QRA Study for Piped Natural Gas Plant & CNG Storage at Toyota by McD Built Environment

Project Objective

The primary goal of the Quantitative Risk Assessment (QRA) study was to quantitatively evaluate and assess the risks associated with process hazards at the Toyota Kirloskar Motors facilities. This assessment aimed to identify potential accidental release scenarios, analyse their likelihood and consequences, and provide recommendations to mitigate the identified risks.

Project overview

• Toyota Kirloskar Motor Private Limited (TKM) is a leading joint venture that combines the expertise of Toyota Motor Corporation (TMC) from Japan and the Kirloskar Group, recognized for its innovation in the automotive sector.
• TKM has partnered with McD Built Environment Research Laboratory Private Limited to undertake critical safety assessments for their manufacturing facility.
• iFluids Engineering has been engaged by McD to perform a comprehensive Quantitative Risk Assessment (QRA), ensuring the safety and efficiency of the facility operations.
• The manufacturing facility is strategically located in the Bidadi Industrial Area, within the Bidadi Ramanagaram District, and is conveniently situated about 35 kilometers from Bangalore city.
• Its prime location near the Bangalore Mysore State Highway enhances accessibility and logistics for production and distribution.
• TKM’s state-of-the-art manufacturing plant is essential for producing high-quality passenger cars, significantly contributing to the automotive industry and bolstering economic growth in the region.

Quantitative Risk Assessment

What is Quantitative Risk Assessment

A Quantitative Risk Assessment (QRA) is a systematic approach used to analyze the probability and potential outcomes of hazardous incidents. It employs objective numerical information to assess both the likelihood and the consequences associated with a given risk.

Risk Analysis is an essential management tool for evaluating safety performance in the Chemical Process Industry. Although robust management systems, including engineering codes and thorough reviews, are in place, recent global catastrophes underscore the necessity for advanced quantitative methods. These methods help identify potential incidents and assess the effectiveness of control strategies.

The Quantitative Risk Assessment (QRA) study addresses four critical questions:

• What can go wrong?
  Understanding the possible failure scenarios that may arise in chemical processes.
• What are the causes?
  Identifying the root causes behind potential incidents and system failures.
• What are the consequences?
  Evaluating the potential impacts of identified risks on safety, health, and the environment.

Risk Concept

Risk is defined as a measure of potential economic loss or human injury based on the probability and magnitude of occurrence. The QRA study quantifies risks to rank them according to severity and probability. Results were categorized into Individual Risk (IR) and Societal Risk (SR).

• Individual Risk (IR): IR represents the likelihood of fatality resulting from accidents at a plant or along transportation routes. It is expressed in relation to the distance from the activity and presented geographically. Risk contours developed can assess potential risk to the surrounding community and aid in land use planning decisions. It mainly focuses on the risk impacting a specific individual.
• Societal Risk (SR): SR involves the summation of risk from events involving many fatalities within specific population groups. It focuses on the risk to society rather than specific individuals. SR considers the scale of incidents in terms of the number of people impacted and is expressed as cumulative risk to onsite and offsite populations.
• How likely is it?
  Assessing the probability of occurrence for each identified risk scenario to inform decision-making.

By leveraging comprehensive QRA methodologies, organisations can enhance their risk management frameworks and improve safety outcomes in the Chemical Process Industry.

QRA Methodology

QRA Methodology

The QRA methodology involved:

1. Identifying potential scenarios for accidental releases.
2. Assessing the likelihood and consequences of these scenarios.
3. Evaluating the Location-Specific Individual Risk (LSIR) and Individual Risk (IR) for people.
4. Assessing Societal Risk.
5. Providing recommendations based on the findings.

Key Findings

1. Location-Specific Individual Risk (LSIR) and Individual Risk (IR) for People:

One of the fuel tank farms in the facility was identified within the ALARP (As Low As Reasonably Practicable) region.The impact radius for various risk levels ranged up to maximum of 223 meters from the fuel tank farm under ALARP.

All the other locations considered in the study were within the ACCEPTABLE region for Individual Risk Per Annum.

ALARP Principle

Societal Risk:

The societal risk for the overall population was within the ACCEPTABLE region.

Recommendations

To reduce the risk level from ALARP to ACCEPTABLE at the high-risk fuel tank farm, the following measure was recommended:

1. Gas Detectors: Install adequate gas detectors and conduct an F&G Mapping Study to assess their effectiveness.

Existing Safeguards

To maintain operational safety, Toyota Kirloskar Motor Pvt Ltd was advised to continue adhering to the following safety measures:

1. Safety Procedures and Training: Regular safety drills and training sessions.
2. Equipment Upgrades: Upgrade aging or high-risk components.
3. Safety Barriers: Implement physical safety barriers.
4. Controlled Access: Restrict access to hazardous areas.
5. Emergency Shutdown Systems: Ensure effective systems are installed and maintained.
6. Fire Suppression Systems: Maintain reliable fire suppression systems.
7. Safety Signage: Use standardized safety signage.
8. Regular Inspections: Conduct routine inspections and maintenance.
9. Emergency Response Plan: Develop and regularly update the plan.
10. Community Engagement: Communicate safety procedures and emergency contacts with the local community.
11. Risk Assessment Reviews: Periodically review and update the risk assessment.
12. Control of Ignition Sources: Implement measures to control ignition sources.
13. Pipeline Inspection and Corrosion Prevention: Identify critical pipelines and implement corrosion protection measures.
14. Overfill Prevention Systems: Ensure arrangements for periodic proof testing.
15. Earthing Arrangement: Regular inspection of the earthing arrangement.

Conclusion

The QRA study conducted by iFluids Engineering for McD Built Environment Research Laboratory Pvt Ltd provided Toyota Kirloskar Motor Pvt Ltd with a detailed risk assessment and actionable recommendations to enhance safety at their facilities. By implementing the suggested measures, Toyota Kirloskar can significantly mitigate risks and ensure a safer working environment.