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TATA STEEL LIMITED - KALINGANAGAR

HAZOP STUDY FOR


PROPANE STORAGE & PROPANE DILUTION SYSTEM

HAZOP WORK SHEETS


(Rev. 0)
EQMS INDIA PRIVATE LIMITED

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


Community Centre, Karkardooma, Delhi 110 092

TATA STEEL LTD


KALINGANAGAR

HAZOP WORK SHEET

PROPANE STORAGE & PROPANE


DILUTION SYSTEM

S. No.

Section

1.

Propane Storage System

2.

Dilution System

EQMS INDIA
PRIVATE
LIMITED

Page
No.
4
14

Page 2 of 25

HAZOP WORK SHEET

TATA STEEL LTD

EQMS INDIA
PRIVATE
LIMITED

PROPANE STORAGE & PROPANE


DILUTION SYSTEM

KALINGANAGAR

List of Nodes

SL NO

NODE-NO

SYSTEM

PAGE NO

301

ROAD TANKER TO PROPANE STORAGES

302

SUPPLY OF PROPANE TO CONSUMER

303

PROPANE DILUTION SYSTEM

14

Page 3 of 25

HAZOP WORK SHEET

TATA STEEL LTD


KALINGANAGAR

PROPANE STORAGE & PROPANE


DILUTION SYSTEM

Node:
301
Design
Intent

EQMS INDIA
PRIVATE
LIMITED

P&ID No. G/P&I/6654/2013

Propane Storage System

Tanker to Storage

Deviation

Cause

Consequence

Safeguard

No/ Less
Flow

Compressor C01/02/03 Malfunction

Low filling rate in


storage tank
T1/T2/T3

Standby
Compressor
Provided C01/02/03

ROV-1 Stuck Close

No filling in Storage
tank

Compressor Trip
at 21Kg/cm2

T1/T2/T3

Tanker designed
for 21kg/cm2

Increase in
Pressure in Tanker

Pressure gauge
&, Pressure
safety Valve has
been provided
on tanker

Recommendation

Remark/Acti
on

Pressure
Safety valve
testing
should be
incorporated
in
maintenance
schedule

Page 4 of 25

HAZOP WORK SHEET

TATA STEEL LTD


KALINGANAGAR

PROPANE STORAGE & PROPANE


DILUTION SYSTEM

Node:
301
Design
Intent

EQMS INDIA
PRIVATE
LIMITED

P&ID No. G/P&I/6654/2013

Propane Storage System

Tanker to Storage

Deviation

Cause

More Flow

More pressure
difference in Tanker
and Tank

Consequence
Static Charge
possible

Safeguard

Recommendation

Line ,Tanker and


Tank is Earthed

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

Remark/Acti
on
Resistance is
to be checked
for all earthing
Strip and Earth
pit and a
record is to be
maintained..

Page 5 of 25

HAZOP WORK SHEET

TATA STEEL LTD


KALINGANAGAR

Node:
301
Design
Intent
Deviation

EQMS INDIA
PRIVATE
LIMITED

PROPANE STORAGE & PROPANE


DILUTION SYSTEM

P&ID No. G/P&I/6654/2013

Propane Storage System

Tanker to Storage
Cause

Consequence

Safeguard

Recommendation

Remark/Acti
on

flanges
R-1
Reverse
Flow

Not possible

Higher
Pressure

Over pressurization by
compressor

Lower
Pressure

Covered in Less flow

Damage of tank

Tank is designed
for high pressure.
compressor trip
at 21kg/cm2

Page 6 of 25

HAZOP WORK SHEET

TATA STEEL LTD


KALINGANAGAR

PROPANE STORAGE & PROPANE


DILUTION SYSTEM

Node:
301
Design
Intent

EQMS INDIA
PRIVATE
LIMITED

P&ID No. G/P&I/6654/2013

Propane Storage System

Tanker to Storage

Deviation

Cause

Consequence

Safeguard

Higher
Temperatur
e

External fire

Fire and Explosion


Hazard

PRV-01 and PG01,12,13,14


Provided

High pressure

Recommendation

Remark/Acti
on

Gas detector
provided GLD 1,
2, 3 Provided.
Water Sprinkler
provided for the
Storage tanks
and Tanker
unloading station
PSV provided.

