Kerrigan suffered a nightmare debut in last year's Ashes but has returned to the squad for this week's match.
And Vaughan believes the 25-year-old is not ready to win his second cap.
"I fear for Simon Kerrigan," Vaughan said on Radio 5 live. "England have thrown him back into the environment of international cricket far too soon."
Matches: 66; Wickets: 213; Average: 27.81; Best figures: 9-51; Strike-rate: 58.7
Kerrigan was surprisingly selected for the fifth Test against Australia at The Oval last year, but failed to justify his inclusion as he conceded 53 runs from just eight overs.
He never recovered from a brutal early assault from Australian batsman Shane Watson as his first two overs went for 28 runs.
And Vaughan believes a repeat of that experience could be fatal to Kerrigan's international career.
"If the second one goes badly, he can never come back from that again," the former England opener said.
"If he goes out on Thursday and all of a sudden the Indians climb into him and it's like that situation against Watson, he won't come back from that for a long time."
Kerrigan has taken 28 wickets for Lancashire this season at an average of 34.25, and Vaughan believes the left-armer should be left to learn his trade at county level.
"He's not pulled up any trees for Lancashire this season. Why rush the lad back in?
"Throwing him out to bowl at Lord's against an Indian batting line-up who can play spin with their eyes shut - I just think is unfair."
England are searching for a spinner following the retirement of Graeme Swann last year, and have turned to batsman Moeen Ali as a part-time option in this summer's Tests against Sri Lanka and India.
But Swann believes that the additional workload on the England seamers may force coach Peter Moores to turn to Kerrigan, whom he coached during his stint at Lancashire.
"I think he'll play," Swann said. "By all accounts he's bowled very well in the nets and Peter Moores rates him very highly. Moeen's just not up to it as a spinner at the moment."
Seamers Chris Jordan and Chris Woakes are the other options available to Moores if he wishes to change the team that drew the first Test at Trent Bridge.
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