Hazop Study
Hazop Study
PROCEDURE AND PREPARATION FOR HAZOP STUDY
STUDY
CONTRACT NO : 010/SP/DIR/XI/2015
DOC NO : GGCP-00-P0-ES-010-PP
GGCP-00-P0-ES-010-PP
CONSULTANT :
PT Rekayasa Engineering
REV.
DATE DESCRIPTION PREPARED CHECKED APPROVED
NO.
3 08/11/2016 Approval
Issued for Approval ANG SAW GWN/FIA FP
2 20/10/2016 Approval
Issued for Approval ANG SAW GWN/FIA FP
1 01/10/2016 Approval
Issued for Approval ANG SAW GWN/FIA FP
0 30/08/2016 Review
Issued for Review ANG SAW GWN/FIA FP
JOB NO : 781502
PROCEDURE AND
DOCUMENT NO : GGCP-00-P0-ES-010-PP
PREPARATION FOR HAZOP
STUDY DATE : 08/11/2016
REV : 3
0 30/08/2016 Review
Issued for Review
DISTRIBUTION ORDER
CHIEF SHE
TRACTEBEL / CONNUSA ENGINEERIN
ENGINEERING
G MANAGER
CONSTRUCTION MANAGER
PROCUREMENT
PROCUREMENT MANAGER
SHE MANAGER
QC MANAGER
CHIEF ENGINEERING
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PROCEDURE AND
DOCUMENT NO : GGCP-00-P0-ES-010-PP
PREPARATION FOR HAZOP
STUDY DATE : 08/11/2016
REV : 3
TABLE OF CONTENT
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DOCUMENT NO : GGCP-00-P0-ES-010-PP
PREPARATION FOR HAZOP
STUDY DATE : 08/11/2016
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1. INTRODUCTION
1.1. Scope
This document stipulates the procedure of the Hazard & Operability (HAZOP) Study in terms of
objective, scope, resources requirements and methodology for the Gresik Gas Cogeneration Plant
(GGCP) Project.
1.2.. Definition
1.2
The following words shall have the meaning indicated when used herein:
Owner : PT. PUPUK INDONESIA ENERGI
Consultant PMC : TRACTEBEL ENGINEERING S.A.& PT. CONNUSA ENERGINDO
Contractor : PT. PP (Persero) Tbk – DIVISI EPC
Engineering Consultant : PT. REKAYASA ENGINEERING
Vendor/Subcontractor
Vendor/Subco ntractor : The party that manufactures or supplies equipment and services to
perform the duties specified by the Owner or Contractor
1.3.. Project Re
1.3 Reference
ference Document
Basic Engineering Design Data, GGCP-00-P0-ES-001-PP 4.
GGCP-00-P0-ES-001-PP Rev 4.
1.4.. Abbreviations
1.4
The following abbreviations are used within this document:
API American Petroleum Institute
BFW Boiler Feed Water
EPC Engineering, Procurement, and Construction
ESD Emergency Shutdown.
GGCP Gresik Gas Cogeneration Plant
GPSA Gas Processors Suppliers Association
HRSG Heat Recovery Steam Generator
HAZOP Hazard Operability
HVAC Heating, Ventilations & Air Conditioning.
HMB Heat & Mass Balance.
IFB Instruction for Bidder
LP Low Pressure
MP Medium Pressure
MCC Motor Control Centre.
PKG Petrokimia Gresik
PSD Plant Shut Down
SOP Standard Operating Procedure
UBB Utilitas Batu Bara
USD Unit Shut Down
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PROCEDURE AND
DOCUMENT NO : GGCP-00-P0-ES-010-PP
PREPARATION FOR HAZOP
STUDY DATE : 08/11/2016
REV : 3
2.1. Objectives
It should be underlined that the HAZOP study is not a design review therefore the team should be
reminded to avoid spending too much time for “Design Solutions”. The following items shall be subject
to the HAZOP study:
1. Process line
Major process lines and related utility lines contained in the subject P&IDs.
2. Chemicals
All Hazardous material such as flammable,
flammable, explosive and toxic.
