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HAZID STUDY REPORT
SARASWATI OIL FIELD DEVELOPMENT – PHASE 2
CONTENTS
1. INTRODUCTION ..............................................................................................................................1.1
6. STUDY RECOMMENDATIONS......................................................................................................6.1
Annexure – I: HAZID Record Sheet
Annexure – II: Marked-Up Plot Plan
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HAZID STUDY REPORT
SARASWATI OIL FIELD DEVELOPMENT – PHASE 2
1. INTRODUCTION
Cairn Energy India Ltd. is the Operator of contract area RJ-ON-90/1 in the state of Rajasthan,
India. The current operations in Rajasthan are focused on production from the largest Oil field
Mangala, Raageshwari Deep Gas & Bhagyam fields. The other fields in operation are RAAG Oil
& Saraswati.
The oil from Mangala field is processed in an onshore oil and gas processing facility known as
Mangala Processing Terminal (MPT). This is located about 25 kms from Barmer in Barmer
district, in the state of Rajasthan.
Cairn Energy India Pty Limited (CEIL) is exploring the possibility of developing Saraswati oil
field which is a marginal field development. CEIL intents to produce the wells that are currently
available for development in phased development. As part of Phase-2, standalone production
facilities are planned in Oil well Pad 1.
Petro6 has carried out ‘Engineering of Saraswati Oil Field Development Project – Phase 2.
Being a responsible organization CEIL wish to ensure that they have identified the hazards
associated with proposed modifications. They have therefore commissioned IRCA to facilitate a
HAZID study of Engineering of Saraswati Oil Field Development Project – Phase 2.
This document presents IRCA's report on the HAZID study.
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HAZID STUDY REPORT
SARASWATI OIL FIELD DEVELOPMENT – PHASE 2
Abbreviation
HAZOP Hazard and Operability
HAZID Hazard Identification
QRA Quantitative Risk Assessment
FERA Fire & Explosion Risk Analysis
EERA Escape & Evacuation Risk Analysis
BFPD Barrel Fluid Per Day
HP High Pressure
LP Low Pressure
Max. Maximum
Min. Minimum
SCFD Standard cubic feet per day
WP Well pad
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HAZID STUDY REPORT
SARASWATI OIL FIELD DEVELOPMENT – PHASE 2
2. FACILITY DESCRIPTION
2.4 Separator
Three phase horizontal vessel that separates the pre-heated well fluids in to gas, oil and water.
Residence of 10 min for water and 10 min for oil is provided for separation. The vessel contains
all necessary internals and control devices for efficient separation and continuous uninterrupted
operation. The degassed oil will flow to the Export Oil Storage Vessel under liquid level control
and produced water will flow to the PW Degasser under liquid level control for further
stabilization. Also the evolved gas from the separator will be routed to the Fuel Gas system
under pressure control.
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HAZID STUDY REPORT
SARASWATI OIL FIELD DEVELOPMENT – PHASE 2
Block Diagram
2.8 Utilities
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HAZID STUDY REPORT
SARASWATI OIL FIELD DEVELOPMENT – PHASE 2
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HAZID STUDY REPORT
SARASWATI OIL FIELD DEVELOPMENT – PHASE 2
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HAZID STUDY REPORT
SARASWATI OIL FIELD DEVELOPMENT – PHASE 2
4. STUDY METHODOLOGY
The Hazard Identification (HAZID) process involves the following steps:
Identify Hazards
Develop recommendations
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HAZID STUDY REPORT
SARASWATI OIL FIELD DEVELOPMENT – PHASE 2
Hazards Extract from ISO 17776 Checklist for HAZID/ENVID in oil & gas industry, indicted as
under, is proposed to be used in this HAZID/ENVID study.
The hazards which are applicable in CEIL Rajasthan Field are taken from ISO 17776 checklist.
