DSR Book Vol 2 2016 (English Version) Final

HAZARD AND OPERABILITY STUDY FOR
VIZAG-SECUNDERABAD LPG PIPELINE

(VSPL)
For
GAIL (INDIA) LIMITED

VISAKHAPATNAM (A.P), INDIA
Prepared By
(Consultancy Division of)

BELL ENGINEERING SOFTWARE TECHNOLOGISTS LTD
PUNE, INDIA
Project No. BEST/ IND / CON / 1380 GAIL Vizag/ ORD 15-16 / 002- 01
GAIL (INDIA)LIMITED
Visakhapatnam (A.P)
HAZOP for Vizag-Secunderabad LPG Pipeline-VSPL
BEST/ IND / CON / 1380 GAIL Issue: Final Rev. C
Vizag / ORD 15-16 / 002- 01 Date : 19-02-16
PROJECT:
HAZOP for Vizag-
Secunderabad
Pipeline-VSPL
COMPANY:
HAZOP Study for
GAIL (INDIA)
Vizag-Secunderabad Pipeline-VSPL of LIMITED
GAIL (INDIA)LIMITED,VISAKHAPATNAM (A.P) VISAKHAPATNAM
(A.P)
CONSULTANT:
Unit :
BELL ENGINEERING
Vizag-Secunderabad Pipeline
SOFTWARE
TECHNOLOGISTS
LIMITED
Prepared By:
Mr. Anwar P. Shaikh REPORT:
HAZOP REPORT No.
BEST/ IND / CON /
1380 GAIL Vizag /
Reviewed By: ORD 15-16 / 002- 01
Mr. Mallikarjun Malgatte
Approved By: © 2008 Bell Engineering

Software Technologists
Mr. C.G.Kulkarni Ltd., Pune, India
This document is the

property of Bell. It shall
not be reproduced in
whole or in part, nor
disclosed to a third party,
without the written
permission of concerned
parties.
Page 2 of 28
GAIL (INDIA)LIMITED
Visakhapatnam (A.P)
Vizag / ORD 15-16 / 002- 01 Date : 19-02-16
Disclaimer
Bell Engineering Software Technologists Ltd completed this document on the basis of a defined
program of work and terms and conditions agreed with the CLIENT. We confirm that in preparing
this document, we have exercised all reasonable skill and care, taking into account the project
objectives, the agreed scope of work, prevailing site conditions and the degree of manpower and
resources allocated to the project.
Bell Engineering Software Technologists Ltd or any of its subsidiaries / group companies accepts
no responsibility to any parties whatsoever, following the issue of the document, for any matters
arising outside the agreed scope of the work.
This document is issued in confidence to the CLIENT and Bell Engineering Software
Technologists Ltd and has no responsibility to any third parties to whom this document may be
circulated, in part or in full, and any such parties that rely on the contents of the report solely at
their own risk.
GAIL reserves the right to make reference, reproduce and circulate in part or in full; solely at their
own risk. Unless specifically assigned or transferred within the terms of the agreement, Bell
Engineering Software Technologists Ltd asserts and retains all Copyright, and other Intellectual
Property Rights, in and over the Report and its contents.
Any questions or matters arising from this Report should be addressed in the first instance to the
Project Manager.
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GAIL (INDIA)LIMITED
Visakhapatnam (A.P)
Vizag / ORD 15-16 / 002- 01 Date : 19-02-16
CONTENTS
1 EXECUTIVE SUMMARY...........................................................................................4
1.1 Preamble 4
1.2 HAZOP Objective 4
1.3 HAZOP Session 4
1.4 Recommendations 5
1.5 INTRODUCTION 8
1.6 Project Overview 8
1.7 Objectives 9
1.8 Scope 9
1.9 Project Team 10
2 HAZOP METHODOLOGY.......................................................................................11
2.1 Overview 11
2.2 Methodology 11
2.2.1 Document Review .................................................................................... 11
2.2.2 HAZOP Worksheet ................................................................................... 13
3 HAZOP WORKSHOP .............................................................................................15
3.1 Hazop Nodes 16
3.2 Hazop Worksheet 17
4 REFERENCES ......................................................................................................18
APPENDICES
Appendix A HAZOP Worksheets
Appendix B Abbreviations
Appendix C Node Marked-Up P&IDs
Appendix D Attendance Sheet
LIST OF TABLES
Table 1 – HAZOP Nodes ....................................................................................................... 4
Table 2 – Units in Scope of Work ......................................................................................... 10
Table 3 - HAZOP Team Members ........................................................................................ 10
Table 4 – List of HAZOP team member present for Cherlapalli, Vizag & G Konduru respectively
.................................................................................................................................. 15
Table 5 - HAZOP Nodes..................................................................................................... 16
LIST OF FIGURES
Figure 2-1 HAZOP Methodology Schematic........................................................... 13
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GAIL (INDIA)LIMITED
Visakhapatnam (A.P)
Vizag / ORD 15-16 / 002- 01 Date : 19-02-16
1 EXECUTIVE SUMMARY
1.1 Preamble
GAIL (India) Limited laid approximately 577.9 km long pipeline from Vizag to
Secunderabad for the purpose of transmission of LPG and this pipeline is called Vizag
– Secunderabad LPG Pipeline or VSPL. The pipeline system is designed for a normal
throughput of 1.164 MMTPA and maximum throughput of 1.33 MMTPA with design
pressure of 98 kg/cm².
1.2 HAZOP Objective

a) Intention – The intention defines how the facility under study is expected to operate.
b) Deviation – These are departure from the intention which is discovered by
systematically applying the guide words.
c) Cause – These are the reasons for which deviations might occur.
d) Consequence – These are the results of the deviation should they occur.
e) Safeguard – These are the protections provided and operating instruction or design
review requirement for smooth operation of the system.
f) Recommendation – These are hardware and software changes required for
protecting and smooth operating of the system.
1.3 HAZOP Session

Hazop worksheets were presented and discussed with the team comprising of GAIL
engineers/managers listed here below with respective dates.
Table 1 – HAZOP Nodes represents the nodes which were identified and were discussed in the
HAZOP workshop:
Table 1 – HAZOP Nodes
Node No Node Description

Node: 1 LPG supply from GAIL terminal at HPCL Refinery
Node: 2 LPG hook up from outer Harbor storage facilities
Node: 3 LPG supply from EIPL facility
Node: 4 HPCL feed booster pumps 10-PA-CF-101 A/B operation at Vizag Exim park
EIPL feed booster pump 10-PA-CF-103A/B operation and filtration in basket
Node: 5
filter 10-GN-BK-103 A/B
Node: 6 Booster pump discharge to Main line pump suction at Vizag DT
LPG feed from cavern source filtration at Vizag DT in Basket filter 10-GN-BK-
Node: 7
00-102 A/B
LPG Main line Pumps operation at DT Vizag 10-PA-CF-102 A/B/C to feed to
Node: 8
LPG main line.
Node: 9 Flare system at DT Vizag
Node:10 Diesel storage in 10-TT-CR-102 A/B and usage
Node:11 Intermediate pigging station -1(IP-1) Rajahmundry
Node:12 LPG Supply to HPCL Bottling plant Veeralankapalli
Node:13 Booster Pump operation 30-P-0101 A/B at G Konduru
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GAIL (INDIA)LIMITED
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Vizag / ORD 15-16 / 002- 01 Date : 19-02-16

Node 14: LPG supply to HPCL receiving Terminal (TOT/Booster Station, G Konduru)
Node 15: LPG supply to HPCL Receiving Terminal, Kondapalli
Node 16: LPG supply to IOCL Receiving Terminal (TOT/Booster Station, G Konduru)
Node 17: LPG supply to IOCL Receiving Terminal, Kondapalli
Node 18: LPG supply to BPCL Receiving Terminal from IOCL tapping
Node 19: LPG transfer from G-Konduru to Cherlapalli RT
Node 20: LPG supply to HPCL bottling plant from Cherlapalli RT
Node 21: LPG supply to BPCL bottling plant from Cherlapalli RT
Node 22: LPG Supply to IOCL from Cherlapalli RT
Node 23: Fire Hydrant System- Cherlapalli
Pigging Operation
Node 24: Cavern Feeder Line scrapping from HPCL old bottling plant to Vizag DT
Node 25: Main Line scrapping From Vizag to Rajahmundry
Node 26: Main Line scrapping from Rajahmundry to G Konduru
Node 27: Spur Line scrapping from G. Konduru to HPCL Bottling plant
Node 28: Spur Line scrapping from G. Konduru to IOCL Bottling plant
Node 29: Main Line scrapping from G. Konduru to Suryapet
Node 30: Main Line scrapping from Suryapet to Cherlapalli
1.4 Recommendations
Node : 02 LPG hook up from outer Harbor storage facilities
1.1.1.1 P&ID-1128 to be updated
Node : 05 EIPL feed booster pump 10-PA-CF-103A/B operation and filtration in basket filter 10-
GN-BK-103 A/B
1.1.1.1 Gas Detector Adequacy to be checked
Node : 08 LPG Main line Pumps operation at DT Vizag 10-PA-CF-102 A/B/C to feed to LPG main
line
1.1.1.1 Stand by pumps MOV should be closed during normal operation
Node : 09 Flare system at DT Vizag
1.1.1.1 P&ID 5329 to be updated
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GAIL (INDIA)LIMITED
Visakhapatnam (A.P)
Vizag / ORD 15-16 / 002- 01 Date : 19-02-16
Node : 10 Diesel storage in 10-TT-CR-102 A/B and usage
1.1.1.1 LI/LG to be provided to diesel storage tank

1.1.1.2 Adequate lights in diesel yard, road to be provided specially keeping in
view of statutory requirement of putting high mast off on Tuesday and
Thursday
Node : 17 LPG supply to IOCL Receiving Terminal, Kondapalli
1.1.1.1 P&ID to be updated for cause & effect ( 1.1.2 PSHH 1501 actually it is
PSHH 1502 ), reducer's standard symbols to be used
Node : 19 LPG transfer from G-Konduru to Cherlapalli RT
1.1.1.1 PG, PT to be provided to the basket filters.
Node : 23 Fire Hydrant System- Cherlapalli
1.1.1.1 P & ID to be updated for PT, TSV
PIGGING OPERATION
Node : 24 Cavern Feeder Line scrapping from HPCL old bottling plant to Vizag DT
1.1.1.1 Provide PG and drain points at appropriate location to depressurize the scraper

receiver and launcher
1.1.1.2 Provide positive isolation system for scraper receiver and launcher
Node: 25 Main Line scrapping From Vizag to Rajahmundry
1.1.1.1 Provide PG and drain points at appropriate location to depressurize the
scraper receiver and launcher

Node :26 Main Line scrapping from Rajahmundry to G Konduru
Node 27: Spur Line scrapping from G. Konduru to HPCL Bottling plant
Node 28: Spur Line scrapping from G. Konduru to IOCL Bottling plant
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GAIL (INDIA)LIMITED
Visakhapatnam (A.P)
Vizag / ORD 15-16 / 002- 01 Date : 19-02-16
Node 29: Main Line scrapping from G. Konduru to Suryapet

Node 30: Main Line scrapping from Suryapet to Cherlapalli


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GAIL (INDIA)LIMITED
Visakhapatnam (A.P)
Vizag / ORD 15-16 / 002- 01 Date : 19-02-16
ISSUE RECORD
ISSUE DATE REVISION HISTORY
Final 19th February 2016 Final Report
DISTRIBUTION
1. Mr. L.S. Rao – GAIL Vizag.

