Hazard Identification & Risk Analysis Report of GAIL …...CEIL/9530/HIRA/GAIL GAS KOTA/AKS/20 Page - 1 - of 70 Hazard Identification & Risk Analysis Report of GAIL Gas Limited, Kota

CEIL/9530/HIRA/GAIL GAS KOTA/AKS/20 Page - 1 - of 70

Hazard Identification & Risk Analysis Report of

GAIL Gas Limited, Kota (Rajasthan)

By

Certification Engineers International Limited

Dates of survey : 27.02.2015 to 28.2.2015 Number of days : 02 (Two) Days

HIRA Report of GAIL Gas Limited, CGD Network, Kota (Rajasthan)

CEIL/9530/15-16/HIRA/GAIL Gas Kota/AKS/20 Page - 2 - of 70

CONTENTS

Sl. No. Topic Page No.

1 Abbreviation 03 2 Executive Summary 05 3 About CEIL 07 4 Scope 09 5 HIRA Methodology 10 6 Facility Description 17 7 Documents referred 19 8 Closing Meeting 20

9 Conclusion 20 10 Confidentiality 20 11 Management plan for intolerable risk 21 11 Annexures :

Annexure 1: HIRA Work Sheets Annexure 2: Attendance Sheet Opening Meeting Annexure 3: Attendance Sheet Closing Meeting Annexure 4: List of Industrial and Commercial Customers Annexure 5: Kota CGD Project: Gail Gas Limited Annexure 6: Steel and MDPE Pipe Line Network Of Gail Gas, Kota Annexure 7: Piped Natural Gas (PNG) Distribution Network Of Gail Gas Ltd. at Mahavir Nagar I, Kota

26



1. ABBREVIATIONS :

S. N Abbreviation Expansion 1. ESD Emergency Shut Down 2. CIPL: Close Interval potential Logging 3. CGD: City Gas Distribution 4. CGS: City Gate Station 5. CP Cathodic Protection 6. CNG Compressed natural Gas 7. DCP Dry Chemical Powder 8. DCS Distributed control systems 9. DCVG Direct Current Voltage Gradient 10. DDMA District Disaster Management Authority 11. DGFASL Directorate General, Factory Advice

Service and Labour Institutes 12. DPRS: District Pressure Regulating Station 13. EMS Energy Management System 14. ECU Emergency Control Unit 15. ERDMP Emergency response to disaster

management planning 16. ESA: External Safety Audit 17. FRS: Field Regulating Skid 18. GPS: Global Positioning System 19. HAZCHEM: Hazardous Chemicals 20. HAZOP: Hazardous Analysis and Operability/

Hazardous Operations 21. HDD: Horizontal Direct Drilling 22. IR: Infra-Red 23. LPG: Liquefied Petroleum Gas 24. MDPE Medium Density Poly Ethylene 25. MoE&F: Ministry of Environment and Forests 26. MoP&NG Ministry of Petroleum and Natural Gas 27. MoST&H Ministry of Surface Transport and Highways 28. MRS: Metering Regulating Skid 29. MSDS: Material safety data sheet 30. MSIHC

Manufacture, Storage and Import of Hazardous Chemical



31. NDMA: National Disaster Management Authority 32. MV Act: Motor Vehicle Act 33. NFPA: National Fire Protection Association 34. NG: Natural Gas 35. OISD: Oil Industry Safety Directorate 36. OMC: Oil Manufacturing Companies 37. PCV: Pressure Control Valve 38. PESO: Petroleum and Explosive Safety

Organization 39. PNGRB: Petroleum and Natural Gas Regulatory

Board 40. P/L Pipeline 41. PNG: Piped Natural Gas 42. POL: Petroleum, Oil and Liquid 43. PRI: Pressure Regulating Installation 44. PSP Pipe to Soil Potential 45. PSV: Pressure safety Valve 46. QRA: Quantitative Risk Assessment 47. SIL: Safety Integrity Level 48. SCCDA Stress Corrosion Cracking Direct Assessment 49. SDRF State Disaster Response Force

50. SV: Sectionalizing Valve/ Strategic Valve 51. TLP: Test Lead Point 52. TPIA: Third Party Inspection Agency 53. TR: Transformer Rectifier 54. TREM: Transport Emergency Management 55. TT: Tank Truck 56. VTS: Vehicle Tracking System



2. EXECUTIVE SUMMARY :

M/s GAIL Gas Limited have 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, Kota region.

Gail Gas Ltd., Kota has a spread of approximately 40.04 km of steel pipeline network and 52.2 km of MDPE pipe network. GAIL Gas Kota has 18 industrial customers and 192 PNG connections.

CEIL Team comprising of two specialists visited the site during 27-28 February, 2015 at Kota, Rajasthan 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 alongwith 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. Strong commitment of O&M employees. 2. Strong track record of 14424 Man hours accident free record (2011 to

31.01.2015) i.e. no major accident since start of the GAIL Gas. 3. Standard display of HSE Policy, Emergency Telephone numbers, PPE and

Fire Fighting equipment provided. 4. Regular meeting with District authorities. Sensitization of local public

through awareness campaign and personal contacts.



