leaders in risk engineering and ehs solutions · 2019-05-28 · leaders in risk engineering and ehs...

LEADERS IN RISK ENGINEERING

AND EHS SOLUTIONSAN ISO 9001:2015 CERTIFIED CONSULTING ORGANISATION

Tending towards operational excellence in Oil Terminals – Using Process Safety as a key tool

Prepared by:

Ramesh Ramalingam K, Associate Vice President; Nagarajan R, Senior General Manager

Cholamandalam MS Risk Services Ltd, India

PRESENTER’S PROFILE

▪ Graduate Mechanical Engineer with Post Graduate

Masters degree in Industrial Safety

▪ Over 17 years experience in the field of Risk Consulting

▪ Specializes in areas of Process Safety and Logistics Risk

Management and presently heads these divisions at

Chola MS Risk

▪ Approved Safety Auditor – DGFASLI, Govt. of India

▪ ISO 45001 lead certified auditor

▪ Executed numerous projects in the areas of H&S and

process safety across varied industry sectors ranging

from complex oil and gas installations to engineering

industries and service sectors in more than 7 countries.

▪ Presented a number of papers in the field of Process

Safety in national / international seminars.

Mr. Ramesh Ramalingam K

Associate Vice President

Cholamandalam MS Risk Services Ltd

Tending towards operational

excellence in Oil Terminals

–

Using Process Safety as a key tool

INTRODUCTION

▪ Oil Terminals play a vital role in the business of handling and transportation

of the final hydrocarbon liquid products.

▪ In October 2009, a major fire blazed in Jaipur terminal

• Jaipur Oil Terminal Fire in India on 29th Oct 2009

• 11 person killed and 45 persons Injured

• Leakage from MS Tank valve resulted in

leakage for 75 min

• Fire continued for 11 days

▪ In the wake of this accident, many terminals have understood the sense

of vulnerability and need for focus on process safety.

▪ In India, an exhaustive integration of process safety during detailed

engineering stage is still a work in progress.

▪ As the terminal operations expand, ignoring the principles of process safety

such as facility siting is also one of the major concern. Where separation

distances are not met, suitable engineering controls need to be initiated to

mitigate the risk.

▪ Implementation of engineering recommendations during the operational

stage of a terminal not only results in shut down of the terminal but also is

extremely cost and time intensive, forcing the terminal operators to

operate the terminals with mitigation measures.

CHALLENGES

ANALYSIS OF PROCESS SAFETY STUDIES

▪ Detailed analysis of 42 terminals which were in operational stage

▪ Basis – HAZOP and QRA studies

▪ 1600 recommendations

▪ The life of terminals was ranging from more than 60 % of normal design life

(greater than 20 years) and to the recently built terminals.

6%

12%

4%

4%

1%

20%30%

8%

2%

1%

2%

4%

6%

HAZOP Recommendations

Active Fire Protection

Asset Integrity

Hydrocarbon leak detection and alarm system

Emergency Management

Facility Siting

Inherent Design

Instrumentation

Operational Discipline

Mobility

Occupational Health

Passive Fire Protection

Relief Systems

Operating Procedures

ANALYSIS OF HAZOP RECOMMENDATIONS

60% 62%

51% 53%

70%

58%

40% 38%

49% 47%

30%

42%

ACTIVE FIRE PROTECTION ASSET INTEGRITY HYDROCARBON LEAK

DETECTION AND ALARM

SYSTEM

EMERGENCY

MANAGEMENT

FACILITY SITING INHERENT DESIGN

Trends for old and relatively new terminals

Old terminals (More than 20 years of operation) Relatively new terminals (Less than 20 years of operation)

Old terminals seem to have major gaps which if addressed during conceptual stage of project, would

have made operations simpler and resulted in reduced efforts for achieving operational excellence.