2. Dr. S. Ramesh– GAIL Vizag.
3. Mr. A. W. Kurhekar – GAIL Cherlapalli.
4. Mr. Pravin Kshirsagar – GAIL G Konduru
1.5 INTRODUCTION
1.6 Project Overview
The entire Vizag Secunderabad LPG Pipeline (VSPL) with an approximate length of
578km is considered as a single system consisting of 3 base stations namely Vizag
(Despatch Terminal), Booster pumping & Pigging Station at G. Konduru (Vijayawada-
TOT) and Cherlapalli (Secunderabad Receiving Terminal). VSPL is equipped with
intermediate pigging stations at Rajahmundry(IP-1) and Suryapet(IP-2) whereas 37
numbers of sectionalizing valve stations are provided on the pipeline, out of which SV-
2, 4, 6, 8, 9, 10, 12, 13, 14, 15, 17, 19, 20, 22, 23, 25, 26, 27, 29, 30, 32, 33, 35 & 36
are provided with remote operated valves and SV-1, 3, 5, 7, 11, 16, 18, 21, 24, 28, 31,
34& 37 are manually operated.
The pipeline system is designed for a normal throughput of 1.164 MMTPA and
maximum throughput of 1.33 MMTPA at a design pressure of 98 kg/cm².
Vizag Despatch terminal is the major coordination centre and master control station for
entire VSPL. However, ROV’s can be operated from other stations i.e. G Konduru and
Cherlapalli also.
LPG is received at Vizag Despatch Terminal from one of the three sources. (1) HPCL’s
Petro-park Terminal, (2) SALPG’s outer harbour storage facility (Cavern) and (3) EIPL’s
storage facility. LPG is delivered to Rajahmundry (HPCL Bottling Plant), Vijayawada
(HPCL, IOCL & BPCL LPG bottling Plants) and Secunderabad (HPCL, IOCL & BPCL
LPG bottling Plants) from the respective receipt/tap-off terminals.
Feeder Sources:
There are 3 feeder sources.(1) HPCL’s Petro park Terminal, (2) SALPG’s outer harbor
storage facility (Cavern) and (3) EIPL’s storage facility.
1. HPCL Petro park terminal: This pipeline extends from HPCL Petro park
terminal to Exim Park (around 5.3 km length). Pipeline is having 12” nominal
bore and MOC is CS. The pipeline is designed for a pressure of 25 kg/cm².
2. EIPL Storage Terminal: This pipeline extends from EIPL Storage terminal to
Exim Park (around 5.0 km length). Pipeline is having 12” nominal bore and
MOC is CS. The pipeline is designed for a pressure of 25 kg/cm².
3. SALPG Outer Harbor (Cavern) Storage facility: This pipeline extends from
SALPG Outer Harbor (Cavern) Storage facility to Exim Park (around 8.0 km
length). Pipeline is having 12” nominal bore and MOC is CS. The pipeline is
designed for a pressure of 49 kg/cm²
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GAIL (INDIA)LIMITED
Visakhapatnam (A.P)
Vizag / ORD 15-16 / 002- 01 Date : 19-02-16
Vizag Despatch Terminal: There are 04 numbers of Booster Pumps and 03 mainline
pumps for boosting up the pressure received from the feeder sources and supplied to
the VSPL main pipeline. The major equipment in the terminal include basket filters,
mass flow meters, booster and mainline pumps, Scraper receiver and launchers, PLC,
SCADA system, etc. The operating discharge flow with a single mainline pump is 100
MTPH and with dual pumps is 165 MTPH.
Rajahmundry (IP-01) &Suryapet (IP-02) Intermediate Pigging Stations: In addition

to the main maintenance bases, PIG launching & receiving facilities are provided in
Rajahmundry IPS which is 176.4 km from Vizag and Suryapet IPS which is 112.2 km
from G Konduru.
Rajahmundry HPCL Receiving Terminal: This is located 3.2 km from the
Rajahmundry IP-01 and connected with HPCL LPG Bottling plant. This line is of 4”
common bore diameter from the tapping point at Rajahmundry IPS. The operating flow
is 15-25 MTPH.
G Konduru Booster pumping and Tap off Terminal: This is located 176.6 km from
the Rajahmundry IP-01 and connected with HPCL, IOCL and BPCL LPG bottling
plants. HPCL and BPCL bottling plants are 6.5 km and 7 km away from Vijayawada
receipt terminal. There are two booster pumps of which one is standby. The booster
pump can deliver a maximum flow of 176 m³/hr. The discharge header of the pipeline
from Vijayawada till Cherlapalli is of 10” common bore diameter.
Cherlapalli Receiving Terminal: This is located 122.5 km from the Suryapet IPS and
has HPCL, IOCL & BPCL Bottling Plants connected which receives LPG. HPCL bottling
plant is 0.7 km, IOCL bottling plant is 2.5 km, and BPCL bottling plant is 2.5 km from
the Secunderabad Receipt terminal. All the pipelines going to the bottling plants are of
6” nominal bore and the MOC is CS. The pipeline is designed for a pressure of 98
kg/cm².
1.7 Objectives
The objectives of the HAZOP are to achieve the following:
a) Intention – The intention define how the facility under study is expected to operate.
b) Deviation – These are departure from the intention which is discovered by
systematically applying the guide words.
c) Cause – These are the reasons for which deviations might occur.
d) Consequence – These are the results of the deviation should they occur.
e) Safeguard – These are the protections provided and operating instruction or design
review requirement for smooth operation of the system.
f) Recommendation – These are hardware and software changes required for
protecting and smooth operating of the system.
1.8 Scope
This HAZOP study has been conducted for Vizag, G-Konduru, Cherlapalli Regions pipelines & its
associated facilities. The list of these facilities is as given below.
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Vizag / ORD 15-16 / 002- 01 Date : 19-02-16
Table 2 – Units in Scope of Work
Unit No. Unit Name

1. Vizag DT
2. GAIL Terminal: HPCL’s old bottling plant
3. GAIL Terminal: EIPL Storage
4. IP-1
5. G Konduru Booster Station
6. G Konduru - IOCL RT Station
7. G Konduru - BPCL RT Station
8. G Konduru - HPCL RT Station
9. IP-2
10. Cherlapalli RT
11. Cherlapalli - GAIL RT & HPCL
12. Cherlapalli - Receiving Terminal-IOCL
13. Cherlapalli - Receiving Terminal-BPCL
14. Cherlapalli- Fire Water Storage Tanks
1.9 Project Team

Table 3 - HAZOP Team Members lists, the team members who were involved in preparation,
review and quality control of this HAZOP study report
Table 3 - HAZOP Team Members
Sr.No. Name Organization

1. Mr. C.G. Kulkarni Bell Engineering Software Technologists Ltd
2. Mr. M.A. Mujawar Bell Engineering Software Technologists Ltd
3. Mr. Anwar Shaikh Bell Engineering Software Technologists Ltd
4. Mr. Mallikarjun Malgatte Bell Engineering Software Technologists Ltd
5. Mr. Pratap Narayan Bell Engineering Software Technologists Ltd
6. Mr. Bipeen Gadhe Bell Engineering Software Technologists Ltd
7. Mr. Prathamesh Pillay Bell Engineering Software Technologists Ltd
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GAIL (INDIA)LIMITED
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Vizag / ORD 15-16 / 002- 01 Date : 19-02-16
2 HAZOP METHODOLOGY
2.1 Overview
This section outlines the methodology adopted for the HAZOP study conducted for the project
2.2 Methodology
Being an existing refinery that too one of the oldest refineries the methodology followed was as
under. The methodology so adopted was from the point of view of benefiting from the vast
experience of operating personnel gained over years of running of refinery on one hand and on
the other hand operating constraints.
Therefore the Hazop methodology considered these aspects by detailed briefing from all the
concerned engineers along with conventional HAZOP methodology which 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
• Identify a section of plant on the P&I diagram.
• Define the design intent and normal operation conditions of the section.
• Identify a deviation from design intent or operating conditions by applying a system of
guidewords.
• 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.
• For a meaningful deviation, decide what action, if any is necessary.
• 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.
In the HAZOP method, the guidewords are systematically applied to a segment of process
equipment in order 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.
2.2.1 Document Review
Before commencement of the HAZOP, the HAZOP Chairman reviewed the project scope and
developed the HAZOP checklist applicable to the project. Document Review is considered an
important part of the HAZOP workshop as it makes the facilitator aware of the various risks
inherent within the activities involved in the project.
Figure 2.1 presents the HAZOP methodology adopted for the study.
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.
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GAIL (INDIA)LIMITED
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Vizag / ORD 15-16 / 002- 01 Date : 19-02-16
The HAZOP study was based on a set of P&I diagrams for the sections to be covered by study.
The following documents were also referred to during the HAZOP sessions:
• Shut down & trip logic.
• Process description.
• Process Flow Diagrams
• Piping and Instrumentation Diagrams
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GAIL (INDIA)LIMITED
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Describe Design
intention, Operating
Conditions etc.
Consider first or next

guideword or deviation
Identify all causes and

record
Identify all
consequences and
Record
Identify all Safeguards

& record
Agree any action &

record
No
Last
guideword
Yes
Take Next Section
Figure 2-1 HAZOP Methodology Schematic

