ENERGON PETRO PRODUCTS PVT LTD – LPG BOTTLING PLANT HAZOP REPORT

HAZARD & OPERABILITY STUDIES

M/s. ENERGON PETRO PRODUCTS PVT.LTD.

LPG BOTTLING PLANT
SY.NO:9/2 & 10/1
GOLAGAMUDI VILLAGE
VENKATACHALAM MANDAL, SPSR NELLORE DISTRICT,
ANDHRA PRADESH

Sept’2020

PREPARED BY
SV ENVIRO LABS & CONSULTANTS
Recognized by GOI, MOEF, QCI Accredited
Enviro House, B-1, Block –B, IDA, Autonagar,
Visakhapatnam-530012
Andhra Pradesh

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HAZARD & OPERABILITY STUDIES
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CONTENTS

S.No. Description Page. No.

1.0 Introduction 5
1.1 Organization Profile 5
1.2 Process Description 5
1.3 Product Portfolio 9
1.4 Study objectives &Scope of work 11
1.4.1 Study objectives 11
1.4.2 Scope of work 11
2.0 Hazard & Operability Studies (HAZOP) 12
2.1 Preamble 12
2.2 HAZOP: A Study For Hazard Identification 12
2.3 HAZOP Procedure, Significance of Guidewords & 15
Data/Document Required
2.4 HAZOP Guide Words & Possible Deviations 17
2.5 Types of Hazard Considered In the HAZOP Study 18
2.6 Recommendations 60

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LIST OF FIGURES

Figure No. Description Page No.

1.1 Location Map 7
1.2 2 KM Topomap 8
2.1 Site Plan 19
2.2 P&ID 20

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List of Abbreviations used in the HAZOP:-

1. HAZOP Hazard & Operability Study

2. P&ID Piping and instrumentation diagram

3. ROV Remote Operated Valve

4. EFCV Excess Flow Check Valve

5. SRV Safety Relieve Valve

6. NRV Non Return Valve

7. MSDS Material Safety Data Sheets

8. LEL Lower Explosive Limit

9. UEL Upper Explosive Limit

10. TRV Thermostatic Radiator Valve

11. TSV Thermal Safety Valve

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1.0 INTRODUCTION:
This Hazard and Operability Studies report has been prepared for the LPG Bottling
Plant of Energon Petro Products Pvt. Ltd. The LPG Bottling Plant of Energon Petro
Products Pvt. Ltd is situated at Sy.No: 9/2 & 10/1, Golagamudi Village,
Venkatachalam Mandal, SPSR Nellore District . Noticing the damage potential and
thus risk arising due to transportation, storage and handling of the flammable LPG
Energon Petro Products Pvt. Ltd. retained SV Enviro Labs & Consultants,
Visakhapatnam, to undertake the Hazard and Operability Studies for the LPG Bottling
Plant.

1.1 ORGANISATION PROFILE

Energon Petro Products Pvt. Ltd. is established in 2012.Currently the plant is offering
warehousing, storage and handling, transportation, packing, manufacturing of drums,
sales and emulsion manufacturing services to our clients. They are now expanding the
scale of operations to be able to offer all the logistics relating to oil and gas industry

The Total site area of the LPG Plant is 22136.48 Sq.mt. The activity of the plant is to
receive Liquefied Petroleum Gas (LPG) in bulk quantities from refineries / storage
points through tank trucks, store the same, bottle the LPG into cylinders and distribute
to the dealers network. The capacity of the Mounted Storage vessel (bullets) is 30 MT
x 3 Bullets bottling to a capacity of 30000MT LPG Per annum.

Activities of Plant:
1. To receive Liquefied Petroleum Gas (LPG) in bulk quantities from refineries
2. Storage of the LPG in Mounded bullets
3. Bottling of LPG into cylinders
4. Inspection and testing of filled cylinders
5. Dispatch of filled cylinders

1.2 PROCESS DESCRIPTION

1) Receipt of LPG from HPCL

2) Visual Inspection of Bullet Trucks.

3) Weighing of Bullet Truck.

4) Placing of Bullet Truck at tank lorry unloading shed.

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5) Earthing of the truck through jumpers.

6) Connection of Hose for unloading of bulk Bullet trucks.

7) Receipt of empty filled cylinders at gate.

8) Counting of empty cylinders in truck.

9) Visual inspection of truck with empty cylinders.

10) Unloading of the empty cylinders in the feeding conveyor for carousel filling.

11) Auto carousel filling of the empty cylinders.

12) After filling of the cylinders check for leaks and load it into conveyor for loading.

13) Filled cylinders are loaded into the empty trucks and weighed.

14) Filled trucks are invoiced and dispatched.

There will be no chemical process involved and the operation carried out will be receipt
of LPG (Liquid Petroleum Gas) by Bullet tankers from HPCL. After receiving of bulk
LPG in isolated storage vessels filling of LPG into domestic and non-domestic cylinders
using electronic carousel and associated systems. The cylinders filled will be checked for
quality and then transported with packed trucks to distributors, where filled cylinders are
transported to individual customers. In the LPG bottling plant, the storage will be in
pressurized form in mounded storage.

Transport and handling through piping system, handling techniques, specific equipment
used and standard operating procedures etc. the details are given below:

Loading/unloading from bullet trucks

The Bulk LPG is received through road movement by bullet trucks from HPCL. The Bulk
LPG unloaded from tankers and transferred to Mounded storage vessels using differential
pressure principle.

Bottling/filling of LPG in packed cylinders

LPG is transferred from storage vessel to carousels, where filling of cylinders takes place
with help of LPG pump and also to increase the discharge pressure of LPG pump,

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ENERGON PETRO PRODUCTS PVT LTD – LPG BOTTLING PLANT HAZOP REPORT

pressurization takes place from the other bullet to this delivery bullet with help of LPG
compressors.

Dispatching of filled cylinders by stake trucks

The filled cylinders are loaded in stake trucks and are sent to distributors. The movement
of cylinders from one place to other place shall be done with help of trolley without
rolling

Figure 1: Location Map

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Figure 1: 2 KM TopoMap

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1.3 PRODUCT PORTFOLIO

The major chemical handled in the plant is LPG, which is flammable and combustible
substance. If LPG is not handled in accordance with the written procedure in the plant
it may cause of fire and explosion, which may produce large damage to the people
and property in the area. The flammable, toxic and reactivity rating (NFPA Rating) of
LPG is given below.
NFPA RATING FOR HAZARDOUS CHEMICAL
S.No. Chemical Boiling Flash Point oC NFPA Hazard Classification
o
Point C Flammability Health Reactivity
1. LPG -40 to -50 -104 to -60 4 1 0

The explanation of NFPA Classification

A. Health Hazard Classification
4 Materials which in very short exposure could cause death or major residual injury
even though prompt medical treatment were given
3 Materials, which on short exposure could cause serious temporary or residual injury
even though prompt medical treatment, were given
2 Materials, which on intense or continued exposure could cause temporary
incapacitation or possible residual injury unless prompt medical treatment, is given
1 Materials, which on exposure would cause irritation but only minor residual injury,
even if no treatment is given
0 Materials, which on exposure under fire conditions, would offer no hazard beyond
that of ordinary combustible material
B. Flammability Classification
4 Materials, which will rapidly or completely vaporize at atmospheric pressure and
normal ambient temperature, or which are readily dispersed in air and which will
burn readily.
3 Liquids and solids that can be ignited under almost all ambient temperature
conditions.
2 Materials that must be moderately heated or exposed to relatively high ambient
temperatures before ignition can occur
1 Materials that must be preheated before ignition can occur.
0 Materials that will not burn

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C. Reactivity Classification
4 Materials, which in themselves are readily capable of detonation or of explosive
decomposition or reaction at normal temperature and pressures.
3 Materials, which in themselves are capable of detonation or explosive reaction but
require a strong initiating source or which must be heated under confinement before
initiation or which react explosively with water.
2 Materials, which in themselves are normally unstable and readily undergo violent
chemical change but do not detonate. Also materials, which may react violently with
water or which may from potentially explosive mixtures with water.
1 Materials which in themselves are normally stable, but which can become unstable at
elevated temperature and pressure or which may react with water with some release
of energy but not violently.
0 Materials which in themselves are normally stable, even under fire exposure
conditions, and which are not reactive with water.

i. Toxicity Hazard
Health hazard for the LPG is equal to one (Nh=1). Adequate safety arrangements are
provided to facilitate a Quick First Aid for the worker exposed to the chemicals.
ii. Flammability Hazard
The highest flammability rating is reported for LPG. (Nf=4) according to NFPA.
iii. Reactivity Hazard
Reactivity hazard rating for LPG is zero.
Following elements/events which can be lead to a major accident:
 Large scale fire and explosion in storage area due to damage of the bulk
storage MSV pipeline.
 Over turning of LPG road tankers and other transport hazard.
 Flash fire due to leakage of LPG.
 Equipment failure/malfunction like relief valve failure, flange gasket failure,
pumps mechanical seals etc. resulting in leakage of LPG to atmosphere.
 Accident due to overfilled cylinders or fire in the vicinity.
 Lack of adequate fire protection facilities available at different places of LPG
unloading, loading and usage.
 Experience level of personnel involved and their capacity to cope with
emergency situation.

