Post on 15-Jan-2016
IMSISO 9001ISO 14001
OHSAS 18001FIVE STAR
BSC
SWORD OF HONOR
SARVASHRESHTASAFETY AWARD
OISD AWARD
By : Sukant Ku. Singh, Manager(F&S), GAIL- Vijaipur, MP.
22
GAS PIPELINES
Length : 10,000 KMS
Capacity : 157 MMSCMD
Spread : 11 STATES
LPG PIPELINE
Length : 1922 KMS
Capacity : 3.8 MMTPA
Spread : 6 states
GAS PROCESSING
No. : 7 PLANTS
Capacity : 1.2 MMTPA LPG
Spread : 5 states
COMPRESSOR STATION
No. : 08
PETROCHEMICALS
No. : 01
GANDHARVAGHODIA
USAR
VIJAIPUR
PATA LAKWA
NATURAL GAS PIPELINE
LPG PIPELINE
LPG PLANT
PETROCHEM PLANT
TRIPURA
KG BASIN
VSPL
CAUVERYBASIN
HVJ, DVPL
JLPL
RAJASTHAN
GAIL (India) Limited, India’s Principal Gas transmission and
Marketing company, own and operates Country’s largest Natural Gas Transmission network.
Pipe Line
Compressor Station
OPERATIONS AT GAIL-VIJAIPUR
O&M Headquarter of HVJ pipeline system comprising of HVJ, GREP, DVPL & VDBPL Pipelines
Operates HVJ pipeline compressor station having 14 nos. compressors discharging flow of 450 - 500 KSCM//hr.
This is the largest single gas grid of GAIL & 100% uninterrupted gas availability to its customers since last 27 Years
This is Chapter-3(Applicability) as per Notification of PNGRB for ERDMP
Gas Processing Unit
Consumer Terminals
OPERATIONS AT GAIL-VIJAIPUR
Operates two LPG recovery
units having the production
capacity :
LPG : 406000 TPA
Propane : 130000 TPA
Pentane : 42000 TPA
Naphtha : 24000 TPA
Which is equivalent to more than one lakh LPG cylinders per day in the domestic circle.
This is Chapter-3(applicability) as per Notification of PNGRB for ERDMP
OBJECTIVES OBJECTIVES TARGETS SET TARGETS SET
TARGET ACHIEVEDTARGET ACHIEVED
20072007 20082008 20092009 20102010 20112011
FATAL ACCIDENTS FATAL ACCIDENTS ZERO ZERO ZEROZERO ZEROZERO ZEROZERO ZEROZERO ZEROZERO
REPORTABLE ACCIDENTSREPORTABLE ACCIDENTS ZERO ZERO ZERO ZERO ZERO ZERO ZERO ZERO ZERO ZERO ZERO ZERO
HSE INDEX HSE INDEX 98% 98% 100%100% 100%100% 100%100% 100%100% 100%100%
LEGAL COMPLIANCESLEGAL COMPLIANCES 100%100% 100%100% 100%100% 100%100% 100%100% 100%100%
FIRE INCIDENTS – MAJOR FIRE INCIDENTS – MAJOR ZERO ZERO ZERO ZERO ZERO ZERO ZERO ZERO ZERO ZERO ZERO ZERO
INTERNAL SAFETY AUDITINTERNAL SAFETY AUDIT 04 PER YEAR 04 PER YEAR 44 4 4 44 44 44
EXTERNAL SAFETY AUDITEXTERNAL SAFETY AUDIT 01 PER YEAR 01 PER YEAR 11 11 11 11 11
SAFETY COMMITTEE SAFETY COMMITTEE MEETINGMEETING
LPGLPG 04 PER YEAR 04 PER YEAR 4 4 44 4 4 4 4 44
HVJHVJ 04 PER YEAR 04 PER YEAR 44 44 44 44 44
MOCK DRILLMOCK DRILL 04 PER YEAR 04 PER YEAR 44 44 44 44 44
DISTRIBUTION OF SAFETY DISTRIBUTION OF SAFETY KITS KITS
100 % GAIL 100 % GAIL EMPLOYEES EMPLOYEES 100%100% 100% 100% 100%100% 100%100% 100%100%
HSE INTERNAL TRAINING HSE INTERNAL TRAINING 100 % 100 %
EMPLOYEES EMPLOYEES 100%100% 100% 100% 100%100% 100%100% 100%100%
OBJECTIVES & TARGETS ACHIEVED 2007 TO 2011 By GAIL-Vijaipur
This is as per Chapter-4.2(Intent) as per Notification of PNGRB for ERDMP
HSE INDEX100 Marks
HSE LEADERSHIP & COMMITMENT-
12
INCIDENT REPORTING,
INVESTIGATION & ANALYSIS- 15
ENVIRONMENT MONITORING -05
OCCUPATIONALHEALTH MONITORING
-10
