EMERGENCY RESPONSE & DISASTER MANAGEMENT PLAN KKBMPL (Phase 1), GAIL (India) Limited, Kochi Revision : 0 Date : 12.12.2012 EMERGENCY RESPONSE & DISASTER MANAGEMENT PLAN C-10/1 Chapter – 10 P P r r e e E E m m e e r r g g e e n n c c y y P P l l a a n n n n i i n n g g (As per Clause No 10.0 of PNGRB regulations)
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EMERGENCY RESPONSE & DISASTER MANAGEMENT PLAN
KKBMPL (Phase 1), GAIL (India) Limited, Kochi
Revision : 0 Date : 12.12.2012 EMERGENCY RESPONSE & DISASTER MANAGEMENT PLAN C-10/1
CChhaapptteerr –– 1100
PPrree EEmmeerrggeennccyy PPllaannnniinngg
(As per Clause No 10.0 of PNGRB regulations)
EMERGENCY RESPONSE & DISASTER MANAGEMENT PLAN
KKBMPL (Phase 1), GAIL (India) Limited, Kochi
Revision : 0 Date : 12.12.2012 EMERGENCY RESPONSE & DISASTER MANAGEMENT PLAN C-10/2
Pre- Emergency Planning (As per Clause No. 10)
Hazard Identification (As per Clause No. 10.1):
KKBMPL (Phase 1), GAIL (India) Limited, Kochi GAIL (India) Limited, is involved in
transportation of Natural Gas through cross country pipeline. The major hazard for our industry is
Natural Gas which is highly inflammable in nature.
Natural gas is a mixture of hydrocarbon gases having very low boiling point. Methane the
first member of paraffin series makes up for approximately 80% of the natural gas. Ethane,
Propane, Butane and higher hydrocarbons up to Heptanes are also present.
Natural gas has no distinct odor. Its important properties are as under:
Calorific value 8600 KCa/Nm3
Molecular weight 16.3
Explosive Range 5.3 to 14%
Auto-ignition Temperature 535 Dego C
TLV 3 Mg/m3
The degree of fire and explosion hazards of natural gas is high, mainly for the following reasons:
• Extremely low boiling point.
• Poor visibility of ignitable mixture and high burning velocity that can injure instantly anyone
coming into contact with it on account of high calorific value.
• Highly inflammable.
• Under atmospheric pressure and low concentration, natural gas is not toxic for human being. Its
TLV is 3 Mg/M3. However, at high concentrations, hydrocarbon gases displace Oxygen
causing asphyxia.
• In case of inhalation if concentration is high, it will displace oxygen in air. Too little Oxygen
can increase breathing and pulse ratio, disturb muscle coordination, emotional aspect, fatigue,
nausea, vomiting, respiratory collapse, even death.
EMERGENCY RESPONSE & DISASTER MANAGEMENT PLAN
KKBMPL (Phase 1), GAIL (India) Limited, Kochi
Revision : 0 Date : 12.12.2012 EMERGENCY RESPONSE & DISASTER MANAGEMENT PLAN C-10/3
The identified potential On-Site and Off-Site hazards are duly classified in Chapter 6 under Clause
6.0 of Regulation.
The Material Data Safety Sheet of Natural Gas having the information on physical,
chemical & toxicological properties and their mitigation methods in prescribed format attached as
Annexure I.
GAIL (India) Limited, is handling huge quantity of flammable gas and connected through
the gas pipeline network at Kochi. Objective of this study is to make an assessment of:-
1. The risk to the health and safety of employees to which they are exposed to whilst they are at
work and
2. The risk to the health and safety of persons who are not employees arising out of or in
connection with the conduct by the employees of the undertaking.
The ERDMP study focused upon:
� Critical deviations and points in process may be the source of any undesirable event.
� To identify the potential hazards and operating difficulties posed by any possible deviation by
carrying out Hazard& Operability Study.
� To assess the consequence of identified failure scenarios for determination of hazard distances
and impact zones.
� To assess the risk posed by the facilities to the surroundings.
� To suggest measures to reduce hazards and risks.
This study included localized incidents that may lead to onsite damages as well as all the
incidents, which would cause off-site causalities. The most probable hazards have been identified
and consequence analysis was done.
