Escolar Documentos
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For
PROJECT:
HAZOP for Vizag-
Secunderabad
Pipeline-VSPL
COMPANY:
HAZOP Study for
GAIL (INDIA)
Vizag-Secunderabad Pipeline-VSPL of LIMITED
GAIL (INDIA)LIMITED,VISAKHAPATNAM (A.P) VISAKHAPATNAM
(A.P)
CONSULTANT:
Unit :
BELL ENGINEERING
Vizag-Secunderabad Pipeline
SOFTWARE
TECHNOLOGISTS
LIMITED
Prepared By:
Mr. Anwar P. Shaikh REPORT:
HAZOP REPORT No.
BEST/ IND / CON /
1380 GAIL Vizag /
Reviewed By: ORD 15-16 / 002- 01
Mr. Mallikarjun Malgatte
Page 2 of 28
GAIL (INDIA)LIMITED
Visakhapatnam (A.P)
HAZOP for Vizag-Secunderabad LPG Pipeline-VSPL
BEST/ IND / CON / 1380 GAIL Issue: Final Rev. C
Vizag / ORD 15-16 / 002- 01 Date : 19-02-16
Disclaimer
Bell Engineering Software Technologists Ltd completed this document on the basis of a defined
program of work and terms and conditions agreed with the CLIENT. We confirm that in preparing
this document, we have exercised all reasonable skill and care, taking into account the project
objectives, the agreed scope of work, prevailing site conditions and the degree of manpower and
resources allocated to the project.
Bell Engineering Software Technologists Ltd or any of its subsidiaries / group companies accepts
no responsibility to any parties whatsoever, following the issue of the document, for any matters
arising outside the agreed scope of the work.
This document is issued in confidence to the CLIENT and Bell Engineering Software
Technologists Ltd and has no responsibility to any third parties to whom this document may be
circulated, in part or in full, and any such parties that rely on the contents of the report solely at
their own risk.
GAIL reserves the right to make reference, reproduce and circulate in part or in full; solely at their
own risk. Unless specifically assigned or transferred within the terms of the agreement, Bell
Engineering Software Technologists Ltd asserts and retains all Copyright, and other Intellectual
Property Rights, in and over the Report and its contents.
Any questions or matters arising from this Report should be addressed in the first instance to the
Project Manager.
2
GAIL (INDIA)LIMITED
Visakhapatnam (A.P)
HAZOP for Vizag-Secunderabad LPG Pipeline-VSPL
BEST/ IND / CON / 1380 GAIL Issue: Final Rev. C
Vizag / ORD 15-16 / 002- 01 Date : 19-02-16
CONTENTS
1 EXECUTIVE SUMMARY...........................................................................................4
1.1 Preamble 4
1.2 HAZOP Objective 4
1.3 HAZOP Session 4
1.4 Recommendations 5
1.5 INTRODUCTION 8
1.6 Project Overview 8
1.7 Objectives 9
1.8 Scope 9
1.9 Project Team 10
2 HAZOP METHODOLOGY.......................................................................................11
2.1 Overview 11
2.2 Methodology 11
2.2.1 Document Review .................................................................................... 11
2.2.2 HAZOP Worksheet ................................................................................... 13
3 HAZOP WORKSHOP .............................................................................................15
3.1 Hazop Nodes 16
3.2 Hazop Worksheet 17
4 REFERENCES ......................................................................................................18
APPENDICES
Appendix A HAZOP Worksheets
Appendix B Abbreviations
Appendix C Node Marked-Up P&IDs
Appendix D Attendance Sheet
LIST OF TABLES
Table 1 – HAZOP Nodes ....................................................................................................... 4
Table 2 – Units in Scope of Work ......................................................................................... 10
Table 3 - HAZOP Team Members ........................................................................................ 10
Table 4 – List of HAZOP team member present for Cherlapalli, Vizag & G Konduru respectively
.................................................................................................................................. 15
Table 5 - HAZOP Nodes..................................................................................................... 16
LIST OF FIGURES
Figure 2-1 HAZOP Methodology Schematic........................................................... 13
3
GAIL (INDIA)LIMITED
Visakhapatnam (A.P)
HAZOP for Vizag-Secunderabad LPG Pipeline-VSPL
BEST/ IND / CON / 1380 GAIL Issue: Final Rev. C
Vizag / ORD 15-16 / 002- 01 Date : 19-02-16
1 EXECUTIVE SUMMARY
1.1 Preamble
GAIL (India) Limited laid approximately 577.9 km long pipeline from Vizag to
Secunderabad for the purpose of transmission of LPG and this pipeline is called Vizag
– Secunderabad LPG Pipeline or VSPL. The pipeline system is designed for a normal
throughput of 1.164 MMTPA and maximum throughput of 1.33 MMTPA with design
pressure of 98 kg/cm².
