Sheet 1 of 6

HAZOP REPORT ON
R/S TANK PERMANENT INSTALLATION

FIELD: Ha’py

FACILITY : West Harbor

PROJECT: R/S Tank Permanent Installation

Prepared Checked Checked Approved

Issue Description Details
By By By By

Signature
0 Issued for Comments
Date

Signature

Date

Signature

Date

Signature

Date

Signature

Date

Signature

Date

C:\Documents and Settings\elnaa2\My Documents\Fields\Ha'py\Hazop Report.doc

 CONTENTS

1.0 INTRODUCTION
1.1 Purpose of the Hazop
1.2 Hazop Team
1.3 Hazop Methodology
2.0 SYSTEM INTENTION

3.0 HAZOP FINDINGS

APPENDICES
Appendix I Hazop parameters and guidewords
Appendix II Hazop Worksheets
Appendix III Copies of the P&IDs

Title: Issue: Sheet:

0 2 of 6
HAZOP Report on
R/S Tank Permanent Installation
Document No.:
1.0 INTRODUCTION

1.1 Purpose of the Hazop

The purpose of the Hazop was to review the Permanent Installation P&ID for the Ras
Shukeir Tank. The Hazop review also covered interfaces with the following systems:

• Slug Catcher.

• Blowdown System.

The purpose of this report is to formally record the results from the Hazop review of the
P&IDs.

The review was carried out on 14th August 2003 in West Harbor Facilities at Port Said.
Personnel from Gupco and BP attended throughout the review.

1.2 Hazop Team

The following personnel participated in the Hazop review:

Team: Ahmed El-Naggari Chairman & Secretary - BP

Steve Reber Engineering Manager – Gupco WH
Ahmed El Khawaga Production Manager – Gupco WH
Hany Gazal Production – Gupco WH
Ismail Abdel Gawad Reservoir – Gupco WH
Mohamed Reda Engineering – Gupco R/S
Khaled Abdel Hamid Facilities - BP

1.3 Hazop Methodology

The review was carried out to assess the potential hazard of mal-operation or
malfunction of individual items of equipment and the consequential effects on the plant
as a whole. The conventional practice of breaking the system up into logical sections
(nodes) and examining deviation in various operating parameters was followed. The
system was subdivided into three (3) nodes for full Hazop review as detailed in
Appendix II.

The Hazop parameters and guidewords used are given on the HAZOP Worksheets in
Appendix I. These “guidewords” suggest various operational deviation modes for
process parameters such as Flow, Temperature, Pressure, Level, Composition,
Operational Conditions, etc. Each parameter and guideword (None, More, Less, etc) is
considered to decide a possible cause of the deviation, the resultant consequences,
and to evaluate the likely consequences against the protection provided and to agree
any proposed recommendations.

Title: Issue: Sheet:

0 3 of 6
HAZOP Report on
R/S Tank Permanent Installation
Document No.:
2.0 SYSTEM INTENTION

Gas with associated condensate and water, together with injected glycol; arriving
onshore through the 30” subsea pipeline is fed to the slug catcher (0300-VQ-001).
Initially, separated hydrocarbon liquids and glycol from the slug catcher were routed to
the glycol/hydrocarbon separator (0210-VA-001). Currently, glycol from the slug catcher
cannot be routed to the glycol/hydrocarbon separator for the following reasons:

1. The recovered glycol from the sealine has a very low concentration and a high
salt content, which disturbs the downstream regeneration process.

2. The facility is now using MEG while the glycol from the sealine is DEG.

During the operations phase, it became inevitable that regular draining of DEG from the
slug catcher is required. The purpose of the new tank is to provide containment for the
drained glycol from the slug catcher until the fluids are safely drained using a vacuum
truck.

The draining operation is manual. Regular sampling is made in order to ensure that
minimum amounts of condensate flow to the new tank during the draining operation.
The new tank will be floating on the flare header pressure.

It should be noted that the original design initially included a burn pit, which was
deleted as the project progressed because of their environmental impact.

Title: Issue: Sheet:

0 4 of 6
HAZOP Report on
R/S Tank Permanent Installation
Document No.:
3.0 HAZOP FINDINGS

The detailed recommendations from each of the three (3) nodes are given on the
Hazop Worksheets (Appendix II) which constitute the formal record of the sessions.
Copies of all the P&IDs hazoped are given in Appendix III together with a piping
isometric drawing.

