Draft Hazop Report - Ambala & Kurukshatra - HOGPL - 09.08.2019

06-08-2019 Qualitative Risk Assessment
Draft Report HAZARD & OPERABILITY (HAZOP) Study
HazOp – Desktop Process Safety Review (DPSR)
PROJECT
HPOIL GAS PRIVATE LIMITED (HOGPL)
City Gas Distribution Project
Ambala - Kurukshetra Districts, Haryana
Ambala District Pipeline Length - 33.33 KM.

Kurukshetra District Pipeline Length – 49.59 KM.
Total Pipeline Length - 82.92 KM
HSE RM Solutions
ON BEHALF OF: VCS QUALITY SERVICES PVT. LTD.
HSE-RM Solutions
Hazard & Operability (HazOp) Study
Qualitative Risk Assessment Study Report

Prepared for
HPOIL GAS PRIVATE LIMITED (HOGPL)
PAGE 1 REF.: HSERM/PT/VCS/PO/19-20/03/12-06-2019/Project 18&19/060619

City Gas Distribution Project
Ambala - Kurukshetra
Study Report Prepared on Behalf Of Study Conducted & Report Prepared By

VCS Quality Services Pvt. Ltd. HSE – RM Solution
707 & 708, 7Th Floor, Tower-1 Reg. Office:
Assotech Business Cresterra F-405, Sharan Residency- 2,
Sector-135, Noida-201301, New C. G. Road, Chandkheda,
U.P.
Ahmedabad-382424
Ph.: +91-9824663306
Email: support@hse-rm.com
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QUALITY CONTROL SHEET
Report Releasing Date: 06-08-2019
Prepared By HSE-RM Advisory Members
Reviewed & Approved By
Released By
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INDEX
SR. NO. CONTENT PAGE NO.
1. FORWARD 04
2. ACKNOWLEDGEMENT 05
3. PREFACE: INTRODUCTION OF HAZOP - DESKTOP PROCESS 06

SAFETY REVIEW (DPSR)
4. ABBREVIATION 08
5. INTRODUCTION TO SITE 09
6. DESIGN CRITERIA 11
7. APPLICABLE CODES & STANDARDS 21
8. HAZARD AND OPERABILITY (HAZOP) STUDY 22
9. REFERENCES 24
AMBALA DISTRICT HAZOP STUDY

10. NODE LIST AMBALA DISTRICT 27
11. AMBALA DISTRICT DESIGN INTENT 32
12. AMBALA DISTRICT HAZOP WORK SHEET 35
HAZOP STUDY: NODE - 1 36

KURUKSHETRA DISTRICT HAZOP STUDY
13. NODE LIST KURUKSHETRA DISTRICT 68
14. AMBALA DISTRICT HAZOP WORK SHEET 70
15. CONCLUSION 83
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FORWORD
It is to be noted that this consulting service offered for HazOp (Hazard & Operability) - Desktop Process Safety Review
(DPSR) is carried out based on the information, details, data etc. as provided by the VCS Quality Services Pvt. Ltd.
(VCSQSPL) management and as observed by Risk Assessor during their document review & verifications.
We have exercised all reasonable skills, care and diligence in conducting the HazOp – DPSR. However, this report
should not be treated as undertaking warranty or certificate. The consulting service of this collective data is being carried-
out for the first time. During the study/review, we have observed and assessed some gaps which are collectively
mentioned in recommendations, corrective measures are also suggested in this report for compliance & Best practices.
Disclaimer: The consulting service conducted by HSE-RM Solutions (The “Company”) were performed using generally
accepted guidelines, standards, and/or practices, which the Company considers reliable. Although the Company
performed its consulting services pursuant to reliable and generally accepted practices in the industry, the Company
does not guarantee or provide any representations or warranties with respect to VCS Quality Services Pvt. Ltd. Or

principle organization (Client) use, interpretation or application of the findings, conclusions, and/or suggestions of the
consulting services provided by the Company. Moreover, the findings, conclusions, and the suggestions resulting from
the consulting service are based upon certain assumptions, information, documents, and procedures provided by the
Client. AS SUCH, IN NO EVENT AND UNDER NO CIRCUMSTANCE SHALL THE COMPANY BE LIABLE FOR
SPECIAL, INDIRECT, PUNITIVE, OR CONSEQUENTIAL DAMAGES OF ANY NATURE WHATSOEVER, INCLUDING
WITHOUT LIMITATION, ANY LOST REVENUE OR PROFITS OF THE CLIENT OR ITS CLIENT, AGENTS, AND
DISTRIBUTORS, RESULTING FROM, ARISING OUT OF OR IN CONNECTION WITH, THE SERVICES PROVIDED
BY THE COMPANY. The Client agrees that the Company shall have no liability for damages, which may result from
Client use, interpretation or application of the consulting services provided by the Company. Client logo has been used
for report purpose only.
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ACKNOWLEDGEMENT
We, M/s. HSE RM Solutions, Ahmedabad, Gujarat sincerely thank VCS Quality Services Pvt. Ltd., Noida for appointing
us to conduct HAZOP - Desktop Process Safety Review (DPSR) Qualitative Risk Assessment of the HPOIL Gas Private
Limited (HOGPL) – City Gas Distribution Project of Ambala – Kurukshetra Districts, Haryana.
We express our sincere thanks to management & employees of “VCS Quality Services Pvt. Ltd., Noida, their courtesy,
co-operation & unstinted support extended to our team, to conduct DPSR for client job no. PI / HPCL / 033 / 18 – 19,
Dated 22.11.2018, our entry no. Project 18 &19: 12.06.2019
To conduct HAZOP - Desktop Process Safety Review (DPSR) Qualitative Risk Assessment, the Advisory team of M/s.
HSE RM Solutions, Ahmedabad, Gujarat comprises:
Mr. Piyush Tripathi (MD)
Mr. R. C. Sharma (Advisor)
The team was assisted & guided by M/s. VCS Quality Services Pvt. Ltd., Noida.
Reference Documents for HAZOP - Desktop Process Safety Review (DPSR) Qualitative Risk Assessment Comprises
• Process Design Basic for HPOIL Gas Private Limited (HOGPL) – City Gas Distribution Project of Ambala –

Kurukshetra District and Kohlapur District.
• P & ID for City Gate Station cum Mother Station at Jalbera - Ambala,
• Drawing No. 1007 - AMB – PC – PID - 1001, Rev.D3.
• Drawing No. 1007 -AMB – PC – PID - 1002, Rev.D3.
• Drawing No. 1007 - Ambala – PC – PID - 1003, Rev.D3.
• P & ID for Ambala CGD Facilities at Kirti Azad Chowk: Drawing No. 1007 -AMB – PC – PID - 1004, Rev.D3.
• P & ID for Ambala CGD Facilities at Devi Oil Pump: Drawing No. 1007 -AMB – PC – PID - 1005, Rev.D3.
• P & ID for Ambala CGD Facilities up to Chainage 20.37 KM : Drawing No. 1007 -AMB – PC – PID - 1006, Rev.D3.
• P & ID for Ambala CGD Facilities up to Chainage 14.42 KM: Drawing No. 1007 -AMB – PC – PID - 1007, Rev.D3.
• Block Flow Diagram – Station cum Mother Station at Jalbera – Ambala: Drawing No. 1007 -AMB – PC – PID –
1008
• It was informed by the Client that P & ID for Kurukshetra District City Gate Station cum Mother Station and
GCD are identical as Ambala District P & ID’s.
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PREFACE
INTRODUCTION OF HAZOP - DESKTOP PROCESS SAFETY REVIEW (DPSR)
The objective of a DPSR is to assess the hazard potential of mal-operation or malfunction of individual items of equipment
and the consequent effects on the facility as a whole. This is done via the application of a systematic critical examination
of the design intents of the equipment, in order to identify potentially hazardous deviations from the design intents.
The DPSR technique is a systematic, line-by-line review of the latest Piping & Instrumentation Diagram (P &ID) with
respect to all technical safety and operability aspects (including equipment fire protection), until every piece of equipment
within the scope of the study has been reviewed. This is to ensure that the operating system will handle all foreseeable
operating conditions, including maintenance, start-up and shut down (both normal and emergency), in a safe, healthy
and reliable manner, with minimum environmental impact. To facilitate progress, reviewed systems will be marked in an
easily identified color on the P & ID studied by the team leader.
The review includes:
 Identification of possible deviations from the actual design intent
 Identification of possible causes for deviations and determination of the consequences
 Identification of deviations from design practices, guidelines and recommendations on technical HSE, fire safety

and operability issues
 Evaluation of the impact of the consequences on the technical and fire safety and operability) of the plant and
its interconnected facilities and on the environment.
HAZOP
The aim of the Hazard & Operatability Study (HAZOP study) is to identify potential hazardous events and significant
operability problems associated with the proposed operations. This aim is inherent for all HAZOP
studies.
A HAZOP study is a hazard study which concentrates on how the design will cope with abnormal
conditions, rather than on how it will perform under normal conditions. The study is comprised of
a review of each unit operation, examining each for possible causes of a wide range of process
abnormalities and their consequences.
HAZOP provides the opportunity for people to think creatively and examine ways in which
hazards or operating problems might arise. To reduce the chance of missing something, a
HAZOP is carried out in a systematic manner, using guide words to consider each pipeline and
each type of hazard in turn. The study is carried out by a team so that input from all areas of functional expertise can be
provided.
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The results of a HAZOP depend heavily upon the
experience and attitudes of the team members and
on the leadership style adopted. In this study, the
members of the team had good experience,
knowledge and skills and had the authority to
approve the actions decided upon.
The HAZOP study of plant by procedure given

below:
The process design engineer outlined the broad
purpose of the section of design under study and
display of relevant P&ID’s on the wall. This outline should includ design features, operating conditions, description of
fittings and details of equipment.
The first section or area will be, typically an area where material flows into the plant.
Through general discussion core understanding of process material flow and provision of safety measures and controls
will be discussed.
The detailed "line by line" study at this point is qualitative
base. The HAZOP leader will lead through the HAZOP guide

words. Each guide word is a prompt, such as "MORE / LESS
/ NO FLOW", which identifies a deviation from normal
operating conditions that may lead to a hazardous event or
significant operability problem. This is used to prompt
discussion of the possible causes and effects of flow at an
undesirably high rate. If, in the opinion of the team, the
safeguards for the combination of the consequences and
likelihood of a credible event are inadequate then an action will be recorded in the minutes.
For major risk areas the need for action is assessed quantitatively (by Hazard or Reliability Analysis). For less significant
risks the need for action can be based on experience and judgement. For this study, all actions should be addressed by
the nominated HAZOP team members / company.
The reason for this approach is that a positive, open, questioning mindset is required from the team members. This
allows creative brainstorming to identify possible abnormal plant conditions that may lead to potential hazardous events
and/or significant operability problems.
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ABBREVIATION
HOGPL HPOIL Gas Private Limited (HPOIL - M/s Hindustan Petroleum Ltd. and Oil India Ltd.)
CGD City Gas Distribution
CGS City Gas Station
DRS District Regulating Station
OLS On Line Station
MS Mother Station
DB Daughter Booster Station
DFR Detailed feasibility report
D/s Downstream
U/s Upstream
GAIL Gas Authority of India Ltd
VCSQSPL VCS Quality Services Private Limited
NG Natural Gas

Min Minimum
Max Maximum
RLNG Regasified Liquefied Natural Gas
PCV Pressure Control Valve
PRS Pressure Regulation Station
PSV Pressure Safety Valve
SDV Shut Down Valve
CRV Creep Relief Valve
SCADA Supervisory Controls And Data Acquisition
TOP Tap Off Point
UG Under Ground
MMSCMD Million Metric Standard Cubic Meter Per Day
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INTRODUCTION TO SITE
M/s HPOIL, a joint venture of M/s Hindustan Petroleum Ltd. and Oil India Ltd, has been awarded by M/s PNGRB to set
up CGD facilities in Two Geographical Areas, Ambala & Kurukshetra at Haryana and Kohlapur in Maharashtra.
M/s HPOIL has sourced the natural gas from existing pipelines of M/s GAIL separately at Ambala and Kurukshetra, and
another at Kohlapur.
Accordingly, One CGS will be set up at Adhoya Village, receiving Gas from M/s GAIL’s Haridwar Long distance
pipeline at SV-6 for CGD system at Kurukshetra GA.
Similarly, another CGS will be set up at Jalbera Village, receiving gas from M/s GAIL’s same pipeline from SV-7
for CGS distribution of Ambala GA.
Another CGS will be set up at Mauje Vadgaon Village, receiving gas from M/s GAIL pipeline’s IP2 for CGS distribution
of Kohlapur GA.
VCS Quality Services has been appointed as Engineering Consultant by M/s HPOIL to provide Engineering consultancy
services for setting up “City Gas Distribution Facilities at Ambala – Kurukshetra GA at Haryana and Kohlapur GA
at Maharashtra”.
Project under Study

This project foresees transportation of PNG and/ or R-LNG to the various consumers and CNG for vehicle transportation
sections in Ambala – Kurukshetra in Haryana.

