draft hazop study
DESCRIPTION
HAZOPTRANSCRIPT
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Sample-CokeovenLicensed To : HAMSAGARS
HAMS-GPS : HAZOP Study for :
ACTION REPORT
Project/Plant stage at HAZOP : Detailed engineering stage
Date: 14/01/2012:53:45 PM
Part-1a Action by Report- Design intension wise
Design intention (Operation): A.0
Description of design intention:
Whether Cokeoven Technology procured with HAZOP Study Report?
Node: A.0
Sop reference: N.A.Hazop study Number: A.0P and I Dwg. No. N.A.
Parameter : A.0
HAZOP GUIDE WORD
RECOMMENDATION FOR BETTER HAZARD CONTROL Action by: Name , Designation, Department
Action Date
For future Technology Procurement agreements, may make it mandatory for all Projects to include HAZOP study as part of Technology package.
(1) NO (NOT OR NONE)
Future Project Authorities
Action taken:
For future Technology Procurement agreements, may make it mandatory for all Projects to include HAZOP study as part of Technology package.
SIL/LOP: 1
Design intention (Operation): A. Separate Gas and Liquid at required Temperature
Description of design intention:
Separate Gas and Liquid at required Temperature
Node: A.1 Gas from Battery to byproduct
Sop reference: N.A.Hazop study Number: A.1P and I Dwg. No. PD-1055
Parameter : A.1 Temperature
HAZOP GUIDE WORD
RECOMMENDATION FOR BETTER HAZARD CONTROL Action by: Name , Designation, Department
Action Date
1. Consider HT Alarm for gas2. Provide LP Alarm for ammonia liquor in CCR 3. Bleeding of gas requires ignition and auto ignition to be provided
(2) MORE OF Project authority
Action taken:
1. Consider HT Alarm for gas2. Provide LP Alarm for ammonia liquor in CCR 3. Bleeding of gas requires ignition and auto ignition to be providedSIL/LOP: 1
Provide on all cases of piping & all Flanges as per OISD-110. Normally bonding is done using round wires. Ihis is not correct. It is necessary to follow for Strip specs IS-3043 & IS-7689 and OISD-108.
(17) STATIC CHARGE
Project authority
Action taken:
Provide on all cases of piping & all Flanges as per OISD-110. Normally bonding is done using round wires. Ihis is not correct. It is necessary to follow for Strip specs IS-3043 & IS-7689 and OISD-108.SIL/LOP: 1
Design intention (Operation): A.1 Separate Gas and Liquid at required Pressure
Description of design intention:
Separate Gas and Liquid at required Pressure
Node: A.1 Gas fro Battery to Byproduct
Sop reference: N.A.Hazop study Number: A.1.1P and I Dwg. No. PD-1055
Parameter : A.1 Pressure
HAZOP GUIDE WORD
RECOMMENDATION FOR BETTER HAZARD CONTROL Action by: Name , Designation, Department
Action Date
As under High Temperature(2) MORE OF Project authority
Action taken:
As under High Temperature
SIL/LOP: N.A.
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Part-1a Action by Report- Design intension wise
Design intention (Operation): A.2 To cool the gas by 2-stage Process water chilled water from 80 to 22 Deg C.
Description of design intention:
To cool the gas by 2-stage Process water chilled water from 80 to 22 Deg C.
Node: A.2 Primary Gas cooler
Sop reference: N.A.Hazop study Number: A.2P and I Dwg. No. PD-1055
Parameter : A.2 Temperature
HAZOP GUIDE WORD
RECOMMENDATION FOR BETTER HAZARD CONTROL Action by: Name , Designation, Department
Action Date
Provide Nitrogen injection facility for purging at PGC(1) NO (NOT OR NONE)
Project authority
Action taken:
Provide Nitrogen injection facility for purging at PGC
SIL/LOP: N.A.
Ptovide Steam line to lines CLLG-10abc & 18abc(2) MORE OF Project authority
Action taken:
Ptovide Steam line to lines CLLG-10abc & 18abc
SIL/LOP: N.A.