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1.4 STUDY OBJECTIVES & SCOPE OF WORK

1.4.1 Study Objectives
 To identify the hazards that might have been overlooked
 To analyze chemical and process hazards, i.e. to ascertain the possible pathways
of occurrence of an unintentional event that may lead to any accident
 To evaluate the protection measures that are already incorporated in terms of their
effectiveness, adequacy, response time and resource mobilization
 To provide management a basis for safety management program
 Finally, to ensure safe operation of the plant

1.4.2 Scope of Work

To carry out Hazard & Operability Study (HAZOP) of the entire plant and to identify
potential hazards incorporating the following aspects:
1. Verification and study of all piping and instrumentation diagram (P&I) and
electrical distribution network.
2. Study of measuring instruments, alarms, controls, safety, fire prevention &fire
fighting systems provided and what if analysis.
3. Simulation of HAZOP process cycle for all possible deviations to identify
potential hazards for all the operations.
4. Identification and listing of remedial measures & training needs

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2.0 HAZARD & OPERABILITY STUDIES (HAZOP)

2.1 PREAMBLE
A HAZOP study identifies hazards and operability problems. The concept involves
investigation into the plant deviation from the design intent. The HAZOP study is
done at various stages of the project implementation (from inception to production).
In the present study “Guide Word” HAZOP has been done. The main objectives of
this HAZOP study are:
i. To verify adequacy of the plant safety measures
ii. To check operability/safety procedures
iii. To verify that safety instrumentation is reacting to its best parameters
Since the bottling plant is under pre construction phase, main aim of the present study
is to predict the problems which prevent efficient operation and suggest necessary
safety systems. While doing the present HAZOP studies following specific
consequences are considered:
i. Plant Personnel safety
ii. Damage to plant or equipment
iii. Loss of LPG
iv. Liability
v. Insurability
vi. Public safety around the plant

2.2 HAZOP: A STUDY FOR HAZARD IDENTIFICATION

In petro-chemical industry there is a great awareness of the necessity to apply more
systematic approach to safety and ease of operation, particularly in design. Addition,
there is an increasing pressure from government & society to improve standards of
safety and for the protection of the environment. The major hazard identification tools
include checklists, Hazard indices (FEI & TI), what – if analysis and HAZOP.
Combinations of all these techniques have been used in this study.

Early detection of hazards and visualization of disastrous situation helps to impart

safety in a systematic way. The plants can continue to operate for many years and can
be modified several times in its life span, so due care must be given to avoid any
compromise on the safety concept included in the original plant design and operating
conditions.

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HAZOP is structured methodology, which allows its user to employ imaginative

thinking in the identification of hazards and operational problems. It involves a
systematic, methodical examination of design document that describe the facility. A
multidisciplinary team to identify hazards or operability problems that could result in
an accident performs the study. Deviations from the design value of key parameters
are studied, using guide words to direct the process of evaluation. This technique
presumes that the design values of flows, temperatures and other process variable are
inherently safe and operable.

This HAZOP guideword approach was originally developed by Imperial Chemical

Industries Ltd, (ICI); which was further modified and made user friendly by the
American Institute of Chemical Engineers – Center for Chemical Process Safety.

The Hazard & Operability Study results in:

 Assisting the management with information of where the potential hazard may
exist and facilitate recommendations towards improved safety.
 Providing the safety – related documentation of every line and piece of equipment
in the plant, which is very useful when modifications are carried out.
 Furnishing a prioritized basis for subsequent risk analysis work.
If HAZOP study is performed and findings are subsequently implemented to mitigate
the risk, then it can be said that the plant is operating at comparatively lower risk than
before the study. HAZOP helps to find the “Weak link” in a plant and to provide a
basis for developing procedural or engineering controls to remove or lessen the risks
from the identified problem area.

Definition of HAZOP terminology:

Hazard: Anything (Chemical reaction, equipment malfunction, or operator error) that
can lead to an unwanted event.
Operability: Anything that causes the operator to improvise in his actions.

These definitions are an important part of the basic HAZOP premise that the process
does not have inherent hazards or operating problems when the unit is operating as
designed, and as defined by the basic documents such as the process flow diagrams,
equipment specifications, and operating procedures. In other words, if there are no
deviations from the norm, there are no problems.

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HAZOP is a recommended tool when making plant extension, modifications or

revamps, since the changes introduce opportunities for error that might not be obvious
unless reviewed as part of a “system” instead of a localized change. HAZOP is also
very useful for existing facilities, where they can be used for evaluating hazards and
operations from an unbiased view point, to identify possible process improvements or
as a quality – assurance effort.

PHA-Pro (Version 8.0)

PHA-Pro, the leading Process Hazard Analysis and HAZOP software, assists
organizations with the implementation of risk studies easily and thoroughly, resulting
in a more responsive and efficient business process. Used across process industries
such as oil and gas, chemicals, and pharmaceuticals.

PHA-Pro offers a user-friendly, flexible, and knowledge-based solution that has

evolved through extensive commercial use over the last decade to meet the
requirements at many of the world’s largest companies. It is proven software solution,
with preformatted standard PHA templates and a myriad of features that are user-
friendly and intuitive. In addition to pre-populated libraries, PHA-Pro allows you to
capture language from previous risk assessments to help build corporate libraries and
promotes knowledge sharing by ensuring that engineering expertise is retained and
accessible for future assessments.

Challenges of Process Hazard Analysis

Incidents can result in time lost due to injuries, capital and production losses,
environmental damage, and loss of company reputation as well as possible litigation.
Companies need to be making every effort to meet regulations and reduce process
risks by performing Process Hazard Analysis. Today’s rapidly evolving and more
complex process industry is under increasing strain as organizations must abide by
more stringent safety and environmental regulatory requirements and simultaneously
drive business revenues, increase efficiencies and decrease costs.

The success or failure of the HAZOP depends on several factors:

o The completeness and accuracy of drawings and other data used as a basis
for the study
o The technical skills and insights of the team

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o The ability of the team to use the approach as an aid to their imagination in
visualizing deviations, causes, and consequences.
o The ability of the team to concentrate on the more serious hazards which are
identified.

The process is systematic and it is helpful to define the terms that are used:
a. STUDY NODES - The locations (on piping and instrumentation drawings and
procedures) at which the process parameters are investigated for deviations.

b. INTENTION - The intention defines how the plant is expected to operate in

the absence of deviations at the study nodes. This can take a number of forms
and can either be descriptive or diagrammatic; e.g., flow sheets, line diagrams,
P&ID.

c. DEVIATIONS - These are departures from the intention which are

discovered by systematically applying the guide words (e.g., "more pressure").

d. CAUSES - These are the reasons why deviations might occur. Once a
deviation has been shown to have a credible cause, it can be treated as a
meaningful deviation. These causes can be hardware failures, human errors, an
unanticipated process state (e.g., change of composition), external disruptions
(e.g., loss of power),etc.

e. CONSEQUENCES - These are the results of the deviations should they occur
(e.g., release of toxic materials). Trivial consequences, relative to the study
objective, are dropped.

f. GUIDE WORDS - These are simple words which are used to qualify or
quantify the intention in order to guide and stimulate the brainstorming
process and so discover deviations. The guide words shown in the following
table are the ones most often used in a HAZOP; some organizations have
made this list specific to their operations, to guide the team more quickly to
the areas where they have previously found problems. Each guide word is
applied to the process variables at the point in the plant (study node) which is
being examined.

