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140 views22 pagesGB088 2013 200 HS PP 002 - 0
111111111111111111111111111111111111111111111111111111111111111111vvvv
Uploaded by
Mohammed AbdallaCopyright
© © All Rights Reserved
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/ 22
Pc CONTRACT Fo
3 GAZPROM | FFEcONRACTEOR | Petrofac @
BADRA OIL FIELD, IRAQ.
DOCUMENT DETAILS
ENPLOYER CONTRACT NO, + o0e-12-90442-00,
PROWECT TM (PF PHASE 1 AT BADRA Ot FIELD
EHPLOVER Gazprom Nef Bara B.V.
CONTRACTOR Petrofacinteratonal (UAE) LLC
CONTRACTOR JOB NO, 2013
PROJECT DOCUMENT HO. 1 GROBE-2012-200-H5-PP-02
REMSION NO. 0 No.of age (nel Coversheet: 22
DOCUMENT DESCRIPTION HAZOP TERNS OF REFERENCE
REVEION BEATS
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REY, DESCRIPTION Date —[ PRPOT| CHRD | APPOT| —APED
Erecvonie Fie Name: GBOB52015-200 HS PP-002 Revo Doo See Aa cemeoaewae | one: treunr| Petrofac |
ae rao DSTI 7
my Tied for Review
j° Re-ved for Review (lent Comments carports)
| Document Number Changed as er new numbering precede
“Ths Report was previously fed as 202-O0D-H5-RPT-O05-001 Rev A
e Issued for Approval
° sued for Design
Sa pan Description ot ont jeu | eee | sterem |petrofac @
ee
res
4.0. INTRODUCTION.
4a. Seope and Purpese un ssnnn seoninnneed
1 Project OverveW nnn a
2.0 DEFINITIONS & ABBREVIATIONS...
2a. Definitions.
2.2, Abbreviations
20. RESPONSIBILITY AND AUTHORITY...
‘4.0. DESCRIPTION OF ACTIVITES.
4.3. Key Personne valved in the Stuy
42. Team Composition enn
43. HAZOP Suppor System,
44, HAIOP Schedule
45. Information Requirement.
5.0 HAZOP TECHNIQUE...
6.0 FOLLOW-UP AND CLOSE OUT .
6.4. Management of Change
6.2, Recor
7.0 APPENDICES... “
7.1. Example HAZOP Guidewords nine
17.2. Flow Scheme of HAZOP Review : 7
7.3, Typical HAZOP Pre-Requiste Chel ccsnnnnnnn 18
20
7.4. Duly Completed Worksheet Sample enn cQimmm | Summ | Metee|petrofac
1.0 INTRODUCTION
1.1, Scope and Purpose
‘The purpose of thi Terms Of Reference (TOR) is to define the content and manner in
lihicn a Hazard and Operablity (HAZO®) review is performed and the cise Out of the
AZOP setons
‘This TOR apples tothe performance of HAZOP Studies on Ot & Gas feclty projects
executes by Petrofac nteratianel. The scope of this TOR includes:
“+ Key personnel ivetved inthe HAZOP sty
“+The make-up and the competency requirements ofthe HAZOP team;
‘+The roles and responses ofthe HAZOP team;
“+ HAZOP support system requirement;
+The documentation requirements;
+The HAZOP study methodctoy;
+The mechanisms and responsibilities for the close out of the HAZOP
Fecommendetions.
1.2. Project Overview
“The scope of work consists ofthe fllowing main systems fr the Phase
Three Crude Ot Trains as A,B C including future installation of te Desalters
for eseh tala
Two oi storage tans and associated faites and systems
Cit Booster pup station and Ol Export pum station
(lt commercial metering unit (OCNU)
Fare system
Fuel gas system
Chemicals injection packages
Fresh water storage and treatment
Fire water area
= blesel ful storage and hanaing system, pump station
Diesel truck loading and unloading station
= Electric Power generation and distribution system
tities generation (i, Nitrogen, etc) ef cazenam SEARS | one ome | Petrofac ©
Lutes (Chemicals)
Waste water treatment and strm water basin
Sewage water treatment package and storage area
Evaporation pond
Incinerator
(otner related and essential systems.
2.0 DEFINITIONS & ABBREVIATIONS
2.4. Definitions
“Thraughout this ocument te following definitions shall apply
[EMPLOYER: means Gazprom NeftBadra8.V. and its sucessors-in interest and assigns.
‘CONTRACTOR: means Petrofac International (UAE) LLC.