4
GAIL (INDIA)LIMITED
Visakhapatnam (A.P)
HAZOP for Vizag-Secunderabad LPG Pipeline-VSPL
BEST/ IND / CON / 1380 GAIL Issue: Final Rev. C
Vizag / ORD 15-16 / 002- 01 Date : 19-02-16
1.4 Recommendations
Node : 05 EIPL feed booster pump 10-PA-CF-103A/B operation and filtration in basket filter 10-
GN-BK-103 A/B
Node : 08 LPG Main line Pumps operation at DT Vizag 10-PA-CF-102 A/B/C to feed to LPG main
line
5
GAIL (INDIA)LIMITED
Visakhapatnam (A.P)
HAZOP for Vizag-Secunderabad LPG Pipeline-VSPL
BEST/ IND / CON / 1380 GAIL Issue: Final Rev. C
Vizag / ORD 15-16 / 002- 01 Date : 19-02-16
1.1.1.1 P&ID to be updated for cause & effect ( 1.1.2 PSHH 1501 actually it is
PSHH 1502 ), reducer's standard symbols to be used
PIGGING OPERATION
Node : 24 Cavern Feeder Line scrapping from HPCL old bottling plant to Vizag DT
1.1.1.1 Provide PG and drain points at appropriate location to depressurize the
scraper receiver and launcher
1.1.1.2 Provide positive isolation system for scraper receiver and launcher
Node :26 Main Line scrapping from Rajahmundry to G Konduru
1.1.1.1 Provide PG and drain points at appropriate location to depressurize the
scraper receiver and launcher
1.1.1.2 Provide positive isolation system for scraper receiver and launcher
Node 27: Spur Line scrapping from G. Konduru to HPCL Bottling plant
1.1.1.1 Provide PG and drain points at appropriate location to depressurize the
scraper receiver and launcher
1.1.1.2 Provide positive isolation system for scraper receiver and launcher
Node 28: Spur Line scrapping from G. Konduru to IOCL Bottling plant
6
GAIL (INDIA)LIMITED
Visakhapatnam (A.P)
HAZOP for Vizag-Secunderabad LPG Pipeline-VSPL
BEST/ IND / CON / 1380 GAIL Issue: Final Rev. C
Vizag / ORD 15-16 / 002- 01 Date : 19-02-16
1.1.1.1 Provide PG and drain points at appropriate location to depressurize the
scraper receiver and launcher
1.1.1.2 Provide positive isolation system for scraper receiver and launcher
7
GAIL (INDIA)LIMITED
Visakhapatnam (A.P)
HAZOP for Vizag-Secunderabad LPG Pipeline-VSPL
BEST/ IND / CON / 1380 GAIL Issue: Final Rev. C
Vizag / ORD 15-16 / 002- 01 Date : 19-02-16
ISSUE RECORD
DISTRIBUTION
8
GAIL (INDIA)LIMITED
Visakhapatnam (A.P)
HAZOP for Vizag-Secunderabad LPG Pipeline-VSPL
BEST/ IND / CON / 1380 GAIL Issue: Final Rev. C
Vizag / ORD 15-16 / 002- 01 Date : 19-02-16
Vizag Despatch Terminal: There are 04 numbers of Booster Pumps and 03 mainline
pumps for boosting up the pressure received from the feeder sources and supplied to
the VSPL main pipeline. The major equipment in the terminal include basket filters,
mass flow meters, booster and mainline pumps, Scraper receiver and launchers, PLC,
SCADA system, etc. The operating discharge flow with a single mainline pump is 100
MTPH and with dual pumps is 165 MTPH.
G Konduru Booster pumping and Tap off Terminal: This is located 176.6 km from
the Rajahmundry IP-01 and connected with HPCL, IOCL and BPCL LPG bottling
plants. HPCL and BPCL bottling plants are 6.5 km and 7 km away from Vijayawada
receipt terminal. There are two booster pumps of which one is standby. The booster
pump can deliver a maximum flow of 176 m³/hr. The discharge header of the pipeline
from Vijayawada till Cherlapalli is of 10” common bore diameter.
Cherlapalli Receiving Terminal: This is located 122.5 km from the Suryapet IPS and
has HPCL, IOCL & BPCL Bottling Plants connected which receives LPG. HPCL bottling
plant is 0.7 km, IOCL bottling plant is 2.5 km, and BPCL bottling plant is 2.5 km from
the Secunderabad Receipt terminal. All the pipelines going to the bottling plants are of
6” nominal bore and the MOC is CS. The pipeline is designed for a pressure of 98
kg/cm².
1.7 Objectives
The objectives of the HAZOP are to achieve the following:
a) Intention – The intention define how the facility under study is expected to operate.
b) Deviation – These are departure from the intention which is discovered by
systematically applying the guide words.
c) Cause – These are the reasons for which deviations might occur.
d) Consequence – These are the results of the deviation should they occur.
e) Safeguard – These are the protections provided and operating instruction or design
review requirement for smooth operation of the system.
f) Recommendation – These are hardware and software changes required for
protecting and smooth operating of the system.
1.8 Scope
This HAZOP study has been conducted for Vizag, G-Konduru, Cherlapalli Regions pipelines & its
associated facilities. The list of these facilities is as given below.
9
GAIL (INDIA)LIMITED
Visakhapatnam (A.P)
HAZOP for Vizag-Secunderabad LPG Pipeline-VSPL
BEST/ IND / CON / 1380 GAIL Issue: Final Rev. C
Vizag / ORD 15-16 / 002- 01 Date : 19-02-16
9. IP-2
10. Cherlapalli RT
10
GAIL (INDIA)LIMITED
Visakhapatnam (A.P)
HAZOP for Vizag-Secunderabad LPG Pipeline-VSPL
BEST/ IND / CON / 1380 GAIL Issue: Final Rev. C
Vizag / ORD 15-16 / 002- 01 Date : 19-02-16
2 HAZOP METHODOLOGY
2.1 Overview
This section outlines the methodology adopted for the HAZOP study conducted for the project
2.2 Methodology
Being an existing refinery that too one of the oldest refineries the methodology followed was as
under. The methodology so adopted was from the point of view of benefiting from the vast
experience of operating personnel gained over years of running of refinery on one hand and on
the other hand operating constraints.
