quantitative risk analysis report capacity lpg...

Quantitative Risk Analysis (QRA) & HAZOP Study Report for Proposed

TMTPA capacity LPG Bottling Plant at Village

Dist- Rayagada, Odisha

ABC Techno Labs India Pvt. Ltd.

Quantitative Risk Analysis (QRA) & HAZOP Study

for Proposed 60 TMTPA capacity LPG Bottling Plant at

Village –Seskhal, Dist

M/s Hindustan Petroleum Corporation Limited

Submitted by

Village – Pitamahal, Tehsil

Quantitative Risk Analysis (QRA) & HAZOP Study Report for Proposed

TMTPA capacity LPG Bottling Plant at Village – Pitamahal, Tehsil

Rayagada, Odisha


Quantitative Risk Analysis & HAZOP Study Report Proposed 60 TMTPA

capacity LPG Bottling Plant at – Pitamahal, Tehsil

Seskhal, Dist- Rayagada, Odisha

Hindustan Petroleum Corporation Limited

Prepared

at

Pitamahal, Tehsil- Seskhal, DistRayagada, Odisha

Quantitative Risk Analysis (QRA) & HAZOP Study Report for Proposed 60

Pitamahal, Tehsil- Seskhal,

Quantitative Risk Analysis Report

Proposed 60 TMTPA capacity LPG Bottling Plant at

Pitamahal, Tehsil- Rayagada,

Hindustan Petroleum Corporation Limited

Prepared by

Seskhal, Dist-


TMTPA capacity LPG Bottling Plant at Village – Pitamahal, Tehsil- Seskhal,



PROJECT DETAILS

Name of Publication

Quantitative Risk Analysis (QRA) & HAZOP Study Report for Proposed 60 TMTPA capacity LPG Bottling Plant at Village – Pitamahal, Tehsil- Seskhal, Dist- Rayagada, Odisha

Project Number Version 2 Released July 2018

CONTACT DETAILS

ABC Techno Labs India Pvt Ltd.

#400, 13th Street,

SIDCO Industrial Estate (North Phase)

Ambattur – 600 098

Land Mark: Near National Productivity Council

Ph: +91-44-2616 1123 / 24 / 25.

Fax: +91-44-2616 3456

E-mail: [email protected]

DISCLAIMER

ABC Techno Labs has used information provided to it by the Client and governmental registers, databases, departments and agencies in the preparation of this report. ABC Techno Labs does not know, nor does it have any reason to suspect, that the information provided to it was false, inaccurate, incomplete or misleading at the time of its receipt. This report is supplied on the basis that while ABC Techno Labs believes all the information in it is deemed reliable at the time of publication, it does not warrant its accuracy or completeness and to the full extent allowed by law excludes liability in contract or otherwise, for any loss or damage sustained by any person or body corporate arising from or in connection with the supply or use of the whole or any part of the information in this report through any cause whatsoever.

ABC Techno Labs also believes that the facts presented in this report are accurate as on date it was written. However, it is impossible to dismiss absolutely, the possibility of errors or omissions. ABC Techno Labs therefore, specifically disclaim any liability resulting from the use or application of the information contained in this report. The information is not intended to serve as legal advice related to the individual section.





CONTENTS

CHAPTER 1: INTRODUCTION ...................................................................................................................................... 7

1.1 Preamble ................................................................................................................................................................. 7 1.2 Scope for QRA As Specified By HPCL ....................................................................................................................... 8 1.3 Objectives of QRA .................................................................................................................................................... 9 1.4 Approach & Methodology for Risk Assessment .....................................................................................................10 1.5 Format of QRA Report ............................................................................................................................................12

CHAPTER 2: PROJECT DESCRIPTION ........................................................................................................................ 14

2.1 Introduction ...........................................................................................................................................................14 2.2 Project Location .....................................................................................................................................................14 2.3 Infrastructure ........................................................................................................................................................15 2.3.1 Compound Wall, Gates and Fencing .......................................................................................................................15 2.3.2 Kerb Wall Fencing ..................................................................................................................................................16 2.3.3 Storage Vessel ........................................................................................................................................................16 2.3.4 Filling Cum Empty Cylinder Shed ...........................................................................................................................17 2.3.5 LPG Filling Facility .................................................................................................................................................18 2.3.6 Filled Cylinder Storage Shed ..................................................................................................................................18 2.3.7 Inhouse Pressure Testing Facility ..........................................................................................................................19 2.3.8 Chain Conveyor System ..........................................................................................................................................19 2.3.9 Electronic Carousel ................................................................................................................................................20 2.3.10 LPG Pump / Compressor Shed ...............................................................................................................................20 2.3.11 Admin. / AmenityBuilding / Planning Room .........................................................................................................20 2.3.12 Security Cabin ........................................................................................................................................................20 2.3.13 Engineering/Consumables Stores..........................................................................................................................20 2.3.14 MCC & HT Room .....................................................................................................................................................20 2.3.15 DG Set Shed ............................................................................................................................................................21 2.3.16 HT Yard ..................................................................................................................................................................21 2.3.17 Vehicles Parking for Employees ............................................................................................................................21 2.3.18 Inspection Platform ...............................................................................................................................................21 2.3.19 Valve Changing Shed ..............................................................................................................................................21 2.3.20 Weighbridge ..........................................................................................................................................................21 2.3.21 Tank Lorry Gantry-Nos of bays-8Nos .....................................................................................................................21 2.3.22 Truck Parking Area/Drainage System ...................................................................................................................22 2.3.23 PCVO Crew Rest Room/Barrier Gate......................................................................................................................22 2.3.24 Fire Protection Facilities........................................................................................................................................22 2.3.25 Gas Monitoring System ..........................................................................................................................................23 2.3.26 Air Compressor / Receiver / Dryer ........................................................................................................................23 2.3.27 Plant Security System ............................................................................................................................................23 2.3.28 Vapour Seal ............................................................................................................................................................23 2.3.29 Electrical System ....................................................................................................................................................24 2.3.30 Bore Well ...............................................................................................................................................................24 2.3.31 Roads .....................................................................................................................................................................24 2.3.32 Communication System .........................................................................................................................................24 2.4 Process Parameters & Design Basis .......................................................................................................................24 2.5 Filling/Testing Equipments ...................................................................................................................................25 2.6 Safety Philosophy ...................................................................................................................................................26 2.6.1 LPG Installations - Codes & Standards ...................................................................................................................26 2.6.2 Mounded Storage for LPG ......................................................................................................................................27 2.7 Physical Properties of LPG .....................................................................................................................................28 2.8 Meteorological Data ...............................................................................................................................................28 2.8.1 Meteorological Conditions in Project Area ............................................................................................................28

CHAPTER 3: HAZARD ANALYSIS ............................................................................................................................... 32

3.1 Introduction ...........................................................................................................................................................32 3.2 Risk Assessment and Hazard Identification ..........................................................................................................32 3.3 Liquefied Petroleum Gas (LPG) ..............................................................................................................................32 3.4 Hazards from LPG Storage and Handling ...............................................................................................................34 3.4.1 Boiling Liquid Expanding Vapour Explosion .........................................................................................................34 3.4.2 Jet Fire ....................................................................................................................................................................34 3.4.3 Vapour Cloud Explosion .........................................................................................................................................34 3.4.4 Flash Fire ...............................................................................................................................................................34 3.5 Hazardous Conditions Due To Release of LPG .......................................................................................................35 3.5.1 Thermal Effects ......................................................................................................................................................35 3.5.2 Delayed Ignition and Explosion .............................................................................................................................35 3.6 Identification of Hazard for LPG Unloading, Storage and Bottling Facilities .........................................................36





3.6.1 Categories of Hazards ............................................................................................................................................36 3.6.2 Hazard Identification (HAZID) ...............................................................................................................................36 3.6.3 Release and Outcome Scenarios ............................................................................................................................36

CHAPTER 4: HAZARD & OPERABILITY (HAZOP) STUDY .......................................................................................... 41

4.1 HAZOP Study for Mounded Storage of LPG ............................................................................................................41 4.2 Methodology for HAZOP Study ...............................................................................................................................41 4.3 Undertaking the Study ...........................................................................................................................................42 4.4 Facilities Considered For HAZOP Study .................................................................................................................42 4.5 HAZOP Worksheets ................................................................................................................................................42

CHAPTER 5: CONSEQUENCE ANALYSIS ..................................................................................................................... 79

5.1 Preamble ................................................................................................................................................................79 5.2 Selected Scenarios for Consequence Analysis .......................................................................................................79 5.3 Consequence Analysis ............................................................................................................................................80 5.3.1 Model Used For Consequence Analysis ..................................................................................................................80 5.4 Consequence Analysis for LPG Release Scenarios .................................................................................................80 5.4.1 Rupture of Transfer Piping for unloading of LPG from Bullet Truck .....................................................................80 5.4.2 Catastrophic Rupture of Bottom Line (200 mm NB) ..............................................................................................83 5.4.3 Leak (25 mm) from Bottom Line (150 mm NB) .....................................................................................................86 5.4.4 Release from SRV on Mounded Bullets ..................................................................................................................88 5.4.5 Leak from LPG Pump .............................................................................................................................................91 5.4.6 Leak from LPG Compressor ...................................................................................................................................93 5.4.7 Catastrophic Rupture of LPG Bullet Truck (18 MT) ...............................................................................................96 5.4.8 Catastrophic Rupture of LPG Cylinder ...................................................................................................................98 5.4.9 LPG Leak from Gun at Carousel ............................................................................................................................ 101 5.4.10 LPG Leak from Central Column Failure of Carousel Machine .............................................................................. 103 5.4.11 LPG Hose Failure at Carousel Machines ............................................................................................................... 104

CHAPTER 6: FREQUENCY ANALYSIS........................................................................................................................ 108

6.1 Preamble .............................................................................................................................................................. 108 6.2 Failure Frequency Data Base ............................................................................................................................... 108 6.3 Pipeline Failure Frequencies ............................................................................................................................... 109 6.4 Process Piping Failure Frequencies ..................................................................................................................... 109 6.5 Valves Failure Frequencies .................................................................................................................................. 110 6.5.1 Control Valves ...................................................................................................................................................... 110 6.5.2 ESD Valves ............................................................................................................................................................ 110 6.5.3 Check Valves ........................................................................................................................................................ 111 6.5.4 Flanges ................................................................................................................................................................. 111 6.5.5 Pressure Vessel (Mounded Bullet Storage) ......................................................................................................... 112 6.6 Pumps Failure Frequencies ................................................................................................................................. 112 6.7 Frequencies Data Base from TNO ........................................................................................................................ 113 6.8 Probability of Ignition .......................................................................................................................................... 114

CHAPTER 7: RISK ANALYSIS AND SUMMATION ...................................................................................................... 116

7.1 General ................................................................................................................................................................. 116 7.2 Software Model Used Risk Summation ................................................................................................................ 116 7.3 Risk Summation ................................................................................................................................................... 117 7.3.1 Individual Risk ..................................................................................................................................................... 117 7.3.2 Societal Risk ......................................................................................................................................................... 117 7.4 Risk Acceptance Criteria ...................................................................................................................................... 118 7.4.1 Criteria Adopted for Individual Risk ................................................................................................................... 118 7.4.2 Criteria Adopted for Societal Risk Criteria .......................................................................................................... 119 7.5 Individual Risk Due To Proposed LPG Bottling Plant Facilities ........................................................................... 119 7.6 Societal Risk ......................................................................................................................................................... 119 7.7 Findings of Risk Analysis ..................................................................................................................................... 123