There are total 6 Charge areas in the district of Ambala – Kurukshetra Haryana.
In Ambala District there are Three Charge areas (CA’s) at Charge Area-1 (Naraingarh), Charge Area-2 (Ambala)
and Charge Area-3 (Barara).
In Kurukshetra District there are Three Charge areas (CA’s) at Charage Area 4 (Shahbad), Charge Area 5
(Pehowa) and Charge Area 6 (Kurukshetra).
The Peak Realizable Demand of Natural Gas on 25th year from Domestic Sectors, Commercial Sectors, Industrial
Sectors and Automobile Sectors for Ambala and Kurukshetra District (Covering 6 CA’s) considered at 0.754 MMSCMD
and the Peak Load Demand arrives at 1.418 MMSCMD.
Network design of Ambala GA carried out considering the Peak Load Demand of 54,480 SCMH equivalent to 1.3
MMSCMD with 30 % spare capacity available in the pipeline.
Network design of Kurukshetra GA carried out considering the Peak Load Demand of 18,000 SCMH equivalent
to 0.432 MMSCMD with 30% spare capacity available in the pipeline.
Network Design consideration for Ambala – Kurukshetra Districts, Haryana:
1. Tap-off from Existing Natural Gas Pipeline.
2. City Gate Station (CGS) cum Mother Station adjacent to Tap-off Point. The CGS will have Filtration, Pressure
Reduction and check Metering facility, Odorizing facility, Pig Launcher Facility. However, at each CGS Facility,
OLS cum Mother station facilities also provided.
3. Steel Pipeline Network to supply Natural Gas from CGS to (i) Domestic, Commercial and small industrial
Consumers through District Regulating Station (DRS), (ii) Large Industrial Consumers through Pressure
Regulating Station (PRS) and Automobile Consumers through On-Line Compressor stations.
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Subsequent to steel pipelines automobile sectors demand are met through CNG Cascades where steel pipelines
are not viable. The demand is met through Cascade and Booster Compressor at Daughter Booster Station (DB)
and from Cascades at Daughter Station. However, gas supply to CNG Cascades is met from on-line Compressor
Stations cum mother stations.
4. From DRS Low pressure (4-6 Kg/cm2.g) MDPE pipelines will be laid to supply to Domestic, Commercial and small
industrial Consumers.
5. On-line CNG Station: CNG Compressors are to be installed to compress Natural Gas supplied through steel
pipelines to 250 Kg/cm2.g The Compressed gas will be dispensed through twin arm Car/Auto Dispensers or Single
arm Bus Dispensers. Stationary CNG Cascade of 3000 WL capacity will be installed in each compressor cum
dispenser station to keep buffer storage of CNG when Dispensers are not dispensing. Cascade’s CNG will also
be used to dispense to Automobiles when Compressors are not to run.
6. On-line cum Mother Station: All facilities as stated in OLS as stated above along with Cascade filling will be called
On-Line-Mother Station. Dispensing to automobiles at Mother Station may or may not be present.
BATTERY LIMITS
Process Facility: From tap off point.
Utilities: Up - to Domestic, Commercial, Industrial and Automobile Consumers.
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DESIGN CRITERIA
Product: Natural Gas / RLNG
Unit of Measurement
Gas Flow : SCMH (Standard Cubic Meter per Hour)
Pressure : kg / cm2g (Kilogram per Centimeter Square)
Temperature : 0C (Degree Celsius)
Velocity : m / sec (Meter per Second)
1. System Load Calculations

The Peak Realizable Demand of Natural Gas on 25th year from Domestic Sectors, Commercial Sectors, Industrial
Sectors and Automobile Sectors for Ambala and Kurukshetra District (Covering 6 CA’s) considered at 0.754 MMSCMD
and the Peak Load Demand arrives at 1.418 MMSCMD
Parameter For Ambala District For Kurukshetra District
Peak Realizable Demand (25th 54,480 SCMH equivalent to 1.3 18,000 SCMH equivalent to 0.432
Year) MMSCMD with 30% spare capacity MMSCMD with 30% spare capacity
available in the pipeline. available in the pipeline.
Network design 54,480 SCMH with 30% spare 18,000 SCMH with 30% spare capacity
capacity available considering the available considering the Peak Load

Peak Load Demand in the pipeline. Demand in the pipeline.
2. DISTRIBUTION PLAN & FACILITIES up to 25th year of 54480 SCMH at Ambala GA:
Facilities For Ambala District For Kurukshetra District
(Up to 25th year of 54480 SCMH at (Up to 25th year of 18,000 SCMH at
Ambala GA) Kurukshetra GA)
CNG Compressors (Capacity 23 Nos 05 Nos
1200 SCMH)
DRS (Capacity 1000 SCMH) 15 Nos. 08 Nos.
IPRS (Capacity 1000 SCMH) 03 Nos. 01 Nos.
Total Maximum 45,600 SCMH. 15,000 SCMH.

(with 20 % extra 54,480 SCMH) (with 20 % extra 18,000 SCMH)
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3. PIPELINE THICKNESS: FOR AMBALA & KURUKSHETRA DISTRICT: Pipeline thickness
calculated as per ASME B 31.8
Pipeline Diameter 12 ‘’ - 4”,
Grade 12” Dia – API 5L Grade 60 / > 12” Dia – API 5L Grade B
Minimum Pipeline Wall Thickness 6.4 mm
Total Pipeline length 28.77 Km
4. Sectionalizing Valve (SV)

4.1 Ambala District
Manual operated full-bore ball valve installed underground in a pit at an interval of around 3 Km across the
length of Steel Pipeline.
Sr. no. SV no. Size in Inch Rating Location

1 SV-1 12.0 300# 3 Km from CGS
2 SV-2 12.0 300# 6 Km from CGS
3 SV-3 12.0 300# 3 Km from Kirti Azad Chowk
4 SV-4 6.0 300# 3 Km from Model Town Morh

4.1 Kurukshetra District

Manual operated full-bore ball valve installed underground in a pit at an interval of around 3 Km across the length
of Steel Pipeline.
Sr. no. SV no. Size in Inch Rating Location
1. SV-1 8.0 300# 3 Km from CGS

2. SV-2 8.0 300# 6 Km from CGS
3. SV-3 8.0 300# 9 Km from CGS
4. SV-4 8.0 300# 12 Km from CGS
5. SV-5 8.0 300# 15 Km from CGS
6. SV-6 8.0 300# 21 Km from CGS
7. SV-7 8.0 300# 24 Km from CGS
8. SV-8 8.0 300# 27 Km from CGS
9. SV-9 8.0 300# 30 Km from CGS
10. SV-10 8.0 300# 33 Km from CGS
11. SV-11 8.0 300# 36 Km from CGS
12. SV-12 8.0 300# 21 Km from CGS
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13. SV-12 6.0 300# 3 Km from Pipli Chowk
5. Online Stations (OLS) and District Regulating Stations (DRS)

5.1 Ambala District
Sr. From To Pipe CNG DRS PRS
No. Length OLS/MS Capacity No. Capacity No. Capacity
(Km) (No.) (SCMH) (SCMH) (SCMH)
Each Each Each
1 Jalbere CGS 1 1200 - -
2 Jalbere CGS Ambala Sec. 9 5 - - 1 1000
3 Ambala Sec. 9 Ambala Sec. 9 0.94 2 1200 2 1000
4 Ambala Sec. 9 Kirti Azad 2.1 1 1200 1 1000

Chowk
5 Kirti Azad Model Town 1.42 1 1200 1 1000
Chowk

6 Model Town Baldev Nagar 3.77 1 1200 2 1000 1 1000
Morh
7 Model Town Indira Chowk 5 1 1200 2 1000 1 1000
Morh
8 Indira Chowk Vishwakarma 1.1 1 1200 1 1000 1 1000
Chowk
9 Vishwakarma Saha Road 2.3 1 1200 1 1000
Chowk
10 Saha Road Saha. Chowk 10.3 4 1200 1 1000
Saha Chowk Extension 25.9 4 1200 1 1000
Note: Sr. No. 10 - Pipeline of 10.3 Km from Saha Road to Saha Chowk and 25.9 Km from Saha Chowk to Extension
not to be laid. Only provisions indicated.
4” tap-off provided in Pipeline to connect to OLS / MS and DRS, PRS.

Sr. From To Pipe CNG DRS PRS
no. Length OLS/MS Capacity No. Capacity No. Capacity
(Km) (No.) (SCMH) (SCMH) (SCMH)
1 Adhoya CGS 1 1200 - -
2 Adhoya Shahbad 18.91 - - 1 1000
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3 Shahbad Pipli Chowk 22.08 1 1200 1 1000
4 Pipli Chowk HSID C 0.79 1 1200 1 1000 1 1000
5 Pipli Chowk Bus Stop 2.58 1 1200 1 1000
6 Bus Stop Old Bus Stop 2.82 1 1200 1 1000
7 Old Bus Stop Kurushetra 2.41 1 1200 1 1000
8 Kurushetra Pehowa Road 10.34 1 1200 2 1000
University
Note: Pipeline of 10.34 Km from Kurukshetra University to Pehowa Road is not to be laid. Only provisions indicated.
Load is considered and 4” tap-off provided in Pipeline to connect to OLS / MS and DRS, PRS.
6. TAP OFF FACILITY

6.1 Ambala District
The tap-off point feeding the Ambala CGD Network is from SV-7, Jalbera Tap-off from GAIL’s Dadri – Bawana -
Nangal Pipeline. The tap-off is approximately 9 km from Centre of the Ambala city.
M/s GAIL will provide necessary Filtration, Pressure-Reduction and Metering facility at the tap- off to supply at a
flow rate of 54480 SCMH at a maximum pressure of 49 Kg/cm2.g.
The tap-off point feeding the Kurukshetra GA CGD Network is from SV 6, Adhoya Tap-off from GAIL’s Dadri
- Bawana – Nangal Pipeline. Tap off is approx. 18 KM from Shahbad.

M/s GAIL will provide necessary Filtration, Pressure-Reduction and Metering facility at the tap-off to supply at a
flow rate of 18000 SCMH at a maximum pressure of 49 Kg/cm 2g.
7. CITY GAS STATION (CGS) CUM MOTHER STATION (MS) FACILITY
Facilities For Ambala District For Kurukshetra District
City Gate Station (CGS) cum At Jalbera, close to Tap-off facility At Adhoya close to Tap Off facility
Mother Station facility consisting
the following facilities
Twin Stream Cartridge Filters Capacity 1000-54480 SCMH, 300# Capacity 1000 – 18000 SCMH, 300#
Twin Stream Pressure Reduction Each stream consisting of Slum-Shut Each stream consisting of Slum-Shut
unit (as specified in PNGRB’s Valve, Active Regulator and Monitor Valve, Active Regulator and Monitor
guidelines) Regulator. (capacity 1000 - 54480 Regulator. (capacity 1000 - 18000
SCMH), 300#. SCMH), 300#.
Inlet pressure 49 Kg/cm2.g Outlet Inlet pressure 49 Kg/cm2.g Outlet
pressure up-to 10 years 19 Kg/cm 2.g pressure up-to 10 years 19 Kg/cm 2.g
and once demand increase up to 35 and once demand increase up to 35
Kg/cm2.g Kg/cm2.g
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Creep Relief Valve Yes Yes
Single stream Check metering Yes Yes

facility with Turbine Flow Meter
Odorization unit Natural Gas supplied to CGD network Natural Gas supplied to CGD network
shall have a distinct odour, strong shall have a distinct odour, strong
enough to detect its presence. In case enough to detect its presence. In case
Methyl Mercaptan is used as an Methyl Mercaptan is used as an
odorant, the concentration range shall odorant, the concentration range shall
be 7 to 12.5 ppm. be 7 to 12.5 ppm.
Pig Launcher Unit 12” Diameter X 18”; 300 # (8” Diameter X 14”: 300#) - From CGS
to Pipli Chowk: Pig launcher at CGS of
8”X12”- 300#. (Pipe length 41km). Pig
Receiver at Pipli Chowk
Branch Pipeline for Gas Engine 1 no. (Future Provision with one 1 no. (Future Provision with one More
driven 1200 SCMH capacity CNG More Gas Engine driven 1200 SCMH Gas Engine driven 1200 SCMH
Compressor capacity CNG Compressor). capacity CNG Compressor).
Stationary CNG Cascade of 3000 1 No. Future provision of one more 1 No. Future provision of one more
WL capacity cascade. cascade.
LCV Filling Station 1 no. with a provision of one more 1 no. with a provision of one more LCV
LCV filling. filling.