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2.3 HAZOP PROCEDURE, SIGNIFICANCE OF GUIDEWORDS & DATA

/DOCUMENTS REQUIRED:
Hazard & Operability study systematically analyses all foreseeable deviations from
normal operating conditions, which includes description of deviations, the causes of
these deviations, the possible consequences and the necessary preventive measures to
be taken.

HAZOP study involves a set of standardized GUIDE WORDS, which are used to
initiate the discussion in the team. All possible deviations in process parameters in a
reactor or a pipeline are considered to determine their causes and consequences. If a
hazard is identified, first the existing protective measures are analyzed with respect to
the intensity of the hazard. If the protective measures are not adequate,
recommendations are given to mitigate the hazard.

The sequence of steps used to conduct the HAZOP is as follows:

 Select and confirm the scope of node
 Explain the general design intentions and operating conditions of the node.
 Specify the node’s process parameters.
 Select a process parameter (Flow, pressure etc.) and specify the design
intention relating to this parameter.
 Apply a deviation (more, less etc.) to the parameter and develop meaningful
causes, hazards of the deviation from the intention.
 Identify all scenarios, cause / hazards of the deviation from the intention.
 Identify all major consequences associated with each cause without regards to
safeguards.
 Specify predominant safeguard against each consequence.
 Make recommendation to mitigate the consequence if the severity is
unacceptable.
 Reiterate the above steps for other guide words.
 Reiterate the above steps for all other nodes in review

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2.4 HAZOP GUIDE WORDS & POSSIBLE DEVIATIONS

Guide Word Deviation

None No forward flow when there should be, i.e. no flow or reverse
flow.
More or higher More of any relevant physical property than there should be,
e.g. flow (rate or total quantity), higher temperature, higher
pressure, higher viscosity, etc.
Less or low Less of any relevant physical property than there should be e.g.
lower(rate or total quantity), lower temperature, lower pressure,
etc.
Part of Composition of system different from what it should be, e.g.
change in rate of components, component missing, etc.
More than present More components present in the system than there should be,
e.g. extra phase(vapor, solid), impurities (air, water, acids,
corrosion products), etc.

Other than what else can happen apart from normal operation, e.g. start-up, shutdown,
up rating, low rate running, alternative operation mode, failure of plant services,
maintenance, catalyst change, etc.

Hazard & Operability Study require prior understanding of the behavior and hazards
of the hazardous chemicals being used in the plant, which mainly includes:
 Physical & Chemical Properties
 Fire & Explosion Characteristics
 Toxicological Properties, if any

First HAZOP sheets are prepared and then the team discusses on possibilities of
occurrence of various deviations from the intended operating conditions by employing
the guidewords; thereafter responses of the control equipments for these deviations
are analyzed. Then, consequences of the deviations are examined for vulnerability
towards occurrence of unsafe situations and suggestions are made to improve system
reliability, if required.

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To carry out HAZOP, a team was formed to carry out the assessment for effective and
systematic study of the LPG storage and bottling process. Accordingly following team
was formed.

 Mr I.Paul Durai From M/s Energon Petro Products Pvt Ltd

(Plant Manage)
 Mr. T. Sravanth From M/s. SV Enviro Labs & Consultants, Vizag

Inputs Required for HAZOP Study are as follows:

 Plot plan
 Process Manuals & Process flow Diagrams
 P&I diagrams

2.5 TYPES OF HAZARD CONSIDERED IN THE HAZOP STUDY

Following types of hazard have been considered in the study
1. Hazard to plant personnel working in the study
2. Damage to plant equipments
3. Hazard to and from product specification
4. Hazard to outside public
5. Hazard to Environment

Hazard & Operability studies for various sections:

Hazard & Operability studies have been carried out for the Energon Petro Products
Pvt. Ltd. LPG Bottling Plant by applying the significant guide words and adequacy of
safety systems are evaluated; and suggestions have been made accordingly in
worksheets.

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Fig 2.1 SITE PLAN

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Fig 2.2P&ID

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HAZOP Study Worksheet

Node: 1. Liquid Line Section from Tank Lorry Decanting Shed to Mounded Storage Vessels

Recommendations
Guide Word Deviation Parameter Causes Consequences Status/Action taken
Recommendations/Action required

No No Flow Flow 1 No LPG left in tanker Transfer pipe line There should be Will be provided
under pressure provision for Suction
pressure tripping
system for compressor

2 Tank trucks unloading No flow of LPG Valve positioning must

arms closed be ensured before
starting bulk unloading
operation

3 Loading Arms/ pipe Transfer pipe line There should be Will be Provided
line blockage under pressure provision for high
discharge pressure
tripping system for
compressor

4 Unloading arm failure Transfer pipe line Excess Flow Check EFCV will be provided
under pressure Valve on tanker side
as well as on hose
side should close
automatically

5 Any of the valves Transfer pipe line There should be Will be Provided
between road tanker under pressure provision for high
and MSV is closed discharge pressure
tripping system for
compressor

Less Low Flow Flow 1 Pressure differential is More time for Excess Flow Check Will be checked
less between the MSV frequently during the

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Node: 1. Liquid Line Section from Tank Lorry Decanting Shed to Mounded Storage Vessels

Recommendations
Guide Word Deviation Parameter Causes Consequences Status/Action taken
Recommendations/Action required

and road tanker decantation Valve to be checked Operation phase

2 Vapour compressor More time for Pressure gauges to be Will be Provided

fails to develop decantation provided
required pressure

3 Excess Flow Check Self explanatory Self explanatory Self explanatory

Valve of the tanker is
partially closing at a
pressure differential
less than rated

Less Less/Low Pressure 1 Some leakage or Fire Hazards Ensure proper working Self explanatory
Pressure compressor not able to of LPG compressor
create adequate
differential pressure

Less Less/Low Temperature 1 Very low ambient None. Since boiling None Self explanatory
Temperature temperature point of LPG is -9
deg. C and freezing
conditions in LPG
pipelines will not
occur because
lowest temperature
at Energon does not
reach -9 deg. C

More More/High Flow 1 Not possible None None EFCV will be provided
Flow

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Node: 1. Liquid Line Section from Tank Lorry Decanting Shed to Mounded Storage Vessels

Recommendations
Guide Word Deviation Parameter Causes Consequences Status/Action taken
Recommendations/Action required

More More/High Pressure 1 Isolation valves closed Transfer line In case of high Auto tripping system will
Pressure in error while subjected to pressure stop be provided
compressor running pressure operation and check
the transfer line

More More/High Temperature 1 LPG at higher If temperature rise Cool the pipeline by Will be followed
Temperature temperature due to fire not controlled water spray and
in vicinity transfer pipeline will regular patrolling is
rupture hence fire desired
hazards

Other than Corrosion Corrosion 1 Pure LPG is not Pipeline failure Periodic internal Periodic internal
corrosive but hence release of inspection of pipeline inspection will be done
mercaptan added to it LPG vapour may should be done to & thickness of pipeline
may corrode pipeline occur leading to Fire detect any corrosion will be measured ultra
hazards in the sonically
presence of ignition

Other than Maintenance Maintenance 1 During maintenance of LPG vapour/liquid Proper purging/water Will be followed
Hazards valves/pumps/compres may come out flushing before
sors/Testing of causing Fire hazards maintenance
Mounded Storage
vessels

Other than Start- Start- 1 Leakage from flange LPG vapour/liquid Strict supervision to Will be
up/Shutdown up/Shutdown joints at the time of may come out be followed at the followed
hazards connection/disconnecti causing Fire hazards time of Start-
on up/Shutdown
operations

2 Dry run of LPG

compressors

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Node: 1. Liquid Line Section from Tank Lorry Decanting Shed to Mounded Storage Vessels

Recommendations
Guide Word Deviation Parameter Causes Consequences Status/Action taken
Recommendations/Action required

As well as Flow of Contamination 1 Water present in LPG No hazardous Water draining from Water draining is done
foreign road tanker coming consequences MSV desired and as per established
material along with LPG draining be done as procedure
with LPG per the established
procedure to
minimize LPG
release

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HAZOP Study Worksheet

Node: 2. Vapour Line between Mounded Storage Vessels and Compressor Suction side

Recommendations

Guide Word Deviation Parameter Causes Consequences Status/Action taken

Recommendations/Action
required

No No Flow Flow 1 The MSV is Knocking of High liquid level Liquid level tripping
accidentally filled up compressor tripping system system will be
and no space for should be provided in provided. Further high
vapour suction side level alarm will be
provided in MSV and
hence no chance of
overfilling in MSV

2 The vapour line Compressor cylinder Low suction tripping Will be Provided
blockage/valve is heated up system should be
closed provided

3 Compressor failure The decantation If power failure is for Will be followed

due to power failure or operation of Tanker longer time D.G. sets
other reasons Lorry stops should be operated.

