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Norpetco Hazop Report
Norpetco Hazop Report
ABRAR STATION
June, 2023
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HAZOP STUDY FOR NORPETCO RENTAL HEATING PACKAGE
CONTENTS
1. Executive Summary
2. Definitions
3. Abbreviation
4. Part A: Introduction
5. Part B: Methodology
6. Part C System
7. Part D Output
8. Attachments
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HAZOP STUDY FOR NORPETCO RENTAL HEATING PACKAGE
1. EXECUTIVE SUMMARY
The scope of the Hazard and Operability (HAZOP) study was to assess APRAR Heating Package
Process, as indicated in Section (A-1) and as detailed in the Process and Instrumentation
Diagrams (P&IDs) and (PFD) (Appendix B).
The HAZOP workshop was performed over two sessions in head office in Cairo, as follows:
A total of 15 Actions were raised during the HAZOP Workshop. A summary of the HAZOP Actions
is provided in (D-1) table.
The following generic comments have been made by the HAZOP Chairman:
There is a significant issue (Errors, Omission, Missing, etc.) with the information provided on
the P&IDs, Flow Diagram and all relevant documents need to be available and updated to reflect
the current design.
There is a significant issue (Alarm System not connected to area Control Room) and it give only
alarm on local screen for Burner Management System (BMS) and it need quick intervention from
PICO Operator only (NORPETCO Operation is not involved).
There are many switches not connected according to the original heater design, without any
specific studies being performed; hence, there are many Inherent Safety & Operability concerns,
at all levels (Hardware & Software).
There are significant design concerns and many HSE Design Principles not accounted for during
the initial package laydown. For example: segregation/separation is very inadequate
Overall, there is a significant lack of detailed Operational Procedures and even where they
exist, they are not always followed.
In addition, the following HAZOP specific comments have been made by HAZOP Chairman:
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HAZOP STUDY FOR NORPETCO RENTAL HEATING PACKAGE
There are no fire system and monitors for rental heating package washing and receiving tank,
only portable fire extinguishers in the area which will be difficult to be used during a major
fire (as the operator has to approach very close to the fire).
Originally there are no foam system and no foam cart to fight limited HC fire around PICO
rental heater, washing and receiving tank.
Overall, the active firefighting equipment and procedure had a lot of concern and require
immediate study.
Based on the above, the HAZOP Chairman clearly indicated to the team that the overall FW design
is not acceptable and is not safe.
The nodes of the HAZOP are defined in Section (B-2), the HAZOP findings are indicated in Section
5 and the noded HAZOP P&IDs are provided in Appendix B.
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HAZOP STUDY FOR NORPETCO RENTAL HEATING PACKAGE
2. DEFINITIONS
HAZARD IDENTIFICATION The pinpointing of material system, process and plant characteristics
that can produce undesirable consequence through the occurrence
of an accident.
RISK ASSESSMENT The Process by which the results of a risk analysis is used to make
decisions, either through relative ranking of risk reduction strategies
or through comparison with the risk targets.
HUMAN ERROR Any human action that exceeds some limits of acceptability (i.e., an
out of tolerance action) where the limits of human performance are
defined by the system. Includes actions by designers, operators, or
managers that may contribute to or result in accidents.
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HAZOP STUDY FOR NORPETCO RENTAL HEATING PACKAGE
3. ABBREVIATION
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HAZOP STUDY FOR NORPETCO RENTAL HEATING PACKAGE
4. PART A : INTRODUCTION
A-1): System Overview
The main purpose of the rental heater packages facility is to partially treat the crude oil received
from the production wells, increase the crude temp. up to set point to separate water and gas
from the crude oil (three phase heater) then send it to wash tank and then to oil receiving tank
which send it to NORPETCO storage tank via pumps.
The produced gas sent to the cold vent and the produced water send to skimmer tank then to
lined drain pit.
a) Heater.
b) Washing Tank.
c) Oil Receiving tank.
d) Shipping Pumps.
e) Skimmer Tank.
f) Washing Water tank.
g) Air Compressor.
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HAZOP STUDY FOR NORPETCO RENTAL HEATING PACKAGE
NORPETCO assigned MODERN INTEGRATED SYSTEMS to provide HAZOP study for rental heating
packages.
The scope of the HAZOP study was to assess the rental heating package facilities and utilities, as
indicated in the HAZOP P&IDs and PFD (Appendix B) and summarized below:
Process: NORPETCO rental heating package has a significant impact in the company
production.
Hence, in order to simplify the HAZOP Study, NORPETCO selected a number of typical importing
activities sections for the assessment.
Identify the potential hazards from the operation of the Heater & Equipment;
Assess whether the reaction of the plant or equipment to upsets will produce effects which are
harmful to People, the Environment, Assets;
Investigate the operability of the Heater & Equipment; and
Recommend corrective actions which will mitigate or eliminate the identified hazards.
