REPORT NO.

:-GCCIPL/V/AGCL/HAZOP/2010-11/SEP/RMS-075/R01

HAZOP STUDY

REPORT
PREPARED FOR

P.O. DULIAJAN
DIST DIBRUGARH
ASSAM 786 602
INDIA

CONDUCTED & PREPARED BY

GREEN CIRCLE CONSULTANTS (I) PVT LTD.

Environmental, Health, Hygiene, Safety, Risk, & Quality
Consulting Engineers & Trainers

(An ISO 9001: 2008 Certified Company)

REGD. OFFICE: 204, Chanakya, 2nd Floor, Opp. Vimalnath Complex, High Tension Road
Crossing, Vadodara-390023 (Gujarat), India

ALSO AT
NEW DELHI MUMBAI PUNE BANGALORE HYDERABAD
OVERSEAS: AUSTRALIA OMAN AFRICA
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REPORT NO.:-GCCIPL/V/AGCL/HAZOP/2010-11/SEP/RMS-075/R01

QUALITY CONTROL SHEET

Prepared Reviewed Approved

Rev. Date Reason History
By By By

00 01/10/10 Draft Report of HAZOP Study KP DD YD

Revised Draft Report of HAZOP YD
01 17/12/10 KP DD
Study
- 31/12/10 Final Report of HAZOP Study KP DD YD

KP : Kavita Patwardhan
DD : Dipali Desai
YD : Yogendra Dave

Prepared by Kavita Patwardhan, Associate Consultant - RMS

Signature

Reviewed by Dipali Desai, Dy. Manager - RMS

Signature

Approved by Yogendra Dave, HOD & Corporate CEO

Signature

Released by Nachiket Joshi, Group Manager-Accounts & Finance

Signature

GREEN CIRCLE CONSULTANTS (I) PVT LTD,

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HAZOP STUDY REPORT

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ACKNOWLEDGEMENT

WE EXPRESS OUR SINCERE THANKS TO MANAGEMENT & EMPLOYEES

OF ASSAM GAG COMPANY LTD, ASSAM (INDIA) FOR THEIR CO-

OPERATION & UNSTINTED HELP WITHOUT WHICH THE ‘HAZOP

STUDY’ COULD NOT HAVE BEEN POSSIBLE. THE COURTESY

EXTENDED TO OUR TEAM IS HIGHLY APPRECIATED.

For: GREEN CIRCLE CONSULTANTS (I) PVT.LTD.

AUTHORISED SIGNATORY

GREEN CIRCLE CONSULTANTS (I) PVT LTD,

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ABBREVIATIONS

IS Indian Standard
EPA Environment Protection Act
MoEF Ministry of Environment & Forest
OS&H Occupational Safety & Health
PPE Personal Protective Equipment
MSIHC Manufacturing, Storage & Import of Hazardous Chemicals
FA Factories Act
SMPV Static Mobile & Pressure Vessel
LFB Laminar Flow Booth
USA United States of America
OHC Occupational Health Center
SHE Safety Health & Environment
MSDS Material Safety Data Sheet
SOP Standard Operating Procedure
MOM Minutes of Meeting
MPCB Maharashtra Pollution Control Board.
IE Indian Electricity
GW Guide Word
P& IDs Piping and instrumentation diagram

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INDEX

Sr. No. Content Page No.

1. CREDITS 3
2. EXECUTIVE SUMMARY 4
3. INTRODUCTION OF HAZOP 5
4. HAZOP STUDY SCOPE 6
5. HAZOP PROCESS 7
6. HAZOP RECORDING 11
7. HAZOP WORKSHEETS 13
8. RECOMMENDATIONS 21

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CREDITS

M/s. Assam Gas Company Ltd, Assam, appointed M/S. GREEN CIRCLE CONSULTANTS (I) PVT. LTD.,
VADODARA to conduct HAZOP Study. Hazop team to plant site comprising Mr. Pradeep Joshi –
Managing director from M/S GREEN CIRCLE CONSULTANTS (I) PVT. LTD. In presence of committee of
M/s. Assam Gas Company Ltd, Assam

The auditors from M/S. Green Circle Consultants (I) Pvt. Ltd. Conducted the audit from 29th JUNE 2010
at Khopoli site with standard (Reference Std. IS 14489:1998 – Code of Practice for Occupational
Safety & Health Audit) procedures & methodology including close interactions & interviews of the
Employees of the plant.

