HAZARD IDENTIFICATION (HAZID) STUDY

DIESEL ENGINE GENERATOR (DEG)

3RD RIVER WATER INTAKE

0 ISSUED FOR INFORMATION 28.04.2020 MSM BS MRR

MS

Rev Description Date Prepared by Reviewed by Approved by

HAZID_Report DEG Page 1 of 16

 TABLE OF CONTENT

1. ...................................................................................... 3
2. ............................................................................................... 4
3. ........................................................................................................... 6
4. ............................................................................................................... 6
5. .................................................................................. 6
6. .................................................................................................. 6
7. ................................................................................................ 8
7.1. ......................................................................................... 8
7.2. ....................................................................................... 8
7.3. ..................................................................................................... 8
8. ....................................................................................... 8
9. ........................................................................................ 9
10. .................................................................... 10
11. Appendix /2/HAZID Worksheets ...................................................................... 12

HAZID_Report DEG Page 2 of 16

1. EXECUTIVE SUMMARY

The Hazard Identification (HAZID) study workshop for Provision of Supply. Installation
and Commissioning of DieselEngine Generator (DEG) conducted on 28 April2020 which
objective to analyse potentialhazards and risks that may be present for DEG installation.

The methodology adopted for the study is based on PTG 16.71.02 Hazard Identification
(HAZID).

ßased on the guidewords referred to PTG 16.71.02. potential risks event were brainstormed
and qualitatively assessed in terms of its likelihood of occurrence and impact to
People. Environme Asset and Reputation. PETRONAS Risk Assessment Matr ix is used to
assess the RISK either Low Medium High or Very High.

The study has identified a number of potential operational hazards associated with the
operation of this DEG. Recommendations were given in light of the inadequacy of safeguards
for each issues or cause within each deviation. A totalof 22 recommendations were proposed
to mitigate all hazards and reduce risks to ALARP.

HAZID_Report DEG Page 3 of 16

2. INTROOUCTION

Third River Water IntakeπRWI) Facilities is part of Water Management System (WMS) Phase 1
Project to provide main source for water for Garra f Water Injection Program. The facility
is located alongside Third River 34 km from GTo provide electricity for its operation for TRWI
a new power generation system required until the OHTL project from GIFT is completed
and proved to be stable

For that. in March 2019 Third River Water Intake (TRWI) Power Generation Project was
completed. The facilities includes three (3) units of Oiesel Electrical Generator (DEG) with
capacity of 1.25 MW @ 550eg C each operated as N+1concept

6esides the facilities are also equipped with two (2) diesel storage tank each with 50 000
litre capacity Electrical House (E-House) to accommodate 6.6 kV and 0.4 kV switchgear
230V AC UPS Oistribution 60ard (06).

The E-House is equipped with A/C system to controlthe temperature inside the building.
Figure below shows the generallayout of TRWI Power Generation facilities.

However in 24th Oec 2019 a fire incident has damaged the OEG#2.The incident has
decrease the availability of power at Third River by half.

Without DEG#2 TRWI water export will be limited to 100kbwd.Since the WMS will require
more than 100kbwd by Nov2020 to meet Garraf WI plan the replacement of this unit is very
critical to ensure reliable power supply to TRWI

HAZID_Report DEG Page 4 of 16

 - -_ -- -_ - -"" -
r
--" '
"""
E.House

CQ " ..

DEG Layout

Dese!
Shed

The DEG#2 shall be replaced as per specification stated in the table below. same with
existing model at TRWI

The design shall be as per approved AFC.No design improvement is allowed. This is because
the cost will be partly be recovered through Group insurance. hence the replacement shall
be like to like basis.

NO. Descr
1 Generator Type
i 6.6kV.Prime Rated
2 Rating 1500kVA/1250kW
3 Manufacturer FG Wilson (Engineering) Ltd
4 ModelNo FGWRRPES6PMAP03813
5 Engine Model Perkins Engines
6 Generator Model Leroy Somer
7 Quantity (unit) 1

HAZID_Report DEG page 5 of 16

3. PURPOSE

The purpose of the HAZID is for the identification of potential hazards and threats related to
DEG. The HAZID is essentially:

a. A means of identifying and describing HSE hazards and threats as well as identni g
the major accident hazards (MAH) for the facility

b. A meeting employing a highly experienced multi-discipline team using a structured

brainstorming technique. based on a checklist of potential HSE issues. to assess the
applicability of potentialhazards

c. A rapid identification and description process only. ot a forum for trying to solve
potential proble lS

Identification and assessment of the criticalHSE hazards and MAH through the HAZID process
is intended to provide essential input in terms of managing the risk in accordance to ALARP
level.