3. Equipment
All process equipment identified on the subject
subject P&IDs.
4. Instrument Controls
All basic process control system shall be considered for the effect during hazard identification. In
addition to this, main interlock system may be considered on the subjected P&IDs basis.
5. Operating Conditions
HAZOP study shall investigate the potential hazard and problem which are likely to occur during typical
normal operating conditions. Consideration should also be taken for start-up, normal shutdown and
emergency shutdown as a deviation from the reference (normal condition).
2.2.. Scope of Study
2.2
The scope of study covers all P&IDs latest achieved NO OBJECTION status revision that has been
developed by the Contractor as part of the Design Drawing. Those include all facilities in the Gresik
Gas Cogeneration Plant (GGCP) Project. System or unit are classified as in Table 3 below, shall be
subjected to the HAZOP Study.
3 Table 1. Process Units (Section)
3 P&ID HRSG
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STUDY DATE : 08/11/2016
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In order to proceed with HAZOP work effectively, subjected units (sections) as listed in Table 3 above
will be divided into study NODEs. The study nodes defined mainly represent specific process lines,
equipment or units operated under same operating condition or specific process intentions.
In addition to the P&ID’s, the following documents (preferred latest revision) may be referred in the
HAZOP Study:
2.4.1.
2.4.1. Study Te
Team
am Compo siti on
HAZOP Review shall be carried out by OWNER, PMC, CONTRACTOR and Subcontractor which
define as the following members;
1. HAZOP Chairma
Chairman n (Subcon
(Subcontractor)
tractor)
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PREPARATION FOR HAZOP
STUDY DATE : 08/11/2016
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2. HAZOP Secr
Secretary
etary (Subco
(Subcontractor)
ntractor)
3. Process Engineer (OWNER, PMC and CONTRACTOR)
4. Operating Represe
Representative
ntative (OWNER)
5. Other Discipline Engineer (OW
(OWNER,
NER, PMC and CONT
CONTRACTOR)
RACTOR)
6. OEM Engineers (GE, Macchi), whenever possible.
possible. 3
The core of the HAZOP Study team shall consist of a Chairman and Study Secretary. The process
engineers of CONTRACTOR project team and OEM Engineers (whenever possible) will attend the
Study Meeting and give explanation about process, instrumentation philosophy, operation and
maintenance for the facilities.
OWNER and PMC also will attend the HAZOP Meeting. CONTRACTOR will request the OWNER
and PMC should assign adequate personnel of engineers including OWNER’s operating personnel.
Other engineers, such as mechanical, electrical, instrument, piping, civil and HSE engineer of
CONTRACTOR team will attend as required (on call basis) by the
t he Chairman.
2.4.2.
2.4.2. Study Te
Team
am Responsi bilit ies
a) HAZOP Chairman
The following are principal responsibilities of the HAZOP Chairman throughout the HAZOP
Review:
1. Pre-HAZOP meeting w works:
orks:
- Plan the key items of the HAZOP
3 - Submit NODE identification for CONTRACTOR review and Approval prior to HAZOP study
commencement.
2. HAZOP Review mee meetings:
tings:
- Lead the review meetings so as to identify exhaustively potential hazards and operational
concerns.
- Settle discussion to a conclusion and ddefine
efine recommended HAZOP actions.
actions.
- Control the progress of the HAZOP review meetings as sched
scheduled.
uled.
- Be aware of the mental and p physical
hysical conditions of team membe
members
rs to maintain their interests
and energy levels, taking breaks appropriately.
- Ensure the HAZOP Scribe to record the HAZOP findings and prepare the HAZOP action
sheets.
b) HAZOP Secretary
HAZOP Secretary is the assistant of HAZOP Chairman and responsible for conducting
documentations as listed below under instruction of HAZOP Chairman:
1. Assist Chairman in preparing the discussion
discussion material
2. Record and filing all meeting resu
results
lts
3. Prepare minute ooff meeting and meeting report
are responsible
- Provide to conduct
technical info productive
information
rmation HAZOP review
and experiences meeting
for each through
discipline area the following roles:
areas.
s.
