University of Nairobi Quantitative Risk Assessment & HAZOP and Risk Analysis

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Question Description

Q1)The elimination of hazards is the first order of safety. The control of physical condition is basic and frequently difficult in a plant and it requires the best of scientific, engineering and management information for its accomplishment. The evaluation and control of mechanical and physical hazards encompass four engineering aspects: design, construction, operation and maintenance.

Choose a suitable process industry and conduct a HAZOP and risk analysis study for a particular section of the industry or the total plant. List out the various factors and identify the issues taken into consideration about the discrepancies in the design, operation, control and maintenance of the plant. Through this analysis also bring out various protection methodologies presently adopted by the industry and discuss its ability in meeting the safety norms and standards.

Q2) Industrialization and related activities in the last few decades resulted in many issues with the use and handling of hydrocarbons and other components used in oil and gas process industry. Major accidents represent the ultimate, most catastrophic way in which a process industry project can go wrong. Accidents cause death, suffering & pollution of the environment and disruption of business. To minimize accidents it is highly important to assess and analyze various risk scenarios associated with the industry and projects.

Briefly explain about Quantitative Risk Assessment (QRA) techniques and mention its basic difference from other type of hazard analysis. Explain the objectives, methodologies and the procedural steps adopted in QRA. Choose any process industry and by using process flow diagram (PFD), briefly describe its salient features. Identify all possible hazards in the chosen section of the plant and tabulate process parameters (make suitable assumptions).List out minimum five failure scenarios and asses the risk quantitatively by assuming suitable failure frequencies

Note:

Q1) minimum 2000 words Q2) minimum 2000 words

- Paraphrase

- include relevant calculation, and justification wherever necessary.

Include relevant pictures, diagrams, charts, graphs, tables etc. Give proper in-text-citations and reference (APA/Harvard style)