Less Less Flow Flow 1 Sudden decrease of Vapour formation too No action required as Self explanatory
temperature low resulting this condition is not
decrease in storage likely occurred as
pressure temperature in winter
is always more than 2
deg. C (as per 30
years IMD data) and
boiling point of LPG
is less than 0 deg. C
(-9 deg. C)

Less Less/Low Temperature 1 Very low ambient If ambient No action required as MSV will be inspected
Temperature temperature (below 0 temperature goes this condition is not by third party
deg. C) below boiling point of likely occurred as
LPG, the gas may be temperature in winter
freezed and bullet is always more than 2

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Node: 2. Vapour Line between Mounded Storage Vessels and Compressor Suction side

Recommendations

Guide Word Deviation Parameter Causes Consequences Status/Action taken

Recommendations/Action
required

shell rupture may deg. C (as per 30

take place years IMD data) and
boiling point of LPG
is less than 0 deg. C
(-9 deg. C)

More More/High Flow 1 Valve leak Vapour LPG release Inspect the valve Inspection will be done
Flow in case hence asphyxiation before start up of
excess flow problems and Fire compressor
check valve hazards
not working
2 Pipeline leak due to Vapour LPG release Inspection of line Inspection will be done
impact or other hence asphyxiation required before
reasons problems and Fire starting the
hazards compressor

3 Heat or flame on bullet Vapour LPG release If fire is grave the fire Auto medium velocity
hence asphyxiation hydrant can be sprinkler system will be
problems and Fire operated. Hence the provided and fire
hazards fire hydrant ring fighting will be done as
should always remain per Disaster
pressurized. Fire Management Plan
should also be
controlled by DCPs

More More/High Pressure 1 High pressure in bullet Vapour line burst Excess flow check Will be Provided
Pressure and release of LPG valve should be
may result into fire provided on bullet

2 Fire/ heating on LPG vapour release If fire is grave the fire Jockey pump shall be
external surface of in fire near the safety hydrant can be installed
bullet valve or a jet fire operated. Hence the
may ensure fire hydrant ring
should always remain

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ENERGON PETRO PRODUCTS PVT LTD – LPG BOTTLING PLANT HAZOP REPORT

Node: 2. Vapour Line between Mounded Storage Vessels and Compressor Suction side

Recommendations

Guide Word Deviation Parameter Causes Consequences Status/Action taken

Recommendations/Action
required

pressurized.

More More/High Temperature 1 Some fire in the vicinity Vapour pressure/ Proper maintenance SRV shall be installed
Temperature internal pressure rise of SRV's desired. Fire that will actuate and
in bullet due to fire in control measures auto-medium velocity
the vicinity. It may should work properly. sprinkler system will be
cause SRV actuation Auto-medium velocity provided which will
hence fire hazards water sprinkler bring down the
system should be temperature to normal
operated.

If SRVs fail to Same as explained Same as explained

actuate/ or fire is not above above
controlled bullet may
rupture

Other than Corrosion Corrosion 1 Pure LPG is not Pipeline failure Periodic internal Inspection will be done
corrosive but hence release of inspection of major and bullets will be
mercaptan added to it LPG vapour may piping and LPG hydraulically tested by
may corrode occur leading to Fire bullets after each five CCE approved third
pipeline/bullet hazards in the years should be done party
presence of ignition to detect any
corrosion

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ENERGON PETRO PRODUCTS PVT LTD – LPG BOTTLING PLANT HAZOP REPORT

HAZOP Study Worksheet

Node: 3. Vapour Line between compressor discharge and TLD shed

Recommendations

Guide Word Deviation Parameter Causes Consequences Status/Action taken

Recommendations/Action
required

No No Flow Flow 1 Compressor not Tank lorry cannot be LPG pumps and Preventive maintenance
working decanted compressors are schedule will be followed
most critical
equipment of plant
therefore there
should be preventive
maintenance and
daily inspection of
equipment

2 Power failure Same as explained The D.G. set should D.G. set installed will be
above be regularly tested for operated
fool proof operation.
Compressor can be
started after
transferring plant load
from state grid to
D.G. set

3 Pipeline blockage Back pressure on There should be Check Valve will be

compressor provision in discharge provided
pipeline to prevent
compressor from
back pressure effect

Less Less/Low Pressure 1 Compressor not Desired results not Proper maintenance Preventive maintenance
Pressure working properly obtained pertaining of compressor schedules will be followed
to decantation of desired
lorry but no fire
hazards

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ENERGON PETRO PRODUCTS PVT LTD – LPG BOTTLING PLANT HAZOP REPORT

Node: 3. Vapour Line between compressor discharge and TLD shed

Recommendations

Guide Word Deviation Parameter Causes Consequences Status/Action taken

Recommendations/Action
required

Less Less/Low Temperature 1 LPG at low ambient None None Self explanatory
Temperature temperature

More More/High Temperature 1 Cylinder jacket of The compressor There should be Cooling water interlocking
Temperature compressor not being heats up and it regular check for pressure switch will be
cooled properly fails/trips proper cooling water provided in the return line
line and its operation

2 The discharge line of The pipeline/ hose The fire fighting Fire fighting arrangement
compressor heated up may fail due to heat arrangements be will be checked at regular
due to external fire or radiation hence inspected and intervals
flame asphyxiation checked at regular
problems and Fire intervals
hazards

Other than Corrosion Corrosion 1 Pure LPG is not Pipeline failure Periodic internal Periodic internal inspection
corrosive but hence release of inspection of pipeline will be done & thickness of
mercaptan added to it LPG vapour may should be done to pipeline will be measured
may corrode pipeline occur detect any corrosion ultra sonically

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ENERGON PETRO PRODUCTS PVT LTD – LPG BOTTLING PLANT HAZOP REPORT

HAZOP Study Worksheet

Node: 4. Inlet/Outlet Liquid LPG pipeline from MSV to LPG pump suction

Recommendations

Guide Word Deviation Parameter Causes Consequences Status/Action taken

Recommendations/Action
required

No No Flow Flow 1 Any of the valve from Operational delay Regular and Preventive
MSV to LPG pump preventive maintenance of valves
suction or TLD shed to maintenance of will be done as per
bullet closed valves desired schedules formulated

2 Pipeline blockage LPG pumps heats up The pipeline should Line strainer will be
due to wearing and be cleaned after each provided on suction
increased vibration two years side of pump
level on account of
cavitation developed
in the pump

3 No LPG in MSV LPG pump heats up Some interlocking Low pressure tripping
system be provided device will be provided
so that if there is no
flow of LPG from
bullet to pipeline it
should trip

Less Less Flow Flow 1 Blockage in the LPG pump will lose Clear blockage open A tripping system will
pipeline or the valves its NPSH (Net valve fully be provided
are not fully open Positive Suction
Head)

