PS-0000-1130-322-E Rev 01 HAZOP Report - Utility Systems

Groupement Reggane
HAZOP Report (Utility Systems)
Reggane Nord Development Project Surface Facilities
TABLE OF CONTENTS
GLOSSARY .......................................................................................................................... 5
EXECUTIVE SUMMARY ...................................................................................................... 6
1 INTRODUCTION .................................................................................................... 7
1.1 Project Description ................................................................................................. 7
1.2 Purpose .................................................................................................................. 8
1.3 Meeting Details ....................................................................................................... 8
1.4 HAZOP Team ......................................................................................................... 8
2 SCOPE & APPROACH ........................................................................................ 10
2.1 Study Scope ......................................................................................................... 10
2.1.1 Inclusions ............................................................................................................. 10
2.1.2 Exclusions ............................................................................................................ 10
2.2 Study Approach .................................................................................................... 10
2.3 Study Recording & Actions ................................................................................... 11
3 STUDY BASIS ..................................................................................................... 12
3.1 Master Documents ............................................................................................... 12
3.2 HAZOP (Utility) Nodes .......................................................................................... 16
3.3 Risk Assessment .................................................................................................. 17
3.4 Node Descriptions ................................................................................................ 18
3.5 Assumptions & Assurances .................................................................................. 25
4 MAIN FINDINGS .................................................................................................. 27
4.1 Summary .............................................................................................................. 27
4.2 Full List of Recommendations............................................................................... 27
5 REFERENCES ..................................................................................................... 37
APPENDIX A: HAZOP GUIDEWORDS ......................................................................... 38
APPENDIX B: HAZOP (UTILITY) MASTER P&IDS ....................................................... 39
APPENDIX C: HAZOP (UTILITY) STUDY WORKSHEETS ........................................... 40
Genesis Page 2 of 40 Date: June 13

File name: PS-0000-1130-322-E Rev 01 HAZOP Report (Utility Systems)
Groupement Reggane
Table of Figures
Figure 1-1: Location of Reggane Nord Perimeter............................................................. 7
Figure 3-1: HAZOP Worksheet Template....................................................................... 18
Table of Tables
Table 1-1: HAZOP Team Members .................................................................................. 9
Table 3-1: Primary / Master Documents ......................................................................... 12
Table 3-2: Secondary / Supporting Documents.............................................................. 14
Table 3-3: HAZOP (Utility) Nodes .................................................................................. 16
Table 3-4: List of Assumptions & Assurances ................................................................ 25
Table 4-1: Recommendations ........................................................................................ 27

Groupement Reggane
HOLDS LIST
HOLD Description Section
REVISION HISTORY
Rev. Description Section
00 Report updated to address client comments received 30/04/13. 3.1, 3.4,

Table 3-4,
Appendices B
&C
01 Report updated to address client comments dated 16/05/13. -

Groupement Reggane
GLOSSARY
ALARP As Low As Reasonably Practicable
AZSE Azrafil South East
BdV Base de Vie
ESD Emergency Shutdown
FEED Front End Engineering Design
GRN Groupement Reggane
GTP Gas Treatment Plant
HAZOP Hazard and Operability
HSSE Health, Safety, Security and Environment
KH Kahlouche
KHS Kahlouche South
P&ID Piping & Instrumentation Diagram
PFD Process Flow Diagram
PHA Process Hazard Analysis
SIMOPS Simultaneous Operations
ToR Terms of Reference
UFD Utility Flow Diagram

Groupement Reggane
EXECUTIVE SUMMARY
Genesis has carried out FEED studies for the Reggane Nord facilities, including HAZOP
studies for the Process and Utility Systems, to identify hazards with a potential for safety,
environmental impact or operability consequences. The aim of this Report is to
document the HAZOP study of the Utility Systems.
The HAZOP scope covers the Reggane Nord facilities up to the tie-in to the existing
Sonatrach GR5 pipeline. The P&IDs identified in Table 3-1 were reviewed by the
HAZOP team, in accordance with the agreed Terms of Reference (Ref. 1).
The HAZOP findings are summarized in the worksheets contained in Appendix C.

Actions are identified in the worksheets (178 off). Key assumptions and assurances (12
off) identified during the workshop are summarized in Table 3-4.
No major issues were identified during the HAZOP, but some of the more significant
issues / those with a wider impact, are summarised below:
1. Vendor packages should be subject to formal HAZOP once the detailed design has
been defined by the vendor;
2. The presence of SDVs at the liquid outlet of vessels should be reviewed so that their
benefits (preventing gas blowby) are assessed against their drawbacks (potential
generation of high liquid level and overspill).
Issues requiring verification and close-out will be addressed via the HSSE Action
Tracking Register (Ref. 3).

Groupement Reggane
1 INTRODUCTION
1.1 Project Description
Groupement Reggane (GRN), comprising Sonatrach, Repsol Exploración Argelia S.A.,

RWE Dea AG and Edison International are developing the Reggane Nord Project located
in the Reggane Basin, approximately 1,500 km southwest of Algiers (refer to Figure 1
below). The Surface Facilities include a gas gathering system connecting widely
dispersed wells to a Central Processing Facility where the gas will be processed to sales
specification. The gas will then be compressed, metered and exported via a pipeline to a
tie-in on the main gas transport system in the region. The Reggane Nord Surface
Facilities will be located in a desert region, but near of an oasis area and some highly
populated centres. Livelihood of local inhabitants depends largely on agricultural
activities and herding. The protection of the resources on which these communities
depend is of utmost importance.
Figure 1-1: Location of Reggane Nord Perimeter

Groupement Reggane
1.2 Purpose
The purpose of this Report is to document the findings of the HAZOP (Utilities) study,
which has been carried out as per the principles outlined in the Terms of Reference (Ref
1).
The aim of this HAZOP study was to identify hazards with a potential for safety,
environmental impact or operability consequences. This was achieved by reviewing the
Utility P&IDs.
The review is considered to be a preliminary (FEED Stage) HAZOP, due to the

provisional level of design definition. More detailed HAZOP reviews will be undertaken
during the EPC stage of the project when the design is more developed.
Vendor packages have not been reviewed as part of this HAZOP. P&IDs produced as
part of FEED are indicative only. Prospective vendors will design their own package
given inlet conditions and discharge product specifications. Most vendor packages are
currently shown only as an empty box on current P&IDs, and a full HAZOP of the
package P&IDs is therefore neither possible nor appropriate at this FEED design stage.
Relevant P&IDs (or parts thereof) are subject to engineering review / coarse HAZOP in
order to identify key hazards. Actions arising can then be highlighted in enquiry /
purchase specifications for the package or, for those hazards extending beyond the
package boundary, considered in FEED design or in future design phases as
appropriate.
This report is structured to give an introduction to the project in Section 1, providing

context for the HAZOP review of Utility Systems. The study scope and approach are
covered in Section 2. The study basis is documented in Section 3 and the main findings
and references are highlighted in Sections 4 and 5, respectively. The HAZOP
guidewords are provided in Appendix A, along with the Master P&IDs (with nodes
identified) attached as an embedded file in Appendix B. The HAZOP study worksheets
are contained in Appendix C.
1.3 Meeting Details
The HAZOP was performed on 25th February – 1st March, and 4th – 6th March, 2013 in
the 2nd Floor Conference Room of Genesis’s offices at 262 High Holborn, London.
1.4 HAZOP Team
The HAZOP was performed by the team listed in Table 1-1. The make-up of the team
varied on a day-by-day basis.

