Hazard Identification & Risk Analysis Report...CEIL/9530/HIRA/GAIL GAS Firozabad/SI/26 Page - 1 - of 65 Hazard Identification & Risk Analysis Report Of GAIL Gas Limited, Firozabad

CEIL/9530/HIRA/GAIL GAS Firozabad/SI/26 Page - 1 - of 65

Hazard Identification & Risk Analysis Report

Of

GAIL Gas Limited, Firozabad

By

Certification Engineers International Limited

HIRA Study dates: 16.09.2015-17.9.2015

HIRA GAIL Gas Limited, CGD Network, Firozabad

CEIL/9530/HIRA/GAIL GAS Firozabad/SI /26 Page - 2 - of 65

TABLE OF CONTENTS

Sl. No. Topic Page

No. 1 Abbreviation 03 2 Executive Summary 05 3 About CEIL 07 4 Scope 07 5 HIRA Concept & Methodology 08 6 Facility Description 12 7 Documents referred 14 8 Closing Meeting

a) Highlights b) Points to be attended

15

9 Management plan for intolerable risk 16

10 Conclusion 20 11 Confidentiality 20 12 Activity List of Firozabad 21 13 Annexures :

Annexure 1: HIRA Work Sheets Annexure 2: Attendance Sheet Opening /Closing Meeting Annexure 3: List of Industrial and Commercial Customers

22



1. ABBREVIATIONS :

ESD: Emergency Shut Down CIPL: Close Interval potential Logging CGD: City Gas Distribution CGS: City Gate Station CP: Cathodic Protection CNG: Compressed Natural Gas DCP: Dry Chemical Powder DCS: Distributed control systems DCVG: Direct Current Voltage Gradient DDMA: District Disaster Management Authority DGFASLI: Directorate General, Factory Advice Service and Labor Institutes DRS: District Regulating Skid EMS: Energy Management System ECU: Emergency Control Unit ERDMP: Emergency response to disaster management planning ESA: External Safety Audit FRS: Field Regulating Skid GPS: Global Positioning System HAZCHEM: Hazardous Chemicals HAZOP: Hazardous Analysis and Operability/ Hazardous Operations HDD: Horizontal Direct Drilling HIRA: Hazards Identification and Risk Analysis IR: Infra Red LPG: Liquefied Petroleum Gas MDPE Medium Density Poly Ethylene MoE&F: Ministry of Environment and Forests MoP&NG: Ministry of Petroleum and Natural Gas MoST&H: Ministry of Surface Transport and Highways MRS: Metering Regulating Skid MSDS: Material safety data sheet MSIHC: Manufacture, Storage and Import of Hazardous Chemical MV Act: Motor Vehicle Act NDMA: National Disaster Management Authority NFPA: National Fire Protection Association NG: Natural Gas OISD: Oil Industry Safety Directorate OMC: Oil Manufacturing Companies



PCV: Pressure Control Valve PESO: Petroleum and Explosive Safety Organization PNGRB: Petroleum and Natural Gas Regulatory Board P/L : Pipeline PNG: Piped Natural Gas POL: Petroleum, Oil and Liquid PRI: Pressure Regulating Installation PSP: Pipe to Soil Potential PSV: Pressure safety Valve QRA: Quantitative Risk Assessment SIL: Safety Integrity Level SCCDA Stress Corrosion Cracking Direct Assessment SDRF: State Disaster Response Force SV: Sectionalizing Valve/ Strategic Valve TLP: Test Lead Point TPIA: Third Party Inspection Agency TR: Transformer Rectifier TREM: Transport Emergency Management TT: Tank Truck VTS: Vehicle Tracking System



2. EXECUTIVE SUMMARY :

M/s GAIL Gas Limited has awarded FOI No. GGL/70/13-14/5300000455 dated 27.11.14 for carrying out External Safety Audit and HIRA Study of CGD Networks at Dewas, Kota, Meerut, Sonipat, Agra and Firozabad under GAIL Gas Ltd. This HIRA Report includes entire steel and MDPE Pipeline network and associated facilities CGS, DRS, MRS, Mother and Daughter stations (CNG Stations) etc. under GAIL Gas, Firozabad region.

The Firozabad city gas distribution supply natural gas to various industries mainly glass industries in and around Firozabad town. The network has various sizes of pipes i.e.1”, 1.5”, 2”,3”,4”, 8” & 10” spread over the town of Firozabad. Length of the network is about 80.1KM and it passes through and nearby highways, service roads, by lane small congested streets etc. It is protected through cathodic protection through impressed current cathodic protection system.

CEIL Team comprising of two specialists visited the site during 16-17 September, 2015 at Firozabad, UP to examine facilities and hold discussions in order to identify, assess and analyze various hazards pertaining to CGD Network.

Standard methodology of Opening Meeting, HIRA Review session and Closing Meeting was adhered to. GAIL Gas Team consisting of members from Projects, O&M, HSE and E&I took part in the HIRA Study along with CEIL Team. The entire CGD operations were discussed in detail and key O&M activities were listed. Further these identified activities were assessed from hazard point of view using a dedicated Hazard Identification Sheet covering the hazard, severity, probability and overall risk. Mitigating measures were discussed amongst the members present and summarized. Points which need to be attended are listed as under:

Highlights:

1. Track record of 33192 Man-hours accident free record (16.11.2011 to 31.08.2015). 2. Standard display of HSE Policy, Emergency Telephone numbers at strategic locations. 3. PPE and Fire Fighting equipment provided as per requirement. 4. Regular meeting held with District authorities. 5. Sensitization of local public through awareness campaign, distribution of safety leaflets

& display of safety banners etc.



3. ABOUT CEIL

Incorporated in 1994, Certification Engineers International Limited-a Public Sector Undertaking under MoPNG and wholly owned subsidiary company of Engineers India Limited is a leading Third Party Inspection Agency (TPIA) in area of Oil & Gas projects, Cross country Natural Gas pipe lines etc. CEIL is certified with ISO 9001as well as accredited as TYPE-A Inspection Body as per ISO 17020 by NABCB. CEIL is also an approved TPIA for certification of T4S, ERDMP and IMS for midstream and downstream activities of Oil & Gas sector by PNGRB.

CEIL has significant track record of carrying out of T4S, ERDMP, ESA and IMS Audits of Cross-country NG Pipeline & Compressors, LPG, Multiproduct pipeline, CGD Network,

POL Terminals, LPG Bottling plants, LNG Terminals and Process Plants.

4. SCOPE

The scope of this HIRA Study is limited to the Steel and MDPE pipeline network of GAIL Gas Limited, Firozabad region. This include facilities like off sites, utilities, products storage and Dispensing, stores, Odorisation Unit, Office Buildings, CGS, CNG stations, DRS, MRS,Domestic and Commercial connections, Pipeline Networks, Gas distribution to various Customers and PNG distribution, Control Rooms, SCADA/Server Rooms.

5. HIRA CONCEPT AND METHODOLOGY:

Hazard Identification is a systematic process of examining each work area and work task for the purpose of identifying all the hazards which are ‘inherent’ in the activity/job. Risk Analysis is a systematic process of appreciating the risks associated with each of these hazards identified so that the nature of risk can be understood. This includes the nature of

The damage/harm that may result from the hazard, the severity of that damage/harm and the likelihood of this occurring. Risk Control details out taking actions to eliminate safety and health risks as far as is reasonably practicable. Where risks cannot be eliminated, then implementation of control measures is required, to minimize risks as far as is reasonably practicable.



Hazard: Anything (condition, practice, behavior etc.) that has potential to cause harm, including injury, disease, death, environmental, property and equipment damage. Few examples of various types of hazards are as under:

• Slips and trips • Workplace transport • Moving heavy object • Sharpening tools • Working at height • Manual handling • Noise • Electricity • Confined spaces • Fire

Risk: The likelihood, or possibility, that harms (injury, disease, death, damage) may occur from exposure to a hazard.

KEYWORDS

• Activity : It defines the basic work being carried out. • Concern : It defines the possible hazard that may occur during

carrying out the activity. • Impact explanation : It defines the consequence/loss that may occur

because of the hazard. • Probability Rating : It defines the chances of occurrence of a particular

hazard. • Severity Rating : It defines the extent of damage/loss in case a hazard

occurs. • Overall Risk Rating : It is overall figure of Probability Rating times the

Severity Rating. • Existing Control Measures : It defines those control measures which are already in

place/existing to mitigate a particular hazard. • Additional Control Measures : It defines those control measures which need to be

taken over and above existing control measures to mitigate a particular hazard.



• Residual Risk/Impact : It defines the assessment of risk after the implementation of existing control measures and additional control measures, if required.

