Template Hazid Report
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Client: Project:
Fine Print
Educational/ Training Material Issued as a service to the industry for Free Distribution
HAZID STUDY REPORT
EPC Contractor: Engg Consultant:
Rev
Job No
Date
Issued For
Sec No
By
Contract No
Chk’d App’d Engg Consultant
Document No
Contractor
Client
HAZID
Worksheets
ABC XYZ FIELD DEVELOPMENT PROJECT
Central Facilities
ABBREVIATIONS & DEFINTIONS ABBREVIATIONS • • • • • • • • • • • • • • • • • • • • • • • • • • •
AIV ALARP CO2 CPP EIA FEED FIV FP FPSO FSO GRE H2S HAZID HP LNG LP LQ MOC NOx P&ID PFD QRA SCUBA SIMOPS SOx VOC WHP
Acoustic Induced Vibration As Low As Reasonably Practicable Carbon di Oxide Central Process Platform Environmental Impact Assessment Front End Engineering Design Flow Induced Vibration Flare Platform Floating Production Storage and Offtake Floating Storage and Offtake Glass Reinforced Epoxy Hydrogen Sulphide Hazard Identification Study High Pressure Liquefied Natural Gas Low Pressure Living Quarters Material of Construction Nitrogen Oxides Process and Instrumentation Diagram Process Flow Diagram Quantitative Risk Analysis Self-Contained Underwater Breathing Apparatus SIMultaneous OPerationS Sulphur Oxides Volatile Organic Chemicals (Benzene, toluene etc considered carcinogens) Wellhead Platform
DEFINTIONS • • •
CLIENT CONSULTANT CONTRACTOR
Note: This report is based on the documents referred to in Appendix A. Modifications or revisions to these documents may invalidate the observations and conclusions recorded in this report.
REPORT NUMBER:
REV: A 26 MAY 2009
PAGE 2 OF 17
HAZID
Worksheets
ABC XYZ FIELD DEVELOPMENT PROJECT
Central Facilities
Table of Contents 1.0 INTRODUCTION ...........................................................................................................................4 1.1 PURPOSE..................................................................................................................................4 1.2 REFERENCES ..........................................................................................................................4 2.0 OBJECTIVES ................................................................................................................................5 3.0 SCOPE OF WORK........................................................................................................................6 3.1 Process Systems Studied..........................................................................................................6 3.2 Locations Studied ......................................................................................................................6 3.3 Schedule ....................................................................................................................................6 3.4 Deliverables ...............................................................................................................................6 3.5 HAZID Team Members..............................................................................................................7 3.6 HAZID Software .........................................................................................................................7 3.7 HAZID Session ..........................................................................................................................7 4.0 HAZID STUDY BASIS ...................................................................................................................8 4.1 Process Facilities .......................................................................................................................8 4.1.1 Flowlines, well fluid manifold system and receivers ...........................................................8 4.1.2 Oil systems:.........................................................................................................................8 4.1.3 Gas systems:.......................................................................................................................8 4.1.4 Utility and Auxiliary Systems...............................................................................................8 4.2 Facilities Layout .........................................................................................................................9 4.3 Facility Information...................................................................................................................10 4.4 Safety Studies ..........................................................................................................................12 5.0 HAZID STUDY.............................................................................................................................13 5.1 Methodology.............................................................................................................................13 5.2 Findings....................................................................................................................................13 5.3 Key Findings ............................................................................................................................13 APPENDIX A – HAZID Study Reference Documents ...............................................................14 APPENDIX B – HAZID Study Worksheets ................................................................................14 APPENDIX C – HAZID study Summary of Recommendations.................................................14 APPENDIX D – HAZID Explained..............................................................................................15
HOLD LIST– This identifies holds in following sections Section
REPORT NUMBER:
Hold Description
REV: A 26 MAY 2009
PAGE 3 OF 17
HAZID
Worksheets
ABC XYZ FIELD DEVELOPMENT PROJECT
Central Facilities
1.0 INTRODUCTION 1.1 PURPOSE This document presents the findings of a Hazards Identification (HAZID) Study conducted for the ------- on ---------- at ------------. One paragraph on the project ----------------------------Hazard Identification (HAZID) is a systematic risk assessment study carried out by a team of engineers from different disciplines. The team looks at each part of a plant or facility, considers potential hazards, analyses their consequences against any existing safeguards. Criteria include safety, asset, environment, reputation, society, etc. HAZID study records the identified hazards without proposing any solution. The record serves as a guide to determine the Health, Safety and Environment (HSE) issues to be resolved during the project. HAZID is a guideword driven brainstorming technique, which requires a properly constructed team.
1.2 REFERENCES The HAZID study was conducted in accordance with the following documents • ISO-17776 : Petroleum and natural gas industries – Offshore production installations – Guidelines on tools and techniques for hazard identification and risk assessment, 1st Edition, 2000-10–15 Project documents referred to during the study is listed in Appendix A.
REPORT NUMBER:
REV: A 26 MAY 2009
PAGE 4 OF 17
HAZID
Worksheets
ABC XYZ FIELD DEVELOPMENT PROJECT
Central Facilities
2.0 OBJECTIVES The objectives of the HAZID study are: • Identify potential hazards and risks associated with a project and process facilities of this nature to identify early safety and operational issues • Understand these hazards or risks and determine their potential consequences • Determine (design and procedural) safeguards or risk reduction measures incorporated and evaluate their adequacy and • Recommend additional safeguards or operational procedures as necessary.
REPORT NUMBER:
REV: A 26 MAY 2009
PAGE 5 OF 17
HAZID
Worksheets
ABC XYZ FIELD DEVELOPMENT PROJECT
Central Facilities
3.0 SCOPE OF WORK The HAZID study covered the design, construction and operational phases of the facility, identifying threats that are of global in nature, that is, applicable to all the process systems and plant area; then it identified threats that are specific to a system or location Drilling phase is not adequately addressed in this study as drilling operations subject matter experts did not participate in the study.