Groupement Reggane
Table 1-1: HAZOP Team Members
Name Role
Angus Keddie Chairman - Utility Systems
James Stephens Study Scribe
GRN Personnel
Jose Enrique Gomis (P/T) Surface Facilities co-Manager

Manuel De Vega Carrasco Process Engineer
Jose Contreras (P/T) Instrument Engineer
Juan Andres Server HSE Engineer
Genesis Personnel
Chris Amies (P/T) Process Engineer – Lead

Danielle Hamel (P/T) Process Engineer
Simon Simpson (P/T) Process Engineer
Matthew Smith Instrument Engineer
Len Dickins (P/T) Instrument Engineer – Lead
Sukhdev Dhanjal (P/T) Safety Engineer
Andrew McKinven (P/T) Safety Engineer – Lead

Groupement Reggane
2 SCOPE & APPROACH

2.1 Study Scope
The Terms of Reference (TOR) for this study have been defined separately (Ref. 1).
A summary of the scope and approach is provided below.
2.1.1 Inclusions
 All new equipment and lines shown on project P&IDs, except as listed in
Section 2.1.2.
2.1.2 Exclusions
 Systems beyond the tie-in point of the Reggane facilities to the existing
Sonatrach GR5 pipeline;
 Future facilities;
 Vendor packaged items;
 Base de Vie Water Supply Systems.
2.2 Study Approach
The Genesis process engineer provided an overview of the FEED design (Ref. 2) and an
overall description of the process.
Each utility system was subdivided as necessary into sections, or nodes. For each
node:
 The extent of the node was proposed by the Chairman, and agreed by the
team;
 The Chairman marked up the node on the relevant P&IDs (see Appendix B);
 The process engineer defined the design intent of the node, which was
recorded on the worksheets;
 The pressure and temperature limits of system design envelope were
recorded, together with the parameters for normal operation;
 The mode of operation to be reviewed (normal, SIMOPS, other, etc) was
recorded;
 Credible deviations from normal operating conditions were then identified
using a checklist of key parameters and guidewords included in Appendix A to
provide structure to the review;
 The causes and consequences of each deviation were recorded on the
worksheets, together with the safeguards incorporated into the design to
contain or control potential hazards, to identify that a deviation had occurred,
and where necessary to initiate executive action;
Groupement Reggane
 Any actions agreed by the team as necessary to provide further protection to

prevent a hazardous event or to mitigate its consequences were recorded and
allocated to an appropriate party for implementation or rebuttal.
When the HAZOP had been completed, the deviations for which actions were
recommended were subjected to a risk assessment to confirm that the risk had been
reduced to a tolerable level by the action.
Where no action had been recommended the team considered that the risk was already
tolerably low, as judged by experience and good practice. This assumption was agreed
to be reasonable since all the utility units incorporated established and conventional
technology - there were no new or unusual aspects in the design.
2.3 Study Recording & Actions
Assumptions made, and Assurances required, are summarized in Table 3-4.
The HAZOP study findings are recorded in full on the worksheets, which are included in
Appendix C, and summarised in Section 4.
The discussions were recorded in full on the worksheets, and not by exception.

Groupement Reggane
3 STUDY BASIS
The HAZOP review was conducted in accordance with the Terms of Reference (Ref. 1),
and applying the Repsol and Sonatrach HAZOP procedures (Refs. 4 and 6). The review
started by establishing the intent of the design and operations by discussion of the
supplied documents, prior to formal review.
3.1 Master Documents
Documents used for the study are listed below in Table 3-1 and Table 3-2. The Master
documents used for the HAZOP (Utility) have been included in Appendix B (with nodes
identified) for ease of reference. The Process P&IDs are also included in Appendix B
(with nodes identified to highlight Process / Utility interfaces).
Table 3-1: Primary / Master Documents

Document Number Title Rev.
P&IDs (Process)
PD-1412-1153-203-D P&ID AMINE REGENERATION 0B
P&IDs (Utilities)
PD-1417-1153-102-D UTILITY P&ID - ATMOSPHERIC FLARE COLLECTION HEADER 0A
PD-1417-1153-103-D UTILITY P&ID - ATMOSPHERIC FLARE KO DRUM & PUMP 0B
PD-1417-1153-104-D UTILITY P&ID - ATMOSPHERIC FLARE STACK 0B
PD-1417-1153-105-D-1 UTILITY P&ID - HP WET FLARE COLLECTION 0A
PD-1417-1153-105-D-2 UTILITY P&ID - HP COLD FLARE COLLECTION 0A
PD-1417-1153-105-D-3 UTILITY P&ID - HP DRY FLARE COLLECTION 0A
PD-1417-1153-106-D UTILITY P&ID - HP FLARE KO DRUM, HEATER AND PUMP 0B
PD-1417-1153-107-D UTILITY P&ID - HP FLARE STACK 0B
PD-1417-1153-108-D UTILITY P&ID - LP FLARE COLLECTION HEADER 0A
PD-1417-1153-109-D UTILITY P&ID - LP FLARE KO DRUM AND PUMP 0B
PD-1417-1153-110-D UTILITY P&ID - LP FLARE STACK 0B
PD-1417-1153-201-D UTILITY P&ID - GTP BURN PIT 0B
PD-1417-1153-301-D UTILITY P&ID - GAS VENT DRUM 0B
PD-1417-1153-302-D UTILITY P&ID - ACID GAS VENT STACK 0B
PD-1418-1153-102-D UTILITY P&ID - PRODUCED WATER DEGASSER 0B
PD-1418-1153-103-D UTILITY P&ID - PRODUCED WATER CARTRIDGE FILTERS 0B
PD-1418-1153-104-D UTILITY P&ID - PRODUCED WATER COALESCER PACKAGE 0B
PD-141A-1153-101-D UTILITY P&ID - HEATING MEDIUM FIRED HEATERS 0B
PD-141A-1153-103-D UTILITY P&ID - HEATING MEDIUM EXPANSION DRUM 0B
PD-141A-1153-104-D UTILITY P&ID - HEATING MEDIUM DUMP COOLER 0B

Groupement Reggane

PD-141A-1153-105-D UTILITY P&ID - HEATING MEDIUM FILTER 0B
PD-141A-1153-107-D UTILITY P&ID - HEATING MEDIUM CIRCULATION PUMPS 0B
PD-141A-1153-201-D UTILITY P&ID - START-UP FUEL GAS HEATER 0B
PD-141A-1153-202-D UTILITY P&ID - HP FUEL GAS HEATER 0B
PD-141A-1153-203-D UTILITY P&ID - HP FUEL GAS SEPARATOR 0B
PD-141A-1153-204-D UTILITY P&ID - LP FUEL GAS SEPARATOR 0B
PD-141A-1153-205-D UTILITY P&ID - LP FUEL GAS HEATER 0B
PD-141A-1153-206-D UTILITY P&ID - LP FUEL GAS DISTRIBUTION 0C
PD-141A-1153-301-D UTILITY P&ID - MAIN POWER GENERATION PACKAGE A 0B
PD-141A-1153-302-D UTILITY P&ID - MAIN POWER GENERATION PACKAGE B 0B
PD-141A-1153-303-D UTILITY P&ID - MAIN POWER GENERATION PACKAGE C 0B
PD-141A-1153-304-D UTILITY P&ID - GTG WASTE HEAT RECOVERY UNIT A 0B
PD-141A-1153-305-D UTILITY P&ID - GTG WASTE HEAT RECOVERY UNIT B 0B
PD-141A-1153-306-D UTILITY P&ID - GTG WASTE HEAT RECOVERY UNIT C 0B
UTILITY P&ID - AMINE REGENERATION CHEMICAL INJECTION 0B
PD-141A-1153-404-D PACKAGE
PD-141A-1153-405-D UTILITY P&ID - GTP CHEMICAL INJECTION PACKAGE 0B
PD-141A-1153-501-D UTILITY P&ID - DIESEL STORAGE TANK & FILTRATION 0B
PD-141A-1153-503-D UTILITY P&ID - DIESEL COALESCER 0B
PD-141A-1153-601-D UTILITY P&ID - OILY WATER COLLECTION 0B
PD-141A-1153-602-D UTILITY P&ID - OILY WATER SEPARATOR 0B
PD-141A-1153-603-D UTILITY P&ID - OPEN DRAINS CPI 0B
PD-141A-1153-608-D UTILITY P&ID - CLOSED DRAINS COLLECTION 0B
PD-141A-1153-609-D UTILITY P&ID - CLOSED DRAINS SUMP & SUMP PUMP 0B
UTILITY P&ID - COMPRESSED AIR GENERATION & DRYER 0B
PD-141A-1153-701-D PACKAGE
PD-141A-1153-703-D UTILITY P&ID - INSTRUMENT AIR RECEIVER 0B
PD-141A-1153-704-D UTILITY P&ID - INSTRUMENT AIR DISTRIBUTION 0B
PD-141A-1153-705-D UTILITY P&ID - PLANT AIR RECEIVER 0B
PD-141A-1153-706-D UTILITY P&ID - PLANT AIR DISTRIBUTION 0B
UTILITY P&ID - GTP UTILITY WATER PUMP AND DESANDER 0B
PD-141A-1153-801-D (TYPICAL)
PD-141A-1153-802-D UTILITY P&ID - GTP RAW WATER STORAGE 0B
PD-141A-1153-803-D UTILITY P&ID - GTP SERVICE WATER TREATMENT PACKAGE 0B
PD-141A-1153-804-D UTILITY P&ID - GTP SERVICE WATER STORAGE & DISTRIBUTION 0B