RISK MATRIX

The Risk Matrix defines various levels of Severity and Probability of Occurrence which are as under. The CEIL and GAIL Gas Team discussed and decided upon various levels as under:

Categorization of Probability of occurrence:

Probability of occurrence

Rating

Once in a year 1

Once in six months 2

Once in three months 3

Once in a month 4

Categorization of Severity:

Severity

Rating

No injury only material loss 1

Minor to moderate injury or health effects OR Minor asset damage

2

Moderate to severe injury or health effects OR Major asset damage

3

Permanently disabling injury or fatality OR complete loss of asset

4



The overall Risk Matrix is as under:

The overall Risk Ranking is as under:

Risk Ranking

Rating

1-3 Acceptable

4-7 Moderate

8-12 High

13-16 Unacceptable

The Residual Risk Ranking is as under:

Risk Ranking

Rating

1-3 Tolerable

4-16 Intolerable

FRE

QU

EN

CY

4 Moderate High Unacceptable Unacceptable

3 Acceptable Moderate High High

2 Acceptable Moderate Moderate High

1 Acceptable Acceptable Acceptable Moderate

1 2 3 4

SEVERITY



Note:

After implementing Existing Control Measures and Additional Control Measures, if the Risk Ranking decreases to less than 4, the Residual Risk will be treated as Tolerable.

Even after implementing Existing Control Measures and Additional Control Measures, the Risk Ranking decreases but remains in the range of 4-16, the Residual Risk will be treated as Intolerable.

CEIL Team Leader carried out planning together with GAIL Gas Limited Noida and Firozabad HSE Coordinator in terms of Methodology, Team members, Time Schedule and Special requirements of the contract. Following points were considered.

i. Scope of HIRA Study ii. Special requirements of the contract iii. Type & nature of installation iv. Acceptance criteria v. Deployment Schedule

Prior to start of HIRA Study, an Opening Meeting was held at GAIL Gas Limited office at Firozabad on 17th September 2015 which was attended by GAIL Gas Limited officials of Firozabad office and CEIL team. The WIC gave a presentation regarding facilities at GAIL Gas, Firozabad and briefed various critical operations and maintenance activities. CEIL team also gave a brief presentation regarding modalities of the Study. After completion of HIRA Study, Closing Meeting was held on 17th February 2015, CEIL team gave a presentation listing observations/ remarks.

HIRA Methodology in brief is as under:

• Explanation of HIRA Concept, Purpose, Methodology, Keywords, Risk Matrix to GAIL Gas officials.

• Formation of GAIL Gas Team consisting of members from Projects, O&M, HSE and E&I for taking part in the HIRA Study along with CEIL Team.

• Detailed interaction on entire CGD operations • Listing out key Operation and Maintenance activities.



• Identification of possible/potential hazards in these identified activities. • Analysis of these hazards using a dedicated Hazard Identification Sheet covering the

hazard, severity, probability and overall risk. • Decide Control Measures and check if existing control measures are adequate or

additional control measures are required. • Check the residual risk level after considering all control measures. • Summarization of actionable points which need to be attended during Closing Meeting.

Reference Documents:

i. OHSAS 18001 ii. IS 15656 iii. IS 14489 reaffirmed 2002(Code of Practice on Occupational Health and Safety). iv. OISD Standard-226 (Cross Country NG Pipelines’ and ‘CGD Pipe line network) v. Applicable Statutory Regulations / National/ International Standards, Industrial Safe

practices.

6. FACILITY DESCRIPTION:

The Firozabad city gas distribution supply natural gas to various industries mainly glass industries in and around Firozabad town. The network has various sizes of pipes i.e.1”, 1.5”, 2”,3”,4”, 8” & 10” spread over the town of Firozabad. Length of the network is about 80.1KM and it passes through and nearby highways, service roads, by lane small congested streets etc. It is protected through cathodic protection through impressed current cathodic protection system. There are five nos. CP transformer rectifier (CP T/R units) installed at various location /. The power supply to these CPPSM/TR units is supplied by state electricity board/DG sets backed by batteries. Some length of the pipeline is under road or concrete.

Firozabad Region Pipeline Details :-

NAME OF SPURLINE LENGTH (KM)

DIAMETER (INCHES)

TYPE OF COATING

NO. OF TRU

FIROZABAD CITY GAS DISTRIBUTION NETWORK

17.2 10 3LPE

5

32.6 8 3LPE 25.6 4 3LPE

6.5 3 3LPE/ Coal tar

8.1 2/1.5/1 3LPE/ Coal tar

TOTAL 90



The impressed current system has been provided for the cathodic protection of the pipeline. Main features of ICCP system are: Firozabad City Gas Distribution network

SL.NO LOCATION AREA RATING 1 FCGS Raja Ki Tal TR UNIT/ CPPSM

UNIT 2 CDGI UPIDC 3 Akashdeep

Potteries Mini bypass

4 Shri Sitaram Glass

Dholpura road

5 Advance Lamp & TLC

Makhanpur

i) No. of CP stations: 05 Nos. ii) No. of Manual Test Stations: 215 Nos. (175 nos at consumer end and rest at city gate station and along the pipeline in city.)

Manual test stations for potential measurement are installed at approx Every 500 Meter along the pipeline. Barring at few location where it is 1.5 Kms apart. iii) Type of anode ground bed configurations in use are: Deep anode ground bed # 05nos. Distribution pressure or District Regulating Station(DPRS/DRS):

Sr No

Location No of DRS

01 Firozabad 02

• Individual Meter regulating Station (IPRS):

Sr No

Location No of MRS

01 Firozabad 202

7. DOCUMENTS REFERRED

In general, following documents were referred:



i. HSE Policy / Manual ii. List of Equipments / Facilities/Fire Fighting equipment.

iii. P & I Diagrams, Process Flow Diagram (PFD), Electrical Power (Single Line) Diagrams iv. Design / Operating Technical Data, e.g. Capacity, Pressure, Temperatures etc. v. MSDS of Hazardous Materials stored, handled, produced or transported

vi. Emergency Organogram, Fire & Safety Organization Chart vii. Fire & Safety System

viii. Statutory Clearance(s) ix. Standard Operating Procedures x. Hot Work Permit System.

xi. Monthly inspection report of valves. xii. Monthly checking report of lighting and fittings.

xiii. Maintenance of fire extinguishers monthly report xiv. CP Reports

8. CLOSING MEETING Closing Meeting was held on 17th September, 2015 and presided over by WIC. Observations during External audit were summarised as below:-

I) Highlights:

1. Track record of 33192 Man-hours accident free record (16.11.2011 to 31.08.2015).

2. Standard display of HSE Policy, Emergency Telephone numbers at strategic locations. 3. PPE and Fire Fighting equipment provided as per requirement. 4. Regular meeting held with District authorities. 5. Sensitization of local public through awareness campaign, distribution of safety leaflets

& display of safety banners etc.



II) Points to be attended:

1. Pipeline Coating Health Survey of Steel Pipeline network to be carried out. 2. Combined Conclusion and recommendation of CIPL and DCVG Surveys to be done in Steel Pipeline network. 3. Pipeline thickness measurement to be carried out. 4. Moisture content in gas composition to be monitored regularly. 5. First Aid Training to be organized. 6. Basic Electrical O&M Training to be organized. 7. Odorisation system to be made functional. Mercaptan Neutralising agent should be

available at the storage site. 8. Odour level tests should be carried out at last mile connectivity to ensure proper odorisation. 9. Designated person for handling Odorisation System to be identified. 10. Training and sensitisation to contractors of other utility companies sharing the same

corridor should be imparted. 11. A utility coordination team consisting of representative from all other utility companies and civil authorities may be formed. 12. GIS Mapping of entire CGD Network to be carried out. 13. Effectiveness of patrolling frequency to be periodically reviewed. 14. O-rings of dispensing nozzle to be checked periodically. 15. Customer Waiting Area should be outside the dispensing premises. 16. Periodic calibration of all PSVs to be ensured. 17. Air Compressor interlocks to be checked during Preventive Maintenance Schedule. 18. During Compressor maintenance, no loose clothes to be worn by maintenance personnel. 19. Periodic calibration of LEL and UV Detectors to be carried out as per Preventive Maintenance Schedule. 20. If calibration is outsourced, random witness of calibration of said instruments to be carried out by GAIL Gas personnel. 21. Periodic Hydro test of cascades should be ensured as per Gas Cylinder Rules i.e. once in three years. 22. During Stationery Cascade maintenance, surprise checks by GAIL Gas personnel

should



be carried out. 23. During Stationery Cascade maintenance, Non-sparking tools should be used for such maintenance. 24. Consequences of LCV accident/fire to be briefed during public awareness. 25. Line Diagram of the connection piping should be fixed at the entrance of group housing societies/cluster of houses. 26. Mock Drills with all consumers to be carried out periodically. 27. For LMC at Industrial and Commercial consumers, Leakage Surveys to be carried out depending upon the congestion in area (Highly congested areas-once in 3 months, Less congested areas-once in a year)

9. Management Plan for intolerable Residual Risk S.No Risk Action required for reducing the risk to

ALARP level 1 Odorisation of gas 1. Inspection of Dosing Unit should be done

periodically. 2. Designated person for handling Odorisation

System to be identified. 3. Sodium Hypochlorite as neutralizer or other

similar chemicals should be available at the odorizing storage system for neutralization in case of leakage.