- include conclusion for etch quotation

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Hazard Identification and management in oil and Gas industry using HAZOP In this section, we will discuss how to conduct in detail an HAZOP study for a speciific example, which I will illustrate you step by step. So, this section is dedicated to hazard identification and management in oil and gas sector using HAZOP methodology. Let us quickly recapitulate why and what are all the important factors which lead us to do HAZOP study. Oil and gas industry plays a major role in world's economy. Huge investments are made to upkeep the facilities in order to increase the production capacity, even marginally. Any accident like blowout, oil spill, operational problems, shall cause heavy economic loss to the industry. Several techniques are available to identify and assess these hazards. For example, hazard and operability study which we call as HAZOP which are now focusing in the present lecture. Failure mode effect analysis which is called FMEA, which we will discuss in the subsequent lectures. Quantitative risk assessment (QRA), which we will discuss in the next module. Event tree analysis and fault tree analysis ETA and FTA respectively which we will discuss in the subsequent modules. Let us quickly recapitulate that HAZOP is actually applicable at four stages of operation. You can apply HAZOP at the drawing board stage which we call as a design stage. You can also apply HAZOP at the construction stage or the process stage. You can also apply HAZOP when you want to make any process modifications or finally, you can also do an HAZOP study once the accident has occurred. We specifically call this kind of action as accident investigation report - AIR. Now, I want you to take through a case study which we will discuss and prepare an HAZOP report for this case study. This is actually an application problem of a group gathering station. I hope you all understand what do I mean by a group gathering station. I will explain very briefly what is the segment of analysis of a GGS considered in the present study. I have identify group gathering station and tried to located the hazard and operability problems of that station because a group gathering station in general has potential to cause damage to the operation plant personnel and environment as well. So, the objective of this study could be to eliminate or to reduce the probability and consequences of incidence. Remember the catch word here is not an accident. Incident is related to hazard, hazard is a scenario. As long as the hazard or the scenario is not realized into an accident, there is no risk. So, to eliminate or reduce the probability and consequence of incidents in the installation and an operation of a group gathering station. So, this HAZOP study is applied to a GGS at the installation and operation stage itself. I have used a software by name PHA-pro version 7 for preparing the HAZOP worksheet. You can recollect that HAZOP worksheet can be recorded in two formats. You can have a full recording format which includes all possible deviations from the design intent given therefore, the report is very comprehensive. So, here what I am describing to you is a full recording format of an HAZOP worksheet which is prepared or generated using a software by name PHA-pro version 7.0. Let us quickly go through the methodology how this case study was done. In a given group gathering station from the piping and instrumentation diagram given to you in detail, study carefully the P and I diagram and identify at least one section of the plant. Now, we call this section identified as node in the study. Now, for that identified section of the plant of the group gathering station define the design intent and the normal operational conditions of this section. Once you have defined the design intent then identify subsequently at least one deviation of this design intent or operating conditions by now applying a system of guide words. Recollect that the guide words are primary and secondary keywords which we discussed in the last lecture. Try to make a list of possible keywords which can be appropriately used for the selected problem like a group gathering station. Pick up those appropriate keywords and try to list them before you start doing an HAZOP study. Then identify the possible causes related consequences and existing safeguards for the identified deviations. Based on your detailed investigation carried out on this level, suggest or recommend actions to reduce or to eliminate these deviations. Finally record the complete discussions you have or you intend to have with the management and also what recommendations you propose in terms of reducing or eliminating or mitigating the envisaged risk on the plant. These are as 8the following six steps of what we will do to carry out the HAZOP report for the case study of the group gathering station. Now, the case study considered is a group gathering station I have a figure of the station in the next slide. So, this is the group gathering station. I will explain this process very quickly using this figure then I will explain what is actually happening in each of them slightly in detail. This is a process and flow diagram of a GGS. There are many manifolds which supply oil from the wells which are a type of non enhanced oil recovery feed. I call them as group header, because the name group header qualifies that this is a header which collects from different groups of wells in one. So, I can have many number of group headers. Here in this P and ID, I have got two set of group headers - group header one and group header two. The group header one and two receive the oil supply from the drilling well to this collection point. From the group header one and two, the substance or the content starts flowing to what we call as bath heater. There are many bath heaters located in this scenario, there are about five in numbers. I simply say one to five. The purpose of a bath heater is, it will separate oil, water, and gas from the accumulated substance from group header one and two. To do this, I need a chemical dosing tank for enhancing this process. So, I supply a dosing chemical from this tank to this bath heater. This diagram do not show any of the instrumentation and the valves located because this is simply a process flow diagram. If you want to look at the location of valves and other pressure gauges and instrumentations in the system you should look at what we call as process and instrumentation diagram. So, from the PFD diagram once the substance is collected in the bath heaters which is separating oil, water, and gas from the inlet