MAJOR FIRE AT ONGC HAZIRA

PLANT – 24.09.2020

INCIDENT ANALYSIS

HAZIRA PLANTONGC Gas received from Mumbai

Offshore Fields of ONGC

Critical supplier to domestic industries; Power & Fertilizer, receiving gas from Hazira-Vijaipur-Jagdishpur (HVJ) trunkline.

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02

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India's largest Gas-Processing facility ; 32 MMSCMD processed at Hazira.

SEQUENCE OF MAJOR EVENTS

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0730

HRS

0700

HRS

0600

HRS

0330

HRS

0311

HRS

0310

HRS

0308

HRS

0304

HRS 0220 HRS

0218

HRS

0215

HRS

0215

HRS

VAPOUR CLOUD OBSERVED

& CISF MAIN GATE CONTROL

ROOM, FIRE STATION & MAIN

LPG CONTROL ROOM

INTIMATED

CCTV CONTROL ROOM

INTIMATED GAS

TERMINAL CONTROL

ROOM (GTCR). FURTHER

INFORMED GSP & LPG

SHIFT INCHARGES &

MAIN CONTROL ROOM OUTBREAK OF FIRE FIRE FIGHTING

BEGUN

CISF OBSERVED

HEAVY LEAKAGE &

FORMATION OF GAS

CLOUD VIA CCTV.

CLOSURE OF

PRESSURE CONTROL

VALVE AT 36”

PRESSURE

REDUCING SKID

GSP CONTROL ROOM

OFFSHORE

INFORMED TO STOP

GAS SUPPLY AT

GAVIER 36” & ABHWA

42”

CLOSURE OF

SECTIONALIZING

VALVE AT GAVIER

36” & ABHWA 42”

CLOSURE OF

ISOLATION VALVE-

MOV 3 IN 36”s INLET

CISF FURTHER

INFORMED CCTV

CONTROL ROOM

ALL CLEAR

DECLARED

FIRE SUBSIDED &

CONTROLLED

ANALYSIS Heavy leakage of HC

commenced around 0212 hrs.

Inspection indicated that

leakage occurred from the

retaining plate of orifice in

the condensate metering

skid.

Gas cloud development in

the absence of wind .

Gas cloud ignition by

exposed flameproof lamp.

ROOT CAUSES

USE OF NONSTANDARD “O” RING

LACK OF CONTROL OVER MATERIAL SOURCING

LOSS OF CONTAINMENT IN THE CONDENSATE METERING AREA DUE TO FAILURE OF O RING OFTHE RETAINING PLATE OF

ORIFICE IN THE CONDENSATE METERING SKID.

IGNITION OF GAS CLOUD DUE TO EXPOSED ELECTRICAL FITTING

INADEQUATE PREVENTIVE MAINTENANCE SYSTEMS

NON ISOLATION OF 36”PIPELINE OPERATION

“ Safety should never be a

priority,

It should be a PRECONDITION

-Paul O’Neill

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KEY REMEDIAL ACTIONS

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FIREFIGHTING

CAPACITY TEST OF

EACH FIRE PUMP TO

BE EXECUTED AS PER

OISD STANDARD.

PERIODIC

INSPECTION &

MAINTENANCE OF

FIRE WATER PUMPS &

PRESERVATION OF

RECORDS TO BE

CARRIED OUT AS

PER OISD STANDARD

SAFETY

FIRE DRILL DATA i.e.

ACTIONS

TAKEN/OBSERVATION

S &

RECOMMENDATIONTO

BE FILLED/

UPLOADED IN SAP.

ACTION PLAN FOR

HEAVY PRODUCT

/GAS LEAKAGES

FROM PIPELINE/

TANK RUPTURE BE

DOCUMENTED IN

ERDMP

SAFETY

DEVELOPMENT OF

CHECKLIST FOR

SSA AUDIT.

AUDIT FOR 3-4

DAYS BIANNUALLY

BE CONDUCTED

STATUS REPORTS

OF ESA

RECOMMENDATIO

NS & COMPLIANCE

TO BE MADE

AVAILABLE.

P&ID TO BE CHECKED AND APPROVED WITH AS BUILT CONFIGUARATION & PREFERABLY DIGITISED.

FIELD INSTRUMENTS TO BE CONFIGURED IN DCS WITH PROPER ALARMS, EVENTS & HISTORY ARCHIVING

FACELITIES

KEY REMEDIAL ACTIONS

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ELECTRICAL

MAINTENANCE

ALL FLAME PROOF

ELECTRICAL FITTING

& JUNCTION BOXES

TO HAVE PROPER

IDENTIFICATION

TAGS.

PERIODIC

INSPECTION &

PREVENTIVE

MAINTENANCE OF

ELECTRICAL

FITTINGS TO BE

DONE &

DOCUMENTED.

PIPELINES

PROMPT CORRECTIVE ACTION TO BE TAKEN WHERE METAL LOSS IS BEYOND ACCEPTABLE LIMITS

PIPELINES

PIPELINE THICKNESS DATA FOR YEAR 2011 & 2017 MAY ACT AS BASELINE DATA & THICKMESS MEASUREMENT TO BE DONE IN 2020 & 2021 .

CORRELATION STUDY TO BE DONE TO IDENTIFY CORROSION AREAS.

METERS

PROPER SOP TO BE DEVELOPED ALONG WITH CHECKLIST FOR MAINTENANCE WORK ON HIGH PRESSURE GAS/LIQUID PIPELINE METERING SYSTEM.

MAINTENANCE MAINTENANCE MAINTENANCE

THANK YOU

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