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Sample HAZOP Study Bulk Maritime offloading facility
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WSP CEL Limited CEL House, Westwood Way
Westwood Business Park Coventry UK CV4 8HS
Tel +44 (0)24 7686 2000 Fax +44 (0)24 7686 2200
Registered office: WSP House, 70 Chancery Lane, London WC2A IAF | Registered in England No. 3877626 | VAT Reg. No. GB 747 8097 84 ver1 2010
HAZOP REPORT
FOR
CALABAR – PORTSIDE INDUSTRIAL PARK FUEL RETICULATION PROJECT
For
AIKENBECK RESOURCES LIMITED - NIGERIA
Issue No. 1 2 3 4 5
Compiled By Peter Dixon
Approved By
Date 27/03/2012
Ref: E5178 – HAZOP Report Issue: P1 Date: 27th March 2012
CALABAR PORTSIDE HAZOP REPORT 27TH MARCH 2012 AIKENBECK RESOURCES LTD - NIGERIA REF: E5178 / CALABAR PORTSIDE HAZOP SUMMARY Issue P1
CONTENTS Page No
REVISION RECORD 1
SECTION 1 INTRODUCTION 2
SECTION 2 STUDY DATES 2
SECTION 3 STUDY TEAM 2
SECTION 4 DOCUMENTATION 3
SECTION 5 METHODOLOGY 3
SECTION 6 SUMMARY OF HAZOP & KEY ISSUES ARISING 4
ANNEX 1 HAZOP AGENDA
ANNEX 2 HAZOP TEAM MEMBERS LIST
ANNEX 3 HAZOP COPY OF P&ID
ANNEX 4 HAZOP GUIDE WORD KEY SHEET
ANNEX 5 HAZOP RECORD
CALABAR PORTSIDE HAZOP REPORT 27TH MARCH 2012 AIKENBECK RESOURCES LTD - NIGERIA REF: E5178 / CALABAR PORTSIDE HAZOP SUMMARY Issue P1
REVISION RECORD
Issue No.
Description of Revision Page/Paragraph No.
P1 Preliminary first issue for comment
CALABAR PORTSIDE HAZOP REPORT 27TH MARCH 2012 AIKENBECK RESOURCES LTD - NIGERIA REF: E5178 / CALABAR PORTSIDE HAZOP SUMMARY Issue P1
SECTION 1 INTRODUCTION
The Cross River Sate Government (CRSG) is embarking on a Portside Development in the Calabar area of Nigeria for petroleum product receiving and storage. This report details the outcome of a HAZOP Study covering the proposed installation.
Two dolphin berths are to be provided near the bank of the Calabar River to handle tankers of 25,000 DWT (Dead Weight Tonnage). Fuel is to be unloaded (or loaded) by hose connection to pipework which connects the dolphin platforms to a manifold system located in a common systems bunded area. The manifold system will initially allow for three different fuel types to be handled and distributed to seven separate tenant sites for storage. Mixed fuel from manifold flushing will be stored in an Intermix Tank within the common systems area. “Intermix” will then be either dosed back into bulk fuel during transfer or taken off site by road tanker.
The three different fuel types are to be handled initially are gasoline, kerosene and fuel oil. The HAZOP study focussed on the unloading of unleaded gasoline due to its very low flash point (-46°C) and high vapour pressure (boiling range 32 to 225°C), compared to the other two products.
SECTION 2 STUDY DATES
The HAZOP study took place over two days on 19th and 20th March 2012 at the La Cour Hotel, Ikoyi, Lagos. The agenda is included as Annex 1.
SECTION 3 STUDY TEAM
The team members were:
Niyi Oginni Chief Op. Officer Aikenbeck Resources Ltd Unimawho Awafung Proj. Dev’t Manager Aikenbeck Resources Ltd Dr. Okey Onyemelukwe Principal Partner GWC Chris Amgeehi Project Manager GWC Ebola Lawal Civil/Structural Eng. IAA Associates Dr. Ambekeh A Udida Director Cross River State M of L&H Margaret Eslen Director Cross River State M of L&H Manderson Okpo Director Cross River State M of L&H Utan Uye Utan Terminal Manager ECM Terminal Ukemeabasi Udo Comm’l Manager ECM Terminal
CALABAR PORTSIDE HAZOP REPORT 27TH MARCH 2012 AIKENBECK RESOURCES LTD - NIGERIA REF: E5178 / CALABAR PORTSIDE HAZOP SUMMARY Issue P1
John Wilmot Cost Consultant WSP Nigeria Fransisco Doregos Design Manager WSP Nigeria Richard Baard Director WSP Industrial Jock Litterick Principal Associate WSP Consulting Mark Pitout Associate WSP Industrial Clint Lakey Mechanical Eng. WSP Industrial Peter Dixon Proc Eng / Leader WSP CEL A “Team Members” list completed at the meeting is included as Annex 2. Representatives from CAA Associates and the Ministry of Lands and Housing were present for the first day only, during which Section 1 was studied.
SECTION 4 DOCUMENTATION
Copies of all design reports and drawings were available to the meeting. Principal documents referred to during the meeting were:
W702 M-830 Rev. 6 P&ID – Oil Pipeline Reticulation System
W702 M-801 Rev. P2 3D Model – Fuel Reticulation System
W702 M-802 Rev. P1 GA – Fuel Reticulation System c/w Dock
W702 M-802 ??