CHAPTER 8: RISK REDUCTION MEASURES ............................................................................................................. 125

8.1 Preamble .............................................................................................................................................................. 125 8.2 Risk Mitigation Measures LPG Bottling Plant ...................................................................................................... 125 8.2.1 LPG Unloading Facilities ...................................................................................................................................... 125 8.2.2 Cylinder Filling Facilities ..................................................................................................................................... 125 8.2.3 Safety/ Security System ....................................................................................................................................... 126 8.2.3.1 Automatic Fire Protection System ....................................................................................................................... 127 8.2.3.2 Gas Detection System ........................................................................................................................................... 128 8.2.3.3 Gas Extraction System .......................................................................................................................................... 128





8.2.4 Other Equipment/ System ................................................................................................................................... 128 8.2.4.1 Bottling Pumps .................................................................................................................................................... 128 8.2.4.2 LPG Compressor ................................................................................................................................................... 129 8.2.5 Evacuation Facility For Sick/ Leaky Cylinders ..................................................................................................... 129 8.2.6 Purging of New Cylinders/ Tankers ..................................................................................................................... 130 8.2.7 Electrical Area Classification ............................................................................................................................... 130 8.2.8 Mounded Bullets .................................................................................................................................................. 131 8.2.9 Procedure For Unloading Tank Trucks ............................................................................................................... 133 8.2.10 Handling & Storage of LPG Cylinders in cylinder filling and cylinder storage shed ............................................ 135 8.2.11 Maintenance Schedules........................................................................................................................................ 135 8.2.12 Electrical Hazards ................................................................................................................................................ 136 8.2.13 Fire Fighting Facilities ......................................................................................................................................... 136 8.2.14 Control Room ....................................................................................................................................................... 137 8.2.15 Personal Protection Equipment ........................................................................................................................... 137 8.2.16 Work Permit System ............................................................................................................................................ 137 8.2.17 Safety Audit and Inspection ................................................................................................................................. 138 8.2.18 Induction and Refresher Safety Trainings ........................................................................................................... 138 8.2.19 Emergency Response Plan ................................................................................................................................... 138 8.2.20 LPG Truck Checks ................................................................................................................................................ 138 8.2.21 Checks Required to be Carried Out Before Issuing Loading Memo (During The Course of Unloading opertions)139 8.2.22 Mock Drill Exercises ............................................................................................................................................ 140 8.3 Safety Management System (SMS) ....................................................................................................................... 140 8.3.1 Elements of Safety Management .......................................................................................................................... 141

ANNEXURE 1: ORGANOGRAM .................................................................................................................................. 143





CHAPTER 1

INTRODUCTION





CHAPTER 1: INTRODUCTION

1.1 PRE AM BLE

Hindustan Petroleum Corporation Limited (HPCL) is a Government of India Enterprise

with a Navaratna Status, and a Forbes 2000 and Global Fortune 500 company. HPCL owns

& operates refineries producing a wide variety of petroleum fuels & specialties,

petroleum product pipeline network of more than 3370 km for transportation of

petroleum products, and a vast petroleum product marketing network consisting of 13

Zonal offices in major cities and 106 Regional Offices facilitated by a Supply &

Distribution infrastructure comprising terminals, pipeline networks, aviation service

stations, LPG Bottling Plants, Inland Relay Depots & Retail Outlets, Lube and LPG

distributorships.

Oil marketing companies have projected an increase in demand of Liquefied Petroleum

Gas (LPG) in future due to increase in its domestic use. The demand is likely to increase

substantially over the years to come. Even in the present scenario, it is very difficult to

meet the market demand of Rayagadaand adjoining areas by Hindustan Petroleum

Corporation Limited. As per directive of the Ministry of Petroleum and Natural Gas,

Government of India, different Oil companies are required to augment / construct new

facilities to meet the growing demand.

In line with the requirement envisaged and to ensure fulfillment of demand,

HindustanPetroleum Corporation Limited proposes to construct proposed 60 TMTPA

Capacity LPG Bottling Plant at Pitamahal in Rayagada Districtwith a storage capacity of 3

x 300 MT. This proposed LPG bottling plant shall meet the short supply of LPG Cylinders

in the area.

The location of proposed LPG bottling plant on google satellite imageand surrounding

area is shown in Figure 1.1.

M/s ABC Techno Labs India Private Limited (ABC Techno Labs) has been engaged by M/s

HPCL to carry out HAZOP and Quantitative Risk Analysis (QRA)for the proposed LPG

bottling plant.





Figure 1.1: Location of Proposed LPG bottling plant of HPCL

1.2 SC O PE FO R QRA AS SPE CIFIED BY HPCL

The following scope of work has been kept in mind for carrying out Quantitative Risk

Analysis (QRA) for proposed LPG storage and bottling plant.

A. Hazard analysis (HAZAN) and Risk Assessment:

i. Identification of major fire, explosion and other hazards.

ii. Assessment of consequences of worst-case and most credible accident scenarios

on human life, property and environment in terms of radiation, BLEVE, blast

waves, dispersion and study the impacts from cascade effects.

iii. Plotting of damage contours.

iv. Evaluation of the damage/ vulnerable zones/risk qualitative within and outside

the proposed plant.

v. Suggestions and measures to eliminate control or minimize the occurrence of fire

and explosion and other hazardous situations.





B. HAZOP Study

i. Identification of hazards arising out equipment, human or operational errors or

deviations from design intentions.

ii. Listing of effects and consequences of potential hazards in terms of damage to

human beings, equipment or environment.

iii. Review of proposed safety controls and interlocks, suggestions and measures to

eliminate, control or minimize the occurrence of potential hazards.

The HAZOPand QRA study have been conducted as per standard procedures stipulated by

Statutory Government bodies & International procedures/practices followed:

The study has covered the following objectives:

1. Identification of major risks / hazards

2. Consequence analysis of the major hazards for determination of hazard distances

and impact zones.

3. Estimation of individual risk along the pipeline section

4. Graphical representation of the hazard distances to depict affected areas.

5. Representation of Individual risk by means of risk transects.

6. Suggestion of mitigating measures to eliminate / reduce hazard level.

1.3 OBJE C TIVES OF QRA

Quantitative Risk Analysis (QRA)will be carried out covering LPG transport, unloading,

storage andbottling facilities to assess the consequence of the complete range of potential

hazards associated with the proposed facility. Broadly, Quantitative Risk Analysis will

cover following aspects comprehensively:

Identification of hazards associated with handling of LPG and operations

Generation of release scenarios for escape of flammable substances from the

facilities at terminals and along the pipeline route

Estimation of damage distances for the accidental release based on different

scenarios





Estimation of probability of occurrence of hazardous event through event tree

analysis

The risk to personnel is to be expressed in terms of Individual Risk (IR)

represented by Risk Transects and group risk/societal risk represented by F-N

curves.

Finally, QRA shall demonstrate that the risk tolerability criteria have been met.

The extent of study is to perform a QRA for calculating numerical individual,

environmental, employee, and public risk level values for comparison with

regulatory risk criteria and also to assess the potential risks associated with the

operation of the proposed project. Therefore, QRA shall consider the risk to

personnel from all major risk contributors.

Suggestions of risk mitigation measures for handling and storage of LPG.

1.4 APPRO AC H & ME THOD OLOGY F OR RISK ASSE SSMENT

The approach and methodology by ABC Techno Labs followed for the QRA study are

described hereunder:

System Description

The first step of the QRA is the definition of the project limits, where the potential hazards

are associated with the transportation, unloading, storage and LPG bottling facilities.

Information about design details, process and operating conditions will be described

under system descriptionrequired for the risk analysis. It includes site location, environs,

weather data, P&ID, layout drawing, operating and maintenance procedures, and thermo

physical property data, etc.

Identification of Hazards Analysis

Various possible hazards will be identified during transportation, unloading, storage and

LPG bottling facilities including associated pump houses, etc. The release sources and

potential accidents scenarios associated with each hazardswill belisted. For each selected

release sources, several scenarios may be possible depending upon the failure mode

causing loss of containment. The criteria used for selection of scenarios for the

consequence analysis will be the Maximum Credible Accidental (MCA) scenarios.





Hazards & Operability (HAZOP) Analysis

The basic philosophy behind the HAZOP is that if a process operates within the intended

design parameter, hazards will not occur, and by identifying how a process can deviate

from the intended parameters and preventing these deviations process hazards can be

minimized. The emphasis of the HAZOP technique is on identifying potential process

hazards, not on finding solutions to reduce or eliminate them. The HAZOP study is carried

out using the traditional HAZOP guide word method, which utilizes set of guide words

that will be applied on each line of process diagram.

Effects & Consequence Estimation

Effects & consequence distance estimation will be performed to determine the potential

for damage or injury from the selected scenarios. The incident outcomes will be analyzed

using release rates, dispersion, combustion, heat radiation and explosion models from fire

and explosion.Damage distance computation will be based on jet fire, flash fire, and

vapour cloud explosion (VCE) and boiling liquid expanding vapour explosion (BLEVE)

scenarios, as applicable.

Failure Frequency Analysis

Failure frequency analysis will be done for mounded bullets, pumps, valve, flange and

piping, etc.Standard international database will be referred for estimation of

probabilities.

Failure rate data is essentially derived from internationally well known generic

databases. The generic failure data base selected for calculating the failure frequencies

and the values in the database are used to reflect the mechanical and process design of

the pipeline and process facilities

Risk Summation

Risk quantification and summation will be based on probabilities from standard

international database. The risk to personnel will be expressed in terms of Individual Risk

(IR) represented by Iso Risk Contours and Group Risk/Societal risk represented by F-N

Curves based on risk tolerability criteria.





Risk Mitigation Measures

Based on consequence analysis andrisk summation findings, risk mitigation measures

will be suggested in view of applicable standards, guidelines and best practices to reduce

risk and enhance safety at the proposed transportation, unloading, storage and LPG

bottling facilities.

1.5 FO RM AT OF QRA RE POR T

Quantitative risk analysis report has been organized in the following chapters.A brief

description of each Chapter is presented below:

Executive Summary at the beginning.

Chapter 1: Introduction describes background of the project, objective and approach of

Quantitative Risk Analysis.

Chapter 2: Project Description describes site location, facility description,

meteorological data for the project site,

Chapter 3: Hazard Analysis describes hazard identification including hazards associated

with transportation, unloading, storage and LPG bottling facilities. Maximum credible

scenarios for consequence analysis have also been developed in this chapter.

Chapter 4: HAZOP describes hazard associated with operability during transportation,

unloading, storage and LPG bottling facilities which could lead to risk to personnel,

property and environment or operational problems.

Chapter 5: Effect and Consequence Analysis describes selection of release scenarios

and outcomes of consequence analysis for selected release/failure scenarios.