SUBCONTRACTOR: means any company or person to whom CONTRACTOR has
subcontracted any part ofthe WORK
SUPPLIER: means any person, fm oF company, which manufacture ox supply
{equipment or service fr the performance of any kem ofthe WORK.
PARTIES: means CLIENT and CONTRACTOR andthe affiliates companies to the extent
they partlelpate inthe Project.
PROJECT: means the “Detal Engineering Design of Production Infrstrecure for Badra
Die Phase in rag,
WORK: means the works and/or services entrusted by CONTRACTOR under the
Contract with CLENT.
HAZARD: These are defined as having the potential to cause harm to peopl, damage
te propery, products ar the envranment, production loses or increased liabilities.
HAZOP: HAZOP (Hazard and Operabilty Study) is the application of a formal
‘ystematic examination of the process and engineering intentions of faites to
‘est the potential mel-opeation or maunetion of individual items of equipment
find their consequential eects onthe fclity asa whol,
CGUIDEWORD: Guide words (Such as No/Less! More) are used to ident potential
deviation af process parameters (Such as Flow(No/ More/Less, Tempe atue (ah
lw) ete ram the design intent or intended eperational made of the plan.
DEVIATION: The combination f process parameters and guide wards e.. no flow,
‘more temperature etc. Asxram came ananusrran | MO | petrofac |
2.2. Abbreviations
‘The fllowing abbreviations are used in this document:
+ CRE: Cause and Erfect
“+ DCN: Design Change Notice
+: Emergency Shut Down
“+ FAG: Fie and Gas
“+ FHA: Fire Hazara Assessment
‘+ G16: Gas Turbine Generator
‘+ HaZoP: Hazard and Operability Study
“+ IDI: Inter Discipline information Tranter
“+ PID: Piping and instrumentation Diagram
+ Pen: Project Engineering Manager
+ PEC: Petrofac Engineering and Construction
PHA: Works: Process Hazard Anaysis+ Works Softvare
+ TEG: Trethylene Glycol
3.0 RESPONSIBILITY AND AUTHORITY
chairman: The Hazop Chairman shal be independent of the Project ane have a level
lof experience in conducting HAZOPS of sila facilities that & to the satisfaction of
the client and the (ead HSE (Design) engineer. Th Chairman shall mark-up the HAZO®
‘master PAID. The HAZOP report shal be prepared by the Chairman.
Secretary: The secretary shall have a level of experience or training for acting 2s
HAOP secretary that Is to the satisfaction of the Lead Process Engineer and the
Charman The secretary shall atend and minute all HAZOP sessions and may assis In
Seveloping the HAZOP report.
Lead HSE Design Engineer: The lead HSE (Design) Engineer on the project shall
censure thatthe HAZOP is performed to the standards set out In thls TOR, The lead
SE (Design) engineer shall ensure the administrative tasks necessaty te perform the
HAZOP are completed (organizing the team, providing HAZOP software, Chairman
Selectin, booking and confirming the venve}. ef cazenum cmaanaerera | Siem | Petrofac |
Lead Process Engineer: Lead Process Engineer shall be responsible to ensure
competion of process design documents necessary paar tothe HAZOP.
Lead Process Engineer shall ensue effective resolution and implementation of the
HATOP action tems onthe project documents.
Fellow Up: The follow up coordinator shall be nominated by the Project Engineering
anager (PEA) who can make project decisions on the conflicting requemants. The
o-rdinator shal act on behall ofthe PEN to facilitate and expedite tho satisfactory
lore out of the recommendations rased by the HAZOP. The overall responsiblity of
HATOP close-out process les withthe PER.
4.0 DESCRIPTION OF ACTIVITIES
4.1. Key Personnel Involved in the Study
+ Chaieman
+ Secretary
+ Lead HSE Design Engineer
+ Lead Process Engineer
4.2. Team Composition
‘A HAZOP team, for any one particular session or sitting should comprise between sk
fnd tweive people, including the Charman end Secretary. anymore ane the meeting
fend ta pencnedl tn Howdy, Any less an the required expertise snot at hand
‘The required expertise shall be determined by the HAZOP Chalrman prior to the
sessions and communicated to the lead HSE Design Engineer to enaire that the
Fesources are avaliable
‘The HAZOP team shall Include full and part time members as well as Vendor's!
Licensor’ representatives as required.