Points to be attended:

1. Pipeline Coating Health Survey of Steel Pipeline network to be carried out. 2. CIPL and DCVG Surveys to be carried out to monitor corrosion 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. Odour level tests should be carried out at last mile connectivity to ensure

proper odorisation. 8. Designated person for handling Odorisation System to be identified. 9. Training to contractors of other utility companies sharing the same corridor

should be imparted. 10. A utility coordination team consisting of representative from all other utility

companies and civil authorities may be formed. 11. GIS Mapping of entire CGD Network to be carried out. 12. Effectiveness of patrolling frequency to be periodically reviewed. 13. O-rings of dispensing nozzle to be checked periodically. 14. Customer Waiting Area should be outside the dispensing premises. 15. Periodic calibration of all PSVs to be ensured. 16. Air Compressor interlocks to be checked during Preventive Maintenance

Schedule. 17. During Compressor maintenance, no loose clothes to be worn by

maintenance personnel. 18. Periodic calibration of LEL and UV Detectors to be carried out as per

Preventive Maintenance Schedule. 19. If calibration is outsourced, random witness of calibration of said

instruments to be carried out by GAIL Gas personnel. 20. Periodic Hydrotest of cascades should be ensured as per Gas Cylinder

Rules. 21. During Stationery Cascade maintenance, surprise checks by GAIL Gas

personnel should be carried out. 22. During Stationery Cascade maintenance, Non-sparking tools should be

used for such maintenance. 23. Liasioing with relevant civic authorities to be maintained.



24. Consequences of LCV accident/fire to be briefed during public awareness.

25. Training to contractors of other utility companies sharing the same corridor should be imparted.

26. Line Diagram of the connection piping should be fixed at the entrance of group housing societies/cluster of houses.

27. Mock Drills with all consumers to be carried out periodically. 28. 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)



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 9001 as 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 City Gas distribution network of GAIL Gas Limited, Kota region. This include CNG stations, Gas distribution to various customers and PNG distribution, DRS, MRS, IV, LMC etc.



5. HIRA CONCEPT AND METHODOLOGY:

1) 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:

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

2) Risk: The likelihood, or possibility, that harms (injury, disease, death,

damage) may occur from exposure to a hazard 3) 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.

4) Risk Assessment is a systematic process of assessing 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.

5) Risk Control details out taking actions to eliminate safety and health risks so far as is reasonably practicable. Where risks cannot be eliminated, then implementation of control measures is required, to minimize risks so far as is reasonably practicable.



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 :

FREQ

UEN

CY

4 Moderate High Unacceptable

Unacceptable

3 Acceptabl Moderat High High



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

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.

e e

2 Acceptable

Moderate

Moderate High

1 Acceptable

Acceptable

Acceptable

Moderate

1 2 3 4

SEVERITY



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.

However, as ‘Fatality’ is considered as the most serious consequence, hence, if there is an Overall Risk of 4 wherein ‘Fatality’ is involved, such risk will still be treated as ‘Intolerable’.

Intolerable risks have been classified as having potential for single or multiple fatalities. For such risks where the hazard involves loss of human life, remedial action of some kind has to be undertaken. There are four ways of handling any type of risks:

• Terminate • Treat • Tolerate • Transfer

All operational risks fall under these four categories. Suitable mitigating measures are devised and implemented to contain the risks. For the risks which are intolerable, an Incident Management Plan is prepared and activities are carried out in case of an incident, the Incident Management Plan is activated. In no case, an activity related to intolerable risks are stalled merely because they are intolerable as there is a well-defined Incident Management Plan in place.

CEIL Team Leader carried out planning together with GAIL Gas Limited Noida and Dewas 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 Dewas on 29th October 2015 which was attended by GAIL Gas Limited officials of Dewas office and CEIL team. The OIC gave a presentation regarding facilities at GAIL Gas, Dewas 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 30th October 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.



Listing out key Operation and Maintenance activities.

• Identification of possible/potential hazards in these identified activities. • Assessment 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/ Applicable standards:

vi. IS 14489 reaffirmed 2002 (Code of Practice on Occupational Health and Safety).

vii. OISD Standard-226 (Cross Country NG Pipelines’ and ‘CGD Pipe line network)

viii. OHSAS 18001 ix. Applicable Statutory Regulations/National/International Standards,

Industrial Safe practices. x. IS-15656- Code of practice for Hazard Identification & Risk Analysis.



6. FACILITY DESCRIPTION:

a) GAIL Gas Limited Kota receives gas from GAIL (India) Limited Vijaipur through GAIL terminal at Sri Ram fertilizers Kota. Gas supply is for 18 industries as per annex list (Annexure 3), and one commercial customer M/s Student Complete Care, 192 PNG customers. There are two CNG stations one at RIICO and one in JK Nagar and one CNG daughter station Sainik Filling Station, which is operated by private organization. Average gas requirement is about 20000 SCM which is distributed through. 40.04 km steel pipe network of 8”/10” and 52.2 km MDPE pipe line network of 63/32/20 mm size (Details of the Steel and MDPE pipe line network shown at Annexure 4 and 5). GAIL Gas Kota has Mutual Aid agreement with Shri Ram Rayons, Bharat Petroleum and HPCL. All SOPs are in place.

b) Odorisation:

Regular odourisation of gas is being done as per norms. Ethyl Mercaptan is received in drums and is transferred to the storage tank by the supplier. The empty drums are taken back. Dosing of Mercaptan is automatic in the pipeline. The system is in manual mode hence fixed quantity is being dosed.

c) TR Units:

There are 2 TR unit both inter connected one at Naya Nohara and other at JK Nagar

d) Mother Stations & Daughter Station:

RIICO: Have stationary cascades, and also provision for mobile cascade unit, fitted on LCV. Compressor of capacity 1200 SCM/Hr starts at 185 Kg and stops at 245 Kg pressure. 2flame detector, 2 LEL and Co2 flooding system is provided in the compressor system.