COMPLIANCE AUDIT (EXTERNAL & INTERNAL HSE
AUDIT) - 15
EMPLOYEE PARTICIPATION (NEAR
MISS & SAFETY SUGGESTION) - 05
PROCESS SAFETY
INFORMATION - 05
HSE TRAINING- 05
SAFETY MANAGEMENT SYSTEM
OPERATION & MAINTENANCE (FIRE APPLIANCES,FIRE WATER BASED & NON
WATER BASED SYSTEM, CALIBRATION STATUS OF PSV, FIRE DETECTION &
ALARM SYSTEM) -15
EMERGENCY PLANNING &
RESPONSE – 05
CONTROL OF DEFEATS & RELIABILITY OF CRITICAL
SYSTEM & DEVICES-03
INSPECTION & MAINTENANCE - 04
RISK ANALYSIS & MANAGEMENT - 01
This is mainly as per Chapter-8( Consequences of default or non-compliance) as per Notification of PNGRB for ERDMP
Chapter-12.2( Training) as per Notification of PNGRB for ERDMP
(SIMULATION OF BLEVE)
TRAINING FACILITIES AT GAIL, VIJAIPURMore than 15nos Training models are available.
EMERGENCY CONTROL CENTERE(ECC)At GAIL, VIJAIPUR, MP
There is a vital importance of emergency control room in case of any emergency situation arises in the factory premises. The various coordinators are required to report in the emergency control room during emergency for coordination purpose. Keeping in view the same, the emergency control room is shifted at Fire station building which is located a safe distance (as per QRA study).
Dr U D Choubey, C&MD, GAIL inaugurated the ECC
FACILITIES AVAILABLE
1.Satellite phone.2.P&T Phone.3.3. HVJ Phone.4.Public Address system.5.Projectors & PC 6.Flow chart of Communication system.7.On site EAP.8.Off site EAP.9.Roles & Responsibility Manual.10. All P&ID Diagram.11. All Standards.12. Telephone list.13.Copy of ERDMP of GPU.14.Copy of ERDMP of HVJ.15. MSDS.
Chapter-15.1( for ECC) as per Notification of PNGRB for ERDMP
There are two types of Emergency Action Plan There are two types of Emergency Action Plan at GAIL, Vijaipur:at GAIL, Vijaipur:
ON SITE EMERGENCY ACTION PLAN:-ON SITE EMERGENCY ACTION PLAN:-This On-Site This On-Site Emergency Action Plan is based on the Disaster Emergency Action Plan is based on the Disaster Management Plan, which was prepared on the basis of Management Plan, which was prepared on the basis of Risk analysis and consequence analysis, and meets the Risk analysis and consequence analysis, and meets the requirement of the Indian Factories Act, 1948, and also requirement of the Indian Factories Act, 1948, and also complies with the requirement of ERDMP.complies with the requirement of ERDMP.
OFF SITE EMERGENCY ACTION PLAN:- OFF SITE EMERGENCY ACTION PLAN:- Plan has Plan has
been approved by district administration i.e. Collector.been approved by district administration i.e. Collector.
EMERGENCY PREPAREDENESSEMERGENCY PREPAREDENESS
Chapter-16( Declaration of On site & off site emergency) as per Notification of PNGRB for ERDMP
ON-SITE EAP GPUON-SITE EAP GPU
Chapter-14( Emergency Organization & Responsibility, Organization Chart ) as per Notification of PNGRB for ERDMP
ON-SITE EAP HVJON-SITE EAP HVJ
EMERGENCY SIREN CODE AS PER OISD STD 116
SMALL FIRE: No siren
MAJOR FIRE: A wailing siren for two minutes. Sirens will be sounded three times for thirty seconds with an interval of fifteen second in between.