Less Less/Low Temperature 1 LPG at low None None Self explanatory

Temperature temperature

2 Ambient temperature None None Self explanatory

very low

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ENERGON PETRO PRODUCTS PVT LTD – LPG BOTTLING PLANT HAZOP REPORT

Node: 4. Inlet/Outlet Liquid LPG pipeline from MSV to LPG pump suction

Recommendations

Guide Word Deviation Parameter Causes Consequences Status/Action taken

Recommendations/Action
required

More More/High Flow 1 Not possible None None EFCV will be provided
Flow

More More/High Temperature 1 External fire on Pipeline failure and The hydrant should Fire hydrant valves &
Temperature pipeline LPG pool formation be operated to kill the DCP will be used to kill
on ground hence fire fire in the incipient the fire
hazards stage

2 External fire on bullets The high intensity The SRV should start Yearly inspection/
may cause shell functioning if the testing of SRV will be
rupture hence pressure in bullet is done by the competent
vapour cloud equivalent to its person
formation and fire design pressure.
hazards Hence proper
functioning of SRV be
ensured

Other than Corrosion Corrosion 1 Internal corrosion on Flammable LPG Periodic internal Inspection will be done
piping and pipe fittings vapour release inspection of pipeline during Operation phase
should be done to
detect any corrosion

Reverse/ Reverse/ Flow 1 Not possible due to None None Self explanatory
Misdirected Misdirected presence of NRV (Non
Flow of LPG return valve) on bullet
side as well as on
pump suction side

As well as Flow of foreign Flow 1 Flow of water along No hazardous Water draining for Water draining will be
material along with LPG. Water consequences each new parcel id done as per established
with LPG draining not done for desired procedure
each new parcel
received

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ENERGON PETRO PRODUCTS PVT LTD – LPG BOTTLING PLANT HAZOP REPORT

HAZOP Study Worksheet

Node: 5. LPG Pump discharge line

Recommendations

Guide Word Deviation Parameter Causes Consequences Status/Action taken

Recommendations/Action
required

No No Flow Flow 1 Pump not working Bottling process will Check motor faults, The pumps and
be stopped Impeller mechanical machineries will be
automatically seal failure in other maintained as per their
words good maintenance schedule.
maintenance of pump
and motor is desired

2 All liquid LPG going Same as explained Regular checking of Regular checking will
back to suction line above pump and pipeline be done
through circulation line desired

3 Some valve erratically Bottling operation in Proper maintenance Valve will be properly
closed filling shed stops of valve is required maintained. Schedules
formed for maintenance
will be strictly followed

4 Sudden power failure Bottling process will If power failure is D.G. set installed will be
be stopped prolonged the D.G. operated
automatically set may be used

5 No LPG available at Same as explained Ensure availability of Will be ensured

suction above LPG in MSV before
starting pump

Less Less Flow Flow 1 Some obstruction in LPG pump will lose Clear the blockage A tripping system will
pipeline or some its NPSH. The be provided
leakage in leaked LPG may
pipeline/LPG pump cause fire &

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ENERGON PETRO PRODUCTS PVT LTD – LPG BOTTLING PLANT HAZOP REPORT

Node: 5. LPG Pump discharge line

Recommendations

Guide Word Deviation Parameter Causes Consequences Status/Action taken

Recommendations/Action
required

explosion hazards

Less Less/Low Temperature LPG at low No consequence None Self explanatory

Temperature temperature in bullet
due to low ambient
temperature

Less Less/Low Pressure Some leakage in Fire and explosion Operate fire fighting Adequate fire fighting
Pressure discharge line hazard system arrangements will be
provided

More More/High Flow Throttling valve not The downstream LPG pump being a Self explanatory
Flow functioning properly discharge line will be centrifugal pump only
under pressure churning will take
place and discharge
pressure will increase
than rated pressure.
No fire hazards
anticipated

More More/High Pressure Suction line pressure The discharge line Control the discharge Maintenance of DP
Pressure higher than normal subjected to higher pressure by using the valve, TSV (Thermal
pressure valve on the Safety Valve) and Pop
circulation line action valve (Safety
provided in pump, as Relief Valve) will be
well as DP done through
(differential pressure) maintenance schedule
valve provided in the formulated
discharge line may
be used. Pop action
relief valves are
provided in the
pipeline segments to
take care of higher

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ENERGON PETRO PRODUCTS PVT LTD – LPG BOTTLING PLANT HAZOP REPORT

Node: 5. LPG Pump discharge line

Recommendations

Guide Word Deviation Parameter Causes Consequences Status/Action taken

Recommendations/Action
required

discharge pressure

More More/High Temperature 1 The pipeline is at a The pipeline may fail Stop pump and auto Procedure mentioned in
Temperature higher temperature if fire is severe and medium velocity last column is followed
due to flame or fire there may be fire water sprinkler to be
hazards operated to kill the
fire. If fire is severe
then fire hydrant
water discharge can
also be used

Other than Corrosion Corrosion 1 Pure LPG is not Pipeline failure Periodic internal Periodic internal
corrosive but hence release of inspection of pipeline inspection will be done
mercaptan added to it LPG vapour may should be done to & thickness of pipeline
may corrode pipeline occur detect any corrosion will be measured ultra
sonically

Reverse/Misdi Reverse/Misdir Flow 1 Not possible due to None None Self explanatory
rected ected Flow NRV (Non return
valve) at discharge
side of LPG pump and
filling machines

As well as Flow of Contamination 1 Water draining not No hazardous Water draining for Water draining will be
foreign done in MSV on consequences each new parcel is done as per established
material along regular basis and desired procedure
with LPG water is pumped along
with LPG

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ENERGON PETRO PRODUCTS PVT LTD – LPG BOTTLING PLANT HAZOP REPORT

HAZOP Study Worksheet

Node: 6. LPG Mounded Storage Vessel

Recommendations

Guide Word Deviation Parameter Causes Consequences Status/Action taken

Recommendations/Action
required

No No Flow Flow 1 No LPG in MSV Compressor cylinder Low level suction Will be Provided
to/from bullet heats up and tripping for pump and
damages to LPG compressor are
pump desired to prevent the
damage

2 Inlet line/ Outlet line More pressure in Fire hydrant valves Dedicated fire fighting
closed transfer hose and and fire protection system provided
pipeline and this may measures should
cause transfer hose work fail safe
rupture hence fire
hazards

3 Pressure differential Decantation process Regular patrolling of Regular patrolling will

not adequate due to of LPG tanker will be pipeline desired be done
some leakage or some slow and low flow to
valve partially opened LPG pump thereby
in pipeline effect on bottling
process

Less Less flow to Flow Leakage in the Regular patrolling of Regular patrolling
and from MSV valves or pipeline. It pipeline desired and maintenance of valves
may cause fire proper maintenance will be done as per
hazards of valves desired maintenance schedules
formulated

The decantation Same as explained Same as explained

takes more time above above

More More/High Flow 1 Not possible None None

Flow
EFCV will be provided

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ENERGON PETRO PRODUCTS PVT LTD – LPG BOTTLING PLANT HAZOP REPORT

Node: 6. LPG Mounded Storage Vessel

Recommendations

Guide Word Deviation Parameter Causes Consequences Status/Action taken

Recommendations/Action
required

More More/High Pressure 1 High Liquid level Liquid may knock High liquid level Will be Provided
Pressure compressor suction tripping for
compressor desired

2 Some fire or heat from SRV (Safety Relief Control fire and Fire control done as per
vicinity Valve) may operate ensure proper DMP and SRVs will be
hence fire may maintenance of SRVs tested annually and
aggravate records are maintained

More More Level Level 1 Rochester Gauge not LPG may pass Preventive Preventive
showing value (weigh through SRVs and maintenance of maintenance will be
scale) hence fire and toxic Rochester Gauge done as per the
hazards. No damage desired schedule
to LPG pump and
compressor because
these will trip due to
high level tripping
system

More More/High Temperature 1 External fire in the SRVs actuate and Adequate fire The fire fighting system
Temperature vicinity passes large vapour protection facilities will be provided as per
flow required and fail safe OISD requirements.
working of these
facilities required Temperature indicator
will be provided

