutory guidelines like Mines Act-1952, OMR-2017, OISD

Consequence Analysis:

Consequence Analysis and Estimation is the methodology used to determine the potential damage or injury from specific incidents.

Completion Period

The period of completion of project is 1 year.

Deliverables

• A draft report and final report of the studies shall be issued after incorporation of comments with OIL.
• Emergency Measure & statutory requirements will be Recommended
• Preparation and submission of Consequence Analysis report along with recommendations as to how to implement the same.
• Necessary training module & training materials required shall be provided.
• Submission of three sets of all the reports in digital format as well as in hard copy for each installation.

Oil India Limited(OIL) has awarded iFluids Engineering to carry out As-built engineering information for the oil and gas productions/process units. Oil India Limited (OIL) is a premier national Oil Company engaged in the business of Exploration, Production & Transportation of Crude Oil & Natural Gas. Its operations are largely based in Assam and Arunachal Pradesh the north eastern part of India.

Over the years various developments, related to oil/gas production, has taken place accordingly, the production/process installations for oil and gas have also been modified /augmented. However, engineering information for the changes could not be updated or maintained in proper form so as to access them easily at the time of need. Considering this, OIL has planned to create As-built engineering information for the oil and gas productions/process units, & plan to maintain this updated information in a scientific way through latest software tools so as to get the relevant information at the click of a mouse. This will in-turn help OIL to carry out various risk analysis study. These studies will help in taking appropriate measure and bring down the risk to as low as reasonably practicable and thereby minimize losses in the event of an incident.

Scope of Study

Following requirements have been identified in the scope of study

To create engineering information for the following type of installations spread over Assam and Arunachal Pradesh

• Oil Collecting Stations
• Early Production Setup
• Quick Production Setup / Well Head Setup

To convert all as-built engineering information of above installations to digital format using appropriate software tools

The tentative list of installations in Assam are:

OCS	EPS	QPS/WHS
OCS-1	BAGHJAN	HWDH
OCS-2	BHEKULAJAN	NKF
OCS-6	HATIALI	CHABUA-3
OCS-8	KUMCHAI	HJC
JOYPUR OCS	DEROI	DIAN
		TAI
		NADUWA
		BALIJAN
		BAREKURI
		MFJ

Mobilization & Creation of As-built P&ID and PFD Drawings using Intelligent P&ID software

• Mobilize personnel and required equipment
• Collection of input data through physical survey, input verification & creation of P&IDs and PFDs for each installation in acceptable international standard practice by surveyors and create the as built information as input for creation of AutoCAD drawing for all the installations
• Customization of P&ID symbols as required for creation of P&IDs /PFDs in Intelligent Format in conformation to ISA or other international standards. Intelligent P&IDs in intelligent format shall fully reflect the P&IDs and plant items contained therein (equipment, piping components, instrument components and signal lines etc.) along with all relevant attribution information shown on the face of original P&IDs.

Electrical Single Line diagrams (SLDs) to As-built status

• Collection of input data through physical survey from field installations, input verification & creation for followings.
  • Input verification of Single Line Diagrams (SLDs).
  • SLD creation to the As-built status using Smart Plant Electrical or equivalent in A2 size

As-built Piping & Plant Layout, Electrical, Instrumentation, Optical Fibre cable diagrams, Cable Schedule Layouts, Electrical System & equipment earthing and Fire Fighting System Drawings in AutoCAD Format

• Piping & plant Layout drawings with detail data to the scale as per OIL's standard and conversion into AutoCAD format in a Single Sheet (Scale 1:300) for each installation. These drawing will have demarcation of Hazardous Area Classification (Zone Classification).
• Electrical, Instrumentation, Optical Fibre cable diagrams, Cable Schedule Layouts, Electrical System & equipment earthing Drawings in AutoCAD Format in a Single Sheet

SOP, O&M Manual- Startup operating manuals for the units updated with and data sheet (Standard Operation and Maintenance Manual)

• Collection of manual/ input data for preparation and digitization of SOP and O&M procedure to the As-built status.

• Permanent writing of piping/equipment IDs will be carried out by painting/stencilling on the body of the piping/equipment and also by embossing on Aluminium Tag attached to the piping/equipment. Tagging and inscription specification will have to be approved by OIL
• Creation & Updation of Operating Manuals and Standard Operation and Maintenance Procedures (SOMPs) to As Built status including Conversion to Acrobat format. Operating and Start-up if it is  not available  it will be created using  the guidelines  of OIL.

To carry out Hazard and Operability (HAZOP) study

• Design Verification (Hazards)
• Process Hazards.
• Maintenance Hazards
• Electrical Hazards
• Instrument Hazards
• Fire & toxic Hazards etc.

