Hazop (Risk MGMT)

3/7/2013
Risk Mitigation in
Construction Projects
By
Prof.P.Muralidhar
NICMAR CISC, Hyderabad
HAZOP ANALYSIS
Hazard analysis involves identification & quantification of various

hazards that may exist at a factory / site
The various hazard analysis techniques are Hazard & operability
studies ( Hazop), fault tree analysis,
(FTA), event tree analysis (ETA) & Failure-mode-effect- analysis (
FMEA)
About the project
M/s Lanco power limited was awarded the setting up of 355 MW
combined cycle power project at Kondapalli industrial area,
Vijayawada (A.P state)
HPCL is setting up a pipeline from visakahpatnam refinery to
kondapalli with facility to store the fuel in HPCL storage tanks &
supply the same to the power plant through a dedicated pipe line
The primary fuel for the proposed project will be Naphtha
Prof.P.Muralidhar NICMAR
Hyderabad
Recommendations
The storage tanks in the storage yard should be spaced
adequately such that the radiation intensity level on any
adjoining tank in the event of fire is less than 32 kw/sq.m
Tank fire should be considered as an credible accident &
measures need to be taken to tackle them
Providing green belt around the plant boundary will go a long
way in reducing the radiation intensity level outside the plant
boundary
It is worthwhile to install sprinklers/ adequate fire
hydrants/monitors in the gantry areas for protection in the
event of an eventuality
Disaster Management Plan

A disaster is a catastrophic situation in which people are
plunged into helplessness & suffering & as a result of which
they need protection, shelter, social care, medical treatment
& other necessities of life
Disasters resulting from natural phenomenon are
earthquakes, volcanic eruptions, cyclones, avalanches,
landslides etc
Disasters resulting from man made vents are factory fires,
explosions, leak of toxic gases, river pollution, structural
collapse, road accidents etc
However, all disasters bring in their wake similar
consequences that calls for immediate action in the form of
relief & rescue to victims
Hence, the need for DISASTER MANAGEMENT PLAN
Hyderabad
Objectives of DMP
To minimise damage to property & environment
To carry out the relief & medical treatment of those
who have suffered injuries
Secure the safe rehabilitation of affected people
Contain & bring the situation under control
Preserve records for subsequent enquiry into the
cause & circumstances & to prevent its recurrence.
Hyderabad
Hyderabad
Emergencies envisaged in the plant

Contamination of food/ water
Structural failures
Fire @ chlorination plant
Fires during unloading operations
Fires in the tanks that are storing Naphtha &
HSD
Slow / isolated fires
Hyderabad
3/7/2013
Scope of the study

The scope includes study of proposed operations, storage &
handling of raw materials with respect to hazard
identification, risk assessment, & preparation of disaster
management plan ( DMP)
Based on the hazard identification & analysis, major disaster
scenarios are worked out to estimate the consequence of
failure.
A DMP would also be evolved to meet the emergency
situation which addresses occupational health & safety
List of flammable & corrosive materials

Naptha
High speed diesel
Naptha tanks
HDS tanks
Chlorine
Hydrochloric acid
Sodium hydroxide
Identification of Disaster scenarios
Disaster scenarios for this purpose of study is defined as an
accident viz fire, explosion, release of toxic substances where
there may be multiple casualties & significant loss to power
plant & surrounding areas.
Hyderabad
Assessment of risk @ lanco Power ltd

Block /areas
Hazard identified
Turbo generator
Fires in:
oil system
Cable galleries
Short circuit
Explosion due to
leakage of hydrogen &
consequent fire
Lube
Chlorination plant
Release of toxic chlorine
Hydrochloric acid
Corrosive
Naphtha tanks, HSD

tanks
Fire
Boilers
Fire & explosion
Hyderabad
Risk & consequent analysis of fire

The risk analysis study covers the storage & unloading facilities
for naphtha & HSD at the tank farm terminal with a view to :
Identifying the possible causes of failure of the facilities
mentioned above, which might affect the population &
property both within & outside the boundary
Assessment of consequential effect on surrounding
population & property
Suggest recommendations based on consequence analysis
relevant to the situations
Description of facilities
The storage and the handling facilities should suffice for atleast a
fortnight & hence the vessels of Naphtha & HSD will be located
in separate places separated by dyke walls
Hyderabad
Loading Gantry
Dispersion & evaporation of hazardous gases are highly
dependent on meteorological conditions. The loading gantry
needs to be located in the downward direction of plant so
that vapours are away from plant premises.
Methodology
The major failure scenarios were evaluated to assess the
effect on people & property within & outside the plant
premises.
The effect of fire on people will be due to thermal radiation.
Therefore, criteria needs to be fixed for deciding the
maximum level of thermal radiation to which the population
can be subjected.
Hyderabad
Hyderabad
Damage due to radiation intensities

Radiation
Type of damage
(kw/sq.m)
62
Spontaneous ignition of wood
38
sufficient to cause damage to
process equipment
12.5
Min. energy required to ignite
wood & melting of plastic
4.5
Sufficient to cause pain to
personnel if he/ she is unable to
reach the cover in 20 sec.
Causes first degree burns
1.6
Equivalent to solar radiation
Hyderabad
3/7/2013
Methodology
For the present study, the scenarios under consideration
assume that the peak level of radiation will not occur suddenly.
It is found that it requires 20-30 minutes before the tank fire
grows to full size.
A criteria of 4.5 kw/sq.m has been selected to judge the
acceptability of scenarios.
A surface flux of 120kw/sq.m is considered to be appropriate
Hyderabad
Specific anticipated emergencies

The consequences of fire can be disastrous as they involve huge
quantities of fuel.
Toxic release of substances can affect the workers who are
working in that area
During the study of risk assessment, the probability of
occurrence of hazards is worked out along with the nature of
damage
Hence, risk assessment in done in conjunction with DMP
Emergency organization
A senior executive who has control over the affairs of the plant
would be heading the emergency operation.
Emergency coordinators should be appointed who would
undertake the responsibilities like fire fighting, rescue,
rehabilitation & provide essential services
Hyderabad
Spread of fire
Effective cooling of adjoining tanks is the
most important aspect for prevention of fire
from one tank to another.
At the plant storage, all the tanks should be
provided with sprinklers
Drainage needs to be checked for its
adequacy to carry the applied water
Hyderabad
In each shift, electrical supervisor, electrical fitters & other

maintenance staff would be drafted for emergency operations
In the event of power failure / communication failure, some of
the office/pant staff would be utilised as messengers for
passing of communication. All these personnel would be
declared as working on emergency duty
Site controller
On receiving information about emergency, he /she should
rush to emergency control centre, assess the magnitude of
situation & on the advice of incident controller should decide:
Whether the affected area needs to be evacuated
Hyderabad

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Hazop (Risk MGMT)

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3/7/2013

Hazard analysis involves identification & quantification of various

Disaster Management Plan

Emergencies envisaged in the plant

Scope of the study

List of flammable & corrosive materials

Assessment of risk @ lanco Power ltd

Release of toxic chlorine

Naphtha tanks, HSD

Fire & explosion

Risk & consequent analysis of fire

Damage due to radiation intensities

Specific anticipated emergencies

In each shift, electrical supervisor, electrical fitters & other

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