P

Port Gentil
F
Fertilisser Plant

E
ESIA Add
dendum -

H
HAZOP REVIEW
R

O
October 201
12

U
UNITED
K
KINGDOM &
IR
RELAND

Preparedfor:
G
Gabon Fertiliser Company

Pa
age1of15

Table of Content

1.0

Introduction

1.1

Background

1.2

Purpose of report

2.0

Objective of HAZOP review

3.0

HAZOP Procedure

3.1

Preparation

3.2

Assumptions

3.3

Methodology

3.3.1 Nodes

3.3.2 Parameters and Deviations

4.0

HAZOP Review

4.1

Ammonia Production Unit

4.2

Ammonia Storage Unit

4.3

Compression unit

10

4.4

Urea synthesis unit

11

4.5

Urea granulation unit

12

4.6

Cooling water system

13

4.7

Steam generation and boiler feed water unit

14

5.0

Summary

15

Page2of15

1.0

INTRODUCTION

1.1

Background
The Gabon Fertilizer Company (GFC), a Joint Venture between Olam International
Limited, Singapore and the Republic of Gabon (RoG) is planning to construct a
grass root ammonia-urea fertilizer complex at Cap Lopez, near Port-Gentil in the
Republic of Gabon. Olam International Ltd, Singapore (http://www.olamonline.com)
is a leading global integrated food ingredients and industrial raw material supplier
with operations in 65 countries and employing over 18000 people worldwide.
A land area of 120 ha has been allocated for the project site within the industrial
park developed at Cap Lopez.

The proposed fertilizer complex will comprise of:

Single stream ammonia plant licensed by HALDOR TOPSOE A/S,

Single stream urea synthesis plant licensed by SAIPEM S.p.a,

Single stream urea granulation plant by UHDE FERTILIZERS

TECHNOLOGY B.V.

Urea storage warehouse (Concrete / Pre-Engineered Building)

Ammonia storage (Double Wall Double Integrity Atmospheric Storage Tank)

Cooling water system

Water supply / treatment & storage

Power generation (Gas turbine) / Emergency Diesel Generator set

Steam generation (Waste heat of Gas Turbine and Auxiliary Boiler integrated
to process plant waste heat steam generation)

Effluent Management and Disposal (including sanitary effluents)

The Off-sites and other utilities units

Flare stacks

The support facilities (Administration buildings, workshops, ware house for

products)

1.2

Purpose of report
This report presents the HAZOP review carried out for the various units viz.

Ammonia production unit

Ammonia storage unit

Compression unit

Urea synthesis unit

Page3of15

Urea granulation unit

Cooling water system

Steam generation and boiler feed water unit of the proposed fertilizer
project.

The above review involved specialists from

Company (Gabon Fertilizer Company),

Contractors (Technip) and

The Licensors {Haldor Topsoe A/S (HTAS), Denmark and Saipem SpA,
Italy}.

Specialists engaged by GFC.

A Hazard and Operability Review (HAZOP) for the Gabon Fertilizer Project was
held in the Technip (Paris) offices, La Dfense, France. The review was conducted
by a third-party Chairman from HazOptima and Bureau Veritas.

2.0

Objective of HAZOP review

The objective of the HAZOP was to identify process hazards in a systematic
approach so that they can be assessed, eliminated at source if possible, controlled
and/or mitigated otherwise. Thus HAZOP provides a qualitative review of the
process hazards and operability issues and enables actions for reducing or
eliminating hazards and operability problems in the plant.
HAZOP review focuses on process deviations, i.e. situations where a process
parameter diverges from normal operating conditions. The review focused on
consequences for people, environment and asset.
The HAZOP review covered normal operation of systems within the scope of work,
as well as operability aspects (including start-up, shut-down and maintenance as
general guidewords) of each system.
The HAZOP review was limited to all Process units and some Utilities.
The HAZOP review covered the following Process units and Utilities:

Unit 10 Ammonia unit (all sections including compression)

Unit 20 Urea synthesis unit (all sections)

Unit 30 Urea granulation unit (all sections)

Unit 40 & 60 Utilities unit and Offsite unit but limited to:

Steam generation and boiler feed water (Unit 40 section 80)

Cooling water system (Unit 40 section 30)

Ammonia storage system (Unit 60 section 50)

The HAZOP review was of qualitative type.