Provide drain point for water line in PGC(16) MAINTENANCE
Project authority
Action taken:
Provide drain point for water line in PGC
SIL/LOP: N.A.
Provide Air vent at CWRLG01abc(19) SAFETY Project authority
Action taken:
Provide Air vent at CWRLG01abc
SIL/LOP: 2
Design intention (Operation): A.3 To eliminate tar residue from gas
Description of design intention:
None
Node: A.3 ETP
Sop reference: N.A.Hazop study Number: A.3P and I Dwg. No. PD-1055
Parameter : A.3 Voltage
HAZOP GUIDE WORD
RECOMMENDATION FOR BETTER HAZARD CONTROL Action by: Name , Designation, Department
Action Date
Provide positive isolation of Gas Equipment to ensure LOTO.(16) MAINTENANCE
Project authority
Action taken:
Provide positive isolation of Gas Equipment to ensure LOTO.
SIL/LOP: 1
Design intention (Operation): A.3.1 To ensure Oxygen content in the gas ;ess than 0.8% vy vol.
Description of design intention:
To ensure Oxygen content in the gas ;ess than 0.8% vy vol.
Node: A.3.1 ETP
Sop reference: N.A.Hazop study Number: A.3.1P and I Dwg. No. ES.LG1.GY.22-0103
Parameter : A.3.1 Oxygen
HAZOP GUIDE WORD
RECOMMENDATION FOR BETTER HAZARD CONTROL Action by: Name , Designation, Department
Action Date
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Part-1a Action by Report- Design intension wise
1. Consider airtight explosion flap or a rupture disk as appropriate that automatically relieves explosion pressure.
(2) MORE OF Project authority
Action taken:
1. Consider airtight explosion flap or a rupture disk as appropriate that automatically relieves explosion pressure.
SIL/LOP: 1
Design intention (Operation): B.1 To suck the gas from cokeoven battery and supply to byproduct unit for cleaning
Description of design intention:
None
Node: B.1.1 Exhauster
Sop reference: N.A.Hazop study Number: B.1.1P and I Dwg. No. ES.LG1.GY.22-0104
Parameter : B.1.1 Output Pressure
HAZOP GUIDE WORD
RECOMMENDATION FOR BETTER HAZARD CONTROL Action by: Name , Designation, Department
Action Date
Provide independent drain valves CLLG25ab, 29ab.(1) NO (NOT OR NONE)
Project authority
Action taken:
Provide independent drain valves CLLG25ab, 29ab.
SIL/LOP: 2
Down straem SOP adherence will keep down stream pressure under control
(2) MORE OF Production
Action taken:
Down straem SOP adherence will keep down stream pressure under control
SIL/LOP: 1
Provide CO detector in the Exhauster house(19) SAFETY Project authority
Action taken:
Provide CO detector in the Exhauster house
SIL/LOP: 1
Design intention (Operation): C.1 To cool the Gas before sending to Desulphurizer columns from 45 deg. C to 25 Deg. C
Description of design intention:
To cool the Gas before sending to Desulphurizer columns from 45 deg. C to 25 Deg. C
Node: C.1 Precooling Tower of Desulphurizer
Sop reference: N.A.Hazop study Number: C.1P and I Dwg. No. ES.TL1.GY.22-0104
Parameter : C.1 Pressure drop across column
HAZOP GUIDE WORD
RECOMMENDATION FOR BETTER HAZARD CONTROL Action by: Name , Designation, Department
Action Date
1. Provide positive isolation system to enable short duration maintenance under LOTO.
(16) MAINTENANCE
Project authority
Action taken:
1. Provide positive isolation system to enable short duration maintenance under LOTO.
SIL/LOP: 1
Design intention (Operation): D.1 To remove H2S from Cokeoven gas
Description of design intention:
To remove H2S from Cokeoven gas
Node: D.1 Desulphurization tower
Sop reference: N.A.Hazop study Number: D.1P and I Dwg. No. ES.TL1.GY.22-0104
Parameter : D.1 Pressure
HAZOP GUIDE WORD
RECOMMENDATION FOR BETTER HAZARD CONTROL Action by: Name , Designation, Department
Action Date
Friday, January 14, 2011 Page 3 of 11Friday, January 14, 2012
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Part-1a Action by Report- Design intension wise
Provide Nitrogen inlet point at gas inlet line to both towers(1) NO (NOT OR NONE)
Project authority
Action taken:
Provide Nitrogen inlet point at gas inlet line to both towers
SIL/LOP: 1
Provide positive isolation system to enable short duration maintenance under LOTO.