CNG Dispenser -- 2 nos. for filling Car and Auto.
The following facilities are identical for Ambala & Kurukshetra Districts.
8. COMPRESSOR STATIONS FOR AUTOMOBILE DISPENSING
A. MOTHER STATION (MS):
1. Each Mother Station (MS) comprises Compressor/s, Stationary Cascade/s and Cascade Filling
facilities. Total 3 nos. connection of 2” diameter is provided to connect to each compressor. Stationary
cascade of 3000 WL capacity for each compressor to be provided. Compressor inlet pressure limited to 14-
19 kg / cm2. g. In case of inlet pressure increase one PRS (One filter + twin stream of (one SDV cum
PCV and another Monitor PCV) and 1 CRV) to be installed to reduce the pressure from max 35 kg/cm2g.
to 14-19kg/cm2. g.
2. Compressor: (Guiding Code: API 618/API 11P) Reciprocating Compressor with multiple stages (mostly
3 stages) with inter stage coolers to be installed to supply compressed natural gas at an outlet pressure of
255 kg/cm2. g. and 520 C (maximum) temperature. Compressor to be provided with 5-line priority panel for
automatic filling of Cascade and also stationary Cascade. Compressor inlet will have twin online
cartridge filters and Three number Coriolis Mass flow meter 1 no. for Gas Engine Driven Compressor and
2 nos. for Electric Motor Driven Compressor.
The Compressor to be installed in steel cabinet with fire detection and Carbon Di-Oxide flooding system.
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The capacity of Compressor will be mostly 1200 SCMH. Wherever required 650 SCMH capacity
compressor will be installed.
At Mother Station (MS) Gas Engine Driven Compressor will be installed. In case of scarcity of Natural
Gas, Electric Motor Driven Compressor to be used.
3. Cascade-Stationary: (Guiding Code: IS 7285 Part-II): 3000 WL capacity Stationary cascade to be installed
with compressor. If permits one stationary cascade per compressor to be installed.
4. Mobile cascade of capacity minimum 3000WL and maximum 4500 WL capacity mounted on LCV or HCV
will be parked for getting filled with CNG with pressure up to 250 kg/cm 2. g. The Cascade with a minimum
pressure 30 kg/cm2. g will be returned to MS for filling through Compressor.
B. ON-LINE STATION CUM MOTHER STATION (OLS CUM MS):

1. Each On-Line cum Mother Station comprises, Compressor/s, Stationary Cascade/s and Cascade
Filling facilities, Dispensers for Car/Auto filling and/or Dispensers for Bus filling facilities. Total 3 nos.
2” diameter connection provided on 4” diameter branch line to connect to each compressor. Stationary
cascade of 3000 WL capacity for each compressor to be provided. The compressor inlet pressure is
limited to 14-19 kg/cm2. g. In case of inlet pressure increase one PRS (One filter + twin stream of
(one SDV cum PCV and another Monitor PCV) and 1CRV) to be installed to reduce the pressure
from max 35 kg/cm2g. to 14-19 kg/cm2. g.
2. Compressor: (Guiding Code: API 618 / API 11P) Reciprocating Compressor with multiple stages
(mostly 3 stages) with inter stage coolers to be installed to supply compressed natural gas at an outlet
pressure of 250 kg/cm2. g. and 300 C temperature. Compressor to be provided with 9-line priority panel

for automatic filling of Cascade and also stationary Cascade.
Compressor inlet pipeline will have twin online cartridge filters and One number Coriolis Mass flow
meter to be installed at compressor outlet.
The Compressor to be installed in steel cabinet with fire detection and Carbon Di-Oxide flooding
system.
compressor may be installed.
Natural Gas Engine Driven compressor will be installed. In case of scarcity of Natural Gas,
Electric Motor to be used.
3. Cascade-Stationary: (Guiding Code: IS 7285 Part-II): 3000 WL capacity Stationary cascade to be
installed with compressor. If permits one stationary cascade per compressor to be installed.
4. Mobile Cascade of capacity minimum 3000WL or 4500 WL maximum capacity mounted on LCV or
HCV will be parked for getting filled with CNG with pressure up to 250 kg/cm 2. g. The Cascade with a
minimum pressure 30 kg/cm2. g will be returned to MS for filling through Compressor.
5. Dispensers:
5.1. Car / LCV Dispenser: Each dispenser is provided with twin arms to dispense two car or Auto at a
time. The dispensing capacity is 15 kg / minute per arm. Coriolis mass flow meter to be installed with
Weights and Measures certification per arm.
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5.2. Bus Dispenser: Each dispenser is provided with single arm to dispense one bus at a time. The
dispensing capacity is 80 kg / minute. Coriolis mass flow meter to be installed with Weights and
Measures certification per arm.
C. ON-LINE STATION (OLS)
1. Each On-Line station comprises, Compressor, Stationary Cascade and Dispensers for Car / Auto filling
and / or Dispensers for Bus filling facilities. Total 3 nos. 2” diameter connection provided on 4” diameter
branch line to connect to each compressor. Stationary cascade of 3000 WL capacity for each
compressor to be provided.
The compressor inlet pressure is limited to 14 - 19 kg/cm2. g. In case of inlet pressure increase one
PRS (One filter + twin stream of (one SDV cum PCV and another Monitor PCV) and 1CRV) to be
installed to reduce the pressure from max 35 kg/cm2g. to 14-19 kg/cm2. g.
2. Compressor: (Guiding Code: API 6 A) Reciprocating Compressor with multiple stages (mostly 3
stages) with inter stage coolers to be installed to supply compressed natural gas at an outlet pressure
of 250 kg/cm2. g. and 300 C temperature. Compressor to be provided with 9-line priority panel for
automatic filling of Cascade and also stationary Cascade.
Compressor inlet pipeline will have twin online cartridge filters and One number Coriolis Mass flow
meter to be installed at compressor outlet.
system.

Natural Gas Engine Driven compressor will be installed. In case of scarcity of Natural Gas,
Electric Motor to be used.
4. Dispensers: (Guiding Code: NZS)
4.1. Car / LCV Dispenser: Each dispenser is provided with twin arms to dispense two car or Auto at a
time. The dispensing capacity is 15 kg / minute per arm. Coriolis mass flow meter to be installed with
Weights and Measures certification per arm.
4.2. Bus Dispenser: Each dispenser is provided with single arm to dispense one bus at a time. The
dispensing capacity is 80 kg / minute. Coriolis mass flow meter to be installed with Weights and
Measures certification per arm.
D. DAUGHTER BOOSTER STATION (DBS)
1. Each DBS comprises, Mobile Cascade CNG unloading, Booster Compressor, Stationary Cascade and
Dispensers for Car/Auto filling. Natural Gas through Steel Pipeline will NOT BE AVAILBALE. Mobile
Cascade will be used to supply CNG to Booster Compressor and to dispensers. Stationary cascade
of 3000 WL capacity for each compressor to be provided. The compressor inlet pressure will vary from
200 - 30 kg / cm2. g.
2. Booster Compressor: (Guiding Code: API 6A) Reciprocating multiple stages (mostly 3 stages)
Compressor with inter stage coolers to be installed to supply compressed natural gas at an outlet
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pressure of 250 kg/cm2. g. and 300 C temperature. Compressor to be provided with 5-line priority
panel for automatic filling of Cascade and also stationary Cascade.
One number Coriolis Mass flow meter to be installed at the inlet of compressor.
system.
Booster compressor will be hydraulically operated and driven by Electric Motor.
4. Dispensers: (Guiding Code: IS 7285 Part-II):
4.1. Car Dispenser: Each dispenser is provided with twin arms to dispense two car or Auto at a time. The
dispensing capacity is 15 kg / minute per arm. Coriolis mass flow meter to be installed with Weights
and Measures certification per arm. Same dispenser is also used for LCV filling.
4.2. Mobile cascade of minimum capacity 3000WL/4500WL mounted on LCV/HCV will be parked to
supply CNG with pressure up to 250 kg/cm2 g. The cascade will be cut off once the cascade
pressure falls to 30 kg/cm 2g
E. DAUGHTER STATION (DB)
Each DB will have Mobile Cascade CNG unloading, Stationary Cascade and Dispensers for Car / Auto

filling. Natural Gas through Steel Pipeline will NOT BE AVAILBALE. Mobile Cascade will be used to
supply CNG to dispensers. Stationary cascade of 3000 WL capacity to be provided.
All other facilities are similar to DBS except for Booster Compressor.
9. DISTRICT REGULATING STATION (DRS):

DRS is an inter-phasing unit to Supply Low Pressure Natural Gas (4-6 kg/cm2. g) to Domestic,
commercial and Industrial Consumers using low-pressure natural Gas. DRS will receive high pressure
gas (35-15 kg/cm2. g) from Steel Pipeline network and supply at pressure (4-6 kg/cm2. g) to MDPE
network.
DRS will be designed as per the guidelines of PNGRB. Each DRS will be housed inside a steel cabinet.
Each DRS will consist of twin stream Filtration, Twin Stream Pressure Reduction unit (consisting of
slum shut valve cum PCV and PCV Monitor) creep relief valve. Providing meter in DRS is optional.
Standard Capacity of each DRS unit:
1. 1000 SCMH with inlet pressure from 35-15 kg/cm2. g and outlet pressure of 46 kg/cm2. g.
Inlet to PRS will be 2” and outlet 4”.
2. 2000 SCMH with inlet pressure from 35-15 kg/cm2. G and outlet pressure of 46 kg/cm2. g.
3. 5000 SCMH with inlet pressure from 35-15 kg/cm2. G and outlet pressure of 46 kg/cm2. g.
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10. SUPPLY OF NATURAL GAS TO DOMESTIC, COMMERCIAL, INDUSTRIAL
CONSUMERS THROUGH DRS AND MDPE PIPELINE:
▪ Piped Natural Gas (PNG) to Domestic, Commercial and Industrial Consumers (using low pressure gas) will
be supplied through MDPE Network.
▪ MDPE Network will be laid underground downstream of DRS to consumer location. GI / MS pipeline will be
laid above ground to connect to consumer.
▪ Service Regulator will be installed to supply PNG to Multi-storied buildings or High-rise buildings. Only meter
will be provided to consumer location. For individual house Pressure regulator and meter will be installed at
each location.
▪ For Commercial consumer Pressure Regulator and meter will be installed at each consumer location.
▪ For Industrial consumer twin stream Pressure Reduction unit and single meter to be installed
MDPE Pipeline details:
Material MDPE
Design pressure 7 Kg/cm2.g (Max)
Operating pressure 4-6 Kg/cm2.g (Max)
Diameter (OD) (mm) 180, 125, 90, 63, 32, and 20,
Wall Thickness SDR 11
Material Strength PE 100 / PE 70

11. DESIGN PARAMETER
Design Life 25 Years
Design Pressure 49 Kg/cm2.g (Steel Pipeline)

7 Kg/cm2.g (MDPE Pipeline)
Operating Pressure 19-49 Kg/cm2.g (Steel pipeline)
4-6 Kg/cm2.g (MDPE Pipeline)
Design Class 300# for Steel Pipeline,
150# down-stream of DRS
Design Temperature - 29 to 65 °C
Operating Temperature - 5 to 25 °C
Safety Class Class-4 (Factor 0.4)
Design Codes and Standards PNGRB (T4), OISD-179, ASME B 31.8
Pipelines API 5L Gr. 60 for 10” and above

API 5L 52 for below 10”
Corrosion Allowance 0.5 mm for pipelines, 3 mm for equipment and Tank
Design Gas Velocity 20 m / sec (Max before Filtration)
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12. Natural Gas Composition: (Composition of Dry Gas): a typical one
Sr. no. Component Volume %
1 Methane 90.94
2 Ethane 4.43
3 Propane 0.61
4 n-Butane 0.01
5 i-Butane 0.02
6 Carbon Di Oxide 3.82
7 Nitrogen 0.12
Total 100%
12.1. Natural Gas Properties and Hazards
1. Product Name Natural Gas, Compressed
2. Composition Methane (+ Impurities - As above - 12)

3. CAS No. 74 – 82 - 8
4. UN No. 1971, Natural Gas, Compressed
5. Classification according to Regulation (EC) Flammable Gas 1 – Extremely Flammable Gas

No. 1272 / 2008 / EC (CLP / GHS)
6. Classification according to Directive 67 / 548 / Extremely Flammable
EEC & 1999 / 45 / EEC
7. Risk advice to human & Environment In high concentration may cause asphyxiation
8. Appearance / Colour Colourless Gas
9. Melting Point - 1820C
10. Boiling Point - 1610C
11. Critical Temperature - 820C
12. Autoignition Temperature 5950C
13. Flammability Range 4.4 % (V) – 15 % (V)
14. Vapour Density (Air = 1) 1.6
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APPLICABLE CODES AND STANDARDS:

Following codes and standards (latest versions) followed for City Gas distribution system.
REGULATION OF PETROLEUM AND NATURAL GAS REGULATORY BOARD (PNGRB): G.S.R. 612(E)
Code No. Access code for City or Local Natural Gas Distribution Network.
GSR 612(E) Technical Standards & Specifications including Safety standards for City or Local Natural
Gas Distribution
GSR 720(E) Network : Code of practice for Quality of Service for City or Local Natural Gas Distribution
Network
OIL INDUSTRIES SAFETY DIRECTORATE (OISD)

OISD-226 Natural Gas Transmission Pipelines & City Gas Distribution
OISD- 141 Networks : Design and Construction requirements for cross country hydrocarbon
pipelines
OISD-118 Layouts for Oil and Gas Installations
OISD 179 Safety requirements for compression, storage, handling and refuelling of CNG for use in
automotive sector.
OISD 113 Classification of areas for electrical installations at hydrocarbon processing and handling
facilities
BUREAU OF INDIAN STANDARDS

IS 14885 Specification for manufacture of Polyethylene pipes

IS 1239 (Part-I) Specification for manufacture of Carbon Steel Pipe.
IS 1239 (Part-II) Specification for manufacture of Carbon Steel Fittings
IS 5572/IS 5571 Guide for selection of electrical equipment for hazardous area
IS 7285 CNG Cylinder Design Code
AMERICAN PETROLEUM INSTITUTE (API)

API - 1104 Welding of Pipelines and Related Facilities
API - 607 Fire Test for Soft Seated Quarter Turn Valves
API - 6FA Specification for Fire Test for Valves
API - 5L Specification for Line pipe
API - 6D Specification for Pipeline Valves (Gate, Plug, Ball and Check Valves)
API – 1102 Specification for steel pipeline crossing & highways.
API – 500 Recommended Practice for Classification of Locations for Classification of Locations for
Electrical Installations at Petroleum Facilities classified as Class I, Div. 1 and 2
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HAZARD AND OPERABILITY (HAZOP) STUDY

HAZOP is a well-recognized technique of risk assessment to identify hazards & deviations from intended process criterias
/ standards which may prevent an efficient operation and lead to a hazard and to identify suitable control measures at
design level to prevent deviations.
HAZOP is a technique to critically examine a system, part by part, in a systematic manner, to find out the cause and
consequence of every conceivable deviations in the normal operation of the system. The method enables prediction of
all possible deviations in which a hazard or an operating problem could arise, whether the design takes preventive care
of them and if not, recommending changes may be necessary.
HAZOP Pre-requisite
1. Process Flow Diagrams
2. Process description
3. Process & Instrument Diagrams (P&IDs)
4. Process Design and Operating conditions
5. Route Map and Plot Plan
Objectives
The objective of HazOp study is:
1. To identify the hazard that exists,
2. The consequences that might occur as a result of hazards,
3. The likelihood that events might take place that would cause an accident with such a consequence and the
likelihood that safety system,
4. Mitigating systems and emergency alarms and evaluation plan would function property and

