HazOp Pipeline 20 - 010509 PDF

EPPM / SIRI GSA
NODE: 1
Section from : pumps trains n° 1-2 and 3 Unit : BRN Pressure: 80 bar g Team: See attendance list
to: pipeline / pig launcher P&Id n°: 10224 1-2/2 Temperature: 17 / 40 °C
Intention: oil collection from existing pumping stations Date: Jan. 5th, 2009 Flow rate: 100 / 1600 m3/h
960 m3/h (normal operating flow)
Parameter Guide Word Causes Consequences Safeguards / Notes Recommendations N°
Flow No / Less Pump stop n.s. for safety; no or lower transfer rate
Manual valve closed by no or lower transfer rate Flow measurement in Berkine
mistake on single
headers
Manual valve closed by no oil transfer BRN pumps protected in case of
mistake on common blocked discharge; flow
header measurement in Berkine
Flow More Low pressure Over-speed of transfer pumps; mechanical Over-speed protection for pumps;
downstream damage to pumps flow measurement in BRN (FI-5,
FI-304) and in Berkine
Maximum number of n.s. flow measurement in BRN (FI-5,
pumps running FI-304) and in Berkine
(including stand-by
pump)
Flow Reverse Pump failure on train 3 Oil backflow from train 1 / 2 into the Check valve on the train 3 pumps
while trains 1 / 2 are in storage tank upstream train 3 pumps, via common header; SDV closed in
service minimum flow line case of all pumps stopped
Flow Loss of Random rupture (e.g. Oil spill Fire&Gas detection system;
containment flange leakage) operator inspection tour
Temperature More n.s.
Temperature Less n.s.
Pressure More n.s.
Pressure Loss n.s.
Level More n.a.
Level Less n.a.
Composition More Presence of water due to n.s. if the water presence is discontinuous Regular check on oil for
upstream multiple expedition; automatic sampling
failures/faults unit in Berkine
Salinity increase Higher corrosion rate and depots build-up Regular check on oil for
in the pipeline and downstream lines expedition; automatic sampling
unit in Berkine
Sequence Other than n.s.
Sequence Reverse n.s.
Note: n.a.= not applicable n.s. = not significant n.n.c. = no new causes
New 20” pipeline BRN-BERKINE Pag. 1 January 2009

EPPM / SIRI GSA
NODE: 1
Section from : pumps trains n° 1-2 and 3 Unit : BRN Pressure: 80 bar g Team: See attendance list
to: pipeline / pig launcher P&Id n°: 10224 1-2/2 Temperature: 17 / 40 °C
Intention: oil collection from existing pumping stations Date: Jan. 5th, 2009 Flow rate: 100 / 1600 m3/h
Utilities Loss of Loss of power No oil transfer
Corrosion Problem of See Node 4
Erosion Problem of Sand entrainment in the Lower thickness of pipes in specific Regular check on oil for
oil flow points (e.g. elbows) expedition; erosion check for
specific points on the pipeline
Maintenance Problem of n.s.
Start up Problem of n.s.
Shut down Problem of n.s.
Sampling Problem of n.s.
Draining Problem of n.s.

EPPM / SIRI GSA
NODE: 2
Section from : pig launcher Unit : BRN Pressure: 80 bar g Team: See attendance list
to: pipeline P&Id n°: 10224 2/2 Temperature: 17 / 40 °C
Intention: pipeline pigging / pig launcher filling and Date: Jan. 5th, 2009 Flow rate: 100 / 400 m3/h
emptying
Flow No / Less Manual valve closed Delay in the pigging completion 01-XI-001 and 002
Flow More Excessive number of Pig damage; pig stuck inside the pipeline ; Operating procedure and operators
pumps in service delay in the pigging completion experience; FI-5 and FI-304
(operator mistake)
Flow Reverse n.s.
Flow Loss of Wrong operation Oil spill Specific operating procedure to be
containment followed; operators experience;
01-PI-001
01-TSV-001 leaks Minimum oil flow-rate sent to existing
through closed drain collection system
Temperature More Pig launcher full of Thermal expansion due to solar radiation; 01-TSV-001 Confirm that at least the manual valve 2.1
liquid and blocked-in overpressure on one of the lines to the collecting
drain vessels is locked open; a specific
note must be reported in P&Id 10224
2/2
Pressure More Pig launcher full of Spill of liquid under pressure; bad injuries Specific operating procedure to be
liquid and under to operator followed; operators experience;
pressure, while someone 01-PI-001; mechanical interlock to
tries to open it avoid opening
External fire during Pig launcher exposed to thermal radiation Pig launcher / receiver standard
pigging doesn’t require a PSV sized for
external fire.
The pigging operation is attended;
fire&gas detection system;
firefigting system to cool-down the
launcher.
Pigging operation is foreseen
1/year; the launcher is full of liquid
for less than 2 hours
Residual pressure in the HC vapours release when opening the 01-PI-001 can be used to remove
pig launcher before launcher the residual pressure inside the
starting pig introduction launcher