DISASTER: Same type of siren as in case of Major Fire but the same will be sounded for three times at the interval of one minutes.
ALL CLEAR (For fire): Straight run siren for two minutes.
ON ON ON
OFF OFF
30 SEC 30 SEC 30 SEC15 SEC 15 SEC
DisasterOFF OFF
2 MIN 2 MIN 2 MIN1MIN 1 MIN
Disaster Disaster
EMERGENCY CONTROL CENTRE IS IN FIRE STATION FIRST FLOOR ROOM NO.10, HVJ NO- 1444, 2443, 2444, 274250
ON ON ON
TEST: Straight run siren for two minutes on Friday at 7PM to 7.15PM.
Chapter-14.2.5.9 ( Siren Code) as per Notification of PNGRB for ERDMP
Assembly Points1-EIL Building2-LPG C/R / Lab Bldg.3-Fire station.4-LPG C&P Store.5-HVJ MCR gate6-C2C3 Project site.
CISF gate/Colony
Fire StationLPG C/R
HVJ MCR Gate
C&P Store
C2C3 Project
EIL Building
GAIL(India) Limited, Vijaipur, MP
CISF gate C2C3 Project
NFL Gate
Way To Emergency Exit
First Aid centerHospital
Chapter -13( Zoning & Maps), Chapter-15.2( Assembly point), as per Notification of PNGRB for ERDMP
COMMUNICATION SYSTEM
TYPES OF COMMUNICATION
SYSTEMRANGE
NOS OF COMMUNICATION
SYSTEMHVJ Phone - Every where
available as per req.
Walkie Talkie 1 KM range 04(Fire Stn.)Paging system(PA) All plants, offsite,
loading, storage, etc
Siren electric motor 10KM 05nosManual Siren 1KM 01(Fire Stn.)Mobile phone - 01
BGU/ MCPs - 67(LPG) & 53(HVJ)
Satellite phone (INMARSET TEL.)
World Wide 05
Chapter-14.2.5.8 ( Communication Services) as per Notification of PNGRB for ERDMP
SL NO NOS OF INDUSTRIES
WITH MAS & NAME
WRITTEN
AGREEMENT
EXISTS OR
NOT
DETAILS OF
SYSTEMS UNDER
MAS:
01 M/S NATIONAL FERTILIZER
LIMITED, VIJAIPUR
YES i. FIRE FIGHTING
ii. RESCUE
iii. LOGISTICS
iv. ENGG SUPPORT &
v. OTHER HELP.
02 M/S INDIAN OIL LTD.
DONGER, VIJAIPUR
YES i. FIRE FIGHTING.
ii. RESCUE.
iii. ENGG SUPPORT &
iv. OTHER HELP.
MUTUAL AID SYSTEM (MAS)
Chapter-12.3( Mutual Aid) as per Notification of PNGRB for ERDMP
FIRE DRILL ON MONTHLY BASIS(Level-1)
MAJOR MOCK DRILL / ON SITE EMERGENCY PLAN DRILL ON QUARTERLY BASIS(Level-2).
OFF SITE DRILL- ONCE IN A YEAR BY DISTRICT ADMINISTRATION INVOLVING MUTUAL AID MEMBERS(Level-3).
OFF SITE DRILL(Level-III_
ON SITE DRILL(Level-II)
FIRE DRILL-(Level-1)
CLASSIFICATION OF EMERGENCY
Chapter-6 ( Classification of emergency) as per Notification of PNGRB for ERDMP
This is as per Schedule-IV( Resource Mobilization)
PUMP INDICATION AUTOMATIC TURN OUT SLIP
LOCATIONIOD MANUAL CALL POINTS INDICATION OF FIRE WATER TANKS
PLC control Fire station having facilities of Real Time data of followings,Wind Speed.Wind DirectionAmbient Air TemperatureRelative HumidityRainfallSolar Radiation, etc.