Groupement Reggane

UTILITY P&ID - DEMINERALISED WATER STORAGE & 0B
PD-141A-1153-805-D DISTRIBUTION
PD-141A-1130-901-D UTILITY P&ID - FIREWATER PUMPS 0B
PD-141A-1130-902-D UTILITY P&ID - FIREWATER STORAGE 0B
PD-141A-1130-903-D UTILITY P&ID - FIREWATER JOCKEY PUMPS 0B
PD-141A-1130-904-D UTILITY P&ID - FIRE WATER DISTRIBUTION A1
PD-141A-1153-905-D UTILITY P&ID - FOAM STORAGE TANK AND TRANSFER PUMPS 0B
PD-141A-1153-906-D UTILITY P&ID - FOAM DISTRIBUTION A1
UTILITY P&ID - UTILITY P&ID - NITROGEN GENERATION PACKAGE 0B
PD-141A-1153-A01-D & RECEIVER
PD-141A-1153-A03-D UTILITY P&ID - NITROGEN DISTRIBUTION 0B
UTILITY P&ID - BASE DE VIE UTILITY WATER PUMP AND 0A
PD-1430-1153-201-D DESANDER (TYPICAL)
PD-1430-1153-202-D UTILITY P&ID - BASE DE VIE UTILITY RAW WATER STORAGE 0A
UTILITY P&ID - BASE DE VIE UTILITY SERVICE WATER 0A
PD-1430-1153-203-D TREATMENT PACKAGE
UTILITY P&ID - BASE DE VIE UTILITY SERVICE WATER STORAGE & 0A
PD-1430-1153-204-D DISTRIBUTION
PD-1430-1153-205-D UTILITY P&ID - BASE DE VIE CHEMICAL INJECTION PACKAGE 0B
UTILITY P&ID - BASE DE VIE UTILITY WATER PUMP AND 0A
PD-1430-1130-201-D DESANDER (TYPICAL)
PD-1430-1130-202-D UTILITY P&ID - BASE DE VIE RAW WATER STORAGE 0A
UTILITY P&ID - BASE DE VIE SERVICE WATER TREATMENT 0A
PD-1430-1130-203-D PACKAGE
UTILITY P&ID - BASE DE VIE SERVICE WATER STORAGE & 0A
PD-1430-1130-204-D DISTRIBUTION
Note:
P&IDs that include vendor packages are subject to engineering review / coarse HAZOP, as discussed in
Section 1.2.
Table 3-2: Secondary / Supporting Documents

P&ID Legend Sheets
PD-0000-1153-001-D P&ID - Legend Sheet 1 0A

Groupement Reggane

PFDs
PD-1410-1153-323-D Overall Process Flow Diagram 00
PD-1410-1153-314-D PFD - Amine Regeneration System 02
PD-1410-1153-315-D PFD - Condensate Storage 01
PD-1410-1153-316-D PFD - Condensate Stabilisation 02
PD-1410-1153-317-D PFD - Condensate Separation and Desalting 02
PD-1410-1153-318-D PFD - Gas Compression and Export 02
PD-1410-1153-319-D PFD - Gas HC Dewpointing 02
PD-1410-1153-320-D PFD - Gas Dehydration 02
PD-1410-1153-321-D PFD - Amine Sweetening 02
PD-1410-1153-322-D PFD - Inlet Facilities 01
PD-1310-1153-300-D PFD - RG-1 & RG-2 Field Well Site Gathering System 00
PD-2310-1153-300-D PFD - AZSE Field Well Site Gathering Station 01
PD-3310-1153-300-D PFD - KL and KLS Field Well Site Gathering Station 01
UFDs
PD-1410-1153-301-D UFD - Chemical Storage and Injection 01
PD-1410-1153-302-D UFD - Produced Water Treatment and Storage 0A
PD-1410-1153-303-D UFD - Acid Gas Vent 01
PD-1410-1153-304-D UFD - HP, LP and Atmospheric Flare 02
PD-1410-1153-305-D UFD - Open Drains System 02
PD-1410-1153-306-D UFD - Closed Drains System 02
PD-1410-1153-307-D UFD - Diesel Fuel System 02
PD-1410-1153-308-D UFD - Power Generation 02
PD-1410-1153-309-D UFD - Amine Storage and Amine Drains 02
PD-1410-1153-310-D UFD - Heating Medium System 02
PD-1410-1153-311-D UFD – GTP Raw Water, Utility Water, Potable Water & Demin Water 0B
PD-1410-1153-312-D UFD - Compressed Air and Inert Gas System 02
PD-1410-1153-313-D UFD - Fuel Gas System 02
PD-1410-1153-324-D UFD - Condensate Burn Pit 01
PD-1410-1130-300-D UFD - Fire Water Foam 01
PD-1430-1153-301-D UFD - Base De Vie Plant/Fresh Water and Fire Water 0A
H&M Balance

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PS-1410-1153-466-E Overall Heat and Material Balance
Layouts & Plot Plans
PD-1410-1155-361-D Site Plan - GTP 0A
PD-1410-1155-362-D Plot Plan - GTP 0A
PD-1430-1152-300-B Base De Vie Layout 0A
PD-1450-1152-300-B Security Camp Layout 0A
Philosophies
PS-1410-1153-468-E Process Design Philosophy 01
PS-1410-1153-478-E Utility Design Philosophy 00
PS-1410-1153-481-E Relief and Blowdown Philosophy 01
PS-1410-1153-484-E Vent and Drainage Philosophy 01
PS-1410-1153-485-E Material Selection Criteria and Corrosion Control Philosophy 0A
PS-0000-1130-303-E Safety Philosophy 0A
PS-1410-1155-302-E Piping Philosophy & Design Criteria 00
PS-1410-1159-300-E Instrumentation, Control and Telemetry Philosophy 00
PS-1440-1159-301-E Telecommunication System Philosophy 01
PS-0000-1158-300-E Electrical Design Philosophy 02
PS-0000-1153-334-E Isolation Philosophy 01
PS-0000-1153-302-E Emergency and Process Shutdown Philosophy 01
Other Documents
PS-0000-1153-300-E Basis of Design 00
PS-1440-1159-303-E Specification for Telecommunication System. 0A
PS-1410-1153-480-D Equipment List 0A
PS-0000-1153-304-D Process Cause and Effects Charts 0A
3.2 HAZOP (Utility) Nodes
The utility systems were divided into 27 nodes (36-62) for review. These nodes are listed
in Table 3-3.
Table 3-3: HAZOP (Utility) Nodes

Node Description
- General Considerations
36 ATM Flare Header System
37 ATM Flare Header Condensate Recovery
38 HP Flare Header System
39 HP Flare Header Condensate Recovery

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Node Description
40 LP Flare Header System
41 LP Flare Header Condensate Recovery
42 Acid Gas Vent System
43 Acid Gas Condensate Recovery
44 GTP Burn Pit
45 Heating Medium Storage, Pumping and Filtration
46 Heating Medium Heating and Use Circuit
47 HP Fuel Gas Heating and Supply to Users
48 LP Fuel Gas Heating and Supply to Users
49 HP and LP Fuel Gas Separator Liquid Outlets
50 Start Up Fuel Gas System (Pipeline Gas)
51 Closed Drain System
52 Oily Water Supply and Water Recovery
53 Open Drains Water Recovery, Oil Recovery and Discharge
54 Diesel Fuel System
55 Aquifer Water Supply from Source
56 Raw Water Supply to Service Water Storage Tank
57 Service Water Supply to Users
58 Demin Supply to Users
59 Firewater Supply System
60 Foam Supply System
61 Plant and Instrument Air System
62 Nitrogen System
3.3 Risk Assessment
On completion of the HAZOP, deviations for which actions were recommended were
subjected to a risk assessment to confirm that the risk had been reduced to a tolerable
level by the action. Where no action had been recommended the team considered that
the risk was already tolerably low, as judged by experience and good practice.
The risk assessment was performed by a small team (GRN and Genesis) at the end of
the HAZOP workshop. This exercise was recorded on the HAZOP template, see Figure
3-1 below.