EPPM / SIRI GSA
NODE: 2
Section from : pig launcher Unit : BRN Pressure: 80 bar g Team: See attendance list
to: pipeline P&Id n°: 10224 2/2 Temperature: 17 / 40 °C
Intention: pipeline pigging / pig launcher filling and Date: Jan. 5th, 2009 Flow rate: 100 / 400 m3/h
emptying
Pressure Less n.s.
Level More n.s.
Level Less n.s.
Composition More n.s.
Composition Other than n.s.
Utilities Loss of Loss of power Pump stops; delay in the pigging
completion
Corrosion Problem of n.s.
Erosion Problem of n.s.
Maintenance Problem of TSV to be removed n.s.; manual isolation valves are provided
upstream and downstream TSV
Draining Problem of Manual valve left closed Pig launcher full of liquid; potential spill Pit for recovery of the spilt oil
in the draining line release when opening the launcher
during pig launcher
emptying

EPPM / SIRI GSA
NODE: 3
Section from : pig receiver in Berkine Unit : Berkine Pressure: < 80 bar g Team: See attendance list
to: ---- P&Id n°: 10225 Temperature: 17 / 40 °C
Intention: pigging operation; pig recovery and receiver Date: Jan. 5th, 2009 Flow rate: 100 / 400 m3/h
emptying
Flow No / Less Manual valve closed Delay in the pigging completion 03-XI-001 and 002
Flow More Excessive number of Pig damage; pig stuck inside the pipeline ; Operating procedure and operators
pumps in service delay in the pigging completion experience; FI-5 and FI-304
(operator mistake)
Flow Reverse n.s.
Flow Loss of Wrong operation Oil spill Specific operating procedure to be
containment followed; operators experience;
03-PI-003
03-TSV-002 leaks Minimum flow-rate of oil sent to 03-V- 03-LI-001 on 03-V-001
through 001 vessel
Temperature More Pig launcher full of Thermal expansion due to solar radiation; 03-TSV-002 Manual valve on draining header to 3.1
liquid and blocked-in overpressure 03-V-001 must be specified Locked
Open
Pressure More Pig launcher full of Spill of liquid under pressure; bad injuries Specific operating procedure to be
liquid and under to operator followed; operators experience;
pressure, while someone 03-PI-003; mechanical interlock to
tries to open it avoid opening
Residual pressure in the HC vapours release when opening the 03-PI-003 can be used to remove
pig launcher before launcher the residual pressure inside the
starting pig introduction launcher
Pressure Less n.s.
Level More n.s.
Level Less n.s.
Utilities Loss of Loss of power Pump stops; delay in the pigging
completion
Maintenance Problem of TSV to be removed n.s.; manual isolation valve is provided
upstream and downstream TSV

EPPM / SIRI GSA
NODE: 3
Section from : pig receiver in Berkine Unit : Berkine Pressure: < 80 bar g Team: See attendance list
to: ---- P&Id n°: 10225 Temperature: 17 / 40 °C
Intention: pigging operation; pig recovery and receiver Date: Jan. 5th, 2009 Flow rate: 100 / 400 m3/h
emptying
Draining Problem of Manual valve left closed Pig launcher full of liquid; potential spill Pit for recovery of the spilt oil
in the draining line release when opening the launcher
during pig launcher
emptying