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EXECUTIVE SUMMARY

Following recommendation should be implemented

Control valve should be installed

Safety inspection should be carried out
Interlocking with PT to be done
Activate DMP is required
-Training should be done periodically
Gas detection system should be installed
Sprinkler system (dedicated system) should be installed
Water monitors and Water curtain should be installed
3rd party C & T every 2 years
Discharge gas temp needs to have TG/RTD

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INTRODUCTION OF HAZOP

HAZARD & OPERABILITY STUDY

An important addition to the methods of hazard identification is the family of techniques known as
Hazard & Operability (HAZOP) studies.

The following description is based on those given by Lawley (1974b) & by the CISHC HAZOP Study
Guide.

A multidisciplinary team, who reviews the process to discover potential hazards & operability
problems using a checklist approach, carries out the studies. They are essentially an application of
the technique of critical examination & their origins in method study are extended by an early
account by Elliott & Owen (1968).

The basis of such a study may be a word model, a process flow sheet, a plant layout or a flow
diagram. There are different types of study which have different objectives & which are done at
different stages of the project. The level of detail & the team composition are accordingly.

Principles of examination

The basic concept of the hazard & operability study is to take a full description of the process & to
question every part of it to discover what deviations from the intention of the design can occur &
what their cause & consequences may be. This is done systematically by applying suitable
guidewords.

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HAZOP STUDY SCOPE

HAZOP (Hazard & Operability) study was developed to identify hazards in plant & to identify
operability problems, which though not hazardous, could compromise the plants ability to achieve
design productivity.

Hazard Evaluation is carried out to identify the hazard that exists, the consequences that might
occur as a result of hazards, the likelihood that events might take place that would cause an
accident with such a consequence, and the likelihood that safety system, mitigating systems and
emergency alarms and evaluation plan would functioning property and eliminate or reduce the
consequences.

HazOp Pre-requisite:

1. Process Flow Diagrams

2. Detailed process description
3. P&IDs
4. Purity of materials
5. Process Safety & Operation Manual
6. Maintenance Schedules & past history.

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HAZOP PROCESS

A. BACKGROUND

HAZOP is a well recognized method of identifying hazards & problem which may prevent an efficient
operation & lead to a hazard .HAZOP is a technique to critically examine a system, part by part ,in a
very systematic manner ,to find out the cause and consequence of every conceivable deviations
in the normal operation of the system .the method enables prediction of all possible ways in which a
hazard or an operating problem could arise ,whether the design takes preventive care of them and
if not , recommend changes may be necessary.

HAZOP is a qualitative assessment of a hazard or an operating problem occurring in a process plant

while risk Analysis is a quantitative assessment of the consequences of a hazard.

The HAZOP study is carried out for all major equipment and/or each pipeline joining the equipment
in a process through series of guide words around which a number of question are formulated to
arrive at the possible deviations . In doing so, valve, instrumentation, nature of chemical process and
unit operation involved are closely examined .The probable cause and the consequences of the
deviation are listed and necessary corrective actions are suggested.

The main purpose of HAZOP is therefore to identify all possible deviations from the way the design is
expected to work and probable causes and consequence of the hazard associated with these
deviations together with recommended changes.

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B. Methodology

A HAZOP study 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 (Reference is invited to Figure 3.1 on next page):

1. Identify a section of plant on the P&I diagram.

2. Define the design intent and normal operation conditions of the section.
3. Identify a deviation from design intent or operating conditions by applying a system of
guidewords.
4. 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.
5. For a meaningful deviation, decide what action, if any is necessary.
6. 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.

HAZOP Worksheet
The HAZOP worksheet that was discussed during the HAZOP sessions included the following details:
Guideword
Parameter
Deviation
Causes
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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
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• 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.

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.

