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ACTION REPORT OF HAZOP STUDY FOR OPAL-DAHEJ PROJECT

Action By
(BHEL Systems in
Node
SL.No Recommendation PE&SD/HY Explanation PE&SD/HYD/
No.
D/Trichy/HP Trichy/HPEP
EP)
Configure a soft selector switch in the
DCS to select trip logic of Naphtha/HSD Noted and P&ID has been revised accordingly. (P&ID no.
1. NODE 1 PE&SD Fuel System
system for filling of naphtha/HSD tanks 1-38101-04290 Rev 06)

Check the design parameters to withstand Tanks have been designed for vacuum condition as per
NODE partial vacuum as per requirement under API 650. Further, Please note that Bleeder vents are
2. PE&SD Fuel System
1,4,6 the code simple & mechanical items. Failure of bleeder vents does
not happens.
As per EIL Design philosophy (Cl.7.3.4 of
6-51-0099 Rev 5) self-conducting structures having metal
Check requirement of Lightening
NODE thickness of more than 4.8mm, lightning protection with
3. arrestors on tanks PE&SD Fuel System
1,4,6 aerial rod and down conductors is not required.
Hence, Lightening arrestor on tank is not required & not
provided.
Interlock to trip screw pumps on closing
PE&SD Noted and P&ID has been revised accordingly.(P&ID no.
4. NODE 2 of both UV6771/78 Fuel System
1-38101-04290 Rev 06)

Interlock to trip screw pumps on closing


PE&SD Noted and P&ID has been revised accordingly.(P&ID no.
5. NODE 2 of UV6773 Fuel System
1-38101-04290 Rev 06)

Interlock to trip forwarding pumps on


PE&SD Noted and P&ID has been revised accordingly.(P&ID no.
6. NODE 2 closing of UV6772 Fuel System
1-38101-04290 Rev 06)

Interlock to trip centrifuge on closing of


PE&SD Noted and P&ID has been revised accordingly.(P&ID no.
7. NODE 2 UV6774 Fuel System
1-38101-04290 Rev 06)

Configure LAL6711 from LT6711 PE&SD Noted and P&ID has been revised accordingly.(P&ID no.
8. NODE 2 Fuel System
1-38101-04290 Rev 06)

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ACTION REPORT OF HAZOP STUDY FOR OPAL-DAHEJ PROJECT

Ensure Periodic water draining from the


PE&SD
9. NODE 2 clean oil tank - as part of SOP Noted and shall be addressed in SOP. Fuel System

For ensuring that raw oil does not go to clean oil tank,
one more Pressure switch (PSH) is provided on dirty oil
Identify solution to ensure raw oil does header in addition to pressure switch (PSL) on clean oil
10. NODE 2 not go to clean oil tank PE&SD header,. P&ID has been revised accordingly. Fuel System

Please refer PAH 6722B in Sh 02 of 14 od Drg. No.


13810104290 (HSD P&ID Rev 07) on dirty oil header
Interlock to trip GT forwarding pumps on
PE&SD Noted and P&ID has been revised accordingly.(P&ID no.
11. NODE 2 closing of both UV6775/79 Fuel System
1-38101-04290 Rev 06)

Configure LAL6711 PE&SD Noted and P&ID has been revised accordingly.(P&ID no.
12. NODE 2 Fuel System
1-38101-04290 Rev 06)
Configure interlock of LALL6707 to close
PE&SD Noted and P&ID has been revised accordingly.(P&ID no.
13. NODE 2 the clean oil outlet valve UV6775/79 Fuel System
1-38101-04290 Rev 06)

Ensure accumulator N2 pressure is


NODE
checked and made up periodically- PE&SD
14. 3, Noted and shall be addressed in SOP. Fuel System
3A,5,8A include in Operating Manual

Configure PAH6705 PE&SD Noted and P&ID has been revised accordingly.(P&ID no.
15. NODE 3 Fuel System
1-38101-04290 Rev 06)
Configure FAL6731 PE&SD Noted and P&ID has been revised accordingly.(P&ID no.
16. NODE 3 Fuel System
1-38101-04290 Rev 06)
Configure PAH from PT 6704 PE&SD Noted and P&ID has been revised accordingly.(P&ID no.
17. NODE 3 Fuel System
1-38101-04290 Rev 06)
Provide FAH 6731. Operator intervention Noted and P&ID has been revised accordingly.(P&ID no.
to trip pump - part of SOP (in case of PE&SD 1-38101-04290 Rev 06).
18. NODE 3 Fuel System
alarm from HC detectors also)
Noted and shall be addressed in SOP.
NODE PE&SD Noted and P&ID has been revised accordingly.(P&ID no.
19. Interlock UV6771/78 to trip PC0727 when Fuel System
3A 1-38101-04290 Rev 06)