Therefore the Hazop methodology considered these aspects by detailed briefing from all the
concerned engineers along with conventional HAZOP methodology which is a formal systematic
procedure used to review the design and operation of a potentially hazardous process facility. It
is used to identify deviations from normal safe operation, which could lead, to hazards or
operability problems, and to define any actions necessary to deal with these.
The study is performed by a team of people who are familiar with the plant design and operation,
working under the guidance of a leader who is experienced in use of the HAZOP method.
The method involves several repetitive steps
• Identify a section of plant on the P&I diagram.
• Define the design intent and normal operation conditions of the section.
• Identify a deviation from design intent or operating conditions by applying a system of
guidewords.
• Identify possible causes for, and consequences of, the deviation. A deviation can be
considered meaningful if it has credible cause and can result in harmful consequences.
• For a meaningful deviation, decide what action, if any is necessary.
• Record the discussion and action.
Step 3 to 6 is repeated until all the guidewords have been exhausted and the team is satisfied
that all meaningful deviations have been considered. The team then goes back to step 1 and
repeats the procedure for the next section of the plant.
In the HAZOP method, the guidewords are systematically applied to a segment of process
equipment in order to promote discussion on possible deviations from the design intention. The
guidewords represent deviations to the design intent and their use leads to systematic
highlighting of hazards and operability problems.
2.2.1 Document Review
Before commencement of the HAZOP, the HAZOP Chairman reviewed the project scope and
developed the HAZOP checklist applicable to the project. Document Review is considered an
important part of the HAZOP workshop as it makes the facilitator aware of the various risks
inherent within the activities involved in the project.
Figure 2.1 presents the HAZOP methodology adopted for the study.
The method identifies the causes of a deviation from the design intent by application of the
guidewords. The ultimate consequences are then identified and recorded without reference to
the safeguards, which are in place (examples of safeguards are plant design, control systems,
and procedures). The consequences are then compared with the safeguards and the HAZOP
team then decides whether the current safeguards are adequate. If the team considers them
inadequate, then a recommendation is made to consider or add further safeguards.
11
GAIL (INDIA)LIMITED
Visakhapatnam (A.P)
HAZOP for Vizag-Secunderabad LPG Pipeline-VSPL
BEST/ IND / CON / 1380 GAIL Issue: Final Rev. C
Vizag / ORD 15-16 / 002- 01 Date : 19-02-16
The HAZOP study was based on a set of P&I diagrams for the sections to be covered by study.
The following documents were also referred to during the HAZOP sessions:
• Shut down & trip logic.
• Process description.
• Process Flow Diagrams
• Piping and Instrumentation Diagrams
12
GAIL (INDIA)LIMITED
Visakhapatnam (A.P)
HAZOP for Vizag-Secunderabad LPG Pipeline-VSPL
BEST/ IND / CON / 1380 GAIL Issue: Final Rev. C
Vizag / ORD 15-16 / 002- 01 Date : 19-02-16
Describe Design
intention, Operating
Conditions etc.
Identify all
consequences and
Record
No
Last
guideword
Yes
Take Next Section
13
GAIL (INDIA)LIMITED
Visakhapatnam (A.P)
HAZOP for Vizag-Secunderabad LPG Pipeline-VSPL
BEST/ IND / CON / 1380 GAIL Issue: Final Rev. C
Vizag / ORD 15-16 / 002- 01 Date : 19-02-16
• Causes
• Consequences
• Safeguards
• Recommendations
• Remarks
Guideword
A guideword provides the team with a starting point to identify issues. Using a comprehensive list
of guideword is important to achieve maximum benefit from the HAZOP study. A HAZOP
checklist shall be used to act as an ad-memoir to identify any hazards that may have been over-
looked during the brainstorming session. For each hazard, the root cause, the consequence, any
safeguards already implemented in the design will be identified.
Parameter
Parameter is an aspect of the process that describes it physically, chemically or in terms of what
is happening.
Deviation
Deviation is defined as unreasonable / undesired change in the parameter. Deviation is formed
by a combination of the parameter and guideword.
Cause
For each hazard, the root cause is determined, such that the appropriate safeguards for the
causal events are determined.
Consequence
In assigning a level of consequence to the hazards, the HAZOP team took into consideration the
following factors:
• The present design status of the safeguards and controls
• Physical and working environment conditions
• Levels of training, experience, skills, education etc of the facilities personnel
Safeguards
The study identified the existing design safeguards for each hazard. The types of safeguards
commonly include:
• Preventive safeguards, which aim to prevent the event cause from occurring
• Detective safeguards, which aim to improve the response time to an event
• Protective safeguards, which aim to protect from the escalation consequences and are
always used regardless of whether the event has occurred
• Mitigation safeguards, which aim to reduce the severity of the escalation consequences
and are activated once the event cause and escalation consequences have occurred.
Actions / Recommendations
Where the associated safeguards are not adequate, further recommendations are proposed.
14
GAIL (INDIA)LIMITED
Visakhapatnam (A.P)
HAZOP for Vizag-Secunderabad LPG Pipeline-VSPL
BEST/ IND / CON / 1380 GAIL Issue: Final Rev. C
Vizag / ORD 15-16 / 002- 01 Date : 19-02-16
3 HAZOP WORKSHOP
Hazop worksheets were presented and discussed with the team comprising of GAIL
engineers/managers listed here below alongwith respective dates.