The HAZOP study was based on a set of P&I diagrams for the sections to be covered by study. (A
copy of the P&I diagrams used for the study are compiled in Appendix I). The following back-up
documents were also used during the HAZOP sessions:

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HAZOP RECORDING

Two methods of recording of a HAZOP study can be employed:

1. Complete - in which details of all discussion points are noted. &
2. By Exception - in which only those deviations that require action are recorded.

Recording of this study is 'complete recording' wherein all discussions of significance were recorded.

The discussion from the study is recorded on log sheets. Information is recorded in columns on the log
sheets as follows:

Guide Words
Parameters
Deviations
Causes
Consequences
Safeguards
Recommendations

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C) NODE, GUIDEWORDS & DEVIATION

The main guidewords & their meanings are summarized below.

TABLE 1 MEANING OF GUIDEWORDS

Sr.No. Guideword Meaning
1. NO or NOT Quantitative increase
2. LESS Quantitative decrease
3. AS WELL AS Qualitative increase
4. PART OF Qualitative decrease
5. REVERSE Logical opposite of intention
6. OTHER THAN Complete substitution

The application of these guide words may be illustrated by the example already described:
TRANSFER A, The guide words may be applicable to either the word TRANSFER or the word A. Thus for
this case, the meaning might include the following:

NO or NOT No Flow of A.

MORE Flow of A more than design flow.

LESS Flow of A less than design flow.

AS WELL AS Transfer of some component additional to A.

Occurrence of some operation/event addition to transfer

PART OF Failure to transfer all components of A.

Failure to achieve all that is implied by TRANSFER.

After having listed all the deviation under each guide word, possible causes for the deviation are
identified & consequences are assessed.

Finally, the study of each pipeline or equipment carried out is document in the form of a worksheet.
Worksheets indicate particular deviation leading to potential hazards and/or operating difficulties

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which may not have been anticipated during design stage & incorporates recommendations to
prevent or ameliorate the consequences of a deviation.

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HAZOP WORKSHEETS

Hazop worksheet for compressor

Plant : Compressor ( Unit 5) Process Section :

Node : Phase :
Process Line/Equipments : Suction line to outlet of Date : Time :
scrubber

Parameter: Pressure

GW Deviation Causes Consequences Existing Recommendations Risk Remark

Controls Ranking s
Less/No - From -Business loss -PM -Training 1
supplier -damage -PG - Gas detection
-Valve compressor -Suppliers system
partly or -Rise in temp inf -Sprinkler system
completely -Fire & -Half hrly (dedicated
closed explosion monitoring system)
-Human -Maintenance -Periodic - Water monitors
error problems Draining - Water curtain
-Strainer is
choked
-Leakage or
puncture in
the pipeline
-Breaking of
gasket
-Presence of
Oil &
condensate
in the
pipeline
More - From - Popping of -PRV is - 3rd party C & T 1
supplier/line PRV (set provided every 2 years
- Shut down, pressure 175 -PM
the trapping PSI,20 PSI more -
of gas in the than the Calibration

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scrubber suction & testing of

pressure) PRV
- Hazardous
GW Deviatio Causes Consequence Existing Recommendations Risk Rema
n s Controls Ranking rks
As well as - Vent is - Suction will - WI - Training is
open & drop - requires
suction is - Process
on by delay
human - Abnormal
error sound

Part of Air ingress Not hazardous Gas detection

till no leak system
takes place
Other than
Maintenanc Crude oil & Maintainability Liquid level - PM
e condensat is - Drain
e maintaine
d in
scrubber
Level of
scrubber is
interlocked
with shut
down

GW Deviation Causes Consequences Existing Recommendations Risk Remarks

Controls Ranking
As well - Entry of - 3rd party
as scrubber Malfunctioning check every
media valve year
into the - sludge NDT like US
suction formation test is
valve carried out

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Plant : Compressor Process Section :

Node : Discharge Phase :
Process Line/Equipments : Date : Time :