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ACTION REPORT OF HAZOP STUDY FOR OPAL-DAHEJ PROJECT

both UVs close

NODE Configure PAH from PT 6712 PE&SD Noted and P&ID has been revised accordingly.(P&ID no.
20. Fuel System
3A 1-38101-04290 Rev 06)
NODE
Consider all inlet valve to be LO PE&SD Noted and P&ID has been revised accordingly.(P&ID no.
21. 3B,8,10, Fuel System
1-38101-04290 Rev 06)
10A
Interlock summary to be updated
NODE indicating LAH to start and LAL to stop PE&SD Noted and P&ID has been revised accordingly.(P&ID no.
22. Fuel System
3B drain tank submersible pumps 1-38101-04290 Rev 06)

BLV67200/02 to be converted to LC post


NODE Noted & Note has been put in revised P&ID.(P&ID no. 1-
23. commissioning of NG operations PE&SD Fuel System
3B 38101-04290 Rev 06)

Note of the above to be included in the


NODE PE&SD Noted & Note has been put in revised P&ID.(P&ID no. 1-
24. P&ID and also include in OM Fuel System
3B 38101-04290 Rev 06)

NODE Configure LAL from LT 66008 PE&SD Noted and P&ID has been revised accordingly.(P&ID no.
25. Fuel System
4,6 1-38101-04293 Rev 05)
Noted and P&ID has been revised accordingly. Please
NODE Consider removing the NRV PE&SD refer line no 12”-FO-46-66004-A1A; 12” NRV has been
26. Fuel System
4,6 removed ahead of BLV 66012 (Same was figuring in
rev04).
NODE Configure LT66008 to give LAH PE&SD Noted and P&ID has been revised accordingly..(P&ID no.
27. Fuel System
4,6 1-38101-04293 Rev 05)
Periodic monitoring through lab analysis
NODE of water content in Naphtha to be PE&SD
28. Noted and shall be addressed in SOP. Fuel System
4,6 ensured

HSD system to be on hot stand-by - to be


PE&SD
29. NODE 5 part of SOP Noted and shall be addressed in SOP. Fuel System

Explore requirement of HSD system to be PE&SD There is no requirement of HSD system to be hot standby
30. NODE 5 Fuel System
on hot stand-by to prevent HRSG fuel trip as per tender specification and same is not envisaged by

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ACTION REPORT OF HAZOP STUDY FOR OPAL-DAHEJ PROJECT

in case of naphtha supply failure BHEL.

Configure PAH from PT 66036 PE&SD Noted and P&ID has been revised accordingly..(P&ID no.
31. NODE 5 Fuel System
1-38101-04293 Rev 05)
Provide FAH 66067. Operator
intervention to trip pump - part of SOP PE&SD Noted and P&ID has been revised accordingly..(P&ID no.
32. NODE 5 Fuel System
(in case of alarm from HC detectors also) 1-38101-04293 Rev 05)

Ensure periodic cleaning of strainer PE&SD


33. NODE 7 Noted and shall be addressed in SOP. Fuel System
Ensure tapping from tank for pump is
PE&SD
34. NODE 7 taken sufficiently above tank bottom. Reviewed and tapping is in order Fuel System

Explore requirement of HSD system to be


There is no requirement of HSD system to be hot standby
NODE on hot stand-by to prevent HRSG fuel trip
35. PE&SD as per tender specification and same is not envisaged by Fuel System
8A in case of naphtha supply failure BHEL

NODE Configure PAH from PT 66036 Noted and P&ID has been revised accordingly..(P&ID no.
36. PE&SD Fuel System
8A 1-38101-04293 Rev 05)
Provide FAH 9202. Operator intervention Noted and P&ID has been revised accordingly..(P&ID no.
NODE to trip pump - part of SOP (in case of 1-38101-04293 Rev 05)
37. PE&SD Fuel System
8A alarm from HC detectors also)
Noted and shall be addressed in SOP.
Configure LALL6804 A/B LALL6807
Noted and P&ID has been revised accordingly.(P&ID no.
38. NODE 9 A/B PE&SD Fuel System
1-38101-04352 Rev 06)