(16) MAINTENANCE
Project authority
Action taken:
Provide positive isolation system to enable short duration maintenance under LOTO.
SIL/LOP: N.A.
Provide isolation valves for both towers at outlet lines of water seal outlet VTL-01AB for both towers
(19) SAFETY Project authority
Action taken:
Provide isolation valves for both towers at outlet lines of water seal outlet VTL-01AB for both towers
SIL/LOP: N.A.
Design intention (Operation): D.1 To remove H2S from Cokeoven gas
Description of design intention:
To remove H2S from Cokeoven gas
Node: D.1 Desulphurization tower
Sop reference: N.A.Hazop study Number: D.1.1P and I Dwg. No. ES.TL1.GY.22-0104
Parameter : D.1 Temperature of Solution
HAZOP GUIDE WORD
RECOMMENDATION FOR BETTER HAZARD CONTROL Action by: Name , Designation, Department
Action Date
Provide Steam flushing at scrub liquor side and water flushing facilities at water side of heat exchanger tubes
(2) MORE OF Project authority
Action taken:
Provide Steam flushing at scrub liquor side and water flushing facilities at water side of heat exchanger tubes
SIL/LOP: 1
Design intention (Operation): E.1 To regenerate Sulphur from H2S solution
Description of design intention:
To regenerate Sulphur from H2S solution
Node: E.1 Sulphur production
Sop reference: N.A.Hazop study Number: E.1P and I Dwg. No. ES.TL1.GY.22-0104 (2)
Parameter : E.1 Air flow
HAZOP GUIDE WORD
RECOMMENDATION FOR BETTER HAZARD CONTROL Action by: Name , Designation, Department
Action Date
Provide Air flow controller for Tower A also(1) NO (NOT OR NONE)
Project authority
Action taken:
Provide Air flow controller for Tower A also
SIL/LOP: N.A.
As under No-Air flow(3) LESS OF Project authority
Action taken:
As under No-Air flow
SIL/LOP: N.A.
Provide a Exhaust Hood above the Sulphur Foam Tank and release the vapours at suitable height or send to scrubber as appropriate
(19) SAFETY Project authority
Action taken:
Provide a Exhaust Hood above the Sulphur Foam Tank and release the vapours at suitable height or send to scrubber as appropriate
SIL/LOP: 0
Friday, January 14, 2011 Page 4 of 11Friday, January 14, 2012
Licensed To : HAMSAGARS 33
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HAMS-GPS : HAZOP Study for : Sample-CokeovenHAMS-GPS : HAZOP Study for : Project/Plant stage at HAZOP : Detailed engineering stage
Part-2a HAZOP Report-Recommendations only
Design intention (Operation):
A.0
Hazop study Number: A.0
Licensed To : HAMSAGARS
P and I Dwg. No. : N.A.
Sop reference: N.A.
Existing controls:Units:
Control Range:
Description of design intention:
Whether Cokeoven Technology procured with HAZOP Study Report?
A.0
Parameter. : A.0Node:
HAZOP GUIDE WORD
LIKELY DEVIATION LIKELY CAUSES LIKELY CONSEQUENCES
PRESENT CONTROLS THEIR
LIMITATIONS
RECOMMENDATI-ON FOR BETTER
HAZARD CONTROL
HAZOP GUIDE WORD
Cokeoven technolohy has not been procured with HAZOP study
Technology procurements did not include requirement of HAZOP study
Hazards and Operability issues required to be addressed at technology procurement stage not covered may result in retention of certain Hazaeds and operability issues
Pre-detailed Engineering HAZOP being done.