Fire Water Line
Above Ground (KM)
UnderGround(KM)
Total
LINE SIZE-4’’ To 24’’
26.259 Kms 6.225 Kms 32.484 Kms
FIRE WATER NETWORK AT HVJ & LPG PLANT WITH INDICATION OF ISOLATION VALVES, MONITORS,
HYDRANTS
JP-C DP-G EP-D EP-E
FWPH IN HVJ AREA
OLD FIRE WATER PUMP HOUSE LPG
NEW FIRE WATERPUMP HOUSE LPG
DP-A
DP-B
DP-C
DP-D
JP-A
JP-B
EP-A
EP-B
DP-E
DP-F
EP-C
LEGENDDP- Diesel driven pump
EP –Electric driven pump
Technical Data Fire Tender-2
Fire Tender-2
Fire Tender-2
Emergency Rescue Tender
Registration No. of the Fire Tender
MP08A1493 MP08D0821 MP08GA0703 Mobile Flare Unit
Chassis Make/Details TATA 1210 TATA ASHOK LEYLEND 1616
High Mast Flooding Light
Water Tank Capacity 1000 Lit. 2000Lit 4000Lit Cutter/Spreader
Foam Tank Capacity 1200 Lit. 500Lit 1000Lit Lifting tools
Dry chemical powder Vessel
1000 Kg Monex 1000Kg- Monex & 1000Kg Olfex
500Kg of Monex & 500Kg Olfex.
Gen. Set
No. of EXP. Gas /Nitrogen cylinders
4 in main Line and4 in standby.
4 in main line and 4 in standby.
2 in main line and 2 in standby.
Chlorine Kit
*Throw range of DCP monitor
50 m horizontally & 25m in Verical
50 m horizontally
50 m horizontally Fire Fighting equip.
Discharge of DCP monitor
Selective (15, 25 & 40 Kg/sec.)
-- Selective (15, 25 & 40 Kg/sec.)
PPEs
Delivery outlet for Hose 4 Nos. X 63 mm dia 4 Nos. X 63 mm dia 4 Nos. X 63 mm dia. Portable Pump with double head
FIRE APPLIANCE AVAILABLE AT GAIL, VIJAIPUR
Chapter-17( Resource for Controlling Emergency) as per Notification of PNGRB for ERDMP
FIRE PROTECTION SYSTEM FIRE WATER NETWORK WITH
WATER HYDRANTS AND WATER MONITORS.
AUTOMATIC WATER SPRAY SYSTEM THROUGH ROV
LONG RANGE HIGH VOLUME / STANDARD WATER MONITORS .
HOSE BOXES & HOSE REEL.
WET RISER FOR MAIN CONTROL ROOM AND SUB-STATIONS
WATER CURTAINS.
FOAM POURER & FOAM TROLLEY
CO2/ FM-200 TOTAL FLOODING SYSTEM IN GTC , GTG & C/R.
FIRST AID FIRE FIGHTING EQUIPMENTS.
HORTON SPHERES, BULLETS, HYDROCARBON HANDLING PUMPS AND LOADING GANTRIES ARE PROVIDED WITH HIGH / MEDIUM VELOCITY FIRE WATER SPRAY SYSTEM.
WATER DRENCHERS ARE PROVIDED ON THE TOP OF HORTON SPHERES.
WATER SPRAY SYSTEM ARE PROVIDED WITH REMOTE OPERATIONS FROM RESPECTIVE CONTROL ROOMS AS WELL AS MANUAL OPERATION FROM SITE.
FIRE PROTECTION SYSTEM
DETECTION AND ALARM SYSTEM Gas detection installed in GTG and GTC.
LEL detectors & PLC monitors in controls room.
Heat detectors and U-V detectors in GTG and GTC.
Smoke detectors in control building(UV & Optical Detectors).
Fire bells connected with alarm system followed by PLC C/R.
Break glass type fire alarm system(MCPs) connected with emergency siren at control room and fie station C/R. CCTV Camera for critical areas.
COMPREHENSIVE MANUALS DEVELOPED
CONTRACTOR SAFETY MANUAL
POCKET SAFETY MANUAL
WORK PERMIT MANUAL
PPE’S MANUAL
CORPORATE HSE MANUAL
FIRE FIGHTING MANUAL
TRAINING MANUAL
HSE TRAINING CALENDER
ROAD SAFETY MANUAL
MANUALS & SOPs
Chapter-21 ( Information to Public) as per Notification of PNGRB for ERDMP
DISSIMINATION OF SAFETY INFORMATION
Chapter-21 ( Information to Public) as per Notification of PNGRB for ERDMP
TRANSPORTATION OF HAZARDOUS CHEMICALS
o Transportation of LPG, Propane, Pentane and Naphtha is carried out through tankers. (after thorough safety check of tanker as well as documents)
o Transportation of LPG is also carried out through Rail wagons as well as underground pipeline
Chapter-28 ( ERDMP for Road Transportation) as per Notification of PNGRB for ERDMP
MAJOR STEPS TAKEN BY GAIL AFTER JAIPURMAJOR STEPS TAKEN BY GAIL AFTER JAIPUR FIRE INCIDENTINCIDENT
Board Level HSE Sub Committee Members visited GAIL, Vijaipur.Board Level HSE Sub Committee Members visited GAIL, Vijaipur.