4. MSDS should be displayed at the unit. 5. Emergency contact number should be

displayed for use in case of emergency. 6. Fire extinguishers should be available at site. 7. PPE should be available 8. Eyewash system should be installed near the

unit. 2 Leakage & Fire in Pipelines 1. PM Schedule of the isolation valves & pits

should be done so that the affected section can be isolated easily.

2. Awareness program for the general public



should be conducted at regular intervals to spread awareness among the general public.

3. Liaison with local authority should be done so that necessary help can be obtained during any major emergency.

3 Third party damage 1. Awareness program for the general public should be conducted at regular intervals to spread awareness among the general public.

2. Liaison with local authorities should be done so that necessary help can be obtained during any major emergency.

3 Corrosion 1. CIPL/DCVG Surveys to be carried out to monitor corrosion in Steel Pipeline network.

2. Instant Pipe to Soil Off Potential measurement for entire pipeline.

3. Pipeline thickness measurement to be carried out.

4 Leakage & fire in compressor 1. Leak test should be done periodically 2.PM Schedule of the compressor package should

be done. 3. Calibration of measuring instruments & safety

valves should be done periodically 4. Checking of fire detection & alarm &

firefighting systems should be done periodically.

5. O&M procedure should be followed for operation & maintenance of the compressor.

6. F&S training should be imparted to compressor operators to handle the emergency in the incipient stage.

5 Leakage & fire in dispenser 1.Leak test should be done periodically 2.PM Schedule of the dispenser should be done. 3. Calibration of measuring instruments & safety



valves should be done periodically 4. O&M procedure should be followed for

operation & maintenance of the compressor. 5. F&S training should be imparted to dispenser

operators to handle the emergency in the incipient stage.

6. Awareness training program for CNG customers should be conducted ar regular intervals.

6 LCV Cascade filling, leakage & fire

1. Leakage survey should be done periodically. 2. Calibration of the measuring should be done

periodically. 3. Standard O&M procedure should be followed. 4. Crash Guard should be provided for protection

of the LCV filling point. 5. Awareness training to the LCV driver should

be conducted. 7 Leakage &Fire in GEG 1. Overloading should be avoided.

2. Leak test should be done on the inlet gas pipe line.

3. F&S training should be done for the CNG staff to handle the emergency.

8 Earthing & electrocution 1. Electrical isolation procedure should be followed during job on the electrical system.

2. Proper tools should be used while working on the electrical system.

3. Trained personnel should be engaged for any work on electrical system.

4. PPE should be used. 5. PM Schedule of the earth pit should be done &

records should be maintained. 9 Vehicle & Passenger movement

in the CNG station 1. Safety awareness program for public coming to

the CNG station should be conducted at regular intervals. Distribution of safety leaflets to the



general public to create safety awareness.

2. Vehicle marshalling should be done in a way that the vehicles should come in a row & exit after filling.

3. It is to be ensured that, no passengers are present while the filling is under progress.

10 Working at height 1. Working platform or telescopic ladder should be used for working at height.

2. Personal protective equipment should be used while working at height.

3. Work permit system should be followed. 11 Leakage & fire in customers’

premises. 1. Leakage survey should be done to detect the

leakage. 2. Safety awareness campaign should be

conducted periodically for the customers. 3. Display of emergency contact number should

be done so that the customer can contact in case of any emergency.

ALARP- As low as reasonably practicable

10. CONCLUSION

The HIRA Study for GAIL Gas Limited, Firozabad CGD Network has been carried out covering all key activities as identified during the study. A list of actionable points has been recommended by the CEIL Team for implementation.

CEIL Team: Mr. Sathish Iyengar (Team Leader) Mr. Amol Sonawane (Surveyor)



11. CONFIDENTIALITY

This HIRA Study Report is confidential and an original report will be available only with the entity.

Sign: Sign:

Mr. Sathish Iyengar Mr. Amol Sonawane



12. GAIL GAS CGD NETWORK ACTIVITY LIST

Location: Firozabad

S. No. SECTION ACTIVITY

1 CGS Odorisation

2 Steel Pipeline Network Gas transmission, Isolation

3 DRS & MRS Filtration, Pressure Reduction , Metering , Isolation , Gas delivery

4

CNG Station-Mother Compression, Dispensing, Manual handling of Lube Oil Drums, Mobile Cascade filling, Mobile Cascade transport, Power generation through Gas Engine Generator, Air compression, Electrical system, CNG customer vehicle movement, Passenger movement, Working at height, Stationary Cascade.

5 MDPE Pipeline Network Gas distribution, Isolation, Surveillance.

6 Last Mile Connectivity-Commercial & Domestic

Isolation, Pressure reduction, Metering

7 Cathodic Protection System

Cathodic Protection of steel pipe line

8 SVs and IVs Isolation


CEIL/9530/HIRA/GAIL GAS Firozabad/SI /26 Page 21 of 65

13. HAZARD IDENTIFICATION & RISK ANALYSIS FORMAT (Annexure –1)

Name of the Project : Location:

Main Activity : Date:

S. NO

ACTIVITY HAZARD IMPACT

EXPLANATION

PRO

BABI

LITY

RA

TIN

G

(1-Y

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4-F

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OVERALL RISK =

PROBABILITY x SEVERITY

RISK RANK

(Acceptable/Mod

erate/ High/

Unacceptable)

EXISTING CONTROL MEASURES ADDITIONAL

CONTROL MEASURES

RESIDUAL RISK



HAZARD IDENTIFICATION & RISK ANALYSIS

Name of the Project : CGD Network Location: Firozabad

Main Section : CGS Date : 16.09.15

S. NO


EXPLANATION

PRO

BABI

LITY

RA

TIN

G

(1-Y

earl

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-Hal

fyea

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3-Q

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4-

Fata

lity

OVERALL RISK=

Probability X

Severity

RISK

RANK (Acceptable/Moder

ate/ High/ Unacceptabl

e)

EXISTING CONTROL MEASURES

ADDITIONAL CONTROL MEASURES

RESIDUAL RISK

1 Odorisation Spillage

Air pollution Being highly toxic, health gets affected.

1 2 2

Acceptable

1. SOP for handling and disposal is available.

2. Chemical Suit and required PPE available.

3. Safety Shower and Eyewash available.

1. Inspection of dosing unit should be done periodically.

2. Designated person for handling Odorisation System to be identified.

3. Sodium Hypochloriteas neutralizer or other chemicals should be

Tolerable



S. NO


EXPLANATION

PRO

BABI

LITY

RA

TIN

G

(1-Y

earl

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-Hal

fyea

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3-Q

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4-M

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(1-N

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4-

Fata

lity

OVERALL RISK=

Probability X

Severity

RISK

RANK (Acceptable/Moder

ate/ High/ Unacceptabl

e)



RESIDUAL RISK

available

Being highly flammable, fire may occur, asset damage, human injury

1 4 4 Moderate

1. Fire extinguishers available. 2. Fire Fighting Training

imparted to concerned personnel.

3. Emergency plan is in place.

1. MSDS should be displayed at the unit.

2. Emergency contact number should be displayed for use in case of emergency.

Tolerable





Main Section : Steel Pipeline Network Date : 16.09.15

S. NO


EXPLANATION

PRO

BABI

LITY

RA

TIN

G

(1-Y

earl

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fyea

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4-Fa

talit

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OVERALL RISK=

Probability X

Severity

RISK

RANK (Acceptable/Moderate/ High/

Unacceptable)



RESIDUAL RISK

1 Gas transmission

Leakage

-Major asset damage

-Environment gets affected

1 3

3

Acceptable

1. Routine Patrolling is done. 2. Periodic Awareness

campaign for general public is done.

3. ERV Vehicle is available for any emergency.

4. SOP for Steel Pipeline Network in place.

5. O&M team available for leak repair.

1. PM Schedule of SV should be implemented to ensure its operation during emergency.

2. The pit maintenance should be done.

3. Adequate number of markers should be installed at specified intervals for identification of the pipe line underground.

4.Training to contractors of

Tolerable



S. NO


EXPLANATION

PRO

BABI

LITY

RA

TIN

G

(1-Y

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OVERALL RISK=

Probability X

Severity

RISK


Unacceptable)



RESIDUAL RISK

other utility companies sharing the same corridor should be imparted to avoid third party damage.

