Introduction
iFluids Engineering and Consultancy WLL was awarded to perform HAZID studies for EPIC at various facilities of Qatar Gas, including:
- HAZID Study for the Upgrade of Plant and Admin Building Sewage Pumping System
- HAZID Study for the Utilization of Spare Liquefaction Capacity at the AKG Facility
- HAZID Study for the Replacement of Obsolete Air Blowers Unit
- Study for the Installation of Filters in LR1 and LR2 Feed Condensate Lines
The primary objective of HAZID (Hazard Identification) case studies, is to focus on identification of hazards and risk assessment in the context of various industrial projects. The projects involve upgrades, utilisation of spare capacity, replacement of obsolete equipment, and installation of filtration systems.
The overarching goal is to ensure the HSE (health, safety, and environmental integrity) of the facilities, as well as to maintain operational efficiency and reputation. Each case study presents unique challenges and solutions, reflecting the complexity and diversity of the industries involved, from LNG production to refinery operations. The methodologies employed, such as HAZID workshops and systematic examination, highlight a commitment to proactive risk management and compliance with safety and environmental standards.
Case study 1: HAZID Study for the Upgrade of Plant and Admin Building Sewage Pumping System:
This case study summarises the proceedings of the HAZID workshop carried out for EPC: Upgrade of Plant and Admin Building Sewage Pumping System. The primary objective of this study was to assess the hazards and their impacts of the proposed project in terms of risk to Health, Safety, the Environment, (HSE) and the company’s reputation.
The HAZID workshop was conducted by a multi-disciplinary team involving all stakeholders, i.e., Qatar Gas, DOPET, Worley and facilitated by iFluids. The detailed methodology adopted for the HAZID workshop is included in the subsequent sections of the case study.
Qatar Gas (QG) operates various facilities in Ras Laffan Industrial City (RLIC) to support the production and shipping of LNG. The staff and facilities that support operations generate effluent that is collected in the QG1 Utilities area of the effluent collection facility, which was constructed in the mid-1990s. With the expansion of LNG facilities starting in 2005, plant areas such as QG2 / QG3 & 4 / LR / RLTO, QG OPCO support staff have grown multi-fold in both non-plant areas and off-site areas.
This increase in employees to support the new facilities has resulted in the current effluent gathering system and treatment facilities running close to maximum capacity or above. Effluent generated from some sources, like LR, CLNG, RLTO, etc., is trucked to the treatment plant (within RLIC) for processing. A study has been conducted to review all the fluid streams for present and future situations that are generated and identify the shortcomings within the collection and treatment system. FEED has been performed for the above study and proceeded for the EPC works.
Case Study 2: HAZID Study for the Utilisation of Spare Liquefaction Capacity at the AKG Facility:
The AKG facility is designed for 2000 MMSCFD sales gas production and operates based on market demand. In AKG assets, natural gas from inlet facilities is routed to the Acid Gas Removal Unit (AGRU) to remove acid gases, followed by dehydration and mercury removal units for water, meraptans, and mercury removal before being fed to the NGL Recovery Unit to avoid freezing at low temperatures.
In the NGL Recovery Unit, ethane and heavier hydrocarbons are recovered from the gas and fed to the Fractionation and Treating Unit for further processing, while the residue gas (product sales gas) is sent to the sales gas header. In the dehydration unit, during drier regeneration, residue gas is utilised as regeneration gas and later treated in the regeneration gas treating unit (Selexol unit) to remove Mercaptans. The treated gas is water-saturated, meets sales gas specifications, and is further re-injected into the sales gas stream by an excess gas compressor (EGC).
AKG-1 has a dedicated Excess Gas Compression Unit. Selexol-treated spent regeneration gas is sent after fuel gas demand in AKG-1 is extracted. The excess gas compressor boosts excess gas pressure for re-injection into the sales gas stream. AKG-2 also has a dedicated compression facility within the Selexol unit where the excess gas compressor boost pressure of excess gas for re-injection into the sales gas stream.