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Figure 3-1: HAZOP Worksheet Template
The Repsol HAZOP guide (Ref. 4) provides the following description of the risk
assessment steps:
‘C, P, S, R: Identification of the risk following the CEL method where the consequences (C) are
evaluated, simultaneously considering the probability (P) of occurrence of the scenario or
consequence and the exposure (E) to the risk of the vulnerable element. The composition of the
three magnitudes will determine the assigned risk ®, which is obtained using a numerical value.’
The CEL (Consequence, Exposure and Likelihood) risk assessment method is described
further in the Repsol PHA guide document (Ref. 5, Annex IX). This indicates the use of
three independent matrices (Ref. 7) which are calibrated to the Repsol risk acceptability
criteria.
The risk (R) is calculated as a direct product of the three components.
The HAZOP (Utilities) study has recorded, as part of the risk evaluation, the
consequences for applicable scenarios, including the potential for equipment damage,
but excluding the potential for injury to personnel. The SIL (Utilities) study is based on
the identified HAZOP hazard scenarios, including current or recommended safeguards.
Where necessary, the SIL study has developed the HAZOP risk evaluation, taking into
account the risk of injuries or fatalities to personnel, to facilitate the assignment of a
target SIL to the relevant SIF.
3.4 Node Descriptions
The following node descriptions have been included for further clarity.
General Node
A number of general points affecting some or all of the nodes were discussed, and are
recorded here in order to avoid the need to repeat them in the worksheet for every node.

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• Unplanned operation of BDVs:

Every isolatable section within the GTP has a BDV that is intended to discharge
the inventory in an emergency once the section has been isolated by the closure
of the upstream and downstream isolations. As a general principle, the rate at
which blowdown valves discharge to depressure the isolatable section within a
given time is significantly smaller than the normal production flowrate through the
isolatable section.
If a BDV fails open, or is inadvertently opened for any reason, it will therefore have
little or no observable effect on the production system. Although this failure or mal-
operation will be one way in which a misdirected flow could be achieved, it will
only be detected by the position indicators on the valve and/or the flare monitoring
system that will detect an unplanned flow.
This failure has not, therefore, been recorded for any node.
• PSV lifting below its set pressure:

It is possible during normal operation for a PSV to lift below its normal set
pressure, either because it was not set up properly, or because a spring has
failed. It is also possible for a PSV to leak, often because it has not re-seated
properly after an upset that caused it to lift. This failure may have a significant
effect on the operation if, for example the PSV is sized for full flow, or it may not if
the PSV is sized for a lesser relieving case such as thermal expansion.
These failures are another way in which a misdirected flow could be achieved, but
it will generally be the flare monitoring system that will detect the unplanned flow
first rather than any change in operating conditions.
This failure has not, therefore, been recorded for any node.
• Loss of Containment:
Where Loss of Containment was considered credible, its consequences were
considered by the team.
• Fire protection:
Any significant release of flammable material that ignites will be detected by the
fire detection system, and confirmed fire will initiate an ESD level 1 shutdown
which shuts in and blows down every isolatable section.
Fire has not therefore been addressed as a general issue in the HAZOP
worksheets. Credit is given where equipment that can be isolated with trapped
inventory is protected by a PSV. At the time of the HAZOP, the PSV sizing cases
were on hold and it was assumed that they would be adequately sized for fire.
Fixed fire fighting measures located in the process area include: deluge and
monitors (fire water / foam). These systems are further defined in the Specification
for Active Fire Protection (Ref. 8).
• Vendor Packages:

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Vendor packages were not reviewed as no detailed information was available at

this stage of the design process. It is assumed that they will be subject to a
HAZOP review during the EPC stage.
• Electrical Heaters:
It was noted that some electric heaters had instrumentation notation which was
incorrectly displayed. Accordingly, all plant electrical heaters should be reviewed
to ensure internal trips are correctly displayed (ie no reference to ESD for internal
trips)
• Closed Drain System:

Ensure that all process lines feeding the Closed Drain system are reviewed for 2
phase flow and designed appropriately.
• Economic Consequence:
An additional Economic Consequence was agreed for use, which refers to loss of
production or cost impact.
• Winterisation Study:
It was noted at several points that freezing of stagnant water in low ambient
temperature conditions was credible. Accordingly, a Winterisation Study is to be
performed where ever such a risk is perceived.
• SDV/ESDV Labelling:
Rationalise labelling of SDVs (used in non process areas) and ESDVs (isolating
process areas in case of fire or other emergency) to ensure consistency across
facility.
• Simultaneous Pump Running:

Running more than one duty pump at the same time is not considered a credible
cause
• Cause and Effects Update:

It was noted that the Cause and Effect matrix for Nodes 59 and 60 were not
complete at the time of review. This needs to be rectified.
• Bird Screens:
Given the use of bird screens can cause problems as well as alleviating them,
their use on the facility is to be reviewed.
• Definition of Likelihood:
As it was not clearly stated in the Guidance Notes, it was agreed in the Review
that, when carrying out the Risk Ranking exercise, the likelihood (L) parameter is
taken to be the probability of propagation taking existing safeguards and
recommended actions into account
• Impact of Vessel Burial:

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If decision is made for 141A-V-601/2 to not be buried, a full safety review must be
carried out on the new design.
• Chemical Injection Systems:

Chemical Injection Systems were not separately reviewed as they are package
systems and were considered for more flow and no flow deviations in the systems
into which they are provided.
Node 36: ATM Flare Header System

The Atmospheric Flare Header Collection pipework receives releases from the GTP
Demin Water Treatment Storage Tank and transfers it to the Atm Flare Drum. From here,
the separated gas is directed to the Atm Flare where it is burned.
Node 37: ATM Flare Header Condensate Recovery

Any liquid contained in the Atmospheric Flare Header Collection Pipework is knocked out
in the Atm Flare Drum and pumped to the Closed Drain Collection via the Atm Flare
Drum Pumps.
Node 38: HP Flare Header System

The HP Flare Collection System pipework receives releases from multiple sources, which
are routed to the HP Flare Drum. The separated gases are then transferred to the HP
Flare, where they are burned.
Node 39: HP Flare Header Condensate Recovery

Any liquid contained in the HP Flare Header Collection Pipework is knocked out in the
HP Flare Drum and pumped to the Closed Drain Collection via the HP Flare Drum
Pumps.
Node 40: LP Flare Header System

The LP Flare Collection System pipework receives releases from multiple sources, which
are routed to the LP Flare Drum. The separated gases are then transferred to the LP
Flare, where they are burned.
Node 41: LP Flare Header Condensate Recovery

Any liquid contained in the LP Flare Header Collection Pipework is knocked out in the LP
Flare Drum and pumped to the Closed Drain Collection via the LP Flare Drum Pumps.

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Node 42: Acid Gas Vent System

The Acid Gas Vent Collection System pipework receives releases from multiple sources,
which are routed to the Acid Gas Vent Drum. The separated gases are then transferred
to the Acid Gas Stack, where they are released to atmosphere.
Node 43: Acid Gas Condensate Recovery

Any liquid contained in the Acid Gas Collection Pipework is knocked out in the Acid Gas
Vent Drum and pumped to the Rich Amine Flash Drum via the Acid Gas Vent Drum
Pumps.
Node 44: GTP Burn Pit

The GTP Burn Pit is used when produced condensate has to be disposed of. The
collection pipework receives excess condensate from multiple sources, which drain to the
Burn Pit, where they are combusted.
Node 45: Heating Medium Storage, Pumping and Filtration

Heating Medium, which is water, is used to vapourise liquid in the Amine Regeneration
Column. In this node, the Heating Medium Expansion Drum is charged and topped up
with Demin Water. Heating Medium is then pumped round the circuit via the Heating
Medium Circulation Pumps, from which a side stream is sent to the Heating Medium
Filters, to remove any accumulated solids, and then returned to the main circuit.
Node 46: Heating Medium Heating and Use Circuit

Heating Medium, which is water, is used to vapourise liquid in the Amine Regeneration
Column. In this node, the water is heated to its required temperature by the Heating
Medium Fired Heaters and the GTG Waste Recovery Units. It is then transferred to the
Amine Regeneration System (ARS) for use. In the event of a shutdown of the ARS, the
Heating Medium Dump Cooler may be called on to cool water which has been heated by
residual duty from the GTG Wasteheat Recovery Units. Water is then returned to the
Heating Medium Expansion Drum.
Node 47: HP Fuel Gas Heating and Supply to Users

HP Fuel Gas is used as seals for the Booster Compressors and to run the Gas Turbines
for Power Generation. In this node, the dewpointed HP Fuel Gas is supplied from the
Gas Dehydration Outlet Filter, superheated by the HP Fuel Gas Heater, and then fed to
the HP Fuel Gas Separator. The gas is then fed to users and the LP Fuel Gas System.