Parameter : Pressure

GW Deviatio Causes Consequences Existing Recommendation Risk Remark

n Controls s Rankin s
g
Less/N - Low suction -Business loss - SOP/WI
o - Customer - Training
higher - PM
consumption
- Low RPM
-Human error
- Low
lubrication in
piston
- Engine fails
More - Higher - Discharg -Flare
RPM e valve are
- Sudde will blow ( provide
n Less 320 PSI,22 d
consu Kg/cm3)
mption - Problems
by the towards
consu customer
mer side,
- Valve hazardou
compl s
etely
or
partiall
y
closed

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Parameter : Temperature

GW Deviatio Causes Consequence Existing Recommendation Risk Remark

n s Controls s Rankin s
g
Less/N -Seasonal effect No hazard - TG
o
More - Insufficien - - Discharge gas
t cooling - temp needs to
- Suction have TG/RTD
pressure
low
- Summer

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Wroksheet for Pipelines

Plant : Process Section : BVFCL(LP)16”(10.5 Kg/cm2 to

Customers 6 Kg/cm2) 1.4 mmscmd
Node : 1-1’ Phase : Gas
Process Line/Equipments : Flow meters(orifice) ,Drain Date : 24/6/2010 Time : 9.40 am
pots, vents, line valves, pig trap ( MS )

Parameter : Pressure

GW Deviatio Causes Consequenc Existing Safety Recommendatio Risk Remark

n es Controls ns Rankin s
g
More -from supplier -Chances of -Isolation valves Control valve 1
-Human error leakage fire -Inf from supplier
& valve is & -PG
closed explosion(haz -Orifice meters
- ) are observed
Malfunctionin
g of valve
Less/N -From supplier -Business loss -Inf from -Safety
o -Leakage or -Hazardous supplier/consum inspection
puncture in situation, fire er -Interlocking with
pipeline & explosion -Public/police PT
-Gasket -Public at intimation -Activate DMP
failure large may be -PG
-Sabotage affected -PM
-Terrorist -Air pollution -Hydro tests
attack -Calibration &
-Damage testing
due to public
activity/erosio
n

Parameter : Flow

GW Deviation Causes Consequences Existing Recommendations Risk Remarks

Safety Ranking
Controls
More -From -Haz(high -Orifice is -Control valve/PT 1

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supplier pressure) provided

Less/No Same as
Low
pressure
Reverse -Human -Business loss -Orifice -NRV
error & -Training -Training
valve is -Signage -Display of WI
closed

GW Deviation Causes Consequences Existing Recommendations Risk Remarks

Safety Ranking
Controls
As well -Crude oil & -Fire/explosion -Tech To discuss with 1
as condensate (haz) specs suppliers
with gas -Water pollution -Drain
-Damage points &
gauges(PG,RTD) collection
-Decreases the
pipeline
-Less flow
-Business loss
-Environmental
pollution
Other - From Change of Lab
than supplier composition checks
from
supplier

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Plant : Process Section :

Node : 2-2’ Phase : Gas
Process Line/Equipments : BVFCL (20”)LP - From LPG To Date : 24/6/10 Time :
compressor(PG,RTD,Orifice)

Parameter : Pressure

GW Deviation Causes Consequences Existing Recommendations Risk Remarks

Safety Ranking
Controls
Less/No -More -Manned
suction
from
compressor

Parameter : Flow

GW Deviation Causes Consequences Existing Recommendations Risk Remarks

Safety Ranking
Controls
More -Higher Overflow
suction from
compressor

GW Deviation Causes Consequences Existing Recommendations Risk Remarks

Safety Ranking
Controls
Other Same as Hydro 1
than oil/condensate tests/pigging
Drain point may
be provided

Plant : Process Section :

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Node : 7-7” Phase :

Process Line/Equipments : Dulaiajan to NTPS (Namrup Date : Time :
Thermal Power Stn) 20”/HP

Parameter : Pressure

GW Deviation Causes Consequences Existing Recommendations Risk Remarks

Safety Ranking
Controls
More - No - Pressure -Inf from
consumer build-up, Haz. customers
off-take, -Leakages/fire/ -Gauges
with no inf explosion -Manned &
- logbook in
compressor

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RECOMMENDATIONS

Some Recommendation for Compressor Area

¾ Gas detection system should be provided

¾ Sprinkler system (dedicated system) should be provided
¾ Water monitors at Suction line to outlet of scrubber
¾ Water curtain at Suction line to outlet of scrubber
¾ Discharge gas temp needs to have TG/RTD

Pipeline Area

¾ Control valve should be provided on 16” pipeline

¾ Interlocking with PT along the 16” pipeline
¾ Hydro tests/pigging should be carried out
¾ Drain point may be provided on 16” pipeline.