3.1 Process Systems Studied Following process systems were taken note of: • Flowlines, well fluid manifold system and receivers • Oil systems: Separation, Oil Metering and Export, Condensate Export • Gas systems: LP Gas Compression, Glycol Dehydration & Regeneration, HP Gas Compression, Gas Metering and Export • Flare and Vent Systems • Fuel Gas System • Open and Closed Drain System • Produced Water System • Diesel Oil System • Waste Heat Recovery and Hot Oil Systems • Water Injection System • Fire water system and • Chemical Injection Package
3.2 Locations Studied Equipment, as laid out on the following decks is indicated below: • Lower Deck at _-- m: • Main Deck at +-- m: • Upper Deck at +-- m: • Mezzanine Deck at +-- m:
3.3 Schedule The HAZID study was conducted in ----- -------- office from --- to ----- --------------- ---. A presentation of the recommendations was made on ---- ----- ---.
3.4 Deliverables As agreed with the client, the main deliverables of this study are: 1. HAZID methodology and typical worksheet for review, prior to commencement of the study, that is, draft form of this report. This has been done. 2. Interim report on the findings and recommendation of the study. This has been done. 3. Draft report. This report. 4. Final report will be delivered after getting comments on this report This draft report is submitted for review, electronically within 2 weeks of completing the study. The final report will be submitted in 3 hard copies along with electronic copy of native file
REPORT NUMBER:
REV: A 26 MAY 2009
PAGE 6 OF 17
HAZID
Worksheets
ABC XYZ FIELD DEVELOPMENT PROJECT
Central Facilities incorporating review comments from all relevant parties. If necessary a meeting will be arranged between Company/ Contractor/ Consultant to resolve conflicting comments.
3.5 HAZID Team Members HAZID study was held on -------------------. Following persons participated, on part or full time basis as noted. No 1 2 3 4 5 6 7 8
Name
Organization & Role
Dates 1 2
Remarks
3.6 HAZID Software MS-Word based worksheets were used to capture HAZID team discussions and findings.
3.7 HAZID Session The HAZID study was started with an overview of process facilities and platform deck layout. This helped the team members to become familiar with the facility. Safety or incident alerts related to similar facilities were shared. A brief introduction was given on systems with high pressure, high temperature, low temperature and hazardous chemicals.
REPORT NUMBER:
REV: A 26 MAY 2009
PAGE 7 OF 17
HAZID
Worksheets
ABC XYZ FIELD DEVELOPMENT PROJECT
Central Facilities
4.0 HAZID STUDY BASIS 4.1 Process Facilities Process Flow Scheme
4.1.1 Flowlines, well fluid manifold system and receivers 4.1.2 Oil systems: Separation Oil Metering and Export Condensate Export
4.1.3 Gas systems: LP Gas Compression Glycol Dehydration & Regeneration HP Gas Compression Gas Metering and Export
4.1.4 Utility and Auxiliary Systems Flare and Vent Systems Fuel Gas System Open and Closed Drain System
REPORT NUMBER:
REV: A 26 MAY 2009
PAGE 8 OF 17
HAZID
Worksheets
ABC XYZ FIELD DEVELOPMENT PROJECT
Central Facilities Produced Water System Diesel Oil System Waste Heat Recovery and Hot Oil Systems Water Injection System Fire water system and Chemical Injection Package
4.2 Facilities Layout The Central Process Platform CPP is kept separate from Living Quarters and Flare platforms by bridges. It is bridge linked to an adjacent wellhead platform. Fluids from other remote wellhead platforms are brought in by subsea 3 phase pipelines. Platform boat approach is from West while risers are grouped on the southern and northern side. Layout Sketch
Inlet Slug Catchers are located on Lower Deck, while Dehydrator is on the Main Deck. Compressors and Generators are on the Upper Deck. Relative location of major equipment are shown below, in an exploded view
REPORT NUMBER:
REV: A 26 MAY 2009
PAGE 9 OF 17
Deck Sketch Worksheets HAZID
ABC XYZ FIELD DEVELOPMENT PROJECT
Central Facilities
4.3 Facility Information Following information on the facility was presented to the HAZID team members to familiarize them with the facility and its system. : : :
Onshore LNG Refinery
Offshore Oil & Gas Petrochemical
Type of Field
:
Marginal
Normal
Feed Products
: Oil, Gas and Water : Gas compressed, dehydrated and exported via pipeline : Oil stabilized and exported via pipeline : Condensate injected into gas pipeline : Water deoiled and locally disposed
Gas
: Daily Contractual Quantity (DCQ) : Max Daily Quantity (MDQ) : Design : Normal / Maximum : Normal / Maximum/ Design
Type of Facility
Condensate Produced Water Platform
REPORT NUMBER:
: Wellhead : No of Decks XX : Single lift : Bridge linked : Helipad on : Unmanned
Gas & Condensate Chemical/ Fertilizer
XXX MMscfd YYY (DCQ + 10%) ZZZ 125% MDQ XX,000 / YY,000 BPD XX,000 / YY,000 BPD
Process Platform No of Piles YY Weight ZZ,000 t Modular lift Float over Wellhead LQ Flare Tripod LQ on another location Manned
REV: A 26 MAY 2009
PAGE 10 OF 17
HAZID
Worksheets
ABC XYZ FIELD DEVELOPMENT PROJECT
Central Facilities Vertical on platform Cantilevered from platform Separate bridge linked platform
Flare
: :
Pressure Temperature
: Highest 165 barg lift gas; 75 barg export gas : Lowest (–) 40°C HP flare lateral; Highest - 550°C GT exhaust
Shallow Water Deepwater Location : If Deep water, familiar with : Hydrate/ Wax Issues MEG/Methanol Injection : Line Flushing Wetwells Drywells If FPSO/ Semi-sub, familiar with or knows about : Impact of ship motion on topsides Hazardous & Corrosive Materials H2S 500 to 2,000 ppm Mercury Arsenic Lethal, Toxic Components : If H2S : Operator familiar. A few units in operation Material Selection Personal H2S Monitor SCUBA : : Familiar or knows pyrophoric issues If Hg or As
: : :
Removal Handling Aluminum as MOC Low accumulation points Operator familiar Discharge to sea with produced water
: : : : : :
CO2 4 – 6% Acid cleaning - compressor piping Wellfluids High Temp CO2 - H2O from regenerator Hypochlorite solution Operator familiar. A few units in operation Material Selection Knows about wet CO2 issues Familiar or knows asphyxiation issues
Potential incompatibilities
: :
Solids Sand Acid/alkali handling
Catalysts Dust Handling
: :
Mercury Removal None
Firewater system uses
:
GRE pipes
Owner-Operator
: First Installation Operates similar units : Sub-contract operation Operated by own crew : Isolation standards, including Double Block & Bleed : Sampling Draining Venting Philosophy : PSVs are spared not spared : Familiar with Rupture disks, if used
Corrosive If CO2
Drill mud Wax Dehydrator Mol Sieves
PE/ Cement lined pipes
None
Alloy steel
Key Issues • High Levels of H2S • First of a kind for client??