For future Technology Procurement agreements, may make it mandatory for all Projects to include HAZOP study as part of Technology package.
(1) NO (NOT OR NONE)
(1) NO (NOT OR NONE)
Action by: Future Project AuthoritiesRISK LEVEL: Risk level: MEDIUM DAMAGE and LOW CHANCE SIL/LOP 1Documentation
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Part-2a HAZOP Report-Recommendations only
Any other observations
Nil
Nil
n
Any other observations
Nil
Nil
n
Design intention (Operation):
A. Separate Gas and Liquid at required Temperature
Hazop study Number: A.1
Licensed To : HAMSAGARS
P and I Dwg. No. : ES.LG1.GY.22-0103
Sop reference: N.A.
Existing controls: Temperature PressureUnits: Deg C mm WC
Control Range: 75-85 -120 to -300
Description of design intention:
Separate Gas and Liquid at required Temperature
A.1 Gas from Battery to byproduct
Parameter. : A.1 TemperatureNode:
HAZOP GUIDE WORD
LIKELY DEVIATION LIKELY CAUSES LIKELY CONSEQUENCES
PRESENT CONTROLS THEIR
LIMITATIONS
RECOMMENDATI-ON FOR BETTER
HAZARD CONTROL
HAZOP GUIDE WORD
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Part-2b HAZOP Full Report
Any other observations
Nil
Nil
Nil
Any other observations
Nil
Nil
Nil
HAZOP team: Name, Designation, Department
1. Dr. Ram S. Hamsagar, Chair person,2. Mr. Sunil Hamsagar, Softer Simulation Expert,3. Mr. Amar Bountra, Process,4. Mr. Sukumar, Process,5. Mr. Yogendra Babu, Engg,6. Mr. Rakesh Kumar, Engg (Electrical),7. Mr. Sethu Madhavan, Engg (Aut
8. Mr. L. N. Kumar, Engg (Safety), 9. Mr. Pramod, Engg-Env, 10. Mr. KB Panchal, Safety11. Ms. Shikha Sirohi, HSE, 12. Mr. Ankur, Proj Planning - EPIL, 13. Mr. Eldose, Proj quality, EPIL14. Mr. Bhaskar, Proj Maint, EPIL15. Mr. V. Subramanium, EPIL
SIL Generalized View
4 Potential for fatalities in the community
3 Potential for multiple fatalities
2 Potential for major serious injuries or one fatality
1 Potential for minor injuries
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HAMS-GPS : HAZOP Study for : Sample -CokeovenLicensed To : HAMSAGARS
HAMS-GPS : HAZOP Study for :
Part-3 RBI-matrix.
Summary of RISK BASED INVESTIGATION (RBI) MATRIX
0
0
0
0
0
5
30
5
0
0
2
0
0
0
0
0
0
0
0
0
556 0 0 0 0
40 2 0 0
5
32
5
0
556
556 598
93.0 6.7 0.3 0.0 0.0
93.0
0.8
5.4
0.8
0.0
TOTAL
%
TOTAL %
HIGH
MEDIUM HIGH
MEDIUM
LOW
0
0
7
35
0.00
0.00
1.17
5.85
598
100.0
100.00
Chance levels ----------->
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HAMS-GPS : HAZOP Study for : Sample -CokeovenLicensed To : HAMSAGARS
HAMS-GPS : HAZOP Study for :
Summary of RBI-Matrix (conforming to European Process Safety Center's Standard) for selected HAZOP Studies: Date: 11/6/2010 1:00:42 PM
Design intention (Operation):
Number of Risk (Damage-Consequence) level areasMEDIUMMEDIUM
HIGHHIGH LOWNum.