JK Nagar: Have stationary cascades, and also provision for mobile cascade unit, fitted on LCV. Compressor of capacity 1200 SCM/Hr starts at 185 Kg and stops at 245 Kg pressure. 2flame detector, 2 LEL and Co2 flooding system is provided in the Compressor system.

Daughter Station Sainik Filling Station: Mobile cascades. Cascades are filled mostly at JK Nagar CNG station. It can also be filled at RIICO CNG Station.



e) Training GAIL Gas is organizing regular training programs as follows:

• Public awareness • Critical Safety Campaign • Work at Height • Consumer Training: for operators and consumers for safe refueling of

CNG • Contract Employees Training • Fire Fighting.

GAIL GAS CGD NETWORK ACTIVITY LIST

S. No. SECTION ACTIVITY

1 CGS Odorisation

2 Steel Pipeline Network Gas transmission, Isolation

3 DRS Filtration, Pressure reduction, Isolation

4 MRS Filtration, Pressure reduction, Isolation , Metering

5

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.

6 MDPE Pipeline Network

Gas distribution, Isolation, Surveillance.

7 Last Mile Connectivity-Commercial & Domestic

Isolation, Pressure reduction, Metering



7. DOCUMENTS REFERRED

In general, following documents were referred:

i. HSE Policy / Manual ii. List of Equipments / Facilities / Fire Water & Fire Fighting equipments

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. Operating Procedures x. Hot Work Permit System.

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

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



8. CLOSING MEETING Closing Meeting was held on 28th February, 2015 and presided over by OIC.

The Closing Meeting was attended by following officials of GAIL Gas, Kota: Attendees

1. Shri R.P. Srivastav (Chief Manager) 2. Shri V.K. Chaturvedi (SM-CGM) 3. Shri P.J. Gogoi (Manager-PE) 4. Shri P.M. Bhatt (DM-CGM) 5. Shri S.K. Tyagi (Sr. Officer-F&S) 6. Shri P.D. Meena (Officer)

9. CONCLUSION

The HIRA Study for GAIL Gas limited, Kota 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:

1. Mr. Ajay Sharma (Team Leader) 2. Mr. Girish Kumar (Surveyor)

10. CONFIDENTIALITY

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

(Shri. Ajay Sharma) (Shri. Girish Kumar) Team Leader Surveyor



11. 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


CEIL/9530/15-16/HIRA/GAIL Gas Kota/AKS/20 Page 25 of 70

GAIL GAS LIMITED, KOTA

HAZARD IDENTIFICATION & RISK ANALYSIS FORMAT

Name of the Project : Location:

Main Activity : Date:

S. NO ACTIVITY

PRO

BABI

LITY

RA

TING

(L

-May

occ

ur, M

-Can

occ

ur,

H-W

ill o

ccur

)

SEVE

RITY

RA

TING

(L

, M,H

) OVERALL RISK/ IMPACT LEVEL = PROBABILITY

x SEVERITY

EXISTING CONTROL MEASURES

ADDITIONAL CONTROL MEASURES RESIDUAL RISK / IMPACT CONCERN

IMPACT EXPLANATION



GAIL GAS LIMITED

HAZARD IDENTIFICATION & RISK ANALYSIS

Name of the Project : CGD Network Location: Kota

Main Section : CGS Date : 28.02.15

S. NO

ACTIVITY HAZARD IMPACT

EXPLANATION

PRO

BABI

LITY

RA

TING

(1

-Yea

rly, 2

-Hal

fyea

rly, 3

-Qua

rterly

, 4-

Mon

thly

SEVE

RITY

RA

TING

(1

-No

inju

ry, 2

-Min

or, 3

- Mod

erat

e, 4

-Fat

ality

OVERALL RISK=

Probability X

Severity

RISK

RANK (Acceptable/Moderate

/ High/ Unacceptable)


ADDITIONAL CONTROL MEASURES

RESIDUAL RISK

1 Odorisation Spillage

-Air pollution

-Being highly toxic, health gets affected.

1 2 2

Acceptabl

e

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 and records to be maintained.

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

Tolerable



S. NO


EXPLANATION

PRO

BABI

LITY

RA

TING

(1

-Yea

rly, 2

-Hal

fyea

rly, 3

-Qua

rterly

, 4-

Mon

thly

SEVE

RITY

RA

TING

(1

-No

inju

ry, 2

-Min

or, 3

- Mod

erat

e, 4

-Fat

ality

OVERALL RISK=

Probability X

Severity

RISK

RANK (Acceptable/Moderate

/ High/ Unacceptable)



RESIDUAL RISK

Sodium Hypochlorite as neutralizer to be made available.