2.2.2 HAZOP Worksheet
The HAZOP worksheet that was discussed during the HAZOP sessions included the following
details:
• Guideword
• Parameter
• Deviation
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GAIL (INDIA)LIMITED
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• Causes
• Consequences
• Safeguards
• Recommendations
• Remarks
Guideword
A guideword provides the team with a starting point to identify issues. Using a comprehensive list
of guideword is important to achieve maximum benefit from the HAZOP study. A HAZOP
checklist shall be used to act as an ad-memoir to identify any hazards that may have been over-
looked during the brainstorming session. For each hazard, the root cause, the consequence, any
safeguards already implemented in the design will be identified.
Parameter
Parameter is an aspect of the process that describes it physically, chemically or in terms of what
is happening.
Deviation
Deviation is defined as unreasonable / undesired change in the parameter. Deviation is formed
by a combination of the parameter and guideword.
Cause
For each hazard, the root cause is determined, such that the appropriate safeguards for the
causal events are determined.
Consequence
In assigning a level of consequence to the hazards, the HAZOP team took into consideration the
following factors:
• The present design status of the safeguards and controls
• Physical and working environment conditions
• Levels of training, experience, skills, education etc of the facilities personnel
Safeguards
The study identified the existing design safeguards for each hazard. The types of safeguards
commonly include:
• Preventive safeguards, which aim to prevent the event cause from occurring
• Detective safeguards, which aim to improve the response time to an event
• Protective safeguards, which aim to protect from the escalation consequences and are
always used regardless of whether the event has occurred
• Mitigation safeguards, which aim to reduce the severity of the escalation consequences
and are activated once the event cause and escalation consequences have occurred.
Actions / Recommendations
Where the associated safeguards are not adequate, further recommendations are proposed.
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Vizag / ORD 15-16 / 002- 01 Date : 19-02-16
3 HAZOP WORKSHOP
Hazop worksheets were presented and discussed with the team comprising of GAIL
engineers/managers listed here below alongwith respective dates.
Table 4 – List of HAZOP team member present for Cherlapalli, Vizag & G Konduru respectively
A. List of HAZOP team members for Vizag
Sr.No. Name Designation Dates

1 Mr. Anwar P. Shaikh Chairman, Bell Engineering 15-16/12/15
2 Mr. Prathamesh Pillay Scribe, Bell Engineering 15-16/12/15
3 Mr. Amit Das DGM (LPG P/L O&M) 16/12/15
4 Mr. L S Rao CM (LPG P/L O&M) 15-16/12/15
5 Dr. Ramesh Sambana Sr. Manager (LPG P/L O&M) 15-16/12/15
6 Mr. A Prasada Rao Sr. Manager (LPG P/L O&M) 15-16/12/15
7 Mr. Moulinath Bhattacharyya Sr. Manager ( F&S) 15-16/12/15
8 Mr. Peri Vasu Sr. Manager (LPG P/L O&M) 15-16/12/15
9 Mr. A. S. Reddy Sr. Manager (LPG P/L O&M) 15-16/12/15
10 Mrs. S. Vijaya Lakshmi Dy. Manager(LPG P/L O&M) 15/12/15
11 Mr. G S Rao Sr. Engineer (LPGP/L O&M) 15-16/12/15
B. List of HAZOP team members for G Konduru

1 Mr. Anwar P. Shaikh Chairman, Bell Engineering 17/12/15
2 Mr. Prathamesh Pillay Scribe, Bell Engineering 17/12/15
3 Mr. Kishor Singhal CM (LPG-P/L O&M) 17/12/15
4 Mr. Ratnaji Rao Sr. Manager, (LPG P/L O&M) 17/12/15
5 Mr. A Suresh Babu Sr. Manager (LPG P/L O&M) 17/12/15
6 Mr. Madhusudan T L Sr. Manager (LPGP/L O&M) 17/12/15
7 Mr. Pravin Kshirsagar Manager (F&S) 17/12/15
8 Mr. V Ravindranath Manager (LPGP/L O&M) 17/12/15
9 Mr. Srinivasulu M Manager (LPGP/L O&M) 17/12/15
10 Mr. V Madhusudan Manager (LPGP/L O&M) 17/12/15
11 Mr. P Raj kumar Singh Dy. Manager (LPGP/L O&M) 17/12/15
12 Mr. K S Ramachandran Dy. Manager (LPG P/L O&M) 17/12/15
13 Mr. Phani Kumar Dy. Manager (LPG P/L O&M) 17/12/15
14 Mr. V Sandeep Sr. Engineer (LPG P/L O&M) 17/12/15
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C. List of HAZOP team members for Cherlapalli

1 Mr. Anwar P. Shaikh Chairman, Bell Engineering 14/12/15
2 Mr. Prathamesh Pillay Scribe, Bell Engineering 14/12/15
3 Mr. A Mujumdar CM (LPG P/L O&M) 14/12/15
4 Mr. R Vasanth Kumar CM (LPG P/L O&M) 14/12/15
5 Mr. PBV Prasad Sr. Manager (LPG P/L O&M) 14/12/15
6 Mr. A. W. Kurhekar Sr. Manager (F&S) 14/12/15
7 Mr. Mohsin Jamal Aiyubi Manager (GAILTEL-TC) 14/12/15
8 Mr. V. Vengal Rao Manager (LPG P/L O&M) 14/12/15
9 Mr. P. Giribabu Manager (LPG P/L O&M) 14/12/15
10 Mr. Mallesh C Manager (LPG P/L O&M) 14/12/15
11 Mr. J. Srinivasa Rao Dy. Manager (LPG P/L O&M) 14/12/15
12 Mrs. G Manasa Dy. Manager (LPG P/L O&M) 14/12/15
13 Mr. R Srinivas Tech. (LPG P/L O&M) 14/12/15
3.1 Hazop Nodes

The following nodes presented in Table 5 were identified and discussed during the HAZOP
workshop:
Table 5 - HAZOP Nodes

Node: 1 LPG supply from GAIL terminal at HPCL Refinery
LPG supply from Outer Harbour/ Cavern Facility to GAIL terminal at HPCL
Node: 2
refinery
Node: 3 LPG supply from EIPL facility
Node 4: HPCL feed booster pumps 10-PA-CF-101 A/B operation at Vizag Exim park
EIPL feed booster pump 10-PA-CF-103A/B operation and filtration in basket
Node 5:
filter 10-GN-BK-103 A/B
Node 6: Booster pump discharge to Main line pump suction at Vizag DT
LPG feed from cavern source filtration at Vizag DT in Basket filter 10-GN-BK-
Node 7:
00-102 A/B
LPG Main line Pumps operation at DT Vizag 10-PA-CF-102 A/B/C to feed to
Node 8:
LPG main line.
Node 9: Flare system at DT Vizag
Node 10: Diesel storage in 10-TT-CR-102 A/B and usage
Node 11: Intermediate pigging station -1(IP-1) Rajahmundry
16
GAIL (INDIA)LIMITED
Visakhapatnam (A.P)
Vizag / ORD 15-16 / 002- 01 Date : 19-02-16

Node 12: LPG Supply to HPCL Bottling plant Veeralankapalli
Node 13: Booster Pump operation 30-P-0101 A/B at G Konduru
Node 14: LPG supply to HPCL receiving Terminal (TOT/Booster Station, G Konduru)
Node 15: LPG supply to HPCL Receiving Terminal, Kondapalli
Node 16: LPG supply to IOCL Receiving Terminal (TOT/Booster Station, G Konduru)
Node 17: LPG supply to IOCL Receiving Terminal, Kondapalli
Node 18: LPG supply to BPCL Receiving Terminal from IOCL tapping
Node 19: LPG transfer from G-Konduru to Cherlapalli RT
Node 20: LPG supply to HPCL bottling plant from Cherlapalli RT
Node 21: LPG supply to BPCL bottling plant from Cherlapalli RT
Node 22: LPG Supply to IOCL from Cherlapalli RT
Node 23: Fire Hydrant System- Cherlapalli
3.2 Hazop Worksheet

The HAZOP worksheets are presented in Appendix A
17
GAIL (INDIA)LIMITED
Visakhapatnam (A.P)
Vizag / ORD 15-16 / 002- 01 Date : 19-02-16
4 REFERENCES
Following Documents were referred for conducting HAZOP proposed for the VSPL-
Pipeline.
PIPING & INSTRUMENTATION DIAGRAMS
SR NO P&ID NO DESCRIPTION REV.NO.
1. 1110 VIZAG DESPATCH TERMINAL AT EXIM PARK 02
4. 1113 RAJAHMUNDRY-INTERMEDIATE PIGGING STATION 03
5. 1118 TYPICAL SECTIONALZING VALVE STATION 03
VIZAG DESPATCH TERMINAL (AT EXIM PARK) 02

7. 1121
DIESEL ENGINE GENERATOR SYSTEM
HOOK UP TERMINAL AT HPCL LPG BOTTLING
8. 1127 01
PLANT AT VIZAG
HOOK UP FOR LPG FROM EXISTING PIPELINE
9. 1128 02
FROM OUTER HARBOUR STORAGE FACILITES
10. 1129 HOOK UP TERMINAL AT EIPL STORAGE AREA 01
11. 1130 ANALYZERS DETAILS 01

STATIONARY METERING PROVING-
12. 1131 02
ARRANGEMENT AT VIZAG
5329-A2- FLARE SYSTEM -

13.
001A
1 - P&ID-VIJAYWADA PUMPING /PIGGING STATION -
P&ID-VIJAYWADA RECIPT TERMINAL & SPURLINE FOR -

2 -
IOCL
- P&ID-VIJAYWADA RECIPT TERMINAL & SPURLINE FOR -

3
BPCL
P&ID-VIJAYWADA RECIPT TERMINAL & SPURLINE FOR -
4 -
HPCL
18
GAIL (INDIA)LIMITED
Visakhapatnam (A.P)
Vizag / ORD 15-16 / 002- 01 Date : 19-02-16
P&ID-SURYAPET-INTERMEDIATE 04
1 1116
PIGGING STATION(IP-2)
P&ID-SECUNDERABAD RT-FOR 07
2 1117
HPCL
1125 P&ID- SECUNDERABAD RT-FOR 07

3
IOCL
P&ID- SECUNDERABAD RT-FOR 04
4 1126
BPCL
P&ID- SECUNDERABAD RT-FOR 07
5 1075
FIRE WATER NETWORK
PROCESS FLOW DIAGRAMS