Guide Words
SAFE
Part-4a Overall Risk levels-Design intension wise
10A. Separate Gas and Liquid at required Temperature
0 2110A. Separate Gas and Liquid at required Temperature
0 212 11
00A.0
0 2200A.0
0 221 11
00A.1 Separate Gas and Liquid at required Pressure
0 2300A.1 Separate Gas and Liquid at required Pressure
0 230 00
10A.2 To cool the gas by 2-stage Process water chilled water from 80 to 22 Deg C. 0 2210A.2 To cool the gas by 2-stage Process water chilled water from 80 to 22 Deg C. 0 221 00
10A.3 To eliminate tar residue from gas
0 2210A.3 To eliminate tar residue from gas
0 221 00
10A.3.1 To ensure Oxygen content in the gas ;ess than 0.8% vy vol.
0 2210A.3.1 To ensure Oxygen content in the gas ;ess than 0.8% vy vol.
0 221 00
00B.1 To suck the gas from cokeoven battery and supply to byproduct unit for cleaning 0 2300B.1 To suck the gas from cokeoven battery and supply to byproduct unit for cleaning 0 230 00
10B.1 To suck the gas from cokeoven battery and supply to byproduct unit for cleaning 0 2010B.1 To suck the gas from cokeoven battery and supply to byproduct unit for cleaning 0 203 22
10C.1 To cool the Gas before sending to Desulphurizer columns from 45 deg. C to 25 Deg. C 0 2210C.1 To cool the Gas before sending to Desulphurizer columns from 45 deg. C to 25 Deg. C 0 221 00
00D.1 To remove H2S from Cokeoven gas
0 2200D.1 To remove H2S from Cokeoven gas
0 221 11
00D.1 To remove H2S from Cokeoven gas
0 2200D.1 To remove H2S from Cokeoven gas
0 221 11
00E.1 To regenerate Sulphur from H2S solution
0 2200E.1 To regenerate Sulphur from H2S solution
0 221 11
10F.1 To recover Ammonia from Coke oven gas
0 2110F.1 To recover Ammonia from Coke oven gas
0 212 11
00F.1.1 To recover Ammonia from Coke oven gas
0 2200F.1.1 To recover Ammonia from Coke oven gas
0 221 11
00G.1 To distill ammonia from Excess Ammonia Liquor
0 2200G.1 To distill ammonia from Excess Ammonia Liquor
0 221 11
00G.1.1 To Distill ammonia from excess ammonia liquer
0 2200G.1.1 To Distill ammonia from excess ammonia liquer
0 221 11
00H.1 To cool the Gas to ambient Temp
0 2100H.1 To cool the Gas to ambient Temp
0 212 22
00H.1.1 To cool the gas to Ambient Temperature
0 2200H.1.1 To cool the gas to Ambient Temperature
0 221 11
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Design intention (Operation):
Number of Risk (Damage-Consequence) level areasMEDIUMMEDIUM
HIGHHIGH LOWNum.
Guide Words
SAFE
Part-4a Overall Risk levels-Design intension wise
00I.1 To compress air for different plants
0 2200I.1 To compress air for different plants
0 221 11
00J.1 To Separate Tar and ammonia water from gas condensate & Recycle Ammonia Liq. To Battery 0 1900J.1 To Separate Tar and ammonia water from gas condensate & Recycle Ammonia Liq. To Battery 0 194 44
00K.1 To generate Low Pressure Steam from gas Fired Boilers
0 1700K.1 To generate Low Pressure Steam from gas Fired Boilers
0 176 66
00K.1.1 To generate low pressure steam from gas fired boilers
0 2200K.1.1 To generate low pressure steam from gas fired boilers
0 221 11
00L.1 To store and Load Tar for Dispatch and Unload Caustic lye and H2SO4 from tankers 0 2000L.1 To store and Load Tar for Dispatch and Unload Caustic lye and H2SO4 from tankers 0 203 33
00M.1 To produce coke and by product gas from coal
0 1900M.1 To produce coke and by product gas from coal
0 194 44
00N.1 To provide water Pressure in the Firefighting network Min-8 Max-10 Bar 0 2100N.1 To provide water Pressure in the Firefighting network Min-8 Max-10 Bar 0 212 22
00O.1 To ensure early detection of any fire in the offices
0 2300O.1 To ensure early detection of any fire in the offices
0 230 00
700 35
1.17.00.00 5.85
TOTALPERCENT
Applications of RBI-Risk Matrix: Following are the applications of an RBI-Risk matrix