Chapter 6: Frequency Analysis describes failure frequency analysis for mounded

pressure vessel (bullets), piping, pumps, valves, flanges, etc. Event tree analysis has also

been presented in this chapter.

Chapter 7: Risk Summation describes estimation of Individual and Societal risks. Iso

Risk Contours and FN Curves have been drawn accordingly based on risk tolerable

criteria.

Chapter 8: Risk Reduction Measures describes risk mitigation measures to reduce risk

and enhance safety during transportation, unloading, storage and LPG bottling facilities.





CHAPTER 2

PROJECT DESCRIPTION





CHAPTER 2: PROJECT DESCRIPTION

2.1 INTRO DUC TIO N

Hindustan Petroleum Corporation Limited (HPCL) has planned to set up a new 60 TMTPA

LPG Bottling Plant conforming to OISD 144 with LPG Storage in the form of 3 x 300 MT

Mounded Storage Vessels which will be distributed through LPG Cylinders in the region.

2.2 PR OJE C T LO C ATIO N

Hindustan Petroleum Corporation Limited has purchased the Land admeasuring approx.

20.97 Acres for construction of LPG bottling plant. Land is located in Village Pitamahal,

Tehsil Seskhal, District Rayagada in Odisha State, which isabout 3 Km away from the

Rayagada town and well connected by road through State Highway-4 and by rail from

Rayagada station. The layout plan for proposed LPG Bottling plant is shown in Figure 2.1.

Figure 2.1: Location map of Project site





The project site is well connected by road and rail network. The project site is located at

the distance of 400 m from SH-4. The project site is located at Pitamahal Village near

Rayagada in the state of Odisha. The project site is 3.5 Km away from Rayagada Railway

station on Mainline Railway between Dhanbad & Vizianagaram. Bhubaneswar Airport is

located at the distance of 280 Km. A map showing the road network around the site is

given in Figure 2.2.

Figure 2.2: Connectivity Map

2.3 INFR AS TR UC TURE

2.3.1 COM PO UND WALL, GATES AND FEN CIN G

A 3 m high compound wall with 0.6 m high concertina wire fencing on top of the wall

isproposed. One no. of 6 m wide main gate for plant with security office and

emergencygate of 6 m wide has been proposed.





2.3.2 KER B WALL FENCI NG

To segregate the licensed area, 1.0 m height kerb wall with 1.2 meter high chain link

fenceshall be provided at appropriate places.

2.3.3 STO R AGE VESSEL

3 x 300 MT capacity Mounded Storage Vessels have been proposed at the proposed LPG

Plant. CCOE approval shall be obtained for theproposed bullets. Also calibration of bullets

shall be got approved from approvedcalibration agencies by the vendor. Hazardous area

classification of the proposed plant is shown in Figure 2.4.

Figure 2.3: Layout Plan of HPCL’s Proposed LPG Plant at Rayagada





Figure 2.4: Hazardous Area Classification of HPCL’s Proposed LPG Plant at

Rayagada

2.3.4 FILLING CUM EM PTY CYLINDER SHED

Shed size of 25 m x 70 m shall be provided for stacking empty cyinders and cylinders

fillingfacilities.Filling of LPG Cylinders will be done by 1x 24 station electronic carousel

which shall haveall the required upstream and downstream facilities (like cylinder

washing/drying m/c, in-linecheck scales, GD/PT units, correction units, cap hammering

unit, washer replacement loopetc) complying with all guidelines and statutory norms.

Additionally, adequate number ofon-line valve change machines (without evacuation)

shall be installed to take care of thevalve leak detected cylinders.

One number electronic check scale (platform type) of 50 kg capacity to be provided

atunloading bay for random checking of new & pressure tested cylinders as per QAP

Manual.





2.3.5 LPG FILLIN G FACILI TY

One conveyor line shall be provided for filling of 19.35and 47.5 Kg cylinders with

facilityfor Online dosing for BMCG.In the above line a separate inline filling station shall

be provided to fill 5 kg cylinders, with scale accuracy of 10 gm.Special type heavy duty

reversible conveyer shall be provided for safe and easy handling ofthese cylinders.Online

cylinder purging facility shall be provided with capacity 600 cylinder/hr.

The list of equipments is as under.

1. 1 x 24 Station Electronic Carousel with Dynamic check scale, WCU, VLD & OLD.

2. Cylinder washing unit to wash empty cylinders

3. Automatic valve changing machine

4. Purging unit

5. Chain / roller conveyor system with drive units

6. Seal placing machine and One hot air sealing Unit

7. Evacuation machine

8. Vapour extraction system

9. Compact Valve Tester (CVT)

10. Cap Hammer

11. Test Bath

12. Check Scale and correction unit

13. Valve Leak detector

2.3.6 FILLED CYLINDE R STO R AGE SHED

Shed of size 25 m x 15 mwith 10 mx 15 m finger loading platform (to accommodate 2

lorries at a time.) will be provided.Filling shed & filled cylinder shed are interconnected

by 3.0 m wide gangway forconveyors. Similarly, gangway connection shall be provided

between filingshed and valve change shed. Statistical quality control loop (SQC) with

roller conveyor will be provided with an inline check scale and CVT. All the

loading/unloading fingers andgangway shall be provided with sprinkler coverage.





2.3.7 INHO USE PRESS URE TESTIN G FACILITY

Separate shed shall be provided to house PT facility with LPG vent pipefrom 2 x 10 head

test bench extending to a point having 30 m clear distance all around. PT shed to be

located adjacent to Valve Change Shed. Adequate provision of conveyors shall be

considered for movement of cylinders.

The following equipments shall be integral to the PT facilities:

Cylinder Washing tank

Valve screwing & unscrewing machine

Tilting type 2 x 10 head test bench with closed air and water vessels of suitable

capacity

Pneumatic testing facility with air compressor capable of providing 12 kg/cm2 air

pressure

Painting booth with blower

Flameproof/Intrinsically safe platform type electronic weighing scale of upto 50

kg capacity.

Ultrasonic cleaning and valve salvaging machines shall be provided.

The above system will be semi automatic. In addition to the above, open hard standing

will be provided for stacking the cylinders.

2.3.8 CH AIN CON VEYO R SYS TEM

As per the requirement of Electronic carousel, the speed of chain conveyor system shall

bebetween 12 – 22 m/min. On the Introduction line and Ejection line, the speed should

beminimum 22 m/min and 18 m/min up to the test bath. A layout will be developed

showingthe position of OLD/VLD and the location of test bath. The ratings & numbers of

Drive Units will be provided commensurate with the new electronic carousel. One

telescopic chain conveyors and one manual chain Conveyor each for loading

andunloading Fingers shall be provided. This is adequate to cater to the requirement of

24 stations.





2.3.9 ELEC TR ONI C CARO USE L

Careful design shall be planned on floor keeping operational and aesthetics aspects in

mind. Further, conveyors shall be designed to offer high efficiency at designed load with

help ofhigh efficiency motors/helical or direct mount gear boxes etc. Auto on-off

operation of loop conveyers at correction, valve & O-ring change and evacuation

conveyors to be provided. Telescopic conveyors to be provided for unloading/loading of

empty/filled cylinders to and from box lorry with photoelectrical type auto

sensing/tripping system. All electric motors shall be of high efficiency “ Eff 1 “ grade.

2.3.10 LPG PUM P / CO MPRE SSOR SHED

The pump house will be of size 20m x 10m, 2 nos. LPG pumps (50 Cum / hr, 160 mHead)

will be provided for bottling. 2 no. LPG compressor will be provided for unloading of bulk

tank lorries. OneLPG Loading pumps of 50 m3/hr, 80 m Head shall be provided for

loading bulk LPG. Suitable capacity cooling tower with cooling water pumps as per

requirement to be provided.

2.3.11 ADMIN. / AMENI TYBUILDING / PL ANNIN G ROOM

25mx 10 mdouble story building will be provided to accommodate office space,

conference rooms, canteen, amenities etc, with internal partitions / furniture.

2.3.12 SEC URI TY CABI N

3 m x 3 m security office will be provided at the main gate. The time office at second gate

to license premise shall be provided.

2.3.13 ENGINEE RING/CONS UMABLES STO RES

Engineering cum consumables store of 20 mx 10m has been proposed. This would be

ashed with false ceiling for store keeper. A field toilet of 8 m x 10m with emergency

eyewash facility is also proposed adjacent to the stores.

2.3.14 MCC & HT ROOM

20 m x 10m RCC building will be provided to house HT (Vacuum type) Breaker / LT panel

etc. meeting operational and statutory requirements.

Transformer shall be indoor type located behind the MCC Room in a 8m x 8 m enclosure

with minimum safety distance as per IE Rules. Transformer shall be provided with AVR

on HT side, in case necessary to eliminate unwanted power consumption due to voltage





fluctuation. Suitable APFC panel to maintain plant power factor above 0.95 shall be

ensured. Separate arrangement bypassing main LT breaker shall be provided to maintain

power supply to critical areas (i.e. plant lighting, siren, fire control panel & road barriers

etc) incase of emergency shutdown of plant.

2.3.15 DG SE T SHED

DG Sets of capacity 1 x 380 KVA and 1 x 125 KVA having acoustic enclosures will

beprovided adjoining to MCC room in open shed. 380 KVA set will be used for full

loadplant operation while 125 KVA unit will take care of light load and emergency power

requirement. Provision of Diesel Tanks for supply of Diesel to the DG sets will be made

outside the shed.

2.3.16 HT YARD

HT Yard of 8.5m x 7.5m will be provided at the proposed LPG Plant.

2.3.17 VEHI CLES PARKI NG FO R EM PLOYEES

Shed of size 20 mx 5m will be provided for vehicles parking for employees.

2.3.18 INSPE C TIO N PL ATFO R M

At least 1 m wide and 6m long inspection cum counting platforms will be provided in

front of security gate, to check LPG packed lorries.

2.3.19 VALVE CH AN GING SHE D

Valve Changing Shed of 15 m x 10 m will be provided near connecting platform.

2.3.20 WEIG HBRID GE

50 MT capacity electronic way bridge with SAP interface shall be provided. ¼th capacity

dead weights shall be provided for calibration/testing.

2.3.21 TAN K LO R RY GAN TRY-NOS OF BAYS-8NOS

4 Bays TLD gantry of size 24mx 16m for Unloading of tank lorry with MFM oncommon

header to facilitate automation. All unloading bays will be provided with suitableloading

arms with break-away type coupling and earthing interlocks. Additionally, provision of

bulk loading shall be made in two bays.





2.3.22 TR UCK PARKIN G ARE A/DR AIN AGE SYS TEM

Approximately 7675sqm bituminized area will be developed inside the plant boundary

for parking of 52 nos. trucks/lorries. Provision of Solar powered illumination shall

beexplored to illuminate the area as part of HPCL’s RE policy. Open Drainage system will

be provided covering admin/tank lorry parking area.

2.3.23 PCVO CRE W RES T RO OM/BARRI ER GATE

A room of sizes 8 mx10m will be provided nearer to tank lorry parking area for the use of

PCVO crew. Toilet/Wash room will be provided as per requirement. Suitable broadcast

arrangement shall be made for relaying safety messages/films for enhancing PCVO crew

awareness. Solar powered systems shall be explored to illuminate the area as part of

HPCL’s RE policy. Total 4 nos. of lifting barrier gate will be provided, out of which 2 nos.

near to the time office, 1no. at emergency gate and 1noat tank lorry parking area.