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PREPARATION FOR HAZOP
STUDY DATE : 08/11/2016
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2.5. Methodology
2.5.1. Overview
HAZOP Study to be conducted primarily using the HAZOP deviation guideword technique. The
guidewords, in conjunction with the key process/ control parameters, prompt the HAZOP team to
brainstorm possible causes and potential consequences of deviation from design intention. For
example, the deviation “more pressure” would prompt the leader to ask the team “what could cause
more pressure in this section or line segment?” the ‘”possible cause” and potential consequences
scenarios are documented in the report worksheets. The “Existing system and procedure”
(safeguards) that reduce the risk associated with the specific cause/consequences
cause/consequences scenario are then
discussed and documented. For scenarios involving significant risk, “Recommendations” that the
team believes further reduce risk or improve the operability/controllability of the facility are also
documented.
The guide word HAZOP method shall be applied for the review. The work flow of the review and the
list of applicable HAZOP guide word/process deviations are shown in Appendix I, respectively. The
specific steps of the HAZOP methodology used in this study are:
a) Choose study section or node
b) Apply a deviation (guideword+ parameter)
c) Brainstorm cause of deviation
d) Develop each ca cause
use to its global consequences
e) Identify existing safeguards
f) If warranted, ma make
ke recommenda
recommendation tion (s) to red
reduce
uce risk and / or improve the operability of the
facility
This process is repeated for each deviation and section/NODE until the entire process and control
system has been analyzed according to study flow diagram at Appendix II.
2.5.3. Assumption
Following
a. Singleassumptions
failure re sultsshould
results use,during
in hazard
hazard, conducting
as double the
jeopardy is HAZOP
believedstudy:
believed quite re
remote
mote case.
b. Equipment o orr machinery is designed, man manufactured
ufactured and properly inspected w with
ith no defect.
c. The facilities sha shallll be well maintained and operated in accordance with sound, internationa
internationally
lly
acceptable standards. This includes establishing and operating a high standard of housekeeping
throughout the site at all times. All loss prevention, safety and/or security equipment shall be
routinely tested/ recharged as recommended by the manufactures.
d. For duplicate trains /process unit, equipment or machinery is similar designed and
manufactured, therefore the study review shall be carried out only for one train. The study
review result, however, shall be applied for all the duplicated trains / process unit.
e. If all team membe
members rs agree, simplified h
hazardous
azardous review method such as “What IF” m method
ethod may
be used for utility system which is widely available in industrial applications. Team is requested
to discuss most effective hazardous review method for associated utility system prior to the
review
f. Operator are assumed to be competent and appropriately trained
g. Equipment/Instrumen
Equipment/Instrumentt are deemed suitable for design condition
h. Mechanical pro protection
tection devices (PV/PSV) are expe
expected
cted to function on demand
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DOCUMENT NO : GGCP-00-P0-ES-010-PP
PREPARATION FOR HAZOP
STUDY DATE : 08/11/2016
REV : 3
2.5.4.
2.5.4. Study Worksheets
Study worksheets were used during conducting HAZOP review shall consist of, but not limited to:
a) Node,
b) Design Condition/Parameter,
c) Deviation,
d) Cause,
e) Consequence,
f) Safeguard,
g) Recommendation,
h) Responsibility.
The systematic approach of a HAZOP requires deviations (guide works+ parameters) be uniformly
applied to all sections under study. The work flow of HAZOP review in Appendix II shall be used for
each study section/node as much as applicable.
2.5.5. Recommendations
Team emphasized that some of existing safeguards were considered not sufficient; therefore team
could request additional safeguard or further study. HAZOP Secretary under direction of chairman
shall document the recommendation into HAZOP worksheets
Finally, all recommendations should include a person or entity that will be responsible for
recommendation.
implementing the recommendation.
