Annexure - 1 - Propane - Hazop Worksheet

TATA STEEL LIMITED - KALINGANAGAR
HAZOP STUDY FOR

PROPANE STORAGE & PROPANE DILUTION SYSTEM
HAZOP WORK SHEETS

(Rev. 0)
EQMS INDIA PRIVATE LIMITED
304 & 305, Rishabh Corporate Tower, Plot No. 16,

Community Centre, Karkardooma, Delhi 110 092
TATA STEEL LTD

KALINGANAGAR
HAZOP WORK SHEET
PROPANE STORAGE & PROPANE

DILUTION SYSTEM
S. No.
Section
1.
Propane Storage System
2.
Dilution System
EQMS INDIA
PRIVATE
LIMITED
Page
No.
4
14
Page 2 of 25
HAZOP WORK SHEET
TATA STEEL LTD
EQMS INDIA
PRIVATE
LIMITED

DILUTION SYSTEM
KALINGANAGAR
List of Nodes
SL NO
NODE-NO
SYSTEM
PAGE NO
301
ROAD TANKER TO PROPANE STORAGES
302
SUPPLY OF PROPANE TO CONSUMER
303
PROPANE DILUTION SYSTEM
14
Page 3 of 25
HAZOP WORK SHEET
TATA STEEL LTD

KALINGANAGAR

DILUTION SYSTEM
Node:
301
Design
Intent
EQMS INDIA
PRIVATE
LIMITED
P&ID No. G/P&I/6654/2013
Tanker to Storage
Deviation
Cause
Consequence
Safeguard
No/ Less
Flow
Compressor C01/02/03 Malfunction
Low filling rate in

storage tank
T1/T2/T3
Standby
Compressor
Provided C01/02/03
ROV-1 Stuck Close
No filling in Storage
tank
Compressor Trip
at 21Kg/cm2
T1/T2/T3
Tanker designed
for 21kg/cm2
Increase in
Pressure in Tanker
Pressure gauge
&, Pressure
safety Valve has
been provided
on tanker
Recommendation
Remark/Acti
on
Pressure
Safety valve
testing
should be
incorporated
in
maintenance
schedule
Page 4 of 25
HAZOP WORK SHEET
TATA STEEL LTD

KALINGANAGAR

DILUTION SYSTEM
Node:
301
Design
Intent
EQMS INDIA
PRIVATE
LIMITED
P&ID No. G/P&I/6654/2013
Tanker to Storage
Deviation
Cause
More Flow
More pressure
difference in Tanker
and Tank
Consequence
Static Charge
possible
Safeguard
Recommendation
Line ,Tanker and

Tank is Earthed
During operation of
propane liquid
filling from Road
Tanker to Storage
Tank, due to More
or high flow, Stating
Charge is
generated. To avoid
the hazard from
static Charge in
pipeline and
Propane storage
tank, Jumper made
of Copper,
Alluminium or G.I.
strip for electrical
continuity is to be
provided in all
Remark/Acti
on
Resistance is
to be checked
for all earthing
Strip and Earth
pit and a
record is to be
maintained..
Page 5 of 25
HAZOP WORK SHEET
TATA STEEL LTD

KALINGANAGAR
Node:
301
Design
Intent
Deviation
EQMS INDIA
PRIVATE
LIMITED

DILUTION SYSTEM
P&ID No. G/P&I/6654/2013
Tanker to Storage
Cause
Consequence
Safeguard
Recommendation
Remark/Acti
on
flanges
R-1
Reverse
Flow
Not possible
Higher
Pressure
Over pressurization by
compressor
Lower
Pressure
Covered in Less flow
Damage of tank
Tank is designed
for high pressure.
compressor trip
at 21kg/cm2
Page 6 of 25
HAZOP WORK SHEET
TATA STEEL LTD

KALINGANAGAR

DILUTION SYSTEM
Node:
301
Design
Intent
EQMS INDIA
PRIVATE
LIMITED
P&ID No. G/P&I/6654/2013
Tanker to Storage
Deviation
Cause
Consequence
Safeguard
Higher
Temperatur
e
External fire
Fire and Explosion

Hazard
PRV-01 and PG01,12,13,14

Provided
High pressure
Recommendation
Remark/Acti
on
Gas detector
provided GLD 1,
2, 3 Provided.
Water Sprinkler
provided for the
Storage tanks
and Tanker
unloading station
PSV provided.
Page 7 of 25
HAZOP WORK SHEET
TATA STEEL LTD