Fire

-Fatal

-Major asset damage

-Environment affected

1 4

4

Moderate

1. Routine Patrolling is being done.

2. Periodic Awareness campaign for general public is done.


4. SOP for Steel Pipeline Network in place.


6. ERDMP is in place.


2. The pit maintenance should be done.


4. Public awareness programs to be conducted at regular intervals.

Tolerable



S. NO


EXPLANATION

PRO

BABI

LITY

RA

TIN

G

(1-Y

earl

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fyea

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OVERALL RISK=

Probability X

Severity

RISK


Unacceptable)



RESIDUAL RISK

5. Liaison with local authority being done to tackle such emergency

2 Third Party Damage

-Fatal

-Asset damage,

-Gas leakage

-Fire


1 4

4

Moderate

1. Routine surveillance is done.

2. Periodic Meeting with local bodies regarding gas pipeline network is done.

3. Periodic Awareness sensitization campaign for general public, JCB owners/operators and shopkeepers nearby pipelines is done.

4. Availability of Route Markers along the pipelines.

5. Emergency Telephone numbers have been displayed at various places in the city.

1. GIS Mapping should be carried out.

2. Effectiveness of patrolling frequency to be periodically reviewed.

3. Training to contractors of other utility companies sharing the same corridor should be imparted to avoid third party damage.

4. SOP for SV operation to be implemented.

5. Liaison with local authority being done to tackle such emergency.

Tolerable



S. NO


EXPLANATION

PRO

BABI

LITY

RA

TIN

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4-Fa

talit

y

OVERALL RISK=

Probability X

Severity

RISK


Unacceptable)



RESIDUAL RISK

6. Availability of Warning Mats above pipeline in place.

7. Odorisation system in place.



Corrosion

Pipeline integrity gets affected, leakage, fire, -Fatal, Asset damage, Environment gets affected.

3 4

12

High 1. TCP is in place.

1. Coating Health Survey to be carried out.

2. CIPL and DCVG Surveys to be carried out.

3. Pipeline thickness measurement to be carried out.

4. Moisture, CO2 content in gas composition to be monitored regularly.

5. CP system to be maintained properly.

6. Integrity management system to be

Tolerable. Refer

Management Plan



S. NO


EXPLANATION

PRO

BABI

LITY

RA

TIN

G

(1-Y

earl

y, 2

-Hal

fyea

rly,

3-Q

uart

erly

,

4-M

onth

ly

SEV

ERIT

Y RA

TIN

G

(1-N

o in

jury

, 2-M

inor

, 3- M

oder

ate,

4-Fa

talit

y

OVERALL RISK=

Probability X

Severity

RISK


Unacceptable)



RESIDUAL RISK

implemented.





Main Section : MDPE Pipeline Network Date : 17.09.15

S. NO

ACTIVITY

PRO

BABI

LITY

RA

TIN

G

(1-Y

earl

y, 2

-Hal

fyea

rly,

3-Q

uart

erly

, 4-

Mon

thly

SEV

ERIT

Y RA

TIN

G

(1-N

o in

jury

, 2-M

inor

, 3- M

oder

ate,

4-

Fata

lity

OVERALL RISK=

Probability X

Severity

RISK

RANK (Acceptable/Moderat

e/ High/

Unacceptable)



RESIDUAL RISK HAZARD

IMPACT EXPLANATION

1 Gas transmission

Leakage

-Minor asset damage


2 2

4

Moderate

1. Routine Patrolling is done. 2. Periodic Awareness

campaign for general public is done.



5. The pit maintenance being done.



3. Training to contractors of other utility

Tolerable



S. NO

ACTIVITY

PRO

BABI

LITY

RA

TIN

G

(1-Y

earl

y, 2

-Hal

fyea

rly,

3-Q

uart

erly

, 4-

Mon

thly

SEV

ERIT

Y RA

TIN

G

(1-N

o in

jury

, 2-M

inor

, 3- M

oder

ate,

4-

Fata

lity

OVERALL RISK=

Probability X

Severity

RISK


e/ High/

Unacceptable)




IMPACT EXPLANATION

companies sharing the same corridor should be imparted to avoid third party damage.

4.SOP for MDPE Pipeline Network to be implemented.

Fire

- Fatal

-Major asset damage

-Environment affected

1 4

4

Moderate

1. Routine Patrolling is done. 2. Periodic Awareness campaign

for general public is done. 3. ERV Vehicle is available for any

emergency. 4. O&M team available for leak

repair. 5. Liaison with local authority

being done to tackle such emergency.

6. The pit maintenance being done.

1.PM Schedule of SV should be implemented to ensure its operation during fire.

2.Adequate number of markers should be installed at specified intervals for identification of the pipe line underground.

3. SOP for MDPE Pipeline Network to be

Tolerable



S. NO

ACTIVITY

PRO

BABI

LITY

RA

TIN

G

(1-Y

earl

y, 2

-Hal

fyea

rly,

3-Q

uart

erly

, 4-

Mon

thly

SEV

ERIT

Y RA

TIN

G

(1-N

o in

jury

, 2-M

inor

, 3- M

oder

ate,

4-

Fata

lity

OVERALL RISK=

Probability X

Severity

RISK


e/ High/

Unacceptable)




IMPACT EXPLANATION

implemented.

2 Third Party Damage

Asset damage, Moderate human injury, gas leakage, customers gets affected

2 3 6

High

1. Routine surveillance is done. 2. Periodic Meeting with local

bodies regarding gas pipeline network is done.

3. Periodic Awareness sensitization campaign for general public, JCB owners/operators and shopkeepers nearby pipelines is done.

4. Availability of Route Markers along the pipelines.

5. Emergency Telephone numbers have been displayed at various places in the city.

6. Availability of Warning Mats above pipeline in place.

7. Odorisation system in place. 8. ERV Vehicle is available for

1. GIS Mapping should be carried out.

2. Effectiveness of patrolling frequency to be periodically reviewed.

3. Training to contractors of other utility companies sharing the same corridor should be imparted to avoid third party damage.


5. Awareness program for general public should be conducted at regular intervals

Tolerable



S. NO

ACTIVITY

PRO

BABI

LITY

RA

TIN

G

(1-Y

earl

y, 2

-Hal

fyea

rly,

3-Q

uart

erly

, 4-

Mon

thly

SEV

ERIT

Y RA

TIN

G

(1-N

o in

jury

, 2-M

inor

, 3- M

oder

ate,

4-

Fata

lity

OVERALL RISK=

Probability X

Severity

RISK


e/ High/

Unacceptable)




IMPACT EXPLANATION

any emergency. 9. SOP for SV operation in

place. 10. Emergency action plan is in

place.





Main Section : DRS & MRS Date : 17.09.15

S. NO


EXPLANATION

PR

OBA

BILI

TY R

ATI

NG

(1-Y

earl

y, 2

-Hal

fyea

rly,

3-Q

uart

erly

,

4-M

onth

ly

SEV

ERIT

Y RA

TIN

G

(1-N

o in

jury

, 2-M

inor

, 3- M

oder

ate,

4-

Fata

lity

OVERALL RISK=

Probability X

Severity

RISK RANK

(Acceptable/Moderate/

High/ Unacceptab

le)



RESIDUAL RISK

1 Filtration Overpressure

Leakage due to failure of gaskets, asset damage

1 2

2

Acceptable

1. Overpressure protection

available at DRS. 2.Pressure Gauge available for

monitoring

1. PM Schedule of PSV, SSDV, DP Gauges, Filter cleaning to be implemented.

Tolerable

2 Pressure Reduction

High pressure at downstream due to failure of PCV

Consumer gets affected, Gas loss, Line burst.

1 3

3

Acceptable

1. PSV at the d/s of DRS. 2. Active monitor combination

is available. 3. Calibration of Differential

Pressure Gauge being done. 4. Calibration of PSV being

done.

1. PM Schedule including calibration of PSV, SSDV, DP Gauges, Filter cleaning to be implemented.

Tolerable

3 Gas flow Leakage & Fire Loss of gas, Fatal, asset

1 4 4 Moderate

1. Isolation valve provided at inlet && outlet for isolation

1. PM Schedule including calibration of PSV,

Tolerable



S. NO


EXPLANATION

PRO

BABI

LITY

RA

TIN

G

(1-Y

earl

y, 2

-Hal

fyea

rly,

3-Q

uart

erly

,

4-M

onth

ly

SEV

ERIT

Y RA

TIN

G

(1-N

o in

jury

, 2-M

inor

, 3- M

oder

ate,

4-

Fata

lity

OVERALL RISK=

Probability X

Severity

RISK RANK


High/ Unacceptab

le)



RESIDUAL RISK

damage, environment affected.

2.Contact numbers displayed for passing the information.