Page 7 of 25

HAZOP WORK SHEET

TATA STEEL LTD

PROPANE STORAGE & PROPANE


DILUTION SYSTEM

KALINGANAGAR

Node:
301
Design
Intent

EQMS INDIA
PRIVATE
LIMITED

P&ID No. G/P&I/6654/2013

Propane Storage System

Tanker to Storage

Deviation

Cause

Lower
Temperatur
e

No Issue

Higher
Level

Transfer not stopped


at high level

(Storage
Tank T1,2,3)
Lower
Level

No Issue

Concentrati
on

NA

Consequence

Safeguard

Tank Pressurization

LT-11/21/31
,PT11,21,31 are
provided in the
tank same will
close respective
ROV-11/21/31

Recommendation

Remark/Acti
on

Page 8 of 25

HAZOP WORK SHEET

TATA STEEL LTD


KALINGANAGAR

Node:
301
Design
Intent

Tanker to Storage
Cause

Impurity

NA

Utility
Failure

Power

Consequence

Safeguard

Recommendation

No Transfer of
Propane from
Tanker to Storage
Tank.

All ROV and SV


will Close

DG should be
provided for backup
power for the
operation of Propane
storage system

Compressor C-01,
C-02 & C-03 will
stop.

Shut-down

P&ID No. G/P&I/6654/2013

Propane Storage System

Deviation

Start-up

EQMS INDIA
PRIVATE
LIMITED

PROPANE STORAGE & PROPANE


DILUTION SYSTEM

Remark/Acti
on

R-2
Proper SOP is
to be made
for attending
Start Up &
Shutdown of
Propane
system

Page 9 of 25

HAZOP WORK SHEET

TATA STEEL LTD


KALINGANAGAR

PROPANE STORAGE & PROPANE


DILUTION SYSTEM

Node:
301
Design
Intent
Deviation

EQMS INDIA
PRIVATE
LIMITED

P&ID No. G/P&I/6654/2013

Propane Storage System

Tanker to Storage
Cause

Consequence

Safeguard

Maintenanc
e

Recommendation

Remark/Acti
on
Proper
Isolation,
N2-purging &
Permit
System
Should be
included
SOP

Leakage

Corrosion of line

Excess flow of
liquid and
temperature fall

Excess Flow
Check at Tankers

Page 10 of 25

HAZOP WORK SHEET

TATA STEEL LTD


KALINGANAGAR

PROPANE STORAGE & PROPANE


DILUTION SYSTEM

Node:
302
Design
Intent

EQMS INDIA
PRIVATE
LIMITED

P&ID No. G/P&I/6654/2013 R1

Propane Storage System

To Supply Propane to Consumer

Deviation

Cause

Consequence

Safeguard

No/ Less
Flow

ROV stuck close

No supply to
Customer

Standby System
Provided

Recommendatio
n

Remark/Actio
n

Flow meter No91A/B/C provided


More Flow

Leakage

Fall In temperature
Excess flow Pipe
line
More consumption
from Customer
side

EFV-16/26/36
provided

EFV-16/26/36
provided

Page 11 of 25

HAZOP WORK SHEET

TATA STEEL LTD


KALINGANAGAR

PROPANE STORAGE & PROPANE


DILUTION SYSTEM

Node:
302
Design
Intent

EQMS INDIA
PRIVATE
LIMITED

P&ID No. G/P&I/6654/2013 R1

Propane Storage System

To Supply Propane to Consumer

Deviation

Cause

Consequence

Safeguard

Reverse
Flow

Not possible

Higher
Pressure

Covered in higher
Temperature below

Lower
Pressure

Covered in Low flow

Higher
Temperatur
e

Vaporizer V-1/2/3
malfunction

Chances of burst
Pipe

RTD 41/51/61

Water level low

Fire and explosion


hazard

(Water level
indicator)

