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: 781502
DOC NO
: GGCP-00-P0-ES-010-PP
PURPOSE
CONTRACTOR
PT Rekayasa Engineering
REV.
NO.
DATE
DESCRIPTION
PREPARED
08/11/2016
ANG
SAW
GWN/FIA
FP
20/10/2016
ANG
SAW
GWN/FIA
FP
01/10/2016
ANG
SAW
GWN/FIA
FP
30/08/2016
ANG
SAW
GWN/FIA
FP
CHECKED
APPROVED
JOB NO
PROCEDURE AND
PREPARATION FOR HAZOP
STUDY
: 781502
DOCUMENT NO : GGCP-00-P0-ES-010-PP
DATE
: 08/11/2016
REV
:3
REV. NO.
DATE
DESCRIPTION
30/08/2016
01/10/2016
20/10/2016
08/11/2016
DISTRIBUTION ORDER
EXTERNAL ISSUE
PROJECT MANAGER
TRACTEBEL / CONNUSA
ENGINEERING MANAGER
CHIEF ADMINISTRATION
CHIEF SHE
CONSTRUCTION MANAGER
PROCUREMENT MANAGER
PROJECT CONTROL MANAGER
SHE MANAGER
QC MANAGER
CHIEF ENGINEERING
CHIEF PROJECT CONTROL
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JOB NO
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DOCUMENT NO : GGCP-00-P0-ES-010-PP
DATE
: 08/11/2016
REV
:3
TABLE OF CONTENT
1.
INTRODUCTION ......................................................................................................................................... 4
1.1. Scope ................................................................................................................................................... 4
1.2. Definition .............................................................................................................................................. 4
1.3. Project Reference Document ............................................................................................................... 4
1.4. Abbreviations........................................................................................................................................ 4
2.
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JOB NO
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: 781502
DOCUMENT NO : GGCP-00-P0-ES-010-PP
DATE
: 08/11/2016
REV
:3
1. INTRODUCTION
1.1. Scope
This document stipulates the procedure of the Hazard & Operability (HAZOP) Study in terms of
objective, scope, resources requirements and methodology for the Gresik Gas Cogeneration Plant
(GGCP) Project.
1.2. Definition
The following words shall have the meaning indicated when used herein:
Owner
: PT. PUPUK INDONESIA ENERGI
Consultant PMC
: TRACTEBEL ENGINEERING S.A.& PT. CONNUSA ENERGINDO
Contractor
: PT. PP (Persero) Tbk DIVISI EPC
Engineering Consultant
: PT. REKAYASA ENGINEERING
Vendor/Subcontractor
: The party that manufactures or supplies equipment and services to
perform the duties specified by the Owner or Contractor
1.3. Project Reference Document
Basic Engineering Design Data, GGCP-00-P0-ES-001-PP Rev 4.
Process Design Basis, GGCP-00-P0-ES-002-PP Rev 4.
EPC Bid Document Gresik Gas Cogeneration Plant (GGCP) Project Addendum 1.
EPC Bid Document Gresik Gas Cogeneration Plant (GGCP) Project Addendum 2.
EPC Bid Document Gresik Gas Cogeneration Plant (GGCP) Project Addendum 3.
IFB Document for Engineering, Procurement, Construction and commissioning of Gresik Gas
Cogeneration Plant (GGCP) Project.
Heat and Mass Balance from Macchi, GGCP-03-P0-BE-001-PP Rev 1 (1168-C-021).
1.4. Abbreviations
The following abbreviations are used within this document:
API
American Petroleum Institute
BFW
Boiler Feed Water
EPC
Engineering, Procurement, and Construction
ESD
Emergency Shutdown.
GGCP
Gresik Gas Cogeneration Plant
GPSA
Gas Processors Suppliers Association
HRSG
Heat Recovery Steam Generator
HAZOP
Hazard Operability
HVAC
Heating, Ventilations & Air Conditioning.
HMB
Heat & Mass Balance.
IFB
Instruction for Bidder
LP
Low Pressure
MP
Medium Pressure
MCC
Motor Control Centre.