EMERGENCY RESPONSE & DISASTER MANAGEMENT PLAN
KKBMPL (Phase 1), GAIL (India) Limited, Kochi
Revision : 0 Date : 12.12.2012 EMERGENCY RESPONSE & DISASTER MANAGEMENT PLAN C-10/4
Various Layers of Protection in the Pipeline and Associated Facilities:
In the HAZOP study of KKBMPL (Phase 1), GAIL (India) Limited, Kochi, layer of
Protection Analysis (LOPA) approach has been utilized in ranking risk.
HAZOP study deals with the identification of hazards due to process parameter deviations.
When a failure occurs due to deviations, it may take the process outside of its normal operating
ranges. In general, there are several layers of protection measures in a plant in response to a
process deviation. The basic process controls, alarms, safety valves, operator supervision etc. are
the typical protection measures against any harmful consequences due to deviation of process
parameters as shown below:
� Process equipments designed for process operating limits.
� Basic process controls, alarms and operators are adjusted to process deviations.
� Presence of Critical Alarms along with Speedy Response of Operators.
� Safety Interlock System/Emergency Shut Down at operating limits.
� Relief Systems that activate at equipment design limits.
� Mitigation systems that contain the effects of incident.
� Plant emergency response to control the effects of incidents.
(On-site Control Arrangement).
� Emergency response to protect the public from the effects of an incident.
(Offsite Control Arrangement).
The hazard of pipeline handling Natural Gas is the fire and explosion due to release of gas. Even a
hairline fracture in pipeline would release gas. In case of rupture or major leak in buried pipeline
the escaping gas may lead to a fire/explosion hazard.
The following Operations & Installations have been considered during HAZOP study of Gas
pipeline:
1. Receiving terminal
2. Intermediate Pigging Station
3. Sectionalizing Valve Station
4. Customer Terminals.
(Refer Hazop Study Report of M/s MECON India Ltd. In the year 2011)
EMERGENCY RESPONSE & DISASTER MANAGEMENT PLAN
KKBMPL (Phase 1), GAIL (India) Limited, Kochi
Revision : 0 Date : 12.12.2012 EMERGENCY RESPONSE & DISASTER MANAGEMENT PLAN C-10/5
Risk Analysis and Risk Assessment (As per Clause No. 10.2):
The causes of pipeline failure are elaborated as below:
The initial cause of the incident
1. External interference
• The activity having caused the incident (e.g. digging, piling, ground works)
• The equipment involved in the incident (e.g. anchor, bulldozer, excavator, plough)
• The installed protective measures (e.g. casing, sleeves)
2. Corrosion
• The location (external, internal or unknown)
• The corrosion type (galvanic, pitting, stress corrosion cracking “SCC” or unknown)
3. Construction defect/material failure
• The type of defect (construction or material)
• The defect details (hard spot, lamination, material, field weld or unknown)
• The pipeline type (straight, field bend, factory bend)
4. Hot tap made by error
5. Ground movement
6. The type of ground movement (dike break, erosion, flood, landslide, mining, river or
unknown).
7. Other and unknown
• The sub-causes out of category such as design error, lightning, maintenance
• Hazards due to release is depends upon occurrence of ignition or non-ignition
The pipeline handles Natural Gas, which is highly inflammable and mainly possess fire &
explosion hazard due to accidental release. The pipelines are laid underground and all precautions
have been taken for its integrity from design stage up to installation as well as during
commissioning and operation. Safeguards have been taken against corrosion by using cathodic
protection as well as by the application of the other protective coating on the external surfaces.
Hence, chances of corrosion are rare.
EMERGENCY RESPONSE & DISASTER MANAGEMENT PLAN
KKBMPL (Phase 1), GAIL (India) Limited, Kochi
Revision : 0 Date : 12.12.2012 EMERGENCY RESPONSE & DISASTER MANAGEMENT PLAN C-10/6
However, in the event of release of the gas from its containment due to any other reason
there is risk of fire & explosion. Risk Assessment deals with various failure cases (incredible,
credible as well as less credible) leading to various hazard scenarios. Consequence analysis is
basically a quantitative study of hazard due to various failure scenarios to determine the possible
magnitude of damage effects and to determine the distance up to which damage may be affected.