AKG assets suffer production curtailment during the winter when sales gas demand is lower. AKG production has been further impacted since Barzan started production in 2020. Therefore, COMPANY intends to utilise spare capacity of liquefaction to liquefy surplus sales gas using a bi-direction sales gas backup line. The infrastructure for sales gas diversion from AKG is already in place; however, surplus AKG sales gas diversion is not feasible due to water and heavy hydrocarbon contamination in the sales gas due to re-injected excess gas. Therefore, it is required to recycle excess gas back to AGRU so that sales gas will meet LNG specification and can be diverted to LNG trains via existing bi-directional line.
Case study 3: HAZID Study for the Replacement of Obsolete Air Blowers Unit:
The main aim of this study was to evaluate the potential risks and consequences associated with the proposed project in relation to Health, Safety, the Environment (HSE), and the reputation of the company. A set of structured guide words with question prompts was used for the HAZID study. The set of guide words used was as per the HAZID methodology.
Air blowers are installed in the electrochlorination unit at the seawater intake facility to dilute hazardous hydrogen gas accumulated in the dehydrogenation tank into the atmosphere, which is essential for the continuous operation of the unit safely. These blowers are declared obsolete by OEMs. The unit has been in service since 1996. The blower inlet casing, motor base frame, and foundations are badly corroded.
Presently, only one blower is available, and the breakdown of the running blower will lead to the shutdown of the Electro Chlorination unit, which will result in marine growth in the seawater system across QG1 assets.
A modification request has been raised for the obsolescence management of blowers; accordingly, the blower vendor DE CARDENAS is contacted for blower supply.
EPC Contractor shall provide complete project management, engineering, procurement, safety, quality assurance and quality control, construction, installation, pre-commissioning, and commissioning testing and includes the following:
To keep the existing base frame in place and install the new blower along with the base frame inside the existing base frame by demolishing the cross stiffeners inside the existing base frame.
- Installation of a new blower (updated model) with a motor and other accessories such as a filter and silencer, along with the flexible joint at the blower discharge.
- Fabrication and erection of a new base frame and construction of a new foundation
- Blasting of the corroded part of the foundation frame and structure platform (to be checked or clarified)
The discharge piping interface spool is to be supplied with a similar configuration and the same material as per existing to match the new blower and the existing header connections. EPC contractor to arrange the required material (as necessary). The existing transition spool that is being planned to be reused shall be confirmed to the applicable QG specification, and the required inspection and testing activities shall be carried out.
- Verification or testing of the existing cable condition
- Welding of the cracked part of the foundation farm
- Apply protection coating as per QG specification.
- Updating of existing documentation
- Codification and procurement of Spares for the new Blower assembly
- FAT should be conducted to confirm blower performance at vendor facilities.
- Disposal of old air blowers as per QG’s scrap management procedure in coordination with the QG Team
- Vendor supervision at site for Site commissioning and testing activities
Case study 4: HAZID Study for the Installation of Filters in LR1 and LR2 Feed Condensate Line:
The main aim of this study was to evaluate the potential risks and consequences associated with the proposed project, specifically in relation to Health, Safety, the Environment (HSE), and the reputation of the company.
The Hazard Identification Study Method is the application of a formal, systematic examination to each area of the installation with a checklist of hazards. In cases where there is a consensus regarding the presence of a hazard in a specific location, an evaluation of the risk associated with the hazard is conducted, and all available methods for either eliminating the hazard or managing the risk are documented on a HAZID worksheet. Qualitative risk assessment of the hazards is carried out using the Qatargas risk assessment matrix during the HAZID.