Configure PAL6804 2oo3 Noted and P&ID has been revised accordingly.(P&ID no.
39. NODE 9 PE&SD Fuel System
1-38101-04352 Rev 06)
Configure PAL6806 Noted and P&ID has been revised accordingly.(P&ID no.
40. NODE 9 PE&SD Fuel System
1-38101-04352 Rev 06)
Configure TAH6884 Noted and P&ID has been revised accordingly.(P&ID no.
41. NODE 9 PE&SD Fuel System
1-38101-04352 Rev 06)
NODE Configure PAL6808 Noted and P&ID has been revised accordingly.(P&ID no.
42. PE&SD Fuel System
9A 1-38101-04352 Rev 06)
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ACTION REPORT OF HAZOP STUDY FOR OPAL-DAHEJ PROJECT

Check whether Condensate Drain tank


NODE can accommodate gas blow-by from Reviewed and provided drain tank can accommodate gas
43. PE&SD Fuel System
9B upstream blow by from upstream.(P&ID no. 1-38101-04352 Rev 06)

NODE Configure PAL 6811 Noted and P&ID has been revised accordingly.(P&ID no.
44. PE&SD Fuel System
9B 1-38101-04352 Rev 06)
NODE Mention on the P&ID PE&SD Noted and P&ID has been revised accordingly.(P&ID no.
45. Fuel System
10B 1-38101-04369 Rev 06)
Ensure Condensate Drain tank can
NODE PE&SD Provided drain tank can accommodate gas blow by from
46. accommodate gas blow-by from upstream Fuel System
10B upstream

NODE Configure LALL6907 A/B/C PE&SD Noted and P&ID has been revised accordingly. (P&ID no.
47. Fuel System
10B 1-38101-04369 Rev 06)
NODE PAL1102 to be configured PE&SD Noted and P&ID has been revised accordingly. (P&ID no.
48. Steam System
11 1-38101-04256 Rev 03)
NODE provide PAL 1263 Noted and P&ID has been revised accordingly. (P&ID no.
49. PE&SD Steam System
11A 1-38101-04257 Rev 03)
NODE Provide TAH1202 PE&SD Noted and P&ID has been revised accordingly. (P&ID no.
50. Steam System
11A 1-38101-04257 Rev 03)
NODE Configure TAH 1208 PE&SD Noted and P&ID has been revised accordingly. (P&ID no.
51. Steam System
11A 1-38101-04257 Rev 03)
Provide independent TE-TT and trip
NODE interlock with GTV-MOV-1217A/C on PE&SD Noted and P&ID has been revised accordingly. (P&ID no.
52. Steam System
11A temperature high 1-38101-04257 Rev 03)

Provide TAH 1202 (not independent) or


NODE PE&SD Noted and P&ID has been revised accordingly.(P&ID no.
53. consider alternate TAH Steam System
11A 1-38101-04257 Rev 03)

NODE Provide TAL 1209 PE&SD Noted and P&ID has been revised accordingly.(P&ID no.
54. Steam System
11A 1-38101-04257 Rev 03)
NODE Configure FAL1303 Noted and P&ID has been revised accordingly.(P&ID no.
55. PE&SD Steam System
12 1-38101-04258 Rev 03)
NODE PE&SD Noted and P&ID has been revised accordingly.(P&ID no.
56. Provide an alarm at closed position of Steam System
12 1-38101-04258 Rev 03)

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ACTION REPORT OF HAZOP STUDY FOR OPAL-DAHEJ PROJECT

ZI1307/08/02

Provide independent TE/TT d/s of


NODE PE&SD Noted and P&ID has been revised accordingly.(P&ID no.
57. YS1307/08 configure TAH Steam System
12 1-38101-04258 Rev 03)

Provide independent TE/TT d/s of


NODE PE&SD Noted and P&ID has been revised accordingly.(P&ID no.
58. YS1307/08 - Configure TAL Steam System
12 1-38101-04258 Rev 03)

Ensure frequent sampling from CW


NODE PE&SD
59. return line - part of OM Noted and shall be addressed in SOP. STG system
12A