W702 M-804 Rev. P2 GA – Fuel Reticulation System – Haz. Areas
W702 M-805 Rev. P2 GA – Fuel System, Dock – Hazardous Areas
W702 F-881 Rev. P1 Site Layout – Foam System
510168 C1004 Rev. 1 Site Plan
SECTION 5 METHODOLOGY
The conventional HAZOP technique was used for the study, that is:
• Define the intention for each line or sub-system. • Identify relevant deviations (See Guide Word Sheet Checklist -
Annex 4). • Look for causes of each deviation, assess the consequences and
decide whether action(s) is required.
CALABAR PORTSIDE HAZOP REPORT 27TH MARCH 2012 AIKENBECK RESOURCES LTD - NIGERIA REF: E5178 / CALABAR PORTSIDE HAZOP SUMMARY Issue P1
The HAZOP record follows in Annex 5. The record sheets primarily capture those deviations where action(s) was identified; they are not an exhaustive record of all discussion.
SECTION 6 SUMMARY OF HAZOP & KEY ISSUES ARISING
Due to the large number of attendees and extended discussion of many aspects of the project, the HAZOP could not be completed rigorously for all secondary operations. However, the primary operations of fuel transfer in either direction between ship and shore were considered in detail and significant discussion of the secondary operations occurred in parallel. These were then reviewed at the end of the meeting and the actions identified added to the HAZOP record. A follow-up review of the completed design should therefore be considered.
In addition to recommended actions, the HAZOP record highlights the key safeguards intended to mitigate or prevent the consequences of potential process deviations. It should be ensured that these or equivalent safeguards are included within the completed design documentation, particularly a “Trip and Interlock Schedule” and control system “User Requirement Specification”.
Key issues identified by the HAZOP were as follows:
Gasoline has a boiling point range starting at 32°C. Since ambient temperature in the Calabar region will often exceed this, it will be difficult to maintain a prime on the unloading pumps due to vapour formation. Alternatives such as running the ship’s pumps to provide backing pressure will need to be considered.
The ability of the control system to reliably prevent overfilling of tanks should be carefully considered. All tanks should ideally have duplicate and dissimilar high level detection instruments and more than one trip action is likely to be required to achieve an appropriate safety integrity level (SIL). Consideration should also be given to supplementing the PLC by hard wiring or by an independent programmable safety system for these critical trip actions.
A clear interface protocol should be defined between the common systems control PLC and the tenant control systems to ensure that fuel transfer can only commence when a “permissive” signal has been received by the upstream system, and that the downstream receiving system has the priority to immediately stop a transfer.
CALABAR PORTSIDE HAZOP REPORT 27TH MARCH 2012 AIKENBECK RESOURCES LTD - NIGERIA REF: E5178 / CALABAR PORTSIDE HAZOP SUMMARY Issue P1
The reliability of “Emergency Stops” should be considered in comparison to “Process Stops” acting through the process control PLC.
Strict procedures will be required to control the back-loading of fuel to a ship if there is to be no direct link between ship and shore control systems.
Consideration should be given to the inclusion of actuated, fire safe, isolation valves on bottom outlets from large fuel storage tanks.
Provision will be required to separate spilt fuel from rain water, both on the dolphin jetty and in the common systems bund. To this end, separate covered and contained collection of fuel from drainage or pressure relief will be required so that separation is only required from surface run-off.
The extent of hazardous zone surrounding open sumps which may contain fuel should be reconsidered. This will be aided by the segregation of potentially very warm fuel from pressure relief and drainage.
CALABAR PORTSIDE HAZOP REPORT 27TH MARCH 2012 AIKENBECK RESOURCES LTD - NIGERIA REF: E5178 / CALABAR PORTSIDE HAZOP SUMMARY Issue P1
ANNEX 1 HAZOP AGENDA
M:\PROJECTS\WSP\E5178\1 SAFETY\3 HAZARD STUDY\CALABAR - PORTSIDE - HAZOP MEETING AGENDA.DOC ver1 2010
A G E N D A Date: 19th & 20th March 2012 Time: 09.00 Venue: La Cour Hotel, 3, Cooper Road, Lagos Personnel Present: See separate Attendance Schedule Introduction: This is a 2 day Hazard Study meeting to identify any residual
safety and operability issues within the process design for the Portside Industrial Park, Calabar.