2.3.24 FIRE PR O TE C TION FACILI TIES

The following fire fighting facilities will be provided at the proposed LPG bottling plant:

a) Fire water storage; 2 Nos. above ground vertical water tanks each of capacity

2800kl as per OISD requirement will be provided.

b) Fire water pump house (shed): Pumphouse of size 8 m X 26 m will be provided to

accommodate 5 Nos. diesel driven fire water pump sets of 410 KL/Hr and two no.

electric motor driven jockey pumps of 10 KL capacity will be provided. The room

will be provided with OHT (Overhead trolley) suitable to handle the load of the

equipment

c) Fire hydrant system: Fire hydrant ring main covering all facilities will be

providedas per the OISD requirements. Double hydrants (with hose boxes, hoses &

nozzles) and fire water monitors as per the stipulations in the OISD-144 will be

provided.Long range Fire Monitors shall be provided in critical areas with remote

operation.

d) MV Spray system: As per OISD norms for Fire Protection System.

e) Fire Extinguishers: Shall be provided as per OISD norms

f) Deluge Valves: Auto reset type deluge valves having manual quick bypass system

asper OISD norms shall be provided with fire protection wall. Provision for





activationof DV shall be for auto and manual modes (local & remote panel) as per

OISD-144.

g) All the isolation valves used in Fire fighting system should be of rising stem type.

h) MCP: Manual Call Points at strategic locations as enumerated in OISD-144 shall

beprovided to raise alarm (siren) and also shut down LPG operations, in case

ofemergency with suitable hooter on annunciation panel at fire water pump house.

2.3.25 GAS MONI TO RIN G SYS TEM

Gas monitoring system with infra red / Catalytic type sensors shall be provided as

perrevised OISD standard-144. Mimic & repeater panels shall be provided at FWPH (Fire

Water Pump House) /Control room and security gate.

2.3.26 AIR COM PRESSO R / RECEIVE R / DRYE R

Two screw type integrated Air-compressorsalong with refrigerated Air dryers and air

receivers shall be providedto cater to the requirement of instrument air for carousel,

pneumatics, ROV etc.

Shed of Size 8m x 8 m shall be provided for housing this equipment adjacent to DGSets.

2.3.27 PL AN T SE C URI TY SYS TEM

The provision of following facilities shall be ensured:

1. Handheld metal detector for frisking

2. Door Frame Metal detector

3. Mirror trolley

4. Integrated Biometric Access Control System

5. Digital Surveillance through CCTV cameras with memory back-up for 30 days. All

criticalareas i.e. Admin Bldg, Filling shed, LPG Pump House, Tank Farm, TLD

Gantry,Parking and Gate areas to be covered under constant surveillance.

6. Perimeter surveillance

7. Sufficient High mast illumination in parking as well as for plant.

2.3.28 VAPO UR SE AL

Suitable vapour seals to be provided in storm water drain at the following areas:

Drains around filling & filled cylinder sheds

Bulk storage





Boundary

2.3.29 ELEC TRI C AL SYS TEM

Incoming supply will be taken from Jharkhand State Electricity Board preferably through

anindependent feeder to ensure uninterrupted power supply from grid.

2.3.30 BO RE WELL

Total water requirement will be 15 KLD. Bore wells shall be dug to meet the water

requirement. Suitable arrangement for storing and pumping drinking water shall be

made.

2.3.31 RO ADS

Bitumenised Roads 6.0 m wide and arterial roads connecting the main roads having width

of 3.5 m shall be provided inside the plant.

2.3.32 COM M UNIC ATI ON SYS TEM

The following systems to be provided:

Intrinsically Safe Paging System

PA System for announcement at gate

Inter-com at all working stations/points as per advice

Walkie-talkie for designated staff (VHF/UHF)

Display of carousel performance at TC cabin & Planning

2.4 PR O CESS PAR AME TE R S & DESIGN BASIS

The proposed LPG bottling Plant at Rayagada shall be designed based on the following

statutory codes / standards:

1. OISD Standard 144 Latest Revision

2. OISD Standard 150 Latest Revision

3. Static & Mobile Pressure Vessels (Unfired) Rules, 2016.

4. Gas Cylinder Rules – 2016

5. Explosives Act 1884

6. ASME / API / BIS Codes Pertaining To LPG

7. Factories Act – 1948

8. Electrical Installation Under Electricity Rules --1956





Basic process parameters of the new LPG Plant has been mentioned in the below Table

2.1.

Table 2.1: Basic Process Parameters

Particulars Proposed Plant Storage Capacity 3 x 300 MT Volumetric Water Capacity each vessel 690 m3 Plant Layout & Firefighting System As per OISD-144

Liquid To Be Handled LPG Density of LPG 0.5 gm/cm3 Design code BS 5500 (Latest Edition) Design Pressure 14.5 kg/cm2 gauge at Top 1.856

kg/cm2 gauge Radiography 100% before and after Post Weld

Heat Treatment Operating pressure 8-9kg/cm2, ambient Hydraulic Test Pressure As per code Design Temperature -27° C to + 55°C Corrosion Allowance 1.5 mm Wet Fluorescent Magnetic particletesting Required after PWHT Hardness checking of heat Affected Zone (HAZ) Required after PWHT Mapping of Plate Thickness Required Joint Efficiency 1 Length of Pressure Vessel 33000 mm (approx.) Diameter of Vessel 6000 mm Dished Ends Hemisphere Post Weld Heat Treatment (PWHT) Required Wet Fluorescent Magnetic particle testing Required after PWHT Cylinder Capacity To Be Filled 5/14.2/19/35/47.5/5/450 (Kg) Product Receipt By road LPG Cylinder Sheds Yes Property Land Demarcation Yes Licensed Area Demarcation Yes No of Tank Lorry Unloading Bays 4 Captive Power Generating Sets 2

2.5 FILLING/TES TIN G EQ UI PMEN TS

Details of filling and testing equipment have been mentioned in the below Table 2.2.

Table 2.2: Details of Filling and Testing Equipment

Units Numbers

Cylinder Washing Unit 1 Nos





Units Numbers

24 Station Electronic Carousal 1 No

Valve pin leak detector 1 No

O-Ring leak detector 1 No

Cap Hammering unit 1 No

Hot air sealing unit 1 No

Single CVT For SQC 1 No

CVT Verifier 1 No

Cyl. Evacuation Unit 1 No

Purging For New Cylinder 1 No

Hot Air Sealing System 1 Nos

Electronic Check Weigh Scale 1 No

Evacuation Vessels -500 Lts. Each 2 Nos

Weight Correction Unit With Weigh Scale (50 Grams LC) 1 No

On Line Test Bath 1 No

Roller Conveyor & Powered Conveyor System 300 m

2.6 SAFE TY PHILOSO PHY

LPG is a common material used extensively in households as well as industry. If its

characteristics are understood well and proper precautions as stipulated in various codes

and standards are followed, it is an easy and safe material to handle. Accordingly, in most

of the developed /developing countries, where LPG is consumed in million tons / year,

specific codes and standards are available for storing and handling of LPG.

2.6.1 LPG INS TALL ATIONS - CODES & STAN D ARDS

Codes and standards which are generally followed for LPG installations are as follows:

1. NPPA (National Fire Protection Association of USA) Standards - NFPA-58:

Standard for the Storage and Handling of Liquefied Petroleum Gases - NFPA-59:

LP-Gases at Utility Gas Plants

2. API (American Petroleum Institute) Standards - API-2510: Design & Construction

of LPG installations





3. IP (Institute of Petroleum) Standards - IP-9: Liquefied Petroleum Gas - Large Bulk

Storage of Pressurized and Refrigerated LPG

4. The Static and Mobile Pressure Vessels (Unfired) Rules, 2016 of India (SMPV

Rules)

5. OISD (Oil Industry Safety Directorate) Guidelines - OISD RP - 158: Recommended

Practices on Storage and Handling of Bulk Liquefied Petroleum Gas (LPG), 1997.

(This is being followed by Public Sector Refineries and Oil Industry in India. It is

currently a guide and not a mandatory code or standard). LPG storage tanks take

any other pressurized vessels may be designed as per any of thefollowing well

known international or local codes / standards:

ASME, Section VIII, Division I

ASME, Section VIII, Division II

BS 5500

IS 2825

2.6.2 MOUND ED STO R AGE F OR LPG

LPG is normally stored in above ground storage mainly spheres and cylindrical

tanks,namely, bullets & Horton spheres, the advantage being their accessibility for regular

inspection and maintenance which is important for such storage for hazardous service.

But these storages are susceptible to fire impingement and can give rise to Boiling Liquid

Expanding Vapour Explosions (BLEVE).

The reason for selecting mounded or buried bullets for LPG storage is to protect them

from direct flame impingement caused by any eventual fire in the surroundings and thus

prevent initiation of the sequence of events leading to an occurrence of BLEVE.

The mounded storage concept basically originated from Europe and specialized codes

exist in Germany such as:

DIN 4681 Tl: Statutory Steel Pressure Vessels for Liquified Petroleum Gases for Earth

Covered Installations, Dimensions and Equipment.





2.7 PHYSI C AL PR OPER TIE S OF LPG

LPG is mixture of propane and butane. The physical properties of LPG are described

below:

Product Composition : C3 & C4 mixture having nearly 50:50 composition

Liquid Density : 545 kg/m3

Molecular weight of Gas : 51

Heat capacity ratio of the gas

: 1.32 at 11.5barg and 25°C

Latent heat of vaporization : 16167 KJ/Kg mole at 11.5 barg and 25°C

Flash point : -104ºC - 60ºC

2.8 METEO R OLOGI C AL DATA

The climate of the Rayagada is typically tropical to subtropical with three distinct seasons

e.g. summer, winter, and monsoon. December is the coldest month with mean daily

average temperature of 20°C which reaches a maximum of 42°C in May. The rain fall in

the area is mostly from the south west monsoon lasts from middle of June to October. The

average annual rainfall varies from 1030.21 mm to 1569.50 mm.

2.8.1 METEO R OLOGI C AL CO NDITI ONS I N PROJ EC T ARE A

The meteorological and climatological data collected from India Meteorological

Department (IMD) for Bhawani Patna IMD Station has been considered for the study.

Temperature

The mean daily maximum temperature varies from 28.1 oC to 40.9 oC, while the mean

daily minimum temperature varies from 13.1 oC to 27.5 oC. Data collected from Bhawani

Patna IMD indicates that May is hottest month.

Mean Monthly Relative Humidity

Relative humidity is highest during August month (82% at 8:30 hr and 76 % at 17:30 hr)

and lowest during April month (34% at 8:30 hr) and March (26% at 17:30 hr).

Wind Velocity

Wind pattern in the area along the project road is given in Table 2.3.Theprevailing winds

are blown from S towards Nduring morning hours, whilewinds are blown from N towards

S during evening hours throughout year. Calm period is observed for 0 to 6% of the time.