The workshop was chaired by MODERN INTEGRATED SYSTEMS and attended by personnel from
NORPETCO and PICO.
The signed attendance sheets, from the two workshops, are presented in Appendix (C)
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HAZOP STUDY FOR NORPETCO RENTAL HEATING PACKAGE
Part B: Methodology
HAZOP studies are conducted via the use of structured and systematic examinations based on
guide-words.
A HAZOP study is a systematic technique for identifying potential hazards and operability
problems Industries.
The overall objective of a HAZOP is to identify possible causes leading to Hazards and
Operational concerns and to identify the need for appropriate corrective actions.
Hazard identification process relates strongly to the interaction of the team and the individual
diverse backgrounds of the personnel involved;
The ultimate objectives are to facilitate smooth, safe and prompt plant start-up, to minimize
extensive last-minute modifications, and ultimately to ensure trouble-free long-term operation.
HAZOP Procedure takes a full description of the process and systematically questions every part
of it to discover how deviations from the design intent can occur, the consequences of such
deviations are then determined and if significant are reviewed and remedial action either
recommended or flagged for further study.
The study is performed by a team of people who are familiar with the plant design and operation,
working under the guidance of a leader who is experienced in the use of the HAZOP method.
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HAZOP STUDY FOR NORPETCO RENTAL HEATING PACKAGE
Node A3: From Heater outlet to Washing Tank and Receiving Tank.
Node A4: From Receiving Tank to Norpetco Oil Tank via Pumps.
P a g e | 10
HAZOP STUDY FOR NORPETCO RENTAL HEATING PACKAGE
Parameter Deviation
Flow No
Less
More
Reverse
Pressure High
Low
Temperature High
Low
Level High
Low
As well as Contamination
Other Corrosion
Erosion
Relief
Utility failure
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HAZOP STUDY FOR NORPETCO RENTAL HEATING PACKAGE
Part C System
P a g e | 12
HAZOP STUDY FOR NORPETCO RENTAL HEATING PACKAGE
P a g e | 13
HAZOP STUDY FOR NORPETCO RENTAL HEATING PACKAGE
Part D Output
P a g e | 14
HAZOP STUDY FOR NORPETCO RENTAL HEATING PACKAGE
ATTACHMENTS
HAZOP Worksheet.
Heater (P&ID).
Rental Package PFD
Risk Matrix.
HAZOP Members sheet.
P a g e | 16
HAZOP WORK SHEET
Client NORPETCO Date 15/06/2023 Node Description Heater Burner Node No. A1
Working Burner Max. Pressure 7.8 bar reduced to 180 mbar. P&ID N0.
Parameters Max Operating pressure 500-750 mbar.
HAZOP ACTION
Deviation Cause Consequence Safe Guards S P R Action Responsibilities
1.1 Fuel line shutdown 1.1.1 Process upset/ off - BMS shut down burner. 2 D M - All burner parts to be maintained PICO
1. No Gas Flow 1.2 PCV 108 fails close spec. product - Low pressure Alarm. regularly.
1.3 SOV 601 fails close - Maintenance procedure
2. High Gas 2.1 Feed gas line Fails 2.1.1 Process upset - Shut down valve on gas line. 3 C M - Connecting TSSH 105 to BMS
Flow open. 2.1.2 may lead to - BMS shut down burner - All burner parts to be maintained PICO
2.2 PCV 108 stuck open. burner bundle rapture/ - TSHH 105 alarm regularly.
2.3 Low oil level inside deformation - PCV 108 close the inlet gas. - Install audible alarm connected to
heater. - Maintenance procedure Area control room.
2.4 feed reach with
condensate
3. Low Temp 3.1 Flam off 3.1.1 Process upset/ off - BMS shut down burner. 2 D M -- All burner parts to be maintained PICO
3.2 PCV 108 fails close spec. product - Maintenance procedure regularly.
3.3 SOV 601 fails close
4. High Temp 4.1 Poor fuel air ratio 4.1.1 Process upset - Shut down valve on gas line. 3 C M - Connecting TSSH 105 to BMS PICO
4.2 PCV 108 stuck open. 4.1.2 may lead to - BMS shut down burner - All burner parts to be maintained
4.3 Low oil level inside burner bundle rapture/ - TSHH 105 alarm regularly.
heater. deformation - PCV 108 close the inlet gas. - Install audible alarm connected to
4.4 feed reach with - Maintenance procedure Area control room.
condensate
Client NORPETCO Date 15/06/2023 Node Description Heater (water/gas/oil). Node No. A2
Working Parameters Working pressure 10 PSI, Testing pressure 105 PSI P&ID No.