Being flammable, fire may occur ,

-Human Injury

-Asset damage

1 3 3 Acceptable

1. Fire extinguishers available.

2. Fire Fighting Training imparted to concerned personnel.

3. ERDMP is in place. 4. MSDS displayed at the

unit. 5. Emergency contact

number displayed for use in case of emergency

1. Inspection of dosing unit should be done periodically and records to be maintained.

2. Neutralization materials to be made available for containment.

Tolerable



HAZARD IDENTIFICATION & RISK ASSESSMENT


Main Section : DRS & MRS Date : 28.02.15

S. NO ACTIVITY HAZARD

IMPACT EXPLANATIO

N

PR

OBA

BILI

TY R

ATIN

G

(1-Y

early

, 2-H

alfy

early

, 3-

Qua

rterly

, 4-M

onth

ly

SEVE

RITY

RA

TING

(1

-No

inju

ry, 2

-Min

or, 3

- M

oder

ate,

4-F

atal

ity

OVERALL RISK= Probabi

lity X Severity

RISK

RANK (Acceptable/Mod

erate/ High/

Unacceptable)



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




IMPACT EXPLANATIO

N

PRO

BABI

LITY

RA

TING

(1

-Yea

rly, 2

-Hal

fyea

rly, 3

-Q

uarte

rly, 4

-Mon

thly

SE

VERI

TY R

ATIN

G

(1-N

o in

jury

, 2-M

inor

, 3-

Mod

erat

e, 4

-Fat

ality


lity X Severity

RISK


erate/ High/

Unacceptable)



RESIDUAL RISK

3 Gas flow Leakage & Fire

Loss of gas, Fatal, asset damage, environment affected.

1 4 4

Moderate

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

2.Contact numbers displayed for passing the information.

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

1. PM Schedule including calibration of PSV, 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.

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

Tolerable




IMPACT EXPLANATIO

N

PRO

BABI

LITY

RA

TING

(1

-Yea

rly, 2

-Hal

fyea

rly, 3

-Q

uarte

rly, 4

-Mon

thly

SE

VERI

TY R

ATIN

G

(1-N

o in

jury

, 2-M

inor

, 3-

Mod

erat

e, 4

-Fat

ality


lity X Severity

RISK


erate/ High/

Unacceptable)



RESIDUAL RISK

3. Isolation Isolation Valve is passing

Affected part of pipeline cannot be isolated, gas loss.

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 implemented

Tolerable



GAIL GAS LIMITED



Main Section : CNG Station-Mother Date : 27.02.15

S. NO

ACTIVITY HAZARD IMPACT EXPLANATION

PRO

BABI

LITY

RA

TING

(1

-Yea

rly, 2

-Hal

fyea

rly, 3

-Q

uarte

rly, 4

-Mon

thly

SE

VERI

TY R

ATIN

G

(1-N

o in

jury

, 2-M

inor

, 3-

Mod

erat

e, 4

-Fat

ality


lity X Severity

RISK


erate/ High/

Unacceptable)



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



S. NO


PRO

BABI

LITY

RA

TING

(1

-Yea

rly, 2

-Hal

fyea

rly, 3

-Q

uarte

rly, 4

-Mon

thly

SE

VERI

TY R

ATIN

G

(1-N

o in

jury

, 2-M

inor

, 3-

Mod

erat

e, 4

-Fat

ality


lity X Severity

RISK


erate/ High/

Unacceptable)



RESIDUAL RISK

Fire

Fatal

Asset damage

1 4 4

Moderate

1. Flame Detection &Shutdown System in place.

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

3. SOP for CNG Package available.

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

2. O&M and F&S refresher 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.

Tolerable



S. NO


PRO

BABI

LITY

RA

TING

(1

-Yea

rly, 2

-Hal

fyea

rly, 3

-Q

uarte

rly, 4

-Mon

thly

SE

VERI

TY R

ATIN

G

(1-N

o in

jury

, 2-M

inor

, 3-

Mod

erat

e, 4

-Fat

ality


lity X Severity

RISK


erate/ High/

Unacceptable)



RESIDUAL RISK

2 Dispensing

Leakage while dispensing

Gas loss, human injury 3 2

6

Moderat

e

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 operation available.

6. Dos & Don’ts are displayed near dispensing area.

7. Safety precautions should be followed during dispensing

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.

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

Tolerable



S. NO


PRO

BABI

LITY

RA

TING

(1

-Yea

rly, 2

-Hal

fyea

rly, 3

-Q

uarte

rly, 4

-Mon

thly

SE

VERI

TY R

ATIN

G

(1-N

o in

jury

, 2-M

inor

, 3-

Mod

erat

e, 4

-Fat

ality


lity X Severity

RISK


erate/ High/

Unacceptable)



RESIDUAL RISK

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, loss of gas, Fatal

1 4 4

Moderate

1. Fire Extinguishers available

2. Regular training to Dispensing Boys.

3. Awareness Training to CNG consumers.

4. SOP for Dispenser operation available.

5. ERDMP is in place.

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

Tolerable



S. NO


PRO

BABI

LITY

RA

TING

(1

-Yea

rly, 2

-Hal

fyea

rly, 3

-Q

uarte

rly, 4

-Mon

thly

SE

VERI

TY R

ATIN

G

(1-N

o in

jury

, 2-M

inor

, 3-

Mod

erat

e, 4

-Fat

ality


lity X Severity

RISK


erate/ High/

Unacceptable)



RESIDUAL RISK

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.