Other than Corrosion Corrosion 1 Leakage of LPG due to Fire Hazards All pipelines should The pipeline thickness
corrosion be subjected to will be measured
thickness ultrasonically and these
measurements and are also subjected to
hydrostatic tests to hydrostatic tests.
determine strength Record of thickness will
be maintained

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ENERGON PETRO PRODUCTS PVT LTD – LPG BOTTLING PLANT HAZOP REPORT

Node: 6. LPG Mounded Storage Vessel

Recommendations

Guide Word Deviation Parameter Causes Consequences Status/Action taken

Recommendations/Action
required

As well as Other than Contamination 1 Water may come along None hazardous Water draining Water draining will be
LPG with LPG if water should be done for done as per established
draining not done each new parcel procedure
received

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ENERGON PETRO PRODUCTS PVT LTD – LPG BOTTLING PLANT HAZOP REPORT

HAZOP Study Worksheet

Node: 7. LPG Carousel

Recommendations

Guide Word Deviation Parameter Causes Consequences Status/Action taken

Recommendations/Action
required

No No Flow Flow 1 LPG pump not working Filling operation at Rectify the pump Self explanatory
carousel will stop

2 LPG discharge line Fire and explosion Stop pump and repair Necessary hydrostatic
leakage hazard leakage. Patrolling tests for pipeline will be
desired done. Regular patrolling
will also be taken up

3 Filling gun hose Fire and explosion Proper maintenance LPG hoses will be
rupture hazard of hoses desired subjected to
hydrostatic, pneumatic
and electrical continuity
tests once in 4 months

4 Filling gun detached LPG vapour release Proper functioning Self explanatory
from cylinder and maintenance of
carousel desired

Less Less Flow Flow 1 Some leakage in If leakage persists Regular patrolling of Regular patrolling will
pipeline for longer time pipeline desired be taken up
fire/explosion
hazards may occur

2 LPG pump not running The filling time for The pump Will be maintained
at its rated capacity cylinders will maintenance desired
increase

Less Less/Low Temperature 1 Very low ambient None. Since boiling None Self explanatory
Temperature temperature point of LPG is -9
deg. C and freezing
conditions in LPG
pipelines will not
occur because

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ENERGON PETRO PRODUCTS PVT LTD – LPG BOTTLING PLANT HAZOP REPORT

Node: 7. LPG Carousel

Recommendations

Guide Word Deviation Parameter Causes Consequences Status/Action taken

Recommendations/Action
required

lowest temperature
at Energon does not
reach -9 deg. C

Less Less/Low Pressure 1 LPG pump not running Less flow resulting in Proper maintenance Maintenance schedules
Pressure at its rated capacity slow rate of LPG of pump desired of pumps will be
filling at carousel followed

2 Some leakage in Fire and explosion Proper operation of Fire fighting

discharge line hazard fire fighting systems arrangements will be
desired provided as per
statutory requirements

More More/High Flow 1 Not possible None None Self explanatory

Flow

More More/High Pressure 1 Not possible None None Self explanatory

Pressure

More More/High Temperature 1 Some fire in the vicinity Pipeline may rupture Ensure proper Fire fighting
Temperature causing higher causing fire and functioning of fire arrangements will be
pressure on LPG explosion fighting systems provided as per
pump discharge line statutory requirements.
connected to carousel TSV provided between
two flanges

Other than Corrosion Corrosion 1 Pure LPG is not Pipeline failure Periodic internal Periodic internal
corrosive but hence release of inspection of major inspection will be done
mercaptan added to it LPG vapour may piping and LPG & thickness of pipeline
may corrode pipeline occur bullets after each five is measured ultra
or bullet years should be done sonically to detect any
to detect any corrosion
corrosion

As well as Flow of foreign Contamination 1 Water draining not No hazardous Water draining for Water draining will be

Page 39
ENERGON PETRO PRODUCTS PVT LTD – LPG BOTTLING PLANT HAZOP REPORT

Node: 7. LPG Carousel

Recommendations

Guide Word Deviation Parameter Causes Consequences Status/Action taken

Recommendations/Action
required

material along done in MSV on consequence only each new parcel done as per established
with LPG regular basis and water will go along received desired in procedure
water is pumped along with LPG in cylinders MSV
LPG and it will go to
cylinders

Reverse/Misdi Reverse/Misdi Flow 1 Not possible due to None None Self explanatory
rected rected Flow presence of NRV (non
return valve) at
discharge of LPG
pump and at carousel

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ENERGON PETRO PRODUCTS PVT LTD – LPG BOTTLING PLANT HAZOP REPORT

HAZOP Study Worksheet

Node: 8. LPG Compressor suction line

Recommendations

Guide Word Deviation Parameter Causes Consequences Status/Action taken

Recommendations/Action
required

No No Flow Flow 1 The vapour line Compressor cylinder Low level suction Low suction tripping will
blockage/valve is heated up tripping system be provided
closed should be provided

2 No LPG vapour Knocking of High liquid level High liquid level tripping
available for suction in compressor tripping system system will be provided
mounded storage should be provided in
vessel suction side

3 Compressor failure The decantation If power failure is for D.G. sets will be
due to power failure or operation of Tanker longer time D.G. sets operated
other reasons Lorry stops should be operated.

4 NRV stuck Compressor cylinder Low level suction Will be Provided

heated up tripping system
should be provided

Less Less Flow Flow 1 Sudden decrease of Vapour formation too No action required as Self explanatory
temperature low resulting this condition is not
decrease in storage likely occurred as
pressure temperature in winter
is always more than 2
deg. C (as per 30
years IMD data) and
boiling point of LPG
is less than 0 deg. C
(-9 deg. C)

More More/High Flow 1 Pipeline leak due to Vapour LPG release Inspection of line Inspection will be done
Flow in case impact or other hence asphyxiation required before
excess flow reasons problems and Fire starting the
check valve hazards compressor

Page 41
ENERGON PETRO PRODUCTS PVT LTD – LPG BOTTLING PLANT HAZOP REPORT

Node: 8. LPG Compressor suction line

Recommendations

Guide Word Deviation Parameter Causes Consequences Status/Action taken

Recommendations/Action
required

not working 2 Valve leak Vapour LPG release Inspect the valve Inspection will be done
hence asphyxiation before start up of
problems and Fire compressor
hazards

3 Heat or flame on Vapour LPG release If fire is grave the fire Auto medium velocity
mounded storage hence asphyxiation hydrant can be sprinkler system
vessels (MSV and problems and Fire operated. Hence the provided and fire
compressors) hazards fire hydrant ring fighting will be done as
should always remain per Disaster
pressurized. Fire Management Plan
should also be
controlled by DCPs

More More/High Pressure 1 Higher pressure in Vapour line burst Excess flow check Excess flow check
Pressure connection vessels and release of LPG valve should be valve will be provided
such as MSV may result into fire provided on bullet
side

2 Fire/heating on LPG vapour release If fire is grave the fire Jockey pump shall be
external surface of due to actuation of hydrant can be installed
storage vessels the safety relief valve operated. Hence the
or a jet fire may fire hydrant ring
ensure should always remain
pressurized.