EPPM / SIRI GSA
NODE: 4
Section from : BRN (20” pipeline) Unit : Berkine Pressure: < 80 bar g Team: See attendance list
to: Berkine (including connection to OH-3 and OH-4) P&Id n°: 10224 2/2, 10222, 10225 Temperature: 17 / 40 °C
Intention: oil transfer Date: Jan. 5th, 2009 Flow rate: 100 / 1600 m3/h
Flow No / Less 20” manual valve left No oil transfer Flow measurement in BRN and in
closed Berkine. Manual valve at km 46 is
buried and without hand wheel in
place.
03-XV-001 spurious High pressure in the pipeline, not Loss of 03-ZAH-001 will activate
closure (in about 7-10 exceeding the design pressure ESD2 and then ESD1 (pumps
seconds) stopped and SDV closed).
Pipeline designed for 94 bar g.
PSHH-001 A/B/C to stop pumps
and close SDV at 86 bar g
Closure of a valve High pressure in the pipeline, not Pipeline designed for 94 bar g.
downstream 03-XV-001 exceeding the design pressure PSHH-001 A/B/C to stop pumps
(more than 10 seconds and close SDV at 86 bar g.
are required) 04-FAL-001
Flow More Maximum number of n.s. flow measurement in BRN (FI-5,
pumps running FI-304) and in Berkine
(including stand-by
pump)
Flow Reverse Valve closure in OH-3 Potential backflow from OH-3/4 to BRN Two check-valves in series;
or OH-4 pipeline transfer from BRN to OH-3/4 is an
exceptional case
Flow Loss of Generic leak from the Oil spill in the ground; soil contamination Cathodic protection; buried
containment pipeline pipeline; PE external coating; in-
line detection device considered as
an option to be still discussed and
approved (see HazId study) .
Intelligent pigging of the pipeline
every five years.
Manual isolation valve at km 46;
intervention to put a clamp to stop
the leak, according to a proven
procedure.

EPPM / SIRI GSA
NODE: 4
02-TSV-001/002 at km Oil release in the open drain Period check of manual isolation
46 leaks through valve at km 46 by BRN operators;
need to close the manual isolation
valve is considered very unlikely
03-TSV-001 leaks Continuous oil discharge to 03-V-001; Local LI on 03-V-001
through high level in V-001
Temperature Less Extremely cold weather n.s. 03-TAL-001
for a prolonged period
Pressure More Pipeline full of liquid Liquid thermal expansion due to solar 03-TSV-001 or 02-TSV-001/002
blocked in radiation in the above ground parts of the
pipeline; overpressure
Pressure Less Bad pressure control Gas bubble formation inside the pipeline; 03-PAL-001A; 03-FI-001
two-phase flow; vibrations; wrong
metering
Level More n.a.
Level Less n.a.
Composition More n.n.c.
Composition Other than n.n.c.
Viscosity More n.s. No paraffin is foreseen in the
transferred crude oil
Viscosity Less n.s.
Utilities Loss of Loss of air/nitrogen 03-XV-001 is specified Fails Closed; stop Loss of 03-ZAH-001 will activate
of oil transfer ESD2 and then ESD1 (pumps
stopped and SDV closed).
Loss of power (BRN stop of oil transfer
side)
Loss of power (Berkine 03-XV-001 fails closed; no flow and ESD2 activation with stop of oil
side) pressure transfer, by loss of power and by
loss of 03-ZAH-001

EPPM / SIRI GSA
NODE: 4
Corrosion Problem of High salinity content in Lower thickness of the pipe; crack 1 mm of corrosion allowance,
the oil formation, oil spill enough for pipeline lifetime;
possibility for corrosion inhibitor
injection; intelligent pigging
Erosion Problem of Sand entrainment in the Lower thickness of pipes in specific Regular check on oil for
oil flow points (e.g. elbows) expedition; erosion check for
specific points on the pipeline
Maintenance Problem of n.s. Another pipeline is available
Shut down Problem of 03-XV-001 stuck open Prolonged release to TK-1101 in case of 03-PCV-001 will be closed due to
in case of ESD2 PSV opening ESD2 activation.
activation TK-1101 has a large capacity
(there is enough time to close the
manual valve upstream 03-.XV-
001).
Limit switch on 03-XV-001 (03-
ZAH-001)
Draining Problem of Need to empty the TK-1101 is not large enough to receive In case of need to empty the pipeline, 4.1
pipeline (about 14000 the pipeline content a specific procedure must be prepared GSA
m3 of liquid) BRN