Safety relief valve 65 PSI
HAZOP ACTION
Deviation Cause Consequence Safe Guards S P R Action Responsibilities
1. Low 5.1 Manual inlet valve close. 5.1.1 Operation upset. - Low level alarm. 4 D H - Connect level switch to BMS PICO
Level 5.2 Low inlet feed. 5.1.2 Damage to heater - BMS shutdown burner. - Mechanical lock out applies to All PICO/NORPETCO
5.3 Manual drain valve keep open. bundle due to overheat. manual valves.
2. High 6.1 V-401 close. 6.1.1 Process upset. - Level alarm HH only 3 D M - Protect heater against carry over to cold PICO/NORPETCO
Level 6.2 High feed in. 6.1.2 Carry over to cold - Firefighting equipment. flair due to high level. - NORPETCO review
6.3 manual valve before & after V- flair leads to - All Heater function switches to be the connection.
401 closed. environmental impact connected to BMS.
and possible fire.
3. Low 7.1 Low feed gas. 7.1.1 Operation up set. - Pressure alarm low. 2 D M - Ensure check valve functioned properly. PICO
Pressure 7.2 PV 100 fail open. 7.1.2 Carry over to cold - Check valve before - Mechanical lock out applies to All
7.3 PSV 200 stuck open. flair leads to wash tank. manual valves. PICO/NORPETCO
7.4 Manual vent valve keep open. environmental impact - Firefighting equipment.
7.5 PV 100 by pass manual valve and possible fire.
keeps open.
7.6 possible reverse flow from
wash tank.
4. High 8.1 PV 100 fail close. 8.1.1 heater body - Pressure alarm HH. 4 D H - HH pressure alarm should connected to PICO/NORPETCO
Pressure 8.2 Gas outlet block manual valves deformation, or possible - PSV 200. NORPETCO control room.
closed. explode. - Ensure integrity of PSV.
8.1.2 Back pressure to
production manifold.
5. High 9.1 H2S. 9.1.1 Pin Hall. - Sacrificial anode, 2 D M
Corrosion/ 9.2 Salinity. 9.1.2 loss of thickness - Chemical treatment
Erosion 9.3 Sand 9.1.3 loss of production &
oil spill.
Client NORPETCO Date 15/06/2023 Node Description Heater outlet to washing tank and oil tank Node No. A3
Working Tanks Working pressure atmospheric, tank volumes 500 BBL each P&ID No.
Parameters
HAZOP ACTION
Deviation Cause Consequence Safe Guards S P R Action Responsibilities
1. Low Level 1.1.1 Tank drain valve keeps open. 1.1.1 Loss of - Operating 2 D M - Regular check on tank level. PICO
(Wash tank) production. procedures. - Mechanical lock out applies to All PICO/NORPETCO
1.1.2 Oil spill to - Lined drain pit. manual valves.
drain pit.
2. High 2.1 Out let valve closed. 2.1.1 Tank overflow. - Operating 3 C M - Regular check on tank level. PICO
Level 2.2 Fresh water pump working while 2.2.1 Oil spill around procedure.
(Wash tank) tank out let closed. tank. - Dick wall around
tank.
3. Low Level 3.1 Low feed from washing tank. 3.2.1 Loss of - Operating 3 C M - Regular check on tank level. PICO
(Receiving 3.2 Side glass damage. production. procedures. - Study install low level alarm on the PICO/NORPETCO
tank) 3.3 Drain valve keeps open. 3.2.2 Oil spill around - Lined drain pit. tank.
3.4 Tank structure damage. tank. - Fire equipment’s - Mechanical lock out applies to All
3.5 shipping pump keep running 3.3.1 Oil spill to drain manual valves.
pit.
3.4.1 Same as 3.2.2.
3.5.1 Damage to the
pump or possible fire.
4. High 4.1 More feed from washing tank. 4.1.1 Over fill the tank - Operating 3 C M - Regular check on tank level. PICO
Level 4.2 Tank out let valve close. led to oil spill & procedures. - Study install high level alarm on the
(Receiving 4.3 Shipping pump not working. possible fire in - Firefighting tank.
tank) addition loss of equipment.
production.
Client NORPETCO Date 15/06/2023 Node Description Receiving Tank to Norpetco Oil Tank via PICO Node A4
Shipping pumps No.
Working Parameters Pump capacity: P&ID N0.
HAZOP ACTION
Deviation Cause Consequence Safe Guards S P R Action Responsibilities
1. No flow 1.1 Upstream block valve closed. 1.1.1 Over heat the pump may - Operating 3 D M - Mechanical lock out applies to PICO/NORPETCO
1.2 Downstream block valve closed. lead to pump damage or procedures. All manual valves.
1.3 No Level in oil receiving tank. possible fire. - Study installing low flow shut PICO
1.1.2 check oil level before down switch for the pump.
shipping
2. High 2.1 Close Norpetco tank inlet valve. 2.1.1 Pump over heat may - Operating 3 D M - Study install high pressure shut PICO/NORPETCO
Pressure lead to pump damage and procedures. down switch for the pump.
may lead to fire.