Page4of15

3.0

HAZOP PROCEDURE

3.1

Preparation
Prior to the review, with the help of a process engineer, the chairman identified the
nodes and identified the operating modes.
The nodes size varied according to the complexity of the units considered. A
practical rule for changing nodes was at each major equipment / valve or wherever
a critical parameter is changing (flow, pressure, temperature, phase, etc). Each
node was subject of a dedicated analysis and a corresponding set of report
worksheets. The nodes were appropriately defined with clear design intent. They
were then recorded on the HAZOP worksheets.
The node description and full range of operating and design conditions were
described and documented on the worksheets.
The node description was presented to the HAZOP review team prior to its study so
that every team member was on the same understanding of it.

3.2

Assumptions
The HAZOP review was performed on the assumption that design, installation,
commissioning, operation, inspection, maintenance and emergency were at an
adequate level of quality, in line with Company and Project specifications.

3.3

Methodology
The HAZOP review process was divided into the following steps:
Select a node
Describe the nodes design intent and process conditions
Select the first/next parameter
Select the first/next deviation
Determine by brainstorming all the potential causes relevant to this deviation
and agree the credibility of each cause
Identify the potential consequences associated to each cause
Identify the safeguards in place or foreseen against each scenario identified
Propose actions when it appears necessary
Check that implementation of proposed action(s) will adequately solve the
issue
Apply the next deviation until they all have been considered &
Move onto the next node until the whole scope of review is covered

Page5of15

AZOP Chairman facillitated the review prrocess andd ensured that the
The HA
methodo
ology was fu
ully applied..
A schem
matic descrip
ption of thiss methodolo
ogy is prese
ented in the figure 1 below.

Figu
ure 1: HAZO
OP Review process schematic

1
3.3.1

Node
o the HAZ
n
was described
d
to
ZOP review team at tthe beginning of the
Each node
worksho
op so that every
e
team member ha
as the same
e understannding of it.
A syste
em of highlight colors on PIDs was
w
used to
t ensure tthat the lim
mits of the
nodes are fully un
nderstood by the team, and tha
at at the eend of the study the
coverag
ge (what is covered, e
excluded, duplicated
d
section)
s
waas clear. Th
he master
drawing
gs and the PIDs
P
were a
annexed to the report and
a archiveed with the study
s

3.3.2
2

Parame
eters and deviations
d
The HA
AZOP Team successsively selec
cted the co
ombination of Parame
eters and
compattible Guide Word app
plicable to the Node. The param
meters werre be the
followin
ng ones: Flow, Presssure, Temp
perature, Le
evel, Phasee, Compos
sition and
Operation. Typica
al Guide W
Words that was assoc
ciated to thhese param
meters to
charactterise the deviation are: No, Less, More, Reversee, Misdirec
cted, and
Differen
nt.
The typ
pical Parame
eter Guide--Word is rep
presented in
n the combiination table
e below.
This lisst of Param
meters and Guide Word is not limitative annd more pa
arameters,
guidewo
ords or com
mbinations may be us
sed if they are applicaable and make more
sense to the Team
m.

Pa
age6of15

TABLE: LIST OF HAZOP GUIDE WORD

SL.NO.

PARAMETER

1.

FLOW

GUIDEWORD

LESS / NO
MORE
REVERSE
MISDIRECTED

2.

PRESSURE

MORE
LESS

3.

TEMPERATURE

MORE
LESS

4.

LEVEL

HIGH
LOW

5.

PHASE

DIFFERENT

6.

COMPOSITION

DIFFERENT

7.

OPERATION

START-UP
MAINTENANCE
SHUT-DOWN

8.

SEQUENCE (*)

TOO SHORT
TOO LONG

9.

REACTION (*)

INCOMPLETE
RUN AWAY

(*) for batch process

Page7of15

4.0

HAZOP REVIEW

4.1

AMMONIA PRODUCTION UNIT:

HAZOP study carried out from 27.02.2012 to 19.03.2012
List of participants:
Sl.No.

Company

Function

Attendees

1.

HazOptima, France

Chairman

2.

Technip (TP), Paris

Process/scribe

Mr. Laurent Bancod

1. Mr. Benoit Marbach

2. Mr. Antonella Di Ginsto
3. Ms. Sabrina Cimaoma
4. Mr. V. Jayaraman
5. Ms. Annick Honore
6. Mr. Hager Ben- Lakhal

3.