REPORT NUMBER:
REV: A 26 MAY 2009
PAGE 11 OF 17
HAZID
Worksheets
ABC XYZ FIELD DEVELOPMENT PROJECT
Central Facilities A brief presentation was made on HAZID and its methodology. Then the actual HAZID session was started.
4.4 Safety Studies It is noted that following Safety related studies are being or proposed to be conducted for this facility. This will be taken note of while considering design safeguards. Equipment and Building Location Study Smoke & Gas Ingress/ Toxic Gas Risk Analysis Fire & Explosion / Blast Analysis Escape, Evacuation and Rescue Analysis (EERA) Emergency Systems Survivability Analysis (ESSA) Quantitative Risk Assessment (QRA) Environmental Impact Assessment (EIA) Studies Inherent Safety Analysis - Eliminate by process changes, minimize inventory Hazard Prevention - Overpressure protection, Area Classification, SIL Hazard Detection - Fire & Gas Detection, ESD stations Hazard Control - Isolation & Depressurization Hazard Mitigation - Active & Passive Fire Protection, Firewater/ Foam Systems Collision Study Dropped Object study AIV/ FIV Studies Vibration/ Noise Study Pipe Stress Study SIMOPS Study Human Factors
REPORT NUMBER:
REV: A 26 MAY 2009
PAGE 12 OF 17
HAZID
Worksheets
ABC XYZ FIELD DEVELOPMENT PROJECT
Central Facilities
5.0 HAZID STUDY 5.1 Methodology The HAZIP study was conducted in an industry standard approach. It is briefly discussed in Appendix D.
5.2 Findings The HAZID team made a total of about --- recommendations. About 20 are key recommendations. Some are highlighted below. The HAZID study worksheets are in Appendix B while the Summary of Recommendations is in Appendix C.
5.3 Key Findings Following summarizes key findings •
•
Alert the Operation and Maintenance team to potential pyrophoric fire on opening H2S laden vessels and exposing them to air. Suitable caution boxes will be provided in key P&IDs and on equipment to keep the surfaces wet and/or follow company procedures. It is proposed to conduct a transient analysis of seawater pumps and Firewater pumps to avoid pressure surges and make SPR (Single Point Responsibility) mandatory on GRE pipe manufacturer for material, design, and layout review to avoid sharp turns, surge analysis, fabrication and installation for GRE pipes.
REPORT NUMBER:
REV: A 26 MAY 2009
PAGE 13 OF 17
HAZID
Worksheets
ABC XYZ FIELD DEVELOPMENT PROJECT
Central Facilities
APPENDIX A – HAZID Study Reference Documents 1. 2. 3. 4. 5. 6. 7. 8.
XXXX-YYY-ZZZ Rev A - Simplified Block Flow Diagram XXXX-YYY-ZZZ Rev A - PFD 300 MMscfd Gas + 10,000 BPD Condensate to FSO XXXX-YYY-ZZZ Rev A - Equipment Layout - Upper Deck XXXX-YYY-ZZZ Rev A - Equipment Layout - Main Deck XXXX-YYY-ZZZ Rev A - Equipment Layout - Lower Deck XXXX-YYY-ZZZ Rev A - Equipment Layout - Elevation Looking East XXXX-YYY-ZZZ Rev A - Equipment Layout - Elevation Looking West XXXX-YYY-ZZZ Rev A - Facilities Layout – CPP, WHP, LQ, FP
Feedback on FPSO issues http://olf.no/en/FPSO-Experience-Transfer/FPSO-Lessons-overview/
APPENDIX B – HAZID Study Worksheets APPENDIX C – HAZID study Summary of Recommendations
REPORT NUMBER:
REV: A 26 MAY 2009
PAGE 14 OF 17
HAZID
Worksheets
ABC XYZ FIELD DEVELOPMENT PROJECT
Central Facilities
APPENDIX D – HAZID Explained What?
Hazard Identification (HAZID) study identifies hazards or risks in onshore and offshore installations.
When? Any time but done best as early as possible at FEED stage as soon as a preliminary layout and block flow diagrams for process and utility systems are available. If required a follow-on study may be conducted during Detailed Engg stage to follow-up recommendations of previous studies. Early studies enable timely inputs to proposed design. Delayed studies fail to influence or apply course-correction to design decisions. Who?