2. To establish risk mitigation measures and evaluate their effects,
3. To compare units and processes on the basis of risk,
4. To develop trends of risk development of a unit over time and during its life cycle.
1. As an indicator of the risk level of the installation,
556
92.98
Note:Col.-2 gives No. of guie words (Deviations) used out of a total of 23-possible deviations. Col.-3 to 6 give Risk Levels of applied deviations and Col.-7 gives No. safe i.e. no Risk of deviations. Total of Safe levels divided by total of Risks and Safe levels multiplied by total Safe levels gives % Safety pf the facility.
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Part-4b Overall Risk levels-Node wise
HAMS-GPS : HAZOP Study for : Sample-Coke Oven Licensed To : HAMSAGARS
Node:
Number of Risk (Damage-Consequence) level areasMEDIUMMEDIUM
HIGHHIGH SAFE
Summary of RBI-Matrix (conforming to European Process Safety Center's Standard) for selected Nodes:
Num. Guide Words
LOW
10A.1 Gas from Battery to byproduct 0 110A.1 Gas from Battery to byproduct 0 12 2121
00A.0 0 100A.0 0 11 2222
00A.1 Gas fro Battery to Byproduct 0 000A.1 Gas fro Battery to Byproduct 0 00 2323
10A.2 Primary Gas cooler 0 010A.2 Primary Gas cooler 0 01 2222
10A.3 ETP 0 010A.3 ETP 0 01 2222
10A.3.1 ETP 0 010A.3.1 ETP 0 01 2222
00B.1 Exhauster 0 000B.1 Exhauster 0 00 2323
10B.1.1 Exhauster 0 210B.1.1 Exhauster 0 23 2020
10C.1 Precooling Tower of Desulphurizer 0 010C.1 Precooling Tower of Desulphurizer 0 01 2222
00D.1 Desulphurization tower 0 100D.1 Desulphurization tower 0 11 2222
00D.1 Desulphurization tower 0 100D.1 Desulphurization tower 0 11 2222
00E.1 Sulphur production 0 100E.1 Sulphur production 0 11 2222
10F.1 Ammonium Sulphate Plant 0 110F.1 Ammonium Sulphate Plant 0 12 2121
00F.1.1 Ammonium Sulphate Plant 0 100F.1.1 Ammonium Sulphate Plant 0 11 2222
00G.1 Ammonia Distillation Column 0 100G.1 Ammonia Distillation Column 0 11 2222
00G.1.1 Ammonia distillation column 0 100G.1.1 Ammonia distillation column 0 11 2222
00H.1 Final Gas cooler 0 200H.1 Final Gas cooler 0 22 2121
00H.1.1 Final Gas cooler 0 100H.1.1 Final Gas cooler 0 11 2222
00I.1 Air compressor station 0 100I.1 Air compressor station 0 11 2222
00J.1 Gas condensation Plant 0 400J.1 Gas condensation Plant 0 44 1919
00K.1 Boiler 0 600K.1 Boiler 0 66 1717
00K.1.1 Boiler 0 100K.1.1 Boiler 0 11 2222
00L.1 Chemical Storage Area 0 300L.1 Chemical Storage Area 0 33 2020
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HAMS-GPS : HAZOP Study for : Sample-Coke OvenLicensed To : HAMSAGARS
Node:
Number of Risk (Damage-Consequence) level areasMEDIUMMEDIUM
HIGHHIGH SAFE
Summary of RBI-Matrix (conforming to European Process Safety Center's Standard) for selected Nodes:
Num. Guide Words
LOW
00M.1 Coke Oven Battery 0 400M.1 Coke Oven Battery 0 44 1919
00N.1 Fire fighting water Network 0 200N.1 Fire fighting water Network 0 22 2121
00O.1 Offices 0 000O.1 Offices 0 00 2323
700 35
1.17.00.00 5.85
TOTALPERCENT
Applications of RBI-Risk Matrix: Following are the applications of an RBI-Risk matrix