PF
SR.N REV.N
D DESCRIPTION
O O
NO
1 - OVER ALL VSPL PIPELINE NETWORK -
2 - VIZAG TO IP-1(RAJAHMUNDRY) SECTION -

HPCL BOTTLING PLANT & HPCL PETRO PARK TO VIZAG DT
3 - -
SECTION
4 - VIZAG TO IP-1(RAJAHMUNDRY) SECTION -
5 - IP-1 (RAJAHMUNDRY) TO HPCL RAJAHMUNDRY SECTION -
6 - IP-1 (RAJAHMUNDRY) TO VIJAYWADA SECTION -
7 - VIJAYWADA TOT TO VIJAYWADA CUSTOMERS -
8 - VIJAYWADA TOT TO SECUNDERABAD SECTION -
9 - SECUNDERABAD RECEIVING TERMINAL -
10 - VIZAG TO RAJAHMUNDRY SECTION -
11 - RAJAHMUNDRY TO VIJAYWADA SECTION -
12 - VIJAYWADA TO SURAPET SECTION -
13 - SURYAPET TO SECUNDERABAD SECTION -
PROCESS DOCUMENTS
SN DOCUMENT NAME DOCUMENT/ DRAWING NO. REV NO.
1 Design Philosophy 2139 0
2 ESD philosophy and Isolation philosophy 2139 0
3 Pump operation & control philosophy 2139 0
4 BRIEF PROCESS DESCRIPTION-VSLP - 03
19
GAIL (INDIA)LIMITED
Visakhapatnam (A.P)
Vizag / ORD 15-16 / 002- 01 Date : 19-02-16
20
GAIL (INDIA)LIMITED
Visakhapatnam (A.P)
Vizag / ORD 15-16 / 002- 01 Date : 19-02-16
APPENDIX A – HAZOP Worksheets
21
HAZOP Study of VSPL pipeline network and its associate facilities
GAIL (India) Limited
Vizag Region
Page 1 of 81
Worksheet Report
Node : 1 HPCL pump at LPG bottling plant

Node Description: LPG supply from GAIL terminal at HPCL Refinery
P&ID No: 1127
Type : MOV, Piping and piping components
Guideword : More Parameter : Flow
Deviation : More Flow

Causes Consequences Safeguards Recommendations Remarks
1 More flow from HPCL 1.1 More LPG will flow 1.1.1 PT 2701/02 is provided
1.1.2 TSV 2702/03 is provided
1.1.3 SCADA System is provided
1.1.4 FT 2701 is provided

Page 2 of 81
Guideword : Less
Deviation : Less Flow

• 1 MOV 2703 stuck 1.1 Less LPG will supply 1.1.1 PT 2701/02 is provided
close 1.1.2 SCADA system is Provided
• No LPG supply 1.1.3 FT 2701 is provided
• Pipe line leak 1.1.4 GA 2701 is provided

Guideword : Reverse Parameter : Pressure
Deviation : Reverse Pressure

• 1 Due to More 1.1 LPG will flow in reverse 1.1.1 SCADA System is Provided
downstream direction 1.1.2 NRV is provided on supply pump
pressure, discharge
• LPG supply pump
trips

Page 3 of 81

Deviation : Leak

• 1 Due to More 1.1 HSE hazard 1.1.1 Round the clock person available
pressure, 1.1.2 SCADA System is Provided
• Corrosion 1.1.3 Fire extinguishers are provided
• Gasket leak 1.1.4 Thickness testing carried out at
• Vibration defined frequency
1.1.5 External painting at defined
frequency
This report is generated using HAZOP‐Pro software
Page 4 of 81
Worksheet Report
Node : 02 Outer Harbor Storage Facilities

Node Description: LPG hook up from outer Harbor storage facilities
P&ID No: 1128
Type : MOV, piping and piping components

1 More flow from source 1.1 More LPG will flow 1.1.1 PI 2802/04 are provided 1.1.1.1 P&ID‐1128 to be
1.1.2 PT 2801/02 are provided updated
1.1.3 SCADA system
1.1.4 TSV 2802/03 are provided

Page 5 of 81
Guideword : Less Parameter : Flow

• 1 Less flow of LPG 1.1 Less pressure LPG 1.1.1 PI 2802/04 are provided
from upstream supply, Fire 1.1.2 PT 2801/02 are provided
• MOV 2801 stuck 1.1.3 SCADA system
close 1.1.4 Round the clock monitoring
• No LPG supply
• Pipe line leak
Guideword : Reverse Parameter : Flow
Deviation : Reverse Flow

1 If feed pump trips 1.1 LPG will flow in reverse 1.1.1 NRV is provided on pump
direction discharge
1.1.2 PT 2801/02 are provided
1.1.3 SCADA system is provided
Page 6 of 81
Worksheet Report
Node : 03 EIPL Pump PU-203/04

Node Description: LPG supply from EIPL facility
P&ID No: 1129
Type : MOV, Piping and piping components

• More flow from More LPG will flow 1.1.1 PT 2901 is Provided
upstream 1.1.2 PI 2901 is provided
• MOV 2901 stuck 1.1.3 TI 2901 is provided
open 1.1.4 TT 2901 is provided

Page 7 of 81

• Less flow of LPG 1.1 Less pressure LPG will 1.1.1 PT 2901 is provided
from upstream flow 1.1.2 PI 2901 is provided
• MOV 2901 stuck 1.1.3 SCADA System is provided
close

1 If feed pressure 1.1 LPG will flow in reverse 1.1.1 NRV is provided on pump
decreases direction discharge
1.1.2 PT 2901 is provided
Page 8 of 81
Worksheet Report
Node : 4 Vizag Despatch Terminal at Exim Park

Node Description: HPCL feed booster pumps 10-PA-CF-101 A/B operation at Vizag Exim park
P&ID No: 1120
Type : Piping and piping components, MOV, Flow Metering ,Booster pump

• 1 More flow of LPG 1.1 More LPG will flow, 1.1.1 PT 2002 is provided
from upstream Pump will trip on over load 1.1.2 FT 2001 is provided with an alarm
• Two or more current; process upset 1.1.3TSV 2002/05 is provided
pumps running at a 1.1.4 PI 2003 PAH is Provided
time
1.1.5 SCADA System is Provided
• VSD Mal function
1.1.6 Pump reset provision is provided

Page 9 of 81

• 1 Less/ No flow LPG 1.1 Less LPG will flow‐ 1.1.1 PT 2002 is provided
from upstream process upset, Pump dry 1.1.2 FT 2001 is provided
• PV 2001 stuck run 1.1.3 Pump running indicators are
close provided
• Filter choke 1.1.4 PI 1562/63 Provided
• Booster pump trip 1.1.5 SCADA System is Provided
• No LPG supply
1.1.6 PSLL will trip pumps
1.1.7 Low flow alarm provided in
control room
Deviation : flow Reverse

1 IF booster pump trips, 1.1 LPG will flow in reverse 1.1.1 NRV is provided
NRV fail direction, LPG will flow 1.1.2 Isolation valves is provided
towards other source, 1.1.3 SCADA System is Provided
Booster pump rotates in
1.1.4 Pump tripping alarm is provided
reverse direction

Page 10 of 81
Guideword : Parameter : Leak
Deviation : Leak

• 1 Due to more 1.1 HSE Hazard 1.1.1 SCADA System is Provided
pressure 1.1.2 Round the clock persons are
• Corrosion available
• Gasket failure 1.1.3 GA 2001 to 04 are provided
• Mechanical 1.1.4 Fire fighting system is provided
• Vibration 1.1.5 Deluge system provided
• Pump seal failure 1.1.6 Low pressure will trip MOVs and
pumps
1.1.7 Corrosion coupons are provided
1.1.8 Periodic thickness testing carried
out at defined frequency
Deviation : More Temperature

• 1 Due to 1.1 LPG leak 1.1.1 TE 2001/02/05 are provided
atmospheric 1.1.2 TSV 2001 to 06 are provided
condition 1.1.3 GA 2001 to 04 are provided
• Heat source 1.1.4 Fire fighting system is provided
1.1.5 Round the clock vigilance
1.1.6 CCTV is provided
Page 11 of 81
Worksheet Report
Node : 05 EIPL Storage to Vizag

Node Description: EIPL feed booster pump 10-PA-CF-103A/B operation and filtration in basket filter 10-GN-BK-103 A/B
P&ID No: 1110
Type : Piping and piping components, MOV, Pump, Filter

• 1 MOV‐1003 stuck 1.1 More LPG will flow to 1.1.1 FT‐1002 is provided
open will lead to Vizag 1.1.2 PSH‐1001 will stop booster pump
Booster Pump & close MOV‐1001
Malfunctioning, 1.1.3 PT‐1002/03/05/06 are provided
• VSD not working
1.1.4 TSV 1003/04 are provided

Page 12 of 81


• 1 MOV‐1002 stuck 1.1 Less LPG will flow to 1.1.1 PAL‐1001 A/B will stop Booster
close Vizag Pump
• Strainer choke 1.1.2 PI‐1011 is provided
• VSD mal 1.1.3 Pump running indicators are
functioning and provided
pump trips 1.1.4 PT‐1002/03/05/06 are provided
Deviation : Leak

• 1 More pressure 1.1 HSE Hazard 1.1.1 SCADA System is Provided 1.1.1.1 Gas Detector
from upstream 1.1.2 Gas Detector is Provided adequacy to be checked
• Gasket leak
1.1.3 Fire fighting system is Provided
• Pump seal leak

• 1 Due to 1.1 LPG Leak 1.1.1 SCADA System Monitoring
atmospheric heat, 1.1.2 TE‐1001/03 are provided
• Hot LPG received 1.1.3 GA is provided
from EIPL Storage
Page 13 of 81
Worksheet Report
Node : 06 LPG receipt at Main pump station

Node Description: Booster pump discharge to Main line pump suction at Vizag DT
P&ID No: 1120,1131
Type : Piping and piping components, HOV, stationary metering assembly


1 PV 2001 mal functioning 1.1 More LPG will flow , 1.1.1 PAH 2006 is provided
Main line Pump will trip on 1.1.2 SCADA System is provided
high pressure 1.1.3 FT 2001/02 is provided

Page 14 of 81

• 1 Less/ No LPG flow 1.1 Less LPG will flow to the 1.1.1 PT 2006 is provided
from upstream station 1.1.2 PV 2001 is cascaded with PT 2006
• PV 2001 stuck 1.1.3 If Booster pump trips it will trip
close, main line pumps
• Booster pump
1.1.4 FT 2001/02 is provided
trips,
1.1.5 PSLL will trip pumps
• No LPG supply
from source 1.1.6 Low flow alarm provided in
control room
1.1.7 GA 2001 to 04 are provided

• 1 Due to low 1.1 LPG will flow in reverse 1.1.1 NRV is provided on booster pump
pressure in header, direction 1.1.2 PT 2006 is provided
• Booster pump trips 1.1.3 Pump running indicators are
provided
Page 15 of 81
Worksheet Report
Node : 07 Vizag DT at Exim Park