EPPM / SIRI GSA
NODE: 5
Section from : 20” pipeline end Unit : Berkine Pressure: 70 / 8 bar g Team: See attendance list
to: manifold, via skid de comptage fiscale P&Id n°: 10225, 10223 ½, 10226 Temperature: 17 / 40 °C
Intention: oil pressure reduction and flow measurement Date: Jan. 5th, 2009 Flow rate: 100 / 1600 m3/h
Flow No / Less 03-PCV-001 closed High pressure in the pipeline, not PAH-001A
exceeding the design pressure; no oil
transfer
Filter plugging Lower flow rate for oil transfer 04-FAL-001 A; 04-PDI-001 A;
stand-by measurement unit
Flow More n.n.c.
Flow Reverse n.s.
Flow Loss of Random rupture Release of oil Fire&Gas detection system
containment
04-TSV-001 leaks Continuous discharge of oil in the existing
through closed drain
04-PSV-001 leaks Continuous discharge of oil to TK-1101 04-FSH-001 (2oo3 logic) to
through activate ESD2; pilot operated
safety valve (leakage is not likely)
Pressure More 03-PT-001B fails open Overpressure downstream 03-PCV-001; 03-PAH-002; 04-PSV-001 / 002
rupture and large release of oil (redundant); 04-FSH-001 (2oo3
logic) to activate ESD2
03-PCV-001 by-pass 03-PAH-001B; 03-PAH-002; 04-
valve opened by mistake PSV-001 / 002 (redundant); 04-
FSH-001 (2oo3 logic) to activate
ESD2
External fire Stand-by line is full od diesel oil; TSV 04-TSV-001 A/B must be replaced 5.1
exposure to flame; overpressure and with PSVs sized for fire case to EPP
rupture protect the two metering units M
Pressure Less 03-PT-001B fails closed See No Flow
One pump stops in BRN Gas bubble formation inside the pipeline; PT-001A to close 03-PCV-001
and 04-PT-001B failure two-phase flow; vibrations; wrong (over-ride control)
(no pressure control) metering (if the pressure at Berkine
existing manifold is relatively low)

EPPM / SIRI GSA
NODE: 5
Section from : 20” pipeline end Unit : Berkine Pressure: 70 / 8 bar g Team: See attendance list
to: manifold, via skid de comptage fiscale P&Id n°: 10225, 10223 ½, 10226 Temperature: 17 / 40 °C
Intention: oil pressure reduction and flow measurement Date: Jan. 5th, 2009 Flow rate: 100 / 1600 m3/h
Large pressure drop Cavitation and noise PCV will be designed with special
around PCV seals
Level More n.a.
Level Less n.a.
Utilities Loss of Loss of power 03-PV-001 fails closed; stop of oil ESD2 activation after a certain EPPM will compare different 5.2
transfer period of time solutions for pressure control valve EPP
actuation, to be discussed later with M
GSA
Corrosion Problem of Corrosion products Filter plugging in the metering unit
entrainment
Erosion Problem of Presence of sand in the PCV erosion PCV designed for erosion
oil