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APPENDIX I
HAZOP
HAZO P Guidewords & Deviation s
Table I.1 Deviations for HAZOP Study
3
No Description
1 More Flow
2 Less Flow
3 No Flow
4 Reverse Flow
5 Misdirected Flow
6 More pressure
7 Less pressure
8 Vacuum
9 More Temperature
10 Less Temperature
11 More Level
12 Less Level
13 Empty Level
14 Impurities
15 Composition
16 Erosion / Corrosion
17 Commissioning
18 Maintenance
19 Instrumentation/Control
20 Start-Up
21 Shutdown
22 Testing/Sampling
23 Miscellaneous
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The above list of GUIDE WORD is neither mandatory nor comprehensive. It should be treated as a
menu from which relevant words can be selected to from a deviation in conjunction with a Process
Parameter.
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3 APPENDIX II
HAZOP Workflow
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APPENDIX III
HAZOP
HAZOP Works heet Format
APPENDIX
APPENDIX IV
3 HAZOP Node List
No d es Des c r i p t i o n / No d e L i s t No d es Des c r i p t i o n / No d e L i s t
1 Lube Oil System 18 Drain, Blowdown & CBD LP Steam System
2 Hydraulic Oil System 19 BFW System (HRSG)
3 Cooling Water System (GTG Side) 20 Chemical Dosing System
4 Fuel Gas System (GTG Side) 21 Lube Oil System (HRSG)
5 Cooling Air System 22 Fuel Gas System (HRSG Side)
6 Washing Water System 23 Instrument Air (HRSG Side) And Sealing Air System
7 Fire Fighting System 24 Cooling Water System (HRSG Side)
8 Steam/Water System 25 Fuel Gas System
APPENDIX V
3
P&IDs Mark-Up
PIPING SYMBOLS
PI
INSTRUMENT SYMBOLS
PI
EQUIPMENT SYMBOLS
PI
NODE 25
PI
NODE 33
CONSTRUCTION & INVESTMENT
NODE 25
PI
NODE 33
NODE 26
PI
NODE 33
NODE 26
PI
NODE 26
NODE 27
NODE 28
PI
NODE 33 M
NODE 26
NODE 33
NODE 27
PI
GRESIK GAS COGENERATION PLANT PROJECT
NODE 27
PI
NODE 27
PI
NODE 27
PI
NODE 27
PI
NODE 27
PI
NODE 27
PI
NODE 27
PI
NODE 27
PI
NODE 27
PI
PI
NODE 27
NODE 27
PI
GRESIK GAS COGENERATION PLANT PROJECT
NODE 26
NODE 30
NODE 27
PI
NODE 26
ISO 30
PI
NODE 33
PI
ISO 28
NODE 33
PI
NODE 33
PI
NODE 26
NODE 28
PI
NODE 26
NODE 33
NODE 28
PI
NODE 27
NODE 29
PI
NODE 26
CONSTRUCTION & INVESTMENT
PI
NODE 31
CONSTRUCTION & INVESTMENT
NODE 27
NODE 32
PI
NODE 28
NODE 28
PI
NODE 32
PI
NODE 33
NODE 27
PI
PI
NODE 25 PI
NODE 27
PI
NODE 26
PI
ISO 9
PI
NODE 28
PI
NODE 31 PETROKIMIA
GRESIK
NODE 8
NODE 10
NODE 11
DETAIL "A"
DRAIN
MOV
MCC
A1
841mmx594mm
DETAIL "B"
DRAIN
NODE 8
NODE 9
NODE 11
NODE 13
A1
841mmx594mm
A1
841 mm x 594 mm
DETAIL "B"
DRAIN
NODE 10
NODE 11
NODE 13
A1
841mmx594mm
L L L L L L L L L
L L
L
L
L
L
L
L
L
L
L
L
L
NODE 8 L
L
NODE 10
L
NODE 15
L
L
L
L
L
L
L
L
L
L
L
A1
841 mm x 594 mm
NODE 10
NODE 15
A1
841mmx594mm
NODE 12
A1
841mmx594mm
NODE 13
A1
841mmx594mm
NODE 11
DETAIL "B"
DRAIN
MOV
MCC
A1
841mmx594mm
NODE 15
NODE 16
NODE 15
A1
841mmx594mm
NODE 12
NODE 14
A1
841mmx594mm
NODE 12
NODE 14
A1
841mmx594mm
NODE 14
NODE 15
A1
841mmx594mm
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