DILUTION SYSTEM
KALINGANAGAR
Node:
301
Design
Intent
EQMS INDIA
PRIVATE
LIMITED
P&ID No. G/P&I/6654/2013
Tanker to Storage
Deviation
Cause
Lower
Temperatur
e
No Issue
Higher
Level
Transfer not stopped

at high level
(Storage
Tank T1,2,3)
Lower
Level
No Issue
Concentrati
on
NA
Consequence
Safeguard
Tank Pressurization
LT-11/21/31
,PT11,21,31 are
provided in the
tank same will
close respective
ROV-11/21/31
Recommendation
Remark/Acti
on
Page 8 of 25
HAZOP WORK SHEET
TATA STEEL LTD

KALINGANAGAR
Node:
301
Design
Intent
Tanker to Storage
Cause
Impurity
NA
Utility
Failure
Power
Consequence
Safeguard
Recommendation
No Transfer of
Propane from
Tanker to Storage
Tank.
All ROV and SV

will Close
DG should be
provided for backup
power for the
operation of Propane
storage system
Compressor C-01,
C-02 & C-03 will
stop.
Shut-down
P&ID No. G/P&I/6654/2013
Deviation
Start-up
EQMS INDIA
PRIVATE
LIMITED

DILUTION SYSTEM
Remark/Acti
on
R-2
Proper SOP is
to be made
for attending
Start Up &
Shutdown of
Propane
system
Page 9 of 25
HAZOP WORK SHEET
TATA STEEL LTD

KALINGANAGAR

DILUTION SYSTEM
Node:
301
Design
Intent
Deviation
EQMS INDIA
PRIVATE
LIMITED
P&ID No. G/P&I/6654/2013
Tanker to Storage
Cause
Consequence
Safeguard
Maintenanc
e
Recommendation
Remark/Acti
on
Proper
Isolation,
N2-purging &
Permit
System
Should be
included
SOP
Leakage
Corrosion of line
Excess flow of
liquid and
temperature fall
Excess Flow
Check at Tankers
Page 10 of 25
HAZOP WORK SHEET
TATA STEEL LTD

KALINGANAGAR

DILUTION SYSTEM
Node:
302
Design
Intent
EQMS INDIA
PRIVATE
LIMITED
P&ID No. G/P&I/6654/2013 R1
To Supply Propane to Consumer
Deviation
Cause
Consequence
Safeguard
No/ Less
Flow
ROV stuck close
No supply to
Customer
Standby System
Provided
Recommendatio
n
Remark/Actio
n
Flow meter No91A/B/C provided

More Flow
Leakage
Fall In temperature
Excess flow Pipe
line
More consumption
from Customer
side
EFV-16/26/36
provided
EFV-16/26/36
provided
Page 11 of 25
HAZOP WORK SHEET
TATA STEEL LTD

KALINGANAGAR

DILUTION SYSTEM
Node:
302
Design
Intent
EQMS INDIA
PRIVATE
LIMITED
P&ID No. G/P&I/6654/2013 R1
Deviation
Cause
Consequence
Safeguard
Reverse
Flow
Not possible
Higher
Pressure
Covered in higher
Temperature below
Lower
Pressure
Covered in Low flow
Higher
Temperatur
e
Vaporizer V-1/2/3
malfunction
Chances of burst
Pipe
RTD 41/51/61
Water level low
Fire and explosion

hazard
(Water level
indicator)
Recommendatio
n
Remark/Actio
n
NRV-41/51/61
provided
WLI-41/51/61
PRV-41/51/61
provided
Page 12 of 25
HAZOP WORK SHEET
TATA STEEL LTD

KALINGANAGAR

DILUTION SYSTEM
Node:
302
Design
Intent
EQMS INDIA
PRIVATE
LIMITED
P&ID No. G/P&I/6654/2013 R1
Deviation
Cause
Consequence
Safeguard
Lower
Temperatur
e
Covered in more flow
Higher
Level
SV-42/52/62 stuck
open
No Issue
WLI-41/51/61
SV-42/52/62 stuck
closed
Propane gas will

not be generated,
Liquid may flow in
outlet line
Recommendatio
n
Remark/Actio
n
indicates
Water in
vaporizer
V-1/2/3
Lower
Level
Water in
vaporizer
V-1/2/3
RTD 41/51/61
SV-41/51/61 will
close at less than
55 0C
PS-41/51/61
Page 13 of 25
HAZOP WORK SHEET
TATA STEEL LTD

DILUTION SYSTEM
KALINGANAGAR
Node:
302
Design
Intent
EQMS INDIA
PRIVATE
LIMITED
P&ID No. G/P&I/6654/2013 R1
Deviation
Cause
Higher
Concentrati
on
NA
Lower
Concentrati
on
NA
Impurity
NA
Utility
Failure
Power failure
Instrument Air Failure
Consequence
Safeguard
No vaporization
and hence no
supply
None
Control valves
Recommendatio
n
Remark/Actio
n
DG should be
provided for
backup power (R2)
None
Page 14 of 25
HAZOP WORK SHEET
TATA STEEL LTD