Gabon Fertilizer

Process

1. Mr. Varshney Vipul

Company (GFC),
Gabon

2. Mr. P.C. Jain

Specialist

1. Mr. G.M. Koorse

2. Mr. S. Stalin
3. Mr. S. Shankaran

4.

Haldor Topsoe A/S

Process

1. Mr. Ken Larsan

(HTAS), Denmark

2. Mr. F. Hans Christian

HAZOP recommendation:
Number of P&IDs studied

60

Number of Nodes

43

Number of deviations studied

656

Recommendations Process Piping

Number of
recommendations
Action points on
Licensor
Action points on
EPC Contractor
Action points on
Licensor/EPC
Contractor

Instrumentation

Rotating Total

147

05

19

05

176

85

05

16

--

106

60

--

03

05

68

02

--

--

--

02

Page8of15

4.2

AMMONIA STORAGE UNIT:

HAZOP study carried out on 02.03.2012
List of participants:
Sl.No. Company

Function

1.

Chairman

Mr. Jean Roque Constans

Process/scribe

Mr. Mathieu Guitteny

Process

Mr. Varshney Vipul

Gabon

Specialist

Mr. G.M. Koorse

Technip (TPI), India

Process

Mr. A. Ramasubramanian

Bureau Veritas,

Attendees

France
2.

Technip (TPF),
France

3.

Gabon Fertilizer
Company (GFC),

4.

HAZOP recommendation:

Number of P&IDs studied

05

Number of Nodes

01

Number of deviations studied

44

Recommendations

Process

Piping

Instrumentation Rotating Total

Number of
recommendations

11

04

05

--

20

Action points on EPC

Contractor

11

04

05

--

20

Page9of15

4.3

COMPRESSION UNIT:
HAZOP study carried out from 22.02.2012 to 19.03.2012
List of participants:
Sl.No.

Company

Function

Attendees

1.

HazOptima

Chairman

2.

Technip (TP), Paris

Process/scribe

Mr. Laurent Bancod

1. Mr. Benoit Marbach

2. Mr. Antonella Di Giusto
3. Ms. Sabrina Cimaoma
4. Mr. V. Jayaraman
5. Mr. Harra Al Jarah
6. Ms. Annick Honore
7. Ms. Stphanie Marcy

3.

Gabon Fertilizer

Process/

1. Abdul Khader Kukkady

Company (GFC),

Instrument

2. Mr. Varshney Vipul

Gabon

3. Mridul Bhargava
4. Mr. P.C. Jain
Specialist

1. Mr. S. Stalin
2. Mr. S. Shankaran
3. Mr. G.M. Koorse

4.

Haldor Topsoe A/S

Process

1. Mr. Ken Larsan

(HTAS), Denmark

2. Mr. F. Hans Christian

HAZOP Recommendation:
Number of P&IDs studied

18

Number of Nodes

13

Number of deviations
studied

256

Recommendations Process Piping

Instrumentation

Rotating Total

Number of
recommendations

63

02

02

04

71

Action points on

61

02

02

04

69
Page10of15

EPC Contractor

4.4

Action points on
GFC

01

--

--

--

01

Action points on
GFC/EPC
Contractor

01

--

--

--

01

UREA SYNTHESIS UNIT:

HAZOP study carried out from 01.03.2012 to 12.03.2012
List of participants:
Sl.No.

Company

Function

1.

HazOptima, France

Chairman

2.

Technip (TPF),

Process

Attendees
Mr. Jean-Roch Constans
1. Ms. Sonia Linares

France
3.

2. Ms. Ccile Genin

Technip (TP), Paris

Process/scribe

1. Mr. Patrice Hugues

2. Mr. Mathieu Guitteny

4.

Gabon Fertilizer

Process

1. Mr. R.V. Subramanian

Company (GFC),

2. Mr. Girish Prakash

Gabon
5.