PERCENTAGE NO. OF DAYS WIND FROM

Months

N NE E SE S SW W NW

Calm

(%) A

T 0

83

0

AT

17

30

AT

08

30

AT

17

30

AT

08

30

AT

17

30

AT

08

30

AT

17

30

AT

08

30

AT

17

30

AT

08

30

AT

17

30

AT

08

30

AT

17

30

AT

08

30

AT

17

30

AT

08

30

AT

17

30

January 19 11 4 2 2 1 1 0 2 0 4 1 13 11 24 27 31 47

February 8 8 5 2 3 2 2 1 4 2 8 2 15 17 19 24 36 42

March 6 7 5 4 5 4 5 3 10 4 9 5 16 22 11 21 33 30

April 4 7 13 9 14 14 14 8 17 9 10 5 8 13 3 11 17 24

May 3 6 15 15 25 21 17 14 15 13 4 3 2 3 3 6 16 19

June 2 2 10 9 22 21 25 25 21 16 3 2 1 1 1 2 15 22

July 1 1 8 7 20 18 19 19 22 17 4 3 2 1 1 2 23 32

August 3 1 9 8 23 19 20 17 18 14 1 2 1 2 3 2 22 35

Septembe

r

4 3 9 7 18 14 15 14 16 11 3 3 4 2 4 6 28 42

October 13 4 8 6 9 4 9 5 3 3 2 9 7 9 6 2 44 67

Novembe

r

25 8 10 3 2 1 2 1 1 0 4 5 24 19 1 1 31 64

December 28 11 4 2 1 0 0 0 1 2 1 8 7 1 33 24 24 55

ANNUAL

MEAN

10 6 8 6 12 10 11 9 11 8 4 4 8 8 9 11 27 4

0

Note: I and II indicate observations at morning (8.30 hrs) and evening hours (17.30 hrs),

respectively.

Source : IMD Station Bhawani Patna

Cloudiness

The skies are generally moderately to heavily cloud during the monsoon season and in

winter season. The skies are mainly clear or lightly clouded during the December to

March months.

Meteorological Data Considered for the Study

Dispersion of gases or vapours is influenced to a large extent by the atmospheric stability.

The various Pasquill stability classes are:

A Very Unstable

B Unstable

C Slightly Unstable

D Neutral

E Stable





F Very Stable

The stability class at a particular location is generally dependent upon:

- Time (Day or Night)

- Cloud Cover

- Season

- Wind Speed

Six stability classes from A to F are defined while wind speed can be any numeric value.

However, the number of stability class- wind speed combinations that needs to be

considered for formulating outcome cases in any analysis is very limited. This is due to

the fact that only certain combinations of stability class and wind speed occur. Thus, for

instance many combinations e.g. A-3 m/s or B-5 m/s or F-4 m/s do not occur in nature. As

a result only one or two stability class - wind speed combinations need to be considered

to ensure reasonable completeness of a Risk Assessment. Wind speed does not influence

consequence as much as stability class and for a given stability class, the influence of wind

speed is relatively less. On the other hand consequence varies considerably with stability

class for the same speed.

The following stability class and with wind speed combinations have been considered for

the calculation purpose:

Stability Class B and Wind Speed 3 m/s during day time (B – 3 m/s),

Stability Class D and Wind Speed 3 m/s during day and night time (D – 3 m/s) and

Stability Class E and Wind Speed 2 m/s during night time (E – 2 m/s).





CHAPTER3

HAZARD ANALYSIS





CHAPTER 3: HAZARD ANALYSIS

3.1 INTRO DUC TIO N

Liquefied Petroleum Gas (LPG) plantdeals with handling and storage of LPG, which is

generally hazardous in nature by virtue of their intrinsic chemical properties or their

temperature or pressure of operation or a combination of these. Hazardous Release, Fire,

explosion, or a combination of these are the hazards associated with proposed LPG plant.

These have resulted in the development of more comprehensive, systematic and

sophisticated methods of safety engineeringsuch as hazard analysisand quantitative risk

assessmentto improve upon the integrity, reliability and safety of LPG plants.

The primary emphasis in safety engineering is to reduce risk to human life and

environment. The broad tools attempt to minimize the chances of accidents occurring.

Yet, there always exists, no matter how remote, that small probability of a major accident

occurring. If the accident involves highly hazardous materials like LPG release in

sufficient large quantities, the consequences may be serious to the LPG plant, to

surrounding areas and the populations therein.

3.2 RISK ASSESSME NT AN D HAZARD ID EN TIFIC ATION

Riskis defined as the unwanted consequences of a particular activity in relation to the

likelihood that it may occur. Quantitative Risk Analysis (QRA) thus comprises of two

variables, magnitude of consequences and the probability of occurrence of accident.

The first step in quantitative risk assessment is identification of hazards. Hazardis defined

as a physical or chemical condition with the potential of accident which can cause damage

to people, property or the environment. Hazards are identified by careful review of plant

operation and nature of materials used. The various scenarios by which an accident can

occur are then determined, concurrently study of both probability and the consequences

of an accident is carried out and finally risk assessment is made. If this risk is acceptable

then the study is complete. If the risk is unacceptable then the system must be modified

and the procedure is restarted.

3.3 LIQ UEFIED PE TR OLEUM GAS (LPG)

Liquefied Petroleum Gas (LPG) is a colourless and odourless gas. It is highly flammable at

normal temperature and pressure (flammability limits 2.2% to 9.6 % in air), therefore





there should be no ignition sources in close proximity to areas where LPG is stored and

handled. On release it may give rise to both fire and explosion hazards. LPG is a blend of

Propane and Butane, readily liquefied under moderate pressure. LPG is 1.5 to 2.0 times

heavier than air, therefore, difficult to disperse. It should never be used or stored below

ground, as this could result in asphyxiation when released in a confined space. Since LPG

has only a faint scent, a mercaptan odorant is added to help in detection of its leakage

especially when used as a domestic fuel. In the event of a LPG leak, the vapourisation of

liquid cools the surrounding atmospheric air and condenses the water vapour contained

in it to form a whitish fog, which is easy to observe. LPG in fairly large concentrations

displaces oxygen leading to a nauseous or suffocating feeling.

Physical and chemical properties of LPG are as given below:

Boiling Point : -42 ºC - 0ºC

Vapour Pressure : 300 – 1400 kPa @ 40ºC

Solubility in Water @ 20ºC : <200ppm

Physical State : Liquid (gas at ambient pressure)

Colour : Colourless

Specific Gravity : Liquid 0.51 – 0.58 (water = 1)

Vapour 1.52 – 2.01 (air = 1)

Autoignition Temperature : 466.1 ºC

Flammable Limits LEL

Lower Flammability Limit (LFL) : 2.2% (in air v/v)

Flammable Limits UEL

Upper Flammability Limit (UFL) : 9.6% (in air v/v)

As part of LPG transportation, storage and bottling for local distribution, HPCL has opted

for mounded bullets for storage of LPG. Hence in this case, there is no possibility of

Boiling Liquid Expanding Vapour Explosion (BLEVE) as in the event of early fire, flame

impingement or heating of bullet will not be possible on mounded bullet. Therefore, from

mounded bullets, release of LPG is possible only from leakage in piping, valves or flanges,

etc.





3.4 HAZ ARDS F RO M LPG STO R AG E AN D HANDLIN G

3.4.1 BOILING LIQ UID EX PANDING VAPO UR EX PL O SION

A Boiling Liquid Expanding Vapour Explosion (BLEVE) occurs when there is a sudden loss

of containment of a pressure vessel containing a superheated liquid or liquefied gas from

above ground pressure vessels filled with LPG. The primary cause is usually an external

flame impinging on the shell of a vessel above the liquid level, weakening the container

and leading to sudden shell rupture. A pressure relief valve does not protect against this

mode of failure. It should be noted, however, that a BLEVE can occur due to any

mechanism that results in the sudden failure of containment allowing a superheated

liquid to flash, typically increasing its volume over 200 times. This is sufficient to generate

a pressure wave and fragments. It is resulted as fireball. In mounded storage vessels,

BLEVE will not be occurred, however in the event of fire in LPG tank lorries and LPG

cylinders, BLEVE is possible.

3.4.2 JET FIRE

If released LPG from hole/opening is ignited immediately, jet fire may take place. The

extent of injury to people depends on the heat flux and duration of exposure to heat.

3.4.3 VAPO UR CLO UD EXPL OSION

If released LPG is not ignited immediately, the cloud of vapour LPG will spread in the

surrounding area. LPG vapours are heavier than air and tend to settle down at lower level.

As long as the LPG concentration is between the lower and higher flammability limits, the

LPG vapour cloud may be set on fire by an ignition source. For generation of over

pressure effect, some degree of confinement of the flammable cloud is required.

3.4.4 FLAS H FI RE

When released quantities of LPG are not ignited immediately, vapour cloud of LPG

spreads in the surrounding area, some portion of LPG vapour cloud will have LPG

concentration between the lower and upper flammable limits, the LPG vapour cloud may

be set on fire by an ignition source in entire length of flammable LPG vapour cloud

resulting flash fire. In the event of flash fire, essentially, no over pressure effect is

possible.





3.5 HAZ ARD O US CO NDI TI ONS DUE TO RELE ASE OF LPG

As a result of release of LPG followed by immediate or delayed ignition, following

hazardous conditions may be encountered:

3.5.1 THE RM AL EFFEC TS

In case of jet fire, thermal effect is likely to cause injury or damage to people and damage

to objects. A substantial body of experimental data exists and forms the basis for thermal

effect estimation. The consequence caused by exposure to heat radiation is a function of:

Radiation energy onto the human body [kW/m2];

Exposure duration [sec];

Protection of the skin tissue (clothed or naked body).

The following damage distances for thermal radiation are used in the risk analysis:

37.5 kW/m2 : Damage to process equipment. 100% fatality in 60 s exposure. 1% fatality in 10 s exposure.

12.5 kW/m2 : First degree burn in 10 s exposure

4.0 kW/m2 : First degree burn in 30 s exposure

3.5.2 DEL AYED IGNI TION AN D EX PL OSION

In case of delayed ignition of LPG cloud, two physical effects may occur in following ways:

Flash fire over the whole or part of the LPG vapour cloud;

Vapour cloud explosion that results in blast wave with typical peak overpressures

in circle around the ignition source. Vapour cloud explosion to occur some degree

of confinement is essential.

TNO Multi-energy method is used to calculate the blast overpressure. Table 3.1 gives

extent of damage with respect to the peak overpressure resulting from a blast wave:

Table 3.2 given provides an illustrative listing of damage effects caused by peak

overpressure.





3.6 IDEN TIFIC ATI ON OF HAZ ARD FO R LPG UNL OADI NG, STO R AGE AN D BOTTLIN G

FACILI TIES

3.6.1 CATEG ORIES OF HAZ ARDS

For identification of hazards during unloading, storage and bottling of LPG, it is essential

to identify categories of hazard. Hazard categories, which may be responsible for

accidental release of LPG from proposed LPG bottling plant are listed in Table 3.3.

