Node:

TATA STEEL LTD

KALINGANAGARHAZOP WORK SHEET

PROPANE STORAGE & PROPANE DILUTION SYSTEM

EQMS INDIA PRIVATE LIMITED

TATA STEEL LIMITED - KALINGANAGARHAZOP STUDY FOR PROPANE STORAGE & PROPANE DILUTION SYSTEMHAZOP WORK SHEETS

(Rev. 0)

EQMS INDIA PRIVATE LIMITED

304 & 305, Rishabh Corporate Tower, Plot No. 16,

Community Centre, Karkardooma, Delhi 110 092

S. No.SectionPage No.

1.Propane Storage System4

2.Dilution System14

List of NodesSL NONODE-NO SYSTEMPAGE NO

1301ROAD TANKER TO PROPANE STORAGES4

2302SUPPLY OF PROPANE TO CONSUMER9

3303PROPANE DILUTION SYSTEM14

Node: 301Propane Storage SystemP&ID No. G/P&I/6654/2013

Design IntentTanker to Storage

DeviationCauseConsequenceSafeguardRecommendationRemark/Action

No/ Less FlowCompressor C- 01/02/03 MalfunctionLow filling rate in storage tank T1/T2/T3 Standby Compressor Provided C- 01/02/03

ROV-1 Stuck Close No filling in Storage tankT1/T2/T3

Increase in Pressure in TankerCompressor Trip at 21Kg/cm2Tanker designed for 21kg/cm2

Pressure gauge &, Pressure safety Valve has been provided on tankerPressure Safety valve testing should be incorporated in maintenance schedule

More FlowMore pressure difference in Tanker and TankStatic Charge possibleLine ,Tanker and Tank is EarthedDuring operation of propane liquid filling from Road Tanker to Storage Tank, due to More or high flow, Stating Charge is generated. To avoid the hazard from static Charge in pipeline and Propane storage tank, Jumper made of Copper, Alluminium or G.I. strip for electrical continuity is to be provided in all flanges

R-1Resistance is to be checked for all earthing Strip and Earth pit and a record is to be maintained..

Reverse FlowNot possible

Higher Pressure

Over pressurization by compressorDamage of tankTank is designed for high pressure. compressor trip at 21kg/cm2

Lower PressureCovered in Less flow

Higher TemperatureExternal fireFire and Explosion HazardHigh pressurePRV-01 and PG-01,12,13,14 Provided

Gas detector provided GLD 1, 2, 3 Provided.

Water Sprinkler provided for the Storage tanks and Tanker unloading station

PSV provided.

Lower TemperatureNo Issue

Higher Level(Storage Tank T-1,2,3)Transfer not stopped at high levelTank PressurizationLT-11/21/31 ,PT11,21,31 are provided in the tank same will close respective ROV-11/21/31

Lower LevelNo Issue

Concentration

NA

ImpurityNA

Utility FailurePowerNo Transfer of Propane from Tanker to Storage Tank.Compressor C-01, C-02 & C-03 will stop.All ROV and SV will CloseDG should be provided for backup power for the operation of Propane storage systemR-2

Start-upProper SOP is to be made for attending Start Up & Shutdown of Propane system

Shut-down

MaintenanceProper Isolation,

N2-purging &

Permit System

Should be included SOP

LeakageCorrosion of lineExcess flow of liquid and temperature fallExcess Flow Check at Tankers

Node: 302Propane Storage SystemP&ID No. G/P&I/6654/2013 R1

Design IntentTo Supply Propane to Consumer

DeviationCauseConsequenceSafeguardRecommendationRemark/Action

No/ Less FlowROV stuck closeNo supply to CustomerStandby System ProvidedFlow meter No-91A/B/C provided

More FlowLeakageFall In temperatureExcess flow Pipe lineEFV-16/26/36 provided

More consumption from Customer sideEFV-16/26/36 provided

Reverse FlowNot possibleNRV-41/51/61 provided

Higher PressureCovered in higher Temperature below

Lower PressureCovered in Low flow

Higher TemperatureVaporizer V-1/2/3 malfunctionWater level low

Chances of burst PipeFire and explosion hazardRTD 41/51/61

WLI-41/51/61(Water level indicator)