The following recommendations arising from the Hazop session have been identified
for action:

1. Change the pipe rating from downstream the manual valve (and including the
manual filling branch) to #900.

2. Consider changing the rupture disc by a PSV connected to the flare header.

3. Check the lowest flash temperature against the pipig spec.

4. Carry out a full UT scan on the vessel to determine its integrity.

Title: Issue: Sheet:

0 5 of 6
HAZOP Report on
R/S Tank Permanent Installation
Document No.:
 APPENDICES

Appendix I Hazop parameters and guidewords

Appendix II Hazop Worksheets

Appendix III Copies of the P&IDs

Title: Issue: Sheet:

0 6 of 6
HAZOP Report on
R/S Tank Permanent Installation
Document No.:
 HAZOP Parameter-Guideword Matrix
GUIDE WORDS

OTHER THAN
AS WELL AS

REVERSE
PART OF
MORE

LESS
NO
FLOW
P
A PRESSURE*
R T E M P E R AT U R E
A
M LEVEL
E Other
OtherOperations
Operations
T P H AS E •• Draining/venting
E Draining/venting
•• Isolation
R C O M P O S IT IO N Isolation
S •• (phased)
(phased)
O P E R AT IO N Construction
Construction
•• Commissioning/
Commissioning/
* NORMAL PARAMETERS start-up
start-up
NOT USED
•• Shut
Shutdown
down
USUAL
•• etc.
etc.
P O S S IB LE
HAZOP Worksheet West Harbor Gas Treatment Plant
Node No: 1 Meeting Date: 14 August 2003 System: Project No:
Node Details: From/To: Slug Catcher/R/S New Tank P&ID No: Rev:

FLOW PRESSURE TEMPERATURE COMPOSITION

o
( ) (bar) ( C)

DESIGN
NORMAL Manual Operation Up 95/down <0.5 Ambient Glycol/Cond.

G.WORD DEVIATION CAUSES CONSEQUENCES EVALUATION RECOMMENDATIONS BY P No:

No Flow Manual Valve closed. No consequences Line fully rated up to the last manual
valve.

Hydrate blockage Overpressure and line rupture The line downstream the last manual 1. Change the pipe rating from
valve is #150 and in case of blockage downstream the manual valve
the line will be pressurized up to the (and including the manual
slug catcher 95 bar pressure. filling branch) to #900.

Blockage due to sludge Same as hydrate blockage

Less Flow No causes identified

Reverse Flow No causes identified

More Pressure Backpressure from the flare Disc ruptures and continuous gas Rupture disc set at 0.5 barg. 2. Consider changing the rupture
header during facilities blowdown flow to atmosphere. Maximum flare header pressure disc by a PSV connected to
during blowdown is unknown. the flare header.

Less Pressure No causes identified

More Temperature No causes identified

Less Temperature Condensate flashing 3. Check the lowest flash

temperature against the pipig
spec.

No Level Normal Operation

14 August 2003 Page - 1 of 2

HAZOP Worksheet West Harbor Gas Treatment Plant
Node No: 1 Meeting Date: 14 August 2003 System: Project No:
Node Details: From/To: Slug Catcher/R/S New Tank P&ID No: Rev:

G.WORD DEVIATION CAUSES CONSEQUENCES EVALUATION RECOMMENDATIONS BY P No:

More Level Manual valve fully open. Spill over to Flare KOD Flare KOD is instrumented to
control level and S/D facility on
HH level.

More Level Manual valve fully open. Rupture disc fails Spill contained in the dike.

Other than Operation Old vessel. 4. Carry out a full UT scan on

the vessel to determine its
integrity.

14 August 2003 Page - 2 of 2

HAZOP Worksheet West Harbor Gas Treatment Plant
Node No: 2 Meeting Date: 14 August 2003 System: Project No:
Node Details: From/To: R/S New Tank/Vent KOD P&ID No: Rev:

FLOW PRESSURE TEMPERATURE COMPOSITION

o
( ) (bar) ( C)

DESIGN
NORMAL <0.5 Ambient

G.WORD DEVIATION CAUSES CONSEQUENCES EVALUATION RECOMMENDATIONS BY P No:

No Flow Manual valve closed. Disc ruptures Manual valve is carseal open.

More Flow Condensate flashing Disc ruptures

Less Flow No causes identified

Reverse Flow No causes identified

More Pressure Backpressure from the flare Refer to More Pressure under
header during facilities blowdown Node 1.

Less Pressure Manual valve closed during Vacuum Manual valve is carseal open.
draining the vessel to a vacuum
truck.

More Temperature No causes identified

Less Temperature No causes identified

14 August 2003 Page - 1 of 1

HAZOP Worksheet West Harbor Gas Treatment Plant
Node No: 3 Meeting Date: 14 August 2003 System: Project No:
Node Details: From/To: R/S New Tank/Drain P&ID No: Rev:

FLOW PRESSURE TEMPERATURE COMPOSITION

o
( ) (bar) ( C)

DESIGN
NORMAL <0.5 Ambient

G.WORD DEVIATION CAUSES CONSEQUENCES EVALUATION RECOMMENDATIONS BY P No:

No Flow Manual valves closed. Normal operation.

More Flow Manual valves fully open. Gas to atmosphere. Seal leg prevents gas breakthrough.

Less Flow No causes identified

Reverse Flow No causes identified

More Pressure No causes identified

Less Pressure Manual valve closed during Vacuum Manual valve to flare carseal open.
draining the vessel to a vacuum
truck.

More Temperature No causes identified

Less Temperature No causes identified

14 August 2003 Page - 1 of 1