2. To establish risk mitigation measures and evaluate their effects,
3. To compare units and processes on the basis of risk,
4. To develop trends of risk development of a unit over time and during its life cycle.
1. As an indicator of the risk level of the installation,
556
92.98
556 x 100 / 598 = 92.98SAFE :
35 x 100 / 598 = 5.85LOW :
7 x 100 / 598 = 1.17MEDIUM :
0 x 100 / 598 = .MEDIUM HIGH :
0 x 100 / 598 = . HIGH :
Friday, January 14, 2012 Page 2 of 2Friday, January 14, 2011
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Count RemarksRisk Levels for HAZOP
HAMS-GPS : HAZOP Study for : Sample-Coke OvenLicensed To : HAMSAGARS
HAMS-GPS : HAZOP Study for :
Part-4a SIL-LOP requirements-Overall
Over all Risk Levels
SIL/LOP Required
1/14/2012 5:58:59 PM
Risk level: MEDIUM DAMAGE and MEDIUM CHANCE 2 Medium Critical 2
Risk level: MEDIUM DAMAGE and LOW CHANCE 29 Medium Low Critical 1
Risk level: MEDIUM HIGH DAMAGE and LOW CHANCE 5 Medium Low Critical 1
Risk level: LOW DAMAGE and LOW CHANCE 4 Low Critical 0
Risk level: NO DAMAGE and NO CHANCE 29 Safe N.A.
SIL Generalized View
4 Potential for fatalities in the community
3 Potential for multiple fatalities
2 Potential for major serious injuries or one fatality
1 Potential for minor injuries
Note: Design team to check and ensure the SIL requirements for safety instruementation system and LOP for equipments safety as applicable are avaible. If not the SIL/LOP requirements to be provided.
Friday, January 14, 2011 Page 1 of 1Friday, January 14, 2012 149
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Count RemarksRisk Levels for HAZOP
HAMS-GPS : HAZOP Study for : Sample-Coke OvenLicensed To : HAMSAGARS
HAMS-GPS : HAZOP Study for :
Part-5b SIL-LOP requirements-Category wise
Summary of Category wise
SIL/LOP Required
1/14/2012 6:00:38 PM
Category
Engineering 1 Medium Critical 2
Hazard. 1 Medium Critical 2
Documentation 1 Medium Low Crit 1
Hazard. 33 Medium Low Crit 1
Hazard. 2 Low Critical 0
Quality. 2 Low Critical 0
Engineering 1 Safe N.A.
Hazard. 10 Safe N.A.
Maintenance 8 Safe N.A.
Operability. 10 Safe N.A.
SIL Generalized View
4 Potential for fatalities in the community
3 Potential for multiple fatalities
2 Potential for major serious injuries or one fatality
1 Potential for minor injuries
Note: Design team to check and ensure the SIL requirements for safety instruementation system and LOP for equipments safety as applicable are avaible. If not the SIL/LOP requirements to be provided.
Friday, January 14, 2012 Page 1 of 1Friday, January 14, 2011 150
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Count RemarksRisk Levels for HAZOP
HAMS-GPS : HAZOP Study for : Sample-Coke OvenLicensed To : HAMSAGARS
HAMS-GPS : HAZOP Study for :
Part-5c SIL-LOP requirements-Design Intention wise
Risk Levels (Design intention wise)
SIL/LOP Required
1/14/2012 6:01:43 PM
Design Intention
A.1 Separate Gas and Liquid at required Pressure 1 Safe N.A.
A.2 To cool the gas by 2-stage Process water chilled water from 80 to 22 Deg C. 3 Safe N.A.
D.1 To remove H2S from Cokeoven gas 2 Safe N.A.
E.1 To regenerate Sulphur from H2S solution 2 Safe N.A.
F.1 To recover Ammonia from Coke oven gas 3 Safe N.A.