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HAZID STUDY REPORT
SARASWATI OIL FIELD DEVELOPMENT – PHASE 2
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HAZID STUDY REPORT
SARASWATI OIL FIELD DEVELOPMENT – PHASE 2
Risk Probability
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HAZID STUDY REPORT
SARASWATI OIL FIELD DEVELOPMENT – PHASE 2
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HAZID STUDY REPORT
SARASWATI OIL FIELD DEVELOPMENT – PHASE 2
HAZID Recording:
Two methods of recording of a HAZID study can be employed:
Complete - in which details of all discussion points are noted.
&
By Exception - in which only those deviations that require action are recorded.
Recording of this study is ‘complete recording’ wherein all discussions of significance are to be
recorded using software PHA-PRO from DYADEM of USA for which IRCA is a licensed user.
The discussion from the study is recorded on log sheets. Information is recorded in columns on
the log sheets as follows:
• Hazard Reference
• Top Event
• Threat / Causes
• Consequences
• Risk Matrix
• Safeguards
• Recommendations
• Revised Risk Matrix
• Remarks
HAZID Record sheet are attached as Annexure I. A copy of the Plot plan with Nodes marked up
is attached as Annexure II.
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HAZID STUDY REPORT
SARASWATI OIL FIELD DEVELOPMENT – PHASE 2
5. PROJECT TEAM
The HAZID sessions were conducted at Petro6 Office in Chennai and involved following team
members:
Scan copy of attendance sheet is as under:
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HAZID STUDY REPORT
SARASWATI OIL FIELD DEVELOPMENT – PHASE 2
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HAZID STUDY REPORT
SARASWATI OIL FIELD DEVELOPMENT – PHASE 2
6. STUDY RECOMMENDATIONS
The Preventive & Mitigation Measures expected to be in place, as emerged from this HAZID
study are listed as under. For details on causes and consequences reference is invited to HAZID
Record Sheets placed at Annexure-I.
1. In case PT/TT tapping is required to monitor the parameters during flowing condition, it
shall be located downstream of wing SSV.
2. Ensure shutdown is actuated from hardwired push button from a control room.
3. Ensure gas detectors location is with reference to density of gas (heavier than air).
4. Verify through dispersion analysis, the adequacy of separation distance from process area to
Control room.
5. Ensure proper slop for the flooring in loading bay leading to a sump.
6. Oil spill kits to be provided.
7. SOP for tanker loading.
8. Ensure provision of fall arrestor designed to applicable codes / standard.
9. Optimize the location of loading bay with reference to turning radius required by heavy
vehicles
10. Ensure LPG cylinder for black start is removed from plant area after start-up operation.
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Annexure – I
HAZID Record Sheets
0
Node: 1. Sarasvati Oil Field Development - Phase 2
Plot Plan: [SARAS-PD-1000] Rev-B
Revised
Top Events Threats / Risk Matrix Safeguards
Ref. No. Hazard Description Consequences Recommendations Risk
(Activities) Causes
L S R Preventive Mitigating L S R
H-01 Hydrocarbons
H-01.01 Crude oil under pressure / Formation well Leakage from X- Blowout X-mas tree is 1. In case PT/TT tapping
Hydrocarbons in fluid leakage mas tree valve / for rated is required to monitor
formation flanges / pressure the parameters during
instrument flowing condition, it
tapings etc. Periodic shall be located
2 5 5 testing of X- downstream of wing 1 5 10
mas tree SSV.
Minimum
instrument
tapings
H-01.02 Hydrocarbon under Well fluid release Leakage from Oil spillage, potential QA QC Process 2. Ensure shutdown is
pressure - Topside valve / flanges / of fire procedure, shutdown actuated from
Facilities piping / SOPs, PM from control hardwired push button
instrument 3 4 7 room is from a control room. 2 2 19
tapings etc. possible, Fire
fighting
system,
H-01.03 Hydrocarbon under NA
pressure - Liquid pipeline
H-01.04 Condensate, NGL Condensate leak Leakage from Potential fire / QA QC Process
valve / flanges / explosion procedure, shutdown
piping / SOPs, PM from control
instrument 2 4 11 room is 1 2 21
tapings / pump All junction possible, Fire
seal etc. boxes are for fighting
classified area system
H-01.05 Hydrocarbon gas Gas release Leakage from Potential fire QA QC Process 3. Ensure gas detectors
valve / flanges / procedure, shutdown location is with
piping / SOPs, PM from control reference to density of
instrument room is gas (heavier than air).
tappings etc. possible, Fire
3 4 7 All junction fighting 4. Verify through 2 2 19
boxes are for system dispersion analysis,
classified area the adequacy of
separation distance
from process area to
Control room.