Age of the terminals Vs Process safety aspects

Age of the terminals Vs Process safety aspects

54%

65%

95%

85%

76%

40%

62%

46%

35%

5%15%

24%

60%

38%

INSTRUMENTATION OPERATIONAL

DISCIPLINE

MOBILITY OCCUPATIONAL

HEALTH

PASSIVE FIRE

PROTECTION

RELIEF SYSTEMS OPERATING

PROCEDURES

Trends for old and relatively new terminals

Old terminals (More than 20 years of operation) Relatively new terminal (Less than 20 years of operation)

Older terminals have challenges in active and passive fire protection, facility siting, asset integrity and

operational discipline aspects

Top 10 Process Safety Areas impacting

Operational Excellence

❶ INHERENT DESIGN

Key aspects for operational excellence:

✓ Selection of transfer pumps (API, double mechanical seals) and availability of stand by pumps

✓ Selection of electrical fittings based on Hazardous Area Classification (HAC) and updating the HAC.

✓ Configuration of storage tank inlet/outlet piping valves like ROSOV, MOV.

✓ Collection sump/pit for wagon siding, transfer pump houses and tank farm, which is then routed to Oil Water Separator (OWS)

✓ Online density meters for improving the reliability during changeover of product, mass flow meters for pipeline transfer operations

✓ Double isolation valves for gauges, transmitters, sample points in transfer pump houses

✓ Surge study analysis to understand the sudden closure of manual/ automated valves in the pipeline transfer operations

✓ ESD pushbuttons integration in wagon siding, transfer pump house, tank farm area

58 % 42 %

Terminals >20 years Terminals <20 years

20 % HAZOP 25 % QRA

Gaps in Inherent Design

❷ASSET INTEGRITY


✓ Selection of metallic braided loading and unloading hoses, increasing the frequency of

inspection for based on the usage and practice to discard the hoses after 2 years

✓ Inspection of pipelines, storage tanks when there is change in service

✓ Corrosion management program, Long Range Ultrasonic Test for underground tanks

✓ Identification of dead legs and provision of Thermal Shut-off Valve to prevent over

pressurisation

✓ Adoption of flange management practices as per best practices like ASME B31.4/31.3

✓ Post Weld Heat Treatment (PWHT) for pipes/ piping welding where Ethanol is handled

✓ Adoption of practices like gasket management, spare valve philosophy (for OWS dyke)

✓ Predictive maintenance (like vibration test) of transfer pumps

62 % 38 %


12 % HAZOP 30 % QRA

Gaps in Asset Integrity

❸OPERATIONAL DISCIPLINE


✓ Opening of expansion valves after wagon decantation operation

✓ Capping of Ethanol handling hoses to avoid ingress of moisture

✓ Periodic sampling of OWS for oil, grease, Volatile Organic Compounds (VOC),

Chemical Oxygen Demand (COD) and Biological Oxygen Demand (BOD)

✓ Effective communication practices (recording) with other stake holders when

combined operations need o be carried out

✓ System of valve tagging and display of desired valve positioning in field for reference

✓ Minimising the presence of operators at the transfer pump houses

65 % 35 %


8 % HAZOP 8 % QRA

Gaps in Operational Discipline

❹ INSTRUMENTATION


✓ Redundant level controls for the storage tanks (H, HH, HHH), provision of radar gauge

and servo gauge (SIL rated). Ideally the tank level control system to be SIL rated.

✓ Automation system for terminal based on the ullage selected, involving the tank gradient along with the parcel logic

✓ Provision of low pressure switch for the transfer pumps suction and high pressure switch

at pump discharge, interlock mechanism to trip pump and shut off discharge valve

✓ Provision of differential pressure indicators on strainers/ filters in transfer pump suction/

discharge

✓ Provision of overfill protection system to stop truck loading pumps

✓ Monitoring of the storage tank dyke valve positioning

54 % 46 %


30 % HAZOP 16 % QRA

Gaps in Instrumentation

❺ACTIVE FIRE PROTECTION


✓ Reviewing adequacy of the water network when major changes occur in the terminal

✓ When thermal radiation is impacting the public, provision of water curtains to minimise

the thermal impact to public

✓ Water sprinkler system for wagon siding, gantry areas

✓ Provision of Medium Expansion Foam Generators (MEFG) for the OWS collection pits

✓ Replacement of fire stench with fixed sprinkler system around the storage tanks

