Vol v Esia Vol 3 Part 2a-2g Hazop

7/25/2019 Vol v Esia Vol 3 Part 2a-2g Hazop

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I

P

ort Gertilis

SIA Ad

AZOP

ctober 201

NITEDINGDOM &ELAND

reparedfor:

abon Fertilise

entiler Pla

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2

r Company

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Table of Content

1.0 Introduction 3

1.1 Background 3

1.2 Purpose of report 3

2.0 Objective of HAZOP review 4

3.0 HAZOP Procedure 5

3.1 Preparation 5

3.2 Assumptions 5

3.3 Methodology 5

3.3.1 Nodes 6

3.3.2 Parameters and Deviations 6

4.0 HAZOP Review 8

4.1 Ammonia Production Unit 8

4.2 Ammonia Storage Unit 9

4.3 Compression unit 10

4.4 Urea synthesis unit 11

4.5 Urea granulation unit 12

4.6 Cooling water system 13

4.7 Steam generation and boiler feed water unit 14

5.0 Summary 15


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1.0 INTRODUCTION

1.1 Background

The Gabon Fertilizer Company (GFC), a Joint Venture between Olam International

Limited, Singapore and the Republic of Gabon (RoG) is planning to construct a

grass root ammonia-urea fertilizer complex at Cap Lopez, near Port-Gentil in the

Republic of Gabon. Olam International Ltd, Singapore (http://www.olamonline.com)

is a leading global integrated food ingredients and industrial raw material supplier

with operations in 65 countries and employing over 18000 people worldwide.

A land area of 120 ha has been allocated for the project site within the industrial

park developed at Cap Lopez.

The proposed fertilizer complex will comprise of:

Single stream ammonia plant licensed by HALDOR TOPSOE A/S,

Single stream urea synthesis plant licensed by SAIPEM S.p.a,

Single stream urea granulation plant by UHDE FERTILIZERS

TECHNOLOGY B.V.

Urea storage warehouse (Concrete / Pre-Engineered Building)

Ammonia storage (Double Wall Double Integrity Atmospheric Storage Tank)

Cooling water system

Water supply / treatment & storage

Power generation (Gas turbine) / Emergency Diesel Generator set

Steam generation (Waste heat of Gas Turbine and Auxiliary Boiler integrated

to process plant waste heat steam generation)

Effluent Management and Disposal (including sanitary effluents)

The Off-sites and other utilities units

Flare stacks

The support facilities (Administration buildings, workshops, ware house for

products)

1.2 Purpose of report

This report presents the HAZOP review carried out for the various units viz.

Ammonia production unit

Ammonia storage unit

Compression unit

Urea synthesis unit


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Urea granulation unit

Cooling water system

Steam generation and boiler feed water unit of the proposed fertilizer

project.

The above review involved specialists from

Company (Gabon Fertilizer Company),

Contractors (Technip) and

The Licensors {Haldor Topsoe A/S (HTAS), Denmark and Saipem SpA,

Italy}.

Specialists engaged by GFC.

A Hazard and Operability Review (HAZOP) for the Gabon Fertilizer Project was

held in the Technip (Paris) offices, La Dfense, France. The review was conducted

by a third-party Chairman from HazOptima and Bureau Veritas.

2.0 Objective of HAZOP review

The objective of the HAZOP was to identify process hazards in a systematic

approach so that they can be assessed, eliminated at source if possible, controlled

and/or mitigated otherwise. Thus HAZOP provides a qualitative review of the

process hazards and operability issues and enables actions for reducing or

eliminating hazards and operability problems in the plant.

HAZOP review focuses on process deviations, i.e. situations where a process

parameter diverges from normal operating conditions. The review focused on

consequences for people, environment and asset.

The HAZOP review covered normal operation of systems within the scope of work,

as well as operability aspects (including start-up, shut-down and maintenance as

general guidewords) of each system.

The HAZOP review was limited to all Process units and some Utilities.

The HAZOP review covered the following Process units and Utilities:

Unit 10 Ammonia unit (all sections including compression)

Unit 20 Urea synthesis unit (all sections)

Unit 30 Urea granulation unit (all sections)

Unit 40 & 60 Utilities unit and Offsite unit but limited to:

Steam generation and boiler feed water (Unit 40 section 80)

Cooling water system (Unit 40 section 30)

Ammonia storage system (Unit 60 section 50)

The HAZOP review was of qualitativetype.


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3.0 HAZOP PROCEDURE

3.1 Preparation

Prior to the review, with the help of a process engineer, the chairman identified the

nodes and identified the operating modes.