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.



S. NO


PRO

BABI

LITY

RA

TING

(1

-Yea

rly, 2

-Hal

fyea

rly, 3

-Q

uarte

rly, 4

-Mon

thly

SE

VERI

TY R

ATIN

G

(1-N

o in

jury

, 2-M

inor

, 3-

Mod

erat

e, 4

-Fat

ality


lity X Severity

RISK


erate/ High/

Unacceptable)



RESIDUAL RISK

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 Moderat

e

1. Stoppers are available.

2. SOP for LCV filling in place.

3. Leak Test is done before filling

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.

Tolerable

Leakage from hose pipe, tube

1 4 4

Moderate

1. Portable LEL Detector available for leak test.

1. Awareness training to the LCV drivers should be imparted

Tolerable



S. NO


PRO

BABI

LITY

RA

TING

(1

-Yea

rly, 2

-Hal

fyea

rly, 3

-Q

uarte

rly, 4

-Mon

thly

SE

VERI

TY R

ATIN

G

(1-N

o in

jury

, 2-M

inor

, 3-

Mod

erat

e, 4

-Fat

ality


lity X Severity

RISK


erate/ High/

Unacceptable)



RESIDUAL RISK

and fittings, Fatal

2. PM Schedule of hose and coupling is done.

3. Odorisation System in place.

periodically. 2. Periodic calibration of

measuring instruments should be done.

3. Periodic leakage survey should be done.


4

Power generation through Gas engine Generator

Leakage from fuel

line

Gas loss, Human injury. 1 3 3 Accepta

ble

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 provided.

Tolerable



S. NO


PRO

BABI

LITY

RA

TING

(1

-Yea

rly, 2

-Hal

fyea

rly, 3

-Q

uarte

rly, 4

-Mon

thly

SE

VERI

TY R

ATIN

G

(1-N

o in

jury

, 2-M

inor

, 3-

Mod

erat

e, 4

-Fat

ality


lity X Severity

RISK


erate/ High/

Unacceptable)



RESIDUAL RISK

3. Housekeeping should be ensured.

4. Regular maintenance of the generator to be ensured.

5. SOP to be followed for safe operation

Electroc

ution 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



S. NO


PRO

BABI

LITY

RA

TING

(1

-Yea

rly, 2

-Hal

fyea

rly, 3

-Q

uarte

rly, 4

-Mon

thly

SE

VERI

TY R

ATIN

G

(1-N

o in

jury

, 2-M

inor

, 3-

Mod

erat

e, 4

-Fat

ality


lity X Severity

RISK


erate/ High/

Unacceptable)



RESIDUAL RISK

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 place.

4. Electrical O&M & safety training being imparted.



3. Deployment of trained personnel to be ensured.


5. PPE should be used for while working.

Tolerable

Improper /

Discontinued

Earthing

-Damage to asset,

Fatal 1 4 4

Moderate

1 Earth Pits provided. 2. Periodic monitoring

of Earth Pits Resistance is done.




3. Deployment of trained personnel to be

Tolerable



S. NO


PRO

BABI

LITY

RA

TING

(1

-Yea

rly, 2

-Hal

fyea

rly, 3

-Q

uarte

rly, 4

-Mon

thly

SE

VERI

TY R

ATIN

G

(1-N

o in

jury

, 2-M

inor

, 3-

Mod

erat

e, 4

-Fat

ality


lity X Severity

RISK


erate/ High/

Unacceptable)



RESIDUAL RISK

ensured. 4. SOP to be followed for

safe operation. 5. PPE should be used for

while working.

6

CNG customer vehicle movement

Sudden moveme

nt 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 the vehicle.

4. Awareness training for CNG customers arranged regularly.

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 filling to be ensured.

3. SOP to be followed for safe filling.

Tolerable



S. NO


PRO

BABI

LITY

RA

TING

(1

-Yea

rly, 2

-Hal

fyea

rly, 3

-Q

uarte

rly, 4

-Mon

thly

SE

VERI

TY R

ATIN

G

(1-N

o in

jury

, 2-M

inor

, 3-

Mod

erat

e, 4

-Fat

ality


lity X Severity

RISK


erate/ High/

Unacceptable)



RESIDUAL RISK

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 the safety in the CNG station

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

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

Tolerable



S. NO


PRO

BABI

LITY

RA

TING

(1

-Yea

rly, 2

-Hal

fyea

rly, 3

-Q

uarte

rly, 4

-Mon

thly

SE

VERI

TY R

ATIN

G

(1-N

o in

jury

, 2-M

inor

, 3-

Mod

erat

e, 4

-Fat

ality


lity X Severity

RISK


erate/ High/

Unacceptable)



