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QRA FOR AMMONIA BASED REFRIGERATION PLANT  AT BIAL CAMPUS BANGALORE AIRPORT

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:

Objectives:

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

  • Cross country pipelines of 278 km of diameters 4,6,8,12,18 inches
  • Isolation valves – Manually, Remotely or Automatically activated
  • Relief valves – Pressure or Thermal
  • Casing sleeves under Road / Rail crossing
  • Leak Detection system
  • Pig launchers Receivers

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

Sl NoStation NameLocationGas Supplier Name
1NANNILAM GCSNANNILAM GCSONGC
2KAMALAPURAM GCSKAMALAPURAM GCSONGC
3ADIYAKKAMANGALAM GCSADIYAKKAMANGALAM GCSONGC
4TIRUVARUR EPSTIRUVARUR EPSONGC
5NARIMANAM GCSNARIMANAM GCSONGC
6NALLUR EPSNALLUR EPSONGC
7KUTHALAM GCSKUTHALAM GCSONGC
8AKM – MEMATHURAKM – MEMATHURONGC & HOEC
9RAMNAD (VALANTHARAVAI) GCSRAMNAD (VALANTHARAVAI) GCSONGC
10BHUVANAGIRI GAS DESPATCH TERMINAL - ONGCLBHUVANAGIRI GAS DESPATCH TERMINAL - ONGCLONGC
  • Sectionalizing Valve station
Sl NoStation NameLocationMaintenance Base
1SV-1 MARAKKANCHAVADYMarakkanchavadyNARIMANAM
2SV-2 THIRUMARUGALThirumarugalNARIMANAM
3SV-3 MEMATHURMemathurKUTHALAM
  • List of Gas RT/CT in Cauvery Basin Pipeline Network
Sl NoRT/CTMaintenance Base
1CHENNAI PETROLEUM CORPORATIONNarimanam
2KIRAN SILICATE (P) LTDNarimanam
3NANNILAM SILICATE (P) LTDNarimanam
4EZHIL CHEMICALS (P) LTDNarimanam
5SUNDRISE SILICATE (P) LTDNarimanam
6MADRAS CHEMICALS (BOOTH)Narimanam
7REENA SILICATE IND. (P) LTDNarimanam
8SREE JAYADEVI INDUSTRIESNarimanam
9PREM CHEMICAL INDUSTRIESNarimanam
10PONDY CHEM (P) LTDNarimanam
11SILICATE INDIANarimanam
12HENKEL SPIC INDIA LTDNarimanam
13H&R JOHNSONNarimanam
14KOTHAVARI SUGARS & CHEM. LTDNarimanam
15R.J. CHEMICALSNarimanam
16BOSS PROFILES LIMITEDNarimanam
17REGENCY CERAMICS LIMITEDNarimanam
18SOUNDARARAJA COTTON MILLSNarimanam
19MMS POWERNarimanam
20MURUDESHWAR CERAMICSNarimanam
21GODREJ SARA LEE, TIRUNALLARNarimanam
22ADITYA FERRO ALLOYSNarimanam
23KAMAKSHI CHEMICALSNarimanam
24KARAIKAL INDUSTRIESNarimanam
25VAIGAI INDUSTRIESNarimanam
26GODREJ SARA LEE, NEDUNGADUNarimanam
27CHEMPLAST SANMARNarimanam
28PONDICHERRY POWER CORP. LTDNarimanam
29VANJUR SILICATENarimanam
30RAGHAVENDRA ALKALIESAdiyakamangalam
31DIAMOND SILICATEAdiyakamangalam
32NARIMANAM SILICATEAdiyakamangalam
33SOUTHERN REFRACTORYAdiyakamangalam
34TNCSC, TIRUVARURAdiyakamangalam
35SOUTH INDIA EDIBLE OIL PVT.LTDAdiyakamangalam
36TNEB (TIRUMAKKOTTAI)Adiyakamangalam
37PREM CHEMCOAdiyakamangalam
38TNEB POWERKuthalam
39ABAN POWERKuthalam
40OPG ENERGYKuthalam
41SAHELI EXPORTSKuthalam
42KAVERI GAS POWERKuthalam
43TNEB (VALUTHUR)Ramnad
44COROMANDAL ELECTRICRamnad
45ARKAY ENERGYRamnad
46ARKAY ENERGY (RAMESWARAM)Ramnad
47SAI REGENCY POWER CORP.Ramnad
48NEYCER TERMINAL (VADALUR)Bhuvanagiri

What is Quantitative Risk Assessment?

Quantitative Risk Assessment is a systematic approach to spot hazards, evaluate the danger & include appropriate measures to manage and mitigate risk for any work process or activity, In this method, the evaluated/estimated risk is quantified numerically.

What is Qualitative Risk Assessment?

Qualitative Risk Analysis involves identifying threats (or opportunities), how likely they're to happen, and therefore the potential impacts. Qualitative Risk Assessment is administered by Risk Index Method. In this method, the evaluated/estimated risk is described in words (Low, Medium and High as per the danger assessment criteria).

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

risk assessment

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

Time Dependent threat

1. External Corrossion

2. Internal Corrosion

3. Stress Corrosion

Stable Threats

  • Manufacturing related defects.

4.Defective pipe seam

5.Defective pipe

  • Welding / fabrication related

6. Defective pipe girth weld

7. Defective fabrication weld

8. Wrinkle bend or buckle

9. Stripped threads /broken pipe /coupling failure

  • Equipment

10. Gasket O-ring failure

11. Control/relief equipment malfunction

12. Seal pump packing failure

13. Miscellaneous

Time Independent Threats

  • Third party / mechanical damage

14.Damage inflicted by first, second or third party (instantaneous /immediate failure)

15. Previously damaged pipe (delayed failure mode)

16. Vandalism

17. Rat bites

18. Electric Arching 19. Weather related and outside force

  • Weather related
  • Lightning
  • Heavy Rains or Floods

20. Earth Movements

21. Incorrect operational procedure

Risk Assessment Methodology

The Risk Assessment Study includes the following steps:

  • Initial Data gathering, review and validation
  • Identifying potential threats to the integrity
  • Relative Risk Scoring Based Pipeline Risk Management Manual
  • Consequence and impact Analysis
  • Estimation of Risk assessment from total failure frequencies
  • Classification of pipelines based on risk
  • Integrity Assessment

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 :

  • Feed Quality Analysis w.r.t. CO2, H2S, Cl, S, moisture/water, condensate, pH value etc.,
  • Scrapper pigging
  • Pig residue analysis Record of quantity and quality of deposits (pig residue) collected after descaling shall be examined to monitor the condition of the Pipeline w.r.t. Fe, Fe2O3, Si, S, H2O, pH value, SRB, sulphates, carbonates, etc.,
  • Internal Corrosion Monitoring
  • Intelligent Pigging Survey
  • Regular line patrolling
  • Inspection of the leak detection system
  • Inspection of communication and control system
  • Pressure testing (Hydro testing)
  • Risk assessment
  • Fatigue Testing (for ERW and LSAW pipes)
  • Design conformity Test
  • Coating survey (CAT/ DCVG/CIPS)
  • Soil Testing
  • Cathodic protection, monitoring, upgrading and effectiveness testing

Software Used:

DNGVL PHAST SAFETI 8.22

Recommendations

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

FIRE WATER ADEQUACY STUDY NETWORK

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:

Upcoming new facilities to be cover under the study are:

Indmax Project:

BS-VI Project:

Completion Schedule:

Documents Required:

Deliverables:

Safety Integrity level

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:

Completion Schedule:

Documents required:

Deliverables:

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