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Node 48: LP Fuel Gas Heating and Supply to Users

LP Fuel Gas has a variety of users on the plant. In this node, Fuel Gas is let down from
the HP System and received from a number of other sources. The combined stream is
then fed to the LP Fuel Gas Separator. The gas is then superheated by the LP Fuel Gas
Heater and supplied to users.
Node 49: HP and LP Fuel Gas Separator Liquid Outlets

Any condensate formed in either the HP or LP Fuel Gas Systems will be knocked out in
the HP and LP Fuel Gas Separators respectively. In this node, any liquid collected in the
HP System is transferred to the Condensate Inlet Separator Feed Heater, while any
liquid collected in the LP System is transferred to the Closed Drain System.
Node 50: Start Up Fuel Gas System (Pipeline Gas)

In order to start the plant up, fuel gas is required. In normal circumstances, this is
sourced from the pipeline. In this node, dew pointed pipeline gas is passed through the
Fuel Gas Filter and superheated by the Pipeline Start Up Heater before being fed to the
HP Gas System. In the event of a requirement to ‘Black Start’, the raw gas is supplied
from the Slugcatchers.
Node 51: Closed Drain System

The purpose of the Closed Drain System is to collect and process liquid hydrocarbon
discharges from the plant. This node comprises collection of these discharges from
various sources, which are then transferred to a Closed Drain Vessel. This vessel
incorporates a Heater, which ensures that any low temperature discharge does not result
in freezing. The collected liquids are then pumped out to the Condensate Inlet Separator
Feed Heater for reprocessing.
Node 52: Oily Water Supply and Water Recovery

Oily water from the plant is collected and fed via a header to the Water compartment of
the Oily Water Separator, where water and hydrocarbons become disentrained.
Separated HC passes over a baffle into the HC compartment, where it is pumped by the
Oily Water Drains Oil Pump to the Closed Drains System. The remaining water is
pumped by the Oily Water Drains Water Pump to the Open Drains CPI Separator.
Node 53: Open Drains Water Recovery, Oil Recovery and Discharge
The purpose of this system is to purify waste water such that it can be discharged without
infringing environmental thresholds. Coursely treated water from the Oily Water
Separator and discharges from the Open Drains are fed to the CPI Separator. It first
passes through a Sand Trap to remove any entrained solids. It is then fed to a

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Corrugated Plate Separator, which acts to disentrain residual hydrocarbons from water.
Separated hydrocarbons pass over a baffle into a collection pot, which feeds an Oil
Sump. From here, the Waste Oil Pump transfers the oil to the Closed Drain System.
Meanwhile, the separated water passes under the baffle into the Clear Water Sump, and
is then pumped to the Evaporation Pond.
Node 54: Diesel Fuel System

Diesel is used on the plant to power one of the Fire Water Pumps and the Emergency
Power Generator. In this node, the diesel is transferred from road tankers to the Raw
Diesel Storage Tank, and is then pumped by the Diesel Transfer Pumps via the Diesel
Filter Coalescer to users.
Node 55: Aquifer Water Supply from Source

Aquifer water is used to supply all the plant’s water needs. In this node, water is supplied
from aquifers via the Well Aquifer Water Desanders to the GTP Raw Water Tank.
Node 56: Raw Water Supply to Service Water Storage Tank

Raw Water is transferred by the Raw Water Transfer Pumps to the GTP Service Water
Treatment Package, where it is treated such that it meets the required Service Water
specifications. Sodium Hypochlorite is then added (to minimise biological growth) and it
is fed to the Service Water Storage Tank.
Node 57: Service Water Supply to Users

Service Water is supplied to various users by the Service Water Pumps and is
additionally treated to Demin Water quality in the Demin Water Treatment Package. This
water has an oxygen scavenger added to it and is then fed to the Demin Water Storage
Tank.
Node 58: Demin Supply to Users

Demin Water is supplied to various plant users by the Demin Water Transfer Pumps.
Node 59: Firewater Supply System

Firewater is sourced from Raw Water downstream of the Aquifer Water Desanders, from
which it is supplied to the Firewater Storage Tanks. Firewater Jockey Pumps are used to
maintain the pressure in the Firewater Ringmain. When required, the Firewater Pumps
supply water to extinguish fires on the plant.

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Node 60: Foam Supply System

Foam is considered the most suitable material for extinguishing a hydrocarbon pool fire
which may occur on the plant. Consequently a system is provided to provide foam
concentrate when required. The node comprises a Foam Concentrate Storage Vessel,
from which foam concentrate is pumped to the ring main.
Node 61: Plant and Instrument Air System

Air is provided to feed the Plant and Instrument Air Systems by the Air Compressors. It is
then dried in the Instrument Air Dryer Package and subsequently transferred to the Plant,
Instrument Air Receivers and Nitrogen Generation Package. It is then fed to instrument
Air Users and Plant Air Distribution.
Node 62: Nitrogen System

Nitrogen is used in the plant for inerting, pressurising and as a back up to prevent air
ingress into the flare system. This node considers the Nitrogen Generation Package and
then addresses the feed to the Nitrogen Receiver and onwards to the nitrogen
distribution.
3.5 Assumptions & Assurances
The design intent defined in the supplied information was modified and clarified during
the HAZOP study. These clarifications form part of the study basis as agreed by the
HAZOP team and are summarised in Table 3-4. It will be necessary to verify the validity
of these assumptions and assurances to ensure the study findings remain valid.
Table 3-4: List of Assumptions & Assurances

Ref Assumption By
A1 If no recommendation has been made then the team believes EPC
that the risk is ALARP. Contractor
A2 One day’s production from the GTP is worth €250,000. EPC
Contractor
A3 Short term production loss can be made up. EPC
Contractor
A4 Flowline rupture will cost €300,000. EPC
Contractor
A5 DRILLEX is €15,000,000 per well. EPC
Contractor
A6 When there are two actions for the same event then the worst EPC
case is risk assessed. Contractor
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Ref Assumption By
A7 Actions to confirm that logic controllers perform as they are EPC
supposed to are assumed to be ALARP on the basis that the Contractor
logic will be reviewed in detail once it has been defined.
A8 All recommendations related to operational improvement (e.g. EPC
removing redundant trips) are classified as ‘ALARP’ because Contractor
they do not affect risk.
A9 Where actions are placed on vendors it is assumed that they will EPC
be satisfactorily addressed so, at this stage of the design Contractor
process, they will be classified as ALARP.
A10 Failure of ESDVs on pump suctions will cause those pumps to EPC
trip. Contractor
A11 Node 38: EPC
Amine discharge to HP flare system not considered credible Contractor
therefore no need to have dedicated system to collect and
dispose expensive amine.
A12 Node 49: EPC
HAZOP Assumption 16: Fuel Gas KO Drums (141A-V-202 and Contractor
141A-V-201) are run with no liquid inventory
The close-out of these actions will be performed via the HSSE Action Tracker (Ref. 3).
Assumptions A1-9 also apply to the HAZOP of Process Systems.
Any changes to the assumptions will need to be reviewed by GRN to assess their
significance and the requirement for any follow-up reviews.

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4 MAIN FINDINGS
4.1 Summary
The P&IDs listed in Table 3-1 were reviewed in accordance with the HAZOP process
described in the ToR (Ref. 1).
The HAZOP findings are summarized in the worksheets contained in Appendix C.

Actions are identified in the worksheets (178 off). Key assumptions and assurances (12
off) identified during the workshop are summarized in Table 3-4.
No major issues were identified during the HAZOP, but some of the more significant
issues / those with a wider impact, are summarised below:
1. Vendor packages should be subject to formal HAZOP once the detailed design has
been defined by the vendor;
2. The presence of SDVs at the liquid outlet of vessels should be reviewed so that their
benefits (preventing gas blowby) are assessed against their drawbacks (potential
generation of high liquid level and overspill).
Issues requiring verification and close-out will be addressed via the HSSE Action
Tracking Register (Ref. 3).
4.2 Full List of Recommendations
A full list of the recommendations is given in Table 4-1.
Table 4-1: Recommendations

Node Action By
General Node.
G1 Electrical Heaters: Genesis Process
It was noted that some electric heaters had instrumentation notation which was
incorrectly displayed. Accordingly, all plant electrical heaters should be reviewed to
ensure internal trips are correctly displayed (ie no reference to ESD for internal
trips).
G2 Closed Drain System: Genesis Process
Ensure that all process lines feeding the Closed Drain system are reviewed for 2
phase flow and designed appropriately.
G3 Winterisation Study: EPC Contractor
It was noted at several points that freezing of stagnant water in low ambient
temperature conditions was credible. Accordingly, a Winterisation Study is to be
performed where ever such a risk is perceived.

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Node Action By
G4 SDV/ESDV Labelling: Genesis Process

Rationalise labelling of SDVs (used in non process areas) and ESDVs (isolating
process areas in case of fire or other emergency) to ensure consistency across
facility.
G5 Cause and Effects Update: Genesis Process
It was noted that the Cause and Effect matrix for Nodes 59 and 60 were not
complete at the time of review. This needs to be rectified.
G6 Bird Screens: EPC Contractor
Given the use of bird screens can cause problems as well as alleviating them, their
use on the facility is to be reviewed.
G7 Impact of Vessel Burial: EPC Contractor
If decision is made for 141A-V-601/2 to not be buried, a full safety review must be
carried out on the new design.
Node 36: ATM Flare Header System.
36 36.1. Ensure that flare packages have O2 analysers on flare stacks (1417-PU-108) EPC Contractor
36 36.2. Show 1417-ESDV-1024 as FO on PD-1417-1153-102-D (Rev 0A) Genesis Process
36 36.3. Remove high pressure alarm 1417-PI-1011 H, which does not provide any Genesis Process
additional useful information.
36 36.4. Verify means of safely maintaining rotameter 1417-FI-1042. EPC Contractor
Node 37: ATM Flare Header Condensate Recovery
37 37.1. Add HH trip to 1417-LI-1007 in accordance with note 6 (PD-1417-1153-103- Genesis Process
D), determine appropriate voting rules and update Cause and effects accordingly.
37 37.2. Review purpose of SDV-1001 and remove if perceived benefits are Genesis Process
outweighed by disadvantages.
37 37.3. Determine the voting system and add designation to 1417-LI-1007 (PD-1417- Genesis Process
1153-103-D) and update Cause and effects accordingly.
37 37.4. Remove 1417-V-101 minimum recycle line (PD-1417-1153-103-D). Genesis Process
Node 38: HP Flare Header System
38 38.2. Show 1417-ESDV- Genesis Process

1009/1010/1011/1012/1013/1015/1017/1018/1019/1020/1021/1022/1023 as FO on
PD-1417-1153-105-D sheets1,2,3 (Rev 0A)
38 38.4. Verify means of safely maintaining rotameter 1417-FI-1020/1021/1023/1017/ EPC Contractor
1016/1025/1027/1032/ 1036/1037/1039/1034/ 1030.
Node 39: HP Flare Header Condensate Recovery
39 39.1. Add HH trip to 1417-LI-1009 in accordance with note 8 (PD-1417-1153-106-D) Genesis Process
and determine appropriate voting rules and update Cause and Effects accordingly
39 39.2. Review cause and effect matrix to confirm correct shutdown scenarios. Genesis Process

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Node Action By
1153-106-D). Update Cause and Effects accordingly
39 39.6. Confirm existence of internal high temperature trip to 1417-HE-101. EPC Contractor
Node 40: LP Flare Header System
40 40.2. Show 1417-ESDV-1008/1007 as FO on PD-1417-1153-108-D (Rev 0A) Genesis Process
40 40.4. Verify means of safely maintaining rotameter 1417-FI-1012/1013. EPC Contractor
Node 41: LP Flare Header Condensate Recovery
41 41.1. Add HH trip to 1417-LI-1008 in accordance with note 7 (PD-1417-1153-109-D) Genesis Process
and determine appropriate voting rules. Update Cause and Effects accordingly
41 41.2. Review cause and effect matrix to confirm correct shutdown scenarios. Genesis Process
Node 42: Acid Gas Vent System
42 42.1. Review purpose of 1417-FI-3001 (PD-1417-1153-301-D) and consider Genesis Process

removal of instrument if not required by legislation.
42 42.3. Consider adding H2S analyser instrument in feed stream to incinerator. Genesis Process
Node 43: Acid Gas Condensate Recovery
43 43.3. Delete note 3 on PD-1417-1153-301-D, as not required. Genesis Process
43 43.4. Remove 1417-TI-3001 H alarm, as not required. Genesis Process
43 43.5. Delete minimum recycle line associated with 1417-P-301A/B, as not required. Genesis Process
Node 44: GTP Burn Pit
44 44.1. Show 1417-ESDV-2001 as FO on PD-1417-1153-201-D Genesis Process

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Node Action By
44 44.2. Add slope indication to burn pit feed pipes (PD-1417-1153-201-D) Genesis Process
44 44.3. Review P&ID and confirm design of burn pit with respect to ignition philosophy. EPC Contractor
44 44.4. Prepare operating and start up procedures and philosophy for GTP burn pit EPC Contractor
system
44 44.5. Review design of pit lining to prevent crack development EPC Contractor
44 44.6. Remove 1417-AI-2001. Genesis Process
Node 45: Heating Medium Storage, Pumping and Filtration
45 45.0. Design pressure of 141A-V-101 to be revised following reduction in operating Genesis Process
conditions.
45 45.1. Review "safe location" of vent, based on anticipated conditions of 141A-PSV- EPC Contractor
1019A/B discharge.
45 45.2. Consider swapping failure modes of 141A-PV-1016 and 141A-PV-1017. Genesis Process
45 45.3. Review use of a single line for dosing more than one chemical in terms of EPC Contractor
operability and hold up in the dosing line.
45 45.4. Review method for inerting heating medium system for start up, specifically EPC Contractor
where nitrogen will be charged and vented
Node 46: Heating Medium Heating and Use Circuit
46 46.1. Modify executive action of 141A-FI-1011 LL to only trip 141A-H-101. Update Genesis Process
Cause and Effects accordingly
46 46.2. Review requirement for 141A-PI-1024 HH trip and delete if not required. Genesis Process
(141A-FV-1008/1009/1010 will act to protect 141A-P-101A/B/C)
46 46.3. Align P&ID with Cause and Effects, with respect to 141A-TI-1019 such that H Genesis Process
temperature pre-alarm and HH temperature trip are both shown.
46 46.4. Review line sizing basis of 12"-HMS-141A-10714-3A3-H. Line is not required Genesis Process
to be full flow.
46 46.5. Additional ´´package tripped´´ tag required from package to ESD system to be Genesis Process
added to cause and effects and P&IDs. (141A-XS-1012 duplicated)
46 46.6. Review requirement for 141A-PSV-3001/3002/3003 Genesis Process
46 46.7. If 141A-PSV-3001/3002/3003 are retained, review "safe location" of vent, EPC Contractor
based on anticipated conditions of 141A-PSV-3001/3002/3003 discharge.
46 46.8. Add positive isolation around 141A-H-301A/B/C and ensure consistency EPC Contractor
between P&IDs (vendor packages).
Node 47: HP Fuel Gas Heating and Supply to Users
47 47.1. Revise tag numbering of 141A-PV-2014, to give unique number (PD-141A- Genesis Process
1153-203-D).
47 47.2. Review sizing criteria for 141A-PSV-2012A/B to ensure appropriate sizing for EPC Contractor
failure of 141A-PV-2014. Also consider relocating 141A-PSV-2029A/B to cover
valve failure case from either start-up or main route.
47 47.3. Review sizing criteria for 141A-PSV-2012A/B to ensure appropriate sizing for EPC Contractor
failure of 141A-PV-2014C/D.

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Node Action By
47 47.4. Review location of 141A-HE-203A/B with respect to optimum fuel gas EPC Contractor
processing
47 47.5. Add high and low alarm to 141A-PIC-2014. Genesis Process
47 47.6. Review Cause and effects with respect to executive action of 141A-PI-2011 Genesis Process
LL.
47 47.7. Review duplication of tag 141A-ESDV-2018, and consider deleting if not Genesis Process
required.
Node 48: LP Fuel Gas Heating and Supply to Users
48 48.0. Verify pressure control valve tag numbers at inlet to LP fuel gas separator. Genesis Process
48 48.1. Revise 141A-PV-2008C to fail closed (PD-141A-1153-204-D). Genesis Process
48 48.2. Add check valve downstream of 141A-ESDV-1002. Genesis Process
48 48.3. Ensure that downstream equipment are designed to deal with small quantities EPC Contractor
of liquid drop-out.
48 48.4. Add high and low pressure alarm to 141A-PIC-2008. Genesis Process
48 48.5. Review executive action of 141A-PI-2009 LL trip. Genesis Process
Node 49: HP and LP Fuel Gas Separator Liquid Outlets
49 49.1. Review requirement to close ESDVs to heating medium fired heater on 141A- Genesis Process
LI-2003 HH trip. Update Cause and Effects accordingly
Node 50: Start Up Fuel Gas System (Pipeline Gas)
50 50.1. Review requirement to use raw gas during start up under LP well operation GRN Project
Node 51: Closed Drain System
51 51.1. Update PD-141A-1153-609-D to show 141A-LI-6001 as 141A-LIC-6001 Genesis Process
51 51.2. Add an independent level indication with trip function to stop 141A-P-601 in Genesis Process
case of low low level on 141A-V-601 (PD-141A-1153-609-D). Update Cause and
Effects accordingly
51 51.3. Add appropriate instrumentation, including high HC alarm to leak detection Genesis Process
equipment on 141A-V-601.
51 51.4. Ensure that 141A-PSV-6001 A/B is appropriately sized for reverse flow from EPC Contractor
1413-V-101, in conjunction with check valve mitigation.
51 51.5. Consider rationalisation of check valves in liquid discharge line from 141A-V- Genesis Process
601
51 51.6. Verify sizing of 141A-PSV-6001A/B for uncontrolled heating. EPC Contractor
51 51.7. Review requirement for vessel heater in 141A-V-601, and remove if not Genesis Process
required.
51 51.8. Review failure modes of 141A-PCV-6004/6005 Genesis Process
51 51.9. Verify that 141A-V-601 is designed for full vacuum. EPC Contractor
51 51.10. Add low pressure alarm and pump inhibition to 141A-PI-6020. Update Cause Genesis Process
and Effects accordingly