Item Description Responsibility Time
1. Attendee Introductions
All 09.00
2. Introduction to HAZOP Procedure PJD
3. Introduction and Overview of Project
WSP Nigeria
4. HAZOP
PJD
Unloading line flush to Intermediate Tank
Fuel unloading to tenant site
Drains, platform sump and sump transfer
Drains, bund area sump and sump transfer
Tanker loading
Intermix tank transfers / dosing
Flow proving
5. Conclusions and next steps
All
6. Project Meeting All
CALABAR PORTSIDE HAZOP REPORT 27TH MARCH 2012 AIKENBECK RESOURCES LTD - NIGERIA REF: E5178 / CALABAR PORTSIDE HAZOP SUMMARY Issue P1
ANNEX 2 HAZOP TEAM MEMBERS LIST
CALABAR PORTSIDE HAZOP REPORT 27TH MARCH 2012 AIKENBECK RESOURCES LTD - NIGERIA REF: E5178 / CALABAR PORTSIDE HAZOP SUMMARY Issue P1
ANNEX 3 HAZOP COPY OF P&ID
CALABAR PORTSIDE HAZOP REPORT 27TH MARCH 2012 AIKENBECK RESOURCES LTD - NIGERIA REF: E5178 / CALABAR PORTSIDE HAZOP SUMMARY Issue P1
ANNEX 4 HAZOP GUIDE WORD KEY SHEET
CALABAR PORTSIDE HAZOP REPORT 27TH MARCH 2012 AIKENBECK RESOURCES LTD - NIGERIA REF: E5178 / CALABAR PORTSIDE HAZOP SUMMARY Issue P1
ANNEX 5 HAZOP RECORD
Company: Aikenbeck ResourcesFacility: Portside Industrial ParkDwg No: No. W702-M-830 Rev 6Dwg Title: Fuel Reticulation System - PID
SectionFirst Action Number Section Title Description
Section 1 1 Unloading Line Flush To flush each unloading pump in turn for 1 minute each to the Inter-mix Tank. Expected total flush quantity is 12 tonnes. Adequate flushing confirmed by manual sampling.
Section 2 39 Unloading Fuel to Tenant Site To unload fuel from a ship to a tenant site storage tank at a rate of 700 tonnes per hour.
Section 3 66 Loading Fuel to Ship from Tenant Site To load fuel from a tenant site to a ship using tenant's pumps and flow meters at a maximum flow rate of 700 tonnes / hour
Section 4 74 Fuel Dosing and Intermix Loading Dosing of fuel at low rate from the Intermix Tank into the unloading line during transfer to tenant storage, ensuring that overall fuel transfer remains within fuel specification. Also loading of an excess of Intermix to a road tanker.
Section 5 78 Flow Proving Unit Proprietary flow proving unit used to verify the calibration of each product flow meter.
Section 6&7 83 Drains, Sumps and Transfer Drains and pressure relief to the dolphin jetty sump. Transfer to the common services bund sump.Drains and pressure relief to the common services sump. Transfer to the Intermix Tank.
Calabar HAZOP Record - Edited Page 1 of 17 Printed on: 27/03/2012
Company: Aikenbeck ResourcesFacility: Portside Industrial ParkDwg No: No. W702-M-830 Rev 6Dwg Title: Reticulation System - PID
Unloading Line Flush Section name: Section 1Leader / Scribe: PD/PD
Date: 19/03/2012Team: See Report
HAZOP ITEM NUMBER PARAMETER DEVIATION POSSIBLE
CAUSES CONSEQUENCES SAFEGUARDS ACTION NUMBER ACTION REQUIRED ACTION
BY ANSWERS AND COMMENTS
1 Flow No Flow Manual valve closed
Unloading pump runs dead headed 1
Include low current monitoring of pumps to
detect no flowWSP
2 Manual valve closed
Unloading pump runs dead headed 2
Consider position switches on key manual valves and
include feedback information into control
logic
WSP
3 Manual valve closed
Unloading pump runs dead headed 3
Detailed maintenance procedures required to
ensure correct realignment of manual
valves following maintenance operations
ARL
4 Automatic valve closed
Unloading pump runs dead headed
Limit switches to be provided on both open and closed positions
4Sequence must shut down
in the event of a discrepancy
WSP
5No prime on
unloading pumps
Pump cavitationLow pressure on pump
suction.Low current to pump
See action 1
6 Flow Less Flow Manual valve not fully open Incomplete line flush
Manual valves to have facility to be locked open
or closed5
Consider whether any manual valves should be
locked openWSP
7 Flow Reverse FlowRoute open
but pump not running
Unloading header and ship contaminated by
mixed fuel from Intermix Tank
3 NRVs in line to intermix tank.
Discrepancy detected in control system will close
actuated valves
No further action
8 Flow Where Else
Air and fuel bleed to platform
sump
Ship's pump running against substantially
closed head6 Confirm suitability of ship's
pump to run in this way WSP
9
Air and fuel bleed to platform
sump
Extemely flammable liquid discharged into open
sump
Zone 1 hazardous area covers ship and entire
dolphin platform7
Clear operator procedure required to limit flammable
release to a minimumARL
Calabar HAZOP Record - Edited Page 2 of 17 Printed on: 27/03/2012
Company: Aikenbeck ResourcesFacility: Portside Industrial ParkDwg No: No. W702-M-830 Rev 6Dwg Title: Reticulation System - PID
Unloading Line Flush Section name: Section 1Leader / Scribe: PD/PD
Date: 19/03/2012Team: See Report
HAZOP ITEM NUMBER PARAMETER DEVIATION POSSIBLE
CAUSES CONSEQUENCES SAFEGUARDS ACTION NUMBER ACTION REQUIRED ACTION
BY ANSWERS AND COMMENTS
10 Flow Where Else Unloading hose failure
Significant environmental damage to river 8
Unloading operation to be continuously manned. Procedures required to
achieve prompt shutdown from both terminal and
from ship.