3.6.2 HAZ ARD IDEN TIFIC ATI ON (HAZID)

Hazard identification (HAZID) for the proposed LPG unloading, storage and bottling

facilities has been carried out for likely hazardous events which may cause major accident

hazards. A systematic investigation has been carried with special focus on external events

that could potentially impact the operation and safety of LPG unloading, storage and

bottling facilities. Table 3.4 gives for various potential consequence and safeguards for

likely hazardous events for the facility.

3.6.3 RELE ASE AND OUTCO ME SCEN ARI OS

Based on LPG unloading, storage and bottling facilities at the HPCL’s proposed LPG

bottling plant, maximum credible LPG release and outcome scenarios which may result

during LPG unloading, storage and bottling facilities are given in Table 3.5.

Table 3.1: Damage Effects Due to Overpressure

Peak Overpressure Extent of Type

0.830 bar Total Destruction

0.350 bar Heavy Damage

0.170 bar Moderate Damage

0.100 bar Minor Damage

Table 3.2: Illustrative Damage Effects due to Overpressures

Peak Overpressure (Bar) Failure

0.005 5 % Window Shattering

0.02 50 % Window Shattering

0.07 Collapse of a roof of a tank

0.07-0.14 Connection failure of paneling

0.08-0.1 Minor Damage to Steel Framework





Peak Overpressure (Bar) Failure

0.15-0.2 Concrete block wall shattered

0.2 Collapse of Steel Framework

0.2-0.3 Collapse of self framing Steel panel building

0.2-0.3 Ripping of empty oil tanks

0.2-0.3 Deformation of a pipe bridge

0.2-0.4 Big trees topple over

0.3 Panelling torn off

0.35-0.4 Piping failure

0.35-0.8 Damage to Distillation Column

0.4-0.85 Collapse of pipe bridge

0.5 Loaded Train Wagon overturned

0.5 Brick walls shattered

0.5-1.0 Movement of round tank, failure of connecting piping

(Source: TNO)

Table 3.3: Hazard Categories

Extreme Weather and Natural Disasters

High winds;

Squalls;

Lightning;

Earthquake; etc

Human Factors

Occupational accidents;

Improper and Inadequate training;

Non availability of SOPs; etc

Process Upsets

Pressure deviations;

Temperature deviations;

Flow deviations;

Level deviations; etc

Structural Failures

Subsidence;

Seismic;

Corrosion;

Fatigue; etc

Loss of Containment

Corrosion;

Change in fluid properties;

Deviation in Design / Operating Conditions;

Unloading activities;

Inspection and Maintenance

Confined Space;

Non Accessibility;

Reduced visibility;

Non availability of maintenance and inspection schedules; etc





Maintenance activities;

Human errors during:

-operations maintenance;

-Instrumentation; etc

Ignition sources:

- Electrical;

- Hot surface; etc

Table 3.4: Hazids for LPG Unloading, Storage and Bottling Facilities

Sl.No Hazardous Event Potential Consequences

Safeguards

1. Collision of LPG by bullet mounted truck duringtransportation of LPG to LPG bottling plant.

Release of LPG

Fire and Explosion

Training of drivers for safe driving

Transport Emergency (TREM) Card

2. Rupture or hole in Transfer piping from Unloading to storage facility at LPG Bottling Plant.

Release of LPG

Fire and Explosion

SOPs to be followed.

Supervision by trained operator

Regular inspection and maintenance of piping

3. Rupture or hole in bottom line of mounded bullets

LPG release

Fire and Explosion

Ensure corrosion protection

Ensure mechanical integrity time to time

Regular inspection and preventive maintenance of piping.

3. Pump Failure LPG release

Fire and Explosion

Ensure proper operating procedures

Preventive maintenance to follow

4. Failure of Valve LPG release

Fire and explosion

Ensure proper operating procedures

Preventive maintenance of pump

5. Rupture in piping from LPG release Ensure corrosion





Sl.No Hazardous Event Potential Consequences

Safeguards

Mounded Bullets to Bulk Loading Facility.

Fire and explosion protection

Ensure mechanical integrity time to time

Preventive maintenance to follow

6. Leakage from Bullet Truck

BLEVE

Fire and explosion

Proper connection of flanges

Ensure proper operating procedures during loading of bullet truck

7. Natural Disaster such as high winds, earthquake, etc

Damage to piping

LPG release

Fire and explosion

Follow relevant design standards to withstand natural disasters





CHAPTER 4

HAZARD & OPERABILITY (HAZOP)

STUDY





CHAPTER 4: HAZARD & OPERABILITY (HAZOP) STUDY

4.1 HAZOP STUDY FO R MOUND ED STO R AGE OF LPG

The proposed LPG plant at Rayagada will unload and store LPG in mounded bullets and

bottling will take place in cylinders.At the proposed plant, LPG will be handled with the

desired designed operating parameters like temperature, pressure, flow, level etc. In an

unlikely event of any deviation in operating parameters, hazardous conditions may be

arisen. Therefore, systematic Hazard and Operability (HAZOP) study has been carried for

storage and handling of hazardous chemicals. The main purpose of the HAZOP study is to

identify specific hazard and operability issues, which could lead to risks to personnel,

property and environment or operational problems during storage and handling of LPG.

4.2 METH ODOL OGY FO R HAZOP STUD Y

The methodology for the HAZOP was as adopted internationally as per guidelines of ICI,

UK and CCPS, AICHE. Hazard and operability (HAZOP) study was undertaken by the

application of a formal, systematic, and critical examination of the process and

engineering intentions of process design. The potential for hazard was thus assessed and

malfunctions of the individual items of equipment and the consequences for a whole

system were identified. The examination of the design was structured around a specific

set of guidewords, which ensure complete coverage of all possible problems while

allowing sufficient flexibility for an imaginative approach.

The overall aims that a HAZOP study addresses are:

i. To identify all deviations from the way the design is expected to work, their causes

and all the hazards and operability problems associated with these deviations.

ii. To decide whether action is required to control the hazard or the operability

problem and if so to identify the ways in which the problems can be solved.

iii. To identify cases where a decision cannot be made immediately and to decide on

what information or action is required.

Various terms with special meaning are used in conducting a HAZOP study. These

include:

Node Deviation

Parameter Cause





Intention Consequence

Guideword Recommendation

4.3 UNDER TAKIN G THE STUDY

The HAZOP study team considered each part of process design in turn by applying the

HAZOP guidewords and analysing the causes and consequences of possible deviations.

Thus, the study sessions followed through a series of steps repeatedly. The following

seven steps were repeated many times during the HAZOP.

a. Apply the guideword

b. Develop a deviation

c. Examine possible causes

d. Examine consequences

e. Consider hazards or operability problems

f. Decide upon action

g. Make a record of the discussions and decisions

4.4 FACILI TIES CONSIDE R ED FO R HAZOP STUD Y

For proposed LPG plant, four P&I Diagram named as DWG 1, DWG 2, DWG 3 and DWG 4

were considered for HAZOP study. These four P&I Diagramshave been shown in Figure

4.1 to Figure 4.4.

4.5 HAZOP WO RKS HEE TS

By following the above-mentioned methodology, HAZOP worksheets have been

developed for important nodes during HAZOP sessions. The HAZOP worksheets are given

in Table 4.1.





Table 4.1: HAZOP Results for LPG Handling System

Node 1: LPG Line from LPG Unloading Arm (TLD) to Mounded Bullet

Intention: To Transfer of LPG from Bullet Truck to Mounded Bullet Parameter : Flow

Sl.No Guideword Deviation Possible Cause Consequence Action Required

1. No No Flow in Liquid Line

Unloading Arm is not connected properly.

Ball Valve is closed.

Excess Flow Valve is closed.

Pump is not running.

Strainer is chocked.

Piping is chocked.

Rupture of transfer line

Operational Delay

Fire and explosion hazards.

Supervision by trained person during unloading for proper opening of desired valves.

Ensure proper safe operating procedures to be followed.

Unloading Arm should be tested hydraulically once in year and maintained in good conditions. If possible self sealing coupling to be used.

Clean strainer periodically.

Clean piping at regular interval.

Provide LPG detectors at strategic locations.





Node 1: LPG Line from LPG Unloading Arm (TLD) to Mounded Bullet

Intention: To Transfer of LPG from Bullet Truck to Mounded Bullet Parameter : Flow


2. Less Less Flow in Liquid Line


Leakage in cupping of unloading arm.


Piping is chocked.

Leakage or rupture in piping.

Release of LPG during transfer,


Supervision by trained person during unloading for proper opening of desired valves.






3. More More Flow in Liquid Line

Excessive differential pressure

Pump surging



Excess Flow Valve provided.

4. Reverse Reverse Flow in the line

Power failure and pump is not running.

Reverse flow in the line. Non Return Valve (NRV) has been provided.





Node 1: LPG Line from LPG Unloading Arm to Mounded Bullet

Intention : To Transfer of LPG from Bullet Truck to Mounded Bullet Parameter : Pressure


1 Low Low Pressure in LPG line




Piping is chocked.


Operational delay

Release of LPG during transfer,







2 High High Pressure in LPG line

Heating of piping by sun isolation

Unintentionally close valve

Due to thermal expansion of liquid trapped between any two valve

Pressurization and subsequence bursting of the LPG line


Thermal Safety Valve has been provided.





Node 1: LPG Line from LPG Unloading Arm to Mounded Bullet

Intention : To Transfer of LPG from Bullet Truck to Mounded Bullet Parameter : Temperature


1. Low Low Temperature in LPG line

Unloading arm is not connected properly.



Piping is chocked.


No issue

No issues

2. High High Temperature in LPG line

Heating of piping by sun isolation

Pressurization and subsequence bursting of the LPG line

Thermal Safety Valve has been provided.

Node 2: Vapour Line Between Compressor Discharge and Tank Truck at TLD Bay

Intention : Transfer of LPG Vapour from Tank Truck to Compressor Parameter : Temperature


1. None No Flow Line valve is closed High pressure in discharge line

Pressure Safety Valve and Pressure Gauge will be provided in discharge line.

High pressure trip system will be provided in LPG compressor








line.

Compressor is not working due to power failure, malfunction cooling water pump, and other reasons, low lube oil pressure, low suction pressure, high discharge pressure, etc,

Rupture of discharge pipe

Valve is not open.

Pipeline is chocked.

Delay in decantation.

Heating due to extra friction.

Compression Chamber may be damaged due to heating.


Back Pressure on compressor.

Low cooling water and low lube oil pressure trip will be provided.

Standby cooling pump will be provided.

Low suction trip and high discharge trip will be provided.

Gas monitoring system will be provided.

Firefighting facilities will be provided as per OISD standards.

On power failure, DG sets will be operated immediately.

ROV shut down in compressor suction line without Instrument air, if air compressor malfunction.

Delay in unloading of LPG. Standby Air Compressor will be available

Interlock will be provided to stop LPG vapour compressor incase low suction pressure.

2. Less Less Flow Leakage in vapour line

Any valve on discharge line or suction line is

Delay in decantation

Discharge line pressure will increase, Therefore,

High discharge pressure trip at LPG vapour compressor will be provided.








partly open

Pressure Safety Valve (PSV) at discharge line of LPG vapour compressor is partly open.

possibility of LPG release or rupture of line.