3.Fire extinguishers available 4.Dos & Donts in place. 5. ERDMP in place.

SSDV, DP Gauges, Filter cleaning to be implemented.

2. Training should be imparted for safe operation & maintenance & handling of emergency to the O&M team.

3. Awareness programs to be conducted for the customers.


3. Isolation Isolation Valve is passing

Affected part of pipeline cannot be isolated, gas

1 2 2

Acceptable

1. Slam Shut Valve is available. 2. Double Active Monitor is

available.

1. PM Schedule including calibration of PSV, SSDV, DP Gauges, Filter cleaning to be

Tolerable



S. NO


EXPLANATION

PRO

BABI

LITY

RA

TIN

G

(1-Y

earl

y, 2

-Hal

fyea

rly,

3-Q

uart

erly

,

4-M

onth

ly

SEV

ERIT

Y RA

TIN

G

(1-N

o in

jury

, 2-M

inor

, 3- M

oder

ate,

4-

Fata

lity

OVERALL RISK=

Probability X

Severity

RISK RANK


High/ Unacceptab

le)



RESIDUAL RISK

loss. implemented





Main Section : SV and IV Date : 16.09.15

S. NO


EXPLANATION

PR

OBA

BILI

TY R

ATI

NG

(1-Y

earl

y, 2

-Hal

fyea

rly,

3-Q

uart

erly

, 4-

Mon

thly

SEV

ERIT

Y RA

TIN

G

(1-N

o in

jury

, 2-M

inor

, 3- M

oder

ate,

4-

Fata

lity

OVERALL RISK=

Probability X

Severity

RISK RANK


High/ Unacceptab

le)



RESIDUAL RISK

1 Isolation Passing

Downstream section can not be isolated

3 2 6 Moderate

1. Periodic Maintenance

2. Replacement of valve

3. Periodic operational checking of valve

1. Periodic operational test of isolation valve.

Tolerable

Leakage

Environment get effected

Minor Asset Damage

2 2 4

Moderate



3. Periodic LEL checking

4. Regular cleaning of pit

5. painting of pit & water proofing wherever necessary

1. Gas Odorisation system to be installed

2. Continuous odorisation to be ensured

Tolerable



S. NO


EXPLANATION

PRO

BABI

LITY

RA

TIN

G

(1-Y

earl

y, 2

-Hal

fyea

rly,

3-Q

uart

erly

, 4-

Mon

thly

SEV

ERIT

Y RA

TIN

G

(1-N

o in

jury

, 2-M

inor

, 3- M

oder

ate,

4-

Fata

lity

OVERALL RISK=

Probability X

Severity

RISK RANK


High/ Unacceptab

le)



RESIDUAL RISK

2 Fire

Environment get effected

Minor Asset Damage

Human Injury

1 4 4

Moderate



3. Periodic LEL checking

4. Regular cleaning of pit

5. painting of pit & water proofing wherever necessary

1. Gas Odorisation system to be installed

2. Continuous odorisation to be ensured

Tolerable

3 Third Party

Damage

Asset Damage

Gas Leakage and Fire

Human injury

1 4 4

Moderate

1. Heavy cover with lock is in place

2. Routine patrolling 3. Periodic awareness

Campaign, sensitization campaign for general public, JCB owners/operators, customers and shopkeepers nearby pipeline is done.

4. Periodic meeting with local authorities

5. Availability warning

1. warning boards displaying emergency numbers etc. should be placed nearer to SVs and IVs

Tolerable



S. NO


EXPLANATION

PRO

BABI

LITY

RA

TIN

G

(1-Y

earl

y, 2

-Hal

fyea

rly,

3-Q

uart

erly

, 4-

Mon

thly

SEV

ERIT

Y RA

TIN

G

(1-N

o in

jury

, 2-M

inor

, 3- M

oder

ate,

4-

Fata

lity

OVERALL RISK=

Probability X

Severity

RISK RANK


High/ Unacceptab

le)



RESIDUAL RISK

boards displaying emergency numbers etc. along the pipelines nearer to SV and IV

6. SOP in place 7. ERV vehicle available 8. Emergency action plan

in place





Main Section : CNG Station-Mother Date : 17.09.15

S. NO


EXPLANATION

PR

OBA

BILI

TY R

ATI

NG

(1-Y

earl

y, 2

-Hal

fyea

rly,

3-Q

uart

erly

, 4-

Mon

thly

SEV

ERIT

Y RA

TIN

G

(1-N

o in

jury

, 2-M

inor

, 3- M

oder

ate,

4-

Fata

lity

OVERALL RISK=

Probability X

Severity

RISK RANK


High/ Unacceptab

le)



RESIDUAL RISK

1 Compression Leakage Gas loss, Human injury 1 3

3

Acceptable

1. Gas Leak Detection & Shutdown System in place.

2. SOP for CNG Package available.

1. PM Schedule of Compressor, F& G System, Leak Test to be implemented.

2.Periodic O&M & F&S training should be imparted to compressor operators for safe operation.

Tolerable

Fire

Fatal

Asset damage 1 4

4

Moderate

1. Flame Detection &Shutdown System in place.

2. Fire Suppression System (CO2 Flooding System) in place.

1. PM Schedule of CO2 Flooding, fire Detection should be implemented to ensure its availability.

2. O&M and F&S refresher

Tolerable



S. NO


EXPLANATION

PRO

BABI

LITY

RA

TIN

G

(1-Y

earl

y, 2

-Hal

fyea

rly,

3-Q

uart

erly

, 4-

Mon

thly

SEV

ERIT

Y RA

TIN

G

(1-N

o in

jury

, 2-M

inor

, 3- M

oder

ate,

4-

Fata

lity

OVERALL RISK=

Probability X

Severity

RISK RANK


High/ Unacceptab

le)



RESIDUAL RISK

3. SOP for CNG Package available.

training should be imparted to compressor operators for safe operation& emergency handling.

3. Operation & maintenance procedures to be developed & to be implemented for safe operation.

4. SOP to be followed to avoid any accident.

2 Dispensing Leakage while dispensing

Gas loss, human injury 3 2

6

Moderate

1. Shutdown system for Individual Arm & Dispenser available.

2. Portable LEL Detector available.

3. PM Schedule of dispensers being done.

4. Odorisation System in place.

5. SOP for Dispenser

1. O-rings along with conditions of dispensing probe to be checked periodically.

2. Condition of hose to be checked periodically and replaced as when required.

3. Leakage testing of the tubing & fittings of dispenser should be done.

Tolerable



S. NO


EXPLANATION

PRO

BABI

LITY

RA

TIN

G

(1-Y

earl

y, 2

-Hal

fyea

rly,

3-Q

uart

erly

, 4-

Mon

thly

SEV

ERIT

Y RA

TIN

G

(1-N

o in

jury

, 2-M

inor

, 3- M

oder

ate,

4-

Fata

lity

OVERALL RISK=

Probability X

Severity

RISK RANK


High/ Unacceptab

le)



RESIDUAL RISK

operation available. 6. Dos & Don’ts are

displayed near dispensing area.

7. Safety precautions should be followed during dispensing

4. PM Schedule of Pressure Relief Valves. Pressure Gauges and other measuring instruments should be implemented.

5. Periodic maintenance of dispensers to be ensured.

6. SOP to be followed for safe operation.

7. Skilled manpower to be deployed for safe operation of the dispenser.

8. Regular training to be imparted regarding safe handling of dispenser.

9. Regular F&S training should be conducted.

Fire Asset damage, 1 4

4

1. Fire Extinguishers available

1. O-rings along with conditions of dispensing

Tolerable



S. NO


EXPLANATION

PRO

BABI

LITY

RA

TIN

G

(1-Y

earl

y, 2

-Hal

fyea

rly,

3-Q

uart

erly

, 4-

Mon

thly

SEV

ERIT

Y RA

TIN

G

(1-N

o in

jury

, 2-M

inor

, 3- M

oder

ate,

4-

Fata

lity

OVERALL RISK=

Probability X

Severity

RISK RANK


High/ Unacceptab

le)



RESIDUAL RISK

loss of gas, Fatal Moderate

2. Regular training to Dispensing Boys.

3. Awareness Training to CNG consumers.

4. SOP for Dispenser operation available.


probe to be checked periodically.

