The country's second refinery, the Barauni Refinery, was commissioned in July 1964 ,  with a refining capacity of 1 million metric tonnes per annum (MMTPA) to process Assam (Naharkatiya) crude oil. In 2002, the refinery capacity was revamped to 6.0 MMTPA, with secondary processing facilities such as the Hydrogen Generation Unit (HGU-1), Residue Fluidized Catalytic Cracker Unit (RFCCU), and Sulphur Recovery Unit (SRU) as part of  technological advancements.

Indian Oil Corporation Limited has awarded iFluids Engineering to carry out SIL Verification for the identified SIF loops & Preparation of Safety Requirement Specification SRS for Barauni Refinery.

Scope of work

• SIL Verification to be carried out for approximately 250 no. of SIF loops identified in the SIL assessment study of Barauni Refinery.
• Recommendations for implementation to be suggested if any gaps are identified in relation to the existing system during SIL assessment study along with SIL verification report.
• SIL Verification calculations to be done using the commercially  available, reputed, or proven Software
• The  Safety  Requirement   Specification (SRS) to be  made  in  accordance  with EC  61508  I 6151 standards
• SRS to be prepared for all the SIFs that are indicated  in the SIL assessment Report by IOCL

SIL Verification

SIL Verification study is the process of calculating the average probability of failure on demand (or the probability of failure per hour) and architectural constraints for a safety function design to see if it meets the required SIL.

Software Requirements Specification (SRS)

Software Requirements Specification (SRS) is a document that describes what the software will do and how it should perform.

Software used

The software to be used is exSILentia.

Completion of Project

Project to be completed within 6 months from the date of site Handover

Deliverables

• Final SIL Verification report to be submitted along with  the hardware/software modifications applicable for each SIF.
• Final report of SRS to be submitted after incorporation of all comments from IOCL.
• SIL verification workshop to be done at Barauni Refinery
• Final reports shall be submitted in Two soft copies & I hard copy (3 numbers).

GAIL (India) Limited awarded iFluids Engineering to carry out Quantitative and Qualitative Risk Assessment (QRA) study for their 278 km long Cross country Pipeline in Cauvery Basin. The scope of study is to systematically identify the potential hazards associated with GAIL pipelines, respective terminals and SV stations through risk assessment methodologies.

Brief on Client and the Location-specific details
GAIL (India) Limited was incorporated in August 1984 as a Central Public Sector Undertaking (PSU) under the Ministry of Petroleum & Natural Gas. It is the largest state-owned natural gas processing & distribution company.

Pipeline Specification details and what it transports

LIST OF STATION/INSTALLATIONS (RISK ANALYSIS) AT CB PIPE LINE NETWORK

• Dispatch Terminals/Gas Collecting Station

Risk Index Method
The risk factor is an important parameter that determines the ways to develop a Risk Assessment model, using either a data first or a frame first model. Since pipelines usually go across many regions whose conditions vary significantly, it is important to have a complete and universally accepted list of factors that can be used to build a risk assessment model. Risk assessment model parameters viz. Third-Party, Corrosion, Design, and Incorrect Operation would then be summed up and multiplied by the leaked impact (based on Product Hazard, Dispersion, Leak volume, and Receptors) shall be used for assessment of the pipeline integrity

Why Risk Assessment is carried out for pipelines?
Risk Assessment of the pipelines is conducted to identify the location-specific events or conditions, or combination of events and conditions that could lead to loss of pipeline integrity, and provides an understanding of the likelihood and consequences of these events.

This identification of location-specific risks were carried out in consultation with GAIL after analyzing the data like Pipeline routing drawings, mechanical data, CP (Cathodic Protection) data, construction details, historic leak /rupture data, O&M philosophy etc. Which was provided by GAIL. These risks shall be rated as Low, Medium and High as per the risk assessment criteria.

PNGRB guidelines represent 22 root causes for the threat to pipeline integrity. One of the cases reported by the operator is "unknown". The remaining 21 threats have been classified into three groups based on time dependency and further into nine categories of related failure types according to their nature and growth characteristic as shown below

Risk Assessment Methodology

The Risk Assessment Study includes the following steps:

How to evaluate the residual life to minimize failures and sustain pipeline operations.?

Following test methods as per OISD -SOP- Integrity assessment of Petroleum and Natural Gas Pipelines should be performed for pipelines crossing 25 years of design life to assess the health of the pipeline :

Software Used:

DNGVL PHAST SAFETI 8.22

Recommendations

The Recommendation is done as per the OISD Standards and best Engineering practices

Indian Oil Corporation Limited has awarded iFluids Engineering to carry "FIRE WATER ADEQUACY STUDY NETWORK AND ASSOCIATED FACILITIES AS PER OISD-STD-116 FOR BONGAIGAON REFINERY"

Bongaigaon Refinery is a petroleum refinery in Assam, India. It was commissioned on 20 February 1974 by the government of India.Refinery capacity was increased in 1995 to 2.35 million tonnes per year (51400 barrels per day of stream through expansion.