ARL
11 Unloading hose failure
Significant environmental damage to river 9
Confirm that unloading hose system is fully
specified within the piping spec.
WSP
12 Tidal movement Hose overextended
Procedures to determine number of hose sections required for type and size
of ship
No further action
13Intermediate
hose joint leakage
Fuel spill outside of planned contained area 10
Consider extending dolphin platform bund to
capture leakage from intermediate hose
connections
WSP
14Intermediate
hose joint leakage
Fuel spill outside of planned contained area 11
Investigate standard practices for confirming absence of leaks before unloading commences
ARL
15 Flow Where Else
Drain valve left open or relief valve
leakage
Loss of fuel to sumpHigh level switch on sump and automatic pump out
to Intermix TankNo further action
16 Flow Where ElseFlow into header to tenant site
Two actuated isolation valves and ability to
monitor flow in headerNo further action
17 Flow Where Else
Leakage into Intermix Tank
bund and possible fire
Fire fuelled by entire contents of Intermix Tank
(due to bottom entry)12
Actuated isolation valve to be close to tank, to close in event of fire and be fire-
safe design
WSP
18Flow into 2nd
unloading manifold
Cross contamination of headers and possible spill
Only one inlet valve to the Intermix Tank should be
open at any one time13 Add a NRV in each inlet
line to Intermix Tank WSP
Calabar HAZOP Record - Edited Page 3 of 17 Printed on: 27/03/2012
Company: Aikenbeck ResourcesFacility: Portside Industrial ParkDwg No: No. W702-M-830 Rev 6Dwg Title: Reticulation System - PID
Unloading Line Flush Section name: Section 1Leader / Scribe: PD/PD
Date: 19/03/2012Team: See Report
HAZOP ITEM NUMBER PARAMETER DEVIATION POSSIBLE
CAUSES CONSEQUENCES SAFEGUARDS ACTION NUMBER ACTION REQUIRED ACTION
BY ANSWERS AND COMMENTS
19 Pressure More Pressure
Ship's pumps also running
during unloading
Unloading is too fast or line velocity too high 14
Procedures required to ensure ship's pumps not
run at same time as unloading pump
ARL
20 Pressure More Pressure
Blocked flame arrester on
Intermix Tank
Overpressure and rupture of tank 15
Consider whether dual flame arresters with
changeover valve requiredWSP
21 Pressure Less Pressure
Unloading hose air leak causes loss of suction
Unloading pumps cavitateProcedures to maintain
hoses.Spare hoses.
No further action
22 Pressure Less Pressure
High vapour pressure of gasolene in
warm ambient temperature causes loss of suction
Unloading pumps cavitate 16
Confirm expected temperature of fuel in ship
and vapour fraction at unloading pumps.
Consider whether ship's pumps can be used to
provide backing pressure
WSP
23 Pressure Less Pressure
Power fluctuation
Unloading pumps lose prime 17
Review all possible causes of loss of prime of unloading pumps. Check
pump minimum NPSH
WSP
24 Temperature More Temperature
High ambient temperature or solar gain
Pipe expansion Pipework stress design and expansion loops No further action
25 Level Greater Level
Failure of Intermix tank
level transmitter
Overfilling and overflow of intermix tank 18
Provide secondary high level monitoring to provide
adequate safeguard against tank overfill.
Consider SIL assessment
WSP
Calabar HAZOP Record - Edited Page 4 of 17 Printed on: 27/03/2012
Company: Aikenbeck ResourcesFacility: Portside Industrial ParkDwg No: No. W702-M-830 Rev 6Dwg Title: Reticulation System - PID
Unloading Line Flush Section name: Section 1Leader / Scribe: PD/PD
Date: 19/03/2012Team: See Report
HAZOP ITEM NUMBER PARAMETER DEVIATION POSSIBLE
CAUSES CONSEQUENCES SAFEGUARDS ACTION NUMBER ACTION REQUIRED ACTION
BY ANSWERS AND COMMENTS
26 Composition Extra Component
Accumulation of rainwater in
sumps
Cannot pump out to Intermix Tank 19
System required to separate rain water from fuel drainage or spillage.
Fuel sumps to be protected from rain water
WSP
27 Sequence Step Omitted
Line flush omitted before
transfer to tenant
Out of spec transfer 20
Clear procedures / check lists required to ensure that transfer not started without line flush and
sample check
ARL
28 Sequence Step LongerSample
testing takes too long
Cannot achieve target unloading time of 24 hrs 21
Consider providing on site lab / office facility to
ensure rapid turnround of sample test results
ARL
29 Other Shut down
Rapid closure of valves or stopping of
pumps
Pressure surge damages pipework or pipe supports 22
Speed of system shut-down to be determined during commissioning
ARL
30 Other Power/Service Failure
Local power failure Unable to unload ship 23
Consider feasibility of unloading fuel using ship's
pumps. Would require unloading pump bypass.
WSP
31 Other Maintenance/Spares
Lack of pump spares Delayed unloading
Pump spares requirements listed in
pump specificationNo further action
32 Other FireExtent of
flammable zone
Ignition of vapours from common area sump 24
Confirm whether a Zone 2 area is required
surrounding the Zone 1 sump in the corner of the
bund.