2. Condition of hose to be checked periodically and replaced as when required.

3. Leakage testing of the tubing & fittings of dispenser should be done.

4. PM Schedule of Pressure Relief Valves. Pressure Gauges and other measuring instruments should be implemented.

5. Periodic maintenance of dispensers to be ensured.


7. Skilled manpower to be deployed for safe operation of the dispenser.



S. NO


EXPLANATION

PRO

BABI

LITY

RA

TIN

G

(1-Y

earl

y, 2

-Hal

fyea

rly,

3-Q

uart

erly

, 4-

Mon

thly

SEV

ERIT

Y RA

TIN

G

(1-N

o in

jury

, 2-M

inor

, 3- M

oder

ate,

4-

Fata

lity

OVERALL RISK=

Probability X

Severity

RISK RANK


High/ Unacceptab

le)



RESIDUAL RISK

8. Regular training to be imparted regarding safe handling of dispenser.

9. Regular F&S training should be conducted.

3

Mobile Cascade filling

(future provision, )

Positioning of LCV

-Injury,

-Asset damage 1 2 2

Acceptable

1. Comprehensive Safety Checklist for LCV is available and being followed.

2. Stoppers are available. 3. SOP for LCV filling in

place.

1. Awareness training to the LCV drivers should be imparted periodically.

2.Crash guard around the LCV filling point can be provided to protect the equipment.

3.SOP for LCV filling should be followed.

Tolerable

Damage of hose pipe, tube and fittings,Fatal

1 4 4 Moderate

1. Stoppers are available. 2. SOP for LCV filling in

place. 3. Leak Test is done

before filling


2. Crash guard around the LCV filling point can be provided to protect the equipment.

Tolerable



S. NO


EXPLANATION

PRO

BABI

LITY

RA

TIN

G

(1-Y

earl

y, 2

-Hal

fyea

rly,

3-Q

uart

erly

, 4-

Mon

thly

SEV

ERIT

Y RA

TIN

G

(1-N

o in

jury

, 2-M

inor

, 3- M

oder

ate,

4-

Fata

lity

OVERALL RISK=

Probability X

Severity

RISK RANK


High/ Unacceptab

le)



RESIDUAL RISK

Leakage from hose pipe, tube

and fittings, Fatal

1 4

4

Moderate

1. Portable LEL Detector available for leak test.

2. PM Schedule of hose and coupling is done.

3. Odorisation System in place.


2. Periodic calibration of measuring instruments should be done.

3. Periodic leakage survey should be done.


Tolerable

4

Power generation through Gas engine Generator

Leakage from fuel

line

Gas loss, Human injury. 1 3 3 Acceptable

1. Periodic Leak Checks of

gas piping, joints & fitting done periodically

2. Local ESD facility available.

1. PM Schedule of GEG to be implemented.

Tolerable

Fire -Fatal -Asset loss 1 4

4

Moderate 1. Fire Extinguishers

available 2. ERDMP is in place

1. Regular checking to identify the faulty wiring and replacing the same should be ensured.

2. Fencing of GEG should be

Tolerable



S. NO


EXPLANATION

PRO

BABI

LITY

RA

TIN

G

(1-Y

earl

y, 2

-Hal

fyea

rly,

3-Q

uart

erly

, 4-

Mon

thly

SEV

ERIT

Y RA

TIN

G

(1-N

o in

jury

, 2-M

inor

, 3- M

oder

ate,

4-

Fata

lity

OVERALL RISK=

Probability X

Severity

RISK RANK


High/ Unacceptab

le)



RESIDUAL RISK

provided. 3. Housekeeping should be

ensured. 4. Regular maintenance of the

generator to be ensured. 5. SOP to be followed for safe

operation



S. NO


EXPLANATION

PRO

BABI

LITY

RA

TIN

G

(1-Y

earl

y, 2

-Hal

fyea

rly,

3-Q

uart

erly

, 4-

Mon

thly

SEV

ERIT

Y RA

TIN

G

(1-N

o in

jury

, 2-M

inor

, 3- M

oder

ate,

4-

Fata

lity

OVERALL RISK=

Probability X

Severity

RISK RANK


High/ Unacceptab

le)



RESIDUAL RISK

Electrocuti

on Fatal 1 4 4

Moderate

1. MCCB is in service. 2. PPE and tools for safe

electrical operation available.

1. Electrical isolation procedure to be implemented.

2. Inspection of tools should be done before using them.

3. Deployment of trained personnel to be ensured.


5. PPE should be used for while working.

Tolerable

5 Electrical

System(Electrical Panel)

Electrocution

Fatal 1 4 4

Moderate

1. PPE and tools for safe electrical operation available.

2. PM Schedule of Electrical Panels being done.

3. Work Permit System in




Tolerable



S. NO


EXPLANATION

PRO

BABI

LITY

RA

TIN

G

(1-Y

earl

y, 2

-Hal

fyea

rly,

3-Q

uart

erly

, 4-

Mon

thly

SEV

ERIT

Y RA

TIN

G

(1-N

o in

jury

, 2-M

inor

, 3- M

oder

ate,

4-

Fata

lity

OVERALL RISK=

Probability X

Severity

RISK RANK


High/ Unacceptab

le)



RESIDUAL RISK

place. 4. Electrical O&M & safety

training being imparted.



Improper / Discontinu

ed Earthing

-Damage to asset,

Fatal 1 4 4

Moderate

1 Earth Pits provided. 2. Periodic monitoring of

Earth Pits Resistance is done.

3. Work Permit System in place.






Tolerable

6 CNG customer vehicle movement

Sudden movement of vehicle

during filling

Asset damage, human injury 1 3 3

Acceptable

1. SOP for dispensing is in place.

2. Breakaway coupling available

3. Ignition keys removed before filling & all the persons removed from

1. Traffic cone should be placed in front of the vehicle during filling & removed after filling.

2. Removal of ignition key from the vehicle while

Tolerable



S. NO


EXPLANATION

PRO

BABI

LITY

RA

TIN

G

(1-Y

earl

y, 2

-Hal

fyea

rly,

3-Q

uart

erly

, 4-

Mon

thly

SEV

ERIT

Y RA

TIN

G

(1-N

o in

jury

, 2-M

inor

, 3- M

oder

ate,

4-

Fata

lity

OVERALL RISK=

Probability X

Severity

RISK RANK


High/ Unacceptab

le)



RESIDUAL RISK

the vehicle. 4. Awareness training for

CNG customers arranged regularly.

filling to be ensured. 3. SOP to be followed for

safe filling.

CNG customer

vehicle wrong

parking

Minor human injury, damage

to asset 1 3 3

Acceptable

1. Entry & Exit signage in place.

2. Customer traffic movement monitored by security guards.

3. Crash Guards available around dispensers.

1. Vehicle marshalling should be done by the security guard.

2. Safety cones & chains should be placed in such a way that the vehicles can enter in a row & exit safely.

Tolerable

7 Passenger movement

Loitering of passenger

Asset damage, human injury 1 3 3

Acceptable

1. ‘Restricted Area’ for passenger trespass.

2. Dedicated Drop and Pickup point for passengers.

3. Awareness program should be conducted for the passengers to ensure

1. Customer Waiting Area should be outside the dispensing premises.

2. Customer Waiting Area to be displayed at the designated place.

Tolerable



S. NO


EXPLANATION

PRO

BABI

LITY

RA

TIN

G

(1-Y

earl

y, 2

-Hal

fyea

rly,

3-Q

uart

erly

, 4-

Mon

thly

SEV

ERIT

Y RA

TIN

G

(1-N

o in

jury

, 2-M

inor

, 3- M

oder

ate,

4-

Fata

lity

OVERALL RISK=

Probability X

Severity

RISK RANK


High/ Unacceptab

le)



RESIDUAL RISK

the safety in the CNG station

8

Working at height during Electric pole,

Canopy maintenance

Fall Fatal 1 4 4

Moderate

1. Work Permit System in place.

2. Required PPEs available.

1. Trained staff should be deployed.

2. Arrangements like Telescpoic ladders should be available for safe working at height.

3. ‘Working at Height’ training imparted to all concerned.

4. Use of PPE like safety belt to be ensured while working at height.

Tolerable



S. NO


EXPLANATION

PRO

BABI

LITY

RA

TIN

G

(1-Y

earl

y, 2

-Hal

fyea

rly,

3-Q

uart

erly

, 4-

Mon

thly

SEV

ERIT

Y RA

TIN

G

(1-N

o in

jury

, 2-M

inor

, 3- M

oder

ate,

4-

Fata

lity

OVERALL RISK=

Probability X

Severity

RISK RANK


High/ Unacceptab

le)



RESIDUAL RISK

9 Air

Compression Overpress

ure

Major human injury, Asset

loss 1 3 3

Acceptable

1. PSV provided. 2. Start-Stop of compressor

interlock available. 3. Periodic calibration of

PSVs being done.

1. PM Schedule for Compressor and interlocks to be implemented.

2. Thickness test of the vessel should be done periodically.

Tolerable

Trapping between moving

parts

Human injury 1 3

3

Acceptable

1. Belt Guards provided. 2. Overload interlock in

place. 3. Basic instructions for

safe operation to operators.