substance the gas collected is transferred to what we call as flare stack. The oil collected and the water together will be sent to what we call as enhanced recovery tank. The recovery tanks ER, there are about five to eight in numbers in this process. Then the substance is forwarded further to what we call as jumbo heater. The jumbo heater again further purifies oil and water, and whatever content of water has been separated, it has been taken to what we call as ETP. ETP is effluent treatment plant. The oil purified here or separated here is collected in a storage tanks one to four, from the storage tanks one to four the oil is further dispatched through the pump house to a common tank facility from where it will be distributed. So, this is one segment of the process and flow diagram, which is under the present scope of study. These are the nodes which I keep on marking in my P and FD. So, the well fluid emulsion received at the limits of GGS is distributed to three production manifolds. From the main group header well fluid goes to the bath heaters for the first stage of purification where they separate oil, gas and water. The separated oil is subsequently stored in the emulsion recipient tanks, which are called as E R tank associated gas is then separated out and sends to what is called flare stack. The separated water goes to effluent treatment plant what we call as ETP. From the emulsion recipient tank, oil is then subsequently fed to jumbo heater through the feed pump, for further refined treatment. In jumbo heater, further separation of oil and water takes place. The separated oil is then subsequently pumped to what we call as a common tank forum. So, this is my process and flow diagram which I am going to concentrate, and based on this diagram and understanding the process I am going to now do an HAZOP study. Ladies and gentlemen, before we start doing an HAZOP study, we should first understand what is exactly the process happening in the case, and how the flow takes place. Based on this understanding, we should be in a position to select the design intents of different nodes or segments in this case. Subsequently appropriate deviations can be identified, because to prepare a HAZOP report primary and secondary keywords are important. Primary keywords associate to design intent and secondary keywords are associated with deviations. And only this segment of the group gathering station is now currently considered for the HAZOP study. If you have any questions please play back the couple of slides earlier, and try to understand the component level functioning of each one of them for a better understanding of HAZOP report. Remember, if you do not understand the process and the flow sequence of a given PFD, I am sure you will not be able to successfully prepare an HAZOP report. HAZOP report is a perseverance of possible deviations from the design intents of a given process plant. So, mandatory is to understand the process first. I presume you have understood the functioning of a group gathering station. You have understood the importance of the selected nodes in the group gathering station discussed in the previous slide. Now, taking forward or the HAZOP worksheets, which we are going to prepare using a software PHA-pro. For example, let me identify the first node. Name the node as one. Remember this is not a typed excel sheet this is an outcome or a screen saved from basically the software output. So, the software output says node one identified is given as group header which is basically a twelve inches pipe designates 102-A3A class. The deviation from the design intent is low no flow. And the type is a pipe line. So, basically you are talking about a flow, and the deviation could be either there is no flow in the line or there can be a low flow in the line. The design conditions and parameters considered for the study are the following. The liquid rate is about 2500 cubic meters a day. The gas flow is negligible, the operating temperature in pressure 50 degree Celsius and 10 kg per centimeter square. The viscosity of the oil is about 270 cp. And the density at operating temperature is about 966 kg per cubic meter. For the design intent and the deviation identified for the flow to be either low or no what are all the possible causes, what could be the consequence, what could be the safeguard and what are the recommendations, I will focus this specific column slightly later. Let us first identify the first class which can result from either a low or a no flow on a pipe segment twelve inches diameter from a group header. There could a possible leak or rupture on the header, if there is a leak or rupture you can very well understand there could be either no flow or there could be low flow. The consequence this leads to a fire and environmental hazard. There can be loss of material, the process can become upset. So, all these possible consequences are subsequently numbered in an order, even all the causes are also subsequently numbered in an order. You may wonder why this numbering is significantly important. This is necessary, because when we generate a report later by identifying the number I can easily access any specific cause or any specific consequence for any specific deviation in the report. That is electronically possible, because this is software generated report. So, wherever you see any of these recommendations given it automatically generates a number associated under a specific heading. For example safeguard one for example, a new cause again 1, 2, and so on. So, there is an order, there is a format, there is a protocol which is a software initiates by itself, it is very easy and necessary understand why this has happened. After identifying the possible consequences for the causes resulting from these deviation on a twelve inches flow pipe line of a group header, which is operating under the following pressure and temperature, let us examine is there any safeguard present in the system. Remember the availability of safeguard is not seen in process flow diagram, you must look for process and instrumentation diagram. Once you looked at the process and instrumentation diagram, you will know what are the possible existing safeguards or recommended safeguards. For example, these specific case fire protection systems are available in position in the GGS. Considering the due regard for the existing safeguards in the system we recommend the following; the pressure transmitter to be provided for the group header line just to check whether the pressure can record a low flow, because pressure and flow are related anyway quantitatively. So, if my group header has a low flow, because of