F.1.1 To recover Ammonia from Coke oven gas 1 Safe N.A.
G.1 To distill ammonia from Excess Ammonia Liquor 1 Safe N.A.
G.1.1 To Distill ammonia from excess ammonia liquer 2 Safe N.A.
H.1 To cool the Gas to ambient Temp 1 Safe N.A.
I.1 To compress air for different plants 3 Safe N.A.
K.1 To generate Low Pressure Steam from gas Fired Boilers 1 Safe N.A.
K.1.1 To generate low pressure steam from gas fired boilers 1 Safe N.A.
M.1 To produce coke and by product gas from coal 2 Safe N.A.
N.1 To provide water Pressure in the Firefighting network Min-8 Max-10 Bar 5 Safe N.A.
O.1 To ensure early detection of any fire in the offices 1 Safe N.A.
A.2 To cool the gas by 2-stage Process water chilled water from 80 to 22 Deg C. 1 Medium Critical 2
B.1 To suck the gas from cokeoven battery and supply to byproduct unit for cleaning 1 Medium Critical 2
A. Separate Gas and Liquid at required Temperature 2 Medium Low Crit 1
A.0 1 Medium Low Crit 1
A.3 To eliminate tar residue from gas 1 Medium Low Crit 1
A.3.1 To ensure Oxygen content in the gas ;ess than 0.8% vy vol. 1 Medium Low Crit 1
B.1 To suck the gas from cokeoven battery and supply to byproduct unit for cleaning 2 Medium Low Crit 1
C.1 To cool the Gas before sending to Desulphurizer columns from 45 deg. C to 25 Deg. C
1 Medium Low Crit 1
D.1 To remove H2S from Cokeoven gas 2 Medium Low Crit 1
F.1 To recover Ammonia from Coke oven gas 2 Medium Low Crit 1
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Count RemarksRisk Levels for HAZOP
HAMS-GPS : HAZOP Study for : Sample-Coke OvenLicensed To : HAMSAGARS
HAMS-GPS : HAZOP Study for :
Part-5c SIL-LOP requirements-Design Intention wise
Risk Levels (Design intention wise)
SIL/LOP Required
1/14/2012 6:01:43 PM
Design Intention
F.1.1 To recover Ammonia from Coke oven gas 1 Medium Low Crit 1
G.1 To distill ammonia from Excess Ammonia Liquor 1 Medium Low Crit 1
G.1.1 To Distill ammonia from excess ammonia liquer 1 Medium Low Crit 1
H.1 To cool the Gas to ambient Temp 1 Medium Low Crit 1
H.1.1 To cool the gas to Ambient Temperature 1 Medium Low Crit 1
I.1 To compress air for different plants 1 Medium Low Crit 1
J.1 To Separate Tar and ammonia water from gas condensate & Recycle Ammonia Liq. To Battery
4 Medium Low Crit 1
K.1 To generate Low Pressure Steam from gas Fired Boilers 4 Medium Low Crit 1
K.1.1 To generate low pressure steam from gas fired boilers 1 Medium Low Crit 1
L.1 To store and Load Tar for Dispatch and Unload Caustic lye and H2SO4 from tankers
2 Medium Low Crit 1
M.1 To produce coke and by product gas from coal 4 Medium Low Crit 1
N.1 To provide water Pressure in the Firefighting network Min-8 Max-10 Bar 1 Medium Low Crit 1
E.1 To regenerate Sulphur from H2S solution 1 Low Critical 0
K.1 To generate Low Pressure Steam from gas Fired Boilers 2 Low Critical 0
N.1 To provide water Pressure in the Firefighting network Min-8 Max-10 Bar 1 Low Critical 0
SIL Generalized View
4 Potential for fatalities in the community
3 Potential for multiple fatalities
2 Potential for major serious injuries or one fatality
1 Potential for minor injuries
Note: Design team to check and ensure the SIL requirements for safety instruementation system and LOP for equipments safety as applicable are avaible. If not the SIL/LOP requirements to be provided.
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