Laffan Refineries LR1 & LR2 receive feed condensate from all producers in Qatar gas (QG1, QG2, QG3, QG4, RL, RL2, RL3, and AKG) and Barzan assets. Condensate is stored in Laffan Refinery Tank Farm (LRTF) tanks. Condensate is transferred to both refineries via feed condensate pumps in LRTF area to LR1 & LR2 plant sides. Then condensate is received in LR2 by condensate charge pumps and fed to the feed condensate heater, where the main issues arise.
Laffan Refinery Asset recently conducted an RCFA to identify the root cause of feed condensate heater tube choking issues. One of the main recommendations is to consider installing new feed condensate filters at the inlet feed for both refineries to eliminate debris that results in heater chocking issues and improve the availability and reliability of the LR1 & LR2 feed condensate heaters.
Laffan Refinery Asset had also conducted an opportunity study done by Chiyoda Almana, aiming to increase the revenue from the asset. One of the opportunity studies was to study the feed condensate heater performance issues, which resulted in recommendations for installing a filtration facility upstream of feed condensate heater.
However, before going to this project, the asset leadership team decided to conduct a pilot project of a filtration facility, trying to collect more data and analyze it for proper understanding of the filter element design criteria such as size, type, etc., and this pilot testing was successfully conducted. This project has the responsibility to cater for local demand for refinery products by avoiding production losses due to heater choking issues happening every 6 months of continuous operation; hence, it is reducing the financial loss as well as the environmental impacts due to SD / start-ups.
The project scope includes modifications to be done in LR1 & LR2 feed condensate main headers, 18” line feeding the feed condensate pumps in LR1 and LR2 assets, respectively. The modification is required to provide tie-in provisions on the feed condensate stream, flare header, and drainage systems of LR1 and LR2 to fit in the new filtration facility.
HAZID Study methodology
HAZID methodology involves early detection and characterization of HSE hazards and risks, employing a structured brainstorming technique with a checklist of potential issues. The objectives include identifying and describing hazards related to the environment, facilities, health, and project implementation issues. The study aims to rank potential dangers through qualitative risk assessment and swiftly identify and describe potential problems, focusing on problem identification rather than resolution.
HAZID Review’s
The HAZID review’s ultimate goal is to manage and mitigate potential hazards to an acceptable level of risk. It contributes to minimising the cost and schedule impact of risk mitigation measures by identifying risks early in the design phase. Recommendations from the study include mitigation measures, investigations, and studies to quantify hazards and their repercussions.
HAZID Technique
The HAZID technique systematically assesses external and environmental hazards, facility hazards, health hazards, and project implementation issues. The study team, comprising experts from various disciplines, engages in structured idealisation sessions prompted by hazard descriptors. The proceedings are recorded, and a risk treatment plan, along with a HAZID close-out action sheet, is generated for follow-up and closure by the responsible action party.
During the study, potential causes for deviations from the design intent are thoroughly discussed, documented, and evaluated for their effects. Recommendations aim to reduce the likelihood and severity of incidents, request additional information when needed, or seek updates to specific documents.
The HAZID study was developed specifically to reflect the importance of HSE issues in the fundamental decisions that are made at the inception of all development projects (e.g., design concept and location). HAZID is the first opportunity to bring experienced line and HSE staff together to address, in a short time frame, the issues surrounding a new venture, development, or modification project.
The HAZID technique includes the following:
- The objective is to establish methods for early detection and characterization of Health, Safety, the Environment (HSE) hazards and risks during the initial phases of a project or undertaking.
- A meeting of a highly experienced multi-discipline team using a structured brainstorming technique based on a checklist of potential HSE issues was held to assess the applicability of potential hazards.
- Carry out a qualitative risk assessment to rank the hazards.
- The rapid identification and description process of the potential problem is not a forum for trying to solve potential problems.
Hazard Identification (HAZID) is a systematic and methodical approach utilised to assess and evaluate the potential consequences and effects of various factors.
- The surroundings of the facilities
- The facilities in their surroundings.