rupture, if a pressure transmitter is fitted at least from the pressure transmitter reading one will come to understand that there is a problem of this deviation in the line. Number two recommendation: Do periodic hydro testing for the pipelines. Hydro testing is a physical examination category which will tell how a pressure to be maintained in an existing pipeline. We also recommend periodic inspection must be carried out, and thickness measurement of the line to be done. The thickness measurement will give me an idea about the quality and standard of lifetime of the pipeline, because if this is corroded or is the crude deposit is happening along the surface of the pipeline, because if the diameter is effectively reduced, pressure will enormously increase whereas, the flow will not be affected. So, you will be able to understand that by measuring thickness. You can also avoid some further more consequences or deviations on the existing line. When you look at the next cause; for example, isolation valves - in the inlet crude oil line. The inlet crude oil line may have an isolation valves, the isolation valves can also result in a consequence. It can result in pressurization of an upstream section the process can be upset. The safeguards could be pressure gauges are already available to tell whether the pressurization is being done or not, a non-return valve is available just to check that the process is not very seriously upset in the lines. There are also bypass lines available in this GGS, in case any such problem occur, I can bypass this from this line to next line. However, we still recommend the following. A pressure transmitter is to be provided to check whether the pressure is available properly or maintained properly in the line. Of course, we also recommend periodic inspection. Now, you may see here very carefully that the recommendation column has a sequence number 1, 2, 3. Now, three relates to periodic inspection, four also relates to periodic inspection. So, two qualitative recommendation cannot have the same number, because this is periodic inspection and thickness measurement this is a different kind of recommendation, this is periodic inspection and maintenance of isolation valve this is different kind of recommendation. So, whenever in the report you start typing, these kinds of keywords in the software, the new number is automatically generated. Let us look at the further cause, cause number three. Non return valve in inlet line on the oil group, it can result in pressurization of the upstream section, it can also safeguard is there using a pressure gauge, but we recommend to provide a pressure transmitter and a period inspection of and maintenance of non return valve. Ladies and gentlemen, remember that when you say a recommendation of pressure transmitter is to be provided for a GGS it gets the number one, which is as same as the number one what you already have in the previous recommendations. So, you can easily identify that there is no overlap of this numbering in any such situations, and so on and so forth, keep on analyzing the drain valve, the consequence then the safeguard and recommendation. Then choking of the inlet crude oil, the consequence could be pressurization, process can be upset, though pressure gauge is available, you put a pressure transmitter has the same number as it has been given earlier. When you enter for the first time in the software any such kind of recommendation it generates a number automatically, and later on when you try to invoke this particular recommendation the number is carried forward as a constant number through and through of the report. So, absolutely there is no overlap of any specific recommendation. Now, there is a great advantage of this kind of common numbering, because if you really wanted to know what is that recommendation of pressure transmitter to be fixed, simply type this number one in the through and through report, it will easily access and tell me where this recommendations are to be implemented? For example, the recommendation one should be implemented in NRV in the inlet line, in the drain valve in the inlet line, to avoid the chocking of the inlet line; all locations I have to install a pressure transmitter. So, I can easily know where are the nodes which can address what cause this recommendation is satisfied. So, this numbering is having a very exclusive and explicit advantage in recording. Look at the periodic inspection just for recollection, the moment I say periodic inspection it compares existing number and periodic inspection and thickness of measurement of inlet crude oil line is having a different number seven like this. So, let us say, node. The second deviation which is high low, the previous deviation was low or no flow, the type is a pipe line. The conditions of operation remain same. The cause can be if there is a high flow; the high flow from upstream section of this node can cause a pressurization of the line you can already regard for the pressure safety valve provided in the line, but still we recommend to put or install a pressure transmitter in the group gathering line. The recommendation is common for the previous deviation the number is carried forward in the same pressure. Now also remember, if you have already have an existing safeguard like a bypass line etcetera, again the number is carried forward from the previous recommendation. Like this manner, we can keep on identifying different kinds of primary and secondary keywords, identify the deviation, identify the causes, subsequently consequences, check for the existing safeguards, and keep on recommending, whatever action can be deemed fit to either eliminate the consequence completely or to reduce the effect of this consequence on the process. Let us now focus on this specific column, where I am generating what I call as a risk matrix. This particular column has three sub division as you see here. S L and R R; S stands for severity, L stands for likelihood. Ladies and gentlemen, recollect from the previous lectures that risk is a product of these two, and I am quantitatively converting - the qualitative statements into a number and based on this number I give a risk ranking, it is not a rank of 1, 2, 3; I am using a rank of A, B, C, D where A, C, B, etcetera have a specific meaning which I will discuss subsequently in the coming slides. Let us look at the third deviation; there can be reverse flow or there can be misdirected flow on the group header line of 12 inches P 102 A3A under the same operating condition. The isolation valve in the first g ...
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Tutornicabel
School: Boston College