Node Description: LPG feed from cavern source filtration at Vizag DT in Basket filter 10-GN-BK-00-102 A/B
P&ID No: 1111

Type : Piping and piping components, MOV, Filter
Guideword : More Parameter : Pressure
Deviation : More Pressure

1 More pressure from 1.1 More pressure LPG will 1.1.1 FT 1101/02 are provided
source ( CAVERN ) be delivered to DT‐Vizag 1.1.2 PT 1102/05 are provided
1.1.4 TSV 1101 to 06 are provided

Page 16 of 81
Guideword : Less Parameter : Pressure
Deviation : Less Pressure

• 1 Less LPG supply 1.1 Less pressure of LPG 1.1.1 PSLL 1201 will trip both main line
from source ( supply pumps, booster pumps and suction
CAVERN) discharge MOV of all pumps will be
• Filter choke close
• Leak 1.1.2 PT 1102/05 are provided
1.1.3 FT 1101/02 are provided
1.1.4 Gas detector 1101/02 are
provided
Guideword : Reverse Parameter : Pressure

• 1 High pressure at 1.1 LPG will flow in reverse 1.1.1 SCADA system is provided
downstream direction 1.1.2 NRV provided on main pump
• Main pump trips discharge line
1.1.3 PT 1102/05 are provided

Deviation : Leak
Page 17 of 81

• 1 Due to pressure, 1.1 HSE hazard 1.1.1 SCADA system is provided
gasket failure 1.1.2 Round the clock monitoring
• Mechanical 1.1.3 Communication system available
vibration
Page 18 of 81
Worksheet Report
Node : 08 Vizag DT Main Pump

Node Description: LPG Main line Pumps operation at DT Vizag 10-PA-CF-102 A/B/C to feed to LPG main line.
P&ID No: 1112
Type : Piping and piping components, MOV, Pump

• 1 More pressure 1.1 More LPG Flow , 1.1.1 PSHH Main line pump trips 102‐
from upstream process upset A/B/C
• MOV 1202 stuck 1.1.2 PSHH 1202 will close MOV
open 1201/02
• Two pumps 1.1.3 PI 1201/04/05/06 are provided
running, 1.1.4 SCADA system is Provided
1.1.6 TSV 1201/02/05 are provided

Page 19 of 81

• 1 More pressure 1.1 Less LPG Flow ; process 1.1.1 PSLL 1201 A/B will trip the main
from upstream upset line pump
• MOV 1202 stuck 1.1.2 PSLL 1201 A/B will close MOV
close 0201/02
• Filter choke 1.1.3 PI 1201/04/05/06 are provided
• Less supply from 1.1.4 SCADA system is Provided
source
1.1.6 DPT 1202 is provided and
generates an alarms
1.1.7 Minimum suction pressure
tripping provided


• No LPG Supply 1.1 LPG will flow in Reverse 1.1.1 SCADA system is Provided 1.1.1.1 Stand by pumps
• Feed pump trips direction, NRV of stand by 1.1.2 NRV provided on main pump MOV should be closed
pump fails discharge pipe line during normal operation
1.1.3 PI 1201/04/05/06 are provided
1.1.4 Pump running indicators are
provided
Page 20 of 81
Deviation : Leak

• 1 Leak due to more 1.1 EHS hazard 1.1.1 Deluge system is provided
pressure, 1.1.2 Round the clock monitoring
• Flange leak, 1.1.3 Gas detectors are provided
• Mechanical 1.1.4 Fire fighting system is provided
vibration,
• Pump seal leak
1.1.6 Emergency push button is
provided

• 1 Due to 1.1 HSE Hazard; leak 1.1.1 TSV 1201 /03/06/09/10/11 are
atmospheric provided
changes 1.1.2 SCADA system is Provided
• Heat source 1.1.3 TE 1201/02 is provided
Page 21 of 81
Worksheet Report
Node : 09 Flare system

Node Description: Flare system at DT Vizag
P&ID No: 5329
Type : Piping and piping components, PRV, David Assembly, flare system
Guideword : More Parameter : Flow of LPG

• 1 More Flow of LPG 1.1 More LPG at the tip of 1.1.1 PG is provided 1.1.1.1 P&ID 5329 to be
from upstream burner and more heat 1.1.2 TG is Provided updated
• More LPG vented radiation 1.1.3 CCTV is provided
from TSV 1.1.4 Round the clock vigilance
• Line venting,
1.1.5 Flame arrestor is provided
blowdown
• Process line/ 1.1.6 NRV provided on 4" line
equipment 1.1.7 Restricted orifice after the block
emergency valve & before the globe valve
evacuation 1.1.8 Fire fighting, Water monitor are
provided

Page 22 of 81
Deviation : Leak

• 1 Leak from pipe 1.1 EHS hazard 1.1.1 Physical check
• Fittings, 1.1.2 Round the clock monitoring
• Pipe lines, 1.1.3 Fire fighting system is provided
• Flange

Deviation : More Temperature around flare system

1 Due to flare 1.1 Hot atmospheric 1.1.1 Fire fighting system is Provided
condition and HSE hazard

Deviation : Ignition system failure

Due to technical reason LPG cloud will form‐HSE 1.1.1 Manual ignition system is
ignition system fails hazard provided

Page 23 of 81
Worksheet Report
Node : 10 Vizag Diesel storage
Node Description: Diesel storage in 10‐TT‐CR‐102 A/B and usage
P&ID No: 1121
Type : Tank, Pump


1 Mal Functioning of diesel 1.1 More diesel transfer 1.1.1 LT 2102 is provided 1.1.1.1 LI/LG to be provided
transfer pump from storage tank to day to diesel storage tank
tank 1.1.2 SCADA System is Provided 1.1.1.2 Adequate lights in
1.1.3 LAL 2102 is provided diesel yard, road to be
1.1.4 Physical stock checking provided specially keeping
in view of statutory
requirement of putting
high mast off on Tuesday
and Thursday
Page 24 of 81

• 1 Low/No diesel in 1.1 Low diesel in day tank 1.1.1 Physical stock taken on regular
tank basis
• Pipe line choke 1.1.2 LT 2102 is provided
• Pump trips
• Valve close

1 Diesel transfer pump trips 1.1 Diesel will flow in 1.1.1 LT 2102 is provided
reverse direction 1.1.2 NRV is provided
Page 25 of 81
Deviation : Spillage

• Diesel tank 1.1 Diesel spillage, leak 1.1.1 LT 2102 is provided
overflow 1.1.2 Dyke wall is provided
• Drain valve open
• LT line leak
• LT mal functioning
• Flange leak
Page 26 of 81
Worksheet Report
Node : 11 LPG Transfer from Vizag to G Konduru

Node Description: Intermediate pigging station -1(IP-1) Rajahmundry
P&ID No: 1113
Type : Piping and piping components, MOV, Flow Metering , Filter

• 1 More flow of LPG 1.1 More LPG will flow; 1.1.1 TSV 1302/1308 is provided
from upstream process upset 1.1.2 FT 1301 is cascaded with PT 1303
• MOV 1303 stuck 1.1.3 PT 1303 is Provided
open 1.1.4 FT 1301 is provided
• Booster pump mal
1.1.5 High flow alarm is provided
functioning
• Downstream 1.1.6 High current trip is Provided
pressure low
• VSD Mal function

Page 27 of 81


• 1 Less/no flow of 1.1 Less LPG will flow‐ 1.1.1 FT 1301 is cascaded with PT 1303
LPG from process upset 1.1.2 PT 1303 is Provided
upstream 1.1.3 SCADA System is provided
• MOV 1303 stuck 1.1.4 PI 1306 is provided
close
1.1.5 GA 1303 is provided
• Leakage in pipe
line, 1.1.6 DPT 1301/02 is provided
• No supply from
source
• filter choke


1 If supply pressure is low 1.1 LPG will flow in reverse 1.1.1 PT 1303 is Provided
direction 1.1.2 SCADA System is Provided
Page 28 of 81
Worksheet Report
Node : 12 HPCL Receiving terminal

Node Description: LPG Supply to HPCL Bottling plant Veeralankapalli
P&ID No: 1001
Type : Piping and piping components, Filter, FT, MOV, ROV

• 1 More Flow of LPG 1.1 More LPG flow 1.1.1 PT 0201/04/05/06 are provided
from upstream 1.1.2 TSV 0201/03/05/06/08/09/10/11
• PCV 0204 stuck are provided
open, 1.1.3 SCADA system is Provided
• More pressure LPG
1.1.4 FT 0201 provided is Provided
supply from DT‐
Vizag ,

Page 29 of 81


• 1 Less Flow of LPG 1.1 Less/No LPG supply to 1.1.1 PT 0201/04/05/06 is provided
from upstream the system 1.1.2 FT 0201 is provided
• PCV 0204 stuck 1.1.3 SCADA system is Provided
close,
• Less pressure LPG
supply from DT‐
Vizag ,
Deviation : Leak

1 Leak from Flange, fittings 1.1 EHS hazard 1.1.1 Gas detectors are provided
, drain points , 1.1.2 Round the clock monitoring
1.1.3 Fire fighting system is provided
1.1.4 Deluge system is provided

Page 30 of 81


1 Due to atmospheric 1.1 HSE Hazard 1.1.1 TSV 0201/03/05/06/08/09/10/11
condition; heat source are provided
1.1.2 Gas detectors are provided
1.1.4 TE 0201 to 04 are provided

Page 31 of 81
G Konduru Region
Page 32 of 81
Worksheet Report
Node : 13 Booster Pump 30-P-0101 A/B

Node Description: Booster Pump operation 30-P-0101 A/B at G Konduru
P&ID No: 03122009-Booster pump
Type : MOV, Filter, Piping and piping components, Gas Detector

1 More Pressure from Vizag 1.1 More pressure LPG will 1.1.1 FT 1401 is provided
leading to VSD & Pump flow towards Suryapet, 1.1.2 PT 1407 is provided
control mal function Pump will trip on high 1.1.3 PSH 0101/02 will trip P‐0101 A/B,
towards high speed current close MOV 0101/02 & 03/04
respectively
1.1.4 PAH 0103 will stop Booster pump
1.1.5 PAHH 0101/02/03, 2 out of 3
logic will trip 0101 A/B

Page 33 of 81

• 1. Less pressure of 1.1 Less/No LPG supply to 1.1.1 FT 1401 is provided
LPG from upstream Suryapet due to P 0101 A/B 1.1.2 PSL 0101/02 will trip P‐0101 A/B,
• 30‐GN‐BK‐101 A/B will trip on low pressure close MOV 0101/02 & 03/04
choke, less respectively
• LPG supply from 1.1.3 Minimum flow line from pump is
Vizag provided ( Balancing line )
• Pump control mal
1.1.4 PT 0101/03/04 ,1401/02/07 are
function towards
provided
low speed
1.1.5 DPT 1401/02 is provided