1. No loose clothes to be worn by maintenance personnel.

2. PPE should be used during work on air compressor


Tolerable

10 Calibration of

Gas, UV Detectors

Incorrect/No

calibration

Gas leakage & Fire will go undetected

1 4 4

Moderate

1. Periodic calibration of Gas Leak and Flame Detectors being done.

2. Hand Held LEL Detectors available

1. PM Schedule for calibration of Gas and Flame Detectors to be implemented.

Tolerable



S. NO


EXPLANATION

PRO

BABI

LITY

RA

TIN

G

(1-Y

earl

y, 2

-Hal

fyea

rly,

3-Q

uart

erly

, 4-

Mon

thly

SEV

ERIT

Y RA

TIN

G

(1-N

o in

jury

, 2-M

inor

, 3- M

oder

ate,

4-

Fata

lity

OVERALL RISK=

Probability X

Severity

RISK RANK


High/ Unacceptab

le)



RESIDUAL RISK

11

Calibration of Pressure,

Temperature Switches,

Pressure and Temperature Transmitters

Incorrect/No

calibration

-Major asset damage, human injury

1 4 4

Moderate

1. Periodic calibration of Pressure, Temperature Switches, Pressure and Temperature Transmitters is done.

1. PM Schedule for calibration of Gas and Flame Detectors to be implemented.

2. If calibration is outsourced, random witness of calibration of said instruments to be carried out by GAIL Gas personnel.

Tolerable

12 Stationary

Cascade filling and storage

Leakage from

manifold valve,

fittings, cylinder

body

-Major human injury

-Major asset loss

1 3 3

Acceptable

1. PM Schedule of manifold valve and fittings is done.

2. Periodic Hydro test of cascade being done.

1. Periodic Hydro test of cascades should be ensured as per Gas Cylinder Rules i.e. once in three years.

2. Periodic leakage survey to be done.

Tolerable

Fire at

manifold -Fatal 1 4 4

1. Fire extinguishers are available.

1. Surprise checks by GAIL Gas personnel should be done

Tolerable



S. NO


EXPLANATION

PRO

BABI

LITY

RA

TIN

G

(1-Y

earl

y, 2

-Hal

fyea

rly,

3-Q

uart

erly

, 4-

Mon

thly

SEV

ERIT

Y RA

TIN

G

(1-N

o in

jury

, 2-M

inor

, 3- M

oder

ate,

4-

Fata

lity

OVERALL RISK=

Probability X

Severity

RISK RANK


High/ Unacceptab

le)



RESIDUAL RISK

valve, fittings

due to use of normal

tool/in presence of ignition

source

-Major asset loss

Moderate 2. Work Permit System is in place. 3. PPEs are in place.

during such maintenance. 2. Non-sparking tools should be

mandatory for such maintenance.

3. PM Schedule to be implemented.

4. PPE should be used during work.

5. SOP to be followed.





Main Section : LMC-Domestic & commercial Date : 17.09.15

S. NO


EXPLANATION

PRO

BABI

LITY

RA

TIN

G

(1-Y

earl

y, 2

-Hal

fyea

rly,

3-Q

uart

erly

, 4-

Mon

thly

SEV

ERIT

Y RA

TIN

G

(1-N

o in

jury

, 2-M

inor

, 3- M

oder

ate,

4-

Fata

lity

OVERALL RISK=

Probability X

Severity

RISK


Unacceptable)



RESIDUAL RISK

1 LMC-Domestic

Leakage from fittings, valves

-Minor injury

-Minor asset damage

1 1 1

Acceptable

1. Odorisation System in place. 2. Public Awareness Campaign

is done. 3. Safety leaflets should be

distributed for safety awareness.

4. Emergency contact number should be displayed.

1. Periodic Leakage survey should be done.

2. Regular awareness program to be conducted.

3. Emergency contact numbers to be displayed.

Tolerable



S. NO


EXPLANATION

PRO

BABI

LITY

RA

TIN

G

(1-Y

earl

y, 2

-Hal

fyea

rly,

3-Q

uart

erly

, 4-

Mon

thly

SEV

ERIT

Y RA

TIN

G

(1-N

o in

jury

, 2-M

inor

, 3- M

oder

ate,

4-

Fata

lity

OVERALL RISK=

Probability X

Severity

RISK


Unacceptable)



RESIDUAL RISK

2

Fire at fittings, valves, hoses

-Human injury

-Major asset damage

1 4 4

Moderate

1. Emergency Consumer Help

number is available. 2. Public Awareness Campaign

being done.

1. Awareness regarding dos & don’ts during emergency should be conducted periodically.

2. Emergency contact number should be updated upon changes/worn out.

Tolerable

3 LMC-Industrial

Leakage from fittings, valves, flanges

-Major injury

-Minor asset damage

1 3 3

Acceptable

1. Odorisation System in

place. 2. Emergency contact

numbers displayed.

1. Emergency contact number should be updated upon changes/worn out. 2. Periodic Leakage Survey should be done. 3. PM Schedule for valve,

flange, fittings, should be implemented.

Tolerable



S. NO


EXPLANATION

PRO

BABI

LITY

RA

TIN

G

(1-Y

earl

y, 2

-Hal

fyea

rly,

3-Q

uart

erly

, 4-

Mon

thly

SEV

ERIT

Y RA

TIN

G

(1-N

o in

jury

, 2-M

inor

, 3- M

oder

ate,

4-

Fata

lity

OVERALL RISK=

Probability X

Severity

RISK


Unacceptable)



RESIDUAL RISK

Fire at fittings, valves, flanges

-Major injury

-Major asset damage

1 4 4

Moderate

1. Emergency Consumer Help

number available. 2.Consumer Awareness

Campaign is done 3. Fire Fighting equipment

available.

1. Mock Drills with industrial consumers to be carried out.

2. Awareness regarding dos & don’ts during emergency should be conducted periodically.

3. Emergency contact number should be displayed

Tolerable




Name of the Project :CGD Network Location: Firozabad

Main Section : Electrical Systems Date : 17.09.15

S. NO


EXPLANATION

PR

OBA

BILI

TY R

ATI

NG

(1-Y

earl

y, 2

-Hal

fyea

rly,

3-Q

uart

erly

, 4-

Mon

thly

SEV

ERIT

Y RA

TIN

G

(1-N

o in

jury

, 2-M

inor

, 3- M

oder

ate,

4-

Fata

lity

OVERALL RISK=

Probability X

Severity

RISK


Unacceptable)



RESIDUAL RISK

1 Power backup for CP System

Electrical Shocks

Human injury 1 4 4

Moderate

1. Earthing provided and maintained.

2. Rubber Mats provided 3. Electrical Protection devices

such as MCB etc are available

4. SOPs available 5. PPE available

1. Periodic Maintenance to be done

intolerable

2 TR Unit / CPPSM

Electrical Shocks

Human injury 1 2 2

Acceptable

1. Earthing provided and maintained.

2. Rubber Mats provided 3. Electrical Protection

devices such as MCB etc are available

4. SOPs available

1. Periodic Maintenance to be done

Tolerable



S. NO


EXPLANATION

PRO

BABI

LITY

RA

TIN

G

(1-Y

earl

y, 2

-Hal

fyea

rly,

3-Q

uart

erly

, 4-

Mon

thly

SEV

ERIT

Y RA

TIN

G

(1-N

o in

jury

, 2-M

inor

, 3- M

oder

ate,

4-

Fata

lity

OVERALL RISK=

Probability X

Severity

RISK


Unacceptable)



RESIDUAL RISK

5. PPE available

Corrosion of pipe line

Pipeline Integrity get affected.

