IJSTE - International Journal of Science Technology & Engineering | Volume 1 | Issue 11 | May 2015

ISSN (online): 2349-784X

Risk Assessment (HAZOP Study) Method for

Decanting LPG From Dispatching Unit to Road
Tanker
Sandeep Yadav
Assistant Professor
Department of Fire Technology and Safety Engineering
IES-IPS Academy, Indore (M.P), India

Abstract
The aim of this (HAZOP) hazard operability study risk assessment method is to highlighting the safety aspect while decanting
LPG from dispatching unit to road tanker. The LPG gas is highly flammable and have potential hazard of explosion, (BLEVE)
boiling liquid expanding vapor explosion. this explosion may cause to fatality and heavy property damage so that we have
applied this risk assessment (HAZOP) method to find out all relevant potential risk to it and also given required control measure
to reduce or eliminate risk of fire and explosion in order to make the decanting process of LPG safe.
Keywords: BLEVE, HAZOP, LPG, Risk Assessment
________________________________________________________________________________________________________

I. INTRODUCTION
The use of LPG gas prevail in industry now a days it replaced fuel such as coal, wood etc. it is used in different-different industry
for different-different purpose such as in CNC gas cutting machine, Furness, paint shop, canteen and many more. To make this
gas available in the plant transportation and decanting process is required which is having risk of leakage, there is one more risk
of developing electrical charge in tanker which can be cause to source of ignition and because of this fire can take place. This fire
can turn into explosion or (BLEVE) boiling liquid expanding vapor explosion. This would have different-different effect
according to quantity of LPG in tanker. In some cases it turns in major accident and cause heavy property damage, loss of lives,
harm to environment. for avoiding these accident it is important to seek all risk related to operation so that suitable control
measure can be suggested. In order of this (HAZOP) hazard operability study (risk assessment method) plays significant role.
The purpose of applying (HAZOP) method to identify potential hazard and risk associated with decanting process of LPG in
order to keep process safe. For this purpose I have given control measures for avoiding accident.

II. METHOD
The hazard operability method is careful examination which is performed by multi-disciplinary team to collect necessary
information related to process so as to find out all potential hazard involve in the process.
HAZOP is quantitative risk assessment method which can be performed to make sure that existing design and operating
process is safe. it is also performed to improve safety of existing facility most importantly it is conducted to find out deviation in
typical operation and operational failure.
This method involves several steps which are:-
1) Select segment/division of plant on which HAZOP is performed.
2) Identify normal operating process of segment.
3) Find out the deviation by setting or apply appropriate guide word.
4) Identify all possible causes of failure of system.
5) Identify all possible consequence of deviation.
6) Identify what action taken and action required to avoid accident.

A. Some Guide Words are:-

Guide word Meaning Comment

The complete exclusion of these
NO or NOT No part of intent or change takes place.
objectives.
This shows increase in quantity such as mass or in property such as
Quantity increase.
MORE temperature.

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 Risk Assessment (HAZOP Study) Method for Decanting LPG From Dispatching Unit to Road Tanker
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This shows decrease in quantity such as mass or in property such as

LESS Quantity decrease.
temperature.
AS WELL AS Enhance qualitative All objectives are achieved with other activities.

PART OF Decline qualitative. Some objectives are achieved.

RESERVE Logical opposite of objective. Reveres flow of intent objective.

OTHER
Complete replacement No part of original intention is attaining. Something unusual happens.
THAN
These guide word helps to simplify HAZOP method. Person who is applying this method must be familiar with these guide
word.

III. TYPICAL PROCESS DESCRIPTION

In this paper I have described hazardous process involve in decanting highly flammable LPG gas and how it is done safely.
Detail process description:-
1) Transfer of LPG gas from dispatcher to road tanker.
2) Transportation of LPG from the dispatcher to receiving plant.
3) Transfer of LPG from road tanker to storage area.

Fig. 1: Block dia. of Decanting process of LPG safely

HAZOP WORKSHEET
Guide
Deviation Possible cause Consequence Action taken Action required
word
1. Tank should be weighted before
1.Possibility of vacuum
decanting.
and subsequent entry of
NO No material Error in dispatch Nothing special 2. While decanting tank liquid
air
and vapor line should be
2.Material loss
connected.