By a team of engineers. Suggested team members are: Study chairman or facilitator, Scribe, Process engineer, Safety engineer, Layout or Piping engineer and Client representatives. They are supplemented on a call basis by Civil or Structural engineer, and Mechanical engineer.
Areas? Team selects areas to study - either plot or deck wise or system wise. Too many wastes time leading to repetition and waning focus. Too few may miss out a few threats. Experienced judgment is the key. How?
Each system or area of an installation is reviewed against a pre-agreed checklist. When a hazard or risk is identified, (1) All potential causes or scenarios that could initiate or trigger the hazard (2) Their potential consequences - direct as well as escalated (3) Impact on personnel, assets and environment (4) Effectiveness of safeguards/ risk reduction/ or operating procedures present (5) Recommendation, if any, to add to existing mitigation measures were evaluated. This process was repeated for each hazard and each system until all have been studied. HAZID team should not attempt to provide a solution unless one is obvious. Its role is to identify hazards and provide a high level qualitative assessment. The project and discipline engineers should find an acceptable solution as part of design development. Some HAZID studies may assign Risk Ratings for the identified hazards, based on a risk matrix by the client. These ratings help prioritize follow-on actions. Whether there is a risk rating are not, all actions should be properly closed out. During the study, the HAZID worksheet is projected overhead for members to see, comment and concur. Hazards that are not present are not recorded.
Inputs? Field and facility layout drawings, Process and Utility flow diagrams. Next?
Actions or recommendations proposed are assigned to individuals by a project engineer via a suitable tracking system. Actions closed out are recorded in the final HAZID report issued as a project deliverable. A few projects may maintain a Hazard
REPORT NUMBER:
REV: A 26 MAY 2009
PAGE 15 OF 17
HAZID
Worksheets
ABC XYZ FIELD DEVELOPMENT PROJECT
Central Facilities Register wherein identified hazards are input by area and type. The HAZID report is used to populate it. Checklists Each organization has one of its choice or one can be developed as required. Global Issues Hydrocarbon, Chemicals & Utilities 1. Hydrocarbons release - with or without ignition Dropped objects, Swing loads, Corrosion, Small bore pipes, Fitting leaks, Seal failure, low temperature embrittlement, AIV/FIV, Gas blowby 2. Hydrocarbon ingress Hydrocarbon ingress into gas turbine, diesel engine, fired heater air intakes 3. Moisture ingress Water ingress into heated or hot oil storage 4. Draining / Sampling Discharge of produced water (with mercury), mud, cuttings to sea or soil 5. Thermal radiation/ Flaring and Venting Hazardous Chemicals & Health Hazards 6. Hazardous gas, liquids and solids release Mercury, Arsenic, H2S, CO2, CH4, NOx, SOx, VOC 7. Non Process Fire/ Flammable chemicals Fire in LER, GT Enclosure 8. Explosion H2 in Hypochlorite Tank or Battery Room 9. Asphyxiation / Confined space Inert gas release, Smoke, CO2, Vessel entry 10. Particulates (sand, dust, ash) Sand, Catalysts, Desiccant, 11. Radioactive / Explosive material Structural 12. Structural failure Weather, Earthquake, Collision, Overload, Fire, Cyclic loads Occupational Hazards 13. Electrical energy Electrocution, Static electricity 14. Stored energy (Pneumatic / Thermal) High pressure hoses, Hot surfaces 15. Vibration / Noise High pressure drop valves, Machinery, slugging, Water hammer 16. Manual work Rigging, Handling drums, Cutting & Welding, Hand tools, Fall overboard 17. Natural and Environmental Hazards Wind, Cyclones/ hurricanes/ tornadoes, Waves, High tides, tsunami, Sea currents, Floods, Ice, Blizzards, Earthquake, Volcano, Ground slide, Soil subsidence, Summer, Winter, Saliferous or sand/ dust laden wind, Humidity, Heavy rains and Lighting
REPORT NUMBER:
REV: A 26 MAY 2009
PAGE 16 OF 17
HAZID
Worksheets
ABC XYZ FIELD DEVELOPMENT PROJECT
Central Facilities Marine 18. Marine operations Personnel Transfer, Supply boat operations, Passing ships, Helicopter operations 19. SIMOP Emergency, Escape and Rescue 20. Impeded Access / Approach / Escape/ Evacuation Slippery steps, Blocked access, Laydown area, Maintenance activities Man-made Hazards 21. Security issues Unauthorized entry; Sabotage; Piracy, Terrorist activities Construction and Start-up 22. Construction difficulties Poor planning, Legislation, Compliance to local codes & standards 23. Start-up & Shutdown difficulties Poor planning, Missing black start fuel, Low inventory, Untrained crew System or location specific issues Pigging Operation Cellar or Lowest Deck Upper Deck FPSO Poor planning - Hull delivery; Storage volume; hull to shipping standards (batch mode) and topsides to process industry standards (continuous operation) Effect of FPSO’s axial (Surge, Sway, Heave), rotational (Roll, Pitch, Yaw) and static (List, Trim) motions on separation, distillation, liquid levels, internals support Hogging/ sagging of decking plates on equipment support & structures, rotating equipment support Green water waves; Maintenance - storage tanks, sea chest, seawater pumps etc Onshore Location Proximity to population, Ground water contamination, Historical monuments damaged by fumes, Public roads, Nearby land use (Farming/ Fishing) Biological Endemic diseases, Infection, Contaminated water / food, Biological agents (viruses, pathogens, parasites, poisonous reptiles and plants)
Caution: What is normal practice in a company may be a hazardous practice in another company which may not have adequate experience with a particular process or equipment. Example: regenerator insulation failure resulting in hot spots and vessel failure or H2S.