RESIDUAL RISK

8

Working at height during Electric pole,

Canopy maintenanc

e

Fall Fatal 1 4 4

Moderate


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


PRO

BABI

LITY

RA

TING

(1

-Yea

rly, 2

-Hal

fyea

rly, 3

-Q

uarte

rly, 4

-Mon

thly

SE

VERI

TY R

ATIN

G

(1-N

o in

jury

, 2-M

inor

, 3-

Mod

erat

e, 4

-Fat

ality


lity X Severity

RISK


erate/ High/

Unacceptable)



RESIDUAL RISK

9 Air

Compression

Overpressure

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

calibrati

Gas leakage & Fire will go

1 4 4 Moderat

1. Periodic calibration of Gas Leak and Flame Detectors

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

Tolerable



S. NO


PRO

BABI

LITY

RA

TING

(1

-Yea

rly, 2

-Hal

fyea

rly, 3

-Q

uarte

rly, 4

-Mon

thly

SE

VERI

TY R

ATIN

G

(1-N

o in

jury

, 2-M

inor

, 3-

Mod

erat

e, 4

-Fat

ality


lity X Severity

RISK


erate/ High/

Unacceptable)



RESIDUAL RISK

on undetected e being done. 2. Hand Held LEL

Detectors available

implemented.

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



S. NO


PRO

BABI

LITY

RA

TING

(1

-Yea

rly, 2

-Hal

fyea

rly, 3

-Q

uarte

rly, 4

-Mon

thly

SE

VERI

TY R

ATIN

G

(1-N

o in

jury

, 2-M

inor

, 3-

Mod

erat

e, 4

-Fat

ality


lity X Severity

RISK


erate/ High/

Unacceptable)



RESIDUAL RISK

Fire at manifold

valve, fittings due to use of normal tool/in

presence of

ignition source

-Fatal

-Major asset loss

1 4 4

Moderate

1. Fire extinguishers are available.

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

1. Surprise checks by GAIL Gas personnel should be done 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.

Tolerable



GAIL GAS LIMITED



Main Section : LMC Date : 28.02.15

S. NO


EXPLANATION

PRO

BABI

LITY

RA

TING

(1

-Yea

rly, 2

-Hal

fyea

rly, 3

-Qua

rterly

, 4-

Mon

thly

SEVE

RITY

RA

TING

(1

-No

inju

ry, 2

-Min

or, 3

- Mod

erat

e,

4-Fa

talit

y


lity X Severity

RISK

RANK (Acceptable/Moderate/ High/

Unacceptabl

e)

EXISTING CONTROL MEASURES ADDITIONAL CONTROL

MEASURES 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

TING

(1

-Yea

rly, 2

-Hal

fyea

rly, 3

-Qua

rterly

, 4-

Mon

thly

SEVE

RITY

RA

TING

(1

-No

inju

ry, 2

-Min

or, 3

- Mod

erat

e,

4-Fa

talit

y


lity X Severity

RISK


Unacceptabl

e)



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

TING

(1

-Yea

rly, 2

-Hal

fyea

rly, 3

-Qua

rterly

, 4-

Mon

thly

SEVE

RITY

RA

TING

(1

-No

inju

ry, 2

-Min

or, 3

- Mod

erat

e,

4-Fa

talit

y


lity X Severity

RISK


Unacceptabl

e)



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



GAIL GAS LIMITED



Main Section : MDPE Pipeline Network Date : 28.02.15

S. NO

ACTIVITY

PR

OBA

BILI

TY R

ATIN

G

(1-Y

early

, 2-H

alfy

early

, 3-Q

uarte

rly, 4

-M

onth

ly

SEVE

RITY

RA

TING

(1

-No

inju

ry, 2

-Min

or, 3

- Mod

erat

e, 4

-Fa

talit

y


lity X Severity

RISK

RANK (Acceptable/Moderat

e/ High/ Unaccepta

ble)

EXISTING CONTROL MEASURES ADDITIONAL

CONTROL MEASURES RESIDUAL RISK HAZARD

IMPACT EXPLANATIO

N

1 Gas transmission

Leakage

-Minor asset damage

-Environment gets affected

2 2 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. The pit maintenance

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

2. Adequate number of markers should be installed at specified

Tolerable



S. NO

ACTIVITY

PRO

BABI

LITY

RA

TING

(1

-Yea

rly, 2

-Hal

fyea

rly, 3

-Qua

rterly

, 4-

Mon

thly

SEVE

RITY

RA

TING

(1

-No

inju

ry, 2

-Min

or, 3

- Mod

erat

e, 4

-Fa

talit

y


lity X Severity

RISK


e/ High/ Unaccepta

ble)



IMPACT EXPLANATIO

N

being done. intervals for identification of the pipe line underground.

3. Training to contractors of other utility 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 1 4

4

1. Routine Patrolling is done. 2. Periodic Awareness

campaign for general public is done.