✓ Provision of automatic actuated rim seal failure detection and extinguishing system for

floating roof tanks

60 % 40 %


6 % HAZOP 6 % QRA

Gaps in Active Fire Protection

❻ HYDROCARBON LEAK DETECTION AND ALARM SYSTEM


✓ Provision of point type detection at the drain sumps, dyke

✓ Provision of open path detector at the manifold area

✓ Annunciation of Hydrocarbon detector panel

✓ Integration of detectors with the transfer pumps

51 % 49 %


4 % HAZOP 8 % QRA

Gaps in HC Leak Detection & Alarm System

❼OPERATING PROCEDURES


✓ Incorporation of valve sequencing and operating conditions in the Operating

Procedures

✓ Use of sign off checklist to ensure proper sequencing of valve operations in the transfer

pump house

62 % 38 %


6 % HAZOP -

Gaps in Operating Procedures

❽ EMERGENCY MANAGEMENT


✓ Developing the response procedures when the operations needs to be carried out with the neighbouring facilities

✓ Conducting of public awareness programs for the public about products being

handled at the terminal and emergency evacuation procedures

✓ Provision of emergency shutdown valves at strategic locations like transfer pump

houses for ease of isolation

53 % 47 %


4 % HAZOP 1 % QRA

Gaps in Emergency Management

❾ FACILITY SITING


✓ Checking the occupancy of occupied buildings and ensuring the minimum

occupancy for building being affected by thermal radiation or over pressure

✓ Analysing the impact of fire water pump house and fire water storage tanks after any

major expansion

✓ Blast proofing the control room

70 % 30 %


1 % HAZOP 7 % QRA

Gaps in Facility Siting

❿ RELIEF SYSTEMS


✓ Reviewing the sizing of relief valves as design standards gets updated for assurance

✓ Provision of silica gel in the vents for Ethanol storage tanks

✓ Adequacy of the relief valves for emergency vent also as per American Petroleum

Institute (API) 2000

40 % 60 %


4 % HAZOP -

Gaps in Relief Systems

IMPLEMENTING PSM IN INDIAN TERMINALS – IMPACT OF PHA

In Indian terminals, the 5 key PSM elements that require significant focus are presented

below. It is clear that a robust PHA process integrated at the design stage and reviewed

systematically at operations stage drives process safety excellence.

Process Knowledge

Management

Process Hazard Analysis

Operating Procedures

Asset Integrity and

Reliability

Management of Change

THANK YOU

Cholamandalam MS Risk Services Ltd.

Parry House, 4th Floor, No.2, NSC Bose Road,

Chennai – 600001, INDIA

Phone: +91(44) 3044 5620-30

Fax: +91(44) 3044 5550

Toll Free#: 18002001991

Our Offices:

Chennai I Mumbai I New Delhi I

Bangalore I Gurgaon I Pune I

Kuwait I Singapore (Partner Offices)

Email: [email protected]

www.cholarisk.com

http://training.cholarisk.com

ABOUT CHOLA MS RISK SERVICES

25

Chola MS Risk is a 50:50 joint venture between the INR 329 Billion Murugappa Group of India

and Mitsui Sumitomo Insurance Group of Japan.

The Murugappa Group founded in 1900 is one of India’s largest diversified

conglomerates, with 28 business and 32,000 employees in 234 cities.

Mitsui Sumitomo Insurance Group, Japan is one of the largest insurance

groups in the world & biggest in Asia, carrying out overseas businessthrough an international network of 42 countries and regions

▪ Two decades of experience in Risk Engineering & Safety Solutions

▪ More than 200 Safety Professionals

▪ Executed over 8500 risk consultancy projects

▪ Spanning 42 industrial sectors world wide

SCOPE OF OUR RISK ENGINEERING SERVICES

Our expertise blends with clients’ technical requirements, resulting in a spectrum of servicesacross the lifecycle of a project from the conceptualizing stage till decommissioning.

We Partner with clients to manage the Risk Profitably

leaders in risk engineering and ehs solutions · 2019-05-28 · leaders in risk engineering and ehs...

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