WSP
33 Ignition of fuel spill Fire damage to facility
Fire water storage to supply up to 3 foam monitors for 1 hour
25Investigate back-up water
supply to supplement municipal supply
WSP
Calabar HAZOP Record - Edited Page 5 of 17 Printed on: 27/03/2012
Company: Aikenbeck ResourcesFacility: Portside Industrial ParkDwg No: No. W702-M-830 Rev 6Dwg Title: Reticulation System - PID
Unloading Line Flush Section name: Section 1Leader / Scribe: PD/PD
Date: 19/03/2012Team: See Report
HAZOP ITEM NUMBER PARAMETER DEVIATION POSSIBLE
CAUSES CONSEQUENCES SAFEGUARDS ACTION NUMBER ACTION REQUIRED ACTION
BY ANSWERS AND COMMENTS
34 Other Static/Earthing
Static generation during fuel
transfer
Potential vapour explosionEarth bonding and lightning protection
specifiedNo further action
35 Other Environment
Fuel spills on roads and common
areas
Fuel run-off into stormwater channel 26
Consider additional measures to prevent or
separate fuel spills before they enter the storm water
drain / river
WSP
36 Uncontained fuel spill
Spill finds its way to the river 27
Consider options to contain, mitigate or
recover spill from riverARL
37 Other Commisioning
Stroke times of valves
Valve failure trip occurs before valve has reached
end of stroke28
Stroke times and trip delays to be set during
commissioningARL
38 Alarm and trip settings
Process deviations go undetected 29
Alarms and trips required from all process
parameters to be set during commissioning
ARL
39 Other Regs 30
Check applicable advice from "National Oil Spill
Protection and Mitigation Agency"
WSP
40 What Else Bunkering 31 Consider provision for tanker bunkering. ARL
41 What Else Domestic fresh water 32
Consider provision of domestic fresh water
supply to tankerARL
42 What Else
Damage to existing
NNPC oil pipeline
Storm water hits low level
pipePipe fracture and oil spill 33 Confirm civils provision to
protect pipeline WSP
43 What Else
Interaction with future 2nd tanker
berth
Need to flush unloading line
from 2nd berth
Cross contamination between systems
NRVs shown in each unloading line 34
Ensure that valve VBA 184 is suitable for future addition of an actuator
WSP
Calabar HAZOP Record - Edited Page 6 of 17 Printed on: 27/03/2012
Company: Aikenbeck ResourcesFacility: Portside Industrial ParkDwg No: No. W702-M-830 Rev 6Dwg Title: Reticulation System - PID
Unloading Line Flush Section name: Section 1Leader / Scribe: PD/PD
Date: 19/03/2012Team: See Report
HAZOP ITEM NUMBER PARAMETER DEVIATION POSSIBLE
CAUSES CONSEQUENCES SAFEGUARDS ACTION NUMBER ACTION REQUIRED ACTION
BY ANSWERS AND COMMENTS
44 What Else
Cannot flush branches for
future products 4, 5
and 6
P&ID doesn't work as shown
Contamination 35Unloading header must
pass each product take-off branch in turn
WSP
45 What Else
Cannot simultaneousl
y unload products 4 to 7 from each
berth
P&ID doesn't work as shown
Loss of flexibiltiy 36
Unloading header from future 2nd berth must
pass each product take-off branch in turn with
separate connections to each
WSP
46 What Else
Cannot simultaneousl
y unload products 4 to 7 from each
berth
P&ID doesn't work as shown
Loss of flexibiltiy 37
For two unloading systems, VBA 185 and
186 need to be actuated and located downstream
of the last product take-off
WSP
47 What Else
Loss of radio communicatio
n between ship and
shore
Radio fault Inadequate monitoring of unloading operations 38
Procedures required to prove a working radio
channel (at agreed frequency) between ship
and shore (common systems and tenant)
before operations commence.
Communication to be confirmed on regular (e.g.
hourly) basis.
WSP
Calabar HAZOP Record - Edited Page 7 of 17 Printed on: 27/03/2012
Company: Aikenbeck ResourcesFacility: Portside Industrial ParkDwg No: No. W702-M-830 Rev 6Dwg Title: Reticulation System - PID
Unloading Fuel to Tenant Site Section name: Section 2Leader / Scribe: PD/PD
Date: 20/03/2012Team: See Report
HAZOP ITEM NUMBER PARAMETER DEVIATION POSSIBLE
CAUSES CONSEQUENCES SAFEGUARDS ACTION NUMBER ACTION REQUIRED ACTION
BY ANSWERS AND COMMENTS
1 Flow No Flow See actions 1 to 4 WSP
2 Flow No Flow Valve closed on tenant site Pump dead headed
Flow meter will detect lack of flow.
High pressure detection.39
Sequence to abort if flow rate not achieved or high
pressure detectedWSP
3 Flow Less Flow See action 5 WSP
4 Flow Less Flow
Furthest tenant site at
highest elevation
Protracted unloadingPumps specified to
achieve 700 tonnes/hr to highest destination
No further action
5 Flow More Flow
Pumps sized for furthest
tenant site at highest
elevation
Excessive flow rate to nearest sites at lower
elevation.40
Consider control of transfer rate using flow meter and pump VSD. Ensure that max line
velocity to prevent static generation is not
exceeded
WSP
6 Flow Reverse Flow
Tenant tanks at higher
elevation than ship, possibly with bottom
entry
Potential for reverse flow when transfer route
opened
3 NRVs in line to tenant site.
Discrepancy detected in control system will close
actuated valves
41
Check regulations regarding whether top or bottom entry to tenant
tank is preferred
WSP
7 Flow Sooner FlowTenant site
not ready for transfer
Potential spill or flow to wrong destination 42
A transfer permissive signal is required from the
tenant for each of 3 products. Transfer can
only proceed on receipt of this signal.