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 Risk Assessment (HAZOP Study) Method for Decanting LPG From Dispatching Unit to Road Tanker
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Error in dispatch 1. If material is less call

Less
LESS Leakage due to Nothing special Nothing special supervisor.
material
malpractice 2. Check material if it is less.

1. Possible overfilling of 1. Alarm in the storage tank

1. Tank of higher capacity the tank. which show level of material.
2. Ensure that tanker is at least
More
MORE 2.Overfilling of material 2. Possible overfilling of Nothing special 10-15% empty.
material
in road tanker the tank. 3. Decanting operation should be
3.Over pressure of rode performed in the presence of
tanker competent person.
1. Slope should be directed
towards an evaporation area
RCC platform away from pump.
AS WELL Leakage of
Union joint leakage Possibility of fire slope toward pump 2. Wooden chocks should applied
AS LPG
house on each tire.
3. Emergency response plane
should be displayed.
1.Ensure that transporter
emergency card is available in
the crew cabin
OTHER Inspection Check fire 2. Ensure that the spark arrester
Negligence of transporter Possibility of fire
THAN of tanker extinguisher is working properly.
3. Ensure that play card is
displayed on tank.

HAZOP WORKSHEET
Guide
Deviation Possible cause Consequence Action taken Action required
word
1. Hose pipe block. 1. Line should be provided with
1. Pump cavitations and
2. Shut off valve closed. sight glass.
NO No Flow vibration. Nothing special
3. Pump problem. 2. Hose pipe end should be kept
2. Possibility of air entry.
plugged with stopper.
1. The strainer should be cleaned
1. Strainer chocked.
periodically.
LESS Less Flow 2.Partial blockage Process disturbance Nothing special
2. Check list ensure that all valves
in the line are open.
1. Conductivity of the hose should
be checked up periodically.

1. Excessive differential 2. Earth resistance of line should

pressure 1. Excessive static be checked up.
Flanges provided
MORE More Flow electricity charge may
with jumper
2.Pump surging ignite the leak gas 3. Ensure that jumpers are
provided in all the flanges.

4. Proper bonding of union joints

should be ensured.
Due to thermal expansion Pressurization and
More 1. pressure indicators should be
MORE of liquid trapped between subsequence bursting of
pressure provided.
any two valve the line
1.Two isolation valve should be
provided in each cold flare line.
2. The cold flare lines should be
protected against breaking in
stormy weather.
AS WELL Leakage from flare, Spillage and Possibility Single valve
Leakage 3. Union joints should be
AS Union joints, hose of fire isolation provided
replaced by flange joints.
4. Hose should be tested after
every three months to ensure that
it bears a pressure of
37.5Kg/cm2.

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 Risk Assessment (HAZOP Study) Method for Decanting LPG From Dispatching Unit to Road Tanker
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IV. RECOMMENDATION
1) Tank should not fill more than 90 %.
2) LPG road tanker must have spark arrester.
3) While decanting gas, tanker should be properly have earthing system.
4) Driver must have special license for carrying such hazardous gas.
5) Emergency plan should always be available while decanting LPG.
6) The pressure of storage tank and road tanker should be equal before begin decanting process.
7) Decanting process must be performed under competent person.
8) Ensure that source of ignition have been isolated.
9) Standard operating procedure should be displayed.
10) Hose should be checked periodically.
11) Wooden blocks or chocks should applied to avoid roll over.
12) Ensure that transporter emergency card is available in crew cabin.
13) Decanting process should be avoided in night time.
14) Each valve used in decanting process should be checked before begin decanting process.

V. CONCLUSION
In this paper I have represent hazard operability study (HAZOP) method to identify unexpected deviation while decanting LPG
and take action required reducing risk. The hazard operability study is basically performed at design stage. it is qualitative
analysis and helps to develop tree diagram for fault tree analysis which can further help to do quantitative analysis such as fire
and explosion modeling.
This method helps to identify potential hazard related any system or process and contributes to recommend control measures.

REFERENCES
[1] The factory act 1948,M.P./C/G Rules 1962 ,
[2] Fundamentals of Industrial Safety & Health- K.U. Mistry.
[3] James E Rauhten, Nathan cruth field, workplace Hazard Analysis and Review of Associated Risk Job.
[4] Safety at work - John Ridle.
[5] Loss prevention in process industries Frank T.Lees Butterworth.

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