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Hazard identification and analysis 1

Hazard identification and analysis
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Hazard identification and analysis 2

Question one
The era of industrialization has come with it some benefits in the livelihood of human being. It is
through the industrialization that the quantity and quality products have been availed in the
market with the affordable price due to the reduced cost of production brought about by
improvement in technology. Through the industries, employees have been getting the income in
form of the salary and wages. Some of the industries have been taking part in the social activities
such as sports, supporting education just to mention some. Not only that but the industries have
been generating revenues to the government through taxes imposed which has aided the
distribution of resources in form of development to their citizens. With this in place it can be
concluded that industrial sector has played an important role in the in the world’s economy at
large. Taking an example of oil and gas industries, it has improved the sector of transport not
forgetting that the other industries have been depending on them to acquire oil to run out their
machineries for the production to be carried out. For their importance (oil and gas industries),
any oil spillage, operational disorder and any other accident like activities can cause the entire
economy to suffer economically because, the cost has to be incurred in maintenance and services
of the plant. For this to be achieved, there must be some techniques to be applied for the
identification and assessment of the concerned hazard. Some of the techniques used include the
failure mode effect analysis (FMEA), Quantitative risk assessment and the hazard and
operability study (HAZOP). The concern for the report will deal with HAZOP.
HAZOP application can be categorized into four stages of operation including:
i) Drawing Board (Design stage)
ii) Construction Stage
iii) During Process Modification
iv) After Accident Occur (Accident Investigation Stage)
HAZOP study can be the standardized approach to analyze the risk incurred in the plant’s
operations. In order to analyze any risk involved in any industry by use of HAZOP studies
technique, the computerized method of HAZOP study work sheets is put into application. In the
case study, the gathering station will be considered for the technique to apply (Dunjó et
al,.2010). For the preparation of the study worksheet, a PHA-pro version 7 software was used.
The case study of Group gathering Station for the HAZOP study was considered for the HAZOP
analysis to be applied. The group gathering station being in a position to cause some damage in
the industry workforce and the surrounding, HAZOP will be in a position to detect the risk with
its operable problems associated with it. The importance or goal for the carried risk analysis will
be to get rid of or minimize the likelihood and the effects of the hazards. this will only be
applicable installation and operation stage of the group gathering. With the prepared worksheet,
on analyzation, the recording was done in a full recording format though there were other
recording formats which could be used. Considering the case study, the piping and
instrumentation was analyzed in details where a node was identified as the section concerned in

Hazard identification and analysis 3
the whole plant. The report will be carried out by several steps. In the GGS, there are some
manifolds which carry out distribution of oil from different reservoirs. They can collectively be
known as header because of their nature of collecting the oil from several and different reservoirs
and distributing it to a common collector.

Figure 1(a):

Figure 1(b):
The two diagrams figure 1(a) and (b) show the process flow diagram of the group gathering
station indicating the refining process of the crude oil
As depicted in the diagram of the P and ID, two set of group headers are shown. These group
headers are in a position to distribute oil from the well all the way to the point of collection.
Also, in the diagram are the heaters which necessitate the separation of oil, gas and water from
the crude oil siphoned from the reservoir by the group headers. To achieve the separation, a
chemical need to be supplied from the tank through valve to the heater. After the separation, the
gas and water are pumped to the recovery tanks ER eight in numbers after which they are carried

Hazard identification and analysis 4
further to the jumbo heater where further purification takes place. Water being the by-product in
the whole process, it is finally taken to the effluent treatment plant (ETP).
On eliminating the by-product, the purified oil is taken to the common storage tank facility
awaiting distribution to the users. Having undergone through the process incurred in recovering
the refined oil from the reservoir, one is equipped with the design intent’s knowledge of different
nodes in the above case.

Table 1: the table shows a condensed methodology of the HAZOP study analysis
Now the HAZOP study should follow where subsequent appropriate deviations are taken into
consideration with primary and seconda...

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