1.PM Schedule of SV should be implemented to

Tolerable



S. NO

ACTIVITY

PRO

BABI

LITY

RA

TING

(1

-Yea

rly, 2

-Hal

fyea

rly, 3

-Qua

rterly

, 4-

Mon

thly

SEVE

RITY

RA

TING

(1

-No

inju

ry, 2

-Min

or, 3

- Mod

erat

e, 4

-Fa

talit

y


lity X Severity

RISK


e/ High/ Unaccepta

ble)



IMPACT EXPLANATIO

N

damage

-Environment affected

Moderate




6. The pit maintenance being done.

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 implemented.

2 Third Party Damage

Asset damage, Moderate human injury, gas leakage,

2 3 6

1. Routine surveillance is done.

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

3. Periodic Awareness

1. GIS Mapping should be carried out.

2. Effectiveness of patrolling frequency to be periodically reviewed.

Tolerable



S. NO

ACTIVITY

PRO

BABI

LITY

RA

TING

(1

-Yea

rly, 2

-Hal

fyea

rly, 3

-Qua

rterly

, 4-

Mon

thly

SEVE

RITY

RA

TING

(1

-No

inju

ry, 2

-Min

or, 3

- Mod

erat

e, 4

-Fa

talit

y


lity X Severity

RISK


e/ High/ Unaccepta

ble)



IMPACT EXPLANATIO

N

customers gets affected

High

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.


9. SOP for SV operation in place.

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



S. NO

ACTIVITY

PRO

BABI

LITY

RA

TING

(1

-Yea

rly, 2

-Hal

fyea

rly, 3

-Qua

rterly

, 4-

Mon

thly

SEVE

RITY

RA

TING

(1

-No

inju

ry, 2

-Min

or, 3

- Mod

erat

e, 4

-Fa

talit

y


lity X Severity

RISK


e/ High/ Unaccepta

ble)



IMPACT EXPLANATIO

N

10. Emergency action plan is in place.



GAIL GAS LIMITED



Main Section : Steel P/L Date : 28.02.15

S. NO


EXPLANATION

PRO

BABI

LITY

RA

TING

(1

-Yea

rly, 2

-Hal

fyea

rly, 3

-Qua

rterly

, 4-

Mon

thly

SEVE

RITY

RA

TING

(1

-No

inju

ry, 2

-Min

or, 3

- Mod

erat

e,

4-Fa

talit

y


lity X Severity

RISK


Unacceptabl

e)



RESIDUAL RISK

1 Gas transmission

Leakage

-Major asset damage


1 3 3

Acceptable

1. Routine Patrolling is done.



4. SOP for Steel Pipeline Network in place.



2. The pit maintenance should be done.

3. Adequate number of markers should be installed at specified

Tolerable



S. NO


EXPLANATION

PRO

BABI

LITY

RA

TING

(1

-Yea

rly, 2

-Hal

fyea

rly, 3

-Qua

rterly

, 4-

Mon

thly

SEVE

RITY

RA

TING

(1

-No

inju

ry, 2

-Min

or, 3

- Mod

erat

e,

4-Fa

talit

y


lity X Severity

RISK


Unacceptabl

e)



RESIDUAL RISK

intervals for identification of the pipe line underground.

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

Fire

-Fatal

-Major asset damage

-Environment

1 4 4

Moderate

1. Routine Patrolling is being done.



4. SOP for Steel Pipeline Network in place.


2. The pit maintenance should be done.

3. Adequate number of markers should be

Tolerable



S. NO


EXPLANATION

PRO

BABI

LITY

RA

TING

(1

-Yea

rly, 2

-Hal

fyea

rly, 3

-Qua

rterly

, 4-

Mon

thly

SEVE

RITY

RA

TING

(1

-No

inju

ry, 2

-Min

or, 3

- Mod

erat

e,

4-Fa

talit

y


lity X Severity

RISK


Unacceptabl

e)



RESIDUAL RISK

affected 5. O&M team available for leak repair.


installed at specified intervals for identification of the pipe line underground.

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

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

2 Third Party Damage

-Fatal

-Asset damage,

-Gas

1 4 4

Moderate

1. Routine surveillance is done.

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

1. GIS Mapping should be carried out.

2. Effectiveness of patrolling frequency to be periodically

Tolerable



S. NO


EXPLANATION

PRO

BABI

LITY

RA

TING

(1

-Yea

rly, 2

-Hal

fyea

rly, 3

-Qua

rterly

, 4-

Mon

thly

SEVE

RITY

RA

TING

(1

-No

inju

ry, 2

-Min

or, 3

- Mod

erat

e,

4-Fa

talit

y


lity X Severity

RISK


Unacceptabl

e)



RESIDUAL RISK

leakage

-Fire


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.



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.




S. NO


EXPLANATION

PRO

BABI

LITY

RA

TING

(1

-Yea

rly, 2

-Hal

fyea

rly, 3

-Qua

rterly

, 4-

Mon

thly

SEVE

RITY

RA

TING

(1

-No

inju

ry, 2

-Min

or, 3

- Mod

erat

e,

4-Fa

talit

y


lity X Severity

RISK


Unacceptabl

e)



RESIDUAL RISK

Corrosio

n

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 implemented.