4. SCOPE

The scope of the study was confined to identify and analyze the hazards and risk associated
with Diesel Engine Generator.

5. DOCUMENTS INVOLVED

1. The plot plan drawing of DEG

area;
2. PETRONAS HSE Risk Matrix

6. TEAM MEMBER

Details of the participant are given in table below:

No Name Function/Position
1 M Shahrin Mamat Facilitator /Engineering Safety
2 M Rozaidi Project manager
3 Adam Tan B Abdullah Head Power Management Facility
4 Baljinder Singh Head of Facility (HOF)
5 M Reza Melan Executive (Civil)
6 Ahmad Munir Bin Mansor HSE Manager
7 Dharveen AL Kumar Process Engineer
8 IsmailBin Sahat OIMWMS
9 Idham Munir B Mohd Construction Engineer
10 M Shahrul Anuar B M Nasir (GPD/PD&n Executive (Schedule Control
11 M Faiman Ramli Front End Engineer
12 Fahrurrazi Bin Mohamed Raimi ORSA
13 Omar Saufy B M Yasin MechanicalStatic Engineer

HAZID_Report DEG Page 6 of 16

 14 Ahmad Lotfi B Japar MechanicalStatic Engineer

HAZID_Report DEG Page 6 of 16

 15 Hidayat B Hamdani Construction Engineer
16 M Faris Rezza B Joharc Commissioning Engineer
17 Rarichan Joseph Electrical Engineer
18 M Yusairi B M Yusof Commissioning Engineer
19 Aizul Haimi B A Rahim Instrument Engineer
20 M Taufek B Tumali Project Engineer
21 Mohd Nazli Bin Abdul Razak Head Engineering
22 FairozIrfan B Daud Process Engineer
23 Arif B Nasaruddin Rotating Engineer
24 M Idris A Hamid Electrical Engineer
25 Nik Yussri Bin Che Ya ORSA
26 Mohd Rizal Bin Selamat FO
27 Mohd Yusof bin Awang FO
28 Mohd Suhaizi B Mohamed Kamil TTS
29 Ahmad Hazazi Bin Norazli Electrical Tech
30 Mohamad Rizallsmail CBM Engineer

HAZID_Report DEG Page7of 16

7.

7.1.

7.2.

7.3.

8.

1 To check DEG piping and cable connection integrity post tremor PCIHBV - PMF
. (incorporate in OP)
2. To ensure heat stress management implement during work EPCC
execution during summer

3. To include in SOP for DEG parameter reading based on PCIHBV - PMF

identified frequency

4. To prepare maintenance plan based on running hours PCIHBV - PMF

5. DEG protection to be verified during pre-commissioning based on PCIHBV -
Cause and Effect Matrix Project/PMF
6. To incorporate as part WSM 3rd river ERP IAP for Diesel on fire PCIHBV - HSE ER

7. Develop DEG Operating Procedure including isolation process in EPCC

the event of emergency for Operator reference
8. Install fuel solenoid valve for fuel cut-in supply to engine (in between EPCC
fuel day tank and transfer pump) for fire case
9. To revise diesel supply drawing to include solenoid valve between PCIHBV - Project
diesel storage tank and diesel day tank (currently already installed at
site)
HAZID_Report Page 8 of
DEG
7.
10. To install air shut off valve for fire case at DEG enclosure EPCC

HAZID_Report Page 9 of
DEG
 11. Conduct briefing on WMS 3rd river ERP to contractor prior PCIHBV - FO
work execution
12. Develop Fire Safety Design Philosophy as part of detailed design EPCC
to incorporate the minimum fire safety requirement during design
13. To conduct facilities readiness verification prior to DEG start-up PCIHBV -
Project/PMF
14. To revise DEG datasheet to reflect the latest design (only level PCIHBV - Project
gauge for diesel storage tank installed)
15. To revise the Diesel storage tank P&ID to incorporate vendor data PCIHBV - Project

