QRA Study for Uran – Chakan – Shikrapur LPG Pipeline (UCSPL)

Project Overview

The underground cross-country LPG pipeline from Bharat Petroleum Corporation Limited’s (BPCL) Uran LPG Bottling Plant to BPCL’s Shikrapur LPG Plant has been installed by Hindustan Petroleum Corporation Limited (HPCL). This pipeline transports LPG supplied via online pumping from the Mahul–Uran LPG pipeline and LPG mounded storage bullets at BPCL Uran Plant. Key infrastructure includes receiving stations, dispatch stations, and tap-offs.

The pipeline traverses diverse terrains, including rolling, flat, and undulating areas, steep rising terrain, and more rolling terrain. It also passes through developed areas around the Patalganga Industrial Area, Karjat town, and Talegaon MIDC. All terminal locations are situated in industrial zones with robust infrastructure facilities.

Scope of Work

The primary scope of this study is to conduct a Quantitative Risk Assessment (QRA) for the LPG pipeline and its associated facilities. The evaluation focuses on assessing risks that may arise during the project’s operation based on available data. The study aims to:

• Quantify potential risk levels to workers resulting from unintentional releases of hazardous materials.
• Demonstrate that personal risks are within widely recognized safety limits.

Objectives of the QRA

1. Hazard Identification: Identify significant loss of containment (LOC) incidents.
2. Physical Impact Assessment: Calculate physical impacts of failure case scenarios, including estimated distances for:
   • Jet fire
   • Pool fire heat radiation
   • Flammable gas dispersion
   • Boiling Liquid Expanding Vapor Explosion (BLEVE)
   • Overpressure explosion
3. Failure Frequency Evaluation: Determine the probability of failure events.
4. Societal Risk Quantification: Estimate potential loss of life and societal risk using UK HSE risk acceptance criteria.
5. Risk Mitigation: Propose strategies to reduce risks to acceptable levels or as low as reasonably practicable (ALARP).

Methodology

The analysis was conducted using site-specific data and commercially available tools:

• Phast: Process Hazards Analysis Software Tool
• Safeti: Software for the Assessment of Fire, Explosion, and Toxic Impacts (Version 8.4)

These tools are industry-standard for the chemical, oil, and gas sectors, known for their accuracy and validation.

Key Findings

Risk to People

The QRA study aims to assess and quantify risks associated with process hazards along the Uran-Chakan-Shikrapur LPG Pipeline. The following findings were noted:

1. Location-Specific Individual Risk:
   • Defined as the probability of an individual being harmed in an accident within a year while remaining unprotected at a specific location.
   • Individual risks at different locations around the facility were found to be in the ACCEPTABLE and marginally ALARP regions.
2. Individual Risk for People:
   • Provides a measure of the danger at any site based on the area’s occupancy.
   • Risks were broadly classified as ACCEPTABLE and marginally ALARP, assuming continuous presence.
3. Societal Risk:
   • Represents the relationship between the frequency of hazards and the number of affected individuals.
   • The societal risk for the evaluated population falls within the ALARP region.

Risk Mitigation Strategies

To ensure risks are minimized to ALARP levels:

• Regular Monitoring: Conduct periodic inspections of pipeline integrity.
• Emergency Response Planning: Develop and train personnel on robust emergency protocols.
• Infrastructure Enhancements: Implement engineering controls to reduce the likelihood of failures.
• Community Awareness: Engage with local communities to ensure awareness and preparedness for potential hazards.

Conclusion

The QRA study for the Uran – Chakan – Shikrapur LPG Pipeline demonstrates that the risks to both individuals and society are within acceptable limits or ALARP regions. The proposed mitigation strategies ensure compliance with industry standards and safety protocols.