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NAWARA PROJECT
(PIPELINE)
HAZOP / SIL STUDY REPORT FOR 6" BUY BACK GAS PIPELINE
This document is the property of ETAP & OMV. It shall not be copied, reproduced and circulated without the Authorization of ETAP & OMV.
INDEX
Abbreviations .................................................................................................................................. 3
1 EXECUTIVE SUMMARY ......................................................................................................... 4
2 INTRODUCTION ..................................................................................................................... 5
2.1 General............................................................................................................................. 5
2.2 Definitions ......................................................................................................................... 5
2.3 References ....................................................................................................................... 6
2.3.1 Company Standards .................................................................................................. 6
2.3.2 Project Documents .................................................................................................... 6
2.3.3 International Codes and Standards............................................................................ 7
3 SCOPE AND PURPOSE ......................................................................................................... 8
3.1 Scope ............................................................................................................................... 8
3.2 Purpose ............................................................................................................................ 8
4 HAZOP / SIL METHODOLOGY ............................................................................................... 9
4.1 General............................................................................................................................. 9
4.2 Study Basis....................................................................................................................... 9
4.2.1 Review Process ......................................................................................................... 9
4.2.2 Nodes ........................................................................................................................ 9
4.2.3 Parameters and Guidewords ..................................................................................... 9
4.2.4 Safety Integrated Functions ..................................................................................... 10
5 MEETING DETAILS .............................................................................................................. 11
5.1 Location and Timing ....................................................................................................... 11
5.2 Team Members .............................................................................................................. 11
6 HAZOP / SIL FINDINGS ........................................................................................................ 12
7 MANAGEMENT OF RECOMMENDATIONS ......................................................................... 12
8 APPENDIX A – RECOMMENDATIONS SUMMARY.............................................................. 13
9 APPENDIX B – HAZOP WORKSHEETS ............................................................................... 17
10 APPENDIX C – SIL WORKSHEETS...................................................................................... 25
11 APPENDIX D – MARKED-UP HAZOP / SIL MASTER P&IDs ................................................ 27
12 APPENDIX E – HAZOP / SIL SESSIONS ATTENDANCE SHEETS ...................................... 31
This document is the property of ETAP & OMV. It shall not be copied, reproduced and circulated without the Authorization of ETAP & OMV.
ABBREVIATIONS
API American Petroleum Institute
HV Hand Valve
NG Natural Gas
This document is the property of ETAP & OMV. It shall not be copied, reproduced and circulated without the Authorization of ETAP & OMV.
1 EXECUTIVE SUMMARY
This document presents the findings of the HAZOP Study performed for the “Nawara
Project (Pipeline)”.
The HAZOP study has been updated considering the last modification of the Nawara
Project, which implies the installation of a pipeline to secure commissioning gas for its
facilities; The pipeline will transport high pressure gas from STEG terminal station in Gabès
to GTP via 6” pipeline (around 1 km length). This 6” pipeline is designed to run high
pressure commercial gas from 20” existing STEG pipeline to the GTP Pig Receiver area.
During the HAZOP session, a total of 10 Recommendations for Action were identified. The
record of the HAZOP session discussion is reported in Appendix B whereas the summary
of the Recommendations for Action is shown in Appendix A.
This document is the property of ETAP & OMV. It shall not be copied, reproduced and circulated without the Authorization of ETAP & OMV.
2 INTRODUCTION
2.1 General
The objective of the Nawara Development Project is to recover the associated and non-
associated gas reserves from the Nawara Concession, separate and pretreat the fluids
from 9 wells, gather them in Central Processing Facility (CPF), convert them into a
commercial condensate and pre-treated gas, export the condensate via a new pipeline into
the existing TRAPSA pipeline, and export the gas via a new pipeline to Gabès. At Gabès,
the gas will be treated in a dedicated Liquefied Petroleum Gas (LPG) extraction facility to
commercial specification required for end user consumption. In Gabès, the gas will be
conditioned in a Gas Treatment Plant (GTP) into commercial products, and sold to the end
users: STEG and SNDP.
The “NAWARA Project - Pipelines” main characteristics and facilities are as follows:
- A 24” pipeline which will deliver the raw gas from Nawara CPF to a Gas Treatment
Plant (GTP) located at Gabès (L=374km);
- A 6” pipeline which convey to TRAPSA the separate condensate extracted at CPF
(L=12km);
- The export lines for Sales Products for delivery to customers at Gabès selected
custody transfer points. The 20” sales gas is delivered at STEG (L=1 km) while 6”
Propane and 4” Butane are delivered at SNDP (L=1,6 km). The condensate that
may form at GTP is exported by road Tanker.
- The pipeline for secure commissioning of gas to its facilities. The pipeline transports
high pressure gas from STEG terminal station in Gabès to GTP via 6” pipeline (L =
1 km). This 6” pipeline is designed to run high pressure commercial gas from 20”
existing STEG pipeline to the GTP Pig Receiver area
2.2 Definitions
Company: OMV (Tunisien) Production GmbH.
Contractor: Party which carries out all or part of the Procurement, Construction,
Installation and Commissioning for the Project, i.e. BI&MS.
Subcontractor: Party which carries out the Detail Design Engineering for the Project,
i.e. Enereco.
The work: All activities for the construction of the defined elements as detailed in
the scope of work.
2.3 References
A detailed list of all legislations, Company’s Procedures, Company’s Standards and
Philosophies and International Standards that is to be used for HSSE Management and
Design are listed in the Project document “Pipelines Project Codes & Standards” (Ref. [6]).
Company standards, Project Documents and International Codes and Standard that can be
specifically referenced to for HAZOP execution are listed below:
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This document is the property of ETAP & OMV. It shall not be copied, reproduced and circulated without the Authorization of ETAP & OMV.
3.1 Scope
The scope of the HAZOP / SIL study included the last modification of the Nawara
Development Project – Pipelines Facilities, which implies the installation of a pipeline to
secure commissioning gas for its facilities; The pipeline will transport high pressure gas
from STEG terminal station in Gabès to GTP via 6” pipeline (around 1 km length). This 6”
pipeline is designed to run high pressure commercial gas from 20” existing STEG pipeline
to the GTP Pig Receiver area.
3.2 Purpose
The purpose of the HAZOP / SIL Study was to review the new items associated to the
installation of the pipeline to secure commissioning gas for Nawara GTP facilities (i.e.
pipeline transport high pressure gas from STEG terminal station in Gabès to GTP via 1 km
and 6” pipeline) in order to systematically identify all hazards and potential operability /
maintenance problems associated to the system considering the current status of the
design development.
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4.1 General
The HAZOP / SIL Study was carried out in agreement with the guidelines provided in the
applicable International Standards (Ref. [12], [13], [14], [15] and [16]) and in compliance
with the requirements of the Company Standards (Ref.[1], [2] and [3]) as incorporated in the
Project Documents (Ref. [4] and [5]).
4.2.2 Nodes
A total of 1 Node was chosen for the study. Node identification was driven by considering
the composition of the main process stream involved and its operating conditions, in order
to allow a manageable field of analysis.
In general, utility stream lines were not considered as individual nodes, since their credible
failure modes were included in the study directly as causes of deviation in the process
parameters.
The node used is shown in Table 4.2-1.
0F01-321-PR-PID-00003-005
1. 6” Buy Back pipeline for secure 0F03-320-PR-PID-00003-006
commissioning gas to Nawara GTP facilities
0F03-320-PR-PID-00004-C02
The extent of each HAZOP node is shown highlighted on the relevant P&ID, in Appendix
D.
GW
More Less No Reverse Change As well as
Parameter
Flow High Flow Low Flow No Flow Backflow -- --
High Temp. Low Temp.
Temperature -- -- -- --
Overtemp. Freezing
High Pressure
Pressure Low Pressure Vacuum -- -- --
Overpressure
High Level
Level Low Level No Level -- -- --
Overfilling
High Low Change of Wrong Conc.
Composition -- Contaminants
Concentration Concentration State Off-spec
As foreseen in the TOR, additional parameters and guidewords were considered where
appropriate.
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5 MEETING DETAILS
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7 MANAGEMENT OF RECOMMENDATIONS
Enereco will update the Project document “HSSE Action Close Out Report” (Ref. [6]) to
ensure that all actions are comprehensively identified and resolved. The HSSE Action
Close Out Report shall be maintained and updated for all identified issues raised from the
Safety Studies.
Enereco will incorporate agreed actions into the design that are practicable for the Detailed
Design Engineering stage of the Project.
At the end of the Detailed Design, Enereco will transfer all actions that have not been fully
resolved to the ITT package for final resolution in the next phase of the Project.
This document is the property of ETAP & OMV. It shall not be copied, reproduced and circulated without the Authorization of ETAP & OMV.
This document is the property of ETAP & OMV. It shall not be copied, reproduced and circulated without the Authorization of ETAP & OMV.
2 Misdirected flow 15. Generic random 15.1. Release of NG 15.1.1. Proper desing 2. Consider to verify F&G system in STEG COMPANY
rupture with potential covers properly tie-in area and new
fire/explosion event 15.1.2. Periodic installation
inspection and
maintenance
7 Higher pressure 3. High pressure 3.1. Pressure in 6" 3.1.1. According to 3. Include in operating manual to disconnect CONTRACTOR
from Raw Gas buyback pipeline Note 21 in P&ID 0003 6" buyback pipeline after use to avoid any
pipeline during GTP exceeding design 6" buyback pipeline potential high pressure form Raw gas
normal operation pressure leading to will be disconnected pipeline during GTP normal operation
(6" buyback release of NG with before normal
pipeline out of fire/explosion event operation in GTP
service) starts
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2. Human error closing 2.1. Stop of GTP hot 2.1.1. PAL-0525 alarm in 1. Ensure that alignment of CONTRACTOR
manual valve at STEG commissioning activities control room Manual valves on the 6"
tie-in (HV-0595) with no impact on asset or buyback pipeline from
safety 2.1.2. PAL-0340 alarm in STEG is included in the
control room Operating procedures
4. Human error closing 4.1. Stop of GTP hot 4.1.1. PAL-0340 alarm in
manual valves across commissioning activities control room
Allocation Metering with no impact on asset or
NG-PK-320-0005 safety
Less Less Flow 10. Partial blockage of the 10.1. Reduced flow may 10.1.1. Self-regulating
strainer lead to sto of GTP hot pressure control valve
commissioning activities PCV-0390 can compensate
minor variation in
pressure/flow
Other Misdirected flow 12. Human error leaving 12.1. Release of NG in 12.1.1. Double block and
Than open branch to mobile flare GTP receiving area with bleed on mobile flare
connection potential fire/explosion connection
(2"-EG-321-0003-C41Y-V) event
12.1.2. Blind flange on
mobile flare connection
15. Generic random 15.1. Release of NG with 15.1.1. Proper desing 2. Consider to verify F&G COMPANY
rupture potential fire/explosion system in STEG covers
event 15.1.2. Periodic inspection properly tie-in area and
and maintenance new installation
Less Lower Temperature 2. Malfunction of Electrical 2.1. Offspec NG to GTP 2.1.1. TAL-0392 alarm in 1. Define requirement for COMPANY
Heater NPO-HE-321-0001 (low temperature); in case control room automatic action to close
control system of Blowdown of GTP, risk ESDV-0392 for Low Low
of exceeding minimum Temperature on TT-0392
design temperature of the
GTP inlet facilities 2. If required by company CONTRACTOR
(ref. to Action #1
Temperature parameter),
implement automatic action
to close ESDV-0392 for
Low Low Temperature on
TT-0392
Higher pressure 2. High pressure from 2.1. Potential to exceed 2.1.1. Rating of 6" buyback
STEG design pressure thus pipeline is equal to STEG
leading to release of NG pipeline rating
with fire/explosion event
2.1.2. PAHH-05625 closes
ESDV-0505
3. High pressure from Raw 3.1. Pressure in 6" buyback 3.1.1. According to Note 21 3. Include in operating CONTRACTOR
Gas pipeline during GTP pipeline exceeding design in P&ID 0003 6" buyback manual to disconnect 6"
normal operation (6" pressure leading to release pipeline will be buyback pipeline after use
buyback pipeline out of of NG with fire/explosion disconnected before to avoid any potential high
service) event normal operation in GTP pressure form Raw gas
starts pipeline during GTP normal
operation
This document is the property of ETAP & OMV. It shall not be copied, reproduced and circulated without the Authorization of ETAP & OMV.
This document is the property of ETAP & OMV. It shall not be copied, reproduced and circulated without the Authorization of ETAP & OMV.
This document is the property of ETAP & OMV. It shall not be copied, reproduced and circulated without the Authorization of ETAP & OMV.