REPORT NUMBER:
REV: A 26 MAY 2009
PAGE 17 OF 17
Fine Print
Educational/ Training Material Issued as a service to the industry for Free Distribution
HAZID STUDY REPORT
EPC Contractor: Engg Consultant:
Rev
Job No
Date
Issued For
Sec No
By
Contract No
Chk’d App’d Engg Consultant
Document No
Contractor
Client
HAZID
Worksheets
ABC XYZ FIELD DEVELOPMENT PROJECT
Central Facilities
ABBREVIATIONS & DEFINTIONS ABBREVIATIONS • • • • • • • • • • • • • • • • • • • • • • • • • • •
AIV ALARP CO2 CPP EIA FEED FIV FP FPSO FSO GRE H2S HAZID HP LNG LP LQ MOC NOx P&ID PFD QRA SCUBA SIMOPS SOx VOC WHP
Acoustic Induced Vibration As Low As Reasonably Practicable Carbon di Oxide Central Process Platform Environmental Impact Assessment Front End Engineering Design Flow Induced Vibration Flare Platform Floating Production Storage and Offtake Floating Storage and Offtake Glass Reinforced Epoxy Hydrogen Sulphide Hazard Identification Study High Pressure Liquefied Natural Gas Low Pressure Living Quarters Material of Construction Nitrogen Oxides Process and Instrumentation Diagram Process Flow Diagram Quantitative Risk Analysis Self-Contained Underwater Breathing Apparatus SIMultaneous OPerationS Sulphur Oxides Volatile Organic Chemicals (Benzene, toluene etc considered carcinogens) Wellhead Platform
DEFINTIONS • • •
CLIENT CONSULTANT CONTRACTOR
Note: This report is based on the documents referred to in Appendix A. Modifications or revisions to these documents may invalidate the observations and conclusions recorded in this report.
REPORT NUMBER:
REV: A 26 MAY 2009
PAGE 2 OF 17
HAZID
Worksheets
ABC XYZ FIELD DEVELOPMENT PROJECT
Central Facilities
Table of Contents 1.0 INTRODUCTION ...........................................................................................................................4 1.1 PURPOSE..................................................................................................................................4 1.2 REFERENCES ..........................................................................................................................4 2.0 OBJECTIVES ................................................................................................................................5 3.0 SCOPE OF WORK........................................................................................................................6 3.1 Process Systems Studied..........................................................................................................6 3.2 Locations Studied ......................................................................................................................6 3.3 Schedule ....................................................................................................................................6 3.4 Deliverables ...............................................................................................................................6 3.5 HAZID Team Members..............................................................................................................7 3.6 HAZID Software .........................................................................................................................7 3.7 HAZID Session ..........................................................................................................................7 4.0 HAZID STUDY BASIS ...................................................................................................................8 4.1 Process Facilities .......................................................................................................................8 4.1.1 Flowlines, well fluid manifold system and receivers ...........................................................8 4.1.2 Oil systems:.........................................................................................................................8 4.1.3 Gas systems:.......................................................................................................................8 4.1.4 Utility and Auxiliary Systems...............................................................................................8 4.2 Facilities Layout .........................................................................................................................9 4.3 Facility Information...................................................................................................................10 4.4 Safety Studies ..........................................................................................................................12 5.0 HAZID STUDY.............................................................................................................................13 5.1 Methodology.............................................................................................................................13 5.2 Findings....................................................................................................................................13 5.3 Key Findings ............................................................................................................................13 APPENDIX A – HAZID Study Reference Documents ...............................................................14 APPENDIX B – HAZID Study Worksheets ................................................................................14 APPENDIX C – HAZID study Summary of Recommendations.................................................14 APPENDIX D – HAZID Explained..............................................................................................15
HOLD LIST– This identifies holds in following sections Section
REPORT NUMBER:
Hold Description
REV: A 26 MAY 2009
PAGE 3 OF 17
HAZID
Worksheets
ABC XYZ FIELD DEVELOPMENT PROJECT
Central Facilities
1.0 INTRODUCTION 1.1 PURPOSE This document presents the findings of a Hazards Identification (HAZID) Study conducted for the ------- on ---------- at ------------. One paragraph on the project ----------------------------Hazard Identification (HAZID) is a systematic risk assessment study carried out by a team of engineers from different disciplines. The team looks at each part of a plant or facility, considers potential hazards, analyses their consequences against any existing safeguards. Criteria include safety, asset, environment, reputation, society, etc. HAZID study records the identified hazards without proposing any solution. The record serves as a guide to determine the Health, Safety and Environment (HSE) issues to be resolved during the project. HAZID is a guideword driven brainstorming technique, which requires a properly constructed team.
1.2 REFERENCES The HAZID study was conducted in accordance with the following documents • ISO-17776 : Petroleum and natural gas industries – Offshore production installations – Guidelines on tools and techniques for hazard identification and risk assessment, 1st Edition, 2000-10–15 Project documents referred to during the study is listed in Appendix A.
REPORT NUMBER:
REV: A 26 MAY 2009
PAGE 4 OF 17
HAZID
Worksheets
ABC XYZ FIELD DEVELOPMENT PROJECT
Central Facilities
2.0 OBJECTIVES The objectives of the HAZID study are: • Identify potential hazards and risks associated with a project and process facilities of this nature to identify early safety and operational issues • Understand these hazards or risks and determine their potential consequences • Determine (design and procedural) safeguards or risk reduction measures incorporated and evaluate their adequacy and • Recommend additional safeguards or operational procedures as necessary.
REPORT NUMBER:
REV: A 26 MAY 2009
PAGE 5 OF 17
HAZID
Worksheets
ABC XYZ FIELD DEVELOPMENT PROJECT
Central Facilities
3.0 SCOPE OF WORK The HAZID study covered the design, construction and operational phases of the facility, identifying threats that are of global in nature, that is, applicable to all the process systems and plant area; then it identified threats that are specific to a system or location Drilling phase is not adequately addressed in this study as drilling operations subject matter experts did not participate in the study.
