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

NO or NOT

The complete exclusion of these

objectives.

No part of intent or change takes place.

Quantity increase.

This shows increase in quantity such as mass or in property such as

temperature.

MORE

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Risk Assessment (HAZOP Study) Method for Decanting LPG From Dispatching Unit to Road Tanker
(IJSTE/ Volume 1 / Issue 11 / 031)

LESS

Quantity decrease.

This shows decrease in quantity such as mass or in property such as

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
THAN

Complete replacement

No part of original intention is attaining. Something unusual happens.

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
word

NO

Deviation

No material

Possible cause

Consequence

Error in dispatch

1.Possibility of vacuum
and subsequent entry of
air
2.Material loss

Action taken

Action required

Nothing special

1. Tank should be weighted before

decanting.
2. While decanting tank liquid
and vapor line should be
connected.

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Risk Assessment (HAZOP Study) Method for Decanting LPG From Dispatching Unit to Road Tanker
(IJSTE/ Volume 1 / Issue 11 / 031)

LESS

Less
material

Error in dispatch
Leakage due to
malpractice
1. Tank of higher capacity

MORE

More
material

2.Overfilling of material
in road tanker

Nothing special

Nothing special

1. If material is less call

supervisor.
2. Check material if it is less.

Nothing special

1. Alarm in the storage tank

which show level of material.
2. Ensure that tanker is at least
10-15% empty.
3. Decanting operation should be
performed in the presence of
competent person.

1. Possible overfilling of
the tank.
2. Possible overfilling of
the tank.
3.Over pressure of rode
tanker

AS WELL
AS

Leakage of
LPG

Union joint leakage

Possibility of fire

RCC platform
slope toward pump
house

OTHER
THAN

Inspection
of tanker

Negligence of transporter

Possibility of fire

Check fire
extinguisher

1. Slope should be directed

towards an evaporation area
away from pump.
2. Wooden chocks should applied
on each tire.
3. Emergency response plane
should be displayed.
1.Ensure that transporter
emergency card is available in
the crew cabin
2. Ensure that the spark arrester
is working properly.
3. Ensure that play card is
displayed on tank.

HAZOP WORKSHEET
Guide
word

NO

LESS

Deviation

No Flow

Less Flow

Possible cause
1. Hose pipe block.
2. Shut off valve closed.
3. Pump problem.

1. Strainer chocked.
2.Partial blockage

1. Excessive differential
pressure
MORE

More Flow
2.Pump surging

Consequence
1. Pump cavitations and
vibration.
2. Possibility of air entry.

Process disturbance

1. Excessive static
electricity charge may
ignite the leak gas

Action taken

Action required

Nothing special

1. Line should be provided with

sight glass.
2. Hose pipe end should be kept
plugged with stopper.

Nothing special

Flanges provided
with jumper

1. The strainer should be cleaned

periodically.
2. Check list ensure that all valves
in the line are open.
1. Conductivity of the hose should
be checked up periodically.
2. Earth resistance of line should
be checked up.
3. Ensure that jumpers are
provided in all the flanges.
4. Proper bonding of union joints
should be ensured.

MORE

AS WELL
AS

More
pressure

Leakage

Due to thermal expansion

of liquid trapped between
any two valve

Leakage from flare,

Union joints, hose

Pressurization and
subsequence bursting of
the line

1. pressure indicators should be

provided.

Spillage and Possibility

of fire

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.
3. Union joints should be
replaced by flange joints.
4. Hose should be tested after
every three months to ensure that
it bears a pressure of
37.5Kg/cm2.

Single valve
isolation provided

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Risk Assessment (HAZOP Study) Method for Decanting LPG From Dispatching Unit to Road Tanker
(IJSTE/ Volume 1 / Issue 11 / 031)

IV. RECOMMENDATION
1)
2)
3)
4)
5)
6)
7)
8)
9)
10)
11)
12)
13)
14)

Tank should not fill more than 90 %.

LPG road tanker must have spark arrester.
While decanting gas, tanker should be properly have earthing system.
Driver must have special license for carrying such hazardous gas.
Emergency plan should always be available while decanting LPG.
The pressure of storage tank and road tanker should be equal before begin decanting process.
Decanting process must be performed under competent person.
Ensure that source of ignition have been isolated.
Standard operating procedure should be displayed.
Hose should be checked periodically.
Wooden blocks or chocks should applied to avoid roll over.
Ensure that transporter emergency card is available in crew cabin.
Decanting process should be avoided in night time.
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]
[2]
[3]
[4]
[5]

The factory act 1948,M.P./C/G Rules 1962 ,

Fundamentals of Industrial Safety & Health- K.U. Mistry.
James E Rauhten, Nathan cruth field, workplace Hazard Analysis and Review of Associated Risk Job.
Safety at work - John Ridle.
Loss prevention in process industries Frank T.Lees Butterworth.

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