• During the HAZOP each P& ID, PFD, Operation Manuals will  be  considered  in  turn Section wise with defined nodes
• After identification of the operational  hazards, recommendations on appropriate safety measures & stepwise implementation procedure to mitigate the same, is required to be submitted.To suggest recommendation & statutory requirements on Emergency Measures.

To carry out Quantitative Risk Analysis

• Quantitative Risk Analysis includes identification  of  Hazards,  Selection  of  Scenarios, Risk contours, Effects & consequences, Likelihood Estimation & Risk Summation along with control measures. Same to be conducted as per International accepted guidelines
• To Carry out Quantitative Risk Analysis (QRA) and develop an Emergency Response and Disaster Management Plan as per the statutory guidelines like Mines Act-1952, OMR-2017, OISD, etc. that should be concise and informative so that members of the emergency control organization are able to quickly refer to the action plan to determine important functions that are being carried out

To carry out Consequence Analysis

• Consequence Analysis and Estimation is the methodology used to determine the potential for damage or injury from specific incidents. E.g.: Jet fire distances, pool fires, BLEVE etc.,
• The Damage distances contours are plotted to ascertain the effects due to Heat  of Radiation and blast over pressure at various distance from the source and its impact or consequences on the Societal and Individual Risks

End Users Training & Submission of reports

• The end user training shall be imparted to 17 to 20 OIL personnel at Duliajan, Assam.
• Necessary training module & training materials / handout required shall be provided by the contractor.

Time of completion

• The time duration for this project is 3 years

Deliverables:

• Shall do the Mobilization, Survey, Data Collection, Creation & Digitization of Engineering information to the As-Built status & Preparation of manual in MS word.
• Shall suggest HAZOP, QRA recommendation on Emergency Measures as per the statutory guidelines like Mines Act-1952, OMR-2017, OISD
• Shall prepare and submit the Consequence Analysis report along with recommendations as to how to implement
• Shall conduct end user training and Submission of three sets of all the reports in digital format as well as in hard copy for each installation

Indian Oil Corporation Limited has awarded iFluids Engineering to carry out HAZOP Study for Panipat Refinery & Purified Terepthalic Acid unit .The Panipat Refinery is Indian Oil's seventh and most technologically advanced public sector refinery complex in India. Covering approximately 4222 acres of vast land, located in Panipat. The Refinery's capacity was increased to 12 MMTPA in June 2006, and then to 15 MMTPA in December 2010. In addition, there is a plan in the works to increase capacity to 25 MMTPA in the near future to satisfy prospective demand.

The Refinery's major secondary processing units include the Catalytic Reforming Unit, Once Through Hydrocracker Unit, the Resid Fluidised Catalytic Cracking Unit, the Visbreaker Unit, the Bitumen Blowing Unit, the Sulphur Block, and the associated Auxiliary Facilities. A Diesel Hydro Desulphurisation Unit (DHDS) was later commissioned in 1999 to improve diesel quality.

Facilities to be covered under the Study includes:

Total Nos. of P&ID's for HAZOP in PR & PTA units are 1852

Scope of Study

• The Scope of study is to identify the Hazard and Operability problems and to reduce the probability and consequences of an incident in the process facilities which would have a detrimental impact on the personnel plant properties and environment.
• The HAZOP study will cover every piece Of Equipment capable of producing an event that could lead to serious injuries or equipment damage. Scope of study will include all Process and utility P&IDs.

The HAZOP will be conducted to examine the overall Process design searching for operating deviations and procedures that can lead to hazardous situations or operability problems which  include:

• Review of the design and operation of  process facility
• Safety and Occupational health hazards to personnel
• Damage to equipment / assets / environment
• Operability / maintainability Problems
• Plant non-availability/limitation and lack of product quality
• Environmental emissions
• Construction and commissioning hazards
• Identification of all possible causes of deviations from normal operation that could lead to any safety hazard, environmental risk or operability Problem.
• Identification  of  hazards, possible causes  and  consequences and  suggest recommendations for necessary changes / alterations

Objective of the HAZOP Study

• To identify hazards associated with the facilities under the scope of work using the HAZOP study as the hazard evaluation technique.
• To identify all deviations from the way the design is expected to work, their causes and all the hazards and operability problems associated with these deviations.
• To decide whether action is required to control the hazard or the operability problem and if so to identify ways in which the problems can be solved.
• To identify cases where a decision cannot be made immediately and to decide what information or action is required.
• To document the Study in the Cause by Cause (CBC) format.

