HAZOP Study

System: Installation of LPG Condensate Collection in buffer vessel T-402

Nature of Modification: Permanent

Date: 03-May-2018

Team involved in the HAZOP study

1) J Babu , Sr. Terminal Manager.
2) R Prabhakaran, Projects & Main Manager
3) Palanikumar, Safety Officer.
4) Manohar , Sr. Engineer
5) Roshan, Shift Engineer.
6) Jayaprakash, Sr.Engineer.
7) Shivam Kumar, Shift Engineer.
Node 1: LPG CONDENSATE LINE FROM ECONOMISER TUBE SIDE OUTLET TO T 402

Action Plan/
S. Guide Existing
Parameter Possible Causes Consequences Additional
No Word Provisions
Provisions
Flow NO/LESS 1. Condensate I/V -Rate of filing of - Not required -Nil
in economiser T402 is less.
outlet closed or -Receiver level
throttled. increases.
2. LCV 608 in open -
condition.
3. Running
compressor trips
4. LCV 607 in close
condition.
5. Condensate inlet
I/V to T402
6.EFCV activated
 7.T402 high
pressure
MORE 1. HT compressor - Filling rate 1.SOP: HT
running and of T402 - SRV is present. condensate
condensate I/V more. should not be
open. - T402 lined to T402
pressure 2. Pressure
Increases high/low alarm
to be provided
in CR
Pressure HIGH 1. Both LCV 607 - Pressure - TRV available
and LCV 608 in build up.
close condition.
2. Condensate inlet
I/V to T402 and LCV
608 closed.

LOW Nil Nil Nil

 Temperature LOW 1.Economiser shell - Low line - MOC is LTCS 1. Pipeline
side level high temperature -vessel design should be LTCS
temperature material.
(-)35˚C to 2.Temperature
(+)65˚C gauge range to
be changed to
(-)50˚C to
(+)50˚C

HIGH 1. Economiser shell - Line - TRV 1. Temperature

side level low pressure available. gauge range to
2. Economiser hot high be changed to
condensate I/V (-)50˚C to
open. (+)50˚C

Node 2: LPG CONDENSATE LINE FROM T 402 TO LB

S. Guide Existing Action Plan/
Parameter Possible Causes Consequences
No Word Provisions Additional
 Provisions
Flow NO/LESS 1. T402 outlet I/V 1. Buffer tank 1. High level 1. Continues
closed. level and alarm and level/Pressure
2. Differential pressure will pressure gauge monitoring
pressure increase. available. cum alarm to
between T402 be provided.
and tanker is low.
3. T402 pressure is
Low.
4. LB EFCV
activated.

Flow More 1. Differential 1. Buffer tank 1. Pressure gauge 1. Continues

pressure level and available. level/Pressure
between T402 pressure will monitoring
and tanker is reduce. cum alarm to
high. be provided.

PRESSURE LOW Nil Nil Nil Nil

PRESSURE HIGH 1. LB EFCV
 activated.
2. T402 outlet I/V
closed.

TEMPERATURE LOW 1. Buffer tank - Low line - MOC is CS 1. Pipeline

Pressure is very low. temperature should be CS
material.

TEMPERATURE HIGH Nil Nil Nil Nil

Node 3: Hot vapour line to T402
Flow NO/LESS Nil Nil Nil Nil
Flow More Nil Nil Nil Nil
PRESSURE LOW Nil Nil Nil Nil
PRESSURE HIGH Nil Nil Nil Nil
TEMPERATURE LOW Nil Nil Nil Nil
 TEMPERATURE HIGH Nil Nil Nil Nil
Vessel No:T402
LEVEL LOW 1. More liquid off Nil Nil Nil
take from T402
2. T402 to T108 I/V
open.

HIGH 1. Continuous 1. Buffer 1. High level 1. Continues

condensate Pressure is alarm and level/Pressure
collection. increase. pressure gauge monitoring
2. Outlet valve available. cum alarm to
close condition. be provided.
2. Level control
valve to be
provided with
Buffer tank
high level
interlock.
PRESSURE LOW Nil Nil Nil Nil
 HIGH 1. Rise in LPG 1.Buffer 1. Pressure 1. Continues
temperature. Pressure is gauge level/Pressure
2. Hot gas inlet I/V Increase. available. monitoring
in open 2. SRV cum alarm to
condition. available be provided.
TEMPERATURE LOW 1.Economiser shell - Low operating -Vessel design 1.Temperature
side level high temperature temperature gauge range to
(-)35˚C to be changed to
(+)65˚C (-)50˚C to
(+)50˚C

HIGH 1. Economiser shell Nil Nil Nil

side level low
2. Economiser hot
condensate I/V open.
Recommendations from Hazop study:-
1) Buffer vessel Continuous level/Pressure monitoring cum alarm to be provided in control
room and loading bay.
2) Level Control valve to be provided in Buffer vessel inlet line.
3) Temperature gauge range to be changed to (-)50˚C to (+)50˚C.
4) Gas detector to be provided at both ends of the buffer vessel.
5) Buffer vessel Liquid inlet / outlet line MOC to be LTCS.
6) SOP to be prepared for condensate collection and tanker loading operation.