Table 4 – List of HAZOP team member present for Cherlapalli, Vizag & G Konduru respectively
15
GAIL (INDIA)LIMITED
Visakhapatnam (A.P)
HAZOP for Vizag-Secunderabad LPG Pipeline-VSPL
BEST/ IND / CON / 1380 GAIL Issue: Final Rev. C
Vizag / ORD 15-16 / 002- 01 Date : 19-02-16
16
GAIL (INDIA)LIMITED
Visakhapatnam (A.P)
HAZOP for Vizag-Secunderabad LPG Pipeline-VSPL
BEST/ IND / CON / 1380 GAIL Issue: Final Rev. C
Vizag / ORD 15-16 / 002- 01 Date : 19-02-16
17
GAIL (INDIA)LIMITED
Visakhapatnam (A.P)
HAZOP for Vizag-Secunderabad LPG Pipeline-VSPL
BEST/ IND / CON / 1380 GAIL Issue: Final Rev. C
Vizag / ORD 15-16 / 002- 01 Date : 19-02-16
4 REFERENCES
Following Documents were referred for conducting HAZOP proposed for the VSPL-
Pipeline.
18
GAIL (INDIA)LIMITED
Visakhapatnam (A.P)
HAZOP for Vizag-Secunderabad LPG Pipeline-VSPL
BEST/ IND / CON / 1380 GAIL Issue: Final Rev. C
Vizag / ORD 15-16 / 002- 01 Date : 19-02-16
P&ID-SURYAPET-INTERMEDIATE 04
1 1116
PIGGING STATION(IP-2)
P&ID-SECUNDERABAD RT-FOR 07
2 1117
HPCL
PROCESS DOCUMENTS
SN DOCUMENT NAME DOCUMENT/ DRAWING NO. REV NO.
1 Design Philosophy 2139 0
19
GAIL (INDIA)LIMITED
Visakhapatnam (A.P)
HAZOP for Vizag-Secunderabad LPG Pipeline-VSPL
BEST/ IND / CON / 1380 GAIL Issue: Final Rev. C
Vizag / ORD 15-16 / 002- 01 Date : 19-02-16
20
GAIL (INDIA)LIMITED
Visakhapatnam (A.P)
HAZOP for Vizag-Secunderabad LPG Pipeline-VSPL
BEST/ IND / CON / 1380 GAIL Issue: Final Rev. C
Vizag / ORD 15-16 / 002- 01 Date : 19-02-16
21
HAZOP Study of VSPL pipeline network and its associate facilities
GAIL (India) Limited
Vizag Region
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HAZOP Study of VSPL pipeline network and its associate facilities
GAIL (India) Limited
Worksheet Report
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HAZOP Study of VSPL pipeline network and its associate facilities
GAIL (India) Limited
Guideword : Less
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HAZOP Study of VSPL pipeline network and its associate facilities
GAIL (India) Limited
Deviation : Leak
Causes Consequences Safeguards Recommendations Remarks
• 1 Due to More 1.1 HSE hazard 1.1.1 Round the clock person available
pressure, 1.1.2 SCADA System is Provided
• Corrosion 1.1.3 Fire extinguishers are provided
• Gasket leak 1.1.4 Thickness testing carried out at
• Vibration defined frequency
1.1.5 External painting at defined
frequency
This report is generated using HAZOP‐Pro software
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HAZOP Study of VSPL pipeline network and its associate facilities
GAIL (India) Limited
Worksheet Report
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GAIL (India) Limited
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HAZOP Study of VSPL pipeline network and its associate facilities
GAIL (India) Limited
Worksheet Report
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HAZOP Study of VSPL pipeline network and its associate facilities
GAIL (India) Limited
This report is generated using HAZOP‐Pro software
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HAZOP Study of VSPL pipeline network and its associate facilities
GAIL (India) Limited
Worksheet Report
Type : Piping and piping components, MOV, Flow Metering ,Booster pump
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HAZOP Study of VSPL pipeline network and its associate facilities
GAIL (India) Limited
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HAZOP Study of VSPL pipeline network and its associate facilities
GAIL (India) Limited
Deviation : Leak
Causes Consequences Safeguards Recommendations Remarks
• 1 Due to more 1.1 HSE Hazard 1.1.1 SCADA System is Provided
pressure 1.1.2 Round the clock persons are
• Corrosion available
• Gasket failure 1.1.3 GA 2001 to 04 are provided
• Mechanical 1.1.4 Fire fighting system is provided
• Vibration 1.1.5 Deluge system provided
• Pump seal failure 1.1.6 Low pressure will trip MOVs and
pumps
1.1.7 Corrosion coupons are provided
1.1.8 Periodic thickness testing carried
out at defined frequency
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HAZOP Study of VSPL pipeline network and its associate facilities
GAIL (India) Limited
Worksheet Report
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HAZOP Study of VSPL pipeline network and its associate facilities
GAIL (India) Limited
Guideword : Less Parameter : Flow
Deviation : Leak
Causes Consequences Safeguards Recommendations Remarks
• 1 More pressure 1.1 HSE Hazard 1.1.1 SCADA System is Provided 1.1.1.1 Gas Detector
from upstream 1.1.2 Gas Detector is Provided adequacy to be checked
• Gasket leak
1.1.3 Fire fighting system is Provided
• Pump seal leak
This report is generated using HAZOP‐Pro software
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HAZOP Study of VSPL pipeline network and its associate facilities
GAIL (India) Limited
Worksheet Report
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HAZOP Study of VSPL pipeline network and its associate facilities