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Node Action By
51 51.11. Confirm siting philosophy (buried or not buried) GRN Project
Node 52: Oily Water Supply and Water Recovery
52 52.1. Consider conversion of 141A-LI-6008 HH trip to H alarm on vessel 141A-V- Genesis Process
602. Update Cause and Effects accordingly
52 52.2. Remove 141A-LI-6008 HH trips on 141A-V-602 from cause and effects, as not Genesis Process
required
52 52.3. Remove 141A-FI-6003 L alarm. Genesis Process
52 52.4. Consider conversion of 141A-LI-6009 HH trip to H alarm on vessel 141A-V- Genesis Process
602. Update Cause and Effects accordingly
52 52.5. Remove 141A-LI-6009 HH trips on 141A-V-602 from cause and effects, as not Genesis Process
required
52 52.6. Remove 141A-FI-6005 L alarm Genesis Process
52 52.7. Ensure that vent line is adequately sized to prevent vacuum formation in EPC Contractor
vessel 141A-V-602
52 52.8. Consider designing 141A-V-602 for full vacuum EPC Contractor
52 52.9. Review requirement for flame arrestor at vent discharge of 141A-V-602. EPC Contractor
52 52.10. Confirm siting philosophy (buried or not buried). GRN Project
52 52.11. Review note 6 on PD-141A-1153-602-D with respect to whether vessel is EPC Contractor
buried or not
52 52.12. Add appropriate instrumentation, including high HC alarm to leak detection EPC Contractor
equipment on 141A-V-602
Node 53: Open Drains Water Recovery, Oil Recovery and Discharge
53 53.1. Consider replacing 141A-LI-6006 HH trip with H level alarm, and update Genesis Process
Cause and effects accordingly.
53 53.2. Consider replacing 141A-LI-6004 HH trip with H level alarm, and update Genesis Process
Cause and effects accordingly.
53 53.3. Verify that design pressure of 141A-P-605A and associated piping is 3.5 barg. Genesis Process
53 53.4. Include regular sampling of water quality in operating procedures EPC Contractor
53 53.5. Provide appropriate positive isolation on discharge of pump 141A-P-605A EPC Contractor
Node 54: Diesel Fuel System
54 54.1. Review requirement of 141A-FI-5001 H and L alarms Genesis Process
54 54.2. Consider replacing 141A-FV-5001 with restriction orifice on 141A-P-501A/B EPC Contractor
min. flow recycle line
54 54.3. Consider deletion of 141A-PI-5015 HH trip Genesis Process
54 54.4. Update PD-141A-1153-501-D to reflect single diesel transfer pump specified Genesis Process
Node 55: Aquifer Water Supply from Source
55 55.1. Update Cause and effects for 141A-LI-8001 HH executive action to trip 141A- Genesis Process
P-807

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Node Action By
55 55.2. Consider adding sand level probes in 141A-F-801/802/803 EPC Contractor
55 55.3. Update tag number reference table to include relevant instrumentation for EPC Contractor
service water lift pumps 141A-P-802/807 on PD-141A-1153-801-D.
55 55.4. Ensure design pressure of sodium hypochlorite injection system does not EPC Contractor
exceed design pressure of service water supply system.
55 55.5. Ensure adequate overpressure protection is provided in sodium hypochlorite EPC Contractor
injection system
55 55.6. Ensure design pressure of biocide injection system does not exceed design EPC Contractor
pressure of service water supply system.
55 55.7. Ensure adequate overpressure protection is provided in biocide system EPC Contractor
55 55.8. Remove LL notation on 141A-HS-8004 on PD-141A-1153-801-D. Genesis Process
55 55.9. Revise tag number of 1430-SDV-8001 for unit number 141A Genesis Process
55 55.10. Rationalise 141A-PSV-8014 set point with respect to system design pressure EPC Contractor
55 55.11. Relocate biocide injection point onto service water collection header. EPC Contractor
55 55.12. Relocate sodium hypochlorite injection point and 141A-AI-8001 to service EPC Contractor
water collection header.
Node 56: Raw Water Supply to Service Water Storage Tank
56 56.1. Update executive action on 141A-SDV-8002 failure to trip sodium hypochlorite Genesis Process
injection system in cause and effects
56 56.2. Consider trip of 141A-PU-802 on 141A-PI-8010 HH trip. Engineering Genesis Process
56 56.3. Review executive action, name and tag of 141A-P-805A/B trip in Cause and Genesis Process
Effects. (Currently trips itself) Engineering
56 56.4. Update executive action for 141A-P-805A/B trip to stop 141A-PU-802 Genesis Process
56 56.5. Review relative location of chloride analyser 141A-AI-8003 with respect to EPC Contractor
sodium hypochlorite injection points.
56 56.6. Rationalise tag number 141A-AI-8004 on P&IDs PD-141A-1153-803-D and Genesis Process
PD-141A-1153-804-D.
Node 57: Service Water Supply to Users
57 57.1. Update cause and effects such that 141A-LI-8003 HH trips 141A-P-803A/B Genesis Process
and 141A-PU-805.
57 57.2. Define safe location for discharge of 141A-PSV-8042/8044. Design of these EPC Contractor
PSVs shall consider release of fuel gas and possible overfilling of vessel. Tank may
require separate overfilling protection.
57 57.3. Update executive action in Cause and effects, such that 141A-LI-8005 LL trips Genesis Process
141A-PU-805.
57 57.4. Update executive action on 141A-ESDV-8002 failure to trip oxygen scavenger Genesis Process
injection system in cause and effects
57 57.5. Consider requirement for HH pressure trip at discharge of 141A-P-803A/B GRN Project
57 57.6. Consider adding additional executive action to 141A-LI-8005 HH to trip 141A- Genesis Process
PU-805.

Groupement Reggane
Node Action By
57 57.7. Add low alarm to 141A-FIC-8003. Genesis Process
57 57.8. Review system design of piping to domestic consumers to ensure that EPC Contractor
temperature is within safe limits for human exposure (due to solar radiation)
57 57.9. Verify that 141A-PSV-8042/8044 are sized for blocked outlet or inlet valve EPC Contractor
failure open
57 57.10. Review design pressure of 141A-TK-803, in light of gas blanketed vessel Genesis Process
design
57 57.11. Consider additional layer of protection on 141A-TK-803, with respect to Genesis Process
141A-PV-804A failing open
57 57.12. Ensure that 141A-TK-803 is designed for -25 mmWC. EPC Contractor
57 57.13. Modify 141A-AI-8003 to be oxygen analyser Genesis Process
57 57.14. Consider adding conductivity analyser with H alarm downstream of 141A-TK- Genesis Process
803
57 57.15. Review use of a storage tank for the storage of deoxygenated demin. water EPC Contractor
(consider if a vessel design will be better, or a liquid seal overflow).
57 57.16. Review requirement for dedicated oxygen scavenger injection in heating EPC Contractor
medium system
Node 58: Demin Supply to Users
58 58.1. Add low flow alarm to 141A-FI-8014 Genesis Process
58 58.2. Review use of 141A-PCV-8043 as min. flow control valve EPC Contractor
58 58.3. Review usefulness of 141A-PI-8039 HH EPC Contractor
58 58.4. Review requirement for thermal protection on demin water header and piping EPC Contractor
58 58.5. Start up procedure to include method for avoiding oxygen contamination EPC Contractor
during start up
Node 59: Firewater Supply System
59 59.1. Review the control of level in the firewater tanks141A-TK-901A/B. Consider EPC Contractor
acting only on 1430-SDV-8001 and start/stop of additional lift pumps to be controlled
manually.
59 59.2. Revise 141A-LIC-9001/9003 L alarm set point to reflect minimum inventory EPC Contractor
requirement for firewater storage. Also, review level settings for high alarms.
59 59.3. Add low pressure alarms on 141A-PIC-9011/9004/9009 Genesis Process
59 59.4. Consider independent low pressure safety function at most distant point in ring EPC Contractor
main to start firewater pump through ESD system.
59 59.5. Firewater P&IDs PD-141A-1130-901-D and PD-141A-1130-903-D to be Genesis Process
updated with revised control schematic, including reference to identified safeguards
59 59.6. Review how ring main header pressure is maintained in firewater system, e.g. EPC Contractor
use of an expansion vessel vs. continuously running jockey pump
59 59.7. Add line 2"-SW-141A-80414-1P1-B to PD-141A-1153-902-D to both tanks, Genesis Process
141A-TK-901A/B
59 59.8. Consider adding non-return valve into line 2"-SW-141A-80414-1P1-B Genesis Process