‘The ful ime core team members wil include:
‘Chairman ane Secretary
+ Process Engineer
+ HSE Engineer
‘Instrument and Controls Engineer
+ Commissioning Engineer
+ Operator's Representative aeons | deeb | petrofac O|
Part time members will include Project Engineer, Piping, Electrical, Mechanical,
Integrity Assurance team and other asipine engineers invelved i the Project. For
vendor packages a vendor representative may also be called, if considered necessary.
43. HAZOP Support System
+ HAZOP Software (A-Works)
+ Secretaria Services! Technical recede:
+ Projector (219 Nos.)
+ Clip Board Flip Chart for Writing
4.4, HAZOP Schedule
“The main HAZOP was conducted inthe third week of Apel and vendor package HAZOP
{s planned tobe conducted in September. This Is in agreement and asrtiied by the
Project Engingering Manager to the Employer (Ref Letter PIL-GPNS-2013-L0008
ated 7" March 207).
‘The timing must ensre that adequate detall design Information i avaiable to make
the HAZOP study. meaningful, whist also. ensuring. that any HAIOP. fncing/
ecommendations ean be ciosed-out without adversely affecting the project schedule.
‘As a general rule the HAZOP should be scheduled prior to when the PSDs are issued
fr desgn.
4.5. Information Requirement
‘The HAZOP review requires the following Information to be made aualiable, as a
Bass of Desin
‘+ System Design Philosophies
+ Start-up, shutdown, operating and contcl philosophies.
“+ Isolation, drainage, depressurization and venting philosophies
+ HSE Pitsophies
+ Plot pans, contour plans
1+ Process flow diagrams with heat and mass balance
Unity flow diagrams
+ Piping and Instrument diagrams Sree |petrofac ©)
eras
+ Matera selection diagrams
+ SD Cause and Effect diagrams
“+ Equipment Process data sheets
4+ Hazardous area classification
‘+ Matera Safety datasheet
“+ censors, vendors package documents wherever applicable
As a recommended practice to demonstrate HAZOP preparedness, the lead process
fngineer shall complete a "HAZ0? Pre-Requisite checks" and Isue ie the project
team at least a week rior tothe commencement of the HAZOP sesson typical pre
‘eesite checklist fe shawn In Append 7.4
‘eviatons from this lit must be approve by the Employer pri to the HAZOP.
Prior to commencing the HAZOP sessions the HAZOP Chairman and the lead process
{engineer or his nominee shall divide the PRID's nto “Nodes” based on “etr function
andlor complexity.
Selection ofthese nodes will permit the proces stream tobe segregated into discrete
{ection This segregation fs typically based upon the fllowing paramete's:
+ Physical Equipment items;
+ Piping specification class breaks;
‘+ System performance? uty ratings
‘+ Phase changes; and
+ Pressure profes
“Theze nodes shall be marked on the P&!D(s) using highlighters of different colors and
delineates by a numbered Incicatr. Other conventions may be used if agreed
between the HAZOP Chairman and tne Lead Process Engineer. The nodes should caver
all ems such a lines, equipment, instruments associated withthe nade
5.0 HAZOP TECHNIQUE
‘The HAZOP session will commence with the Lead Process Engineer providing an
‘overview of the syetams within the Tacity to be reviewed. The averew 1s to be
Confined to statement of purpose and an obtline ofthe Intended operation of the
systems.
For each new nade, the responsible process engineer shall provide a bee introduction
fof the design intent, function and operating conditions plus a description of the
important equipment tems within that nade efsazenans Semmes | ote temer| petrofac @
HAZOP study shall follow standard approach tizing guide words to deviations from
the normal operating candtone of the node for process parameter e.g. low,
emperature, pressure ete. These are indicated in AppendW 7.1. There are other
parameters (ie reaction, maintenance, addition, compatiblity, those describe other
fan proces. al parameters may be considered inthe HAZOP.
‘The guide words are:
a Guide word | —_ Neen
| Hestion of cesign intent,
1 No Where itshold be, e.g.)
- _ - how, presure ete. |
ess tan the design
2 Less intent ofa parameter it
shoul be, (ow low,
= temperate
More than the design
3 More ihigh Intent ofa parameter it
shouldbe, eg. more
flow, bigh temperature
ete
‘Opposite of cesign intent
4 Reverse eg flow
Complete orsart
5 Other than Subeiuton e.g. Transfer
fof ether materia than the
Intended.
6 As wellas than there stoulé Be
Different conposition of
7 Part of ‘the system than I should
be.