WSP
8 43
Permissive signal to be via fibre optic cable
(preferred for reliability) or ethernet radio
WSP
9 Flow Where Else See actions 8 to 11 WSP/ARL
Calabar HAZOP Record - Edited Page 8 of 17 Printed on: 27/03/2012
Company: Aikenbeck ResourcesFacility: Portside Industrial ParkDwg No: No. W702-M-830 Rev 6Dwg Title: Reticulation System - PID
Unloading Fuel to Tenant Site Section name: Section 2Leader / Scribe: PD/PD
Date: 20/03/2012Team: See Report
HAZOP ITEM NUMBER PARAMETER DEVIATION POSSIBLE
CAUSES CONSEQUENCES SAFEGUARDS ACTION NUMBER ACTION REQUIRED ACTION
BY ANSWERS AND COMMENTS
10 Flow Where Else
Another routing valve
is open or passing
Flow of fuel to incorrect destination 44
Interlocks required to allow only one routing
valve to be open at any time
WSP
11 45
Transfer to be stopped if fuel flow detected on another product flow
meter
WSP
12Inlet valve to Intermix Tank
is passing
Loss of fuel to Intermix Tank during transfer.
Discrepancy between fuel unloaded and fuel
received
46
Consider additional physical safeguard or cover by procedures if transfer discrepancy
detected
WSP
13Loss of radio communicatio
n
Confusion between tenant site and common system
operators
Transfer permissive signal has ultimate control of
transfer47
Procedures required to prove a working radio
channel (at agreed frequency) between ship, tenant site and common
systems control room before operations
commence. Communication to be
confirmed on regular (e.g. hourly) basis.
ARL
14 Flow Where Else
Pipe damage due to
proximity of pipe rack to
roadway
Fuel spill due to pipe fracture caused by vehicle
impact48
Provide increased separation between pipe
rack and roadwayWSP
15 49Install physical barriers to
protect pipework from road vehicles
WSP
16 Pressure More Pressure
Closed valve or ship's
pump running
Transfer line pressure higher than normal
Transfer will be stopped if high discharge pressure
detectedNo further action
17 Pressure Less Pressure See actions 16 and 17 WSP/ARL
Calabar HAZOP Record - Edited Page 9 of 17 Printed on: 27/03/2012
Company: Aikenbeck ResourcesFacility: Portside Industrial ParkDwg No: No. W702-M-830 Rev 6Dwg Title: Reticulation System - PID
Unloading Fuel to Tenant Site Section name: Section 2Leader / Scribe: PD/PD
Date: 20/03/2012Team: See Report
HAZOP ITEM NUMBER PARAMETER DEVIATION POSSIBLE
CAUSES CONSEQUENCES SAFEGUARDS ACTION NUMBER ACTION REQUIRED ACTION
BY ANSWERS AND COMMENTS
18 Temperature More Temperature
High ambient temperature or solar gain
50
Pipework stress design and expansion loops to be
included in tranfer pipe design
WSP
19 Level Greater LevelInsufficient ullage in
receiving tank
Transfer has to be aborted before completion,
resulting in delays to unloading
51
Tenant should be required to issue a "Notice of
Readiness" to confirm that they have sufficient ullage capacity in their receiving tank. Failure to comply should incur penalties.
ARL
20Receiving
tank reaches high level
Tank overflow 52
Tenant design guidelines to require multiple level
monitoring and sufficient control system integrity to
ensure that transfer permissive signal is
withdrawn when high level is reached
WSP
21 53
Consider requirement for secondary safety system (independent of process
PLC) to ensure that transfer is stopped if permissive signal is
withdrawn
WSP
22 Level Less Level Ship empty Unloading pumps cavitateLoss of pressure on the pump discharge will stop
transfer pumpsNo further action
23 Composition Different Stream 54
Procedure required to sample from the ship
before unloading and from the unloading line after
line flush
ARL
Calabar HAZOP Record - Edited Page 10 of 17 Printed on: 27/03/2012
Company: Aikenbeck ResourcesFacility: Portside Industrial ParkDwg No: No. W702-M-830 Rev 6Dwg Title: Reticulation System - PID
Unloading Fuel to Tenant Site Section name: Section 2Leader / Scribe: PD/PD
Date: 20/03/2012Team: See Report
HAZOP ITEM NUMBER PARAMETER DEVIATION POSSIBLE
CAUSES CONSEQUENCES SAFEGUARDS ACTION NUMBER ACTION REQUIRED ACTION
BY ANSWERS AND COMMENTS
24 55
Include procedure to flush unloading line, even if there is no change of
grade.