EPPM / SIRI GSA
NODE: 6
Section from : new manifold inlet Unit : Berkine Pressure: 5 bar g Team: See attendance list
to: existing manifold P&Id n°: 10226 Temperature: 17 / 40 °C
Intention: oil distribution in the export lines Date: Jan. 5th, 2009 Flow rate: 100 / 1600 m3/h
Flow No / Less MOV closed by mistake No oil transfer; high pressure in the MOV status indication in control Provide position switch on the new 6.1
pipeline room MOVs EPP
M
Flow More Selection of a wrong Oil sent to a different storage tank Level measurement in the storage
MOV tanks; MOV status indication in
control room
Flow Reverse Selection of a wrong Potential backflow in case of an upset Check-valves; ESD activation due
MOV, with another (e.g. closure of a valve on the storage tank to high pressure at the beginning of
pipeline feeding the inlet line) the pipeline
same distribution line
inside Berkine
Flow Loss of 05-TSV-001 leaks Continuous discharge of oil to evisting
containment through closed drain
Random rupture Oil release; fire in case of ignition Fire&Gas detection system
Pressure More n.n.c.
Pressure Less n.n.c.
Level More n.a.
Level Less n.a.
Sequence Other than n.s.
Sequence Reverse n.s.
Utilities Loss of Loss of power MOV remains in position; fail safe
condition
Corrosion Problem of n.n.c.
Erosion Problem of n.n.c.
Maintenance Problem of n.s. Top entry MOV

EPPM / SIRI GSA
NODE: 6
Section from : new manifold inlet Unit : Berkine Pressure: 5 bar g Team: See attendance list
to: existing manifold P&Id n°: 10226 Temperature: 17 / 40 °C
Intention: oil distribution in the export lines Date: Jan. 5th, 2009 Flow rate: 100 / 1600 m3/h
Shut down Problem of MOV stuck open when MOV can be closed also manually by
there is high level in the hand wheel
receiving storage tank

EPPM / SIRI GSA
NODE: 7
Section from : drains collection Unit : Berkine Pressure: atm. Team: See attendance list
to: ballon drainage 03-V-001 P&Id n°: 10224 Temperature: 17 / 40 °C
Intention: drains collection from pig receiver / TSVs / 03- Date: Jan. 5th, 2009 Flow rate: variable
PV-001
Flow No / Less Manual valve stuck No liquid removal, small volume of liquid
closed on 03-PCV-001 released during PCV removal
draining line
Flow More Draining line opened by High level in 03-V-001 in a few Two manual valves in series must
mistake with the transfer minutes/hours be opened (unlikely mistake)
line in service
Flow Reverse n.s.
Flow Loss of Leakage from 03-V-001 Oil spill in the pit; no soil contamination Periodic check by operator during
containment inspection tour
Pressure More Plugged flame arrester Overpressure in case of continuous Flame arrester plugging is not Provide a local PI on 03-V-001 7.1
leakage from TSV frequent
Pressure Less Plugged flame arrester Vacuum conditions; implosion
Level More TSV leaks through Overfilling, oil spill in the containment 03-LI-001 (local); periodic check
basin by operator during inspection tour
Level Less n.s. Total emptying of the vessel is
required
Utilities Loss of Loss of power n.s.
Draining Problem of n.n.c.

EPPM / SIRI GSA
NODE: 8
Section from : skid de comptage fiscale Unit : Berkine Pressure: 5-8 bar g Team: See attendance list
to: etalonnage unit and return P&Id n°: 10223 1-2/2 Temperature: 17 / 40 °C
Intention: calibration of the unit de comptage fiscale Date: Jan. 5th, 2009 Flow rate: 960 m3/h
Flow No / Less Manual valve stuck No calibration is possible
closed
Four ways valve or 04-
FCV-002 failure in
closed position
Flow More n.s.
Flow Reverse n.s.
Flow Loss of Leakage from a flange / Oil release; fire in case of ignition Fire&Gas detection
containment valve
04-TSV-005 leaks Continuous loss of oil into the existing
through closed drain
Pressure More External fire Exposure to thermal radiation; Calibration unit is used for a very 04-TSV-003 must be replaced by a 8.1
overpressure short period during a year; when PSV sized for fire case EPP
not in use, it is full of diesel oil M
Pressure Less n.s.
Level More n.a.
Level Less n.a.
Sequence Other than
Sequence Reverse Wrong operation during No flow conditions or bad calibration Operating procedure; the
calibration alignment calibration is done with the
presence of at least two operators
Utilities Loss of Loss of power n.s.; non interruption of the oil transfer