5. Eliminate or reduce the consequences
The main purpose of HAZOP is therefore to identify all possible deviations from the way the design is expected to work
and probable causes and consequence of the hazard associated with these deviations together with recommended
changes.
HAZOP Methodology
A HAZOP study is a formal systematic procedure used to review the design and operation of a potentially hazardous
process facility. It is used to identify deviations from normal safe operation, which could lead, to hazards or operability
problems, and to define any actions necessary to deal with these.
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 use of the HAZOP method.
The method involves several repetitive steps as below:
1. Identify a section of plant.
2. Define the design intent and normal operation conditions of the section.
3. Identify a deviation from design intent or operating conditions by applying a system of guidewords.
4. Identify possible causes for, and consequences of, the deviation. A deviation can be considered meaningful if it
has credible cause and can result in harmful consequences.
5. For a meaningful deviation, decide what action, if any is necessary.
6. Record the discussion and action.
Step 3 to 6 is repeated until all the guidewords have been exhausted and the team is satisfied that all meaningful
deviations have been considered. The team then goes back to step 1 and repeats the procedure for the next section of
the plant.
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In the HAZOP method, the guidewords are systematically applied to a segment of process equipment to promote
discussion on possible deviations from the design intention. The guidewords represent deviations to the design intent
and their use leads to systematic highlighting of hazards and operability problems.
The method identifies the causes of a deviation from the design intent by application of the guidewords. The ultimate
consequences are then identified and recorded without reference to the safeguards, which are in place (examples of
safeguards are plant design, control systems, and procedures). The consequences are then compared with the
safeguards and the HAZOP team then decides whether the current safeguards are adequate. If the team considers them
inadequate, then a recommendation is made to consider or add further safeguards.
HAZOP Process Flow Diagram

List of Guideword and Deviation considered during the HAZOP study:
Parameter Guide Word Deviation
Flow More More Flow
Less / No Less / No Flow
Temperature High High Temperature
Low Low Temperature
Pressure More More Pressure
Less / No Less / No Pressure
Others Others Corrosion,
Static Charge
Leakage
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REFERENCES
Reference Documents for HAZOP - Desktop Process Safety Review (DPSR) Qualitative Risk Assessment
• Process Design Basic for HPOIL Gas Private Limited (HOGPL) – City Gas Distribution Project of Ambala –
Kurukshetra District and Kohlapur District.
• P & ID for City Gate Station cum Mother Station at Jalbera - Ambala,
• Drawing No. 1007 - AMB – PC – PID - 1001, Rev.D3.
• Drawing No. 1007 - Ambala – PC – PID - 1003, Rev.D3.
• P & ID for Ambala CGD Facilities at Kirti Azad Chowk: Drawing No. 1007 -AMB – PC – PID - 1004, Rev.D3.
• P & ID for Ambala CGD Facilities at Devi Oil Pump: Drawing No. 1007 -AMB – PC – PID - 1005, Rev.D3.
• P & ID for Ambala CGD Facilities up to Chainage 20.37 KM : Drawing No. 1007 -AMB – PC – PID - 1006, Rev.D3.
• P & ID for Ambala CGD Facilities up to Chainage 14.42 KM: Drawing No. 1007 -AMB – PC – PID - 1007, Rev.D3.
• Block Flow Diagram – Station cum Mother Station at Jalbera – Ambala: Drawing No. 1007 -AMB – PC – PID –

1008
• It was informed by the Client that P & ID for Kurukshetra District City Gate Station cum Mother Station and
GCD are identical as Ambala District P & ID’s.
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Proposed Steel Network for CGD Project in Ambala with Tap-off at Jalbera
(Network Planned For 25 years)
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Proposed Steel Network for CGD Project in Kurukshetra with Tap - off at
Adhoya (Network Planned For 25 years)
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AMBALA DISTRICT
HAZOP STUDY
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NODE LIST AMBALA DISTRICT: The following NODE have been selected for HazOp Study
HAZOP STUDY: NODE 1
System: City Gate Station; Jalbera CGS CH 0.0 KM to Tangri River (Saha) CH up to 20.37 KM Pipeline
Node Description Tap-off point at SV 7 from GAIL’s Dadri – Bawana - Nangal Pipeline, Gail (Filtration + PRS +
Meterring Skid) Downstream -
Jalbera CGS CH 0.0 KM to Tangri River (Saha) CH up to 20.37 KM
Node Contents CGS / MS – Filtration, Pressure Reduction, Check Metering Facility and Odorizing facility,
• Twin Stream Cartridge Filters (Capacity 1000-54480 SCMH, 300#),
• Twin Stream Pressure Reduction unit (as specified in PNGRB’s guidelines) with each
stream consisting of Slum-Shut Valve, Active Regulator and Monitor Regulator.
(Capacity 1000 – 54,480 SCMH, 300#, Inlet pressure 49 Kg / cm2.g and Outlet pressure
19 Kg / cm2.g - 35 Kg / cm2.g)
• Creep Relief Valve
• Twin stream Check metering facility with Positive Displacement Flow meter and Turbine
Flow Meter.
• Odorization unit: Natural Gas to have a distinct odour.
• Tap off - At CH up to 5 KM / CH up to 6.85 KM (DRS 1001 Station) / At Kirti Azad Chowk

CH within 8.04 KM (To Devi Oil Store) / At CH up to 9.42 (To Jagdot Road) / At CH up
to 12.42 KM (To Kurukshetra) / At CH 13.92 (DRS 1004 Station & OLS- CNG 1004) / At
CH up to 15.42 KM (Ambala Cant) / At CH up to 17.87 KM / At CH up to 20.37 KM
(Tangri River Saha)
• Sectionalizing Valve Station - SV 1 at CH up to 3.0 KM / SV 2 at CH up to 6 KM / SV 3
at CH up to 8 KM / SV 8 at CH up to 9.42 KM / SV 9 at CH up to 12.42 KM / SV 10 at
CH up to 15.42 KM / SV 11 at CH up to 17.87 KM / SV 12 at CH up to 20.37 KM
• BV at CH up to 17.37 KM
Reference P & ID P & ID for City Gate Station cum Mother Station at Jalbera - Ambala,
Block Flow Diagram – Station cum Mother Station at Jalbera – Ambala:
• Drawing No. 1007 -AMB – PC – PID - 1008
P & ID for Ambala CGD Facilities at Kirti Azad Chowk:
P & ID for Ambala CGD Facilities up to Chainage 20.37 KM
• Drawing No. 1007 -AMB – PC – PID - 1006, Rev.D3
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HAZOP STUDY: NODE 2

System: City Gate Station; Jalbera CGS CH 0.0 KM to Devi Oil Store CH up to 14.5 KM Pipeline
Node Description Jalbera CGS CH 0.0 KM to Devi Oil Store CH up to 14.5 KM
19 Kg / cm2.g - 35 Kg / cm2.g)
Flow Meter.
CH within 8.04 KM (To Devi Oil Store / Model Town Morh) / At CH up to 9.0 KM (DRS
1002 Station & HP Petrol Pump OLS CNG 1001) / At Polytechnic Chowk within Ch 10
KM / At CH up to 11 KM / at CH up to 14 KM / At CH up to 14.5 KM (Devi Oil OLS CNG
1002)
Polytechnic Chowk within Ch 10 KM – At Ch up to 10.50 KM (DRS 1003 Station) / At

CH up to 11.5 KM (Shiv Shakti OLS CNG 1003)
at CH up to 8 KM / SV 4 at CH up to 11 KM / SV 5 at CH up to 14 KM
P & ID for Ambala CGD Facilities at Devi Oil Pump:
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HAZOP STUDY: NODE 3

System: Model Town Morh SV Station 8 CH up to 9.42 KM to Jagdot Road SV Station 7 CH 14.42 KM
Pipeline
Node Description Model Town Morh SV Station 8 CH up to 9.42 KM to Jagdot Road SV Station 7 CH 14.42
KM
Node Contents • Tap off - At CH up to 12.42 KM (Baldev Nagar DRS 1005 Station) / At CH up to 13.07KM
(Mahindra Singh OLS CNG 1005) / At CH up to 13.42 KM (Ajeeth Petrol Pump OLS
CNG 1006) / At CH up to 14.42 KM (DRS 1006 Station)
• Sectionalizing Valve Station – SV 8 at CH up to 9.42 KM / SV 6 at CH up to 12.42 KM /
SV 7 at CH up to 14.42 KM
Reference P & ID P & ID for Ambala CGD Facilities up to Chainage 20.37 KM
TOTAL PIPELINE LENGTH
NODE Pipeline From Pipeline To Length Effective

Total Length
Node 1 Jalbera CGS Model Town Morh 08.04 20.37
Model Town Morh Tangri River (Saha) 12.33
Node 2 Jalbera CGS Model Town Morh 08.04 16.00

Model Town Morh Devi Oil Store 06.46
Poly Technic Chowk Ch 11.50 01.50
Node 3 Model Town Morh Jagdot Road 05.00 05.00
Total Effective Length 41.37
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AMBALA DISTRICT - DESIGN INTENT

P & ID for City Gate Station cum Mother Station at Jalbera - Ambala,
Drawing No. 1007 - AMB – PC – PID - 1001, Rev. D3.
UP TO GAIL FACILITY PIPELINE SYSTEM FOR AMBALA

Process Parameter Design Parameter Process Parameter Design Parameter
Fluid Natural Design 600 # Fluid Natural Design 300 #
Gas Class Gas Class
Flow Rate 20 SCMH Design 92 kg/cm2g Flow Rate 20 SCMH Design 49 kg/cm2g
(Min.) / Pressure (Min.) / Pressure
54,480 54,480
SCMH SCMH
(Max.) (Max.)
Operating 92 - 49 kg / Design -29 / 650C Operating 19 kg/cm2g Design -29 / 650C
Pressure cm2g Temperature Pressure (Min.) Temperature
49 kg/cm2g
(Max.)
Operating 00C Min./ Location Class 4 Operating 00C Min./ Location Class 4
Temperature 450C Max. Class Temperature 450C Max. Class
Pipeline Pipeline

CHECK METERING SYSTEM FOR AMBALA
Process Parameter Design Parameter
Fluid Natural Gas Design Class 300 #
Flow Rate 20 SCMH (Min.) / 54,480 SCMH (Max.) Design Pressure 49 kg/cm2g
Operating Range for 20 SCMH (Min.) / 1,900 SCMH (Max.) at Design Temperature -29 / 650C
Positive Displacement 19 kg/cm2g
Flow Meter
Operating Range for 1,500 SCMH (Min.) / Location Class
Turbine Floe Meter 54,480 SCMH (Max.)
Inlet Pressure 49 - 19 kg/cm2g Pipeline Class 4
Operating Temperature 00C Min./ 450C Max. - -
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PIPELINE SYSTEM FOR AMBALA
Flow Rate 20 SCMH (Min.) / Design Pressure 49 kg/cm2g

54,480 SCMH (Max.)
Inlet Pressure 19 kg/cm2g (Min.) Design Temperature -29 / 650C

44 kg/cm2g (Max.)
Operating Temperature 00C Min./ 450C Max. Location Class - Pipeline Class 4
P & ID for Ambala CGD Facilities at Kirti Azad Chowk: Drawing No. 1007 -AMB – PC – PID - 1004, Rev.D3.
FOR HPOIL CITY GAS PIPELINE SYSTEM FOR AMBALA

54,480 SCMH (Max.)

49 kg/cm2g (Max.)
P & ID for Ambala CGD Facilities at Devi Oil Pump: Drawing No. 1007 -AMB – PC – PID - 1005, Rev.D3.


10,800 SCMH (Max.)

49 kg/cm2g (Max.)
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P & ID for Ambala CGD Facilities up to Chainage 20.37 KM:

Drawing No. 1007 -AMB – PC – PID - 1006, Rev.D3

10,800 SCMH (Max.)