KALINGANAGAR

DILUTION SYSTEM
Node:
302
Design
Intent
Deviation
EQMS INDIA
PRIVATE
LIMITED
P&ID No. G/P&I/6654/2013 R1

Cause
Consequence
failure
Start-up
To be considered later
Shut-down
Maintenanc
e
Safeguard
Recommendatio
n
Remark/Actio
n
Provide N2 Line
as a standby for
Air(R-3)
Proper SOP is to
be made for
attending Start
Up & Shutdown
of Propane
system
Proper Isolation,
N2-purging &
Permit System
Should be
included S OP
Page 15 of 25
HAZOP WORK SHEET
TATA STEEL LTD

KALINGANAGAR

DILUTION SYSTEM
Node:
302
Design
Intent
EQMS INDIA
PRIVATE
LIMITED
P&ID No. G/P&I/6654/2013 R1
Deviation
Cause
Consequence
Safeguard
Leakage
Corrosion of line
Excess flow of
liquid and
temperature fall
Excess Flow
Check Valves16/26/36
provided
Recommendatio
n
Remark/Actio
n
Page 16 of 25
HAZOP WORK SHEET
TATA STEEL LTD

KALINGANAGAR
EQMS INDIA
PRIVATE
LIMITED

DILUTION SYSTEM
G/P&I/6855/2013
Node:
303
P&ID
No.
Propane Dilution System
Design
Intent
To Dilute Propane
Deviation
Cause
Consequence
Safeguard
Recommendation
Remark/Action
No/ Less
Flow
Power Failure
Diluted propane
not available
None
DG should be
provided for
backup power
(Mentioned in R2)
Mr .Arindam
Panigrahi
(Propane)
Filter choke-TIF1
No Flow
Less Pressure
PGs-PG2,PG9
inlet and outlet
PI-103
Bypass line with

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

filter
replacement
process to be
incorporated in
SOP
Page 17 of 25
KALINGANAGAR
EQMS INDIA
PRIVATE
LIMITED
HAZOP WORK SHEET
TATA STEEL LTD

DILUTION SYSTEM
G/P&I/6855/2013
Node:
303
Design
Intent
Deviation
No/Less
Flow
(Air)
P&ID
No.

To Dilute Propane
Cause
Consequence
Safeguard
Lack of supply of
Air(tank empty)
Diluted propane
not available
Standby Tank
Provided
Power Failure
Diluted propane
not available
None
Recommendation
Remark/Action
As Propane
Dilution System
will be away from
Propane storage
one more DG
should be
provided for
backup power in
Dilution area.-R-6
Mr .Arindam
Panigrahi
Page 18 of 25
KALINGANAGAR
EQMS INDIA
PRIVATE
LIMITED
HAZOP WORK SHEET
TATA STEEL LTD

DILUTION SYSTEM
G/P&I/6855/2013
Node:
303
P&ID
No.
Design
Intent
To Dilute Propane
Deviation
Cause
Consequence
Safeguard
More Flow
PCV 101,102
malfunction the ratio
Chances of
explosive mixture
SSV 101,102(6
nos for 3 Mixers)
Provided with
PCV
102(propane)
being controlled
by PCV 101(Air)
(Propane/Ai
r)
Reverse
Flow
Not Possible
Recommendation
Remark/Action
NRV is Provided
NRV-101 & 102
(Propane/Ai
r)
Higher
Pressure
Covered in more flow
Page 19 of 25
HAZOP WORK SHEET
TATA STEEL LTD

KALINGANAGAR

DILUTION SYSTEM
Node:
303
To Dilute Propane
Deviation
Cause
Lower
Pressure
Covered in No/Less
Flow
Higher
Temperatur
e
External Fire
Hot Supply from
Vaporiser
(Propane)
Lower
Temperatur
e
P&ID No.
Design
Intent
EQMS INDIA
PRIVATE
LIMITED
G/P&I/6855/2013
Consequence
Safeguard
Fire/Explosion
Fire Fighting
System
Recommendation
Remark/Action
Interlocks in
Vaporizer V1,2,3
provided
Considered in
leakage(below)
(Propane)
Page 20 of 25
HAZOP WORK SHEET
TATA STEEL LTD

DILUTION SYSTEM
KALINGANAGAR
Node:
303
EQMS INDIA
PRIVATE
LIMITED
G/P&I/6855/2013
P&ID No.
Design
Intent
To Dilute Propane
Deviation
Cause
Higher
Level
NA
Lower
Level
NA
Impurity/
Contamina
nt
Dust
Consequence
Safeguard
Recommendation
Improper mixture
Filter ProvidedTIF-1
Bypass line to be
Provided for the
Filter
Remark/Action
(R-4)
Other
material
NA
Utility
Failure
Power failure (Covered