NODE Configure TAH3204 A/B (1oo2) PE&SD Noted and P&ID has been revised accordingly.(P&ID no.
60. STG system
12A 1-317-00-99962 Rev 02)
NODE Configure TAL3204 A/B (1oo2) PE&SD Noted and P&ID has been revised accordingly.(P&ID no.
61. STG system
12A 1-317-00-99962 Rev 02)
NODE configure FAL1426/30 PE&SD Noted and P&ID has been revised accordingly.(P&ID no.
62. Steam System
13 1-38101-04259 Rev 03)
NODE Configure FAL1434 PE&SD Noted and P&ID has been revised accordingly.(P&ID no.
63. Steam System
13 1-38101-04259 Rev 03)
Configure PT1427/39 and PT1431/40 for
NODE Noted and P&ID has been revised accordingly.(P&ID no.
64. PAH PE&SD Steam System
13 1-38101-04259 Rev 03)

Instead of average signal of 2 PTs,


NODE configure 1oo2 with higher signal PE&SD Noted and P&ID has been revised accordingly.(P&ID no.
65. Steam System
13 controlling the PCV, and deviation alarm 1-38101-04259 Rev 03)

NODE Configure TAH-1424 PE&SD Noted and P&ID has been revised accordingly.(P&ID no.
66. Steam System
13 1-38101-04259 Rev 03)
Indicate high alarms for air pollutants (in
NODE Trichy Noted and P&ID has been revised accordingly.(P&ID no.
67. line with GPCB requirements) in P&ID HRSG System
14 3-97-88602 Rev 05)

NODE Indicate high alarms for SPM in P&ID Trichy Noted and P&ID has been revised accordingly.(P&ID no.
68. HRSG System
14 3-97-88602 Rev 05)

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ACTION REPORT OF HAZOP STUDY FOR OPAL-DAHEJ PROJECT

NODE Consider TAH from TT7708 to 7713 Trichy Noted and P&ID has been revised accordingly.(P&ID no.
69. HRSG System
14 3-97-88602 Rev 05)
NODE Consider TAH from TT7714 to 7719 Trichy Noted and P&ID has been revised accordingly.(P&ID no.
70. HRSG System
14 3-97-88602 Rev 05)
Operator intervention for steam venting
NODE Trichy
71. through startup vent as part of SOP Noted and will be included in SOP HRSG System
14

P&ID to be updated to reflect signals


NODE from PT7825/26 (use both PTs, Greater of Trichy Noted and P&ID has been revised accordingly(P&ID no.
72. HRSG System
15 the two values for controlling) 3-97-88602 Rev 05)

Deviation alarm between PT7825 & 7826


NODE
73. in DCS Trichy Already implemented in DCS HRSG System
15

Document for BMS providing interlock


NODE HRSG System
74. logic to be prepared Trichy BMS logics will be sent separately
16,18 & UB system

Consider an alarm when both SDV 7626


NODE to 37 and corresponding SDV 7650 to 61 Noted and P&ID has been revised accordingly(P&ID no.
75. Trichy HRSG System
16 are open 0-00-056-51140 Rev 06)

Fail position of the valves to be indicated


NODE Noted and P&ID has been revised accordingly.(P&ID no.
76. on the P&ID Trichy HRSG System
16 0-00-056-51140 Rev 06)

NODE consider providing Gas/HC detectors 2 No.s gas/HC detectors are envisaged in gas control
77. Trichy HRSG System
16 station skid
P&ID to be updated with the design
NODE Noted and P&ID has been revised accordingly(P&ID no.
78. values Trichy HRSG System
16 0-00-056-51140 Rev 06)

Consider an alarm when both the SDV


and vent valves are open. Operator
NODE Noted and P&ID has been revised accordingly(P&ID no.
79. intervention required - to be documented Trichy HRSG System
16 0-00-056-51140 Rev 06)
in the OM

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ACTION REPORT OF HAZOP STUDY FOR OPAL-DAHEJ PROJECT

NODE PALL 7621/76/77 to trip HRSG Noted and P&ID has been revised accordingly(P&ID no.
80. Trichy HRSG System
17 0-00-056-51140 Rev 06)
Bird screen size at fan suction/
construction to ensure dust /foreign
NODE Noted and indicated in the revised P&ID(P&ID no. 0-00-
81. material do not enter the augmenting air Trichy HRSG System
17 056-51140 Rev 06)
line

Consider relocating the PI7639 to 7645


NODE Noted and P&ID has been revised accordingly(P&ID no.
82. d/s of block valves Trichy HRSG System
17 0-00-056-51140 Rev 06)

