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

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.