PKG
Petrokimia Gresik
PSD
Plant Shut Down
SOP
Standard Operating Procedure
UBB
Utilitas Batu Bara
USD
Unit Shut Down
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DOCUMENT NO : GGCP-00-P0-ES-010-PP
DATE
: 08/11/2016
REV
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No.
Title / Sections
P&ID HRSG
11
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DATE
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No.
Title / Sections
12
13
In order to proceed with HAZOP work effectively, subjected units (sections) as listed in Table 3 above
will be divided into study NODEs. The study nodes defined mainly represent specific process lines,
equipment or units operated under same operating condition or specific process intentions.
3
Title / Sections
NODE
1, 2, 3, 4, 5, 6, 7
8,9,10,11,12,13,14,15,16
P&ID HRSG
17,18,19,20,21,22,23,24
25
26
27
30
33
11
28
12
29
13
31
JOB NO
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DOCUMENT NO : GGCP-00-P0-ES-010-PP
DATE
: 08/11/2016
REV
:3
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JOB NO
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DOCUMENT NO : GGCP-00-P0-ES-010-PP
DATE
: 08/11/2016
REV
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Make every effort to identify, analyze and evaluate possible hazard and operational problems,
not as the designer of its discipline area but as a member of HAZOP team.
2.5. Methodology
2.5.1. Overview
HAZOP Study to be conducted primarily using the HAZOP deviation guideword technique. The
guidewords, in conjunction with the key process/ control parameters, prompt the HAZOP team to
brainstorm possible causes and potential consequences of deviation from design intention. For
example, the deviation more pressure would prompt the leader to ask the team what could cause
more pressure in this section or line segment? the possible cause and potential consequences
scenarios are documented in the report worksheets. The Existing system and procedure
(safeguards) that reduce the risk associated with the specific cause/consequences scenario are then
discussed and documented. For scenarios involving significant risk, Recommendations that the
team believes further reduce risk or improve the operability/controllability of the facility are also
documented.
2.5.2. HAZOP Study Procedure
The guide word HAZOP method shall be applied for the review. The work flow of the review and the
list of applicable HAZOP guide word/process deviations are shown in Appendix I, respectively. The
specific steps of the HAZOP methodology used in this study are:
a) Choose study section or node
b) Apply a deviation (guideword+ parameter)
c) Brainstorm cause of deviation
d) Develop each cause to its global consequences
e) Identify existing safeguards
f) If warranted, make recommendation (s) to reduce risk and / or improve the operability of the
facility
This process is repeated for each deviation and section/NODE until the entire process and control
system has been analyzed according to study flow diagram at Appendix II.
2.5.3. Assumption
Following assumptions should use during conducting the HAZOP study:
a. Single failure results in hazard, as double jeopardy is believed quite remote case.
b. Equipment or machinery is designed, manufactured and properly inspected with no defect.
c. The facilities shall be well maintained and operated in accordance with sound, internationally
acceptable standards. This includes establishing and operating a high standard of housekeeping
throughout the site at all times. All loss prevention, safety and/or security equipment shall be
routinely tested/ recharged as recommended by the manufactures.
d. For duplicate trains /process unit, equipment or machinery is similar designed and
manufactured, therefore the study review shall be carried out only for one train. The study
review result, however, shall be applied for all the duplicated trains / process unit.
e. If all team members agree, simplified hazardous review method such as What IF method may
be used for utility system which is widely available in industrial applications. Team is requested
to discuss most effective hazardous review method for associated utility system prior to the
review
f. Operator are assumed to be competent and appropriately trained
g. Equipment/Instrument are deemed suitable for design condition
h. Mechanical protection devices (PV/PSV) are expected to function on demand
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2.5.5. Recommendations
Team emphasized that some of existing safeguards were considered not sufficient; therefore team
could request additional safeguard or further study. HAZOP Secretary under direction of chairman
shall document the recommendation into HAZOP worksheets
Recommendations should be carefully worded to avoid ambiguity or confusion. Particular effort
should be made to ensure recommendations are clear enough to be understood by project team
members who did not attend or may not have a clear recollection of the HAZOP workshop, or when
read out of context i.e. read separately to the hazard, initiating event, consequences and controls.
Finally, all recommendations should include a person or entity that will be responsible for
implementing the recommendation.
2.6. Report Content
The information gained from the HAZOP shall be translated into a report incorporating, but not limited
to:
Executive Summary.
Introduction, Purpose and Scope of Work.
Brief description of the facilities.
HAZOP Methodology in compliance with the procedure.
Relevant input data including latest revision of drawings, specification sheets, etc.
Summary of recommendation result indicating actions register.
HAZOP Worksheet.
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DOCUMENT NO : GGCP-00-P0-ES-010-PP
DATE
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APPENDIX I
HAZOP Guidewords & Deviations
Table I.1 Deviations for HAZOP Study
3
No
Description
More Flow
Less Flow
No Flow
Reverse Flow
Misdirected Flow
More pressure
Less pressure
Vacuum
More Temperature
10
Less Temperature
11
More Level
12
Less Level
13
Empty Level
14
Impurities
15
Composition
16
Erosion / Corrosion
17
Commissioning
18
Maintenance
19
Instrumentation/Control
20
Start-Up
21
Shutdown
22
Testing/Sampling
23
Miscellaneous
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DOCUMENT NO : GGCP-00-P0-ES-010-PP
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The above list of GUIDE WORD is neither mandatory nor comprehensive. It should be treated as a
menu from which relevant words can be selected to from a deviation in conjunction with a Process
Parameter.
Table I.2 Examples of Deviations
3
No.
Guidewords
Process Parameter
Deviations
More/ Less/No
/Reverse/Misdirected
Flow
More/Less/No/
More/Less/No
Pressure
More/Less/Vacuum Pressure
More/Less
Temperature
More/Less Temperature
More/Less/No
Level
More/Less/Empty Level
Reverse/Misdirected Flow
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DOCUMENT NO : GGCP-00-P0-ES-010-PP
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APPENDIX II
HAZOP Workflow
Page 12 of 15
APPENDIX III
HAZOP Worksheet Format
APPENDIX IV
3
Nodes
Nodes
18
19
20
21
22
23
24
Steam/Water System
25
26
10
27
11
28
12
29
13
30
14
31
15
32
16
33
17
APPENDIX V
P&IDs Mark-Up
PIPING SYMBOLS
PI
GRESIK GAS COGENERATION PLANT PROJECT
INSTRUMENT SYMBOLS
PI
EQUIPMENT SYMBOLS
PI
GRESIK GAS COGENERATION PLANT PROJECT
NODE 25
PI
GRESIK GAS COGENERATION PLANT PROJECT
NODE 33
NODE 25
PI
GRESIK GAS COGENERATION PLANT PROJECT
NODE 33
NODE 26
PI
GRESIK GAS COGENERATION PLANT PROJECT
NODE 33
NODE 26
PI
GRESIK GAS COGENERATION PLANT PROJECT
NODE 26
NODE 27
NODE 28
PI
NODE 33
NODE 26
NODE 33
NODE 27
M
PI
GRESIK GAS COGENERATION PLANT PROJECT
NODE 27
PI
GRESIK GAS COGENERATION PLANT PROJECT
NODE 27
PI
GRESIK GAS COGENERATION PLANT PROJECT
