HAZID & HAZOP Study for ORYX GTL Underground Cooling Water System Replacement

Underground cooling water system

Introduction

iFluids Engineering & Consultancy WLL conducted a comprehensive HAZID (Hazard Identification) and HAZOP (Hazard and Operability) study for the FEED & DED project to replace the underground cooling water system at ORYX GTL facilities. The primary objective was to evaluate and mitigate risks related to health, safety, environmental impacts, and the company’s reputation associated with the proposed project.

Background

The existing underground cooling water system has experienced repeated leaks, leading to operational disruptions. Since 2011, there have been nine cooling water failures, with five incidents causing total facility shutdowns. Each repair took at least ten days to restore normal operations. Despite efforts to strengthen critical joints and improve system reliability, the potential for failure remains high, posing significant operational risks.

To ensure a robust cooling water system, it is recommended to redesign and replace the existing system in accordance with applicable standards. This project aims to eliminate the risk of future leaks and avoid total facility shutdowns.

HAZID Study

Purpose

The HAZID study aims to identify hazardous events that could impact equipment, operators, and production. It focuses on health, safety, and environmental risks at the early stages of project design, ensuring proper mitigation measures are implemented.

Objectives

  1. Identify potential internal and external hazardous events.
  2. Assess the likelihood and consequences of identified hazards.
  3. Evaluate current safety measures and recommend additional controls.
  4. Provide actionable recommendations to mitigate risks to an acceptable level.

Methodology

The HAZID study follows a systematic approach represented by four connected red oval segments. Each segment includes an icon and text: Risk Identification (magnifying glass and hazard icon), Risk Assessment (checklist and hazard icon), Team Collaboration (group teamwork icon), and Recommendations (checkmark and handshake icon)
HAZID study: Risk Identification, Assessment, Collaboration, and Recommendations

The HAZID study follows a systematic approach:

  • Risk Identification: Identify potential health, safety, and environmental hazards using guidewords.
  • Risk Assessment: Rank hazards using qualitative risk assessment techniques.
  • Team Collaboration: Involve a multidisciplinary team for brainstorming and ideation.
  • Recommendations: Provide mitigation measures, further investigations, and studies as necessary.

Key Focus Areas

  • External and environmental risks.
  • Facility and health risks.
  • Project implementation concerns.

Process

  1. Define design intent and operating conditions.
  2. Select facility areas for evaluation.
  3. Apply guidewords to identify hazard scenarios.
  4. Assess causes, consequences, and existing safeguards.
  5. Assign risk rankings using the ORYX GTL risk assessment matrix.
  6. Recommend additional measures for mitigation or further analysis.

HAZOP Study

Purpose

The HAZOP study evaluates potential hazards and operability issues in a structured manner. It identifies deviations from intended operations and assesses their effects on assets, operations, and the environment.

Objectives

  1. Identify hazards and operational concerns.
  2. Evaluate existing safeguards and propose improvements.
  3. Enhance facility design and operations to mitigate identified risks.

Methodology

The HAZOP study employs a “What-If” approach to systematically evaluate each system node:

  1. Define system purpose and operating parameters.
  2. Select nodes for detailed analysis.
  3. Formulate “What-If” questions to identify potential hazards.
  4. Assess causes, consequences, and existing safeguards.
  5. Recommend additional protections where necessary.
  6. Repeat the process for all nodes and systems.

Required Documents

  • Facility layouts and process flow diagrams.
  • Piping and instrumentation diagrams.
  • Risk assessment matrices and safety data sheets.
  • Incident reports and risk registers.
  • Company guidelines and HSE philosophy.

Study Execution

A multidisciplinary team comprising experts from iFluids Engineering, Kentz Engineering International (KEI), and ORYX GTL conducted the HAZID & HAZOP sessions. Participants included professionals from process, piping, instrumentation, electrical, HSE, civil, structural, operations, and maintenance disciplines.

Recommendations

  1. Redesign the underground cooling water system to eliminate potential leaks.
  2. Implement robust safety measures to mitigate risks.
  3. Conduct further studies to assess specific hazards and their impacts.
  4. Strengthen team collaboration for ongoing risk management.

Conclusion

The HAZID and HAZOP studies provided valuable insights into the hazards and operability issues associated with the underground cooling water system replacement project. By implementing the recommended measures, ORYX GTL can ensure a safer and more reliable cooling water system, minimizing operational disruptions and safeguarding its reputation.