16. To prepare/standby drip pan for any lube oil potential spillage during EPCC
pre- commissioning and commissioning
17. To prepare HSE bridging document between PCIHBV and EPCC
Contractor for managing HSE and emergency (PTW, ERP, etc.)
18. To establish demarcation area between construction and existing EPCC
plant operations
19. To prepare DEG Method of Statement (MOS) for EPCC
installation/replacement work (including shelter removal) and approve by
PCIHBV representative
20. Develop commissioning procedure prior to commission activities EPCC

21. Develop and review JHA and Lifting Plan for demolition works EPCC

22. Full supervision by contractor and PCIHBV personnel during EPCC & PCIHBV -
work execution Project

9.

HAZID_Report Page 10 of
DEG
10. Appendix 111 HAZID Guidewords

N Guide words
1 Earthquakes
2 Climate extremes
3 Lightning
4 Erosion
5 Subsidences
6 Continuous Plant Effluent Dischargesto Air
7 Continuous Plant Effluent Dischargesto Water
8 Emergency/upset Discharges toair/water/soil
9 Contaminated Ground
10 Waste Disposal Options
11 Facility Impact
12 Continuous Plant Effluent Discharges to Soil
13 rTiming of Construction
14 Security Hazards
15 ITerrorist Activity
16 Geographical Infrastructure
17 Adjacent Land Use
18 Proximity to Transport Corridors
19 Environmental lssues
20 Normal Com 1unications
21 Communicationsduring e 1ergency
22 Supply Support
23 Manning/operations Philosophy
24 OperationsConcept
25 Maintenance Philosophy
26 Control Philosophy
27 Manning Levels
28 Emergency Response
29 Concurrent Operations
30 Start-up/Shutdown
31 Process Hazards
32 Equipment &Instrument Malfunction
33 nalytical or Sampling Errors
34 Emergency Response Plan
35 lTie-in to Live Plant
36 Electricity
37 Health Hazards
38 Contingency
39 Recovery Measures
40 Competency
HAZID_Report Page 11 of
DEG
 Guide words

Fire and Explosion Hazard

HAZID_Report DEG Page 11 of 16

 HAZID Worksheet DEG

11. Appendix /2/HAZID Worksheets

Project: 1. 3rd river WMS DEG

Sub-Category: 1. Natural and environmental hazards

People Environment Asset Reputation

Guideword Causes Consequence Major Risk Safeguard Recommendation Responsibility
L S R L S R L S R L S R

Earthquakes Tremor 1. Dislodge of cable termination, C 3 C3 C 3 C3 C 3 C3 1. No 1. The weight of foundation designed with 3 times from the weight of DEG 1. To check DEG piping and cable connection integrity post PCIHBV - PMF
potential spark and fire, potential tremor (incorporate in OP)
personnel injury and property
damage

2. High vibration to Generator resulting 2. Anti-vibration pad designed to equipment

in Generator damage

Climate extremes Hot weather during summer 1. Personnel heat stress resulting in C 2 C2 C 3 C3 1. No 1. Heat stress management procedure (implement PETRONAS system) 2. To ensure heat stress management implement during work EPCC
injury execution during summer

2. Engine and winding overheated 2. STOP work on Hot Summer based on Heat Index 3. To include in SOP for DEG parameter reading based on PCIHBV - PMF
resulting fire and property damage identified frequency

3. Rest hours management during hot weather 4. To prepare maintenance plan based on running hours PCIHBV - PMF

4. DEG designed with shelter 5. DEG protection to be verified during pre-commissioning based PCIHBV - Project/PMF
on Cause and Effect Matrix
5. Winding overheating protection at DEG will trip DEG

Flooding 1. Electrocution resulting in personnel B 4 B4 1. No 1. Earthing and bonding

injury

2. Flooding resulting in equipment 2. Designed raise platform level to cater for flood
downtime

High humidity 1. Potential short circuit resulted in fire; C 3 C3 C 3 C3 C 3 C3 1. No 1. DEG Panel designed with IP rated
leading to personnel injury

2. Property damage 2. Anti-condensation designed for DEG panel

Lightning Lightning 1. Personnel injury B 4 B4 C 3 C3 1. No 1. Lighting protection is included as part of design