The reason and purpose of consequence analysis are manifold like:
• For computation of risk
• For formulating safe design criteria and protection system
• For evaluating damage and protective measures necessary for saving other properties
• To ascertain damage potential to public and evolve protective measures
• For formulating effective Disaster Management Plan.
Modes of Failure
There are various potential sources of large/small leakage. The leakage may be in the form
of gasket failure in a flanged joint or snapping of small dia. pipeline connected with main line,
leakage due to corrosion, pipe bursting due to excess pressure, weld failure and other sources of
leakage. Some typical modes of failure and their possible caused are discussed:
Loss of Containment Probable Cause Remarks
Flange/Gasket Failure Incorrect gasket, Incorrect
installation
Careful attention to be taken during
selection of gasket & installation.
Weld failure
• Incorrect use of welding material
and weld procedure
• Lack of inspection during welding
• Incorrect use of design code.
Welding to be done by certified
welder with proper quality of welding
rod under strict inspection with stage
wise checking and acceptance after
final radiography. Proper code to be
followed for welding.
Pipe over stress
causing fracture
• Error in stress analysis, improper
pipe material.
• Inappropriate design code and
Pipe stress may also cause flange
leakage unless there exist a
combination of causes. Stress
EMERGENCY RESPONSE & DISASTER MANAGEMENT PLAN
KKBMPL (Phase 1), GAIL (India) Limited, Kochi
Revision : 0 Date : 12.12.2012 EMERGENCY RESPONSE & DISASTER MANAGEMENT PLAN C-10/7
Identified Loss Scenarios:
Based on the hazard identification and common modes of failure the following cases of
leakage of gas have been considered for the purpose of risk analysis in this report:
� Pinhole / Crack (5 mm)
� Leakage through a hole greater than 20 mm & less than 50 mm
� Instrument tapping failure
� Gasket failure
incorrect support, lack of
inspection during inspection.
• Natural Disaster
analysis of piping and proper support
selection to be done during design,
during erection, strict inspection to be
ensured.
Over pressurization of
pipe causing rapture
• Incorrect setting of SRV and pop
off valve pressures.
• Incorrect SRV/Pop off valve size.
Careful attention is needed for
selection of SRV/Pop off valve size.
Setting of SRVs and pop off valves to
be checked before installation as well
as at regular interval.
Failure of pipe due to
corrosion or erosion H2S, water and soil corrosion
Proper care should be taken against
internal as well as external corrosion
and monitoring of condition of
pipeline to be done regularly.
Leaking valve to
atmosphere
Gland failure packing failure
spindle/plug cock flow out.
Leakage to be rectified at shortest
possible time.
Valve body failure Catastrophic valve body/bonnet
failure Failure to be rectified immediately.
Instrument/connection
failure
Bourdon tube failure, failure of other
instrument connection etc. Failure to be rectified immediately.
Overpressure Inadequate relief, fire impingement Failure to be rectified immediately.
And other suitable action to be taken.
Breakage of Pipelines Natural Disater
Pumping should stop immediately,
prompt mobilization of resources for
emergency mitigation
EMERGENCY RESPONSE & DISASTER MANAGEMENT PLAN
KKBMPL (Phase 1), GAIL (India) Limited, Kochi
Revision : 0 Date : 12.12.2012 EMERGENCY RESPONSE & DISASTER MANAGEMENT PLAN C-10/8
� Release of gas during depressurization
� 20% Cross Sectional Area of pipeline failure
Damage Criteria:
The damage effect of all such failures mentioned above is mainly due to thermal
radiation/explosion due to ignition of gas within the flammability limit. Natural Gas released over
ground accidentally due to any reason will normally be from a gasket or from portion of the
pipeline. In case of leakage from buried portion of the line, the leaking gas will come up through
the ground because of porosity of the soil or by throwing away the covered soil. The gas coming
up may get ignited if it comes in contact with an ignition source forming flash/ jet fire. Thermal
radiation due to flash fire may cause various degrees of burn on human bodies. Also, its effect on
inanimate objects (e.g equipment, piping, building etc) is also there and needs to be evaluated. The
damage effects with respect to thermal radiation intensity are elaborated below: