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HAZID STUDY REPORT

EPC Contractor:
Engg Consultant:

Rev Date Issued For By Chk’d App’d

Engg Consultant Contractor Client

Job No Sec No Contract No Document No

HAZID Worksheets ABC XYZ FIELD DEVELOPMENT PROJECT
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ABBREVIATIONS & DEFINTIONS

ABBREVIATIONS
• AIV Acoustic Induced Vibration
• ALARP As Low As Reasonably Practicable
• CO2 Carbon di Oxide
• CPP Central Process Platform
• EIA Environmental Impact Assessment
• FEED Front End Engineering Design
• FIV Flow Induced Vibration
• FP Flare Platform
• FPSO Floating Production Storage and Offtake
• FSO Floating Storage and Offtake
• GRE Glass Reinforced Epoxy
• H2S Hydrogen Sulphide
• HAZID Hazard Identification Study
• HP High Pressure
• LNG Liquefied Natural Gas
• LP Low Pressure
• LQ Living Quarters
• MOC Material of Construction
• NOx Nitrogen Oxides
• P&ID Process and Instrumentation Diagram
• PFD Process Flow Diagram
• QRA Quantitative Risk Analysis
• SCUBA Self-Contained Underwater Breathing Apparatus
• SIMOPS SIMultaneous OPerationS
• SOx Sulphur Oxides
• VOC Volatile Organic Chemicals (Benzene, toluene etc considered carcinogens)
• WHP Wellhead Platform

DEFINTIONS
• CLIENT
• CONSULTANT
• CONTRACTOR

Note: This report is based on the documents referred to in Appendix A. Modifications or revisions
to these documents may invalidate the observations and conclusions recorded in this report.

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Table of Contents

1.0 INTRODUCTION ...........................................................................................................................4

1.1 PURPOSE..................................................................................................................................4
1.2 REFERENCES ..........................................................................................................................4
2.0 OBJECTIVES ................................................................................................................................5
3.0 SCOPE OF WORK........................................................................................................................6
3.1 Process Systems Studied..........................................................................................................6
3.2 Locations Studied ......................................................................................................................6
3.3 Schedule ....................................................................................................................................6
3.4 Deliverables ...............................................................................................................................6
3.5 HAZID Team Members..............................................................................................................7
3.6 HAZID Software .........................................................................................................................7
3.7 HAZID Session ..........................................................................................................................7
4.0 HAZID STUDY BASIS ...................................................................................................................8
4.1 Process Facilities .......................................................................................................................8
4.1.1 Flowlines, well fluid manifold system and receivers ...........................................................8
4.1.2 Oil systems:.........................................................................................................................8
4.1.3 Gas systems:.......................................................................................................................8
4.1.4 Utility and Auxiliary Systems...............................................................................................8
4.2 Facilities Layout .........................................................................................................................9
4.3 Facility Information...................................................................................................................10
4.4 Safety Studies ..........................................................................................................................12
5.0 HAZID STUDY.............................................................................................................................13
5.1 Methodology.............................................................................................................................13
5.2 Findings....................................................................................................................................13
5.3 Key Findings ............................................................................................................................13
APPENDIX A – HAZID Study Reference Documents ...............................................................14
APPENDIX B – HAZID Study Worksheets ................................................................................14
APPENDIX C – HAZID study Summary of Recommendations.................................................14
APPENDIX D – HAZID Explained..............................................................................................15

HOLD LIST– This identifies holds in following sections

Section Hold Description

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1.0 INTRODUCTION
1.1 PURPOSE
This document presents the findings of a Hazards Identification (HAZID) Study conducted for
the ------- on ---------- at ------------.

One paragraph on the project -----------------------------

Hazard Identification (HAZID) is a systematic risk assessment study carried out by a team of
engineers from different disciplines. The team looks at each part of a plant or facility, considers
potential hazards, analyses their consequences against any existing safeguards. Criteria
include safety, asset, environment, reputation, society, etc.

HAZID study records the identified hazards without proposing any solution. The record serves
as a guide to determine the Health, Safety and Environment (HSE) issues to be resolved during
the project.

HAZID is a guideword driven brainstorming technique, which requires a properly constructed

team.

1.2 REFERENCES
The HAZID study was conducted in accordance with the following documents
• ISO-17776 : Petroleum and natural gas industries – Offshore production installations –
Guidelines on tools and techniques for hazard identification and risk assessment, 1st
Edition, 2000-10–15

Project documents referred to during the study is listed in Appendix A.

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2.0 OBJECTIVES
The objectives of the HAZID study are:
• Identify potential hazards and risks associated with a project and process facilities of this
nature to identify early safety and operational issues
• Understand these hazards or risks and determine their potential consequences
• Determine (design and procedural) safeguards or risk reduction measures incorporated
and evaluate their adequacy and
• Recommend additional safeguards or operational procedures as necessary.

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3.0 SCOPE OF WORK

The HAZID study covered the design, construction and operational phases of the facility,
identifying threats that are of global in nature, that is, applicable to all the process systems and
plant area; then it identified threats that are specific to a system or location

Drilling phase is not adequately addressed in this study as drilling operations subject matter
experts did not participate in the study.

3.1 Process Systems Studied

Following process systems were taken note of:
• Flowlines, well fluid manifold system and receivers
• Oil systems: Separation, Oil Metering and Export, Condensate Export
• Gas systems: LP Gas Compression, Glycol Dehydration & Regeneration, HP Gas
Compression, Gas Metering and Export
• Flare and Vent Systems
• Fuel Gas System
• Open and Closed Drain System
• Produced Water System
• Diesel Oil System
• Waste Heat Recovery and Hot Oil Systems
• Water Injection System
• Fire water system and
• Chemical Injection Package

3.2 Locations Studied

Equipment, as laid out on the following decks is indicated below:
• Lower Deck at _-- m:
• Main Deck at +-- m:
• Upper Deck at +-- m:
• Mezzanine Deck at +-- m:

3.3 Schedule
The HAZID study was conducted in ----- -------- office from --- to ----- --------------- ---. A
presentation of the recommendations was made on ---- ----- ---.

3.4 Deliverables
As agreed with the client, the main deliverables of this study are:
1. HAZID methodology and typical worksheet for review, prior to commencement of the
study, that is, draft form of this report. This has been done.
2. Interim report on the findings and recommendation of the study. This has been done.
3. Draft report. This report.
4. Final report will be delivered after getting comments on this report

This draft report is submitted for review, electronically within 2 weeks of completing the study.
The final report will be submitted in 3 hard copies along with electronic copy of native file

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incorporating review comments from all relevant parties. If necessary a meeting will be arranged
between Company/ Contractor/ Consultant to resolve conflicting comments.

3.5 HAZID Team Members

HAZID study was held on -------------------. Following persons participated, on part or full time
basis as noted.
Dates
No Name Organization & Role 1 2 Remarks
1
2
3
4
5
6
7
8

3.6 HAZID Software

MS-Word based worksheets were used to capture HAZID team discussions and findings.

3.7 HAZID Session

The HAZID study was started with an overview of process facilities and platform deck layout.
This helped the team members to become familiar with the facility. Safety or incident alerts
related to similar facilities were shared. A brief introduction was given on systems with high
pressure, high temperature, low temperature and hazardous chemicals.

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4.0 HAZID STUDY BASIS

4.1 Process Facilities

Process Flow Scheme

4.1.1 Flowlines, well fluid manifold system and receivers

4.1.2 Oil systems:

Separation

Oil Metering and Export

Condensate Export

4.1.3 Gas systems:

LP Gas Compression

Glycol Dehydration & Regeneration

HP Gas Compression

Gas Metering and Export

4.1.4 Utility and Auxiliary Systems

Flare and Vent Systems

Fuel Gas System

Open and Closed Drain System

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Produced Water System

Diesel Oil System

Waste Heat Recovery and Hot Oil Systems

Water Injection System

Fire water system and

Chemical Injection Package

4.2 Facilities Layout

The Central Process Platform CPP is kept separate from Living Quarters and Flare platforms by
bridges. It is bridge linked to an adjacent wellhead platform. Fluids from other remote wellhead
platforms are brought in by subsea 3 phase pipelines. Platform boat approach is from West
while risers are grouped on the southern and northern side.

Layout Sketch

Inlet Slug Catchers are located on Lower Deck, while Dehydrator is on the Main Deck.
Compressors and Generators are on the Upper Deck. Relative location of major equipment are
shown below, in an exploded view

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4.3 Facility Information

Following information on the facility was presented to the HAZID team members to familiarize
them with the facility and its system.

Type of Facility : Onshore Offshore

: LNG Oil & Gas Gas & Condensate
: Refinery Petrochemical Chemical/ Fertilizer

Type of Field : Marginal Normal

Feed : Oil, Gas and Water

Products : Gas compressed, dehydrated and exported via pipeline
: Oil stabilized and exported via pipeline
: Condensate injected into gas pipeline
: Water deoiled and locally disposed

Gas : Daily Contractual Quantity (DCQ) XXX MMscfd

: Max Daily Quantity (MDQ) YYY (DCQ + 10%)
: Design ZZZ 125% MDQ
Condensate : Normal / Maximum XX,000 / YY,000 BPD
Produced Water : Normal / Maximum/ Design XX,000 / YY,000 BPD

Platform : Wellhead Process Platform

: No of Decks XX No of Piles YY Weight ZZ,000 t
: Single lift Modular lift Float over
: Bridge linked Wellhead LQ Flare Tripod
: Helipad on LQ on another location
: Unmanned Manned

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Flare : Vertical on platform Cantilevered from platform

: Separate bridge linked platform

Pressure : Highest 165 barg lift gas; 75 barg export gas

Temperature : Lowest (–) 40°C HP flare lateral; Highest - 550°C GT exhaust

Location : Shallow Water Deepwater

If Deep water, familiar with
: Hydrate/ Wax Issues MEG/Methanol Injection
: Line Flushing Wetwells Drywells

If FPSO/ Semi-sub, familiar with or knows about

: Impact of ship motion on topsides
Hazardous & Corrosive Materials
Lethal, Toxic Components : H2S 500 to 2,000 ppm Mercury Arsenic
If H2S : Operator familiar. A few units in operation
: Material Selection Personal H2S Monitor SCUBA
: Familiar or knows pyrophoric issues

If Hg or As : Removal Handling Aluminum as MOC

: Low accumulation points Operator familiar
: Discharge to sea with produced water

Corrosive : CO2 4 – 6% Acid cleaning - compressor piping

: Wellfluids High Temp CO2 - H2O from regenerator
: Hypochlorite solution
If CO2 : Operator familiar. A few units in operation
: Material Selection Knows about wet CO2 issues
: Familiar or knows asphyxiation issues

Potential incompatibilities : Solids Sand Drill mud

: Acid/alkali handling Wax

Catalysts : Mercury Removal Dehydrator Mol Sieves None

Dust Handling : None

Firewater system uses : GRE pipes PE/ Cement lined pipes Alloy steel

Owner-Operator : First Installation Operates similar units

: Sub-contract operation Operated by own crew
: Isolation standards, including Double Block & Bleed
: Sampling Draining Venting Philosophy
: PSVs are spared not spared
: Familiar with Rupture disks, if used
Key Issues
• High Levels of H2S
• First of a kind for client??

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A brief presentation was made on HAZID and its methodology. Then the actual HAZID session
was started.

4.4 Safety Studies

It is noted that following Safety related studies are being or proposed to be conducted for this
facility. This will be taken note of while considering design safeguards.

Equipment and Building Location Study

Smoke & Gas Ingress/ Toxic Gas Risk Analysis

Fire & Explosion / Blast Analysis

Escape, Evacuation and Rescue Analysis (EERA)

Emergency Systems Survivability Analysis (ESSA)

Quantitative Risk Assessment (QRA)

Environmental Impact Assessment (EIA) Studies

Inherent Safety Analysis - Eliminate by process changes, minimize inventory

Hazard Prevention - Overpressure protection, Area Classification, SIL

Hazard Detection - Fire & Gas Detection, ESD stations

Hazard Control - Isolation & Depressurization

Hazard Mitigation - Active & Passive Fire Protection, Firewater/ Foam Systems

Collision Study
Dropped Object study

AIV/ FIV Studies

Vibration/ Noise Study

Pipe Stress Study

SIMOPS Study

Human Factors

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5.0 HAZID STUDY

5.1 Methodology
The HAZIP study was conducted in an industry standard approach. It is briefly discussed in
Appendix D.

5.2 Findings
The HAZID team made a total of about --- recommendations. About 20 are key
recommendations. Some are highlighted below. The HAZID study worksheets are in Appendix
B while the Summary of Recommendations is in Appendix C.

5.3 Key Findings

Following summarizes key findings

• Alert the Operation and Maintenance team to potential pyrophoric fire on opening H2S
laden vessels and exposing them to air. Suitable caution boxes will be provided in key
P&IDs and on equipment to keep the surfaces wet and/or follow company procedures.
• It is proposed to conduct a transient analysis of seawater pumps and Firewater pumps to
avoid pressure surges and make SPR (Single Point Responsibility) mandatory on GRE
pipe manufacturer for material, design, and layout review to avoid sharp turns, surge
analysis, fabrication and installation for GRE pipes.

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APPENDIX A – HAZID Study Reference Documents

1. XXXX-YYY-ZZZ Rev A - Simplified Block Flow Diagram

2. XXXX-YYY-ZZZ Rev A - PFD 300 MMscfd Gas + 10,000 BPD Condensate to FSO
3. XXXX-YYY-ZZZ Rev A - Equipment Layout - Upper Deck
4. XXXX-YYY-ZZZ Rev A - Equipment Layout - Main Deck
5. XXXX-YYY-ZZZ Rev A - Equipment Layout - Lower Deck
6. XXXX-YYY-ZZZ Rev A - Equipment Layout - Elevation Looking East
7. XXXX-YYY-ZZZ Rev A - Equipment Layout - Elevation Looking West
8. XXXX-YYY-ZZZ Rev A - Facilities Layout – CPP, WHP, LQ, FP

Feedback on FPSO issues http://olf.no/en/FPSO-Experience-Transfer/FPSO-Lessons-overview/

APPENDIX B – HAZID Study Worksheets

APPENDIX C – HAZID study Summary of Recommendations

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APPENDIX D – HAZID Explained

What? Hazard Identification (HAZID) study identifies hazards or risks in onshore and offshore
installations.

When? Any time but done best as early as possible at FEED stage as soon as a preliminary
layout and block flow diagrams for process and utility systems are available. If required
a follow-on study may be conducted during Detailed Engg stage to follow-up
recommendations of previous studies. Early studies enable timely inputs to proposed
design. Delayed studies fail to influence or apply course-correction to design
decisions.

Who? By a team of engineers. Suggested team members are: Study chairman or facilitator,
Scribe, Process engineer, Safety engineer, Layout or Piping engineer and Client
representatives. They are supplemented on a call basis by Civil or Structural engineer,
and Mechanical engineer.

Areas? Team selects areas to study - either plot or deck wise or system wise. Too many
wastes time leading to repetition and waning focus. Too few may miss out a few
threats. Experienced judgment is the key.

How? Each system or area of an installation is reviewed against a pre-agreed checklist.

When a hazard or risk is identified,

(1) All potential causes or scenarios that could initiate or trigger the hazard
(2) Their potential consequences - direct as well as escalated
(3) Impact on personnel, assets and environment
(4) Effectiveness of safeguards/ risk reduction/ or operating procedures present
(5) Recommendation, if any, to add to existing mitigation measures

were evaluated.

This process was repeated for each hazard and each system until all have been
studied. HAZID team should not attempt to provide a solution unless one is obvious.
Its role is to identify hazards and provide a high level qualitative assessment. The
project and discipline engineers should find an acceptable solution as part of design
development.

Some HAZID studies may assign Risk Ratings for the identified hazards, based on a
risk matrix by the client. These ratings help prioritize follow-on actions. Whether there
is a risk rating are not, all actions should be properly closed out.

During the study, the HAZID worksheet is projected overhead for members to see,
comment and concur. Hazards that are not present are not recorded.

Inputs? Field and facility layout drawings, Process and Utility flow diagrams.

Next? Actions or recommendations proposed are assigned to individuals by a project

engineer via a suitable tracking system. Actions closed out are recorded in the final
HAZID report issued as a project deliverable. A few projects may maintain a Hazard

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Register wherein identified hazards are input by area and type. The HAZID report is
used to populate it.

Checklists Each organization has one of its choice or one can be developed as required.

Global Issues
Hydrocarbon, Chemicals & Utilities
1. Hydrocarbons release - with or without ignition
Dropped objects, Swing loads, Corrosion, Small bore pipes, Fitting leaks, Seal
failure, low temperature embrittlement, AIV/FIV, Gas blowby
2. Hydrocarbon ingress
Hydrocarbon ingress into gas turbine, diesel engine, fired heater air intakes
3. Moisture ingress
Water ingress into heated or hot oil storage
4. Draining / Sampling
Discharge of produced water (with mercury), mud, cuttings to sea or soil
5. Thermal radiation/ Flaring and Venting

Hazardous Chemicals & Health Hazards

6. Hazardous gas, liquids and solids release
Mercury, Arsenic, H2S, CO2, CH4, NOx, SOx, VOC
7. Non Process Fire/ Flammable chemicals
Fire in LER, GT Enclosure
8. Explosion
H2 in Hypochlorite Tank or Battery Room
9. Asphyxiation / Confined space
Inert gas release, Smoke, CO2, Vessel entry
10. Particulates (sand, dust, ash)
Sand, Catalysts, Desiccant,
11. Radioactive / Explosive material

Structural
12. Structural failure
Weather, Earthquake, Collision, Overload, Fire, Cyclic loads

Occupational Hazards
13. Electrical energy
Electrocution, Static electricity
14. Stored energy (Pneumatic / Thermal)
High pressure hoses, Hot surfaces
15. Vibration / Noise
High pressure drop valves, Machinery, slugging, Water hammer
16. Manual work
Rigging, Handling drums, Cutting & Welding, Hand tools, Fall overboard
17. Natural and Environmental Hazards
Wind, Cyclones/ hurricanes/ tornadoes, Waves, High tides, tsunami, Sea currents,
Floods, Ice, Blizzards, Earthquake, Volcano, Ground slide, Soil subsidence,
Summer, Winter, Saliferous or sand/ dust laden wind, Humidity, Heavy rains and
Lighting

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Marine
18. Marine operations
Personnel Transfer, Supply boat operations, Passing ships, Helicopter operations
19. SIMOP

Emergency, Escape and Rescue

20. Impeded Access / Approach / Escape/ Evacuation
Slippery steps, Blocked access, Laydown area, Maintenance activities

Man-made Hazards
21. Security issues
Unauthorized entry; Sabotage; Piracy, Terrorist activities

Construction and Start-up

22. Construction difficulties
Poor planning, Legislation, Compliance to local codes & standards
23. Start-up & Shutdown difficulties
Poor planning, Missing black start fuel, Low inventory, Untrained crew

System or location specific issues

Pigging Operation
Cellar or Lowest Deck
Upper Deck
FPSO
Poor planning - Hull delivery; Storage volume; hull to shipping standards (batch
mode) and topsides to process industry standards (continuous operation)
Effect of FPSO’s axial (Surge, Sway, Heave), rotational (Roll, Pitch, Yaw) and static
(List, Trim) motions on separation, distillation, liquid levels, internals support
Hogging/ sagging of decking plates on equipment support & structures, rotating
equipment support
Green water waves; Maintenance - storage tanks, sea chest, seawater pumps etc
Onshore Location
Proximity to population, Ground water contamination, Historical monuments
damaged by fumes, Public roads, Nearby land use (Farming/ Fishing)

Biological
Endemic diseases, Infection, Contaminated water / food, Biological agents (viruses,
pathogens, parasites, poisonous reptiles and plants)

Caution: What is normal practice in a company may be a hazardous practice in another company which may not have adequate
experience with a particular process or equipment. Example: regenerator insulation failure resulting in hot spots and vessel failure or H2S.

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