Asset Damage

Gas Leakage

Fire

Human injury

1 4 4

Moderate

1. Periodic maintenance of TR

Unit

1. Periodic Monitoring to be done Intolerable



ANNEXURE 2 Opening Meeting Attendance Sheet



ANNEXURE-3

LIST OF CONSUMERS AT FIROZABAD

SL. NO. NAME OF CONSUMER

1 A.M. PATEL GLASS INDUSTRIES 2 ADARSH GLASS WORKS 3 ADARSH KANCH UDYOG 4 ADVANCE GLASS WORKS 5 ADVANCE LAMP COMPONENT PVT.LTD. 6 AJANTA GLASS WORKS 7 AJAY GLASS WORKS 8 AKASHDEEP GLASS IND. 9 AKASHDEEP POTTERY

10 AKASHWANI GLASS WORKS 11 ALANKAR GLASS WORKS 12 ALOK GLASS WORKS 13 THE AMRIT GLASS WORKS 14 ANAND GLASS WORKS 15 ANUP GEN. INDUSTRIES 16 ANSAR GLASS WORKS 17 ANUP GLASS INDUSTRIES 18 A-ONE GLASS WORKS 19 BABY GLASS WORKS 20 BAJRANG POTTERIES, 21 BAPU INDUSTRIES 22 BHAGWATI GLASS ENTERPRISES 23 BHARAT TRADING CORPORATION 24 BHAWANI GLASS WORKS 25 BHOORE KHAN SHAHBUDDIN KHAN GLASS BANGLE FACTORY



26 CAPRIHAN CHEMICALS GLASS WORKS 27 CDGI JALESAR RD. FZ 28 CHANDRA GLASS BEADS INDUSTRIES 29 C.A.GLASS WORKS 30 CORONATION GLASS WORKS 31 CROWN GLASS INDUSTRIES 32 DAYALJI INDUSTRIES 33 DELUX GLASS INDUSTRIES 34 DINESH GLASS INDUSTRIES 35 DURGESH BLOCK & CHINA GLASS WORKS LTD. 36 EASTERN GLASS INDUSTRIES 37 ELECTRONIC GLASS IND 38 ELLORA GLASS INDUSTRIES 39 EMPEESIL GLASS WORKS 40 EXPRESS GLASS WORKS 41 FARUKHI GLAS IND. 42 FINE GLASS BEAD MANUFACTURER 43 FIROZABAD BLOCK GLASS ENT. 44 FIROZABAD CERAMICS PVT. LTD. 45 FIROZABAD GLASS SHELL IND. 46 G. NATH GLASS WORKS 47 GANESH BEADS INDUSTRIES 48 GAURAV GLASS INDUSTRIES 49 GAURI SHANKER RAM GOPAL GOPAL WORKS 50 GEETA GLASS WORKS 51 GENERAL TRADERS 52 GIRDHAR GLASS WORKS 53 GIRNAR GLASS WORKS 54 GIRDHARI LAL MANOHAR LAL GLASS WORKS NO.2 (GM) 55 THE GOLDEN GLASS WORKS



56 GYANCHAND MAHAVIR PRASAD JAIN IND. 57 HILITE GLASS PVT. LTD. 58 HIND GLASS INDUSTRIES 59 HODERIA BLOCK GLASS WORKS 60 INDUSTRIAL & BUILDING GLASS INDUSTRIES 61 INDIA OPTICAL & SCIENTIFIC GLASS WORKS 62 INTERNATIONAL GLASS WORKS 63 IRFAN GLASS WORK 64 J.P. GLASS INDUSTRIES 65 JAGDAMBA GLASS WORKS 66 JAGDISH GLASS WORKS 67 JAIN BLOCK GLASS WORKS 68 JAIN INDUSTRIES 69 JAYNA GLASS UDYOG 70 KAYCEE GLASS WORKS 71 KOHINOOR BANGLES INDUSTRIES 72 KWALITY GLASS WORKS, 73 LABOUR GLASS INDUSTRIES 74 LALJI BOARD IND. (P) LTD. 75 THE LIBERTY INDUSTRIES 76 MAHAVEER GLASS WORKS 77 MAHESH GLASS WORKS 78 MATESHWARI GLASS WORKS 79 MATHUR GLASS INDUSTRIES 80 MEERA GLASS INDUSTRIES (BYE PASS) 81 MEERA GLASS INDUSTRIES 82 MILLENIUM GLASS IND. 83 MITTAL CERAMICS 84 MODERN INDUSTRIES 85 MODERN GLASS INDUSTRIES



86 NADAR BUX & CO. GLASS WORKS 87 NANNUMAL GLASS WORKS 88 NATIONAL GLASS INDUSTRIES 89 NATIONAL GLASS WORKS 90 NAVEEN GLASS PRODUCTS 91 NAVJEEVAN GLASS INDUSTRIES 92 NEELAM GLASS INDUSTRIES 93 NEW BANSAL GLASS WORKS 94 NEW BRIGHT GLASS WORKS 95 NEW JAIN ENTERPRISES 96 NOVELTY GLASS WORKS 97 OKAY GLASS INDUSTRIES 98 OM GLASS WORKS 99 ORIENTAL GLASS WORKS 100 PARAS GLASSWARE P LTD 101 P.L.S. AUTO SHELL IND. PVT.LTD 102 PANKAJ GLASS WORKS 103 PIONEER GLASS INDUSTRIES 104 PITAMBER GLASS WORKS 105 POOJA GLASS WORKS 106 PREM GLASS WORKS 107 PRINCE GLASS WORKS 108 PURSHOTTAM GLASS WORKS 109 R.S. GLASS INDUSTRIES

110 R.R. GLASS INDUSTRIES 111 RACHNA INDUSTRIES 112 RAJA GLASS WORKS 113 RENU GLASS WORKS 114 RUBY NOVELTIES GLASS HOUSE 115 S.B. GLASS WORKS



116 S. GOPAL INDUSTREIS 117 S.R. GLASS INDUSTRIES 118 S. RAJEEV GLASS WORKS 119 SANTOSH GLASS WORKS 120 SARASWATI GLASS INDUSTRIES 121 SARASWATI BEADS INDUSTRIES 122 SARVODAYA GLASS INDUSTRIES 123 SAUBHAGYA GLASS INDUSTRIES 124 SEEMA GLASS INDUSTRIES 125 SHIV CHARAN LAL AMBICA PRASAD GLASS WORKS

126 SHIVA INDUSTRIES 127 SHRI B. K. GLASS WORKS 128 SHRI BARDHWAN PROJECT (INDIA) 129 SHRI DURGA GLASS GLASS WORKS 130 SHRI GOVIND GLASS WORKS 131 SHRI INDRA SCIENTIFIC GLASS WORKS 132 SHRI JAGDAMBA IND. 133 SHRI NATHJI GLASS WORKS

134 SHRI PADMAWATI KANCH UDYOG 135 SHREE RAGHAV GLASS WORKS 136 SHRI SATYANARAYAN GLASS WORKS 137 SHRI SHYAMA GLASS WORKS

138 SHRI SITARAM GLASS WORKS 139 SHYAM GLASS WORKS 140 SUBHASH NOVELTIES MEDICAL GDS GLASS WORKS 141 SUHAG KANCH UDYOG 142 SUN GLASS WORKS 143 SUPER GLASS WORKS 144 SWASTIK GLASS ENTERPRISES 145 TECHNICAL GLASS INDUSTRIES



146 THE BANSAL ELECTRICAL IND. 147 THE NARAYAN GLASS WORKS 148 TIGERSONS GLASS INDUSTRIES PVT. LTD. 149 UMA GLASS WORKS 150 UNITED CHEMICAL IND. 151 UNIVERSAL GLASS INDUSTRIES 152 VAIBHAV GLASS IND. 153 VED GLASS IND. 154 VENUS CHEMICAL IND. 155 VISHESH INDUSTRIES 156 WONDER GLASS WORKS 157 YADAV GLASS WORKS 158 ALANKAR INDUSTRIES NO.2 159 B.M.GLASS WORKS 160 BANSAL GLASS WORKS 161 CHOICE GLASS IND. 162 CRYSTAL GLASS IND. 163 DAMMAMAL NANNUMAL GLASS INDUSTRIES 164 EVEREST GLASS INDUSTRIES 165 INDIA ELECTRICAL GLASS WORKS 166 JUPITER GLASS WORKS 167 K.S.MIRZA KHAIRATI BAIG SHAMBHU DAYAL GLASS WORKS 168 MANOHAR GLASS WORKS 169 MUKESH GLASS INDUSTRIES 170 NEW SUPER GLASS IND. 171 PRAGATI INDUSTRIES 172 RADHA GLASS WORKS 173 SANJAY GLASS WORKS 174 SHRI GANESH BLOCK GLASS WORKS 175 SUNRISE GLASS WORKS



176 UTTAM GLASS WORKS 177 VAISH GLASS WORKS 178 HARIOM GLASS INDUSTRIES 179 PREM GLASS INDUSTRIES 180 SHREE RAM GLASS WORKS 181 SHRI KRISHNA GLASS WORKS 182 INDIAN GLASS WORKS 183 SAROJINI NAIDU GLASS WORKS 184 GOYAL IRON & STEEL WORKS 185 BANKEY BEHARI GLASS IND -2 186 N.U. GLASS WORKS 187 CHURI PAKAI BHATTI 188 PAKAI BHATTI VIKASH 189 VINOWA GLASS WORKS 190 JANHIT PAKAI BHATTI SHE SEVA 191 SUHAG NAGRI PAKAI BHATTI 192 GIRDHARI LAL MANOHAR LAL GLASS WORKS 193 ARKEY GLASS WORKS 194 STAR GLASS WORKS 195 SHREE GURU NANAK GLASS WORKS 196 MANOJ GLASS WORKS 197 G.K.GLASS INDUSTRIES 198 QADRI GLASS WORKS 199 MODERN KANCH AUDHYOGIK 200 LAGHU UDHYOG PAKAI BHATTI 201 SHRI SANT GLASS WORKS