EPPM / SIRI GSA
NODE: 8
Section from : skid de comptage fiscale Unit : Berkine Pressure: 5-8 bar g Team: See attendance list
to: etalonnage unit and return P&Id n°: 10223 1-2/2 Temperature: 17 / 40 °C
Intention: calibration of the unit de comptage fiscale Date: Jan. 5th, 2009 Flow rate: 960 m3/h
Draining Problem of n.s. Al least two valves in series must
be open to drain the unit when in
service

EPPM / SIRI GSA
NODE: 9
Section from : skid de comptage fiscale outlet line Unit : Berkine Pressure: 8 bar g Team: See attendance list
to: automatic sampler P&Id n°: 10223 2/2 Temperature: 17 / 40 °C
Intention: automatic sampling of the received oil Date: Jan. 5th, 2009 Flow rate: 0.1 m3/d
Flow No / Less Solenoid valve stuck No sampling for a day
closed
Flow More Solenoid valve stuck Sampling bottle full of liquid Alarm for high level or excessive
open weight
Flow Reverse Pressurized bottle Backflow of gas Check-valve
Flow Loss of Random rupture Small flow-rate of oil released on paved Fire&gas detection system
containment area
Pressure More n.s. Sampling unit designed for 19 bar
Pressure Less n.s.
Level More n.a.
Level Less n.a.
Utilities Loss of Loss of power Stop of automatic sampling
Sampling Problem of Failure of sampling No sampling The flow computer controls the
device automatic sampling, with alarm
Draining Problem of Manual valve left open Continuous discharge of oil into the Provide double isolation manual 9.1
on drain line closed drain system valves on the two draining lines from
the 16”-04-TO-010 line

EPPM / SIRI GSA
NODE: 10
Section from : drains from comptage fiscale / etalonnage Unit : Berkine Pressure: 0.2 bar g Team: See attendance list
units P&Id n°: 10223 1-2/2 Temperature: 17 / 40 °C
to: existing drain collection system Date: Jan. 5th, 2009 Flow rate: variable
Intention: to collect the drains from comptage fiscale /
etalonnage units, sending them into the existing closed
drain
Flow No / Less Manual valve on n.s. (another draining line can be used for
draining line stuck the measurement unit)
closed
Flow More Manual valve opened in Loss of oil into the closed drain There is always a second mean for Provide a second manual isolation 10.1
a draining line when the isolation, except for vent line on valve on ½” vent line on filters of the
process line is in service filter upstream FE metering unit
Flow Reverse n.s.
Flow Loss of n.n.c.
containment
Pressure More n.s.
Pressure Less n.s.
Level More n.s.
Level Less n.s.
Utilities Loss of Loss of power n.s.
Draining Problem of n.n.c.

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EPPM / SIRI GSA

New 20” pipeline BRN-BERKINE Pag. 1 January 2009

New 20” pipeline BRN-BERKINE Pag. 2 January 2009

New 20” pipeline BRN-BERKINE Pag. 3 January 2009

New 20” pipeline BRN-BERKINE Pag. 4 January 2009

New 20” pipeline BRN-BERKINE Pag. 5 January 2009

New 20” pipeline BRN-BERKINE Pag. 6 January 2009

New 20” pipeline BRN-BERKINE Pag. 7 January 2009

New 20” pipeline BRN-BERKINE Pag. 8 January 2009

New 20” pipeline BRN-BERKINE Pag. 9 January 2009

New 20” pipeline BRN-BERKINE Pag. 10 January 2009

New 20” pipeline BRN-BERKINE Pag. 11 January 2009

New 20” pipeline BRN-BERKINE Pag. 12 January 2009

New 20” pipeline BRN-BERKINE Pag. 13 January 2009

New 20” pipeline BRN-BERKINE Pag. 14 January 2009

New 20” pipeline BRN-BERKINE Pag. 15 January 2009

New 20” pipeline BRN-BERKINE Pag. 16 January 2009

New 20” pipeline BRN-BERKINE Pag. 17 January 2009

New 20” pipeline BRN-BERKINE Pag. 18 January 2009

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