Tolerable. Refer

Management Plan





Main Section : SV and IV Date : 28.02.2015

S. NO


PRO

BABI

LITY

RA

TING

(1

-Yea

rly, 2

-Hal

fyea

rly, 3

-Q

uarte

rly, 4

-Mon

thly

SE

VERI

TY R

ATIN

G

(1-N

o in

jury

, 2-M

inor

, 3-

Mod

erat

e, 4

-Fat

ality


lity X Severity

RISK


erate/ High/

Unacceptable)



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 maintenance & operation test.

Tolerable

Leakage

Environment get effected

Minor Asset Damage

1 2 2

acceptable



3. Periodic LEL checking

4. Regular cleaning of pit

5. painting of pit & water proofing wherever

1. Continuous odorisation to be ensured

Tolerable



S. NO


PRO

BABI

LITY

RA

TING

(1

-Yea

rly, 2

-Hal

fyea

rly, 3

-Q

uarte

rly, 4

-Mon

thly

SE

VERI

TY R

ATIN

G

(1-N

o in

jury

, 2-M

inor

, 3-

Mod

erat

e, 4

-Fat

ality


lity X Severity

RISK


erate/ High/

Unacceptable)



RESIDUAL RISK

necessary 6. Odorising of the

gas.

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

1 4 4

1. Heavy cover with lock is in place

2. Routine patrolling 3. Periodic

awareness Campaign, sensitization

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

Tolerable



S. NO


PRO

BABI

LITY

RA

TING

(1

-Yea

rly, 2

-Hal

fyea

rly, 3

-Q

uarte

rly, 4

-Mon

thly

SE

VERI

TY R

ATIN

G

(1-N

o in

jury

, 2-M

inor

, 3-

Mod

erat

e, 4

-Fat

ality


lity X Severity

RISK


erate/ High/

Unacceptable)



RESIDUAL RISK

Human injury Moderate

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

4. Periodic meeting with local authorities

5. Availability warning 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



S. NO


PRO

BABI

LITY

RA

TING

(1

-Yea

rly, 2

-Hal

fyea

rly, 3

-Q

uarte

rly, 4

-Mon

thly

SE

VERI

TY R

ATIN

G

(1-N

o in

jury

, 2-M

inor

, 3-

Mod

erat

e, 4

-Fat

ality


lity X Severity

RISK


erate/ High/

Unacceptable)



RESIDUAL RISK





Main Section : Electrical Systems Date : 28.02.2015

S. NO


EXPLANATION

PRO

BABI

LITY

RA

TING

(1

-Yea

rly, 2

-Hal

fyea

rly, 3

-Qua

rterly

, 4-

Mon

thly

SEVE

RITY

RA

TING

(1

-No

inju

ry, 2

-Min

or, 3

- Mod

erat

e,

4-Fa

talit

y


lity X Severity

RISK


Unacceptabl

e)



1 Power backup for CP System

Electrical Shocks

Human injury 1 4 4

Moderate

5. Earthing provided and maintained.

6. Rubber Mats provided 7. Electrical Protection

devices such as MCB etc are available

8. SOPs available 9. PPE available

1. Periodic Maintenance to be done

2. Alternate Power Source at caparo tubes.

Tolerable

Acid spillage and fumes

Human injury

Environment impact

1 2 2

Acceptable

1. SOPs available 2. PPE available 3. Proper ventilation

provided

Eyewash to be provided Tolerable



S. NO


EXPLANATION

PRO

BABI

LITY

RA

TING

(1

-Yea

rly, 2

-Hal

fyea

rly, 3

-Qua

rterly

, 4-

Mon

thly

SEVE

RITY

RA

TING

(1

-No

inju

ry, 2

-Min

or, 3

- Mod

erat

e,

4-Fa

talit

y


lity X Severity

RISK


Unacceptabl

e)



3 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 5. PPE available

1. Periodic Maintenance to be done

Tolerable

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

Tolerable



ANNEXURE 2

Opening Meeting Attendance Sheet



Annexure 3

Closing Meeting Attendance sheet



Annexure 4:

LIST OF INDUSTRIAL AND COMMERCIAL CUSTOMERS

INDUSTRIAL CONSUMERS Sl. No. Industry Name 1 Shriram Rayons

2 Kota Dall Mill 3 Mahalaxmi Mahila Grah Udyog 4 Mittal Pigments Pvt. Ltd. 5 Pious Foods (India) Pvt. Ltd. 6 SHRISTAB PVT. LTD. 7 Mittal Dhatu Rashayan Udyog 8 Multimetals Limited 9 Guru Amardas Food Product 10 Asian Organo Industries 11 Goyal Chemicals 12 Mittal Polymers 13 MITTAL CHEMICALS 14 P R Industries 15 SNP Enterprises Pvt. Ltd. 16 Praksah Enterprises 17 Shree Rathi Electrode Company 18 Associated Stabplast Chemicals COMMERCIAL CONSUMER

1 M/s. Student Complete Care



ANNEXURE 5

KOTA CGD PROJECT: GAIL GAS LIMITED



ANNEXURE 6

STEEL AND MDPE PIPE LINE NETWORK OF GAIL GAS, KOTA



ANNEXURE 7:

PIPED NATURAL GAS (PNG) DISTRIBUTION NETWORK OF GAIL GAS LTD. AT MAHAVIR

NAGAR I, KOTA