3.1 Process Systems Studied Following process systems were taken note of: • Flowlines, well fluid manifold system and receivers • Oil systems: Separation, Oil Metering and Export, Condensate Export • Gas systems: LP Gas Compression, Glycol Dehydration & Regeneration, HP Gas Compression, Gas Metering and Export • Flare and Vent Systems • Fuel Gas System • Open and Closed Drain System • Produced Water System • Diesel Oil System • Waste Heat Recovery and Hot Oil Systems • Water Injection System • Fire water system and • Chemical Injection Package
3.2 Locations Studied Equipment, as laid out on the following decks is indicated below: • Lower Deck at _-- m: • Main Deck at +-- m: • Upper Deck at +-- m: • Mezzanine Deck at +-- m:
3.3 Schedule The HAZID study was conducted in ----- -------- office from --- to ----- --------------- ---. A presentation of the recommendations was made on ---- ----- ---.
3.4 Deliverables As agreed with the client, the main deliverables of this study are: 1. HAZID methodology and typical worksheet for review, prior to commencement of the study, that is, draft form of this report. This has been done. 2. Interim report on the findings and recommendation of the study. This has been done. 3. Draft report. This report. 4. Final report will be delivered after getting comments on this report This draft report is submitted for review, electronically within 2 weeks of completing the study. The final report will be submitted in 3 hard copies along with electronic copy of native file
REPORT NUMBER:
REV: A 26 MAY 2009
PAGE 6 OF 17
HAZID
Worksheets
ABC XYZ FIELD DEVELOPMENT PROJECT
Central Facilities incorporating review comments from all relevant parties. If necessary a meeting will be arranged between Company/ Contractor/ Consultant to resolve conflicting comments.
3.5 HAZID Team Members HAZID study was held on -------------------. Following persons participated, on part or full time basis as noted. No 1 2 3 4 5 6 7 8
Name
Organization & Role
Dates 1 2
Remarks
3.6 HAZID Software MS-Word based worksheets were used to capture HAZID team discussions and findings.
3.7 HAZID Session The HAZID study was started with an overview of process facilities and platform deck layout. This helped the team members to become familiar with the facility. Safety or incident alerts related to similar facilities were shared. A brief introduction was given on systems with high pressure, high temperature, low temperature and hazardous chemicals.
REPORT NUMBER:
REV: A 26 MAY 2009
PAGE 7 OF 17
HAZID
Worksheets
ABC XYZ FIELD DEVELOPMENT PROJECT
Central Facilities
4.0 HAZID STUDY BASIS 4.1 Process Facilities Process Flow Scheme
4.1.1 Flowlines, well fluid manifold system and receivers 4.1.2 Oil systems: Separation Oil Metering and Export Condensate Export
4.1.3 Gas systems: LP Gas Compression Glycol Dehydration & Regeneration HP Gas Compression Gas Metering and Export
4.1.4 Utility and Auxiliary Systems Flare and Vent Systems Fuel Gas System Open and Closed Drain System
REPORT NUMBER:
REV: A 26 MAY 2009
PAGE 8 OF 17
HAZID
Worksheets
ABC XYZ FIELD DEVELOPMENT PROJECT
Central Facilities Produced Water System Diesel Oil System Waste Heat Recovery and Hot Oil Systems Water Injection System Fire water system and Chemical Injection Package
4.2 Facilities Layout The Central Process Platform CPP is kept separate from Living Quarters and Flare platforms by bridges. It is bridge linked to an adjacent wellhead platform. Fluids from other remote wellhead platforms are brought in by subsea 3 phase pipelines. Platform boat approach is from West while risers are grouped on the southern and northern side. Layout Sketch
Inlet Slug Catchers are located on Lower Deck, while Dehydrator is on the Main Deck. Compressors and Generators are on the Upper Deck. Relative location of major equipment are shown below, in an exploded view
REPORT NUMBER:
REV: A 26 MAY 2009
PAGE 9 OF 17
Deck Sketch Worksheets HAZID
ABC XYZ FIELD DEVELOPMENT PROJECT
Central Facilities
4.3 Facility Information Following information on the facility was presented to the HAZID team members to familiarize them with the facility and its system. : : :
Onshore LNG Refinery
Offshore Oil & Gas Petrochemical
Type of Field
:
Marginal
Normal
Feed Products
: Oil, Gas and Water : Gas compressed, dehydrated and exported via pipeline : Oil stabilized and exported via pipeline : Condensate injected into gas pipeline : Water deoiled and locally disposed
Gas
: Daily Contractual Quantity (DCQ) : Max Daily Quantity (MDQ) : Design : Normal / Maximum : Normal / Maximum/ Design
Type of Facility
Condensate Produced Water Platform
REPORT NUMBER:
: Wellhead : No of Decks XX : Single lift : Bridge linked : Helipad on : Unmanned
Gas & Condensate Chemical/ Fertilizer
XXX MMscfd YYY (DCQ + 10%) ZZZ 125% MDQ XX,000 / YY,000 BPD XX,000 / YY,000 BPD
Process Platform No of Piles YY Weight ZZ,000 t Modular lift Float over Wellhead LQ Flare Tripod LQ on another location Manned
REV: A 26 MAY 2009
PAGE 10 OF 17
HAZID
Worksheets
ABC XYZ FIELD DEVELOPMENT PROJECT
Central Facilities Vertical on platform Cantilevered from platform Separate bridge linked platform
Flare
: :
Pressure Temperature
: Highest 165 barg lift gas; 75 barg export gas : Lowest (–) 40°C HP flare lateral; Highest - 550°C GT exhaust
Shallow Water Deepwater Location : If Deep water, familiar with : Hydrate/ Wax Issues MEG/Methanol Injection : Line Flushing Wetwells Drywells If FPSO/ Semi-sub, familiar with or knows about : Impact of ship motion on topsides Hazardous & Corrosive Materials H2S 500 to 2,000 ppm Mercury Arsenic Lethal, Toxic Components : If H2S : Operator familiar. A few units in operation Material Selection Personal H2S Monitor SCUBA : : Familiar or knows pyrophoric issues If Hg or As
: : :
Removal Handling Aluminum as MOC Low accumulation points Operator familiar Discharge to sea with produced water
: : : : : :
CO2 4 – 6% Acid cleaning - compressor piping Wellfluids High Temp CO2 - H2O from regenerator Hypochlorite solution Operator familiar. A few units in operation Material Selection Knows about wet CO2 issues Familiar or knows asphyxiation issues
Potential incompatibilities
: :
Solids Sand Acid/alkali handling
Catalysts Dust Handling
: :
Mercury Removal None
Firewater system uses
:
GRE pipes
Owner-Operator
: First Installation Operates similar units : Sub-contract operation Operated by own crew : Isolation standards, including Double Block & Bleed : Sampling Draining Venting Philosophy : PSVs are spared not spared : Familiar with Rupture disks, if used
Corrosive If CO2
Drill mud Wax Dehydrator Mol Sieves
PE/ Cement lined pipes
None
Alloy steel
Key Issues • High Levels of H2S • First of a kind for client??