2. Property damage 2. 3rd river WMS facility installed with lightning arrestor at highest point
which cover the DEG area

Erosion No concerns identified

Subsidences No concerns identified

Sub-Category: 2. Environmental damages

People Environment Asset Reputation

Guideword Causes Consequence Major Risk Safeguard Recommendation Responsibility
L S R L S R L S R L S R

Continuous Plant Effluent Exhaust smoke discharge from DEG 1. Environmental pollution (black C 2 C2 1. No 1. DEG designed with acceptable black smoke
Discharges to Air smoke)
2. Maintenance plan as per schedule

Continuous Plant Effluent No concerns identified

Discharges to Water

Emergency/upset No concerns identified

Discharges to air/water/soil

Contaminated Ground No concerns identified

Waste Disposal Options Waste from equipment change (filter) 1. Soil contamination C 1 C1 1. No 1. Waste disposal plan

Facility Impact No concerns identified

Continuous Plant Effluent No concerns identified

Discharges to Soil

Timing of Construction No concerns identified

12
 HAZID Worksheet DEG

Sub-Category: 3. Created (Man-made) Hazards

People Environment Asset Reputation

Guideword Causes Consequence Major Risk Safeguard Recommendation Responsibility
L S R L S R L S R L S R

Security Hazards No concerns identified (Facility monitored by security

guard)

Terrorist Activity No concerns identified (Facility monitored by security

guard)

Sub-Category: 4. Effect of the Facility on the Surroundings

People Environment Asset Reputation

Guideword Causes Consequence Major Risk Safeguard Recommendation Responsibility
L S R L S R L S R L S R

Geographical Infrastructure No concerns identified

Adjacent Land Use No concerns identified

Proximity to Transport No concerns identified

Corridors

Environmental Issues No concerns identified

Sub-Category: 5. Infrastructure

People Environment Asset Reputation

Guideword Causes Consequence Major Risk Safeguard Recommendation Responsibility
L S R L S R L S R L S R

Normal Communications No concerns identified

Communications during Improper access to site location during emergency 1. Delay in emergency response, C 3 C3 C 3 C3 1. No 1. 2 access gate for access 6. To incorporate as part WSM 3rd river ERP IAP for Diesel on PCIHBV - HSE ER
emergency potential for personnel injury, fire
property damage 2. EPCC contractor ERP requirement mentioned in the ITB to be followed

Supply Support No concerns identified

Sub-Category: 6. Control Methods

People Environment Asset Reputation

Guideword Causes Consequence Major Risk Safeguard Recommendation Responsibility
L S R L S R L S R L S R

Manning/operations No concerns identified (manned with HV technician)

Philosophy

Sub-Category: 7. Philosophy

People Environment Asset Reputation

Guideword Causes Consequence Major Risk Safeguard Recommendation Responsibility
L S R L S R L S R L S R

Operations Concept No concerns identified

Maintenance Philosophy No concerns identified

Control Philosophy No concerns identified

Manning Levels No concerns identified

Emergency Response
System isolation for DEG and diesel storage tank 1. Delay in emergency response, C 3 C3 C 3 C3 C 3 C3 1. No 1. Solenoid valve available to shut in fuel supply from diesel storage tank 7. Develop DEG Operating Procedure including isolation process EPCC
does not available and understanding by operators potential emergency escalation to diesel day tank in the event of emergency for Operator reference
leading to personnel injury,
8. Install fuel solenoid valve for fuel cut-in supply to engine (in EPCC
between fuel day tank and transfer pump) for fire case

13
 HAZID Worksheet DEG

Sub-Category: 7. Philosophy

People Environment Asset Reputation

Guideword Causes Consequence Major Risk Safeguard Recommendation Responsibility
L S R L S R L S R L S R
environment damage and property 9. To revise diesel supply drawing to include solenoid valve PCIHBV - Project
damage between diesel storage tank and diesel day tank (currently
already installed at site)

10. To install air shut off valve for fire case at DEG enclosure EPCC

Contractor unaware of PCIHBV ERP 11. Conduct briefing on WMS 3rd river ERP to contractor prior PCIHBV - FO
work execution