The study is performed for checking the adequacy of the existing fire, water network and identify their limitations while considering different combinations of the fire scenarios (as per OISD-STD-1116 ).

Existing facilities to be covered under this study are:

• Crude Distillation Unit (CDU-I & II)
• Delayed Coker Unit (DCU-I & II)
• CRU MSQ Block (NHT, CRU, Coker Naphtha Splitter, SR Naphtha splitter, Light Naphtha ISOM unit)
• DHDT Block (DHDT, HGU, SRU, SWSU, ARU, Nitrogen plant, SRR)
• Captive Power Plant (Boilers (5 Nos.),STG (3 nos.), GTG (1 no.),HRSG (1 No.)
• Hydrocarbon Storage Tanks (122 nos.) and 3 nos. Of LPG Horton spheres, 4 bays of LPG TT loading. Truck, LPG Bullet and Rail Wagon loading facilities/gantries.
• Utilities & Off-sites, WWTP (ETP and TTP), LPG Bottling plant, Hydrogen storage (CRU Unit and DHDT block), Compressed air system, Instrument air system, firewater network
• Flare Systems (Refinery, CRU MSQ units, DHDT Block), DM PLANT,CPU unit, Fuel gas and fuel oil network. KTU, Coke calculations Unit, All Electrical Substations of units, Bongaigaon refinery, CCU, Store & Warehouse.(Storage, Loading/unloading facility of chemicals etc.)

Upcoming new facilities to be cover under the study are:

Indmax Project:

• Indmax FCC unit 740 TMTPA
• Prime-G+ unit 312 TMTPA
• LPG mounded bullets 3 x 3,000 m3
• Cooling tower cells 2 x 2,600 m3/hr

BS-VI Project:

• DHDT revamp 1,600 TMTPA
• HGU revamps 30 KTPA (H2 production)
• New NHT 235 TMTPA
• New SRU 20 TPD
• New ARU 42 m3/hr
• Gasoline tank 8,900 m3

Completion Schedule:

• The contract period is five (5) months from the date of the work order.

Documents Required:

• PFD
• P&ID
• Fire fighting Layout
• Nozzle details
• Isometric diagram
• FW flow calculation
• Pump performance curve
• Piping material Specification
• Operating and control Philosophy
• Fire water Analysis report
• FWS Design basis for jetty area
• Native file of existing FW network software models
• Provide Velocity criteria of each pipe

Deliverables:

• Kick off meeting shall be organized within three weeks of date of work order to discuss the methodology and timeline of the Project.

• Draft report shall be submitted to IOCL Bongaigaon Refinery for review.

• Final report to be submitted 2 weeks from the date of submission of the draft report.

Indian Oil Corporation Limited (IOCL) has awarded iFluids Engineering to carry out Safety Integrity Level (SIL) Assessment for the process units of Gujarat refinery. The Gujarat Oil Refinery is located at Koyali, Vadodara District in Gujarat. It is the second largest and one of the most complex refineries in India.

Gujarat Refinery has about 40 operating units with a present capacity of 13.7 MMT per year and is gearing up for further expansion across an area of 148 acres.The refinery was commissioned in the year 1965.

Below are the list of process units that will be covered under this study.

1. AU1 - ATMOSPHERIC DISTILLATION UNIT -1
2. AU2 - ATMOSPHERIC DISTILLATION UNIT -2
3. AU3 - ATMOSPHERIC DISTILLATION UNIT -3
4. AU4 - ATMOSPHERIC DISTILLATION UNIT -4
5. FPU1 - FEED PREPARATION UNIT -1
6. FPU2 - FEED PREPARATION UNIT -2
7. VDU - VACUUM DISTILLATION UNIT
8. VBU - VIS –BREAKER UNIT
9. BBU - BITUMIN BLOWING UNIT
10. CRU - CATALYTIC REFORMING UNIT
11. FGH - FOOD GRADE HEXANE
12. FCCU - FLUIDISED CATALYTIC CRACKING UNIT
13. MTBE - METHLY TERIARY BUTYL ETHER
14. HGU1 - HYDROGEN GENERATION UNIT -1
15. DCU - DELAYED COKER UNIT
16. SRU3 - SULPHUR RECOVERY UNIT-3

Software used:

• The software to be used in SIL study is PHA Pro latest version

Completion Schedule:

• The proposed SIL study should be completed within five months from the date of transfer from the site.

Documents required:

• Cause & effect diagram
• P&ID's and PFD
• Process description of facility
• Standard Operating Procedure (SOP)
• Emergency Shutdownn philosophy
• HAZOP study report
• Risk Matrix

Deliverables:

• A Kick Off Meeting will be organized to discuss the methodology and timeline of the SIL study.
• A draft report shall be submitted to IOCL Gujarat Refinery for review.
• After incorporating observations on the proposed draft report, the final report shall be submitted.