1 Booster pump trips 1.1 LPG will flow in reverse 1.1.1 NRV is provided on P‐0101 A/B
direction pump discharge line
1.1.3 PT 0101/03/04 ,1401/02/07 are
provided

Page 34 of 81
Deviation : Leak

• 1. More pressure 1.1 Fire, HSE issues 1.1.1 GA 1402 is provided
from upstream 1.1.2 Thickness testing at defined
• Mechanical frequency
vibration 1.1.3 External painting , poly ethylene
• Pump seal and coating done
valves leak
1.1.4 Corrosion coupon are provided
1.1.5 ER Probe is Provided
1.1.6 Gas element is provided
1.1.7 Deluge system, fire hydrant
system are Provided

Page 35 of 81
Worksheet Report
Node : 14 HPCL LPG system

Node Description: LPG supply to HPCL bottling plant from G Konduru Pumping Station
P&ID No: HPCL
Type : Piping and piping components, MOV

1. More Flow of LPG from 1.1 More LPG will flow 1.1.1 FT 1902 is Provided
Vizag leading to more pressure of 1.1.2 TSV 1901/02/03/05 are Provided
LPG to HPCL Process upset
1.1.3 PT 1901/02/03/04 are Provided
1.1.4 PSHH 1901 will close MOV
1901/02/04/06 & ROV 1901

Page 36 of 81

1 Low pressure LPG from 1.1 Low LPG pressure will 1.1.2 FT 1902 is Provided
Vizag lead to dual phase, FT will 1.1.2 SCADA system is provided
mal function, Process upset
1.1.3 PSLL 1901 will close MOV
1901/02/04 ROV 1901
1.1.4 PSLL will close PV 1901

Page 37 of 81
Worksheet Report
Node : 15 HPCL LPG Bottling plant

Node Description: LPG supply to HPCL bottling plant after filtration in Basket filter 31-GN-BK-101
P&ID No: HPCL

1 More Flow from Tap off 1.1 More LPG will flow‐ 1.1.1 FT 1903 is provided
station Process upset 1.1.2 PSHH 1901 will close MOV
1901/02/04/06 & ROV 1901
1.1.4 SCADA system is Provided
1.1.5 TSV 1906/09/11 are provided

Page 38 of 81

• 1 Less/no Flow of 1.1 Less LPG will flow; 1.1.1 FT 1903 is provided
LPG from upstream Process upset 1.1.2 SCADA system is Provided
• ROV 1901 stuck 1.1.3 PT 1905 is provided
close 1.1.4 SCADA system is provided
• Filter choke
1.1.5 DPG is provided for filter
• Leak

Page 39 of 81
Worksheet Report
Node : 16 SPUR Line IOCL
Node Description: LPG supply to IOCL bottling plant from G Konduru Pumping Station
P&ID No: IOCL Spur line
Type : Piping and piping components, MOV, PCV ,FCV

• 1 More Flow of LPG 1.1 More LPG will flow 1.1.1 FT 1502 is Provided
from upstream leading to more pressure of 1.1.2 TSV 1501/02/03/04/05 are
• FV 1501 stuck open LPG to IOCL Process upset Provided
1.1.3 PT 1501/02/04/06 are Provided
1.1.4 PSHH will close MOV 1501/02,PV
1501 will close

Page 40 of 81

Guideword : Low Parameter : Pressure
Deviation : Low Pressure

• 1 Low Pressure of 1.1 Low LPG pressure will 1.1.1 FT 1502 is Provided
LPG from lead to dual phase, FT will 1.1.2 SCADA system is Provided
upstream mal function‐ Process upset
1.1.3 PSLL will close MOV 1501/02
• 1501 stuck close
• No/Low LPG supply
from Vizag 1.1.4 PSLL will close PV 1501
Guideword : Leak Parameter : Leak
Deviation : Leak

• 1 Corrosion 1.1 HSE Hazard ,Fire 1.1.1 Thickness testing at defined
Vibration 1.1.2 External painting , coating done
• Gasket leak
1.1.3 Corrosion coupon is provided
• Pipeline leak
1.1.4 ER Probe is provided
1.1.5 Gas element provided
system are provided
1.1.7 QBD detection system is provided
1.1.8 Earthing & bonding provided
Page 41 of 81
Worksheet Report
Node : 17 LPG SPUR Line IOCL

Node Description: LPG supply to IOCL bottling plant from G Konduru Pumping Station
P&ID No: IOCL Spur line

1 More Flow from Tap off 1.1 More LPG will flow, 1.1.1 FT 1503 is Provided 1.1.1.1 P&ID to be updated
station Process upset 1.1.2 PSHH 1502 will close MOV 1505 & for cause & effect ( 1.1.2
ROV 1506 PSHH 1501 actually it is
PSHH 1502 ), reducer's
1.1.3 SCADA system is Provided
standard symbols to be
1.1.4 PT 1505/07/08 is Provided used
1.1.5 PI 1505/07/08 is provided

Page 42 of 81


• 1 Less/no Flow of 1.1 Less LPG will flow; 1.1.1 FT 1503 is Provided
LPG from upstream Process upset 1.1.2 SCADA system is Provided
• ROV 1506 stuck 1.1.3 ZLL 1506 is Provided
close 1.1.4 DPG is provided for filter
• Filter choke
• Leak

Deviation : Leak

• 1 Corrosion 1.1 HSE Hazard, Fire 1.1.1 Thickness testing at defined
vibration ,
1.1.2 External painting and coating is
• Gasket leak done
• Pipeline leak
1.1.3 Corrosion coupons are provided
1.1.4 ER Probe is provided
system are provided
1.1.7 QBD detection system provided
Page 43 of 81
Worksheet Report
Node : 18 BPCL LPG bottling plant

Node Description: LPG supply to BPCL bottling plant from G Konduru Pumping Station
P&ID No: BPCL drawing

• 1 More flow of LPG 1.1 More LPG will supply to 1.1.2 PSHH 1801 will close MOV
from IOCL tap off BPCL bottling plant‐Process 1804,ROV 1801
• ROV 1801 stuck upset 1.1.3 PT 1801/02 is provided
open 1.1.4 SCADA system is provided
1.1.5 TSV 1801/02 is Provided

Page 44 of 81


1 Due to atmospheric Heat 1.1 HOT LPG in pipe line; 1.1.1 SCADA System is provided
source change Leak 1.1.2 TSV 1906/09/11 are provided
1.1.3 TE 1903/06 are provided
Deviation : Leak

• 1 Corrosion 1.1 HSE Hazard, Fire 1.1.1 Thickness testing at defined
vibration
1.1.2 External painting , coating (PE )
• Gasket leak done
• Pipeline leak
1.1.4 fire hydrant system is provided
Page 45 of 81
Cherlapalli Region
Page 46 of 81
Worksheet Report
Node : 19 LPG Transfer From G-Konduru to Cherlapalli RT

Node Description: LPG transfer from G-Konduru to Cherlapalli RT
P&ID No: 1116,1117
Type : Piping and piping components, Filter

• 1 More LPG will 1.1 More LPG will Flow‐ 1.1.1 TSV‐1602,05/06/07 are provided 1.1.1.1 PG, PT to be
Flow through Process Upset 1.1.2 PT‐1601/03/04 are provided provided around basket
Pipeline from 1.1.3 PG‐1606,10 are provided filter.
upstream
• MOV‐1602 stuck
open
• Booster Pump
malfunctioning

Page 47 of 81


• 1 Less LPG will flow 1.1 Less pressure LPG will 1.1.1 PI‐1601/03/04 are provided
from upstream supply‐Process Upset 1.1.2 Minimum Flow Line is Provided
• MOV‐1603 stuck 1.1.3 PT‐1601/03/04, 1701, 1706 are
close provided
• Filter choke, 1.1.4 PSLL‐1701 will close MOV 1703
• LPG pipe line leak 1.1.5 SCADA System is provided
1.1.6 Low pressure aunnuciator audible
alarms provided
Page 48 of 81


• 1 Less supply 1.1 LPG will flow in Reverse 1.1.1 NRV is provided on Booster Pump
pressure direction 1.1.2 PT‐1601/03/04, PT 1701, PT 1706
• More downstream are provided
pressure 1.1.3 MOV 1703 will close
1.1.5 Low pressure aunnuciator audible
alarms provided
Page 49 of 81

Guideword : More Parameter : More Pressure

1 More pressure due to 1.1 More pressure LPG 1.1.1 TSV 1602/05/06/1703/10 are
ambient condition, process delivered to Secundrabad, provided
upset LPG may leak 1.1.2 PG 1606/10 is provided
1.1.3 Persons taking the round
1.1.4 TT 1603/04 are provided
1.1.5 Gas alarm(GA)
1601/02/1701/02/03 are provided
1.1.5 PT‐
1601/02/05/06/07,1701/02/03/04 /05
are provided
Page 50 of 81
Guideword : Leakage Parameter : Leakage
Deviation : Leakage

1 Leakage from flange, 1.1 LPG leakage, Fire, HSE 1.1.1 Gas alarm(GA)
filter. hazard 1601/02/1701/02/03 are provided
1.1.3Persons taking the round
1.1.4 PT‐
1601/02/05/06/07,1701/02/03/04 /05
are provided
Page 51 of 81
Worksheet Report
Node : 20 Secundrabad RT for HPCL

Node Description: LPG supply to HPCL bottling plant from Cherlapalli RT
P&ID No: 1117
Type : Piping and piping components, MOV,FIC

• 1 More Flow due to 1.1 More flow LPG supply 1.1.1 PT 1702/11 are provided
booster pump to HPCL Leakage 1.1.2 PT 1702/10 are cascaded with
malfunctioning PCV 1701
(Variable Speed) 1.1.3 FT 1702/03 are provided
• PCV 1701 stuck 1.1.4 PT 1703,04 are cascaded with FIC
open 1701
1.1.5 PCV 1702 is provided

Parameter : Flow
Page 52 of 81
Guideword : Less

• 1 PCV 1701 stuck 1.1 Less LPG supply to HPCL 1.1.1 ZLL 1703 is Provided
close 1.1.2 FIC 1701 is Provided
• Filter choke 1.1.3 PT 1701/02/06 are provided
• Less pressure LPG 1.1.4 PIC 1702 will close PCV 1702
from pipe line when pressure falls below 9 kg/cm2
1.1.6 PSLL 1701 close MOV 1703