49 kg/cm2g (Max.)
P & ID for Ambala CGD Facilities up to Chainage 14.42 KM:

Drawing No. 1007 -AMB – PC – PID - 1007, Rev.D3
For HPOIL City Gas Pipeline System for Kolhapur


32,280 SCMH (Max.)
44 kg/cm2g (Max.)
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AMBALA DISTRICT
HAZOP STUDY

WORK SHEET
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NODE 1
City Gate Station, Jalbera CGS CH 0.0 KM
to
Tangri River (Saha) CH up to 20.37 KM Pipeline

HAZOP STUDY WORK SHEET
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NODE 1
System: City Gate Station; Jalbera CGS CH 0.0 KM to Tangri River (Saha) CH up to 20.37 KM Pipeline
Meterring Skid) Downstream -
Jalbera CGS CH 0.0 KM to Tangri River (Saha) CH up to 20.37 KM
19 Kg / cm2.g - 35 Kg / cm2.g)
Flow Meter.
CH within 8.04 KM (To Devi Oil Store) / At CH up to 9.42 (To Jagdot Road) / At CH up
to 12.42 KM (To Kurukshetra) / At CH 13.92 (DRS 1004 Station & OLS- CNG 1004) / At

CH up to 15.42 KM (Ambala Cant) / At CH up to 17.87 KM / At CH up to 20.37 KM
(Tangri River Saha)
at CH up to 8 KM / SV 8 at CH up to 9.42 KM / SV 9 at CH up to 12.42 KM / SV 10 at
CH up to 15.42 KM / SV 11 at CH up to 17.87 KM / SV 12 at CH up to 20.37 KM
• BV at CH up to 17.37 KM
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A: PARAMETER: FLOW GUIDE WORD: MORE
Guide Deviation Causes Consequences Safe Guard / Control Recommendations

Word Measure
More 1. More flow 1.1 1.1.1 1.1.1.1 1.1.1.1

of gas More flow of gas Pressure may PG 1002 / 1006, PI 1004 / Maintenance and
from upstream increase at CGS 1005 PT1004 / 1006 calibration of
(GAIL metering & in Pipe line. installed. Pressure gauges
station) 1.1.2 1.1.1.2 and other
More gas flow to FI 1001 / 1002, FT 1001 / instruments should
downstream 1002, FE 1001 & Flow be carried out as
OLSs cum MSs computer FQR 1001 per schedule and
installed. manufacturer
1.1.1.3 instruction and
MOV 1001 / 1002 records should be
installed. Only one MOV maintained.
will be in operation at
time. MOV can be
operated manually either
locally or from remote
RTU / Scada. Automatic
operation and change
over from low flow to high
flow stream (PD 1001/
TM1001) & vise versa will

be indicated from flow
computer.
1.1.1.4
Twin Stream Pressure
Reduction unit (as per
PNGRB’s guidelines) with
each stream consisting of
Slum-Shut Valve, Active
Regulator and Monitor
Regulator installed.
1.1.1.5
FB FC (XSDV 1001)
installed.
1.1.1.6
Creep Relief valve
installed.
1.1.1.7
Vent min. 3 M high from
nearest highest operating
structure or nearby
structure within 15 M
provided.
1.1.1.8
PG 1001 installed at SV 7
at HPCL Facility.
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Word Measure
More 1.1.1.9
(Contd.) PRS & Metring skid and
Pressure and flow
controllers installed at
GAIL Metering Sked
facility.
1.1.1.10
Pressure Gauge Installed
at all DRS / OLS CNG
Stations
1.2 1.2.1 1.2.1.1 1.2.1.1
Rapture of Loss of Same as 1.1.1.1 and Gas detectors
pipeline containment 1.1.1.2 Testing and
leading to fire calibration should
1.2.1.2
hazard be carried out as
Upstream shutdown as per schedule and
per GAIL O&M manufacturer
procedures. instruction and
1.2.1.3 records should be
Gas detectors provided. maintained.
1.2.1.2
1.2.1.4
Portable firefighting
Isolation valves and appliances Refilling,
Sectionalizing valves SV Inspection and
1 at CH 3.0 KM / SV 2 at Maintenance should
CH 6 KM / SV 3 at CH 8

be conducted as
KM / SV 8 at CH 9.42 KM per IS 2190:2010)
/ SV 9 at CH 12.42 KM / Fire Extinguisher
SV 10 at CH 5.42 KM / Inspection and
SV 11 at CH 17.87 KM / Maintenance
SV 12 at CH 20.37 KM Schedule [Annex C,
installed. Annex D, Annex F]
1.2.1.5 and records should
Potable firefighting be maintained.
appliance available at 1.2.1.3.
every CGS / OLS / MS. Emergency
1.2.1.6 handling
Civil administration procedures should
firefighting systems shall be prepared and
be available implemented.
1.3 1.3.1 1.1.3.1 1.1.3.1.

FI 1001 / 1002, Same as 1.1.1 & Same as 1.1.1.1 & 1.1.1.2 Same as 1.1.1.1
FT 1001 / 1002, 1.2.1 1.1.3.2.
FE 1001 & Flow Flow and pressure
computer FQR indicators and transmitters
1001, MOV 1001 periodic inspection,
/ 1002 FB FC calibration and
(XSDV 1001) maintenance as per
malfunctioning schedule.
showing wrong
reading
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B: PARAMETER: FLOW GUIDE WORD: LESS / NO

Word Measure
Less / 2. Less / No 2.1. 2.1.1 2.1.1.1 2.1.1.1
No Flow of gas Less / No flow of Less / No Gas PG 1002 / 1006, PI 1004 / Maintenance and
gas from Flow to CGS 1005 PT1004 / 1006 calibration of
upstream (GAIL downstream installed. Pressure gauges
metering station) OLS / MS / DRS 2.1.1.2 and other
FI 1001 / 1002, FT 1001 / instruments should
1002, FE 1001 & Flow be carried out as
computer FQR 1001 per schedule and
PD 1001/ TM1001 records should be
installed maintained.
2.1.1.4
Stations
2.2 2.2.1 2.2.1.1 2.2.1.1

CGS Filtration Same as 2.1.1 Same as 2.1.1.1 & 2.1.1.2 Pre- Start-up
unit downstream checklist should be
2.2.1.2
isolation valves, prepared and
Check metering Trained and competent maintained.
skid downstream operator will handle the
process

/upstream valves,
Odorization unit
upstream FB FC
(XSDV 1001), SV
Station valves
partially / fully
closed.
2.3 2.3.1 2.3.1.1 2.3.1.1
FI 1001 / 1002, Same as 2.11 Flow and pressure Same as 2.1.1.1
FT 1001 / 1002, indicators and transmitters
FE 1001 & Flow periodic inspection,
computer FQR calibration and
1001, PD 1001/ maintenance.
TM1001
malfunctioning
showing wrong
readings.
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Word Measure
2.4. 2.4.1 2.4.1.1 2.4.1.1
Leakage in the Fire and Same as 2.1.1.1 & Portable firefighting
aboveground explosion on 2.1.1.2. appliances Refilling,
section of exposure to Inspection and
2.4.1.2.
pipeline. ignition source Maintenance should
Isolation valves and be conducted as
Sectionalizing valves per IS 2190:2010)
installed. Same as 1.2.1.4 Fire Extinguisher
2.4.1.3 Inspection and
Potable firefighting Maintenance
appliance available at Schedule [Annex C,
every CGS / OLS / MS. Annex D, Annex F]
be maintained.
Civil administration 2.4.1.2.
firefighting systems shall
be available Emergency
handling
procedures should
be prepared and
implemented
C: PARAMETER: FLOW GUIDE WORD: REVERSE

Word Measure
Reverse 3. Reverse 3.1. - 3.1.1.1. 3.1.1.1
flow of gas Not envisaged. Isolation valves and Maintenance and
Sectionalizing valves calibration of
installed. Same as Pressure gauges
1.2.1.4 . and other
3.1.1.2 instruments should
Slum Shut valve be carried out as
provided per schedule and
manufacturer
3.1.1.3
instruction and
PG 1002 / 1006, PI 1004
records should be
/ 1005 PT1004 / 1006
maintained.
installed.
3.1.1.4
FI 1001 / 1002, FT 1001
/ 1002, FE 1001 & Flow
computer FQR 1001, PD
1001 / TM1001, FB FC
(XSDV 1001) installed.
3.1.1.5
Pressure Gauge
Installed at all DRS /
OLS CNG Stations
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D: PARAMETER: PRESSURE GUIDE WORD: MORE

Word Measure
More 4. More 4.1. 4.1.1 4.1.1.1 4.1.1.1
pressure of More pressure of Potential risk of High pressure discharge Maintenance and
Natural gas gas from pipeline damage / controls available at calibration of
upstream (GAIL gas leak. GAIL Metering Station. Pressure gauges
metering station) Gas leakage may 4.1.1.2 and other
cause fire and CGS cum Mother Station instruments should
explosion on piping rated design be carried out as
exposure to pressure is 49 kg / cm2g. per schedule and
ignition source. Operating Pressure 19 - manufacturer
49 kg / cm2g. instruction and
Pipeline System for maintained.
Ambala (CGS / MS 4.1.1.2
downstream) rated Gas detectors
design pressure is 49 kg Testing and
/ cm2g. Operating calibration should
Pressure 19 - 49 kg / be carried out as
cm2g. per schedule and
4.1.1.4. manufacturer
PG 1002 / 1006, PI 1004 instruction and
/ 1005 PT1004 / 1006 records should be

4.1.1.5 4.1.1.3
FI 1001 / 1002, FT 1001 Portable firefighting
/ 1002, FE 1001 & Flow appliances Refilling,
computer FQR 1001, PD Inspection and
1001 / TM1001, FB FC Maintenance should
(XSDV 1001) installed. be conducted as
4.1.1.6 per IS 2190:2010)
Twin Stream Pressure Fire Extinguisher
Reduction unit (as per Inspection and
PNGRB’s guidelines) Maintenance
with each stream Schedule [Annex C,
consisting of Slum-Shut Annex D, Annex F]
Valve, Active Regulator and records should
and Monitor Regulator be maintained.
installed. 4.1.1.4
4.1.1.7 Emergency
Creep Relief valve handling
installed. procedures should
4.1.1.8 be prepared and
Vent min. 3 M high from implemented.
nearest highest
operating structure or
nearby structure within
15 M provided.
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More 4.1.1.9
(Contd.) Gas detectors provided
4.1.1.10
Isolation valves and
Sectionalizing valves
installed. Same as
1.2.1.4 .
4.1.1.11
Upstream shutdown as
per GAIL O&M
procedures.
4.1.1.12
Potable firefighting
appliance available at
every CGS / OLS / MS
4.1.1.13
Civil administration
be available.
4.1.1.14
Pressure Gauge
Installed at all DRS / MS
OLS CNG Stations.
4.1.1.15
Vent with flame arrestor
goose neck / rain hood

with bird screen installed
Stations.
4.2. 4.2.1. 4.2.1.1 4.2.
Flow and Same as 4.1.1. Flow and pressure Same as 4.1,1.1
pressure indicators and
indicators and transmitters periodic
transmitters inspection, calibration
malfunctioning. and maintenance.
4.3. 4.3.1. 4.3.1.1 4.3.1.1

Inadvertent Same as 4.1.1. Same as 4.1.1.1 – Same as 4.1.1.1 –
closure of 4.1.1.9. 4.1.1.3.
downstream
valves.
4.4. 4.4.1. 4.4.1.1 4.4.1.1
Pressure rise due Same as 4.1.1. Same as 4.1.1.1 – Same as 4.1.1.1. -
to downstream 4.1.1.9 4.1.1.3
process upset.
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E: PARAMETER: PRESSURE GUIDE WORD: LESS / NO

Word Measure
Less / 5. Less or 5.1. 5.1.1 5.1.1.1. 5.1.1.1.
No No pressure Less or No Downstream Low pressure discharge Pre- Start-up
of Natural pressure of process may controls available at checklist should be
gas. Natural gas from disturb. GAIL Metering Station. prepared and
upstream, GAIL 5.1.2 maintained.
Metering Skid Less / No Gas
Flow to CGS
downstream DRS
/OLSs cum MSs
5.2. 5.2.1. 5.2.1.1. 5.2.1.1.

Isolation valve in Same as 5.1.1 PG 1002 / 1006, PI 1004 Same as 5.1.1.1
the CGS / 1005 PT1004 / 1006 5.2.1.2.
upstream supply installed Maintenance and
line is partially / 5.2.1.2 calibration of
fully closed . Pressure Gauge Pressure gauges
Installed at all DRS / MS and other
Sectionalizing OLS CNG Stations. instruments should
valve(s) partially / 5.2.1.3 be carried out as
fully closed . FI 1001 / 1002, FT 1001 per schedule and
Same as 1.2.1.4 . / 1002, FE 1001 & Flow manufacturer
computer FQR 1001, PD instruction and

1001 / TM1001, FB FC records should be
(XSDV 1001) installed. maintained
5.3. 5.3.1. 5.3.1.1. 5.3.1.1
Flow and Same as 5.1.1 Flow and pressure Same as 5.1.1.1 &
pressure indicators and 5.2.1.2
5.4. 5.4.1 5.4.1.1 5.4.1.1.
Leakage in the Fire and The Pressure at any Gas detectors
aboveground explosion on point of steel network is Testing and
section of exposure to within 15-17 Kg/cm2.g calibration should
pipeline. ignition source and velocity 20 m / sec be carried out as
to supply to OLS, the per schedule and
pipeline thickness manufacturer
considered 6.4 mm API instruction and
5L as per ASME B31.8. records should be
5.4.1.2 maintained.
Gas detectors provided
5.4.1.3
Sectionalizing valves SV
installed. Same as
1.2.1.4 .
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Less / 5.4.1.4 5.4.1.2
No Potable firefighting Portable firefighting
(Contd.) appliance available at appliances Refilling,
every CGS / OLS / MS. Inspection and
Maintenance should
5.4.1.5
be conducted as
Civil administration per IS 2190:2010)
firefighting systems shall Fire Extinguisher
be available. Inspection and
Maintenance
Schedule [Annex C,
Annex D, Annex F]
and records should
be maintained.
5.4.1.3
Emergency
handling
procedures should
be prepared and
implemented.
5.5 5.5.1 5.5.1.1 5.5.1.1
Inadvertent Same as 5.1.1 PG / PI / PIT installed at Same as 5.1.1.1 &
withdrawal of gas CGS / MS downstream 5.2.1.2
at CGS / MS OLS / MS & DRS
downstream OLS
/ MS & DRS.
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F: PARAMETER: TEMPERATURE GUIDE WORD: HIGH
Word Measure
High 6. High 6.1. 6.1.1 6.1.1.1. 6.1.1.1.
temperature Potential risk of
Fire in nearby TG 1001 Installed at SV No vegetation
area of CGS / MS damage to 7 GAIL Metering Skid. should be allowed
& aboveground pipeline / leak to grow in the
and release of 6.1.1.2.
pipeline section. pipeline area.
NG in TG 1001, TT 1002 /
atmosphere 1006, TI 1002 / 1006 are 6.1.1.2.
leading to fire and available for low / high Portable firefighting
explosion. temperature alarm at appliances Refilling,
CGS cum MS at Jalbera. Inspection and
Maintenance should
6.1.1.3. be conducted as
CGS / MS and Piping per IS 2190:2010)
designed for – 290C to Fire Extinguisher
650C temperatures. Inspection and
6.1.1.4. Maintenance
Potable firefighting Schedule [Annex C,
appliance available at Annex D, Annex F]
every CGS / OLS / MS. and records should
be maintained.
6.1.1.5.
be available
6.2. From 6.2.1 6.2.1.1 6.2.1.1

compressor Same as 6.1.1. Same as 6.1.1.1/ 6.1.1.2/ Same as 6.1.1.1 &
discharge end 6.1.1.3/ 6.1.1.4 6.1.1.2
6.2.1.2 6.2.1.2
Reciprocating multiple Inspection &
stages (mostly 3 stages) maintenance of
Compressor with inter compressors should
stage coolers installed be conduced as per
manufacturer
recommendations
and records should
be maintained.
G. PARAMETER: TEMPERATURE GUIDE WORD: LOW