Other than Corrosion Corrosion 1 Pure LPG is not Pipeline failure Periodic internal Periodic internal
corrosive but hence release of inspection of major inspection will be done
mercaptan added to it LPG vapour may piping and equipment & thickness of pipeline
may corrode pipeline/ occur (after each five years) is measured ultra
and storage vessels should be done to sonically to detect any
detect any corrosion corrosion. Storage
vessels are inspected
and subjected to

Page 42
ENERGON PETRO PRODUCTS PVT LTD – LPG BOTTLING PLANT HAZOP REPORT

Node: 8. LPG Compressor suction line

Recommendations

Guide Word Deviation Parameter Causes Consequences Status/Action taken

Recommendations/Action
required

statutory tests once in

five years by CCE
approved third party

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ENERGON PETRO PRODUCTS PVT LTD – LPG BOTTLING PLANT HAZOP REPORT

HAZOP Study Worksheet

Node: 9. LPG Compressor discharge line

Recommendations

Guide Word Deviation Parameter Causes Consequences Status/Action taken

Recommendations/Action
required

No No Flow Flow 1 Compressor not Tank lorry cannot be LPG pumps and Preventive
working decanted compressors are maintenance schedule
most critical will be followed
equipment of plant
therefore there
should be preventive
maintenance and
daily inspection of
equipment

2 Power failure Same as explained The D.G. set should D.G. sets shall be
above be regularly tested for operated
fool proof operation.
Compressor can be
started after
transferring plant load
from state grid to
D.G. set

3 Pipeline blockage Back pressure on There should be Check Valve will be

compressor provision in provided
discharge pipeline to
prevent compressor
from back pressure
effect

Discharge pressure Tripping system to Tripping system will be

is high be provided provided

Less Less/Low Pressure 1 Compressor not Desired results not The proper Preventive
Pressure working properly obtained pertaining maintenance of maintenance schedules
to decantation of compressor desired will be formulated and

Page 44
ENERGON PETRO PRODUCTS PVT LTD – LPG BOTTLING PLANT HAZOP REPORT

Node: 9. LPG Compressor discharge line

Recommendations

Guide Word Deviation Parameter Causes Consequences Status/Action taken

Recommendations/Action
required

lorry but no fire will be followed

hazards

More More/High Temperature 1 Cylinder jacket of The compressor There should be Cooling water
Temperature compressor not being heats up and it regular check for interlocking pressure
cooled properly fails/trips proper cooling water switch will be provided
line and its operation

2 The discharge line of The pipeline/ loading The fire fighting Fire fighting
compressor heats up arms may fail due to arrangements be arrangement will be
due to external fire or heat radiation hence inspected and checked at regular
flame asphyxiation checked at regular intervals
problems and Fire intervals
hazards

Other than Corrosion Corrosion 1 Pure LPG is not Pipeline failure Periodic internal Periodic internal
corrosive but hence release of inspection of inspection will be done
mercaptan added to it LPG vapour may pipeline should be & thickness of pipeline
may corrode pipeline occur done to detect any will be measured ultra
corrosion sonically

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ENERGON PETRO PRODUCTS PVT LTD – LPG BOTTLING PLANT HAZOP REPORT

HAZOP Study Worksheet

Node: 10. LPG Evacuation Compressor (Evacuation Line)

Recommendations

Guide Word Deviation Parameter Causes Consequences Status/Action taken

Recommendations/Action
required

No No Flow Flow 1 Compressor not Evacuation vessels LPG compressors Preventive

working cannot be decanted are most critical maintenance schedule
equipment of plant will be followed
therefore there
should be preventive
maintenance and
daily inspection of
equipment

2 Power failure Same as explained The D.G. set should D.G. set shall be
above be regularly tested operated
for fool proof
operation.

3 Pipeline blockage Back pressure on There should be Check Valve will be

compressor provision in provided
discharge pipeline to
prevent compressor
from back pressure
effect

Discharge pressure Tripping system to Tripping system will be

is high be provided provided

Less Less/Low Pressure 1 Compressor not Desired results not The proper Preventive
Pressure working properly obtained pertaining maintenance of maintenance schedules
to decantation of compressor desired shall be formulated and
Evacuation vessels followed
but no fire hazards

More More/High Temperature 1 Cylinder jacket of The compressor There should be Cooling water
Temperature compressor not being heats up and it regular check for interlocking pressure
proper cooling water

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ENERGON PETRO PRODUCTS PVT LTD – LPG BOTTLING PLANT HAZOP REPORT

Node: 10. LPG Evacuation Compressor (Evacuation Line)

Recommendations

Guide Word Deviation Parameter Causes Consequences Status/Action taken

Recommendations/Action
required

cooled properly fails/trips line and its operation switch will be provided

2 The discharge line of The pipeline may fail The fire fighting Fire fighting
compressor heats up due to heat radiation arrangements be arrangement will be
due to external fire or hence asphyxiation inspected and checked at regular
flame problems & fire checked at regular intervals
hazards intervals

Other than Corrosion Corrosion 1 Pure LPG is not Pipeline failure Periodic internal Periodic internal
corrosive but hence release of inspection of inspection will be done
mercaptan added to it LPG vapour may pipeline should be & thickness of pipeline
may corrode pipeline occur done to detect any is measured ultra
corrosion sonically to detect any
corrosion

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ENERGON PETRO PRODUCTS PVT LTD – LPG BOTTLING PLANT HAZOP REPORT

HAZOP Study Worksheet

Node: 11. Relief Valve on Tanks

Recommendations

Guide Word Deviation Causes Consequences Status/Action taken

Recommendations/Action
required

No No relief valve Isolation of a relief valve Possibility of over Interlocks should be Double relief valves will
in use for maintenance or pressurization of the provided so that in be provided on the tanks
testing. vessels case a relief valve is
isolated for
No provision of multiple
maintenance or
relief valves.
testing remaining

No provision of interlocks valve may continue

in use

No No marking of valves Interchanging of Relief valves will be

identification of Valves marked with
relief valves
-The set pressure

-The discharge rate

-Manufacturer's name &

identification number

Not Vent pipe fitted - Improper height of the In case of ignition of - Maintained the Will be followed
with relief vent outlets discharging gas the condition of vent
valves not of jet fire may become pipes provided with
- Vent pipes bent down
proper design the source of heat to loose fitting rain
wards
the same tank or to caps

- Vent pipes not provided the adjacent tank - In order to avoid

with caps accumulation of

water a bleed hole
should be provided
at the lowest point of
each vent pipe.

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ENERGON PETRO PRODUCTS PVT LTD – LPG BOTTLING PLANT HAZOP REPORT

HAZOP Study Worksheet

Node: 12. Filling of Cylinder

Recommendations

Guide Word Deviation Parameter Causes Consequences Status/Action taken

Recommendations/Action
required

No No Flow Flow 1 LPG pump not working Filling operation at Rectify the pump Self explanatory
carousel will stop

2 LPG discharged line Fire and explosion Stop pump and Necessary hydrostatic
leakage hazard repair leakage. tests for pipeline will be
Patrolling desired done. Regular patrolling
will be taken up

3 Filling gun hose Fire and explosion Proper maintenance LPG hoses will be
rupture hazard of hoses desired subjected to
hydrostatic, pneumatic
and electrical continuity
tests once in 4 months

4 Filling gun detached LPG vapour release Proper functioning Self explanatory
from cylinder and maintenance of
carousel desired

Less Less Flow Flow 1 Some leakage in If leakage persists Regular patrolling of Regular patrolling will
pipeline for longer time pipeline desired be taken up
fire/explosion
hazards may occur

2 LPG pump not running The filling time for The pump Proper functioning of
at its rated capacity cylinders will maintenance desired pumps will be ensured
increase through maintenance
schedules formulated

Less Less/Low Temperature 1 Very low ambient None. Since boiling None Self explanatory
Temperature temperature point of LPG is -9
deg. C and freezing
conditions in LPG
pipelines will not

Page 49
ENERGON PETRO PRODUCTS PVT LTD – LPG BOTTLING PLANT HAZOP REPORT

Node: 12. Filling of Cylinder

Recommendations

Guide Word Deviation Parameter Causes Consequences Status/Action taken

Recommendations/Action
required

occur because
lowest temperature
at Energon does not
reach -9 deg. C

Less Less/Low Pressure 1 LPG pump not running Less flow resulting in Proper maintenance Maintenance schedules
Pressure at its rated capacity slow rate of LPG of pump desired of pumps will be
filling at carousel followed

2 Some leakage in Fire and explosion Proper operation of Fire fighting

discharge line hazard fire fighting systems arrangements will be
desired provided as per
statutory requirements

More More/High Flow 1 Not possible None None Self explanatory

Flow

More More/High Pressure 1 Not possible None None Self explanatory

Pressure

More More/High Temperature 1 Some fire in the vicinity Pipeline may rupture Ensure proper Fire fighting
Temperature causing higher causing fire and functioning of fire arrangements will be
pressure on LPG explosion fighting systems provided as per
pump discharge line statutory requirements
connected to carousel