PRV-41/51/61 provided

Lower TemperatureCovered in more flow

Higher LevelWater in vaporizer

V-1/2/3SV-42/52/62 stuck openNo IssueWLI-41/51/61

indicates

Lower Level

Water in vaporizer

V-1/2/3SV-42/52/62 stuck closedPropane gas will not be generated, Liquid may flow in outlet lineRTD 41/51/61

SV-41/51/61 will close at less than

55 0CPS-41/51/61

Higher ConcentrationNA

Lower ConcentrationNA

ImpurityNA

Utility FailurePower failureInstrument Air FailureNo vaporization and hence no supplyControl valves failureNoneNoneDG should be provided for backup power (R-2)Provide N2 Line as a standby for Air(R-3)

Start-upTo be considered laterProper SOP is to be made for attending Start Up & Shutdown of Propane system

Shut-downTo be considered later

MaintenanceTo be considered laterProper Isolation,

N2-purging &

Permit System

Should be included S OP

LeakageCorrosion of lineExcess flow of liquid and temperature fallExcess Flow Check Valves-16/26/36 provided

Node: 303Propane Dilution SystemP&ID No.

Design IntentTo Dilute Propane

DeviationCauseConsequenceSafeguardRecommendationRemark/Action

No/ Less Flow(Propane)No/Less Flow

(Air)

Power Failure

Filter choke-TIF1

Diluted propane not available

No Flow

Less PressureNone

PGs-PG2,PG9 inlet and outlet

PI-103 DG should be provided for backup power (Mentioned in R-2)Bypass line with isolating valve to be provided for the filter/ Standby Filter (R-4)Provide Low pressure Alarm. (R-5)

Mr .Arindam Panigrahi

Line Drain and filter replacement process to be incorporated in SOP

Lack of supply of Air(tank empty)

Power FailureDiluted propane not available

Diluted propane not available

Standby Tank Provided

NoneAs Propane Dilution System will be away from Propane storage one more DG should be provided for backup power in Dilution area.-R-6

Mr .Arindam Panigrahi

More Flow(Propane/Air)

PCV 101,102 malfunction the ratio Chances of explosive mixtureSSV 101,102(6 nos for 3 Mixers) Provided with PCV 102(propane) being controlled by PCV 101(Air)

Reverse Flow(Propane/Air)

Not PossibleNRV is Provided

NRV-101 & 102

Higher Pressure

Covered in more flow

Lower Pressure

Covered in No/Less Flow

Higher Temperature

(Propane)

External Fire

Hot Supply from VaporiserFire/ExplosionFire Fighting System

Interlocks in Vaporizer V1,2,3 provided

Lower Temperature

(Propane)

Considered in leakage(below)

Higher LevelNA

Lower LevelNA

Impurity/ Contaminant

Dust Improper mixtureFilter Provided-TIF-1Bypass line to be Provided for the Filter

(R-4)

Other materialNA

Utility FailurePower failure (Covered Above)

Calorimeter will not work NoBattery backup may be provided for Dilution system (R-7).

Sampling

NA

MaintenanceTo be considered laterProper Isolation,

N2-purging &

Permit System

Should be included S OP

Loss of containment/ LeakagePropane Pipe line failure/ Flange or Gasket Failure

Methyl Mercaptan pipe line failure. Fire/Explosion

Fall in temperature in Pipeline

Toxic releaseLeak detector and Firefighting System Provided

Gas masks and AnalyzerDuring any leakage in the field, in the Propane Dilution area for taking immediate action , One/ or two CCTV camera may be provided in the field, so that any leakage in the system is immediately noticed by the Control Room official and proper action can be taken without delay.

(R-8)

Proper SOP to be made to attend leakage/ Emergency Handling

HSE/ ergonomic issuesMethyl Mercaptan

Toxic release Gas masks and Portable Analyzer Methyl Mercaptan atmospheric concentration meter may be provided near working area for continuous

monitoring..(R-9)

Regulatory issuesNone

Start-upTo be considered laterProper SOP is to be made for attending Start Up & Shutdown of Propane system

Shut-downTo be considered later

G/P&I/6855/2013

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