Deliverables

• Shall Submit the preliminary reports (observations)
• Shall Submit the HAZOP report
• Shall Submit the final recommendation

Mangalore Refinery and Petrochemicals Limited (MRPL) has awarded iFluids Engineering to carry out HAZOP study for the entire refinery complex and other facilities covering jetty, cross country pipelines, SPM, Aromatic Complex (around 2650 no of P&ID's) of MRPL located in Karnataka.The refinery has got a versatile design with high flexibility to process Crudes of various API and with high degree of automation & a design capacity to process 15 million metric tons per annum (MMTPA).

MRPL owns and operates cross country pipelines to receive crude oil and transport finished products from and to Jetty facilities of New Mangalore Port respectively. Further, MRPL owns and operates Single Point Mooring (SPM) facilities off the coast of Mangalore to receive large to very large crude oil carriers

Facilities to be covered

HAZOP study to be carried out on all latest updated Piping and Instrumentation Diagrams (P&IDs) of Process and Utility plants.

Unit Description	No of P&ID's
CDU-1/VDU-1/NSU-1	43
VBU-1	37
ATU-1/SWS-1	15
SRU -1	12
LPG	I9
LPG/KERO  MEROX-1	19
HYDROGEN-1/PSA	17
NHT-1/CCR-1/PSA	47
HCU-1	71
BBU	05
RSU	11
CPP-1	16
Offsite-1	38
PHASE 1 utilities	33
WWTP-1/2	14
Jetty facilities	20
CDU-2/ VDU-2/ NSU-2	45
MIXED XYLENE	20
VBU-2	37
SRU-2/SPU	14
ISOMERIZATION UNIT	57
SEPU System	04
Naphtha Hydro treating unit	25
PHASE 2 utilities	50
PFCC/PRU	50
CDU/VDU-3	90
Offsite-2	20
SRU-4/SPU	52
HGU-3/RPSA	52
POLYPROPYLENE UNIT	64
N2 Plant	32
CPP-3	79
GOHDS	33
MEROX-	22
PHASE 3 Offsites & Utilities	137
Bitumen Drum filling unit	01
Black Oil Truck Loading Facilities	04
SPU Phase-2	01
White Oil Truck Loading Facilities	04
CCR Regeneration (CCRG)	05
Naphtha Hydro treating unit	25
CCR Platformer unit (CCRP)	38
Shell Sulfolane unit (SSU)	21
Tatoray  unit	15
Block-2 Utility	31
Xylene  fractionation  unit  (XFU)	31
OSBL andISBL Tank farm area	68
Effluent treatment plant (ETP)	27
Solid waste disposal & handling facility	47
Laboratory draining system facility	2
Effluent pre-treatment plant(EPTP)	6
Cooling tower Blow down reverse osmosis plant (CTRO)	6
Fire water system	1
Nitrogen Plant	2
Instrument air & Plant air system(IA & PA)	2
ISOMERIZATION UNIT	57
HYDROGEN-2/PSA	16
LPG/KERO MEROX-2	25
HYDROGEN-2/PSA	16
LNHT	16
PHASE 2 utilities	27
CDU/VDU-3	90
DCU	205
PFCC/PRU	194
CPP-3	79
Bitumen Drum filling uni	01
Black Oil Truck Loading Facilities	04
Block-1 Utility	47
OSBL andISBL Tank farm area	68
Shell Sulfolane unit (SSU)	28
N2 Plant	35
CHT	89

Approximate no of P&ID's for HAZOP study in the refinery is 2650.

Scope of work

• To carry out Hazard & Operability (HAZOP) study for all the units mentioned above.
• Review of Consequence of failure of measuring instrument/devices, final control element (control valve), safety system (PLC) and control system (DCS).
• Review of existing safety controls and interlocks and trip alarm set value
• Review of standards/statutory requirements
• Study report shall consider  operational  controls,  safeguard evaluation, Hazard recognition, recommendations, etc HAZOP study shall be comprehensive.

HAZOP Methodology

• The technique for Hazard and Operability Study was developed to assess the safety and operability of a process system in a systematic manner
• The examination procedure takes a full description of the process, the intention of the design and decides whether these deviations can give rise to hazards. Process unit interconnections shall be considered where ever necessary
• Necessary action plan to mitigate/reduce the hazard is suggested based on available safety provision
• HAZOP should be done to meet the OISD requirement as minimum for each unit operation.

Completion Period

The project will be Completed within 18 months from the date of issue of LOA

Deliverables

• Kick off Meeting (KOM) as per scope/Road map schedule.
• Shall submit HAZOP Study Methodology Procedures
• Shall draft HAZOP Reports for each unit
• Final HAZOP Reports for each unit [Four (4) hard copies and soft editable copy]