Word Measure
Low 7. Low 7.1 - 7.1.1.1 -
temperature Not envisaged. CGS / MS and Piping
designed for – 290C to
650C temperatures.
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NODE 2
City Gate Station, Jalbera CGS CH 0.0 KM
to
Devi Oil Store CH up to 14.50 KM Pipeline

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NODE 2
System: City Gate Station; Jalbera CGS CH 0.0 KM to Devi Oil Store CH up to 14.5 KM Pipeline
Node Description Jalbera CGS CH 0.0 KM to Devi Oil Store CH up to 14.5 KM
19 Kg / cm2.g - 35 Kg / cm2.g)
Flow Meter.
CH within 8.04 KM (To Devi Oil Store / Model Town Morh) / At CH up to 9.0 KM (DRS
1002 Station & HP Petrol Pump OLS CNG 1001) / At Polytechnic Chowk within Ch 10

KM / At CH up to 11 KM / at CH up to 14 KM / At CH up to 14.5 KM (Devi Oil OLS CNG
1002)
Polytechnic Chowk within Ch 10 KM – At Ch up to 10.50 KM (DRS 1003 Station) / At
CH up to 11.5 KM (Shiv Shakti OLS CNG 1003)
at CH up to 8 KM / SV 4 at CH up to 11 KM / SV 5 at CH up to 14 KM
P & ID for Ambala CGD Facilities at Devi Oil Pump:
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Word Measure
More 1. More flow 1.1 1.1.1 1.1.1.1 1.1.1.1
of gas More flow of gas Pressure may PG 1002 / 1006 / 1007 / Maintenance and
from upstream increase at CGS 1008 / 1009, PI 1004 / calibration of
(GAIL metering & in Pipe line. 1005 PT1004 / 1006 Pressure gauges
station) 1.1.2 installed. and other
More gas flow to 1.1.1.2 instruments should
downstream FI 1001 / 1002, FT 1001 / be carried out as
OLSs cum MSs 1002, FE 1001 & Flow per schedule and
computer FQR 1001 manufacturer
installed. instruction and
MOV 1001 / 1002 maintained.
installed. Only one MOV
time. MOV can be

computer.
1.1.1.4
1.1.1.5
FB FC (XSDV 1001)
installed.
1.1.1.6
Creep Relief valve
installed.
1.1.1.7
structure or nearby
provided.
1.1.1.8
PG 1001 installed at SV 7
at HPCL Facility.
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More 1.1.1.9
Pressure and flow
GAIL Metering Sked
facility.
1.1.1.10
Stations
1.2 1.2.1 1.2.1.1 1.2.1.1
1.2.1.2
1.2.1.2
1.2.1.4 Portable firefighting
1 at CH 3.0 KM / SV 2 at Maintenance should
CH 6 KM / SV 3 at CH 8 be conducted as

per IS 2190:2010)
KM / SV 4 at CH 11 KM / Fire Extinguisher
SV 5 at CH 14 KM Inspection and
installed. Maintenance
Schedule [Annex C,
1.2.1.5
Annex D, Annex F]
Potable firefighting and records should
appliance available at be maintained.
every CGS / OLS / MS. 1.2.1.3.
1.2.1.6
Emergency
Civil administration handling
firefighting systems shall procedures should
be available be prepared and
implemented.
1.3 1.3.1 1.1.3.1 1.1.3.1.
FT 1001 / 1002, 1.2.1 1.1.3.2.
FE 1001 & Flow Flow and pressure
computer FQR indicators and transmitters
1001, MOV 1001 periodic inspection,
/ 1002 FB FC calibration and
(XSDV 1001) maintenance as per
malfunctioning schedule.
showing wrong
reading
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Word Measure
Less / 2. Less / No 2.1. 2.1.1 2.1.1.1 2.1.1.1
No Flow of gas Less / No flow of Less / No Gas PG 1002 / 1006 / 1007 / Maintenance and
gas from Flow to CGS 1008 / 1009, PI 1004 / calibration of
upstream (GAIL downstream 1005 PT1004 / 1006 Pressure gauges
metering station) OLS / MS / DRS installed. and other
FI 1001 / 1002, FT 1001 / be carried out as
1002, FE 1001 & Flow per schedule and
computer FQR 1001 manufacturer
installed. instruction and
PD 1001/ TM1001 maintained.
installed
2.1.1.4
Stations
2.2 2.2.1 2.2.1.1 2.2.1.1

2.2.1.2

/upstream valves, process
Odorization unit
upstream FB FC
(XSDV 1001), SV
Station valves
partially / fully
closed.
2.3 2.3.1 2.3.1.1 2.3.1.1
TM1001
malfunctioning
showing wrong
readings.
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2.4. 2.4.1 2.4.1.1 2.4.1.1
2.4.1.2.
be maintained.
handling
procedures should
be prepared and
implemented.

Word Measure
Reverse 3. Reverse 3.1. - 3.1.1.1. 3.1.1.1
1.2.1.4 . and other
manufacturer
3.1.1.3
instruction and
PG 1002 / 1006, PI 1004
records should be
/ 1005 PT1004 / 1006
maintained.
installed.
3.1.1.4
FI 1001 / 1002, FT 1001
/ 1002, FE 1001 & Flow
1001 / TM1001, FB FC
3.1.1.5
Pressure Gauge
OLS CNG Stations
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Word Measure
More 4. More 4.1. 4.1.1 4.1.1.1 4.1.1.1
Ambala (CGS / MS 4.1.1.2
4.1.1.5 4.1.1.3

FI 1001 / 1002 /1007 / Portable firefighting
1008 / 1009, FT 1001 / appliances Refilling,
1002, FE 1001 & Flow Inspection and
computer FQR 1001, PD Maintenance should
1001 / TM1001, FB FC be conducted as
(XSDV 1001) installed. per IS 2190:2010)
4.1.1.6 Fire Extinguisher
Twin Stream Pressure Inspection and
Reduction unit (as per Maintenance
PNGRB’s guidelines) Schedule [Annex C,
with each stream Annex D, Annex F]
consisting of Slum-Shut and records should
Valve, Active Regulator be maintained.
and Monitor Regulator 4.1.1.4
installed. Emergency
4.1.1.7 handling
Creep Relief valve procedures should
installed. be prepared and
4.1.1.8 implemented.
nearest highest
15 M provided.
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More 4.1.1.9
4.1.1.10
installed. Same as
1.2.1.4 .
4.1.1.11
per GAIL O&M
procedures.
4.1.1.12
4.1.1.13
be available.
4.1.1.14
Pressure Gauge
OLS CNG Stations.
4.1.1.15

Stations.
4.2. 4.2.1. 4.2.1.1 4.2.
4.3. 4.3.1. 4.3.1.1 4.3.1.1

closure of 4.1.1.9. 4.1.1.3.
downstream
valves.
4.4. 4.4.1. 4.4.1.1 4.4.1.1
process upset.
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Word Measure
Less / 5. Less or 5.1. 5.1.1 5.1.1.1. 5.1.1.1.
Flow to CGS
downstream DRS
/OLSs cum MSs
5.2. 5.2.1. 5.2.1.1. 5.2.1.1.

Isolation valve in Same as 5.1.1 PG 1002 / 1006 / 1007 / Same as 5.1.1.1
the CGS 1008 / 1009, PI 1004 / 5.2.1.2.
upstream supply 1005 PT1004 / 1006 Maintenance and
line is partially / installed calibration of
fully closed . 5.2.1.2 Pressure gauges
Pressure Gauge and other
Sectionalizing Installed at all DRS / MS instruments should
valve(s) partially / OLS CNG Stations. be carried out as
fully closed . 5.2.1.3 per schedule and
Same as 1.2.1.4 . FI 1001 / 1002, FT 1001 manufacturer
/ 1002, FE 1001 & Flow instruction and

computer FQR 1001, PD records should be
1001 / TM1001, FB FC maintained
5.3. 5.3.1. 5.3.1.1. 5.3.1.1
5.4. 5.4.1 5.4.1.1 5.4.1.1.
5.4.1.2 maintained.
5.4.1.3
installed. Same as
1.2.1.4 .
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Less / 5.4.1.4 5.4.1.2
Maintenance should
5.4.1.5
be conducted as
Maintenance
Schedule [Annex C,
Annex D, Annex F]
and records should
be maintained.
5.4.1.3
Emergency
handling
procedures should
be prepared and
implemented.
5.5 5.5.1 5.5.1.1 5.5.1.1
downstream OLS
/ MS & DRS.
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High 6. High 6.1. 6.1.1 6.1.1.1. 6.1.1.1.
NG in TG 1001, TT 1002 /
CGS cum MS at Jalbera. Inspection and
Maintenance should
be maintained.
6.1.1.5.
be available
6.2. From 6.2.1 6.2.1.1 6.2.1.1

discharge end 6.1.1.3/ 6.1.1.4 6.1.1.2
6.2.1.2 6.2.1.2
stage coolers installed be conducted, as
per manufacturer
recommendations
and records should
be maintained.

Word Measure
Low 7. Low 7.1 - 7.1.1.1 -
650C temperatures.
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NODE 3
ModelTown Morh SV Station 8, CH upto 9,42

KM
to
Jagdot Road SV Station 7, CH up to 14.42 KM
Pipeline
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NODE 3
System: Model Town Morh SV Station 8 CH up to 9.42 KM to Jagdot Road SV Station 7 CH 14.42 KM
Pipeline
Node Description Model Town Morh SV Station 8 CH up to 9.42 KM to Jagdot Road SV Station 7 CH 14.42
KM
Node Contents • Tap off - At CH up to 12.42 KM (Baldev Nagar DRS 1005 Station) / At CH up to 13.07KM
(Mahindra Singh OLS CNG 1005) / At CH up to 13.42 KM (Ajeeth Petrol Pump OLS
CNG 1006) / At CH up to 14.42 KM (DRS 1006 Station)
• Sectionalizing Valve Station – SV 8 at CH up to 9.42 KM / SV 6 at CH up to 12.42 KM /
SV 7 at CH up to 14.42 KM
Reference P & ID P & ID for Ambala CGD Facilities up to Chainage 20.37 KM
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Word Measure
More 1. More 1.1 1.1.1 1.1.1.1 1.1.1.1 Maintenance
flow of More flow of gas Pressure may Same as NODE 2 - and calibration of
gas from upstream (GAIL increase pipe 1.1.1.1 / 1.1.1.2 / 1.1.1.3 Pressure gauges and
metering station) line. / other instruments
1.1.2 1.1.1.4 / 1.1.1.5 / 1.1.1.6 should be carried out
More gas flow / as per schedule and
to downstream 1.1.1.7 / 1.1.1.8 / 1.1.1.9 manufacturer
OLSs cum MSs / 1.1.1.10 instruction and
1.1.1.2. records should be
PG 1011 / 1011 installed. maintained.
1.2 1.2.1 1.2.1.1 1.2.1.1
Rapture of pipeline Loss of Same as NODE 2 - Gas detectors
containment 1.2.1.1 / 1.2.1.2 / 1.2.1.3 Testing and
leading to fire / calibration should be
hazard carried out as per
1.2.1.2.
schedule and
Isolation valves and manufacturer
Sectionalizing valves SV instruction and
1 at CH 3.0 KM / SV 2 at records should be
CH 6 KM / SV 3 at CH 8 maintained.
1.2.1.2
KM / SV 8 at CH 9.42 Portable firefighting
KM / SV 6 at CH 12.42 appliances Refilling,
KM / SV 7 at CH 14.42 Inspection and

installed. Maintenance should
be conducted as per
1.2.1.3 IS 2190:2010) Fire
Potable firefighting Extinguisher
appliance available at Inspection and
every CGS / OLS / MS. Maintenance
1.2.1.4 Schedule [Annex C,
Civil administration Annex D, Annex F]
firefighting systems shall and records should
be available be maintained.
1.2.1.3.
Emergency handling
procedures should be
prepared and
implemented.
1.3 1.3.1 1.1.3.1 1.1.3.1.