Above)
Calorimeter will not

work
No
Battery backup
may be provided
for Dilution
system (R-7).
Page 21 of 25
EQMS INDIA
PRIVATE
LIMITED
HAZOP WORK SHEET
TATA STEEL LTD

DILUTION SYSTEM
KALINGANAGAR
G/P&I/6855/2013
Node:
303
P&ID
No.
Design
Intent
To Dilute Propane
Deviation
Cause
Sampling
NA
Maintenanc
e
Consequence
Safeguard
Recommendation
Remark/Action
Proper Isolation,
N2-purging &
Permit System
Should be
included S OP
Page 22 of 25
HAZOP WORK SHEET
TATA STEEL LTD

KALINGANAGAR

DILUTION SYSTEM
Node:
303
P&ID No.
Design
Intent
EQMS INDIA
PRIVATE
LIMITED
G/P&I/6855/2013
To Dilute Propane
Deviation
Cause
Consequence
Safeguard
Recommendation
Remark/Action
Loss of
containme
nt/ Leakage
Propane Pipe line

failure/ Flange or
Gasket Failure
Fire/Explosion
Leak detector
and Firefighting
System Provided
During any
leakage in the
field, in the
Propane Dilution
area for taking
immediate
action , One/ or
two CCTV camera
may be provided
in the field, so
that any leakage
in the system is
immediately
noticed by the
Control Room
official and proper
action can be
taken without
delay.
Proper SOP to
be made to
attend leakage/
Emergency
Handling
Fall in temperature
in Pipeline
Toxic release
Methyl Mercaptan pipe

line failure.
Gas masks and

Analyzer
Page 23 of 25
KALINGANAGAR
EQMS INDIA
PRIVATE
LIMITED
HAZOP WORK SHEET
TATA STEEL LTD

DILUTION SYSTEM
G/P&I/6855/2013
Node:
303
P&ID
No.
Design
Intent
To Dilute Propane
Deviation
Cause
Consequence
HSE/
ergonomic
issues
Methyl Mercaptan
Toxic release
Regulatory
issues
None
Start-up
Shut-down
Safeguard
Recommendation
Remark/Action
Methyl Mercaptan
Gas masks and
Portable Analyzer atmospheric
concentration
meter may be
provided near
working area for
continuous
monitoring..(R-9)
Proper SOP is to
be made for
attending Start
Up & Shutdown
of Propane
system
Page 24 of 25
TATA STEEL LTD

KALINGANAGAR
HAZOP WORK SHEET

DILUTION SYSTEM
EQMS INDIA
PRIVATE
LIMITED
Page 25 of 25

Annexure - 1 - Propane - Hazop Worksheet

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TATA STEEL LIMITED - KALINGANAGAR

HAZOP STUDY FOR

HAZOP WORK SHEETS

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

TATA STEEL LTD

HAZOP WORK SHEET

PROPANE STORAGE & PROPANE

Propane Storage System

HAZOP WORK SHEET

TATA STEEL LTD

PROPANE STORAGE & PROPANE

ROAD TANKER TO PROPANE STORAGES

SUPPLY OF PROPANE TO CONSUMER

PROPANE DILUTION SYSTEM

HAZOP WORK SHEET

TATA STEEL LTD

PROPANE STORAGE & PROPANE

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

Propane Storage System

Compressor C01/02/03 Malfunction

Low filling rate in

ROV-1 Stuck Close

HAZOP WORK SHEET

TATA STEEL LTD

PROPANE STORAGE & PROPANE

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

Propane Storage System

Line ,Tanker and

HAZOP WORK SHEET

TATA STEEL LTD

PROPANE STORAGE & PROPANE

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

Propane Storage System

Covered in Less flow

HAZOP WORK SHEET

TATA STEEL LTD

PROPANE STORAGE & PROPANE

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

Propane Storage System

Fire and Explosion

PRV-01 and PG01,12,13,14

HAZOP WORK SHEET

TATA STEEL LTD

PROPANE STORAGE & PROPANE

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

Propane Storage System

Transfer not stopped

HAZOP WORK SHEET

TATA STEEL LTD

All ROV and SV

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

Propane Storage System

PROPANE STORAGE & PROPANE

HAZOP WORK SHEET

TATA STEEL LTD

PROPANE STORAGE & PROPANE

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

Propane Storage System

HAZOP WORK SHEET

TATA STEEL LTD

PROPANE STORAGE & PROPANE

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

Propane Storage System