The nodes size varied according to the complexity of the units considered. A

practical rule for changing nodes was at each major equipment / valve or wherever

a critical parameter is changing (flow, pressure, temperature, phase, etc). Each

node was subject of a dedicated analysis and a corresponding set of report

worksheets. The nodes were appropriately defined with clear design intent. They

were then recorded on the HAZOP worksheets.

The node description and full range of operating and design conditions were

described and documented on the worksheets.

The node description was presented to the HAZOP review team prior to its study so

that every team member was on the same understanding of it.

3.2 Assumptions

The HAZOP review was performed on the assumption that design, installation,

commissioning, operation, inspection, maintenance and emergency were at an

adequate level of quality, in line with Company and Project specifications.

3.3 Methodology

The HAZOP review process was divided into the following steps:

Select a node

Describe the nodes design intent and process conditions

Select the first/next parameter

Select the first/next deviation

Determine by brainstorming all the potential causes relevant to this deviation

and agree the credibility of each cause

Identify the potential consequences associated to each cause

Identify the safeguards in place or foreseen against each scenario identified

Propose actions when it appears necessary

Check that implementation of proposed action(s) will adequately solve the

issue

Apply the next deviation until they all have been considered &

Move onto the next node until the whole scope of review is covered


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TABLE: LIST OF HAZOP GUIDE WORD

SL.NO. PARAMETER GUIDEWORD

1. FLOW LESS / NO

MORE

REVERSE

MISDIRECTED

2. PRESSURE MORE

LESS

3. TEMPERATURE MORE

LESS

4. LEVEL HIGH

LOW

5. PHASE DIFFERENT

6. COMPOSITION DIFFERENT

7. OPERATION START-UP

MAINTENANCE

SHUT-DOWN

8. SEQUENCE (*) TOO SHORT

TOO LONG

9. REACTION (*) INCOMPLETE

RUN AWAY

(*) for batch process


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4.0 HAZOP REVIEW

4.1 AMMONIA PRODUCTION UNIT:

HAZOP study carried out from 27.02.2012 to 19.03.2012

List of participants:

Sl.No. Company Function Attendees

1. HazOptima, France Chairman Mr. Laurent Bancod

2. Technip (TP), Paris Process/scribe 1. Mr. Benoit Marbach

2. Mr. Antonella Di Ginsto

3. Ms. Sabrina Cimaoma

4. Mr. V. Jayaraman

5. Ms. Annick Honore

6. Mr. Hager Ben- Lakhal

3. Gabon Fertilizer

Company (GFC),

Gabon

Process 1. Mr. Varshney Vipul

2. Mr. P.C. Jain

Specialist 1. Mr. G.M. Koorse

2. Mr. S. Stalin

3. Mr. S. Shankaran

4. Haldor Topsoe A/S

(HTAS), Denmark

Process 1. Mr. Ken Larsan

2. Mr. F. Hans Christian

HAZOP recommendation:

Number of P&IDs studied 60

Number of Nodes 43

Number of deviations studied 656

Recommendations Process Piping Instrumentat ion Rotat ing Total

Number of

recommendations

147 05 19 05 176

Action points on

Licensor

85 05 16 -- 106

Action points on

EPC Contractor

60 -- 03 05 68

Action points onLicensor/EPC

Contractor

02 -- -- -- 02


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4.2 AMMONIA STORAGE UNIT:

HAZOP study carried out on 02.03.2012


Sl.No. Company Function At tendees

1. Bureau Veritas,

France

Chairman Mr. Jean Roque Constans

2. Technip (TPF),

France

Process/scribe Mr. Mathieu Guitteny

3. Gabon FertilizerCompany (GFC),

Gabon

Process Mr. Varshney Vipul

Specialist Mr. G.M. Koorse

4. Technip (TPI), India Process Mr. A. Ramasubramanian

HAZOP recommendation:


Number of Nodes 01


Recommendations Process Piping Instrumentation Rotating Total

Number ofrecommendations

11 04 05 -- 20

Action points on EPCContractor

11 04 05 -- 20


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4.3 COMPRESSION UNIT:




1. HazOptima Chairman Mr. Laurent Bancod

2. Technip (TP), Paris Process/scribe 1. Mr. Benoit Marbach

2. Mr. Antonella Di Giusto

3. Ms. Sabrina Cimaoma

4. Mr. V. Jayaraman

5. Mr. Harra Al Jarah

6. Ms. Annick Honore

7. Ms. Stphanie Marcy

3. Gabon Fertilizer

Company (GFC),

Gabon

Process/

Instrument

1. Abdul Khader Kukkady

2. Mr. Varshney Vipul

3. Mridul Bhargava

4. Mr. P.C. Jain

Specialist 1. Mr. S. Stalin

2. Mr. S. Shankaran

3. Mr. G.M. Koorse

4. Haldor Topsoe A/S

(HTAS), Denmark

Process 1. Mr. Ken Larsan

2. Mr. F. Hans Christian

HAZOP Recommendation:


Number of Nodes 13

Number of deviations

studied

256



63 02 02 04 71

Action points on 61 02 02 04 69


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EPC Contractor

Action points on

GFC

01 -- -- -- 01

Action points onGFC/EPC

Contractor

01 -- -- -- 01

4.4 UREA SYNTHESIS UNIT:




1. HazOptima, France Chairman Mr. Jean-Roch Constans2. Technip (TPF),

France

Process 1. Ms. Sonia Linares

2. Ms. Ccile Genin

3. Technip (TP), Paris Process/scribe 1. Mr. Patrice Hugues

2. Mr. Mathieu Guitteny

4. Gabon Fertilizer

Company (GFC),

Gabon

Process 1. Mr. R.V. Subramanian

2. Mr. Girish Prakash

5. Saipem SpA, Italy Licensor Mr. Pasquale Gueli



Number of Nodes 34



Number of

recommendations

106 17 31 08 162

Action points on

EPC Contractor

31 07 14 06 58

Action points on

GFC

-- -- -- 01 01

Action points on

Licensor

77 07 19 -- 103


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4.5 UREA GRANULATION UNIT:




1. HazOptima, France Chairman Mr. Jean-Roch Constans

2. Technip (TP), Paris Process/scribe 1. Mr. Patrice Hugues

2. Mr. Mathieu Guitteny

3. Gabon Fertilizer

Company (GFC),

Gabon

Proces 1. Mr. R.V. Subramanian

2. Mr. Girish Prakash

Specialist Mr. Wim Hamlink (Yara)

4. Technip (TPF),

France

Process 1. Ms. Sonia Linares

2. Ms. Ccile GENIN

5. Saipem SpA, Italy Licensor 1. Mr. Alberto Serrafero

2. Mr. Pasquale Gueli



Number of Nodes 11




55 02 07 01 65

Action points on

EPC Contractor

37 01 04 01 43

Action points on

GFC

01 -- 02 -- 03

Action points on

Licensor

16 01 01 -- 18

Action points on

GFC/EPC

Contractor

01 -- -- -- 01


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4.6 COOLING WATER SYSTEM:

HAZOP study carried on 27.02.2012



1. HazOptima, France Chairman Mr. Jean-Roch Constans

2. Technip (TPF),France

Process/scribe 1. Mr. Harra Al Jarah2. Mr. Gautier Wohler3. Mr. Arantia De La Fuente4. Mr. Celine Volpi5. Mr. Mathieu Guitteny

3. Gabon FertilizerCompany (GFC),Gabon

Process Mr.Girish Prakash




Number of Nodes 02


Recommendations Process Electrical Instrumentation Total

Number ofrecommendations 17 01 10 28

Action points on

EPC Contractor

17 01 10 28


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4.7 STEAM GENERATION AND BOILER FEED WATER UNIT:




1. Bureau Veritas,France

Chairman Mr. Jean Roque Constans

2. Technip (TPF),France

Process/scribe/start-up

1. Mr. Bernard Caussanel2. Mr. Julie Gouriou3. Mr. Mathieu Guitteny

3. Gabon FertilizerCompany (GFC),Gabon

Process Mr. Girish Prakash


4. Technip (TPIT),Italy

Process Mr. Antonella Di Giusto



Number of Nodes 10


Recommendations Process Piping Instrumentat ion Total

Number of

recommendations

15 13 14 42

Action points on

EPC Contractor

15 13 14 42

The contents of HAZOPstudy & the recommendations are proprietaryinformation

of Process Licensors.


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5.0 SUMMARY:

The HAZOP review study covering the following units

Ammonia production unit

Ammonia storage unit

Compression unit

Urea synthesis unit

Urea granulation unit

Cooling water system &

Steam generation & boiler feed water unit.

And involving specialists from

Company (Gabon Fertilizer Company),

Contractors (Technip)

Licensors {Haldor Topsoe A/S (HTAS), Denmark and Saipem SpA, Italy}

Process specialist from Yara International, Norway

Above review was conducted at the Technip (Paris) offices, La Dfense, France by

a third-party Chairman from HazOptima and Bureau Veritas, resulted in the

following.

Total deviations studied : 2,224

Total recommendations to be implemented during EPC phase : 564

The above recommendations will be implemented during EPC phase.

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Vol v Esia Vol 3 Part 2a-2g Hazop

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