Saipem SpA, Italy

Licensor

Mr. Pasquale Gueli

HAZOP Recommendation:
Number of P&IDs studied

35

Number of Nodes

34

Number of deviations studied

816

Recommendations Process Piping

Instrumentation

Rotating Total

Number of
recommendations

106

17

31

08

162

Action points on
EPC Contractor

31

07

14

06

58

Action points on
GFC

--

--

--

01

01

Action points on
Licensor

77

07

19

--

103

Page11of15

4.5

UREA GRANULATION UNIT:

HAZOP study carried out from 01.03.2012 to 12.03.2012
List of participants:
Sl.No.

Company

Function

Attendees

1.

HazOptima, France

Chairman

2.

Technip (TP), Paris

Process/scribe

Mr. Jean-Roch Constans

1. Mr. Patrice Hugues
2. Mr. Mathieu Guitteny

3.

Gabon Fertilizer

Proces

1. Mr. R.V. Subramanian

Company (GFC),

2. Mr. Girish Prakash

Gabon
Specialist
4.

Technip (TPF),

Mr. Wim Hamlink (Yara)

Process

1. Ms. Sonia Linares

France
5.

2. Ms. Ccile GENIN

Saipem SpA, Italy

Licensor

1. Mr. Alberto Serrafero

2. Mr. Pasquale Gueli

HAZOP Recommendation:
Number of P&IDs studied

20

Number of Nodes

11

Number of deviations studied

248

Recommendations Process Piping

Instrumentation

Rotating Total

Number of
recommendations

55

02

07

01

65

Action points on
EPC Contractor

37

01

04

01

43

Action points on
GFC

01

--

02

--

03

Action points on
Licensor

16

01

01

--

18

Action points on
GFC/EPC
Contractor

01

--

--

--

01

Page12of15

4.6

COOLING WATER SYSTEM:

HAZOP study carried on 27.02.2012
List of participants:
Sl.No.

Company

Function

Attendees

1.

HazOptima, France

Chairman

2.

Technip (TPF),
France

Process/scribe

3.

Gabon Fertilizer
Company (GFC),
Gabon

Process

Mr.Girish Prakash

Specialist

Mr. G.M. Koorse

Mr. Jean-Roch Constans

1.
2.
3.
4.
5.

Mr. Harra Al Jarah

Mr. Gautier Wohler
Mr. Arantia De La Fuente
Mr. Celine Volpi
Mr. Mathieu Guitteny

HAZOP Recommendation:
Number of P&IDs studied

09

Number of Nodes

02

Number of deviations studied

56

Recommendations Process Electrical Instrumentation

Total

Number of
recommendations

17

01

10

28

Action points on
EPC Contractor

17

01

10

28

Page13of15

4.7

STEAM GENERATION AND BOILER FEED WATER UNIT:

HAZOP study carried out from 27.02.2012 to 29.02.2012
List of participants:
Sl.No.

Company

Function

1.

Bureau Veritas,
France

Chairman

Mr. Jean Roque Constans

2.

Technip (TPF),
France

Process/scribe/
start-up

3.

Gabon Fertilizer
Company (GFC),
Gabon

Process

1. Mr. Bernard Caussanel

2. Mr. Julie Gouriou
3. Mr. Mathieu Guitteny
Mr. Girish Prakash

Specialist

Mr. G.M. Koorse

Process

Mr. Antonella Di Giusto

4.

Technip (TPIT),
Italy

Attendees

HAZOP Recommendation:
Number of P&IDs studied

11

Number of Nodes

10

Number of deviations studied

148

Recommendations Process Piping

Instrumentation

Total

Number of
recommendations

15

13

14

42

Action points on
EPC Contractor

15

13

14

42

The contents of HAZOP study & the recommendations are proprietary information
of Process Licensors.

Page14of15

5.0

SUMMARY:
The HAZOP review study covering the following units

Ammonia production unit

Ammonia storage unit

Compression unit

Urea synthesis unit

Urea granulation unit

Cooling water system &

Steam generation & boiler feed water unit.

And involving specialists from

Company (Gabon Fertilizer Company),
Contractors (Technip)
Licensors {Haldor Topsoe A/S (HTAS), Denmark and Saipem SpA, Italy}
Process specialist from Yara International, Norway

Above review was conducted at the Technip (Paris) offices, La Dfense, France by
a third-party Chairman from HazOptima and Bureau Veritas, resulted in the
following.
Total deviations studied

: 2,224

Total recommendations to be implemented during EPC phase : 564

The above recommendations will be implemented during EPC phase.

------------------******-------------------

Page15of15