NODE 27
PI
GRESIK GAS COGENERATION PLANT PROJECT
NODE 27
PI
GRESIK GAS COGENERATION PLANT PROJECT
NODE 27
PI
GRESIK GAS COGENERATION PLANT PROJECT
NODE 27
PI
GRESIK GAS COGENERATION PLANT PROJECT
NODE 27
PI
GRESIK GAS COGENERATION PLANT PROJECT
NODE 27
PI
GRESIK GAS COGENERATION PLANT PROJECT
NODE 27
PI
GRESIK GAS COGENERATION PLANT PROJECT
PI
GRESIK GAS COGENERATION PLANT PROJECT
NODE 27
NODE 27
PI
GRESIK GAS COGENERATION PLANT PROJECT
NODE 26
NODE 30
NODE 27
PI
GRESIK GAS COGENERATION PLANT PROJECT
NODE 26
ISO 30
PI
GRESIK GAS COGENERATION PLANT PROJECT
NODE 33
PI
GRESIK GAS COGENERATION PLANT PROJECT
ISO 28
NODE 33
PI
GRESIK GAS COGENERATION PLANT PROJECT
NODE 33
PI
GRESIK GAS COGENERATION PLANT PROJECT
NODE 26
NODE 28
PI
GRESIK GAS COGENERATION PLANT PROJECT
NODE 26
NODE 33
NODE 28
PI
GRESIK GAS COGENERATION PLANT PROJECT
NODE 27
NODE 29
PI
M
NODE 26
PI
NODE 31
NODE 27
NODE 32
NODE 28
PI
GRESIK GAS COGENERATION PLANT PROJECT
NODE 28
PI
GRESIK GAS COGENERATION PLANT PROJECT
NODE 32
PI
GRESIK GAS COGENERATION PLANT PROJECT
NODE 33
NODE 27
PI
GRESIK GAS COGENERATION PLANT PROJECT
PI
GRESIK GAS COGENERATION PLANT PROJECT
NODE 25
PI
GRESIK GAS COGENERATION PLANT PROJECT
NODE 27
PI
GRESIK GAS COGENERATION PLANT PROJECT
NODE 26
PI
GRESIK GAS COGENERATION PLANT PROJECT
ISO 9
PI
GRESIK GAS COGENERATION PLANT PROJECT
NODE 28
PI
NODE 31
PETROKIMIA
GRESIK
NODE 8
NODE 10
NODE 11
DETAIL "A"
DRAIN
MOV
O
MOV
O
MOV
C
MOV
C
MVR
B
MVF
B
MVL
B
MVH
B
MVR
MVF
MVL
MVH
MOV
MCC
A1
841 mm x 594 mm
DETAIL "B"
DRAIN
NODE 8
NODE 9
NODE 11
NODE 13
A1
841 mm x 594 mm
A1
841 mm x 594 mm
DETAIL "B"
DRAIN
NODE 10
NODE 11
NODE 13
A1
841 mm x 594 mm
NODE 10
NODE 8
L
L
NODE 15
A1
841 mm x 594 mm
L
L
NODE 10
NODE 15
A1
841 mm x 594 mm
NODE 12
A1
841 mm x 594 mm
NODE 13
A1
841 mm x 594 mm
NODE 11
DETAIL "B"
DRAIN
MOV
O
MOV
O
MOV
C
MOV
C
MVR
B
MVF
B
MVL
B
MVH
B
MVR
MVF
MVL
MVH
MOV
MCC
A1
841 mm x 594 mm
NODE 15
NODE 16
NODE 15
A1
841 mm x 594 mm
NODE 12
NODE 14
A1
841 mm x 594 mm
NODE 12
NODE 14
A1
841 mm x 594 mm
NODE 14
NODE 15
A1
841 mm x 594 mm
A1
841 mm x 594 mm
L=200mm
L=150 mm
L=150 mm
L=150 mm
L=150 mm
A1
841 mm x 594 mm
NODE 20
NODE 19
NODE 18
NODE 17
BFW System
NODE 23
NODE 22
NODE 21
NODE 20
NODE 19
NODE 18
NODE 17
NODE 18
NODE 17
NODE 20
NODE 19
//
A1
841 mm x 594 mm
//
NODE 23
//
//
//
TYPICAL
A1
841 mm x 594 mm
NODE 23
A1
841 mm x 594 mm
NODE 19
A1
841 mm x 594 mm
NODE 21
NODE 24
NODE 17
L
L
A1
841 mm x 594 mm
NODE 24
NODE 22
NODE 23
NODE 22
A1
841 mm x 594 mm
NODE 20
NODE 18
NODE 21
NODE 32
NODE 24
NODE 23
NODE 2
NODE 3
NODE 4
NODE 5
NODE 6
NODE 7
NODE 1
NODE 1
NODE 1
NODE 1
NODE 2
NODE 1
NODE 1
NODE 3
NODE 2
NODE 4
NODE 1
NODE 5
NODE 5
NODE 6
NODE 7
NODE 7
NODE 1
NODE 1