General Recommendation

¾ Safety inspection should be carried out

¾ Training is required
¾ 3rd party C & T every 2 years
¾ Activate DMP

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LEGAL DISCLAIMER & LIABILITY

The consulting services conducted by Green Circle Consultants (I) Pvt Ltd (the
“Company”) were performed using generally accepted guidelines, standards, and/or
practices, which the Company considers reliable. Although the Company performed its
consulting services pursuant to reliable and generally accepted practices in the industry,
the Company does not guarantee or provide any representations or warranties with
respect to Client’s use, interpretation or application of the findings, conclusions, and/or
suggestions of the consulting services provided by the Company. Moreover, the findings,
conclusions, and the suggestions resulting from the consulting service are based upon
certain assumptions, information, documents, and procedures provided by the
Customer. AS SUCH, IN NO EVENT AND UNDER NO CIRCUMSTANCE SHALL THE COMPANY
BE LIABLE FOR SPECIAL, INDIRECT, PUNITIVE OR CONSEQUENTIAL DAMGES OF ANY NATURE
WHATSOEVER, INCLUDING WITHOUT LIMITATION, ANY LOST REVENUE OR PROFITS OF THE
CUSTOMER OR ITS CUSTOMERS, AGENTS AND DISTRIBUTORS, RESULTING FROM, ARISING
OUT OF OR IN CONNECTION WITH, THE SERVICES PROVIDED BY THE COMPANY. The
Customer agrees that the Company shall have no liability for damages, which may result
from Client’s use, interpretation or application of the consulting services provided by the
Company.

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IMPORTANT

• THIS DOCUMENT IS FOR LIMITED USE / CIRCULATION ONLY.

• NO PART OF THIS DOCUMENT IS TO BE REMOVED AND /OR TRANSFERRED
OUT IN ANY MANNER WHATSOEVER WITHOUT THE PERMISSION OF AGCL
MANAGEMENT.
• HOLDER OF THIS DOCUMENT IS TO ENUSRE THE SAFEKEEPING OF IT. NOTHING
IS TO BE WRITTEN OR UNDERLINED IN ANY PAGES OF THIS DOCUMENT. ANY
REVISION REQUIRED SHOULD BE BROUGHT TO THE NOTICE OF DESIGNATED
OFFICER OF AGCL.
• ON CHANGE OF DUTY OR TRANSFER OR OTHERWISE, THIS DOCUMENT IS TO
BE HANDED OVER TO THE NEXT PERSON TAKING UP THE CHARGE OF THE
HOLDER.
• REVISIONS WHEN MADE MUST BE ENCLOSED IN THE DOCUMENT
IMMEDTIALTY REPLACING THE OBSOLETE ONES.

Approved By: Doc. No.: AGCL/HAZOP/03 Issue No.: 01

Controlled By: Rev No.: 00

 ASSAM GAS COMPANY LTD

HAZOP STUDY REPORT

REPORT NO.:-GCCIPL/V/AGCL/HAZOP/2010-11/SEP/RMS-075/R01

AMENDMENT SHEET ( To Issue 01 )

Signature
Sl. Section Page Effective
Amendment Particulars (Amendment
No. No. No. Date
incorporated)

Approved By: Doc. No.: AGCL/HAZOP/03 Issue No.: 01

Controlled By: Rev No.: 00

 ASSAM GAS COMPANY LTD

HAZOP STUDY REPORT

REPORT NO.:-GCCIPL/V/AGCL/HAZOP/2010-11/SEP/RMS-075/R01

This Document is

Approved By B. Borpatragohain, Managing Director

Signature

Controlled By S. Tamuli, Sr. Manager – TS

Signature

Approved By: Doc. No.: AGCL/HAZOP/03 Issue No.: 01

Controlled By: Rev No.: 00