GAIL (India) Limited
This report is generated using HAZOP‐Pro software
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HAZOP Study of VSPL pipeline network and its associate facilities
GAIL (India) Limited
Worksheet Report
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HAZOP Study of VSPL pipeline network and its associate facilities
GAIL (India) Limited
Deviation : Leak
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HAZOP Study of VSPL pipeline network and its associate facilities
GAIL (India) Limited
Causes Consequences Safeguards Recommendations Remarks
• 1 Due to pressure, 1.1 HSE hazard 1.1.1 SCADA system is provided
gasket failure 1.1.2 Round the clock monitoring
• Mechanical 1.1.3 Communication system available
vibration
This report is generated using HAZOP‐Pro software
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HAZOP Study of VSPL pipeline network and its associate facilities
GAIL (India) Limited
Worksheet Report
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GAIL (India) Limited
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HAZOP Study of VSPL pipeline network and its associate facilities
GAIL (India) Limited
Deviation : Leak
Causes Consequences Safeguards Recommendations Remarks
• 1 Leak due to more 1.1 EHS hazard 1.1.1 Deluge system is provided
pressure, 1.1.2 Round the clock monitoring
• Flange leak, 1.1.3 Gas detectors are provided
• Mechanical 1.1.4 Fire fighting system is provided
vibration,
1.1.5 SCADA System is provided
• Pump seal leak
1.1.6 Emergency push button is
provided
This report is generated using HAZOP‐Pro software
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HAZOP Study of VSPL pipeline network and its associate facilities
GAIL (India) Limited
Worksheet Report
Type : Piping and piping components, PRV, David Assembly, flare system
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HAZOP Study of VSPL pipeline network and its associate facilities
GAIL (India) Limited
Deviation : Leak
Causes Consequences Safeguards Recommendations Remarks
• 1 Leak from pipe 1.1 EHS hazard 1.1.1 Physical check
• Fittings, 1.1.2 Round the clock monitoring
• Pipe lines, 1.1.3 Fire fighting system is provided
• Flange
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HAZOP Study of VSPL pipeline network and its associate facilities
GAIL (India) Limited
Worksheet Report
Node : 10 Vizag Diesel storage
Node Description: Diesel storage in 10‐TT‐CR‐102 A/B and usage
P&ID No: 1121
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HAZOP Study of VSPL pipeline network and its associate facilities
GAIL (India) Limited
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GAIL (India) Limited
Deviation : Spillage
Causes Consequences Safeguards Recommendations Remarks
• Diesel tank 1.1 Diesel spillage, leak 1.1.1 LT 2102 is provided
overflow 1.1.2 Dyke wall is provided
• Drain valve open
• LT line leak
• LT mal functioning
• Flange leak
This report is generated using HAZOP‐Pro software
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HAZOP Study of VSPL pipeline network and its associate facilities
GAIL (India) Limited
Worksheet Report
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HAZOP Study of VSPL pipeline network and its associate facilities
GAIL (India) Limited
Guideword : Less Parameter : Flow
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HAZOP Study of VSPL pipeline network and its associate facilities
GAIL (India) Limited
Worksheet Report
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HAZOP Study of VSPL pipeline network and its associate facilities
GAIL (India) Limited
Guideword : Less Parameter : Flow
Deviation : Leak
Causes Consequences Safeguards Recommendations Remarks
1 Leak from Flange, fittings 1.1 EHS hazard 1.1.1 Gas detectors are provided
, drain points , 1.1.2 Round the clock monitoring
1.1.3 Fire fighting system is provided
1.1.4 Deluge system is provided
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HAZOP Study of VSPL pipeline network and its associate facilities
GAIL (India) Limited
Deviation : More Temperature
Causes Consequences Safeguards Recommendations Remarks
1 Due to atmospheric 1.1 HSE Hazard 1.1.1 TSV 0201/03/05/06/08/09/10/11
condition; heat source are provided
1.1.2 Gas detectors are provided
1.1.3 Fire fighting system is provided
1.1.4 TE 0201 to 04 are provided
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HAZOP Study of VSPL pipeline network and its associate facilities
GAIL (India) Limited
G Konduru Region
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HAZOP Study of VSPL pipeline network and its associate facilities
GAIL (India) Limited
Worksheet Report
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GAIL (India) Limited
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GAIL (India) Limited
Deviation : Leak
Causes Consequences Safeguards Recommendations Remarks