- The facilities on the health
- Project Implementation Issues
HAZID review is to identify potentially dangerous and undesirable events that might affect a facility (equipment, operators, and production). The review allows proper identification of HSE hazards at the beginning of a project and provides a detailed list of project hazards and recommended controls to manage those hazards to an acceptable level of risk.
The review additionally delineates the origins and ramifications of these hazardous scenarios and presents suggestions that propose:
- Mitigation measures aimed at eradicating the likelihood of these incidents or curtailing their repercussions
- Research and empirical analyses aimed at quantifying the potential risks and associated consequences
The primary objective of the HAZID review is to ascertain and assess potential hazards while effectively mitigating the associated risks to a level that is deemed acceptable.
The HAZID technique has been developed with the primary objective of identifying and effectively mitigating risks that are associated with design decisions made during the initial phases of a project. By identifying these risks early in the design phase, the cost and schedule impact associated with the risk reduction measures are minimised.
The HAZID process provides an initial opportunity for both experienced line and Health, Safety, and Environment (HSE) personnel to collectively examine and evaluate the various concerns associated with a new venture, development, or modification project. The HAZID methodology employs structured brainstorming sessions facilitated by hazard guide words.
The proceedings file of the HAZID is recorded, and the risk treatment plan (recommendation, action, and query items) is recorded. The corresponding HAZID Close Out Action Sheet is generated for subsequent follow-up and close-out by the responsible action party. It is the responsibility of project teams to diligently monitor and finalise all risk treatment plans and recommendations resulting from the HAZID Study.
During the course of the study, the research team engaged in comprehensive deliberations regarding all potential factors contributing to each instance of deviation from the intended design. Subsequently, these factors were systematically documented and enumerated. After the documentation of all causes, the team directed their attention towards examining the consequences associated with each cause that had been identified.
The documented consequences were those that could plausibly occur as a result of the given cause. After the documentation of the consequences, the team proceeded to evaluate the process design and operations in order to identify any safeguards that could potentially prevent, detect, or mitigate each cause or consequence scenario. Any recommendations made are for additional safeguards that are not currently in use at the facility.
The stated HAZID objectives of the recommendations are as follows:
- To decrease the likelihood of an incident taking place,
- To mitigate the severity of the consequences in the event that an incident does occur,
- To seek additional information in cases where the scenario could not be adequately described due to insufficient data; or
- To request an update or inclusion of a specific document.
The HAZID Study for EPC services for upgrading the capacity of the existing instrument air system was supported with an overall Plot Plan and Process & Instrumentation Diagrams (P&ID) of the project scope. During the HAZID workshop, Health, Safety, Environmental, Reputation hazards were ranked as per the Risk Assessment Matrix (RAM). The present qualitative risk ranking methodology evaluates the probability and impact of potential hazards in order to determine the overall significance of each hazard.
The HAZID study team consisted of a multi-disciplinary team from company, contractor, subcontractor and third-party contractor Disciplines represented in the HAZID Study review include personnel from Process, Piping, Instrumentation & Control, Electrical, HSE, Civil and Structural, System & Control, Project, Operations, and Maintenance.
The HAZID study for EPC Services for upgrading the capacity of the existing instrument air system assessed the hazards and impacts of the proposed project in terms of risk to health, safety, the environment, and the company’s reputation to further reduce the risk to a tolerable / acceptable level.
The HAZID Team was highly qualified and experienced, had excellent representation from important disciplines, and, as a team, did a commendable job with a very high level of dedication, focus, and a very open approach. The study was able to capture and suitably record several very critical issues and existing safeguards based on the experience of similar modification jobs. It is suggested that when any other major redesign or change in construction plan is to be done, the HAZID be validated as per the company’s requirements.
The responsible action party shall formulate action plans, steward all action items, and ensure that the relevant recommendations are suitably implemented.Two (02) recommendations were recorded during the HAZID study. It is important that the existing safeguards identified be strictly adhered to and addressed in a systematic manner during each phase of project execution, including detailed design, construction, commissioning, and operation.