‘The deviations prompted by the HAZOP chairman shall be asessed by the team to
Iaentiy
a
»
o
‘
Possible causes of the deviation, once the deviation has been shown to have
concelvable realistic eauses, its reated meaningful.
Consequences ofthe deviation
Element ofthe design which prevents occurences of causes ofthe deviation to
intigate the consequences thereot(Safeguaresy,
Actions to safequard against the causes and consequences of the deviation
‘were no safeguards (items above) exist or are considered Inadequate;
Parties sponsible to complete the actions of tem (4) efsuzenan companmrszram | oue- means] petrofac
Possible causes include single events, simuitaneously occurring events arising from
‘common causation, and events arising from latent or un revealed fale
Causes arising from simultaneous unrelated failures shall be temed “double
Jeopardy” and assumed to cccur at such low frequencies at they are net considered
“possible” unles detailed frequency analsis or experience detatescthe wise
All comments made during the review ofeach node wil be documented by the HAZOP
Secretary using special purpose software (PHAWORKS) Tor recording FAZOP results
and action points
‘The worksheet shall be projected on to a screen visible to the HAZOP participants. &
‘record of the review findings shall be presented In the HAZOP note. Al guidewords!
Geviatons actully examined (even if subsequently found to be "Not a concern")
‘Should be reported, Devatlons, which are improbable or had insignificant potential
‘whieh are not actualy examined should not be logged.
Specific attention wil be elven to start-up and shutdown operations as hese tend to
Create more deviations) nazardous events than nermal steady state plant operetin.
HAZOP proces is shown schematically in Appendy-73. A typical ied work sheet
is shown as an example In Append. 5. The HAZOP software automatlealy generates
the worksheets recorded curing the mecting,
6.0 FOLLOW-UP AND CLOSE OUT
Upon completion ofthe HAZO®, tne Chairman wil present the fndigso! the study to
8 leroup of Project representatives, The findings wil be in orm ofa report Raving the
Contents as mentioned in Section 6.2. The presentation should. vighlght. the
Fecommencatons, wtih i the Charman’s opinion, have the potential to impact on
Satery, operably, cost and/or schedule
Ie is important thatthe Project allocate adequate resources to nat only perform the
HaZOP ‘but to ensure that the recommendations rlsed in the MAZGP report are
"ntistactoriy closed out. Te PEN shall be resporsbe for ensuring that the resources
fre available to satlsfactorly complete all HAZOP recommendations an time. The
Project Engineering Manager or hz nominee shall expedite the close cut of actions
False inthe HAZOP.
In general majority of HAZOP action stems belong to process group, therefore as a
feneral practice the PEM nominates a process engineer to manage the HAZOP close
fut responses of his discipline and those received from other disciplines. A project
tnaineer shall be assigned to cardinate other dscpne Inputs, monitorand closeout
the actions. The nominated pracess engineer wil prepare and issue the WAZOP close
fut report
‘The formal clove et of al action sheets and customer approval will be coordinated by
the Process engineer with assistance from the Project Engineer. al otter disciplines
wil egoperate in proving the inputs desired by PEM Process Engineer! Project
Enginger eaxzezan cesneaewemes | Gere-smms | Petrofac ©)
[AL dentiied HAZOP actions shall be maintained through HSE action tracing register,
HATOP recommendations shall be Sued by Process Engineer to the actionees on &
HATOP Action close-out shet. A typical sheets shown in Appendix 7.7
compliance with the HAZOP recommendation fs not mandatory. The HAZOP follow-up
Indleating whether the recommendations are implemented inthe design or rejected is
uly auctable documents proces with reference to specific updated PIDs of
‘ther documentation) ang records all ations taken and (alternative) decisions made
By the Project management. A HAZOP fll up repster will be mainiained in this
regard bythe follow up coordinator
Verification’ acceptance of responses and final close out of the FA2OP is the
responsibly ofthe Project Engineering Manager or his nominee,
‘copy ofthe fll HAZOP report shal be hept with the project records along withthe
rode marup Pélbs, The lore aut report will be prepared by the process engineer
Sind maintained in tre Project recor
6.1, Management of Change
Following completion ofthe HAZOP and the resi of the PIDs, che management of
change process will be implemented and managed In accordance with the design
{ont and change management procedie(2013-000-PRI-PRO-009). The project wil
thus track all design modifications between the completion of the HAZOP and the
Draject completion.