Fire and explosion hazards

Preventive maintenance of piping, valves, compressor will be done as per schedule and data will be maintained in SAP system.

Firefighting facilities will be readily available.

Gas monitoring system will be provided.

3. More More Flow Not Likely None None

4. Reverse Flow

Reverse Flow Due to error in line up piping connection

Compressor will trip.


Trip system will be provided in Compressor

5. Other Than Corrosion Pure LPG vapours are not corrosive but Mercaptan added to LPG to create odour, may corrode vapour piping.

Vapourpiping failure hence release of LPG vapour may occur.


Periodic inspection of pipeline will be done

Thickness of pipeline will be measured ultra sonically by CCE approved third party.








1. More High Temperature

Cylinder jacket of compressor is not being cooled properly.

Low flow of cooling water to compressor cylinder jacket and other part of compressor

Cooling water pump trip

The discharge line of compressor heats up due to external file or flame.

Vapour piping heated due to fire in vicinity.

High Ambient Temperature.

High pressure in suction and discharge line of compressor.

The compressor heats up and then fails /trips

Transfer pipeline may burst/leak due to high temperature and subsequently release of LPG


Cooling water interlocking pressure switch will be provided in the return line to ensure cooling water supply to compressor.

Compressors will have trip system at high discharge pressure

PSV will be provided in discharge line of compressor.

Gas Monitoring System will be available near compressors

Firefighting facilities will be available in compressor area

2. Less Low Temperature

Very low Ambient Temperature

None, since freezing point of LPG is -188 oC. Freezing condition in LPG vapour pipeline will not occur because lowest temperature in the area is

None








6oC.


Intention : Transfer of LPG Vapour from Tank Truck to Compressor Parameter : Pressure


1. Less Less Pressure Compressor is not working properly

Leakage LPG from piping

Vapour Compressor suction valve is partially closed.

Low ambient temperature in winter

Delay in decantation of tank truck

Fire & explosion hazards

There will be interlock that compressor will trip at low section pressure

Preventive maintenance of piping, valves and compressor is done as per schedule and data will be maintained in SAP system.

LPG detectors will be installed

Fire network will be available

2. More High Pressure Valve in discharge line of compressor fully or partially closed

High pressure in suction due to higher pressure in mounded bullets/piping

LPG release from PSV due to high pressure

Line gasket may rupture due to high pressure

Rupture/leak of LPG from piping

Compressors will have trip system at high discharge pressure

PSV will be provided in discharge line of compressor.

Gas Monitoring System will be






Intention : Transfer of LPG Vapour from Tank Truck to Compressor Parameter : Pressure


due to high ambient temperature/fire in vicinity

Failure of High Pressure Trip of compressor

Increase in discharge pressure

Fire and explosion hazard

available near compressors

Firefighting facilities will be available in compressor area .

Node 3: Vapour Suction Line Between Mounded Bullet and Compressor

Intention : Transfer of LPG Vapour to Compressor from Mounded Bullet Parameter : Flow


1. None No Flow Valve is not open.

Vapour line ruptured

Storage tank is empty

Low section pressure in compressor

Release of LPG, therefore, possibility of fire & explosion hazard

Low suction tripping system will be provided.

Pressure Indicator and Level indicator will be provided at mounded bullets.

ROV shut if no instrument air

Tripping of vapour compressor at low section pressure

Standby compressor will be available.

Mounded Bullets are mistakenly over filled up and no space for vapours.

Knocking of Compressor High level tripping system with alarm will be provided on mounded bullet. Hence, no possibility of overfilling of LPG in








mounded bullet.

Compressor break down due to power failure or other reasons

Decantation operation of tank truck stopped and operation delay.

DG sets will be operated automatically

Preventive maintenance of compressor will be done as per schedule.

High liquid level in knock out drum

Liquid may ingress in cylinders of compressor.

Low suction pressure in compressor.

Low suction tripping system will be provided in Compressor.

High Level Alarm in Knock out drum will be provided.

LIC will be provided in Knock Out drum.

Knock out drum will be drained daily

2. Less Low Flow Any valve is not open.

Leakage/partially rupture in the vapour line.

Less suction of LPG vapour and therefore low section pressure

Due to release of LPG fire and explosion hazards

Low suction trip will be provided in compressor

LPG detectors will be installed at strategic locations.

Preventive maintenance of piping,








valves will be done as per schedule

3. More High Flow More flow in case excess flow check valves not working

Heating of piping /mounded bullets due to high ambient temperature

Leakage of LPG from flange/burst of vapour line.


Pressure Indicator with alarm and sprinkler will be provided at mounded bullets

Regular inspection is done.

Preventive maintenance of excess flow check valves will be done as per schedule

LPG detectors will be installed.

Auto medium velocity sprinkler system will be provided and firefighting will be done as per requirement.

Firefighting facilities will be readily available

4. Other than Corrosion Pure LPG vapours are not corrosive but Mercaptan added to LPG to create odour, may corrode vapour piping.

Vapour piping failure hence release of LPG vapour may occur.


Periodic internal inspection of pipeline will be done

Thickness of pipeline will be measured ultra-sonically by CCE approved third party.








5. Reverse Flow

Reverse Flow

Due to error in line up piping connection

Compressor will trip.


SOPs for unloading of LPG will be followed

Node 3: Vapour Line Between Mounded Bullet and Compressor Suction Side

Intention : Transfer of LPG Vapour to Compressor from Mounded Bullet Parameter : Temperature


1. More Temperature Fire in the vicinity or high atmospheric temperature

Vapour pressure/ internal pressure rise in piping /bullet due to fire in the vicinity. It may cause SRV actuation hence fire hazards.

If SRVs fails to actuate or fire is not controlled bullet may rupture.

Two SRVs will be installed and will be actuated

Auto medium velocity water sprinkler system provided will bring down the temperature to normal.

Firefighting facilities will be available.



None, since freezing point of LPG is -188 oC. Freezing condition in LPG pipeline will not occur because lowest temperature at the area is about 6oC.

None






Intention : Transfer of LPG Vapour to Compressor from Mounded Bullet Parameter : Pressure


1. More High Pressure Higher pressure in mounded bullet due to high ambient temperature/

Fire/heating on external surface of piping or bottom line of mounded bullets

Vapour line may leak/ burst and subsequently release of LPG

Fire and explosion

Pressure gauge and High-level alarm will be installed.

Two sets pf SRVs will be installed at mounded bullets. Regular testing and calibration of SRVs will be ensured.

Auto medium velocity water sprinkler system will be provided to bring down the temperature to normal in case of heating of surface.

Fire hydrant ring will remain pressurized because jockey pump will be installed.

2. Less Low Pressure Leakage of LPG from piping

Vapour compressor suction valve is partially closed.

Low ambient temperature in winter

Fire & explosion hazards There will be interlock that compressor trips at low section pressure

Preventive maintenance of piping, valves and compressor will be done as per schedule and data is maintained in SAP system.

LPG monitoring system will be installed






Intention : Transfer of LPG Vapour to Compressor from Mounded Bullet Parameter : Temperature



Node 4: LPG Mounded Bullets

Intention : Storage of LPG in Mounded Bullet Parameter : Level


1. Low Low Level Leakage from bottom line.

Leakage from valve.

Leakage from bullets due to corrosion.

Less LPG in the mounded bullets

Release of LPG


Operation delay

Magnetic Level Indicator will be provided

Rocheste Gauge will be provided

SGTP Tube Gauge provided

Cathodic protection will be provided to bullets to prevent corrosion.

Regular inspection and maintenance to maintain integrity of bullets and piping.

2. High High Level Initial quantities in bullet not ascertained faulty level gauge

Human Error in Reading

Over filling of LPG in Bullets

LPG Release

Possibility fire and

High Level Alarm will be provided

Magnetic Level Indicator will be provided

Rocheste Gauge will be provided






Intention : Storage of LPG in Mounded Bullet Parameter : Level


of Rochester Gauge

Fire near mounded bullets

explosion SGTP Tube Gauge provided

Ensure proper operating procedures.

Calibration and maintenance of level gauges.


Intention : Storage of LPG in Mounded Bullet Parameter : Pressure


1. Low Low Pressure Low Ambient Temperature -- --

2. High High Pressure Due to Heat isolation by sun


Possibility of release of LPG

Possibility fire and explosion

Pressure indicator provided.

Temperature indicator provided.

Safety Release Valve (SRV) provided at the bullets.






Intention : Storage of LPG in Mounded Bullet Parameter : Temperature


1. Low Low Temperature

Low Ambient Temperature

-- --

2. High High Temperature

Due to heat isolation by sun




Pressure indicator provided.

Temperature indicator will be provided.

Safety Release Valve (SRV) to be provided at the bullets.


Intention : Storage of LPG in Mounded Bullet Parameter : Water Draining


1. Other Than Other Than Water

Operational Error



Water draining to be done under strict supervision

Written instruction on water draining mechanism to be displayed near drain point.





Node 5 : Inlet/Outlet Liquid LPG Pipeline From Mounded LPG Bullets to LPG Pump

Intention : Transfer of LPG from Mounded Bullet to Pump for Cylinder Parameter : Flow


1. None No Flow Valve on inlet/outlet piping to pump suction is closed.

Inlet/out pipeline chocked.

No LPG in the mounded bullet

ROV on storage tank outlet line is shut without instrument air.

Rupture in pump suction line

Operation delay

LPG pumps heat up due to increased vibration on account of cavitations developed in the pump due to dry running.


Level Indicator (LI) and Pressure Indicator (PI) will be provided at mounded bullets.

Pressure Indicator will be provided in transfer piping.

Pipelines will be cleaned after each two years.

Standby Air Compressor will be available.

Interlocking system will be provided so that if there is no flow of LPG from mounded bullets to pipeline, pump should trip.

Strainer will be provided on suction side of pump which will be cleaned at regular interval.

Regular inspection and maintenance of piping will be ensured.


2. Less Low Flow Valve on pump suction piping to pump suction

Operation delay

Due to less supply of

SOPs will be available and followed to ensure opening of valves on inlet/out








is not properly open.

strainer is partial chocked.

Inlet/out pipeline leaking.

ROV is partially open due to malfunction.

Leakage in LPG pump suction line/Gasket Failure

LPG, vapur locking may occur in pump.


let piping to pump suction.

Regular testing and calibration of ROV will be ensured. Standby Air Compressor will be available.

Maintenance of piping and flange/gasket will be ensured.

Strainer will be cleaned regularly.

LPG detectors will be installed at strategic locations.


3. More High Flow More flow in case of excess flow check valves is not working

Heating of piping / bottom line of mounded bullets due to high ambient temperature

Release of LPG due leakage from piping/ burst of piping.


Pressure Indicator with alarm and sprinkler will be provided at bullets

Preventive maintenance of excess flow check valves will be done as per schedule

LPG detectors will be installed.

Auto Medium velocity sprinkler system will be provided as bullets.

Firefighting facilities will be readily








available

4. Reverse Reverse flow of LPG inlet/out let piping

Not Likely Operation Malfunction As precautionary measures Non Return Valve (NRV) will be provided on the bullet side as well as on pump suction side.

5. As well as Flow of Foreign Material along with LPG

Flow of water along with LPG.