1|Page
Node: 1. Sarasvati Oil Field Development - Phase 2
Plot Plan: [SARAS-PD-1000] Rev-B
Revised
Top Events Threats / Risk Matrix Safeguards
Ref. No. Hazard Description Consequences Recommendations Risk
(Activities) Causes
L S R Preventive Mitigating L S R
H-01.06 Crude oil at low pressure Crude oil Leakage from Oil spillage, potential QA QC Common
leakage export tank / fire procedure, dyke,
valve / flanges / SOPs, PM Fire fighting
piping / 3 4 7 system 2 2 19
instrument
tapings / pump
seal etc.
Leakage of Tank Overfill, Oil spillage, potential QA QC Manned 5. Ensure proper slop for
Crude oil in tank damage, fire procedure operation, the flooring in loading
Loading Bay Leakage from start-stop bay leading to a
loading arm switch for sump.
pump
provided at 6. Oil spill kits to be
loading bay, provided.
fire ring main 7. SOP for tanker
coverage for loading.
3 4 7 loading area 2 2 19
8. Ensure provision of fall
arrestor designed to
applicable codes /
standard.
9. Optimize the location
of loading bay with
reference to turning
radius required by
heavy vehicles
H-02 Refined Hydrocarbons
H-02.01 Lube and seal oil No significant
issue
H-02.02 Leakage of Diesel Diesel leak Leakage from Diesel spillage, QA QC Containment
tank / piping etc. potential fire 3 4 7 procedure, is provided 2 2 19
SOPs, PM
H-03 Other Flammable Materials
H-03.01 Cellulosic materials Fire in control Electric fire Asset damage PM Fire
room extinguisher
2 3 14 2 2 19
2|Page
Node: 1. Sarasvati Oil Field Development - Phase 2
Plot Plan: [SARAS-PD-1000] Rev-B
Revised
Top Events Threats / Risk Matrix Safeguards
Ref. No. Hazard Description Consequences Recommendations Risk
(Activities) Causes
L S R Preventive Mitigating L S R
H-04 Pressure Hazards
H-04.01 Air / gases under Leakage of LPG Leakage from Potential fire QA QC Fire fighting 10. Ensure LPG cylinder
pressure valve / piping / procedure, system for black start is
tubing etc. 2 3 14 SOPs, PM removed from plant 1 2 21
area after start-up
operation.
H-04.02 Liquid under pressure NA
H-04.03 Non hydrocarbon gas NA
under pressure in pipe
works
H-04.04 Air under high pressure Instrument Air Tubing / piping Potential unwanted QA QC
release failure shutdown 2 3 14 procedure, 1 2 21
SOPs, PM
H-05 Hazards Associated with Differences in Height
H-05.01 Personnel at height > Fall from height Slip trip fall Personnel injury Working First Aid box 11. Existing Saraswati IRP
1.8m (Separator PSV platform & at the location is to be updated with
platform, Export handrails reference to Saraswati
Tank, Tanker provided, Phase 2.
Loading SOPs
operations) 2 3 14 1 2 21
Suitable fall
protection
system for
tanker loading
operation.
H-05.02 Dropped Object No significant
issue
H-05.03 Personnel below grade Maintenance Confined space - Personnel injury PTW for First Aid box 12. Ensure proper
(PIT) work on flare lack of adequate confined at the location staircase with single
KOD pump / breathing air space entry fleet.
export oil pump
2 3 14 1 2 21
3|Page
Node: 1. Sarasvati Oil Field Development - Phase 2
Plot Plan: [SARAS-PD-1000] Rev-B
Revised
Top Events Threats / Risk Matrix Safeguards
Ref. No. Hazard Description Consequences Recommendations Risk
(Activities) Causes
L S R Preventive Mitigating L S R
H-06 Dynamic Situation Hazards
H-06.01 Equipment with moving or Contact with Inadequate Personnel injury All rotating
rotating parts moving parts protection machine have
protective
Tanker safeguards
movement on 3 3 13 2 1 24
well pad Approve route
plan for tanker
operations.