1 More pressure from 1.1 LPG will flow in reverse 1.1.1 FIC 1701 is provided
downstream direction 1.1.2 SCADA system is provided
1.1.3Low pressure aunnuciator audible
alarms provided
1.1.4 NRV is provided on booster pump
discharge

Page 53 of 81
Guideword : Parameter : Corrosion / Erosion
Deviation : Corrosion / Erosion

1 Due to moisture; 1.1 Pipe line may leak, HSE 1.1.1 Cathodic protection and, external
corrosion problems coating to the underground pipe line
1.1.2 Regular thickness checking as per
defined frequency
1.1.3 Corrosion coupons fitted into the
pipe line
1.1.4 Electrical probe provided
Deviation : Leak

1 Due to more pressure, 1.1 HSE problem, Fire 1.1.1 Gas detectors are provided
gasket weakens, 1.1.2 SCADA system monitoring
Mechanical vibrations 1.1.3 Fire fighting, Sprinkler system are
provided

Page 54 of 81

Guideword : Parameter : Corrosion
Deviation : Corrosion

• 1 Due to moisture 1.1 Pipe line corrosion , 1.1.1 Cathodic protection is provided
• MIC internal , external and leak 1.1.2 Pipe line cleaning and thickness
• AC interference checking at defined frequency
1.1.3 Proper coating to the pipe line
1.1.4 Leak detection system is provided
1.1.5 Grounding of AC interference
1.1.6 corrosion coupons are provided
1.1.7 Electrical resistance is probe
provided
Page 55 of 81
Worksheet Report
Node : 21 Secundrabad RT for BPCL at Cherlapalli

Node Description: LPG supply to BPCL bottling plant from Cherlapalli RT
P&ID No: 1126
Type : Piping and piping components, MOV,FIC

• 1 More Flow 1.1 More flow of LPG 1.1.2 PT 2601/02/04/06 is provided
from upstream supply to BPCL, 1.1.1 PSHH 2601 will close MOV 2601, ROV 2601
• PCV 2601 stuck Leakage
open 1.1.3 TSV 2603 2601/03/05/06 is provided
• Booster pump
1.1.4 PT 2604 is cascaded with FT 2602
mal
functioning(Vari
able Speed)

Page 56 of 81


• 1 PCV 2601 1.1 Less Pressure LPG 1.1.1 FIC 2601 is Provided
stuck close supply to BPCL 1.1.2 PSLL 2601 will close MOV 2601
• Less pressure in 1.1.3 PIC 2601 is cascaded with PCV 2601
pipe line 1.1.4 PT 2601/02/04/06 are provided

1 More downstream 1.1 LPG will flow in 1.1.1 FIC 2601 is provided
pressure reverse direction 1.1.2 SCADA system monitoring
1.1.3 NRV is provided on booster pump discharge
line
1.1.4 PT 2601/02/04/06 are provided
1.1.5 Low pressure aunnuciator audible alarms
provided

Page 57 of 81


• 1 Due to 1.1 Pipe line corrosion 1.1.1 Cathodic protection is provided
moisture , internal , external and 1.1.2 Pipe line thickness checking at defined
• MIC leak frequency
• AC interference 1.1.3 Proper coating to the pipe line
1.1.4 Leak detection system is provided
Deviation : Leak

• 1. Due to more 1.1 LPG leakage, HSE 1.1.1 Patrolling in three shifts( Once in a shift)
pressure, hazard 1.1.2 SCADA system monitoring for pressure drop
• Gasket leaks and shut down accordingly
• Mechanical
vibration

Page 58 of 81
Guideword : More Parameter : Temperature

1 Due to atmospheric 1.1 Hot LPG supply to 1.1.1 SCADA monitoring is Provided
condition; Heat source BPCL 1.1.2 TE 2602/03/04 are provided
1.1.3 PT 1.1.3 PT 2602, 2603,2604,2606,2607 is
provided
1.1.4 TSV
2601.2602,2603,2604,2605,2606,2607, 2608 are
provided
Page 59 of 81

Worksheet Report
Node : 22 Secundrabad RT For IOCL

Node Description: LPG Supply to IOCL from Cherlapalli RT
P&ID No: 1125

• 1 More pressure 1.1 High pressure LPG will 1.1.1 PT‐2502/04/06 are provided
from upstream flow from Secunderabad RT 1.1.2 PSHH‐2501 will close MOV 2501
• PCV‐2501 stuck for IOCL 1.1.3 TSV‐2501/02/03/06 are provided
open 1.1.4 FT 2602 is provided

Page 60 of 81


• 1 Less Pressure LPG 1.1 Less Pressurized LPG 1.1.1 PT‐2502/04/06 are provided
will flow from transferred to IOCL 1.1.2 PSLL‐2501 will close MOV 2501
upstream 1.1.3 FT 2502 is provided
• PCV‐2501 stuck 1.1.4 Low pressure aunnuciator audible
close alarms are provided


1 Due to more downstream 1.1 LPG will flow in reverse 1.1.1 FT 2502 is provided
pressure direction 1.1.2 PSLL 2501 will close MOV 2501
1.1.3 NRV is provided on Booster pump
discharge line

Page 61 of 81

1 Due to moisture; 1.1 Pipe will get corroded 1.1.1 Cathodic protection is provided
corrosion and may leak 1.1.2 Pipeline thickness checking at
defined frequency
1.1.3 Corrosion coupons provided
Deviation : Leak

• 1 Due to more 1.1 LPG will leak leading to 1.1.1 Gas detectors are provided
pressure, HSE hazard, Fire 1.1.2 SACADA system is Provided
• Gasket leaks 1.1.3 Public awareness
• Mechanical 1.1.4 Wind socks are provided
vibration
1.1.5 Fire fighting system is Provided

Page 62 of 81

Guideword : More Parameter : Temperature

1 Due to atmospheric 1.1 Hot LPG will supply to 1.1.1 TSV 2501/002/04/05 are
condition; hot atmosphere IOCL , leak provided
1.1.2 TE 2502/04 are provided
1.1.3 SCADA monitoring is Provided
1.1.4 Gas detectors is provided

• 1 Due to moisture 1.1 Pipe line corrosion , 1.1.1 Cathodic protection is provided
• MIC internal , external and leak 1.1.2 Pipeline thickness checking at
• AC interference defined frequency
1.1.3 Proper coating to the pipe line
1.1.4 Leak detection system provided
1.1.6 corrosion coupons are provided
1.1.6 Electrical resistance probe is
provided
Page 63 of 81

Worksheet Report
Node : 23 Fire Hydrant System

Node Description: Fire Hydrant System‐ Cherlapalli
P&ID No: 1075
Type : Piping and piping components, Fired Equipment, Filter, Pump, Design Problems, Diesel Operated Fire hydrant pump, Heat Transfer Equipment,
Centrifugal Pump, Jockey pump

1 Both diesel operated 1.1 Fire hydrant line 1.1.1 Pump running indicator provided 1.1.1.1 P & ID to be updated
pump run may leak local panel for PT, TSV
1.2 HSE issue 1.1.2 Firemen’s vigilance
1.1.3 PG 503/04 are provided
1.1.4 PSV provided in the field
1.1.5 PT is provided
1.1.6 Circulation line is provided

Page 64 of 81

Parameter : Flow

Guideword : Less

• 1 Diesel operated 1.1 Emergency may 1.1.1 LT 506/08 are provided
pump not operated take more time to 1.1.2 PG 503/04 are provided
at low pressure mitigate it 1.1.3 PAL 503 provided to start main
• No water in fire diesel pump at 7.5 Kg/cm2g
hydrant tank
1.1.4 Regular battery check up
• Strainer choke
1.1.5 PT is provided
• Discharge batteries

1 NRV stuck open 1.1 Diesel pump will 1.1.1 PT provided
rotate in reverse 1.1.2 Regular maintenance
direction and less 1.1.3 PG 503/04 are provided
hydrant pressure
1.1.4 Manned pump house

Page 65 of 81
Deviation : Leak

1 Due to atmospheric 1.1 MS pipe line will 1.1.1 Pipe lines are coated with suitable
condition like acidic corrode and leak, material
atmosphere, gasket will less pressure 1.1.2 Fire hydrant tank levels monitored
leak hydrant water for
1.1.3 Frequent pump running
emergency
1.1.4 Regular flushing

Page 66 of 81
Pigging Operation
Page 67 of 81
Worksheet Report
Node : 24 Cavern Feeder Line

Node Description: Cavern Feeder Line scrapping from HPCL old bottling plant to Vizag DT
P&ID No: 1111, 1128
Type : Piping and piping components ,Filter, scraper Launcher, scraper receiver

1 More Flow of LPG from 1.1 More LPG will flow , 1.1.1 PT 1101,2802 are provided 1.1.1.1 Provide PG and
source for pigging process. line leak, drain points at appropriate
location to depressurize
the scraper receiver and
launcher
1.1.2 TSV 1102,03, 2801,03 are 1.1.1.2 Provide positive
provided isolation system for scraper
1.1.3 XXI 1102, 2801 are provided
1.1.4 Pig tracker is used
1.1.5 SCADA system
Page 68 of 81


1 Less flow of LPG from 1.1 Pigging will take more 1.1.1 PT 1101,2802 are provided
source time, 1.1.2 XXI 1102, 2801 are provided
Deviation : Leak

1 Leak from Flange, pig 1.1 EHS hazard 1.1.1 Gas detectors are provided
receiver door , drain points 1.1.2 Fire fighting system is provided
Page 69 of 81
Worksheet Report
Node : 25 Main Line (VIZAG TO RAJAHMUNDRY)

Node Description: Main Line scrapping From Vizag to Rajahmundry
P&ID No: 1112,1113
Type : Piping and piping components, Filter, scraper Launcher, scraper receiver

1 More Flow of LPG from 1.1 More LPG will flow , 1.1.1 PT 1204/1301 are provided 1.1.1.1 Provide PG and
launcher
1.1.2 TSV 1203/04/1301/02 are 1.1.1.2 Provide positive
1.1.3 SCADA System receiver and launcher
1.1.4 XXI 1201, 1301/02 are provided
Page 70 of 81


1 Less flow of LPG from 1.1 Pigging will take more 1.1.1 PT 1204/1301 are provided
source time, 1.1.2 XXI 1201, 1301/02 are provided
Deviation : Leak

Page 71 of 81
Worksheet Report
Node : 26 Main Line ( Rajahmundry to G Konduru)

Node Description: Main Line scrapping from Rajahmundry to G Konduru
P&ID No: 1113, Vijayawada pumping/Pigging Station