Recommendatio
n

Remark/Actio
n

NRV-41/51/61
provided

WLI-41/51/61

PRV-41/51/61
provided

Page 12 of 25

HAZOP WORK SHEET

TATA STEEL LTD


KALINGANAGAR

PROPANE STORAGE & PROPANE


DILUTION SYSTEM

Node:
302
Design
Intent

EQMS INDIA
PRIVATE
LIMITED

P&ID No. G/P&I/6654/2013 R1

Propane Storage System

To Supply Propane to Consumer

Deviation

Cause

Consequence

Safeguard

Lower
Temperatur
e

Covered in more flow

Higher
Level

SV-42/52/62 stuck
open

No Issue

WLI-41/51/61

SV-42/52/62 stuck
closed

Propane gas will


not be generated,
Liquid may flow in
outlet line

Recommendatio
n

Remark/Actio
n

indicates

Water in
vaporizer
V-1/2/3
Lower
Level
Water in
vaporizer
V-1/2/3

RTD 41/51/61
SV-41/51/61 will
close at less than
55 0C
PS-41/51/61

Page 13 of 25

HAZOP WORK SHEET

TATA STEEL LTD

PROPANE STORAGE & PROPANE


DILUTION SYSTEM

KALINGANAGAR

Node:
302
Design
Intent

EQMS INDIA
PRIVATE
LIMITED

P&ID No. G/P&I/6654/2013 R1

Propane Storage System

To Supply Propane to Consumer

Deviation

Cause

Higher
Concentrati
on

NA

Lower
Concentrati
on

NA

Impurity

NA

Utility
Failure

Power failure

Instrument Air Failure

Consequence

Safeguard

No vaporization
and hence no
supply

None

Control valves

Recommendatio
n

Remark/Actio
n

DG should be
provided for
backup power (R2)

None

Page 14 of 25

HAZOP WORK SHEET

TATA STEEL LTD


KALINGANAGAR

PROPANE STORAGE & PROPANE


DILUTION SYSTEM

Node:
302
Design
Intent
Deviation

EQMS INDIA
PRIVATE
LIMITED

P&ID No. G/P&I/6654/2013 R1

Propane Storage System

To Supply Propane to Consumer


Cause

Consequence
failure

Start-up

To be considered later

Shut-down

To be considered later

Maintenanc
e

To be considered later

Safeguard

Recommendatio
n

Remark/Actio
n

Provide N2 Line
as a standby for
Air(R-3)
Proper SOP is to
be made for
attending Start
Up & Shutdown
of Propane
system
Proper Isolation,
N2-purging &
Permit System
Should be
included S OP

Page 15 of 25

HAZOP WORK SHEET

TATA STEEL LTD


KALINGANAGAR

PROPANE STORAGE & PROPANE


DILUTION SYSTEM

Node:
302
Design
Intent

EQMS INDIA
PRIVATE
LIMITED

P&ID No. G/P&I/6654/2013 R1

Propane Storage System

To Supply Propane to Consumer

Deviation

Cause

Consequence

Safeguard

Leakage

Corrosion of line

Excess flow of
liquid and
temperature fall

Excess Flow
Check Valves16/26/36
provided

Recommendatio
n

Remark/Actio
n

Page 16 of 25

HAZOP WORK SHEET

TATA STEEL LTD


KALINGANAGAR

EQMS INDIA
PRIVATE
LIMITED

PROPANE STORAGE & PROPANE


DILUTION SYSTEM

G/P&I/6855/2013

Node:
303

P&ID
No.

Propane Dilution System

Design
Intent

To Dilute Propane

Deviation

Cause

Consequence

Safeguard

Recommendation

Remark/Action

No/ Less
Flow

Power Failure

Diluted propane
not available

None

DG should be
provided for
backup power
(Mentioned in R2)

Mr .Arindam
Panigrahi

(Propane)
Filter choke-TIF1

No Flow
Less Pressure

PGs-PG2,PG9
inlet and outlet
PI-103

Bypass line with


isolating valve to
be provided for
the filter/ Standby
Filter (R-4)
Provide Low
pressure Alarm.
(R-5)

Line Drain and


filter
replacement
process to be
incorporated in
SOP

Page 17 of 25

KALINGANAGAR

EQMS INDIA
PRIVATE
LIMITED

HAZOP WORK SHEET

TATA STEEL LTD

PROPANE STORAGE & PROPANE


DILUTION SYSTEM

G/P&I/6855/2013

Node:
303
Design
Intent
Deviation

No/Less
Flow
(Air)

P&ID
No.

Propane Dilution System


To Dilute Propane
Cause

Consequence

Safeguard

Lack of supply of
Air(tank empty)

Diluted propane
not available

Standby Tank
Provided

Power Failure

Diluted propane
not available

None

Recommendation

Remark/Action

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

Mr .Arindam
Panigrahi

Page 18 of 25

KALINGANAGAR

EQMS INDIA
PRIVATE
LIMITED

HAZOP WORK SHEET

TATA STEEL LTD

PROPANE STORAGE & PROPANE


DILUTION SYSTEM

G/P&I/6855/2013

Node:
303

P&ID
No.

