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.
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.
No. of P&ID
HDT offsite HPNU
Project Duration: 04 Months
Software Used: The HAZOP software used was PHA-Pro/PHA
Hindustan Petroleum Corporation Limited (HPCL) has awarded iFluids Engineering to carry out study on "INSPECTION OF TANKS AND PIPELINES FOR HPCL SURYAPET TERMINAL" as per OISD 129,130 for evaluating the current physical condition of assets.
The Suryapet liquids storage terminal owned by HPCL is located in Telangana State of India. This liquids storage terminal became operational in 2002 ,The terminal primarily stores chemical and petroleum products.
Scope of work:
Measuring & evaluating the current physical condition of Tanks,Pipelines, & Chequred plate for corrossion, seepage,cracks ,etc.
Co-relating assets deterioration rate with their actual design life
To Advice the concerned Operational team for future inspection schedules as per remaining life run with reference to OISD- 129, OISD-130
The facilities to be covered under the Inspection are
External Inspection tank 20.5M D*13M H
External Inspection tank 37.5 D*18M H
External Inspection tank 23M D*13M H
External Inspection tank 15.5 M D*9M H
P/L Visual &UT test Inspection
External Inspection of Tanks
All tank features shall be visually inspected for corrosion ,seepage, cracks, sagging ,holes,bulging and deviation from the vertical
Thickness on nozzle shall be measured using Ultrasonic thickness meter, a minimum of 4 readings taken in clockwise manner for nozzles of size 50 mm NB and above.
Shell thickness survey shall be carried out from the zone of shell to annular plate joint . On the first, second course, 3 to 4 readings should be taken on each plate diagonally , The bottom, middle and top positions of the plate must be covered
Rest of the shell course, thickness survey shall be done along the staircase and three compass directions where Bottom, middle and top portions of plates should be covered
Thickness survey readings of tank roofs shall be taken as 5 per plate.
Hammer testing shall be done for out of service tanks along with the thickness survey of the roof plates.
The structural integrity of roof ladders, and roof support system will be evaluated and repaired or replaced if necessary.
Ultrasonic Thickness Survey on Pipelines (UT Test)
UT test shall be done to ascertain the wall thickness of pipelines.
For above ground pipeline outer curvature , UT test with 4 readings in clockwise manner will be taken on bends of the piping network ,First reading at centre of bend & other two readings on the sameline on either side of this reading.
For bottom portions one ultrasonic scan (4 readings) on the entire circumference, upstream and downstream of the weld joint , and pipe downstream of valves shall be done
A Kick off Meeting with Client will be organized
Collecting of P&ID, Isometric drawings, and previous inspection report
Piping Visual Inspection will be assigned to a API 570 certified Piping Inspector
Shall be listing out additional Inspection points in the time of Piping Visual Inspection
Tank Visual Inspection will be handled by API 653 certified Tank Inspector
Checklist will be maintained as per OISD requirement. Observations and Recommendations will be noted in the Checklist and documented with Site Photographs.
UT Kit (through coat) will be Calibrated before QC inspector.
Thickness will be measured by using UT kit and shall listed out in the report.
If any severe abnormality observed, FFS will be suggested.
Remaining life calculation will be performed by Piping Inspectors and report with recommendations will be submitted to client.
The completion period of the project is 1 month.
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.
AU1 - ATMOSPHERIC DISTILLATION UNIT -1
AU2 - ATMOSPHERIC DISTILLATION UNIT -2
AU3 - ATMOSPHERIC DISTILLATION UNIT -3
AU4 - ATMOSPHERIC DISTILLATION UNIT -4
FPU1 - FEED PREPARATION UNIT -1
FPU2 - FEED PREPARATION UNIT -2
VDU - VACUUM DISTILLATION UNIT
VBU - VIS –BREAKER UNIT
BBU - BITUMIN BLOWING UNIT
CRU - CATALYTIC REFORMING UNIT
FGH - FOOD GRADE HEXANE
FCCU - FLUIDISED CATALYTIC CRACKING UNIT
MTBE - METHLY TERIARY BUTYL ETHER
HGU1 - HYDROGEN GENERATION UNIT -1
DCU - DELAYED COKER UNIT
SRU3 - SULPHUR RECOVERY UNIT-3
The software to be used in SIL study is PHA Pro latest version
The proposed SIL study should be completed within five months from the date of transfer from the site.
Cause & effect diagram
P&ID's and PFD
Process description of facility
Standard Operating Procedure (SOP)
Emergency Shutdownn philosophy
HAZOP study report
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.
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