No hazardous consequence only water will go along with LPG

Water draining will be done in bullet as per SOPs.

Node 5 : Inlet/Outlet Liquid LPG Pipeline From LPG Bullets to LPG Pump

Intention : Transfer of LPG from Bullet to Pump for Cylinder Parameter : Temperature



External fire on inlet/outlet pipeline or bottom line of mounded mullets

High Ambient Temperature

Due to high temperature, pressure will increase. Therefore, leak/ rupture in piping/ bottom line of mounded bullets

Rise in pressure in

Temperature indicator and pressure indicator will be provided.

Two SRVs will be provided on bullets.

Fire hazards near LPG piping will be allowed.

Gas monitoring system will be provided at strategic locations






Intention : Transfer of LPG from Bullet to Pump for Cylinder Parameter : Temperature


piping/mounded bullets

Fire & Explosion

Auto Medium Velocity Sprinkler system will be provided at mounded bullets for cooling in the event of fire.




None, since freezing point of LPG is -188 oC. Freezing condition in LPG pipeline will not occur because lowest temperature at Rayagada is about 6oC.

None


Intention : Transfer of LPG from Bullet to Pump for Cylinder Parameter : Pressure


1. More High Pressure External fire on Inlet/outlet pipeline or bottom line of mounded bullets

Pipeline leak/rupture

Fire & explosion

Fire hazards near piping will not be allowed.

Gas detectors system will be provided at strategic locations

Fire hydrant system will be readily






Intention : Transfer of LPG from Bullet to Pump for Cylinder Parameter : Pressure



available to extinguish fire at initial stage

Two sets SRVs will be available at bullets. Proper functioning of SRVs will be ensured.

Medium velocity water sprinkling system will be provided on the mounded bullets.

2. Less Low Pressure Pipeline leak/rupture

Low Ambient Temperature

Fire & explosion

Preventive maintenance of piping will be carried out.

LPG detector will be installed


Node 6 : LPG Pump Discharge Line to Carousel Machine for Cylinder Filling

Intention : Pumping of LPG through Pump for Cylinder Filling Parameter : Flow


1. None No flow LPG Pump not working and all liquid LPG going back to suction line

Operational delay

Cylinder filling process will be stopped

Level gauge with alarm and interlock will be available at mounded bullets.

In the discharge line, pressure








through circulation line

Outlet line valve erratically closed

ROV is closed due to malfunction.

Pipeline is chocked.

LPG liquid discharge line ruptured

Stanier is chocked

Pump is not operating due to power failure Grid power failure

Mounded bullet is empty

automatically

Pump will run dry and possibility of damage

Release of LPG and possibility of fire and explosion.

indicator will be provided

Regular checking of motor/pump fault, impeller mechanical seal failure preventive maintenance of pump and motor will be done,

Preventive maintenance of piping and valves will be carried as per schedule and records will be maintained in SAP System.

If power failure, DG sets will be operated immediately.

2. Less Low flow Strainer is partially chocked.

Line valve is partially open

Leakage in discharge line /LPG pump

Gasket failure

Operational delay in filling of cylinders

LPG pump will lose its Net Positive Suction Head (NPSH).

LPG leakage may result in fire & explosion hazards

Pressure gauge will be provided at pump discharge line near carousel

Tripping system will be provided and it will trip pump as soon as it loose Net Positive Suction Head (NPSH).

Standby pump will be provided.

Regular checking of pumps and








pipeline desired.

Preventive maintenance of pump and piping will be followed,

Gas detectors system will be provided at strategic locations.

Fire fighting facilities will be available.

3. More High Flow High storage pressure in mounded bullets due to high ambient temperature/ fire in the vicinity.

Gasket failure and subsequently release of LPG

Fire and Explosion Hazards

Fire fighting facilities will be readily available.

Medium velocity water sprinkling system will be provided on mounded bullets.

4. Reverse Reverse flow of LPG inlet/out let piping

Pump Trip Operation Malfunction

Delay in Cylinder Filling

As precautionary measures Non-Return Valve (NRV) on the bullet side as well as on pump suction side will be provided.

Stand by pump will be available

5. Other than Corrosion Pure LPG is not corrosive but Mercaptan added to LPG to create odour, may corrode pipeline.

Pipeline corrosion hence possibility of release of LPG.

Periodic internal inspection of pipeline will be carried out at every 5 years to detect any corrosion.








6. As well as Flow of Water as foreign Material along with LPG

Flow of water along with LPG.

No hazardous consequence only water will go along with LPG

Water draining will be done as per established procedure.

Node 6: LPG Pump Discharge Line to Carousel Machine for Cylinder Filling

Intention : Pumping of LPG through Pump for Cylinder Filling Parameter : Tempretaure



Fire in vicinity of piping


High pressure in storage tank and subsequently high pressure in suction and discharge line.

Vapour locking in pump may affect pumping rate.

If temperature raise is not controlled piping may leak or rupture,


Fire hazards near piping, mounded bullets will not be allowed. Gas monitoring system will be provided at strategic locations Fire hydrant system will be pressurized and readily available Medium velocity water sprinkling system will be provided on the mounded bullets to cool the surface.






Intention : Pumping of LPG through Pump for Cylinder Filling Parameter : Tempretaure




None, since freezing point of LPG is -188 oC. Freezing condition in LPG pipeline will not occur because lowest temperature at Rayagada is about 6oC.

None


Intention : Pumping of LPG through Pump for Cylinder Filling Parameter : Pressure


1. More High Pressure Suction line pressure higher than normal

High storage pressure in mounded bullets

External fire on Inlet/outlet pipeline or bottom line of mounded bullets


The discharge line subjected to higher pressure

Line gasket failure and release of LPG

Fire and Explosion Hazards

Two SRVs provided at each mounded bullets

Pressure Indicator and Level Indicator will be provided in mounded bullets each.

Two ROVs will be provided at each mounded bullets.

Pop Action relief valves will be provided in the pipe line segments to take care of higher discharge pressure.






Intention : Pumping of LPG through Pump for Cylinder Filling Parameter : Pressure


Medium velocity water sprinkling system will be provided.

Gas monitoring system will be provided at strategic locations

Fire hydrant system will be pressurized and readily available

2. Less Low Pressure Leakage from Pump/Discharge PipingLow Ambient Temperature

Delay in cylinder filling Release of LPG Fire & explosion hazard

Pressure gauge will be provided in discharge line near carousel machine. Two ROVs provided at each bullet bullets

Preventive maintenance of piping and valves will be carried as per schedule.







Node 7: LPG Cylinder Filling Machine

Intention : Filling of LPG in Cylinders through Rotary Machine Parameter : Flow


1. None No Flow LPG pump not working

LPG discharge line/hose is chocked or ruptured

Filling gun hose is ruptured

Filling gun detached from cylinder at carousal

Filling operation will be stopped and delayed

Release of LPG gas/vapour


Regular inspection and testing of discharge line/hose, and filling gun will be carried out and records will be maintained.

Necessary hydrostatically/ pneumatically tests for pipeline and thickness measurement ultrasonically will be carried out.



Earthing and bonding of filling machine, piping, hose and gun will be ensured.

Electrical continuity tests will be carried out once in 4 months.

2. Less Low Flow LPG discharge line/hose is partially chocked

Filling gun hose is leaking

Operational delay in filling of cylinders.

Release of LPG gas/vapour

Fire and explosion

Regular inspection and testing of discharge line/hose, and filling gun will be carried out and records will be maintained.









LPG pump not running at its rated capacity

hazards


Earthing and bonding of Filling machine, piping, hose and gun will be ensured.

Electrical continuity tests will be carried out once in 4 months.

3. More High Flow Not Possible None None

4. As well as Flow of Foreign Material along with LPG

Water draining is not done in bullets on regular basis. Therefore water is pumped along LPG and filled with LPG in cylinders

No hazardous consequence, only water will filled along with LPG in cylinders

Water draining will be done as per established procedures.

5. Other than Corrosion Pure LPG is not corrosive but Mercaptan added to LPG to create odour, may corrode pipeline.

Pipeline/hose/gun corrosion hence possibility of release of LPG.

Periodic internal inspection and testing of pipeline/hose/filling gun will be done by CCE approved third party.

Cylinders will be tested at regular interval.

6. Reverse Reverse flow Not likely Operation Malfunction Non Return Valve (NRV) will be








provided.


Intention : Filling of LPG in Cylinders through Rotary Machine Parameter : Temperature


1. More High

Temperature

Fire in vicinity of

piping/LPG cylinders

filling shed

If temperature raise is not controlled, piping may leak or rupture,



Gas detectors system will be provided at strategic locations

2. Less Low

Temperature

Very low Ambient

Temperature

None, since freezing

point of LPG is -188 oC.

Freezing condition in

LPG pipeline will not

occur because lowest

temperature at

Rayagada is about 6oC.

None






Intention : Filling of LPG in Cylinders through Rotary Machine Parameter : Pressure


1. More High Pressure Not Possible None None

2. Less Low Pressure in LPG Header at Carousel machines

Carousel machines started without working of LPG blower.

Malfunction of Differential Pressure in line

Leakage from pipe/ hose.


Interlock between Carousel Machine/ Filling Gun and exhaust fan is not working properly.

Less flow resulting in slow rate of LPG filling in cylinders. Desired inlet pressure is 15 to 17 kg/cm2.

Accumulated vapour on the flow/ below carousel machine can result fire and explosion hazards.

Interlock between Carousel Machine/ Filling Gun and exhaust fan interlocks will be provided.

LPG detectors will be installed. Medium velocity water sprinkling

system will be provided. Fire hydrant system will be

pressurized and readily available


Intention : Filling of LPG in Cylinders through Rotary Machine Parameter : Quantity


1. More More Quantity More Quantity of LPG In Cylinder due to malfunction of filling gun.

Excess quantity of LPG in cylinder may increase pressure in cylinder resulting

SOP for weight setting will be followed.

Over filled cylinders will be evacuated.






Intention : Filling of LPG in Cylinders through Rotary Machine Parameter : Quantity


Wrong Selection of tare weight settling

leak or burst of cylinder.

Checking scale will be provided with counter checking

Medium velocity water sprinkling system will be provided in cylinder filling area

2. Less Low Quantity Leakage from pipe/ hose


Less quantity of LPG in Cylinder due to malfunction of filling gun.

Leakage of LPG from ‘O’ ring or cylinder valve

Less flow resulting in slow rate of LPG filling in cylinders


Filled cylinder leakage will be tested by complete immersion in water bath.

Preventive maintenance of piping and valves will be carried as per schedule.

LPG detectors will be installed Fire hydrant system will be

pressurized and readily available Regular checking scale will be

provided with counter checking. Medium velocity water sprinkling

system will be provided in cylinder filled area





Fig 4.1: P&ID for LPG Receipt and Unloading (DWG 1) for Proposed LPG Plant at Rayagada





Fig 4.2: P&ID for LPG Storage (DWG 2) for Proposed LPG Plant at Rayagada





Figure 4.3: P&ID for LPG Storage and Transfer (DWG 3) for Proposed LPG Plant at Rayagada

quantitative risk analysis report capacity lpg...

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