ARL
25 Other Power/Service Failure
Loss of power to control
room.PLC control system failure UPS for control system No further action
26
SCADA system failure. Unloading continues, but
operator loses sight of what is happening
Fail Safe emergency stop provided in control room
to stop transfer56 Consider providing back-
up SCADA system WSP
27
Voltage spikes in incoming
power supply
Damage to PLC or SCADA system 57
Consider provision of under and over voltage detection on incoming power supply to initiate
switch to generator supply
WSP
28 Other Shut down
Unloading hose
uncoupled before
draining complete
Fuel spill to dolphin platform or to river
Procedure to close block valve and drain hoses to dolphin platform sump
before uncoupling hoses
58
Consider key interlock system on double block
and bleed to guard against maloperation
WSP
29 Other Fire
Pumping continues after fire detected
Continued fuel flow to fire 59
Consider interlock to stop transfer operations if fire
protection system is operated
WSP
30 60
Confirm whether fire protection from hydrants is required over entire length
of transfer pipelines
WSP
31 Other Access
Tranfer pipeline
traverses rough ground
Cannot inspect entire length of transfer lines 61
Provide suitable level access for routine
inspection of transfer pipelines
WSP
Calabar HAZOP Record - Edited Page 11 of 17 Printed on: 27/03/2012
Company: Aikenbeck ResourcesFacility: Portside Industrial ParkDwg No: No. W702-M-830 Rev 6Dwg Title: Reticulation System - PID
Unloading Fuel to Tenant Site Section name: Section 2Leader / Scribe: PD/PD
Date: 20/03/2012Team: See Report
HAZOP ITEM NUMBER PARAMETER DEVIATION POSSIBLE
CAUSES CONSEQUENCES SAFEGUARDS ACTION NUMBER ACTION REQUIRED ACTION
BY ANSWERS AND COMMENTS
32 What Else 62Review other Section 1 actions applicable fuel
transfer to tenant storageWSP/ARL
33 What Else Low points in transfer lines
Transfer lines cannot be fully drained for maintenance
63
Ensure that transfer lines rise continuously to tenant
sites to permit gravity draining to common area
sump
WSP
34 64 Consider drainability of expansion loops WSP
35No high point
vents on transfer lines
Transfer lines cannot be fully drained or draining is
slow65
Consider requirement for venting of transfer lines within the tenant site to
permit draining
WSP
36 What Else
Future expansion of
facility to more than 7 tenant sites
Layout issues
Each product header can be extended to create 2nd
tier header above the initial 7 take-offs. Remote
I/O cabinets are expandable
No further action
Calabar HAZOP Record - Edited Page 12 of 17 Printed on: 27/03/2012
Company: Aikenbeck ResourcesFacility: Portside Industrial ParkDwg No: No. W702-M-830 Rev 6Dwg Title: Reticulation System - PID
Loading Fuel to Ship from Tenant Site Section name: Section 3Leader / Scribe: PD/PD
Date: 20/03/2012Team: See Report
HAZOP ITEM NUMBER PARAMETER DEVIATION POSSIBLE
CAUSES CONSEQUENCES SAFEGUARDS ACTION NUMBER ACTION REQUIRED ACTION
BY ANSWERS AND COMMENTS
1 Flow More Flow Pumping down hill
Static electricity hazard (and high reaction forces
on pipework)66
Consider measures required to ensure that transfer rates do not
exceed permitted maximum
WSP
2 Flow Less FlowTenant
pumps too small for duty
Ship delayed at berth, incurring cost 67
Consider including design criteria for back-loading
within tenant design guidelines
WSP
3 Flow Sooner FlowCommon site not ready for
transfer
Potential spill or flow to wrong destination 68
A transfer permissive signal is required to be
sent to the tenant for each of 3 products. Transfer
can only proceed on receipt of this signal.
WSP
4 69
Permissive signal to be via fibre optic cable
(preferred for reliability) or ethernet radio
WSP
5 70
Common site operator must obtain confirmation
from the ship that they are ready to receive transfer
before issuing the permission signal
ARL
6 Level Greater Level Ship's tank overfilled Fuel spill to river
Confirm that sufficient space is available in ship's
tank and that spare tank(s) is available to
provide excess capacity
71
Established and rigorous procedures are required to
prevent overfill of ship's tanks
ARL
7 Composition Different Stream
Wrong fuel grade for
selected lineCross contamination 72
Tenant should provide sample to confirm that fuel
grade is suitable for the selected loading line
ARL
Calabar HAZOP Record - Edited Page 13 of 17 Printed on: 27/03/2012
Company: Aikenbeck ResourcesFacility: Portside Industrial ParkDwg No: No. W702-M-830 Rev 6Dwg Title: Reticulation System - PID
Loading Fuel to Ship from Tenant Site Section name: Section 3Leader / Scribe: PD/PD
Date: 20/03/2012Team: See Report
HAZOP ITEM NUMBER PARAMETER DEVIATION POSSIBLE
CAUSES CONSEQUENCES SAFEGUARDS ACTION NUMBER ACTION REQUIRED ACTION
BY ANSWERS AND COMMENTS
8 Other Power/Service Failure
Unable to close actuated valves and stop flow of
fuel downhill to ship
Stand-by generators available 73
Confirm ability to close electrically actuated
valves in the event of power failure.