• 1. More pressure 1.1 Fire, HSE issues 1.1.1 GA 1402 is provided
from upstream 1.1.2 Thickness testing at defined
• Mechanical frequency
vibration 1.1.3 External painting , poly ethylene
• Pump seal and coating done
valves leak
1.1.4 Corrosion coupon are provided
1.1.5 ER Probe is Provided
1.1.6 Gas element is provided
1.1.7 Deluge system, fire hydrant
system are Provided
This report is generated using HAZOP‐Pro software
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GAIL (India) Limited
Worksheet Report
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GAIL (India) Limited
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GAIL (India) Limited
Worksheet Report
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GAIL (India) Limited
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GAIL (India) Limited
Worksheet Report
Node Description: LPG supply to IOCL bottling plant from G Konduru Pumping Station
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HAZOP Study of VSPL pipeline network and its associate facilities
GAIL (India) Limited
Guideword : Low Parameter : Pressure
Deviation : Leak
Causes Consequences Safeguards Recommendations Remarks
• 1 Corrosion 1.1 HSE Hazard ,Fire 1.1.1 Thickness testing at defined
• Mechanical frequency
Vibration 1.1.2 External painting , coating done
• Gasket leak
1.1.3 Corrosion coupon is provided
• Pipeline leak
1.1.4 ER Probe is provided
1.1.5 Gas element provided
1.1.6 Deluge system, fire hydrant
system are provided
1.1.7 QBD detection system is provided
1.1.8 Earthing & bonding provided
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HAZOP Study of VSPL pipeline network and its associate facilities
GAIL (India) Limited
Worksheet Report
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GAIL (India) Limited
Guideword : Less Parameter : Flow
Deviation : Leak
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HAZOP Study of VSPL pipeline network and its associate facilities
GAIL (India) Limited
Worksheet Report
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GAIL (India) Limited
Deviation : More Temperature
Causes Consequences Safeguards Recommendations Remarks
1 Due to atmospheric Heat 1.1 HOT LPG in pipe line; 1.1.1 SCADA System is provided
source change Leak 1.1.2 TSV 1906/09/11 are provided
1.1.3 TE 1903/06 are provided
1.1.4 GA 1801 is provided
1.1.5 Fire fighting system is provided
Deviation : Leak
This report is generated using HAZOP‐Pro software
Page 45 of 81
HAZOP Study of VSPL pipeline network and its associate facilities
GAIL (India) Limited
Cherlapalli Region
Page 46 of 81
HAZOP Study of VSPL pipeline network and its associate facilities
GAIL (India) Limited
Worksheet Report
Page 47 of 81
HAZOP Study of VSPL pipeline network and its associate facilities
GAIL (India) Limited
Guideword : Less Parameter : Flow
Page 48 of 81
HAZOP Study of VSPL pipeline network and its associate facilities
GAIL (India) Limited
Guideword : Reverse Parameter : Flow
Page 49 of 81
HAZOP Study of VSPL pipeline network and its associate facilities
GAIL (India) Limited
Guideword : More Parameter : More Pressure
Page 50 of 81
HAZOP Study of VSPL pipeline network and its associate facilities
GAIL (India) Limited
Deviation : Leakage
Causes Consequences Safeguards Recommendations Remarks
1 Leakage from flange, 1.1 LPG leakage, Fire, HSE 1.1.1 Gas alarm(GA)
filter. hazard 1601/02/1701/02/03 are provided
1.1.2 SCADA system is provided
1.1.3Persons taking the round
1.1.4 PT‐
1601/02/05/06/07,1701/02/03/04 /05
are provided
Page 51 of 81
HAZOP Study of VSPL pipeline network and its associate facilities
GAIL (India) Limited
Worksheet Report
Page 52 of 81
HAZOP Study of VSPL pipeline network and its associate facilities
GAIL (India) Limited
Guideword : Less
Page 53 of 81
HAZOP Study of VSPL pipeline network and its associate facilities
GAIL (India) Limited
Deviation : Leak
Causes Consequences Safeguards Recommendations Remarks
1 Due to more pressure, 1.1 HSE problem, Fire 1.1.1 Gas detectors are provided
gasket weakens, 1.1.2 SCADA system monitoring
Mechanical vibrations 1.1.3 Fire fighting, Sprinkler system are
provided
Page 54 of 81
HAZOP Study of VSPL pipeline network and its associate facilities
GAIL (India) Limited
Guideword : Parameter : Corrosion
Deviation : Corrosion
Causes Consequences Safeguards Recommendations Remarks
• 1 Due to moisture 1.1 Pipe line corrosion , 1.1.1 Cathodic protection is provided
• MIC internal , external and leak 1.1.2 Pipe line cleaning and thickness
• AC interference checking at defined frequency
1.1.3 Proper coating to the pipe line
1.1.4 Leak detection system is provided
1.1.5 Grounding of AC interference
1.1.6 corrosion coupons are provided
1.1.7 Electrical resistance is probe
provided
This report is generated using HAZOP‐Pro software
Page 55 of 81
HAZOP Study of VSPL pipeline network and its associate facilities
GAIL (India) Limited
Worksheet Report
Page 56 of 81