FI 1001 / 1002, FT Same as 1.1.1 Same as 1.1.1.1 & Same as 1.1.1.1
1001 / 1002, FE & 1.2.1 1.1.1.2
1001 & Flow 1.1.3.2.
computer FQR 1001, Flow and pressure
MOV 1001 / 1002 FB indicators and
FC (XSDV 1001) transmitters periodic
malfunctioning inspection, calibration
showing wrong and maintenance as per
reading schedule.
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Word Measure
Less / 2. Less / 2.1. 2.1.1 2.1.1.1 2.1.1.1 Maintenance and
No No Flow Less / No flow of Less / No Gas Same as NODE 2 - calibration of Pressure
of gas gas from upstream Flow to CGS 2.1.1.1 / 2.1.1.2 / gauges and other
(GAIL metering downstream 2.1.1.3 / instruments should be
station) OLS / MS / 2.1.1.4. carried out as per schedule
DRS 2.1.1.2. and manufacturer
PG 1011 / 1011 instruction and records
installed. should be maintained.
2.2 2.2.1 2.2.1.1 2.2.1.1
CGS Filtration unit Same as 2.1.1 Same as NODE 2 - Pre- Start-up checklist
downstream 2.2.1.1 should be prepared and
isolation valves, maintained.
2.2.1.2
Check metering
skid downstream Trained and
/upstream valves, competent operator
Odorization unit will handle the
upstream FB FC process
(XSDV 1001), SV
Station valves
partially / fully
closed.
2.3 2.3.1 2.3.1.1 2.3.1.1
FI 1001 / 1002, FT Same as 2.11 Flow and pressure Same as 2.1.1.1

1001 / 1002, FE indicators and
1001 & Flow transmitters periodic
computer FQR inspection, calibration
1001, PD 1001/ and maintenance.
TM1001
malfunctioning
showing wrong
readings.
2.4. 2.4.1 2.4.1.1 2.4.1.1
Leakage in the Fire and Same as 2.1.1.1 / Portable firefighting
section of pipeline. exposure to Inspection and
2.4.1.2.
ignition source Maintenance should be
Isolation valves and conducted as per IS
Sectionalizing valves 2190:2010) Fire
installed. Same as Extinguisher Inspection and
1.2.1.2 Maintenance Schedule
2.4.1.3 [Annex C, Annex D, Annex
Potable firefighting F] and records should be
appliance available at maintained.
every CGS / OLS / 2.4.1.2.
MS. Emergency handling
2.4.1.4 procedures should be
Civil administration prepared and implemented.
firefighting systems
shall be available
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C: PARAMETER: PRESSURE GUIDE WORD: MORE
Guide Deviation Causes Consequences Safe Guard / Recommendations

Word Control Measure
More 3. More 3.1. 3.1.1 3.1.1.1 3.1.1.1 Maintenance and
pressure More pressure of Potential risk of Same as NODE 2 – calibration of Pressure
of Natural gas from upstream pipeline damage 4.1.1.1 / 4.1.1.2 / gauges and other
gas (GAIL metering / gas leak. 4.1.1.3 / 4.1.1.4 / instruments should be
station) Gas leakage 4.1.1.5 / 4.1.1.6 / carried out as per
may cause fire 4.1.1.7 / 4.1.1.8 / schedule and
and explosion on 4.1.1.9 / 4.1.1.11 manufacturer instruction
exposure to 3.1.1.2 and records should be
ignition source. Isolation valves and maintained.
Sectionalizing valves 3.1.1.2
installed. Same as Gas detectors Testing and
1.2.1.2 . calibration should be
3.1.1.3 carried out as per
Potable firefighting schedule and
appliance available manufacturer instruction
at every CGS / OLS / and records should be
MS maintained.
3.1.1.4 3.1.1.3
Civil administration Portable firefighting
firefighting systems appliances Refilling,
shall be available. Inspection and
Maintenance should be
conducted as per IS

2190:2010) Fire
Extinguisher Inspection
and Maintenance
Schedule [Annex C,
Annex D, Annex F] and
records should be
maintained.
3.1.1.4
Emergency handling
procedures should be
prepared and
implemented.
3.2. 3.2.1. 3.2.1.1 3.2.
Flow and pressure Same as 3.1.1. Flow and pressure Same as 3.1,1.1
indicators and indicators and
transmitters transmitters periodic
malfunctioning. inspection,
calibration and
maintenance.
3.3. 3.3.1. 3.3.1.1 3.3.1.1
Inadvertent closure Same as 3.1.1. Same as 3.1.1.1 Same as 3.1.1.1 – 3.1.1.4.
of downstream
valves.
3.4. 3.4.1. 3.4.1.1 3.4.1.1
Pressure rise due Same as 3.1.1. Same as 3.1.1.1 Same as 3.1.1.1. - 3.1.1.4
to downstream
process upset.
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D: PARAMETER: PRESSURE GUIDE WORD: LESS / NO

Word Measure
Less / 4. Less or 4.1. 4.1.1 4.1.1.1. 4.1.1.1.
No No Less or No Downstream Low pressure discharge Pre- Start-up checklist
pressure pressure of process may controls available at should be prepared and
of Natural Natural gas from disturb. GAIL Metering Station. maintained.
gas. upstream, GAIL 4.1.2
Flow to CGS
downstream DRS
/OLSs cum MSs
4.2. 4.2.1. 4.2.1.1. 4.2.1.1.
Isolation valve in Same as 4.1.1 / Same as NODE 2 – Same as 4.1.1.1
the CGS 4.1.2 5.2.1.1 / 5.2.1.2 / 4.2.1.2.
upstream supply 5.2.1.3 Maintenance and
line is partially / calibration of Pressure

fully closed . gauges and other
instruments should be
Sectionalizing carried out as per
valve(s) partially schedule and
/ fully closed . manufacturer instruction
Same as 1.2.1.2 and records should be
. maintained
4.3. 4.3.1. 4.3.1.1. 4.3.1.1

Flow and Same as 4.1.1 / Flow and pressure Same as 4.1.1.1 &
pressure 4.1.2 indicators and 4.2.1.2
4.4. 4.4.1 4.4.1.1 4.4.1.1.
Leakage in the Fire and explosion The Pressure at any Gas detectors Testing
aboveground on exposure to point of steel network is and calibration should
ignition source within 15-17 Kg/cm2.g be carried out as per
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Word Measure
section of and velocity 20 m / sec schedule and
pipeline. to supply to OLS, the manufacturer instruction
pipeline thickness and records should be
considered 6.4 mm API maintained.
5L as per ASME B31.8. 4.4.1.2

appliances Refilling,
Inspection and
4.4.1.3
Maintenance should be
conducted as per IS
SV installed. Same as
2190:2010) Fire
1.2.1.2 .
Extinguisher Inspection
4.4.1.4
and Maintenance
appliance available at Annex D, Annex F] and
every CGS / OLS / MS. records should be
4.4.1.5 maintained.

Civil administration 4.4.1.3
firefighting systems Emergency handling
shall be available. procedures should be
prepared and
implemented.
4.5 4.5.1 4.5.1.1 4.5.1.1
Inadvertent Same as 5.1.1 PG / PI / PIT installed Same as 4.1.1.1 &
withdrawal of at CGS / MS 4.2.1.2
gas at CGS / MS downstream OLS / MS
downstream & DRS
OLS / MS &
DRS.
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E: PARAMETER: TEMPERATURE GUIDE WORD: HIGH
Word Measure
High 5. High 5.1. 5.1.1 5.1.1.1. 5.1.1.1.
Fire in nearby Same as NODE 2 - No vegetation
area of CGS / MS damage to 6.1.1.1 / 6.1.1.2 / 6.1.1.3 should be allowed
& aboveground pipeline / leak / 6.1.1.4 / 6.1.1.5 to grow in the
pipeline section. and release of pipeline area.
NG in
atmosphere 5.1.1.2.
leading to fire and Portable firefighting
explosion. appliances Refilling,
Inspection and
Maintenance should
be conducted as
per IS 2190:2010)
Fire Extinguisher
Inspection and
Maintenance
Schedule [Annex C,
Annex D, Annex F]
and records should
be maintained.
5.2. From 5.2.1 5.2.1.1 5.2.1.1

compressor Same as 6.1.1. Same as 5.1.1.1 Same as 5.1.1.1 &
discharge end 6.2.1.2 5.1.1.2

Reciprocating multiple 5.2.1.2
stages (mostly 3 stages) Inspection &
Compressor with inter maintenance of
stage coolers installed compressors should
be conducted, as
per manufacturer
recommendations
and records should
be maintained.
F. PARAMETER: TEMPERATURE GUIDE WORD: LOW

Word Measure
Low 6. Low 6.1 - 6.1.1.1 -
650C temperatures.
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G. PARAMETER: OTHER – CORROSION / ERROSION (GUIDE WORK – MORE)

Word Measure
More 1. More 1.1 External 1.1.1 1.1.1.1. 1.1.1.1.
Corrosion / corrosion of External / Internal Based on the pipeline Cathodic protection
Erosion pipeline / Corrosion / wall thickness study, 6.4 shall be provided
equipment due Erosion will mm wall thickness for underground
to atmospheric reduce pipeline pipeline will be pipeline section.
conditions wall thickness
considered as per 1.1.1.2.
and may cause
pipeline failure, PNGRB, API 5L and
Consequence
leakage and ASME B31.8 codes and
analysis of pipelines
release of natural standards. should be carried
gas in 1.1.1.2 out and Prepare an
atmosphere emergency
A corrosion allowance of
leading to fire and response/action
explosion, if 0.5 mm will be
plan to minimize the
exposed to considered.
damage for
source of ignition 1.1.1.3. employees, society
and possibility of and environment as
For protection of
injury and well as to resume to
external corrosion, a 3-
property damage. the normal
layer polyethylene (PE)
condition as fast as
coating, will be applied
possible.
on the pipeline.
1.1.1.4

Corrosion / Erosion
protection system
provided.
1.1.1.5.
100 % NDT is being
carried out of the
system.
1.2. Internal 1.2.1 1.2.1.1 1.2.1.1

corrosion / Same as above Same as above Same as above
erosion due to
flow of natural
gas through
pipeline.
1.3 Underground 1.3.1 1.3.1.1 1.3.1.1
pipe line Same as above Same as above Same as above
corrosion due to
subsoil
conditions.
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H. PARAMETER: OTHER –STATIC ELECTRIC - STATIC CHARGE (GUIDE WORK –
MORE)

Word Measure
More 1. More 1.1. During the 1.1.1 1.1.1.1 1.1.1.1
static charge transfer of Static charge in The pipeline have Continuity of
accumulation Natural gas (Gas sufficient quantity welded joints. The pipelines and
on NG flow in pipeline) cause jump over flanged joints provided earthing shall be
carrying static may when air with earthing and ensured.
pipeline generate and resistance is bonding jumpers
accumulate on broken and 1.1.1.2
flanges. produces spark, a Integrity of earthing
source of ignition and value of earth
which can lead to pit resistance
fire & explosion. should be
periodically
checked, and
records should be
maintained.
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KURUKSHETRA DISTRICT
HAZOP STUDY
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NODE LIST KURUKSHETRA DISTRICT: The following NODE have been selected for
HazOp Study
HAZOP STUDY: NODE 1

System: City Gas Distribution Network: City Gate Station Adhoya CGS CH 0.0 KM to Kurukshetra
University CH up to 49.59 KM Pipeline
Meterring Skid) Downstream – Adhoya CGS CH 0.0 KM to Kurukshetra University CH up
to 49.59 KM
• Twin Stream Cartridge Filters (Capacity 1,000 – 18,000 SCMH, 300#),
(Capacity 1,000 – 18,000 SCMH, 300#, Inlet pressure 49 Kg / cm2.g and Outlet pressure
19 Kg / cm2.g - 35 Kg / cm2.g)
Flow Meter.
• OLS / MS at – Adhoya CGS / Shahbad - Pipli Chowk / Pipli Chowk – HSID C / Pipli
Chowk – Bus Stop / Bus Stop – Old Bus Stop / Old Bus Stop – Kurukshetra University.
• DRS at – Adhoya - Shahbad/ Shahbad - Pipli Chowk / Pipli Chowk – HSID C / Pipli
Chowk – Bus Stop / Bus Stop – Old Bus Stop / Old Bus Stop – Kurukshetra University.

• PRS at – Pipli Chowk – HSID C
• Sectionalizing Valve Stations
• From CGS - SV 1 at CH up to 3.0 KM / SV 2 at CH up to 6 KM / SV 3 at CH up to
9 KM / SV 4 at CH up to 12 KM / SV 5 at CH up to 15 KM / SV 6 & SV 12 (Pipli
Chowk) at CH up to 21 KM / SV 7 at CH up to 24 KM / SV 8 at CH up to 27 KM /
SV 9 at CH up to 30 KM / SV 10 at CH up to 33 KM / SV 11 at CH up to 36 KM.
• From Pipli Chowk - SV 12 at CH up to 3 KM / SV 13 at CH up to 6 KM / SV 14 at
CH up to 9 KM /
• From Pipli - SV 15 at CH up to 12 KM / SV 16 at CH up to 15 KM
Reference P & ID & • Process Design Basic for HPOIL Gas Private Limited (HOGPL) – City Gas Distribution
Design Intents Project of Ambala – Kurukshetra District and Kohlapur District.
• P & IDs of Ambala District considered for the HAZOP Study as per Client (P & ID
for Kurukshetra District City Gate Station cum Mother Station and GCD are
identical as Ambala District P & ID’s).
• Design Intents – Considered same as Ambala District as per Client.
TOTAL PIPELINE LENGTH

NODE Pipeline From Pipeline To Length Effective
Total Length
Node 1 City Gate Station Adhoya Kurukshetra University CH up to 49.59 49.59
CGS CH 0.0 KM 49.59 KM
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KURUKSHETRA DISTRICT

NOTE: Equipment numbers / IDs considered as per Ambala District P & IDs
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NODE 1
City Gate Station, Adhoya CGS CH 0.0 KM
to
Kurukshetra University CH up to 49.59 KM
Pipeline

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Word Measure
More 1. More flow 1.1 1.1.1 1.1.1.1 1.1.1.1
of gas More flow of gas Pressure may PG 1002 / 1006, PI 1004 / Maintenance and
from upstream increase at CGS 1005 PT1004 / 1006 calibration of
(GAIL metering & in Pipe line. installed. Pressure gauges
station) 1.1.2 1.1.1.2 and other
More gas flow to FI 1001 / 1002, FT 1001 / instruments should
downstream 1002, FE 1001 & Flow be carried out as
OLSs cum MSs computer FQR 1001 per schedule and
MOV 1001 / 1002 records should be
installed. Only one MOV maintained.
time. MOV can be

computer.
1.1.1.4
1.1.1.5
FB FC (XSDV 1001)
installed.
1.1.1.6
Creep Relief valve
installed.
1.1.1.7
structure or nearby
provided.
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More 1.1.1.9
Pressure and flow
GAIL Metering Sked
facility.
1.1.1.10
Stations
1.2 1.2.1 1.2.1.1 1.2.1.1
1.2.1.2
1.2.1.2
1 to SV 16 installed. Maintenance should
be conducted as