1 More Flow of LPG from 1.1 More LPG will flow , 1.1.1 PT 1302, 1401/10 are provided 1.1.1.1 Provide PG and
launcher
1.1.3 XXI 1303/1401/02 are provided receiver and launcher
1.1.5 SCADA System
Page 72 of 81


1 Less flow of LPG from 1.1 Pigging will take more 1.1.1 PT 1302, 1401/10 are provided
source time, 1.1.2 XXI 1303/1401/02 are provided
Deviation : Leak

Page 73 of 81
Worksheet Report
Node : 27 SPUR LINE (G KONDURU TO HPCL BOTTLING PLANT)

Node Description: Spur Line scrapping from G. Konduru to HPCL Bottling plant
P&ID No: SPUR LINE HPCL, VIJAYAWADA RT

1 More Flow of LPG from 1.1 More LPG will flow , 1.1.1 PT 1905 is provided 1.1.1.1 Provide PG and
launcher
1.1.2 TSV 1909/10/11/12 are provided 1.1.1.2 Provide positive
1.1.3 XXI 11901/02/03 are provided isolation system for scraper
1.1.5 SCADA System

Page 74 of 81


1 Less flow of LPG from 1.1 Pigging will take more 1.1.1 PT 1905 is provided
Deviation : Leak

Page 75 of 81
Worksheet Report
Node : 28 SPUR LINE (G KONDURU TO IOCL BOTTLING PLANT)

Node Description: Spur Line scrapping from G. Konduru to IOCL Bottling plant
P&ID No: SPUR LINE IOCL, VIJAYAWADA RT

1 More Flow of LPG from 1.1 More LPG will flow , 1.1.1 PT 1505/07 are provided 1.1.1.1 Provide PG and
launcher
1.1.2 TSV 1509/10/11/12 are provided 1.1.1.2 Provide positive
1.1.3 XXI 1501/02/03 are provided isolation system for scraper
1.1.5 SCADA System

Page 76 of 81


1 Less flow of LPG from 1.1 Pigging will take more 1.1.1 PT 1505/07 are provided
Deviation : Leak

Page 77 of 81
Worksheet Report
Node : 29 MAIN LINE (G KONDURU TO SURYAPET)

Node Description: Main Line scrapping from G. Konduru to Suryapet
P&ID No: VIJAYAWADA PUMPING STATION, 1116

1 More Flow of LPG from 1.1 More LPG will flow , 1.1.1 PT 1407/1601/07 are provided 1.1.1.1 Provide PG and
launcher
1.1.2 TSV 1403/05/14/1601/02 are 1.1.1.2 Provide positive
1.1.5 SCADA System
Page 78 of 81


1 Less flow of LPG from 1.1 Pigging will take more 1.1.1 PT 1407/1601/07 are provided
Deviation : Leak

Page 79 of 81
Worksheet Report
Node : 30 MAIN LINE (SURYAPET TO CHERLAPALLI)

Node Description: Main Line scrapping from Suryapet to Cherlapalli
P&ID No: 1116, 1117
Type : Piping and piping components, scraper Launcher, scraper receiver

1 More Flow of LPG from 1.1 More LPG will flow , 1.1.1 PT 1706 is provided 1.1.1.1 Provide PG and
launcher
1.1.5 SCADA System

Page 80 of 81


1 Less flow of LPG from 1.1 Pigging will take more 1.1.1 PT 1706 is provided
Deviation : Leak

Page 81 of 81
GAIL (INDIA)LIMITED
Visakhapatnam (A.P)
HAZOP for Vizag-Secunderabad Pipeline-VSPL
BEST/ IND / CON / 1380 GAIL Issue: Draft Rev. B
Vizag / ORD 15-16 / 002- 01 Date : 19-02-16
APPENDIX B
ABBREVATION
22
GAIL (INDIA)LIMITED
Visakhapatnam (A.P)
Vizag / ORD 15-16 / 002- 01 Date : 19-02-16
Abbreviation Full Form

2oo2 2 out of 2
2oo3 2 out of 3
BL Battery limit
C&E Cause and Effect
DM Demineralised
DMW Demineralised Water
F&G Fire and Gas
FAL Flow Alarm Low
FCV Flow Control Valve
FI Flow Indicator
FIC Flow Indicator Control
FS-AL Flow Sensor Alarm High
FT Flow Transmitter
FT Flow transmitter
HAZOP Hazard and Operability Study
HC Hydrocarbon
HCV Hand Control Valve
HIC Hand indicating Controller
HP High Pressure
HV Handle Valve
IOCL Indian Oil Corporation Ltd.
LAH Level Alarm High
LAL Level Alarm Low
LALL Level Alarm Low-Low
LCV Level Control Valve
LCV Level Control Valve
LG Level Gauge
LIC Level Indicator Controller
LP Low Pressure
LSHH Level Switch High-High
LSLL Level Switch Low-Low
NDT Non Destructive Testing
NRV Non Return Valve
23
GAIL (INDIA)LIMITED
Visakhapatnam (A.P)
Vizag / ORD 15-16 / 002- 01 Date : 19-02-16
Abbreviation Full Form

OH Overhead
P & ID Piping and Instrumentation Diagram
PAL Pressure Alarm High
PALL Pressure Alarm High-High
PDAH Pressure Differential Alarm High
PDCV Pressure Differential Control Valve
PDI Pressure Differential Indicator
PFD Process Flow Diagram
PI Pressure Indicator
PI-AH Pressure Indicator Alarm high
PIC Pressure Indicator Control
PSLL Pressure Switch Low Low
PSV Pressure Safety Valve
ROT Riser Outlet Temperature
SDV Shutdown Valve
SDV Shut Down valve
SOP Safe Operating Procedure
TAH Temperature Alarm High
TAL Temperature Alarm Low
TI Temperature Indicator
TIAH Temperature Indicator Alarm High
24
GAIL (INDIA)LIMITED
Visakhapatnam (A.P)
Vizag / ORD 15-16 / 002- 01 Date : 19-02-16
UNITS USED
SR. NO. PARAMETERS SYMBOLS UNITS

1 Length “ Inch
M Meter
3
2 Volume m Meter cube
3
cm Centimetre Cube
o
3 Temperature C Degree Celsius
2
4 Pressure kg/cm Kilogram per sq. centimetre
5 Weight Kg Kilogram
MMTPA Metric Million Tonne Per Annum
MT Metric Tonne
6 Concentration ppm Parts per million
ppb Parts per billion
7 Percentage % Percentage
25
GAIL (INDIA)LIMITED
Visakhapatnam (A.P)
Vizag / ORD 15-16 / 002- 01 Date : 19-02-16
APPENDIX C – Node Marked-Up P&IDs
26
GAIL (INDIA)LIMITED
Visakhapatnam (A.P)
Vizag / ORD 15-16 / 002- 01 Date : 19-02-16
APPENDIX D – Attendance Sheet
27

DSR Book Vol 2 2016 (English Version) Final

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DSR Book Vol 2 2016 (English Version) Final

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HAZARD AND OPERABILITY STUDY FOR

VIZAG-SECUNDERABAD LPG PIPELINE

GAIL (INDIA) LIMITED

(Consultancy Division of)

Approved By: © 2008 Bell Engineering

This document is the

1.2 HAZOP Objective

1.3 HAZOP Session

Node No Node Description

Node No Node Description

Node : 02 LPG hook up from outer Harbor storage facilities

1.1.1.1 P&ID-1128 to be updated

1.1.1.1 Gas Detector Adequacy to be checked

1.1.1.1 Stand by pumps MOV should be closed during normal operation

Node : 09 Flare system at DT Vizag

1.1.1.1 P&ID 5329 to be updated

Node : 10 Diesel storage in 10-TT-CR-102 A/B and usage

1.1.1.1 LI/LG to be provided to diesel storage tank

Node : 17 LPG supply to IOCL Receiving Terminal, Kondapalli

Node : 19 LPG transfer from G-Konduru to Cherlapalli RT

1.1.1.1 PG, PT to be provided to the basket filters.

Node : 23 Fire Hydrant System- Cherlapalli

1.1.1.1 P & ID to be updated for PT, TSV

1.1.1.1 Provide PG and drain points at appropriate location to depressurize the scraper

Node: 25 Main Line scrapping From Vizag to Rajahmundry

Node 29: Main Line scrapping from G. Konduru to Suryapet

Node 30: Main Line scrapping from Suryapet to Cherlapalli

ISSUE DATE REVISION HISTORY

Final 19th February 2016 Final Report

1. Mr. L.S. Rao – GAIL Vizag.

Rajahmundry (IP-01) &Suryapet (IP-02) Intermediate Pigging Stations: In addition

Table 2 – Units in Scope of Work

Unit No. Unit Name

5. G Konduru Booster Station

6. G Konduru - IOCL RT Station

7. G Konduru - BPCL RT Station

8. G Konduru - HPCL RT Station

11. Cherlapalli - GAIL RT & HPCL

12. Cherlapalli - Receiving Terminal-IOCL

13. Cherlapalli - Receiving Terminal-BPCL

14. Cherlapalli- Fire Water Storage Tanks

1.9 Project Team

Sr.No. Name Organization

Consider first or next

Identify all causes and

Identify all Safeguards

Agree any action &

Figure 2-1 HAZOP Methodology Schematic

A. List of HAZOP team members for Vizag

Sr.No. Name Designation Dates

3 Mr. Amit Das DGM (LPG P/L O&M) 16/12/15

4 Mr. L S Rao CM (LPG P/L O&M) 15-16/12/15

5 Dr. Ramesh Sambana Sr. Manager (LPG P/L O&M) 15-16/12/15

6 Mr. A Prasada Rao Sr. Manager (LPG P/L O&M) 15-16/12/15

7 Mr. Moulinath Bhattacharyya Sr. Manager ( F&S) 15-16/12/15

8 Mr. Peri Vasu Sr. Manager (LPG P/L O&M) 15-16/12/15

9 Mr. A. S. Reddy Sr. Manager (LPG P/L O&M) 15-16/12/15

10 Mrs. S. Vijaya Lakshmi Dy. Manager(LPG P/L O&M) 15/12/15

11 Mr. G S Rao Sr. Engineer (LPGP/L O&M) 15-16/12/15

B. List of HAZOP team members for G Konduru

Sr.No. Name Designation Dates

3 Mr. Kishor Singhal CM (LPG-P/L O&M) 17/12/15

4 Mr. Ratnaji Rao Sr. Manager, (LPG P/L O&M) 17/12/15

5 Mr. A Suresh Babu Sr. Manager (LPG P/L O&M) 17/12/15