Other than Corrosion Corrosion 1 Pure LPG is not Pipeline failure Periodic internal Periodic internal
corrosive but hence release of inspection of major inspection is done &
mercaptan added to it LPG vapour may piping and LPG thickness of pipeline will
may corrode pipeline occur bullets after each five be measured ultra
or bullet years should be done sonically to detect any
to detect any corrosion
corrosion

As well as Flow of foreign Contamination 1 Water draining not No hazardous Water draining for Water draining will be

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Node: 12. Filling of Cylinder

Recommendations

Guide Word Deviation Parameter Causes Consequences Status/Action taken

Recommendations/Action
required

material along done in MSV on consequence only each new parcel done as per established
with LPG regular basis and water will go along received desired in procedure
water is pumped along with LPG in cylinders MSV
LPG and it will go to
cylinders

Reverse/Misdi Reverse/ Flow 1 Not possible due to None None Self explanatory
rected Misdirected presence of NRV (non
Flow return valve) at
discharge of LPG
pump and at carousel

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HAZOP Study Worksheet

Node: 13. Degassing of Cylinder

Recommendations

Guide Word Deviation Causes Consequences Status/Action taken

Recommendations/Action
required

No NA

Less NA

More NA

Other than NA

As well as NA

Reverse/Misdirect NA
ed

Other Filled cylinder Cylinder received Fire and Dispersion Return the cylinder Will be followed
received without proper of LPG for proper degassing
evacuation

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HAZOP Study Worksheet

Node: 14. Hydro Testing of Cylinder

Recommendations

Guide Word Deviation Parameter Causes Consequences Status/Action taken

Recommendations/Action
required

No No Pressure - No water Process disturbance Check the water filling

- Obstruction of cylinder.
- Valve closed Scrap the leaky
- Cylinder leaked cylinder.

Less Less/Low Pressure Empty cylinder Process disturbance Check the water filling
Pressure Leaky cylinder of cylinder.
Testing pump failure Scrap the leaky
cylinder.
Check testing pump
regularly.
Calibrate pressure
gauge regularly.

More More/High Pressure Breaking of Pipeline. Spillage Test periodically Over pressure safety
Pressure Cylinder Rupture. device shall be installed

Other than NA

As well as NA

Reverse/Misdi Reverse pressure Not Possible

rected

Other Cylinder received Failure of cylinder Return the cylinder for Will be followed
without degassed proper degassing.

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HAZOP Study Worksheet

Node: 15. Painting of Cylinder

Recommendations

Guide Word Deviation Parameter Causes Consequences Status/Action taken

Recommendations/Action
required

No No Flow Flow No paint Process disturbance Paint gun nozzle Pressure gauge and SRV
No air pressure properly checked. shall be installed
Paint gun nozzle The air pressure
chocked properly checked.
Pressure gauge and
SRV calibrated and
checked.

Less Less Flow Improper painting Process disturbance Paint gun nozzle
Nozzle chocked properly checked.
Less air flow The air pressure
properly checked.

More More/High Flow More painting Wastage of paint Air pressure properly Over pressure safety
Flow Breakage of air gun checked. device will be installed
pipe Pressure gauge
properly checked.

Other than NA

As well as NA

Reverse/Misdi NA
rected

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HAZOP Study Worksheet

Node: 16. Air Compressor

Recommendations

Guide Word Deviation Parameter Causes Consequences Status/Action taken

Recommendations/Action
required

No No Flow Flow 1 Compressor not Bottling operation Compressors are Preventive

working hindrance most critical maintenance schedule
equipment of plant will be followed
therefore there
should be preventive
maintenance and
daily inspection of
equipment

2 Power failure Same as explained The D.G. set should D.G. sets will be
above be regularly tested for operated
fool proof operation.
Compressor can be
started after
transferring plant load
from state grid to
D.G. set

3 Regulator failure Potential for the Confirm that the

maximum air supply design is rated for full
pressure to be within air pressure to the
the supply pipe to the final isolation valves
final isolation valve at for each air user
each air user

Less Less/Low Pressure 1 Compressor not Bottling operation The proper Preventive
Pressure working properly hindrance maintenance of maintenance schedules
compressor desired will be formulated and
being followed

More More/High Pressure Compressor Potential for Make sure the vendor Self explanatory
Pressure deadheaded equipment damage package has
appropriate

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ENERGON PETRO PRODUCTS PVT LTD – LPG BOTTLING PLANT HAZOP REPORT

Node: 16. Air Compressor

Recommendations

Guide Word Deviation Parameter Causes Consequences Status/Action taken

Recommendations/Action
required

and possible failure safeguards for

compressor
deadhead and if a
blow off valve /
pressure safety valve
is provided then it
should not yield
unacceptable noise
levels

More More/High Temperature The discharge line of Potential for The fire fighting Fire fighting
Temperature compressor heats up equipment damage arrangements be arrangement are
due to external fire or and possible failure inspected and checked at regular
flame checked at regular intervals
intervals

Other than NA

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HAZOP Study Worksheet

Node: 17. PMCC Room

Recommendations

Guide Word Deviation Parameter Causes Consequences Status/Action taken

Recommendations/Action
required

No No Voltage Voltage DG set self-starter No power generation Sustained routine Preventive

problem maintenance to be maintenance schedule
followed will be followed
Battery failure

Field circuit
open/reverse

No fuel (HSD) in
reserve tank of DG set

Ring/Gear problem

Coupling of generator
is detached

Less Less/Low Voltage Unequal distribution of Operational problem Sustained routine Preventive
Voltage fuel (HSD) in all the maintenance to be maintenance schedules
Due to less voltage
fuel injector followed shall be formulated and
line, current will be
being followed
Partial clogging of the high and if the line
fuel (HSD) filter current is high than
the rated current-
Due to defective
Insulation failure may
governor
occur resulting in

Air gap between rotor terms of accident

and starter is manpower loss

increased

More More Voltage Voltage RPM throttle/governor Load of power will be High voltage relay to Self explanatory
failure affected be provided

Magnetic field tapping Engine High temperature

increase malfunctioning alarm to be provided

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Node: 17. PMCC Room

Recommendations

Guide Word Deviation Parameter Causes Consequences Status/Action taken

Recommendations/Action
required

Temperature will be
high

Other than NA

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HAZOP Study Worksheet

Node: 18 Cylinder de-shaping unit

Recommendations

Guide Word Deviation Parameter Causes Consequences Status/Action taken

Recommendations/Action
required

No No Pressure Pressure -Obstruction Process disturbance Check the valves

- Valve closed
Cylinder cannot be de-
shaped

Less Less/Low Pressure Empty cylinder Process disturbance Check testing pump
Pressure Testing pump failure regularly.
Calibrate pressure
gauge regularly.

More More/High Pressure Breaking of Pipeline. Damage to equipment Test periodically Over pressure safety
Pressure device shall be installed

Other than NA

As well as NA

Reverse/Misdi Reverse pressure Not Possible

rected

Other Cylinder received Failure of cylinder LPG leakage Return the cylinder for Will be followed
without degassed proper degassing.

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2.6 RECOMMENDATIONS
Based on worksheets of Energon Petro Products Pvt. Ltd, LPG Plant, recommendations
to be followed during the construction and Operation Phase are:
1. All the operations should be carried out under the supervision of designated
competent supervisor and carryout NDT as per schedule for weld joints at nozzle and
pipe along with valve examination and replace immediately if found any
inconformity.
2. Ensuring timely Statutory testing of MSV as per SMPV (The Static and Mobile
Pressure Vessels) rule.
3. Ensuring replacement of fasteners, studs, gaskets etc. during hydro testing of vessels.
4. Start of smooth LPG flow during unloading should be ascertained.
5. Inspection of pipes for internal & external corrosion shall be carried out with special
attention.
6. During bottling operation one personnel should be present at each stage of operation.
7. Work permit system to be strictly followed.
8. Electrical fitting/earthing should be checked regularly.
9. Sprinkler system, tripping of compressors and LPG pumps, ROVs, LPG supply and
return lines, actuation of deluge valve should be checked regularly to ensure their
desired operation at the time of actual emergency and this should be followed strictly.
10. Adequate training to be provided to Operators at the time of evacuation of the unit.

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