‘The deslan changes that are necessary will be revved by the Project Engineering
NNanager with process engineer and HSE engineer to assess the changes wil cause
‘major or minor impact, Major changes that have @potenta impact on te safety and
peabiity of the facile wl be subjactea to'anaaorak HAZOP view. Minor
thanges wil be distributed £0 appropriate escipine for review and intorporation in
the sesign.
“The DCN procedure deserives the process to be followed for management of change
‘and shouldbe read in conjunction with this guide. n summary the HAZOP actions salt.
be assessed on the HAZOP close cut sheets, only actlons which affect the design shall.
be commanieted on a DCN, This #8 formal communication to the disiptines to
froceed and implement the design change and any impacts. It sould be noted that
Ibi isnot to be ured for this purpose
‘The PEM shall determine if the HAZOP actlon affect the design and inate the DCN
cordial.
HAZOP actions which do nat affect the design shall not use a CN. demenom | seer | termes [petrofac @
6.2. Records
|A.HAZOP Report shall be produced, in the project agreed format, cantaining the
{allowing sections
+ Contents Uist
‘+ Summary (highlighting major concerns)
+ Introduction, to include:
“+ Reference tothe TOR
1 Scope ofthe Study
Uist of Study Team Members
+ Study Session Date
This section shal azo cover the study methodology, identity any éifiutes in
meeting the Terme of Reference, and include recommendations for furtver studies to
be scaresed
Description of the Layouts
{An introduction to the location of plant and a brief description of the modes of
operation studied
+ Recommendations
‘This section ill include all recommendations with the risk renkings and required
osecut catty es aled Ly tie Chain Principal recommendations shalt Be
Fightighted. Additionally any findings not specific to any single element ofthe design,
fg. crwing Geerepances, general design and operating features, shall be Usted The
Fisk ranking (igh, medium and ow risk) shal be determined for each of the causes
turing the eesion, Rsk raking shall be Ih line with the matrices provided by the
ee.
+ References, to include:
+ Plant Layout
+ stot nades references
+ Allother documentation references curing the study
1+ HAZOP Worksheets
1+ aster Drawings azpRoM cmernnaeaeren — | Dire: neeao2 | potrofac
Copies of al the HAZOP PFD and PélD's reviewed during the study wil te Included ia
the report (A3/ AZ size as required), with the nodes studied clewiy Indicated
(ightphted in color),
lesve of the HAZOP report will enable all actin parties to prepare responses with
‘immediate effect, Action close out sheats vill be isued to capture the final
‘esponses with supporting reference documentation where necessry
7.0 APPENDICES
7.1. Example HAZOP Guldewords
No flow \Wrong routing - blockage - incorrect slip plate = incorrectly fitted
Check valve = burt pipe - large leak - equpment failure ~ (check
Walve, ‘blation valve, pump, vessel, etc.) ~ incerect pressure
ferential olation on error ete
Reverse flow Defective check valve - syphon effect» incorrect. ifferential
pressure = wo = way flow emergency vertng-Incanect operation =
More flow ——_nereasee pumping capacity - increased suction prewure - reduced
Gelivery head’ = grester fluid ensity = exchanger tube leaks
Testrictin orifice plates celeted ~ coss-connection of systems
contral faults ete.
Les low Line restrictions - fter blockage - defective pumps - fouling of
Vessels, valves, restrictor or orice plates = densky or viscosity
problems incorect specification of process fluid etc.
Nore pressure Surge_problems leakage from interconnected HP syster-gas
Breakthrough (inadequate venting) - isolation procedres for elit
valves defective «thermal overpressure-postive csplacement pumps
failed open POVs- et,
Less pressures Generation of vacuum condition - condensation - sa dissolving in
Uigud’ = restricted purmp/comprestor suction tine. undetected
leakage - vessel drainage ete foun | stymmmsmct | Sete petrofac @
More Ambient cantons - fouled or faled exchanged tube-fire situation
‘Temperature cooing water fale - defective contrat - fred heater contol failure
‘intemal fre = eacton contrat fale - et.
Less Ambient conditions - reducing pressure Fouled or felled exchanger
“Temperature tubes Las of heating et.
Compostlen Leaking zolation valves - leaking exchanger tubes -shase change
change Incorrect Teedstock/specifcation ~ Inadequate quality contrat
process control procedures etc
Contamination Leaking exchanger tubes or soaton valves «incorrect operation of
system = interconnected systems ~ effect of conosion ~ weng
Accitives Ingress of r= shutdown and start-up condos» ete
elit Relief Philosophy - type ofrliet device and reliability - rai valve