REPORT NUMBER:
REV: A 26 MAY 2009
PAGE 11 OF 17
HAZID
Worksheets
ABC XYZ FIELD DEVELOPMENT PROJECT
Central Facilities A brief presentation was made on HAZID and its methodology. Then the actual HAZID session was started.
4.4 Safety Studies It is noted that following Safety related studies are being or proposed to be conducted for this facility. This will be taken note of while considering design safeguards. Equipment and Building Location Study Smoke & Gas Ingress/ Toxic Gas Risk Analysis Fire & Explosion / Blast Analysis Escape, Evacuation and Rescue Analysis (EERA) Emergency Systems Survivability Analysis (ESSA) Quantitative Risk Assessment (QRA) Environmental Impact Assessment (EIA) Studies Inherent Safety Analysis - Eliminate by process changes, minimize inventory Hazard Prevention - Overpressure protection, Area Classification, SIL Hazard Detection - Fire & Gas Detection, ESD stations Hazard Control - Isolation & Depressurization Hazard Mitigation - Active & Passive Fire Protection, Firewater/ Foam Systems Collision Study Dropped Object study AIV/ FIV Studies Vibration/ Noise Study Pipe Stress Study SIMOPS Study Human Factors
REPORT NUMBER:
REV: A 26 MAY 2009
PAGE 12 OF 17
HAZID
Worksheets
ABC XYZ FIELD DEVELOPMENT PROJECT
Central Facilities
5.0 HAZID STUDY 5.1 Methodology The HAZIP study was conducted in an industry standard approach. It is briefly discussed in Appendix D.
5.2 Findings The HAZID team made a total of about --- recommendations. About 20 are key recommendations. Some are highlighted below. The HAZID study worksheets are in Appendix B while the Summary of Recommendations is in Appendix C.
5.3 Key Findings Following summarizes key findings •
•
Alert the Operation and Maintenance team to potential pyrophoric fire on opening H2S laden vessels and exposing them to air. Suitable caution boxes will be provided in key P&IDs and on equipment to keep the surfaces wet and/or follow company procedures. It is proposed to conduct a transient analysis of seawater pumps and Firewater pumps to avoid pressure surges and make SPR (Single Point Responsibility) mandatory on GRE pipe manufacturer for material, design, and layout review to avoid sharp turns, surge analysis, fabrication and installation for GRE pipes.
REPORT NUMBER:
REV: A 26 MAY 2009
PAGE 13 OF 17
HAZID
Worksheets
ABC XYZ FIELD DEVELOPMENT PROJECT
Central Facilities
APPENDIX A – HAZID Study Reference Documents 1. 2. 3. 4. 5. 6. 7. 8.
XXXX-YYY-ZZZ Rev A - Simplified Block Flow Diagram XXXX-YYY-ZZZ Rev A - PFD 300 MMscfd Gas + 10,000 BPD Condensate to FSO XXXX-YYY-ZZZ Rev A - Equipment Layout - Upper Deck XXXX-YYY-ZZZ Rev A - Equipment Layout - Main Deck XXXX-YYY-ZZZ Rev A - Equipment Layout - Lower Deck XXXX-YYY-ZZZ Rev A - Equipment Layout - Elevation Looking East XXXX-YYY-ZZZ Rev A - Equipment Layout - Elevation Looking West XXXX-YYY-ZZZ Rev A - Facilities Layout – CPP, WHP, LQ, FP
Feedback on FPSO issues http://olf.no/en/FPSO-Experience-Transfer/FPSO-Lessons-overview/
APPENDIX B – HAZID Study Worksheets APPENDIX C – HAZID study Summary of Recommendations
REPORT NUMBER:
REV: A 26 MAY 2009
PAGE 14 OF 17
HAZID
Worksheets
ABC XYZ FIELD DEVELOPMENT PROJECT
Central Facilities
APPENDIX D – HAZID Explained What?
Hazard Identification (HAZID) study identifies hazards or risks in onshore and offshore installations.
When? Any time but done best as early as possible at FEED stage as soon as a preliminary layout and block flow diagrams for process and utility systems are available. If required a follow-on study may be conducted during Detailed Engg stage to follow-up recommendations of previous studies. Early studies enable timely inputs to proposed design. Delayed studies fail to influence or apply course-correction to design decisions. Who?