HAZOP Study of VSPL pipeline network and its associate facilities
GAIL (India) Limited
Guideword : Less Parameter : Pressure
Page 57 of 81
HAZOP Study of VSPL pipeline network and its associate facilities
GAIL (India) Limited
Guideword : Parameter : Corrosion
Deviation : Corrosion
Causes Consequences Safeguards Recommendations Remarks
• 1 Due to 1.1 Pipe line corrosion 1.1.1 Cathodic protection is provided
moisture , internal , external and 1.1.2 Pipe line thickness checking at defined
• MIC leak frequency
• AC interference 1.1.3 Proper coating to the pipe line
1.1.4 Leak detection system is provided
1.1.5 Grounding of AC interference
Deviation : Leak
Causes Consequences Safeguards Recommendations Remarks
• 1. Due to more 1.1 LPG leakage, HSE 1.1.1 Patrolling in three shifts( Once in a shift)
pressure, hazard 1.1.2 SCADA system monitoring for pressure drop
• Gasket leaks and shut down accordingly
• Mechanical
vibration
Page 58 of 81
HAZOP Study of VSPL pipeline network and its associate facilities
GAIL (India) Limited
This report is generated using HAZOP‐Pro software
Page 59 of 81
HAZOP Study of VSPL pipeline network and its associate facilities
GAIL (India) Limited
Worksheet Report
Page 60 of 81
HAZOP Study of VSPL pipeline network and its associate facilities
GAIL (India) Limited
Guideword : Less Parameter : Pressure
Page 61 of 81
HAZOP Study of VSPL pipeline network and its associate facilities
GAIL (India) Limited
Deviation : Corrosion
Causes Consequences Safeguards Recommendations Remarks
1 Due to moisture; 1.1 Pipe will get corroded 1.1.1 Cathodic protection is provided
corrosion and may leak 1.1.2 Pipeline thickness checking at
defined frequency
1.1.3 Corrosion coupons provided
Deviation : Leak
Causes Consequences Safeguards Recommendations Remarks
• 1 Due to more 1.1 LPG will leak leading to 1.1.1 Gas detectors are provided
pressure, HSE hazard, Fire 1.1.2 SACADA system is Provided
• Gasket leaks 1.1.3 Public awareness
• Mechanical 1.1.4 Wind socks are provided
vibration
1.1.5 Fire fighting system is Provided
Page 62 of 81
HAZOP Study of VSPL pipeline network and its associate facilities
GAIL (India) Limited
Guideword : More Parameter : Temperature
Deviation : Corrosion
Causes Consequences Safeguards Recommendations Remarks
• 1 Due to moisture 1.1 Pipe line corrosion , 1.1.1 Cathodic protection is provided
• MIC internal , external and leak 1.1.2 Pipeline thickness checking at
• AC interference defined frequency
1.1.3 Proper coating to the pipe line
1.1.4 Leak detection system provided
1.1.5 Grounding of AC interference
1.1.6 corrosion coupons are provided
1.1.6 Electrical resistance probe is
provided
This report is generated using HAZOP‐Pro software
Page 63 of 81
HAZOP Study of VSPL pipeline network and its associate facilities
GAIL (India) Limited
Worksheet Report
Node : 23 Fire Hydrant System
Node Description: Fire Hydrant System‐ Cherlapalli
P&ID No: 1075
Type : Piping and piping components, Fired Equipment, Filter, Pump, Design Problems, Diesel Operated Fire hydrant pump, Heat Transfer Equipment,
Centrifugal Pump, Jockey pump
Guideword : More Parameter : Flow
Deviation : More Flow
Causes Consequences Safeguards Recommendations Remarks
1 Both diesel operated 1.1 Fire hydrant line 1.1.1 Pump running indicator provided 1.1.1.1 P & ID to be updated
pump run may leak local panel for PT, TSV
1.2 HSE issue 1.1.2 Firemen’s vigilance
1.1.3 PG 503/04 are provided
1.1.4 PSV provided in the field
1.1.5 PT is provided
1.1.6 Circulation line is provided
Page 64 of 81
HAZOP Study of VSPL pipeline network and its associate facilities
GAIL (India) Limited
Parameter : Flow
Guideword : Less
Deviation : Less Flow
Causes Consequences Safeguards Recommendations Remarks
• 1 Diesel operated 1.1 Emergency may 1.1.1 LT 506/08 are provided
pump not operated take more time to 1.1.2 PG 503/04 are provided
at low pressure mitigate it 1.1.3 PAL 503 provided to start main
• No water in fire diesel pump at 7.5 Kg/cm2g
hydrant tank
1.1.4 Regular battery check up
• Strainer choke
1.1.5 PT is provided
• Discharge batteries
Guideword : Reverse Parameter : Flow
Deviation : Reverse Flow
Causes Consequences Safeguards Recommendations Remarks
1 NRV stuck open 1.1 Diesel pump will 1.1.1 PT provided
rotate in reverse 1.1.2 Regular maintenance
direction and less 1.1.3 PG 503/04 are provided
hydrant pressure
1.1.4 Manned pump house
Page 65 of 81
HAZOP Study of VSPL pipeline network and its associate facilities
GAIL (India) Limited
Deviation : Leak
Causes Consequences Safeguards Recommendations Remarks
1 Due to atmospheric 1.1 MS pipe line will 1.1.1 Pipe lines are coated with suitable
condition like acidic corrode and leak, material
atmosphere, gasket will less pressure 1.1.2 Fire hydrant tank levels monitored
leak hydrant water for
1.1.3 Frequent pump running
emergency
1.1.4 Regular flushing
This report is generated using HAZOP‐Pro software
Page 66 of 81