Concurrent Operations No concerns identified

Start-up/Shutdown Star-up & shutdown procedure not being develop 1. Incorrect operating resulted in C 3 C3 C 3 C3 C 3 C3 1. Vendor operating manual 7. Develop DEG Operating Procedure including isolation process EPCC
and understand by operators personnel injury, environment in the event of emergency for Operator reference
damage and property damage

Sub-Category: 8. Fire and Explosion Hazard

People Environment Asset Reputation

Guideword Causes Consequence Major Risk Safeguard Recommendation Responsibility
L S R L S R L S R L S R

Stored Flammable Diesel day tank and storage tank at site 1. Personnel injury C 3 C3 C 3 C3 C 3 C3 C 1 C1 1. No 1. Spacing layout between diesel storage tank and potential source of
ignition as part of design

2. Property damage 2. Drainage channel provided for draining

3. PTW system

4. Job Hazard Analysis

Source of ignition Generator nearby storage tank 1. Fire resulted in personnel injury B 4 B4 C 3 C3 C 3 C3 B 1 B1 1. No 1. Spacing layout between diesel storage tank and potential source of
ignition as part of design
2. Property damage

Equipment layout DEG installation too near with diesel storage tank 1. Fire resulted in personnel injury B 4 B4 C 3 C3 C 3 C3 B 1 B1 1. No 1. Spacing layout between diesel storage tank and potential source of
ignition as part of design
2. Property damage

Fire Protection and Response Fire detection and protection system not considered 1. Personnel injury C 3 C3 C 3 C3 C 3 C3 C 1 C1 1. No 1. DEG enclosure designed with FM200 suppression system 12. Develop Fire Safety Design Philosophy as part of detailed EPCC
in design design to incorporate the minimum fire safety requirement
during design

2. Property damage 2. DEG designed with fire detection system 13. To conduct facilities readiness verification prior to DEG start- PCIHBV - Project/PMF
up
3. DEG enclosure equipped with motorised louver/damper, to be closed
when confirmed fire detected

4. Portable fire extinguisher provided per design

Sub-Category: 9. Process Hazards

People Environment Asset Reputation

Guideword Causes Consequence Major Risk Safeguard Recommendation Responsibility
L S R L S R L S R L S R

Hazardous Inventory No concerns identified

Release of Inventory No concerns identified

High/ Low Pressure No concerns identified (Common diesel supply

design)

High/Low level High level diesel inside storage tank 1. Overflow of diesel supply, resulting C 3 C3 1. No 1. Manual diesel refill by operator 14. To revise DEG datasheet to reflect the latest design (only PCIHBV - Project
in LOPC level gauge for diesel storage tank installed)
2. Level gauge at diesel storage tank

3. High alarm at Diesel Day Tank

Low level diesel inside storage tank 1. Overflow of diesel supply, resulting C 3 C3 1. No 1. Level gauge at diesel storage tank 15. To revise the Diesel storage tank P&ID to incorporate vendor PCIHBV - Project
in LOPC data
2. Low alarm at Diesel Day Tank

14
 HAZID Worksheet DEG

Sub-Category: 9. Process Hazards

People Environment Asset Reputation

Guideword Causes Consequence Major Risk Safeguard Recommendation Responsibility
L S R L S R L S R L S R

High/ Low Flow No concerns identified (Common diesel supply

design)

Material Problems Incompatibility of piping materials 1. Corrosion resulting in loss of C 3 C3 1. No 1. Piping designed to specification
containment

Leak Leak from diesel tank 1. Loss of containment resulting in spill C 3 C3 1. No 1. Bund wall to be designed to cater 110% capacity of 1 storage tank 16. To prepare/standby drip pan for any lube oil potential spillage EPCC
during pre-commissioning and commissioning

Equipment & Instrument No concerns identified

Malfunction

Analytical or Sampling Errors No concerns identified

Sub-Category: 10. Health Hazards

People Environment Asset Reputation

Guideword Causes Consequence Major Risk Safeguard Recommendation Responsibility
L S R L S R L S R L S R

Disease Hazards No concerns identified

Asphyxiation hazards No concerns identified

Carcinogenic No concerns identified

Toxic No concerns identified

Physical No concerns identified

Mental No concerns identified

Working Hazards No concerns identified

Transport/Passage No concerns identified

Sub-Category: 11. Contingency

People Environment Asset Reputation

Guideword Causes Consequence Major Risk Safeguard Recommendation Responsibility
L S R L S R L S R L S R