NODE Consider DPAH Noted and incorporated in revised P&ID (P&ID no. 1-00-
83. Trichy UBs System
18 056-50595 Rev 09)
Consider an alarm when both SDV 0008
NODE
84. and 0020 open Trichy Noted and will be included in BMS logics UBs System
18

Fail position of the valves to be indicated


NODE Noted and incorporated in revised P&ID (P&ID no. 1-00-
85. on the P&ID Trichy UBs System
18 056-50595 Rev 09)

Boiler trip to be configured from TAHH


NODE Noted and PC, Chennai to revise the P&ID accordingly
86. 9901/02/03 Trichy UBs System
19 (P&ID no. 2-00-301-31677 Rev 04)

NODE Configure PAH from PT 9901/02/03 Noted and PC, Chennai to revise the P&ID accordingly.
87. Trichy UBs System
19 (P&ID no. 2-00-301-31677 Rev 04)
Ensure that the economizer inlet MOV is
NODE Noted and incorporated in the revised Boiler Auxiliaries
88. closed on boiler trip Trichy UBs System
19 Writeup.

TI 8746 to be changed to TIC 8746 and


NODE linked to BLV0004/5 and similarly for the Noted and P&ID has been revised accordingly(P&ID no.
89. Trichy UBs System
19 other parallel loop 0-24-200-80912 Rev 06)

NODE Provide PAH 8701/2 Noted and P&ID has been revised accordingly(P&ID no.
90. Trichy UBs System
19 0-24-200-80912 Rev 06)
NODE Noted and incorporated in revised P&ID (P&ID no. 0-97-
91. Interlock identification along with Trichy UBs System
20 400-80096 Rev 07)
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ACTION REPORT OF HAZOP STUDY FOR OPAL-DAHEJ PROJECT

relevant tag nos. to be documented


(included in the document already
prepared)

ensure run indication/trip alarm


NODE
92. available at the DCS Trichy It is already incorporated in DCS graphics and alarms UBs System
20

NODE Configure PAL 8610 on GR fan discharge Noted and incorporated in revised P&ID (P&ID no. 0-97-
93. Trichy
20 400-80096 Rev 07)
TAL to be configured for main steam
NODE Noted and PC, Chennai to revise the P&ID
94. temperature from TT 9901/02/03 Trichy UBs System
20 accordingly(P&ID no. 2-00-301-31677 Rev 04)

TAL initiator from possible causes to be


NODE
95. listed in the OM Trichy Noted and will be suitably included in O&M UBs System
20

TAH and TAL to be configured from


NODE Noted and incorporated in revised P&ID (P&ID no. 0-97-
96. 8610/11/12 Trichy UBs System
20 400-80096 Rev 07)

Configure TAL 8604/06 on flue gas outlet


NODE Noted and incorporated in revised P&ID(P&ID no. 0-97-
97. line Trichy UBs System
20 400-80096 Rev 07)

Check possibility of oil ingress into


NODE Receivers and ensure draining is done Atomizing air
98. PE&SD Noted and shall be addressed in SOP.
21 periodically system

Check availability of TSV for GT lube oil PE&SD have already incorporated the TSV for GT lube oil
and BFP drive turbine.
NODE coolers and BFP/Naphtha drive turbine PE&SD / Cooling water
99.
22 coolers Trichy system
Confirmed that the TSV for Naphtha Drive Turbine is
provided.
NODE P&ID to be updated to show ZT Noted and P&ID has been revised accordingly.(P&ID no. Condensate
100. PE&SD
23 1-38101-04261 Rev 03) system
NODE Condensate
101. Operator to check Analyzer indication on PE&SD Noted and shall be addressed in SOP.
23 system

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ACTION REPORT OF HAZOP STUDY FOR OPAL-DAHEJ PROJECT

opening of MOV1685/87 - part of OM

NODE Configure FAL1821/35 PE&SD Noted and P&ID has been revised accordingly.(P&ID no. Blow down
102.
24 1-38101-04263 Rev 03) system
Provide independent PT/PIC to control PE&SD Noted and P&ID has been revised accordingly.(P&ID no. Blow down
NODE
103. PV18215 1-38101-04262 Rev 03) system
24

Configure PAL on PT 1968 to trip the PE&SD Noted and P&ID has been revised accordingly.(P&ID no. Blow down
NODE
104. running pumps. 1-38101-04262 Rev 03) system
24

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