WSP
Calabar HAZOP Record - Edited Page 14 of 17 Printed on: 27/03/2012
Company: Aikenbeck ResourcesFacility: Portside Industrial ParkDwg No: No. W702-M-830 Rev 6Dwg Title: Reticulation System - PID
Fuel Dosing / Intermix Loading Section name: Section 4Leader / Scribe: PD/PD
Date: 26/03/2012Team: See Report
HAZOP ITEM NUMBER PARAMETER DEVIATION POSSIBLE
CAUSES CONSEQUENCES SAFEGUARDS ACTION NUMBER ACTION REQUIRED ACTION
BY ANSWERS AND COMMENTS
1
2 Flow Where ElseSpillage
during road tanker loading
Loss of fuel to river 74A contained tanker loading bay is required, draining to
suitable sumpWSP
3 Composition Extra Component
Too much dosing
Fuel transferred goes out of specification
Only about 12 tonnes of Intermix are expected per
flush75
Procedures required to ensure that dosing does not exceed acceptable
amount
ARL
4Dosing of
gasoline into kerosene
Kerosene becomes hazardous in use.
(Gasoline dosing not considered acceptable.)
76Procedures required to
ensure that only appropriate dosing is done
ARL
5 Composition Different Stream
Intermix sold as domestic
fuel
Fire or explosion if used as a domestic fuel 77
Procedures required to ensure that any Intermix
sent off site is appropriately used or redistilled to original
specifications
ARL
6 Other Fire
Road tanker loading not covered by
current Hazardous
Area Classification
Fire during loadingNormal safeguards such as tanker earthing to be
provided78
HAC to be extended to include tanker loading
bay. Remote I/O panels may need to be relocated
WSP
These operations were discussed during the HAZOP study of Sections 1 to 3 and then reviewed at the end of the meeting. There was insufficient time available to complete a full HAZOP procedure. A further review should be considered at the end of detail design.
Calabar HAZOP Record - Edited Page 15 of 17 Printed on: 27/03/2012
Company: Aikenbeck ResourcesFacility: Portside Industrial ParkDwg No: No. W702-M-830 Rev 6Dwg Title: Reticulation System - PID
Flow Proving Unit Section name: Section 5Leader / Scribe: PD/PD
Date: 20/03/2012Team: See Report
HAZOP ITEM NUMBER PARAMETER DEVIATION POSSIBLE
CAUSES CONSEQUENCES SAFEGUARDS ACTION NUMBER ACTION REQUIRED ACTION
BY ANSWERS AND COMMENTS
1
2 Flow Where ElseSpill during operation of flow prover
Loss of fuel to riverFlow prover to be located
within the common systems bunded area
No further action
3 Flow Later Flow
Flow prover shown on Berth 1
unloading line only
Unable to check flowmeters or unload from
future Berth 2 if Berth 1 not available
79 Flow prover must usable with either unloading line WSP
4 Composition Different Stream
Only one transfer tank shown with flow prover
Need to drain flow prover to road tanker or sump / Intermix Tank before use
on different product
80
Consider providing a transfer tank for each
product to enable prover to be drained and refilled with compatible product
WSP
5 Other Maintenance/Spares
Flow prover ball needs to be removed
Mechanical handling injury 81
Ensure sufficient access and mechanical handling aids to assist removal of
ball
WSP
6 What ElseIncorrect
operation of flow prover
Inexperience of operators
Flow meter calibration errors 82
Ensure operators are adequately trained for use
of the flow proverARL
This operation was briefly discussed during the HAZOP study of Sections 1 to 3 and then reviewed at the end of the meeting. There was insufficient time available to complete a full HAZOP procedure of the detailed operation of the proving unit. A further review should be considered at the end of detail design.
Calabar HAZOP Record - Edited Page 16 of 17 Printed on: 27/03/2012
Company: Aikenbeck ResourcesFacility: Portside Industrial ParkDwg No: No. W702-M-830 Rev 6Dwg Title: Reticulation System - PID
Drains, Sumps and Transfer Section name: Section 6 / 7Leader / Scribe: PD/PD
Date: 20/03/2012Team: See Report
HAZOP ITEM NUMBER PARAMETER DEVIATION POSSIBLE
CAUSES CONSEQUENCES SAFEGUARDS ACTION NUMBER ACTION REQUIRED ACTION
BY ANSWERS AND COMMENTS
1
2 Flow No FlowDischarge pumps not
primedCannot empty sumps 83 Ensure that sump transfer
pumps are self priming WSP
3 Composition Extra Component
Accumulation of rainwater in
sumps
Cannot pump out to Intermix Tank See action 19 WSP
4 Composition Contamination
Fuel spill elsewhere on site, outside of proposed
bunds
Fuel washed to river with rain water 84
Design a containment system for all rainwater
run-off from site roads to a single collection / holding point to allow separation
or treatment before discharge to river
WSP
5 Other FireExtent of
flammable zone
Ignition of vapours from common area sump See action 24 WSP
These operations were briefly discussed during the HAZOP study of Sections 1 to 3 and then reviewed at the end of the meeting. There was insufficient time available to complete a full HAZOP procedure for the detailed operation of the sumps. A further review should be considered at the end of detail design.
Calabar HAZOP Record - Edited Page 17 of 17 Printed on: 27/03/2012