NODE A2
Gas Line
controller
NODE 1A
sp
V-1 V-2
Indirect Heater
LG Wash LG recieve
H-1 Tank Tank
Oil outlet
V-3
LG Skimmer
Tank
Node A4
To Water pit
Lab Cabin
LEGEND KEY
Surface Testing Equipment
Fluid SP Sample point
Oil Cold Vent Client : Norpetco Petroleum Company
Line
Gas
Pneumatic Water Drawing : PFD
Norpetco Risk Matrix
Rev.1
LIKELIHOOD
A B C D E
Occurs more than once per year in the Occurred more than once a year in the Common in the industry and in
Qualitative Indicator Never occurred in the industry Previously occurred in industry
industry industry and has occurred in Norpetco Norpetco
On-Site Fatalities more than 3 Extensive damage Catastrophic, where environmental Impact is: Major/ International Impact:
Multiple Permanent disabilities Substantial total loss of plant, or 1- Uncontained hazardous impact • International public attention
equal to or more than 35 % total loss of operation exceeds 2 2- Cannot be controlled by company owned resources/ • Extensive negative attention in international media
One or more fatality for public weeks contracts and national and international policies with severe
Catastrophic
Costs in excess of $5 mm 3- Requiring major treatment and monitoring for 180 impacts to access new areas and receive license or tax
days legislation
4- Require external international resources to control • Potential loss of license to operate an asset or
5 its consequences intervention from the government
5- Major breach to national and international • Widespread adverse social impact
legislations • Damage to relationships with key stakeholders
6- Significant claims and fines
7- Requires regulatory authority investigation
8- Heightened concern of local community
1 to 3 on-site Fatalities Major Damage Major, where environmental impact is: Major Impact:
Multiple Lost work day cases Partial operation shutdown 1- Extensive hazardous impact • National public concern
onsite exceeding one shift up to 2 2- Cannot be controled by company owned resources/ • Extensive negative attention in the national media
One or more serious injury for weeks contracts and/or regional/national political attention with
public Total shut down less than or 3- Requiring long-term rectification, monitoring and potentially restrictive measures and/or impact on
Single permanent disabilities exceed one shift up to 2 weeks treatment more than 90 days and less than 180 days grant of licenses, mobilization of action groups
Major
equal to or more than 35% Costs greater than or equal to 4- Requiring External National aids
4 Multiple Occupational illness $500K and less than or equal to 5- Major breach of number of applicable regulations
$5 mm 6- Considerable and prolonged community adverse
IMPACT (On & Offsite)
Single Lost Work Day Case Local damage Moderate event where environmental impact is: Local Impact:
(LWDC) Partial operation shutdown less 1- Uncontained hazardous impact • Regional public concern
Permanent disability (s) less than one shift 2- Can be controlled by company owned resources, • Extensive negative attention in local media
than 35% Costs greater than or equal to specialists and third party contracts • Slight national media and/or local/regional political
Severe
Multiple reversible $50K and less than $500K 3- Can be rectified within a short to medium term attention with possibly negative stance of local
3 occupational health effect treatment and monitoring more than 30 days and less government and/or action groups
Single occupational illness than 90 days • Local adverse social impact
4- Significant medium-term residual effect
5- Regulatory authority concern
Restricted work day case Minor damage Minor event where environmental impact is: Minor Impact:
(RWDC), Medical treatment Production disruption leads to 1- Contained and low impact • Some local public concern
Significant
case (MTC) or single reversible equipment isolation 2- Can be controlled by company owned resources/ • Some slight local media and/or political attention
health effects from an incident Cost greater than or equal to contracts with potentially negative aspects for company
$2500 and less than $50K 3- Treatment and monitoring requires more than 7 days operations
2 and less than 30 days
4- Low profile media attention
5- Likely level of legal claims
First aid case (s) (FAC) or health Slight damage, no disruption to Insignificant event where environmental impact is: Slight Impact:
exposure causing noticable operations, costs less than 1- Low impact to isolated area • Public awareness of the incident may exist, but there
irritation $2500 2- Treatment and monitoring less than 7 days is no public concern
Minor
3- No permanent or significant effect • Isolated and short term complaints from neighbors
1 4- Low media attention (e.g., complaints about specific noise episode)
5- Legal issued managed by routine procedures
6- Slightly to no level of legal claims
Implement risk reduction measures untill ALARP is demonstrated. Maintain systematic controls
High - Intolerable Risk reduction is mandatory Tolerable if ALARP Low
Continous improvement required where practicable. and monitor