Case Study "Rupture of Unapt Gas Cylinder at IGL CNG Station"
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Case Study
“Rupture of Unapt Gas Cylinder at IGL
CNG Station”
Brief Description
Incident Information
Emergency Response and
Communication.
Chronology of Events
On-Scene- Pictures & Cause of Incident
Corrective and Preventive Action.
2
BRIEF DESCRIPTION A high potential incident occurred on 24.07.2019 in wee hours of the early morning, when an Eicher truck that was heading towards Hardiwar came at Paschim Vihar CNG station under Jail Road Control Room of IGL . Whilst CNG filling was going on, an unapt cylinder that was mounted on dorsal of got ruptured. Fortunately no major injury sustained and no property damage occurred. Only one of the on duty DSM (CNG filler) sustained minor injury and he was administered first aid at the station itself.
The detailed investigation revealed that an Eicher PRO 1059 E HSD vehicle
(Reg. No.- DL-ll-AC-1568) came at 03:30 for refilling at dispenser Compaq 1-B.
The DSM present at the point placed a stand post in front of the vehicle and
verified the validity of the compliance plate (valid till March-2021) and started
filling.
During the process of gas filling, as evident from the CCTV footage the driver
was seen climbing on the back of the vehicle and operating the valves of the
cylinders which were kept at truck’s carriage.
INCIDENT DSM got suspicious and interacted with the driver of the vehicle to know why
those 03 cylinders were placed there, which the driver replied that those were
INFORMATION oxygen cylinders and had to be transported.
At around 03:36, when the vehicle was filled with about 31 Kgs. of gas, a loud
noise came as one of three cylinders kept standing on the back of the vehicle
got ruptured. The intensity of the cylinder rupture was so strong that it broke the
window glasses of the Station Operator's office which is around 12 meters away
and also damaged side wall of the vehicle and created an opening.
One DSM sustained minor injury and was administered the first aid treatment
by the station staff.
4
Emergency Response and Communication
A. Station Staff Response: B. Reporting to Police, PESO and PNGRB:
• DSM (disengaged the nozzle from the • A FIR was registered against the truck owner
affected vehicle. and driver.
• Operated the ESD of all Dispensers and • On reaching the site IGL team after collecting
Compressor Machines. necessary details of the incident shared the
information to PESO thru email as well as
• Station isolation valve was closed.
through phone.
• DCP fire extinguishers were used to avoid
• PNGRB was also made aware about the
any incident of fire.
incident telephonically and formal incident
• All vehicles were manually pushed out of the details submitted online in PNGRB website.
station
• Station was taken into shutdown.
• Information to all concerned , Marketing ,
O&M and Fire and Safety and senior
management was passed regarding the
incident as per the emergency action plan.
5
Chronology of Events
03:30:31 AM – DSM
Checked the compliance
plate of the Vehicle.
03:29 AM – Vehicle ( 2 nos of 80 L water cap.
arrived for refueling each and 2 nos. of 60 L
water cap. each) mounted
below the truck body having
validity upto March 2021.
03:31:22 AM – DSM
after proper fitment of 03:31:29 AM – Vehicle
Nozzle with Driver moved towards the
receptacle started back side of the vehicle.
refueling the vehicle.
6
03:31:32 AM – Vehicle Driver climbed on the truck to approach three unapt cylinders.
03:31:43AM to 03:32:09 – Vehicle Driver opened valves of three cylinders mounted in standing position
in the truck on rear side of driver’s cabin. 7
03:32:16 AM – DSM went to search
the Driver. 03:32:16 AM – DSM saw
driver coming down from
the vehicle and got
suspicious and enquired
driver about 3 cylinders
were there.
03:33:16 AM The driver explained to him that
these are oxygen cylinders.
03:36:18 AM One of the unapt cylinder exploded.
Scene at 03:36:20 AM
By that time around 31 Kg of CNG was already been filled.
Scene at 03:36:38 AM DSM can be seen removing the Scene at 03:36:43 AM Other DSMs can be seen rushing
nozzle from the affected vehicle. for help and pressing the ESD and closing the dispenser
trench valves
Scene at 03:37 DSMs operated the extinguishers to prevent any fire scenario.
Scene at 03:37:41 station staff pushed the vehicle out of station.INCIDENT INVESTIGATION AT PASCHIM VIHAR CNG STATION
ON SCENE PICTURES
VALID COMPLIANCE PLATE
12The affected truck was seen to have 3nos.
of steel strips having fresh welding
signs to hold the three cylinders and also
a small opening on body of the truck to
ON SCENE facilitate passage of tapped piping
connecting to the vertical cylinders
PICTURES
Unauthorized
modification
by using
unapt
cylinders for
CNG filling
Rupture of cylinder mounted
on an Eicher LGV.
13ON SCENE PICTURES
• The 3 nos. of cylinders were having
Floron marking embossed on their
bodies R-134 a, R-410 a, F-22
Earlier used for storing refrigerants.
14ON SCENE PICTURES
In all these cylinders 4-5 mm piping
connection with valves can be seen evidently
that proves a makeshift arrangement to fill
CNG in the cylinders
15ON SCENE
PICTURES
• The ruptured cylinder embossed with R-
134a, and working pressure of 26.7
Kg/cm2 and test pressure of 45 Kg/cm2.
16Points to Ponder
Human error (Complete ignorance about
the fit for purpose CNG cylinders and total
Cause of Incident lack of awareness on part of the CNG
retrofitter, driver/truck owner about the
hazard/implication of their actions)
Unauthorized Misuse (It was sheer attempt to fill more
modification by using CNG by using additional unapt cylinder to
cover more run /distance: as there are not
unapt cylinders for many CNG stations in between Delhi and
Haridwar)
CNG filling practices.
17CORRECTIVE AND PREVENTIVE ACTION TAKEN
• An immediate advisory via email / Letter has
broadcasted/ circulated to all the operators of
CNG Stations, OMC dealers and schools for
keeping a watch on vehicles with such
unauthorised modifications.
• DSM's across IGL immediately advised to keep a
watch at the quantity of gas filled in a particular
vehicle considering the number of cylinders
installed. In case more than normal quantity of gas
is being filled, the DSM must stop the filling
immediately.
• One full day SAFETY AWARENESS Workshop
was organized for CNG kit fitment agencies and
Hydrotesting agencies at INDIA HABITAT
CENTRE.
• Re-sensitization of customers through training
programs & FM Radio done.
• Sharing of case study and CNG safety Training
provided to Executives of all OMCs for strict
enforcement CNG safety practices.
18THANK YOU
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