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).

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.

Vestian Global Limited has awarded iFluids Engineering to carry out a QRA (Quantitative Risk Assessment) study associated with the Ammonia based Refrigeration plant of the SATS Project. The main objective of this QRA study is to address the Risk Assessment and Hazardous operations of the facilities available.

SATS is a food production company planning to set up a unit in  Kempegowda International Airport culminating Business Parks, Hotel, Rental and dining, Entertainment, Concert arenas, city central, Trade centrals, Urban Street restaurants. The QRA study addresses the available and Hazardous operations carried out at the above-mentioned facility.

Scope of work:

• To identify the Safety issues related to possible leakages (minor and major) within premises - Risk and Mitigation.
• To identify the hazards involved with the schematics and the consumption pattern of Ammonia including volume, storage, flow and Technical properties.
• To Identify the Societal risk quantification and Potential Loss of Life estimation.
• To Perform a risk assessment to confirm that risk can be reduced consistent with the ALARP principle according to the UK HSE risk acceptance criteria

Objectives:

• Identification of Hazards and Major Loss of Containment (LOC) events
• Calculation of physical effects of failure case scenarios which include Estimation of Jet Fire, Pool Fire heat radiation distances, Flammable gas dispersion distances, and over pressure 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

Software used:

PHAST SAFETI 8.4 (QRA modelling)

Completion Period:

The proposed completion period of this project is 3 weeks.

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