Propane Dilution System

Design
Intent

To Dilute Propane

Deviation

Cause

Consequence

Safeguard

More Flow

PCV 101,102
malfunction the ratio

Chances of
explosive mixture

SSV 101,102(6
nos for 3 Mixers)
Provided with
PCV
102(propane)
being controlled
by PCV 101(Air)

(Propane/Ai
r)

Reverse
Flow

Not Possible

Recommendation

Remark/Action

NRV is Provided
NRV-101 & 102

(Propane/Ai
r)

Higher
Pressure

Covered in more flow

Page 19 of 25

HAZOP WORK SHEET

TATA STEEL LTD


KALINGANAGAR

PROPANE STORAGE & PROPANE


DILUTION SYSTEM

Node:
303

To Dilute Propane

Deviation

Cause

Lower
Pressure

Covered in No/Less
Flow

Higher
Temperatur
e

External Fire
Hot Supply from
Vaporiser

(Propane)

Lower
Temperatur
e

P&ID No.

Propane Dilution System

Design
Intent

EQMS INDIA
PRIVATE
LIMITED
G/P&I/6855/2013

Consequence

Safeguard

Fire/Explosion

Fire Fighting
System

Recommendation

Remark/Action

Interlocks in
Vaporizer V1,2,3
provided

Considered in
leakage(below)

(Propane)

Page 20 of 25

HAZOP WORK SHEET

TATA STEEL LTD

PROPANE STORAGE & PROPANE


DILUTION SYSTEM

KALINGANAGAR

Node:
303

EQMS INDIA
PRIVATE
LIMITED
G/P&I/6855/2013

P&ID No.

Propane Dilution System

Design
Intent

To Dilute Propane

Deviation

Cause

Higher
Level

NA

Lower
Level

NA

Impurity/
Contamina
nt

Dust

Consequence

Safeguard

Recommendation

Improper mixture

Filter ProvidedTIF-1

Bypass line to be
Provided for the
Filter

Remark/Action

(R-4)
Other
material

NA

Utility
Failure

Power failure (Covered


Above)

Calorimeter will not


work

No

Battery backup
may be provided
for Dilution
system (R-7).

Page 21 of 25

EQMS INDIA
PRIVATE
LIMITED

HAZOP WORK SHEET

TATA STEEL LTD

PROPANE STORAGE & PROPANE


DILUTION SYSTEM

KALINGANAGAR

G/P&I/6855/2013

Node:
303

P&ID
No.

Propane Dilution System

Design
Intent

To Dilute Propane

Deviation

Cause

Sampling

NA

Maintenanc
e

To be considered later

Consequence

Safeguard

Recommendation

Remark/Action

Proper Isolation,
N2-purging &
Permit System
Should be
included S OP

Page 22 of 25

HAZOP WORK SHEET

TATA STEEL LTD


KALINGANAGAR

PROPANE STORAGE & PROPANE


DILUTION SYSTEM

Node:
303

P&ID No.

Propane Dilution System

Design
Intent

EQMS INDIA
PRIVATE
LIMITED
G/P&I/6855/2013

To Dilute Propane

Deviation

Cause

Consequence

Safeguard

Recommendation

Remark/Action

Loss of
containme
nt/ Leakage

Propane Pipe line


failure/ Flange or
Gasket Failure

Fire/Explosion

Leak detector
and Firefighting
System Provided

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

Proper SOP to
be made to
attend leakage/
Emergency
Handling

Fall in temperature
in Pipeline
Toxic release

Methyl Mercaptan pipe


line failure.

Gas masks and


Analyzer

Page 23 of 25

KALINGANAGAR

EQMS INDIA
PRIVATE
LIMITED

HAZOP WORK SHEET

TATA STEEL LTD

PROPANE STORAGE & PROPANE


DILUTION SYSTEM

G/P&I/6855/2013

Node:
303

P&ID
No.

Propane Dilution System

Design
Intent

To Dilute Propane

Deviation

Cause

Consequence

HSE/
ergonomic
issues

Methyl Mercaptan

Toxic release

Regulatory
issues

None

Start-up

To be considered later

Shut-down

To be considered later

Safeguard

Recommendation

Remark/Action

Methyl Mercaptan
Gas masks and
Portable Analyzer atmospheric
concentration
meter may be
provided near
working area for
continuous
monitoring..(R-9)

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

Page 24 of 25

TATA STEEL LTD


KALINGANAGAR

HAZOP WORK SHEET

PROPANE STORAGE & PROPANE


DILUTION SYSTEM

EQMS INDIA
PRIVATE
LIMITED

Page 25 of 25