VSRD International Journal of Technical & Non-Technical Research, Vol. 4 No.

7 July 2013 e-ISSN : 0976-7967, p-ISSN : 2319-2216 VSRD International Journals : www.vsrdjournals.com

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RESEARCH ARTICLE

QUALITATIVE RISK ANALYSIS IN LPG BOTTLING PLANT

1Rajiv
1Assistant

Premi* and 2Nagendra Sohani

Professor, Department of Fire Technology & Safety Engineering, IES-IPS Academy, Indore, Madhya Pradesh, INDIA. 2Associate Professor, Department of Mechanical Engineering IET-DAVV, Indore, Madhya Pradesh, INDIA. *Corresponding Author : rajivpremi01@gmail.com

ABSTRACT
This Paper presents a state of art review of the available techniques and methodologies for carrying out risk analysis in LPG Bottling Plant. Keywords : Risk Assessment, Qualitative Assessment, LPG Bottling Plant, HAZOP, Fault Tree Analysis.

1. INTRODUCTION Catastrophic event over the past few year have been focuses unparalleled attention on the safety of processing, transportation and storage facilities. In the wake of Bhopal most large hazardous material storage facilities undertook comprehensive review of their facilities to determine the potential for large accidents and to evaluate their preparedness for dealing with them. Accidents in such unit caused by material failure (such as crack in the storage vessel), operational mistake (such as raising the pressure, temp/flow rate beyond critical limits). Along with the rapid growth of industrialization and population the risk posed by probable accidents also continues to rise. Successfully managing the safe operation of industrial facilities require pertinent information and good judgments Every industry involves some processes and operations, without use of any flammable material in any form, a process cannot be accomplished. When this material is not handled or stored or transported properly, it may cause a serious impact on human, environment and property. All industrial activities involve a variety of hazards or dangers. All flammable material like LPG has their specific hazards. Proper attention and precautions are to be paid to reduce the degree of hazards. Every refinery & bottling plant everyday processes and handles different type of crude oil, liquids and gaseous petroleum products which are highly inflammable ,volatile in nature and are required to be handled with due care.

2. OBJECTIVE HAZOP Study in LPG Bottling plant. Fault tree analysis of LPG leakage transportation.

during

3. LPG BOTTLING PLANT A plant where LPG is stored and filled into cylinders. Receipt and dispatch of LPG by rail, road and pipeline are also considered under this definition. 4. HAZARD IDENTIFICATION & HAZARD ANALYSIS A Hazard is generally realized as a loss of containment of a hazardous material. The routes for such loss of containment can include release from pipe fittings containing liquid or gas, releases from vents, relief & release from vessel rupture. Adhering to good engineering practices alone may not be adequate for controlling plant hazards thus, a variety of techniques of hazard identification & probability of their occurrence have been developed for analysis of process systems and operations. The main motto of hazard identification is to identify & evaluate the hazards & the unintended events, which could cause an accident. In hazard identification & quantification of probability of occurrence it is assume that they will perform as designed in the absence of unintended events (component & material failure, human errors, external event, process unknown) which may affect the plant & process behavior.

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5. THE PROCESS OF RISK ASSESSMENT

The Process of Risk Assessment

QUALITATIVE TECHNIQUES

QUALITATIVE TECHNIQUES

FREQUENCY

ASSESSMENT

MODEL

Estimate Likelihoods

Risk Evaluation

Absolute and relative risks Major risk contributors Comparisons with other risks

Hazard Identification

CONSEQUENCE

ASSESSMENT

MODEL

Estimate Likelihoods

Qualitative ranking Of recommendation

Qualitative benefits and costs of risk- reduction alternative

6. METHODOLOGIES Standard Procedures can be used to find out hazard in LPG Bottling Plant as given in (AlChE Manual on Guidelines for Hazard Evaluation Procedures, 1985)

7. HAZOP (HAZARD AND OPERABILITY STUDY) HAZOP (Hazard & operability) study is carried out by application of guidewords to identify all possible deviations from design intent having undesirable effects on safety or operability, with the aim of identifying potential hazards.

Table : Main Guidewords to Parameters and Operations Guide Words NO or NOT MORE LESS Meanings The complete negation of these intentions Quantitative increases or decreases Comments No part of the intentions is achieved but nothing else happens. These refer to quantities + properties such as flow rates and temperatures as well as activities like HEAT and REACT.

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AS WELL AS PART OF REVERSE OTHER THAN

A qualitative increase A qualitative decrease The logical opposite of the intention Complete substitution

All the design and operating intentions are achieved together with some additional activity. Only some of the intentions are achieved; some are not. This is mostly applicable to activities, for example reverse flow or chemical reaction. It can also be applied to substances, e.g. POISON instead of ANTIDOTE or D instead of L optical isomers. No part of the original intention is achieved. Something quite different happens.

8. FAULT TREE ANALYSIS (FTA) It is a deductive technique that focuses on one particular accident event and provides a method for determining causes of that accident event. The fault tree itself is a graphical model that displays the various combinations of Fault tree symbols Symbols Type

equipment faults and failure that can result in the accident event. The solution of the fault tree is a list of the sets of equipment failures that are sufficient to result in the accident event of interest

Description

Node Text box

Contains the text for all FT node

Basic event (primary failure)

A random failure event (internally).

Basic event (secondary failure)

An externally induced failure.

Normal event

Expected event in normal system operation

AND Gate

The output occurs input occur together.

only

if

all

of

the

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OR Gate

The output occurs only if at least one input occurs

9. POSSIBLE RESULTS & CONCLUSION Sample of HAZOP Sheet Guide Word No Deviation No Material Possible Cause No Material in Tanker initially Material Completely Transfer due to operators error Consequences Pump Cavitations Vacuum in Road Tanker Action Required Weighting of tanker on entry Checking of rotogauge and document Connect vapor line to tanker for equalization Display decanting procedure with precautions Check level by rotogauge. Calibrate rotogauge periodically Check for adequate capacity of tanker warm supplier

Less More

Less material More material

Material received is less than normal consignment Less size tanker. Over filling of tanker.

Chances of early emptying of tanker. Overfilling of tank. Thermal expansion of liquid locked in pipeline. Increase of tanker pressure.

10.SAMPLE FAULT TREE FOR POSSIBLE LPG RELEASE DURING TRANSPORTATION

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11.CONCLUSION Safety is a very important aspect which is needed to be given a greater importance in our day to day life and as far as our industries are concerned the level of risk is very high in the hazardous material handling industries and this level of risk could be minimized only by a proper system which may achieved by certain risk management techniques which help us know the level of risk as well as the method to minimize it and ensure safety at work. The two methodologies present here is useful to find out certain risk in the LPG bottling plant though large amount of work is already done on this field with analytical data.. The HAZOP study was developed to identify hazards in a process plant and to identify operability problems which though not hazardous, could compromise the plants ability to achieve design productivity. The data require in HAZOP study is detailed plant description such as drawing, procedures and flow charts & the results are the team findings which include identification of hazard and operating problems recommended change in design, procedures etc Fault Tree Analysis is a deductive technique that focuses on one particular event and provides a method for determining causes of that accident event. The fault tree itself is a graphic model that displays the various combinations of equipment faults and failure that can result in the accident

event. The Nature of result is Qualitative with quantitative potential it can be evaluated quantitatively when probabilistic data are available 12.REFERENCES
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