HAZOP Study of VSPL pipeline network and its associate facilities
GAIL (India) Limited
Pigging Operation
Page 67 of 81
HAZOP Study of VSPL pipeline network and its associate facilities
GAIL (India) Limited
Worksheet Report
Type : Piping and piping components ,Filter, scraper Launcher, scraper receiver
Page 68 of 81
HAZOP Study of VSPL pipeline network and its associate facilities
GAIL (India) Limited
Guideword : Less Parameter : Flow
Deviation : Leak
Causes Consequences Safeguards Recommendations Remarks
1 Leak from Flange, pig 1.1 EHS hazard 1.1.1 Gas detectors are provided
receiver door , drain points 1.1.2 Fire fighting system is provided
Page 69 of 81
HAZOP Study of VSPL pipeline network and its associate facilities
GAIL (India) Limited
Worksheet Report
Type : Piping and piping components, Filter, scraper Launcher, scraper receiver
Page 70 of 81
HAZOP Study of VSPL pipeline network and its associate facilities
GAIL (India) Limited
Guideword : Less Parameter : Flow
Deviation : Leak
Causes Consequences Safeguards Recommendations Remarks
1 Leak from Flange, pig 1.1 EHS hazard 1.1.1 Gas detectors are provided
receiver door , drain points 1.1.2 Fire fighting system is provided
Page 71 of 81
HAZOP Study of VSPL pipeline network and its associate facilities
GAIL (India) Limited
Worksheet Report
Type : Piping and piping components, Filter, scraper Launcher, scraper receiver
Page 72 of 81
HAZOP Study of VSPL pipeline network and its associate facilities
GAIL (India) Limited
Guideword : Less Parameter : Flow
Deviation : Leak
Causes Consequences Safeguards Recommendations Remarks
1 Leak from Flange, pig 1.1 EHS hazard 1.1.1 Gas detectors are provided
receiver door , drain points 1.1.2 Fire fighting system is provided
Page 73 of 81
HAZOP Study of VSPL pipeline network and its associate facilities
GAIL (India) Limited
Worksheet Report
Type : Piping and piping components, Filter, scraper Launcher, scraper receiver
Page 74 of 81
HAZOP Study of VSPL pipeline network and its associate facilities
GAIL (India) Limited
Guideword : Less Parameter : Flow
Deviation : Leak
Causes Consequences Safeguards Recommendations Remarks
1 Leak from Flange, pig 1.1 EHS hazard 1.1.1 Gas detectors are provided
receiver door , drain points 1.1.2 Fire fighting system is provided
Page 75 of 81
HAZOP Study of VSPL pipeline network and its associate facilities
GAIL (India) Limited
Worksheet Report
Type : Piping and piping components, Filter, scraper Launcher, scraper receiver
Page 76 of 81
HAZOP Study of VSPL pipeline network and its associate facilities
GAIL (India) Limited
Guideword : Less Parameter : Flow
Deviation : Leak
Causes Consequences Safeguards Recommendations Remarks
1 Leak from Flange, pig 1.1 EHS hazard 1.1.1 Gas detectors are provided
receiver door , drain points 1.1.2 Fire fighting system is provided
Page 77 of 81
HAZOP Study of VSPL pipeline network and its associate facilities
GAIL (India) Limited
Worksheet Report
Type : Piping and piping components, Filter, scraper Launcher, scraper receiver
Page 78 of 81
HAZOP Study of VSPL pipeline network and its associate facilities
GAIL (India) Limited
Guideword : Less Parameter : Flow
Deviation : Leak
Causes Consequences Safeguards Recommendations Remarks
1 Leak from Flange, pig 1.1 EHS hazard 1.1.1 Gas detectors are provided
receiver door , drain points 1.1.2 Fire fighting system is provided
Page 79 of 81
HAZOP Study of VSPL pipeline network and its associate facilities
GAIL (India) Limited
Worksheet Report
Page 80 of 81
HAZOP Study of VSPL pipeline network and its associate facilities
GAIL (India) Limited
Guideword : Less Parameter : Flow
Deviation : Leak
Causes Consequences Safeguards Recommendations Remarks
1 Leak from Flange, pig 1.1 EHS hazard 1.1.1 Gas detectors are provided
receiver door , drain points 1.1.2 Fire fighting system is provided
Page 81 of 81
GAIL (INDIA)LIMITED
Visakhapatnam (A.P)
HAZOP for Vizag-Secunderabad Pipeline-VSPL
BEST/ IND / CON / 1380 GAIL Issue: Draft Rev. B
Vizag / ORD 15-16 / 002- 01 Date : 19-02-16
APPENDIX B
ABBREVATION
22
GAIL (INDIA)LIMITED
Visakhapatnam (A.P)
HAZOP for Vizag-Secunderabad Pipeline-VSPL
BEST/ IND / CON / 1380 GAIL Issue: Draft Rev. B
Vizag / ORD 15-16 / 002- 01 Date : 19-02-16
23
GAIL (INDIA)LIMITED
Visakhapatnam (A.P)
HAZOP for Vizag-Secunderabad Pipeline-VSPL
BEST/ IND / CON / 1380 GAIL Issue: Draft Rev. B
Vizag / ORD 15-16 / 002- 01 Date : 19-02-16
24
GAIL (INDIA)LIMITED
Visakhapatnam (A.P)
HAZOP for Vizag-Secunderabad Pipeline-VSPL
BEST/ IND / CON / 1380 GAIL Issue: Draft Rev. B
Vizag / ORD 15-16 / 002- 01 Date : 19-02-16
UNITS USED
25
GAIL (INDIA)LIMITED
Visakhapatnam (A.P)
HAZOP for Vizag-Secunderabad Pipeline-VSPL
BEST/ IND / CON / 1380 GAIL Issue: Draft Rev. B
Vizag / ORD 15-16 / 002- 01 Date : 19-02-16
26
GAIL (INDIA)LIMITED
Visakhapatnam (A.P)
HAZOP for Vizag-Secunderabad Pipeline-VSPL
BEST/ IND / CON / 1380 GAIL Issue: Draft Rev. B
Vizag / ORD 15-16 / 002- 01 Date : 19-02-16
27