By a team of engineers. Suggested team members are: Study chairman or facilitator, Scribe, Process engineer, Safety engineer, Layout or Piping engineer and Client representatives. They are supplemented on a call basis by Civil or Structural engineer, and Mechanical engineer.
Areas? Team selects areas to study - either plot or deck wise or system wise. Too many wastes time leading to repetition and waning focus. Too few may miss out a few threats. Experienced judgment is the key. How?
Each system or area of an installation is reviewed against a pre-agreed checklist. When a hazard or risk is identified, (1) All potential causes or scenarios that could initiate or trigger the hazard (2) Their potential consequences - direct as well as escalated (3) Impact on personnel, assets and environment (4) Effectiveness of safeguards/ risk reduction/ or operating procedures present (5) Recommendation, if any, to add to existing mitigation measures were evaluated. This process was repeated for each hazard and each system until all have been studied. HAZID team should not attempt to provide a solution unless one is obvious. Its role is to identify hazards and provide a high level qualitative assessment. The project and discipline engineers should find an acceptable solution as part of design development. Some HAZID studies may assign Risk Ratings for the identified hazards, based on a risk matrix by the client. These ratings help prioritize follow-on actions. Whether there is a risk rating are not, all actions should be properly closed out. During the study, the HAZID worksheet is projected overhead for members to see, comment and concur. Hazards that are not present are not recorded.
Inputs? Field and facility layout drawings, Process and Utility flow diagrams. Next?
Actions or recommendations proposed are assigned to individuals by a project engineer via a suitable tracking system. Actions closed out are recorded in the final HAZID report issued as a project deliverable. A few projects may maintain a Hazard
REPORT NUMBER:
REV: A 26 MAY 2009
PAGE 15 OF 17
HAZID
Worksheets
ABC XYZ FIELD DEVELOPMENT PROJECT
Central Facilities Register wherein identified hazards are input by area and type. The HAZID report is used to populate it. Checklists Each organization has one of its choice or one can be developed as required. Global Issues Hydrocarbon, Chemicals & Utilities 1. Hydrocarbons release - with or without ignition Dropped objects, Swing loads, Corrosion, Small bore pipes, Fitting leaks, Seal failure, low temperature embrittlement, AIV/FIV, Gas blowby 2. Hydrocarbon ingress Hydrocarbon ingress into gas turbine, diesel engine, fired heater air intakes 3. Moisture ingress Water ingress into heated or hot oil storage 4. Draining / Sampling Discharge of produced water (with mercury), mud, cuttings to sea or soil 5. Thermal radiation/ Flaring and Venting Hazardous Chemicals & Health Hazards 6. Hazardous gas, liquids and solids release Mercury, Arsenic, H2S, CO2, CH4, NOx, SOx, VOC 7. Non Process Fire/ Flammable chemicals Fire in LER, GT Enclosure 8. Explosion H2 in Hypochlorite Tank or Battery Room 9. Asphyxiation / Confined space Inert gas release, Smoke, CO2, Vessel entry 10. Particulates (sand, dust, ash) Sand, Catalysts, Desiccant, 11. Radioactive / Explosive material Structural 12. Structural failure Weather, Earthquake, Collision, Overload, Fire, Cyclic loads Occupational Hazards 13. Electrical energy Electrocution, Static electricity 14. Stored energy (Pneumatic / Thermal) High pressure hoses, Hot surfaces 15. Vibration / Noise High pressure drop valves, Machinery, slugging, Water hammer 16. Manual work Rigging, Handling drums, Cutting & Welding, Hand tools, Fall overboard 17. Natural and Environmental Hazards Wind, Cyclones/ hurricanes/ tornadoes, Waves, High tides, tsunami, Sea currents, Floods, Ice, Blizzards, Earthquake, Volcano, Ground slide, Soil subsidence, Summer, Winter, Saliferous or sand/ dust laden wind, Humidity, Heavy rains and Lighting
REPORT NUMBER:
REV: A 26 MAY 2009
PAGE 16 OF 17
HAZID
Worksheets
ABC XYZ FIELD DEVELOPMENT PROJECT
Central Facilities Marine 18. Marine operations Personnel Transfer, Supply boat operations, Passing ships, Helicopter operations 19. SIMOP Emergency, Escape and Rescue 20. Impeded Access / Approach / Escape/ Evacuation Slippery steps, Blocked access, Laydown area, Maintenance activities Man-made Hazards 21. Security issues Unauthorized entry; Sabotage; Piracy, Terrorist activities Construction and Start-up 22. Construction difficulties Poor planning, Legislation, Compliance to local codes & standards 23. Start-up & Shutdown difficulties Poor planning, Missing black start fuel, Low inventory, Untrained crew System or location specific issues Pigging Operation Cellar or Lowest Deck Upper Deck FPSO Poor planning - Hull delivery; Storage volume; hull to shipping standards (batch mode) and topsides to process industry standards (continuous operation) Effect of FPSO’s axial (Surge, Sway, Heave), rotational (Roll, Pitch, Yaw) and static (List, Trim) motions on separation, distillation, liquid levels, internals support Hogging/ sagging of decking plates on equipment support & structures, rotating equipment support Green water waves; Maintenance - storage tanks, sea chest, seawater pumps etc Onshore Location Proximity to population, Ground water contamination, Historical monuments damaged by fumes, Public roads, Nearby land use (Farming/ Fishing) Biological Endemic diseases, Infection, Contaminated water / food, Biological agents (viruses, pathogens, parasites, poisonous reptiles and plants)
Caution: What is normal practice in a company may be a hazardous practice in another company which may not have adequate experience with a particular process or equipment. Example: regenerator insulation failure resulting in hot spots and vessel failure or H2S.
REPORT NUMBER:
REV: A 26 MAY 2009
PAGE 17 OF 17
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