SOP in place
H-06.02 Use of hazardous hand Electrocution, Inadequate tools Personnel injury / fire PTW and pre-
3 3 13 1 1 25
tools spark generation use inspection
H-07 Environmental Hazards
H-07.01 Sand storm Sand storm Unfavorable Difficulty in people 13. Establish a written
weather movement and 3 4 7 procedure for action in 3 1 23
operation case of sand storm.
H-07.02 Flood Flood Unfavorable Potential personnel ERP & DMP
weather injury, malfunction for flood is in
3 4 7 3 1 23
instrumentation / place
equipments
H-07.03 High ambient temperature Heat stroke Exposure to high Personnel injury Action plan for
temperature high ambient
3 3 13 2 2 19
temperature is
in place
H-08 Hot Surfaces
H-08.01 Process piping equipment Hot surface People working Potential personnel First Aid box 14. Ensure All piping
(55-150°C) around process burn injury at the location (including flare lines)
piping where temperature is
3 3 13 1 2 21
>55°C is to be covered
by insulation / physical
barrier.
H-08.02 Engine exhaust systems Hot fumes People working Potential personnel 15. Ensure Exhaust height
nearby injury 3 3 13 is 9 meters (as per 1 2 21
applicable code).
H-09 Electricity
H-09.01 Voltage > 50V Electrocution, Improper Personnel injury / fire ELCBs &
spark generation insulation, not 3 3 13 LOTO 1 3 16
following SOPs
4|Page
Node: 1. Sarasvati Oil Field Development - Phase 2
Plot Plan: [SARAS-PD-1000] Rev-B
Revised
Top Events Threats / Risk Matrix Safeguards
Ref. No. Hazard Description Consequences Recommendations Risk
(Activities) Causes
L S R Preventive Mitigating L S R
H-09.01 Electrostatic energy Oil transfer from Flammable Potential explosion Dual earthing 16. For loading area,
Storage Tanks mixture inside inside the tanks for storage static / grounding
the tanks and tanks and PM indicator is to be
electrostatic schedule for provided.
energy causing checking the
source of ignition 3 4 7 earthing 17. Explore the possibility 1 3 16
of providing fuel gas
blanketing on export
oil storage tank to
minimize the chance
of air ingress.
H-10 Physical
H-10.01 Noise No significant
issue
(Permissible
noise level are
covered in
equipment data
sheet)
H-10.02 Vibration No significant
issue
(Permissible
vibration level
are covered in
equipment data
sheet)
H-10.03 Humidity No significant
issue
H-11 Asphyxiating Atmosphere
H-11.01 Oxygen concentration in Vessel entry Unfavorable Potential personnel PTW for
air (imbalance) ambient injury confined
2 3 14 1 3 16
condition space entry
5|Page
Node: 1. Sarasvati Oil Field Development - Phase 2
Plot Plan: [SARAS-PD-1000] Rev-B
Revised
Top Events Threats / Risk Matrix Safeguards
Ref. No. Hazard Description Consequences Recommendations Risk
(Activities) Causes
L S R Preventive Mitigating L S R
H-12.02 Waste Disposal of Un-segregated Environmental issue Waste
waste waste management
3 3 13 1 2 21
system in
place
H-13 Chemicals
H-13.01 Various Chemicals Leakage from de-emulsifier & Chemical Spillage MSDS in place 18. Suitable containment
chemical skid Corrosion to be ensured with the
Inhibitors flange/ 3 3 13 skid. 1 2 21
piping/ valve
failure
6|Page
Annexure – II
Marked-Up Plot Plan
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Node: 01