Geographical Infrastructure No concerns identified

Sub-Category: 12. Emergency Planning

People Environment Asset Reputation

Guideword Causes Consequence Major Risk Safeguard Recommendation Responsibility
L S R L S R L S R L S R

Recovery Measures Non-available medical support/emergency response, 1. Delay in emergency response C 3 C3 1. No 1. Site WMS ERT 17. To prepare HSE bridging document between PCIHBV and EPCC
security for contractor personnel resulted in personnel injury Contractor for managing HSE and emergency (PTW, ERP,
2. Support GFRS at GIFT etc.)

3. Security guard at site

Sub-Category: 13. Competency

People Environment Asset Reputation

Guideword Causes Consequence Major Risk Safeguard Recommendation Responsibility
L S R L S R L S R L S R

Level of Training, Training Incompetent contractor 1. Personnel injury C 3 C3 1. No 1. Requirement of experience personnel specified in contract
Requirements, Level of
Technology Incompetent operator 1. Personnel injury C 3 C3 1. No 1. Competent person (HV technician) operate the DEG as per current
practice

15
 HAZID Worksheet DEG

Project: 1. 3rd river WMS DEG

Sub-Category: 14. Maintenance Hazard

People Environment Asset Reputation

Guideword Causes Consequence Major Risk Safeguard Recommendation Responsibility
L S R L S R L S R L S R

Maintenance activities Equipment spares list not available 1. Interruption in maintenance C 3 C3 1. No 1. Critical spare list provided as per contract (SPIR)
activities, potential operations with
malfunction DEG resulted in
property damage

Equipment preventive maintenance plan not 1. Interruption in maintenance C 3 C3 C 3 C3 1. No 1. Vendor operating manual
developed activities, potential operations with
malfunction DEG resulted in 2. Developed DEG Maintenance Plan based on OEM recommendation
personnel injury and property (MPlan)
damage

Sub-Category: 15. Construction Hazard

People Environment Asset Reputation

Guideword Causes Consequence Major Risk Safeguard Recommendation Responsibility
L S R L S R L S R L S R

Equipment installation DEG #2 installation between existing DEG 1. Personnel injury C 3 C3 C 3 C3 1. No 1. PCIHBV PTW system used for construction activities 18. To establish demarcation area between construction and EPCC
existing plant operations

2. Property damage 2. Site supervision by PCIHBV staff 19. To prepare DEG Method of Statement (MOS) for EPCC
installation/replacement work (including shelter removal) and
3. Competent person conduct commissioning approve by PCIHBV representative

4. PCIHBV HV and discipline staff involvement in commissioning

5. JHA for the activities

On Land Personal Transfer No concerns identified

Dynamic Situation Hazard No concerns identified

Other Flammable Material No concerns identified

Pressure No concerns identified

Associated with Difference in No concerns identified

Height

Electricity High Voltage DEG 1. Personnel injury C 3 C3 C 3 C3 1. No 1. Competent person conduct commissioning 20. Develop commissioning procedure prior to commission EPCC
activities

2. Property damage 2. Competent person (HV technician) operate the DEG 7. Develop DEG Operating Procedure including isolation process EPCC
in the event of emergency for Operator reference

Asphyxiates No concerns identified

Demolition Removal of damaged DEG#2 (e.g. heavy lifting, 1. Personnel injury C 3 C3 C 3 C3 1. No 1. PTW system including isolation (LOTO) 19. To prepare DEG Method of Statement (MOS) for EPCC
congested area, etc.) installation/replacement work (including shelter removal) and
approve by PCIHBV representative

2. Property damage 21. Develop and review JHA and Lifting Plan for demolition works EPCC

22. Full supervision by contractor and PCIHBV personnel during EPCC & PCIHBV - Project
work execution

Breakdown communication during demolition work 1. Personnel injury C 3 C3 1. No 1. PTW system 22. Full supervision by contractor and PCIHBV personnel during EPCC & PCIHBV - Project
between contractor and PCIHBV WMS operator work execution
2. Toolbox talk involvement of PCIHBV staff

16