1.2.1.5 per IS 2190:2010)
Potable firefighting Fire Extinguisher
appliance available at Inspection and
every CGS / OLS / MS. Maintenance
1.2.1.6 Schedule [Annex C,
Civil administration Annex D, Annex F]
firefighting systems shall and records should
be available be maintained.
1.2.1.3.
Emergency
handling
procedures should
be prepared and
implemented.
1.3 1.3.1 1.1.3.1 1.1.3.1.
FT 1001 / 1002, 1.2.1
FE 1001 & Flow 1.1.3.2.
computer FQR Flow and pressure
1001, MOV 1001 indicators and transmitters
/ 1002 FB FC periodic inspection,
(XSDV 1001) calibration and
malfunctioning maintenance as per
showing wrong schedule.
reading
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Word Measure
Less / 2. Less / No 2.1. 2.1.1 2.1.1.1 2.1.1.1
No Flow of gas Less / No flow of Less / No Gas PG 1002 / 1006, PI 1004 / Maintenance and
gas from Flow to CGS 1005 PT1004 / 1006 calibration of
upstream (GAIL downstream installed. Pressure gauges
metering station) OLS / MS / DRS 2.1.1.2 and other
FI 1001 / 1002, FT 1001 / instruments should
1002, FE 1001 & Flow be carried out as
computer FQR 1001 per schedule and
PD 1001/ TM1001 records should be
2.1.1.4
Stations
2.2 2.2.1 2.2.1.1 2.2.1.1

2.2.1.2
process

/upstream valves,
Odorization unit
upstream FB FC
(XSDV 1001), SV
Station valves
partially / fully
closed.
2.3 2.3.1 2.3.1.1 2.3.1.1
TM1001
malfunctioning
showing wrong
readings.
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2.4. 2.4.1 2.4.1.1 2.4.1.1
2.4.1.2.
be maintained.
handling
procedures should
be prepared and
implemented

Word Measure
Reverse 3. Reverse 3.1. - 3.1.1.1. 3.1.1.1
1.2.1.4 . and other
manufacturer
3.1.1.3
instruction and
PG 1002 / 1006, PI 1004
records should be
/ 1005 PT1004 / 1006
maintained.
installed.
3.1.1.4
FI 1001 / 1002, FT 1001
/ 1002, FE 1001 & Flow
1001 / TM1001, FB FC
3.1.1.5
Pressure Gauge
OLS CNG Stations
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Word Measure
More 4. More 4.1. 4.1.1 4.1.1.1 4.1.1.1
Kurukshetra (CGS / MS 4.1.1.2

4.1.1.5 4.1.1.3
FI 1001 / 1002, FT 1001 Portable firefighting
/ 1002, FE 1001 & Flow appliances Refilling,
computer FQR 1001, PD Inspection and
1001 / TM1001, FB FC Maintenance should
(XSDV 1001) installed. be conducted as
4.1.1.6 per IS 2190:2010)
Twin Stream Pressure Fire Extinguisher
Reduction unit (as per Inspection and
PNGRB’s guidelines) Maintenance
with each stream Schedule [Annex C,
consisting of Slum-Shut Annex D, Annex F]
Valve, Active Regulator and records should
and Monitor Regulator be maintained.
installed. 4.1.1.4
4.1.1.7 Emergency
Creep Relief valve handling
installed. procedures should
4.1.1.8 be prepared and
Vent min. 3 M high from implemented.
nearest highest
15 M provided.
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More 4.1.1.9
4.1.1.10
installed. Same as
1.2.1.4 .
4.1.1.11
per GAIL O&M
procedures.
4.1.1.12
4.1.1.13
be available.
4.1.1.14
Pressure Gauge
OLS CNG Stations.
4.1.1.15

Stations.
4.2. 4.2.1. 4.2.1.1 4.2.
4.3. 4.3.1. 4.3.1.1 4.3.1.1

closure of 4.1.1.9. 4.1.1.3.
downstream
valves.
4.4. 4.4.1. 4.4.1.1 4.4.1.1
process upset.
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Less / 5. Less or 5.1. 5.1.1 5.1.1.1. 5.1.1.1.
Flow to CGS
downstream DRS
/OLSs cum MSs
5.2. 5.2.1. 5.2.1.1. 5.2.1.1.

Isolation valve in Same as 5.1.1 PG 1002 / 1006, PI 1004 Same as 5.1.1.1
the CGS / 1005 PT1004 / 1006 5.2.1.2.
upstream supply installed Maintenance and
line is partially / 5.2.1.2 calibration of
fully closed . Pressure Gauge Pressure gauges
Installed at all DRS / MS and other
Sectionalizing OLS CNG Stations. instruments should
valve(s) partially / 5.2.1.3 be carried out as
fully closed . FI 1001 / 1002, FT 1001 per schedule and
Same as 1.2.1.4 . / 1002, FE 1001 & Flow manufacturer
computer FQR 1001, PD instruction and

1001 / TM1001, FB FC records should be
(XSDV 1001) installed. maintained
5.3. 5.3.1. 5.3.1.1. 5.3.1.1
5.4. 5.4.1 5.4.1.1 5.4.1.1.
5.4.1.2 maintained.
5.4.1.3
installed. Same as
1.2.1.4 .
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Less / 5.4.1.4 5.4.1.2
Maintenance should
5.4.1.5
be conducted as
Maintenance
Schedule [Annex C,
Annex D, Annex F]
and records should
be maintained.
5.4.1.3
Emergency
handling
procedures should
be prepared and
implemented.
5.5 5.5.1 5.5.1.1 5.5.1.1
downstream OLS
/ MS & DRS.
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Word Measure
High 6. High 6.1. 6.1.1 6.1.1.1. 6.1.1.1.
NG in TG 1001, TT 1002 /
CGS cum MS at Adhoya. Inspection and
Maintenance should
be maintained.
6.1.1.5.
be available
6.2. From 6.2.1 6.2.1.1 6.2.1.1

discharge end 6.1.1.3/ 6.1.1.4 6.1.1.2
6.2.1.2 6.2.1.2
stage coolers installed be conduced as per
manufacturer
recommendations
and records should
be maintained.

Word Measure
Low 7. Low 7.1 - 7.1.1.1 -
650C temperatures.
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H. PARAMETER: OTHER – CORROSION / ERROSION (GUIDE WORK – MORE)

Word Measure
More 1. More 1.1 External 1.1.1 1.1.1.1. 1.1.1.1.
Corrosion / corrosion of External / Internal Based on the pipeline Cathodic protection
Erosion pipeline / Corrosion / wall thickness study, 6.4 shall be provided
equipment due Erosion will mm wall thickness for underground
to atmospheric reduce pipeline pipeline will be pipeline section.
conditions wall thickness
considered as per 1.1.1.2.
and may cause
pipeline failure, PNGRB, API 5L and
Consequence
leakage and ASME B31.8 codes and
analysis of pipelines
release of natural standards. should be carried
gas in 1.1.1.2 out and Prepare an
atmosphere emergency
A corrosion allowance of
leading to fire and response/action
explosion, if 0.5 mm will be
plan to minimize the
exposed to considered.
damage for
source of ignition 1.1.1.3. employees, society
and possibility of and environment as
For protection of
injury and well as to resume to
external corrosion, a 3-
property damage. the normal
layer polyethylene (PE)
condition as fast as
coating, will be applied
possible.
on the pipeline.
1.1.1.4

Corrosion / Erosion
protection system
provided.
1.1.1.5.
100 % NDT is being
carried out of the
system.
1.2. Internal 1.2.1 1.2.1.1 1.2.1.1

corrosion / Same as above Same as above Same as above
erosion due to
flow of natural
gas through
pipeline.
1.3 Underground 1.3.1 1.3.1.1 1.3.1.1
pipe line Same as above Same as above Same as above
corrosion due to
subsoil
conditions.
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I. PARAMETER: OTHER –STATIC ELECTRIC - STATIC CHARGE (GUIDE WORK –
MORE)

Word Measure
More 1. More 1.1. During the 1.1.1 1.1.1.1 1.1.1.1
static charge transfer of Static charge in The pipeline has welded Continuity of
accumulation Natural gas (Gas sufficient quantity joints. The flanged joints pipelines and
on NG flow in pipeline) cause jump over provided with earthing earthing shall be
carrying static may when air and bonding jumpers ensured.
pipeline generate and resistance is
accumulate on broken and 1.1.1.2
flanges. produces spark, a Integrity of earthing
source of ignition and value of earth
which can lead to pit resistance
fire & explosion. should be
periodically
checked, and
records should be
maintained.
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CONCLUSION
The evaluation of the documents indicative that for designing of the City Gas Distribution Project for Ambala
– Kurukshetra District, the basic requirements of the applicable Codes and Standards are complied, and
control measures have been provided.
• PNGRB (Technical Standards & Specifications including Safety Standards for Natural Gas Pipelines)
Regulations, 2009 (T4S) and its Amendments.
• AMSE B 31.8 (latest)
• OISD 226 – Natural Gas Transmission Pipelines & City Gas Distribution.
• OISD 179 – Safety requirements for compression, storage, handling and refuelling of CNG for use in
automotive sector.
• IS 7285 – CNG Cylinder Design Code.
• API / AGA / ASME B31.8 etc.
However, malfunction of equipment and human error cannot be oversighted, hence, it is recommended
that:

• Only trained and competent operators should handle the process.
• Pre-start-up checklist should be prepared and implemented.
• SOP and Work instructions should be prepared & implemented
• Maintenance, testing and calibration of monitoring and detection equipment and systems (Flow,
Pressure & Temperature etc.) should be carried out periodically as per schedule and manufacturer
recommendations and record of such maintenance, testing and calibration etc. should be maintained.
• Firefighting equipment and appliances should be inspected and tested periodically, and records should
be maintained.
• Preventive maintenance schedules should be prepared and implemented.
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Draft Hazop Report - Ambala & Kurukshatra - HOGPL - 09.08.2019

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Draft Hazop Report - Ambala & Kurukshatra - HOGPL - 09.08.2019

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06-08-2019 Qualitative Risk Assessment

Draft Report HAZARD & OPERABILITY (HAZOP) Study

HazOp – Desktop Process Safety Review (DPSR)

Ambala District Pipeline Length - 33.33 KM.

Hazard & Operability (HazOp) Study

Qualitative Risk Assessment Study Report

HPOIL GAS PRIVATE LIMITED (HOGPL)

PAGE 1 REF.: HSERM/PT/VCS/PO/19-20/03/12-06-2019/Project 18&19/060619

Study Report Prepared on Behalf Of Study Conducted & Report Prepared By

QUALITY CONTROL SHEET

Report Releasing Date: 06-08-2019

Prepared By HSE-RM Advisory Members

Reviewed & Approved By

PAGE 2 REF.: HSERM/PT/VCS/PO/19-20/03/12-06-2019/Project 18&19/060619

SR. NO. CONTENT PAGE NO.

3. PREFACE: INTRODUCTION OF HAZOP - DESKTOP PROCESS 06

7. APPLICABLE CODES & STANDARDS 21

8. HAZARD AND OPERABILITY (HAZOP) STUDY 22

AMBALA DISTRICT HAZOP STUDY

PAGE 3 REF.: HSERM/PT/VCS/PO/19-20/03/12-06-2019/Project 18&19/060619

11. AMBALA DISTRICT DESIGN INTENT 32

12. AMBALA DISTRICT HAZOP WORK SHEET 35

HAZOP STUDY: NODE - 1 36

13. NODE LIST KURUKSHETRA DISTRICT 68

14. AMBALA DISTRICT HAZOP WORK SHEET 70

HAZOP STUDY: NODE - 1 71

PAGE 4 REF.: HSERM/PT/VCS/PO/19-20/03/12-06-2019/Project 18&19/060619

SPECIAL, INDIRECT, PUNITIVE, OR CONSEQUENTIAL DAMAGES OF ANY NATURE WHATSOEVER, INCLUDING

for report purpose only.

Dated 22.11.2018, our entry no. Project 18 &19: 12.06.2019

HSE RM Solutions, Ahmedabad, Gujarat comprises:

Mr. Piyush Tripathi (MD)

Mr. R. C. Sharma (Advisor)

PAGE 5 REF.: HSERM/PT/VCS/PO/19-20/03/12-06-2019/Project 18&19/060619

• Drawing No. 1007 - AMB – PC – PID - 1001, Rev.D3.

• Drawing No. 1007 -AMB – PC – PID - 1002, Rev.D3.

• Drawing No. 1007 - Ambala – PC – PID - 1003, Rev.D3.

GCD are identical as Ambala District P & ID’s.

The review includes:

 Identification of possible deviations from the actual design intent

 Identification of possible causes for deviations and determination of the consequences

PAGE 6 REF.: HSERM/PT/VCS/PO/19-20/03/12-06-2019/Project 18&19/060619

experience and attitudes of the team members and

on the leadership style adopted. In this study, the

members of the team had good experience,

knowledge and skills and had the authority to

approve the actions decided upon.

The HAZOP study of plant by procedure given

PAGE 7 REF.: HSERM/PT/VCS/PO/19-20/03/12-06-2019/Project 18&19/060619

CGD City Gas Distribution

CGS City Gas Station

DRS District Regulating Station

OLS On Line Station

DB Daughter Booster Station

DFR Detailed feasibility report

GAIL Gas Authority of India Ltd

VCSQSPL VCS Quality Services Private Limited

PAGE 8 REF.: HSERM/PT/VCS/PO/19-20/03/12-06-2019/Project 18&19/060619

RLNG Regasified Liquefied Natural Gas

PCV Pressure Control Valve

PRS Pressure Regulation Station

PSV Pressure Safety Valve