Groupement Reggane
Node Action By
59 59.9. Ensure that electric driven firewater pump is protected against electrical EPC Contractor
overload during start up
59 59.10. As this is part of a safety critical system, it should be part of an assurance EPC Contractor
and verification program during the design and operation phases.
Node 60: Foam Supply System
60 60.1. Ensure that level indicator 141A-LI-9005B is in view of filling point EPC Contractor
60 60.2. Consider deletion 141A-LX-9005 Genesis Process
60 60.3. Correct dimensions and capacity unit dimensions of 141A-TK-902. Genesis Process
60 60.4. Add low level alarm to 141A-LI-9005A. Genesis Process
60 60.5. Review pump operation and provide activation methodology EPC Contractor
60 60.6. Confirm foam pumps 141A-P-902A/B are on emergency board. Genesis Process
60 60.7. Review requirement for one pump of 141A-P-902A/B to be diesel driven. Genesis Process
60 60.8. As this is part of a safety critical system, it should be part of an assurance and EPC Contractor
verification program during the design and operation phases.
60 60.9. Provide sun shelter for 141A-TK-902 EPC Contractor
60 60.10. Review characteristics of foam concentrate at low temperature i.e. flow and EPC Contractor
degradation
60 60.11. Provide procedure for filling of 141A-TK-902 and charging of foam distribution EPC Contractor
system prior to start up.
60 60.12. Revise drawing to reflect use of positive displacement pumps for foam Genesis Process
concentrate distribution. Add dip pipe to liquid recycle line and remove 141A-RO-
9001/9002 recycle lines. Change 141A-PV-9018 to PCV and change sensing from
downstream to upstream. Show vessel level instruments to top of vessel. Also
provide note on P&ID that vessel should be kept completely filled.
Node 61: Plant and Instrument Air System
61 61.1. Consider auto-start of standby air compressor in case of duty compressor EPC Contractor
failure
61 61.2. Consider removing non return valve immediately upstream of 141A-V-702 Genesis Process
61 61.3. 141A-PI-7002 LL is shown as closing 141A-ESDV-7001 and 141A-ESDV- EPC Contractor

A001, as well as simultaneously causing ESD Level 2 shutdown. Review trip
settings for these actions. Consider shutting ESDVs prior to causing ESD level 2
shutdown. Reference note 6 on PD-141A-1153-705-D and note 3 on PD-141A-
1153-A01-D.
61 61.4. Review sizing criteria of plant air receiver, since plant air is not a critical EPC Contractor
service.
61 61.5. Confirm that air dryer package is also provided with back up power supply to EPC Contractor
ensure operation during start up
61 61.6. Ensure that air compressors and dryers can be started up in the absence of EPC Contractor
instrument air pressure

Groupement Reggane
Node Action By
Node 62: Nitrogen System
62 62.1. Review function of 141A-PI-A004 LL to close air supply to nitrogen package. EPC Contractor
Consider supplying nitrogen to critical users (e.g. compressors) should be preserved
as much as possible.
62 62.2. Review whether adequate overpressure protection of nitrogen system is EPC Contractor
provided. Consider relocation of nitrogen purge connection to flare stack only on HP
flare system.
62 62.3. Nitrogen is required prior to fuel gas and main power supply start up. EPC Contractor
Therefore, confirm that nitrogen generation system is provided with emergency
power supply.

Groupement Reggane
5 REFERENCES
1. Terms of Reference – HAZOP, PS-0000-1130-308-E, Genesis.
2. Basis of Design, PS-0000-1153-300-E, Genesis.
3. HSSE Action Tracking Register, PS-0000-1130-313-E, Genesis.
4. Guide for the Performance of HAZOP (HAZard and OPerability analysis) Studies,
SCOR G-02, Rev 0, February 2007, Repsol.
5. Guide for the Performance of PHA Studies, SCOR G-01, Rev. 0, September,
2007, Repsol.
6. Methodology for HAZOP Review (Methodologie de la revue HAZOP), Sonatrach

(SH/AMT/Division ENC).
7. 353-NO030-MG: Safety and Environmental Risk Management at Industrial

Assets.
8. Specification for Active Fire Protection, PS-1400-1130-301-E, Genesis.

Groupement Reggane
APPENDIX A: HAZOP GUIDEWORDS

PARAMETERS GUIDEWORDS
Flow No, Less, More, Reverse, Misdirected
Pressure High, Low
Temperature High, Low
Level High, Low
Composition Change
Operations / Activities Problems and Requirements
• Start-up
• Shutdown
• Sampling
• Pigging
• Maintenance & Inspection
• Tie-ins
Services Failure
Operability
Critical spares
Others

Groupement Reggane
APPENDIX B: HAZOP (UTILITY) MASTER P&IDS

HAZOP (Utilities) master P&IDs
Master_HAZOP
Utillity.pdf
HAZOP (Utilities) interface P&IDs

Groupement Reggane
APPENDIX C: HAZOP (UTILITY) STUDY WORKSHEETS

HAZOP (Utilities) Worksheets
REGGANE utility
HAZOP WORKSHEETS


PS-0000-1130-322-E Rev 01 HAZOP Report - Utility Systems

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Groupement Reggane

HAZOP Report (Utility Systems)

Reggane Nord Development Project Surface Facilities

Genesis Page 2 of 40 Date: June 13

Reggane Nord Development Project Surface Facilities

Genesis Page 3 of 40 Date: June 13

Reggane Nord Development Project Surface Facilities

HOLD Description Section

Rev. Description Section

00 Report updated to address client comments received 30/04/13. 3.1, 3.4,

Genesis Page 4 of 40 Date: June 13

Reggane Nord Development Project Surface Facilities

AZSE Azrafil South East

BdV Base de Vie

ESD Emergency Shutdown

FEED Front End Engineering Design

GRN Groupement Reggane

GTP Gas Treatment Plant

HAZOP Hazard and Operability

HSSE Health, Safety, Security and Environment

KHS Kahlouche South

P&ID Piping & Instrumentation Diagram

PFD Process Flow Diagram

PHA Process Hazard Analysis

SIMOPS Simultaneous Operations

ToR Terms of Reference

UFD Utility Flow Diagram

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Reggane Nord Development Project Surface Facilities

The HAZOP findings are summarized in the worksheets contained in Appendix C.

Genesis Page 6 of 40 Date: June 13

Reggane Nord Development Project Surface Facilities

Groupement Reggane (GRN), comprising Sonatrach, Repsol Exploración Argelia S.A.,

Figure 1-1: Location of Reggane Nord Perimeter

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Reggane Nord Development Project Surface Facilities

The review is considered to be a preliminary (FEED Stage) HAZOP, due to the

This report is structured to give an introduction to the project in Section 1, providing

1.3 Meeting Details

1.4 HAZOP Team

Genesis Page 8 of 40 Date: June 13

Reggane Nord Development Project Surface Facilities

Table 1-1: HAZOP Team Members

Angus Keddie Chairman - Utility Systems

James Stephens Study Scribe

Jose Enrique Gomis (P/T) Surface Facilities co-Manager

Chris Amies (P/T) Process Engineer – Lead

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Reggane Nord Development Project Surface Facilities

2 SCOPE & APPROACH

A summary of the scope and approach is provided below.

2.2 Study Approach

Reggane Nord Development Project Surface Facilities

 Any actions agreed by the team as necessary to provide further protection to

2.3 Study Recording & Actions

Assumptions made, and Assurances required, are summarized in Table 3-4.

Genesis Page 11 of 40 Date: June 13

Reggane Nord Development Project Surface Facilities

3.1 Master Documents

Table 3-1: Primary / Master Documents

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Reggane Nord Development Project Surface Facilities

Document Number Title Rev.

Genesis Page 13 of 40 Date: June 13