Sh. R.D Goyal (Director-Projects)Sh. R.D Goyal (Director-Projects)
Sh. U.K Sen (Independent Director)Sh. U.K Sen (Independent Director)
Prof. A.Q Contractor (Independent Director)Prof. A.Q Contractor (Independent Director)
Chapter-12 ( Emergency Drill & Mock drill) as per Notification of PNGRB for ERDMP
REVIEW OF PERFORMANCE OF FIRE FIGHTING SYSTEM BY SENIOR OFFICIALS OF GAIL
Mock Drill at GAIL, Vijaipur on 08.08.2012 by
DMI-Bhopal for Accreditation of ERDMP
Dr. Vijay Kumar, Addl. Director General breaking the MCP
Dr. Vijay Kumar, Addl. Director General-Bhopal, Sh. Rakesh
Dubey, Director, DMI-Bhopal, Sh. B.S. Negi, Ex-Member, PNGRB
and Sh. C M Sharma, Tech Expert, Quality Council of India (QCI) with
GM(O&M) and GM(Project) witnessing the drill at HVJ
Compressor station.
Sh. Rakesh Dubey, Director, DMI-Bhopal, Sh. Harsh Chaturvedi, Dy. Director (IHS)-Gwalior, Sh. B.S. Negi, Ex-Member, PNGRB and Sh. C M Sharma, Tech Expert, Quality Council of India (QCI) with GM(O&M) and GM(Project) witnessing the drill at propane sphere.
Chapter-12 ( Emergency Drill & Mock drill) as per Notification of PNGRB for ERDMP
Coordination of emergency by various coordinator at Emergency control Centre(ECC) at First Floor, Fire Station.
At the end of the exercise, a review meeting was chaired by Dr. Vijay Kumar, Addl. Director General, Bhopal and Chief Incident Controller ED (O&M) & OIC- Vijaipur and Sh. Rakesh Dubey, Director, DMI-Bhopal, Sh. Harsh Chaturvedi, Dy. Director (IHS)-Gwalior, Sh. B.S. Negi, Ex-Member, PNGRB and Sh. C M Sharma, Tech Expert, Quality Council of India (QCI) & other senior officials from GAIL & DMI, Bhopal. Chapter-25 ( Termination of Emergency) as per Notification of PNGRB for ERDMP
Emergency Response Disaster Management Plan(ERDMP) of Gas Processing Unit(GPU) & HVJ Compressor Station
Certified & Accredited by Disaster Management Institute, Bhopal(an accreditation agency of
PNGRB)
2009 2010 2011
1 Oil Industry Safety Award-2008-09 to GPU GAIL, Vijaipur for 6th Times
Oil Industry Safety Award-2009-10 to GPU GAIL, Vijaipur for 7th Times
Oil Industry Safety Award-2010-10 to GPU GAIL, Vijaipur for 8th Times
2 Oil Industry Safety Award-2008-09 to HVJ Pipeline for 13th Times
Oil Industry Safety Award-2009-10 to HVJ Pipeline for 14th Times
Oil Industry Safety Award-2009-10 to HVJ Pipeline for 15th Times
3 Shreshtha Suraksha Puraskar Award to GPU, Vijaipur by National Safety Council, Mumbai.
Suraksha Puraskar Award to GPU, Vijaipur by National Safety Council, Mumbai.
Shreshtha Suraksha Puraskar Award from National Safety Council, Mumbai for Gas processing Unit, Vijaipur.
4Shreshtha Suraksha Puraskar Award to HVJ
Compressor Station, Vijaipur by National Safety Council, Mumbai.
Letter of Appreciation to HVJ Compressor Station, Vijaipur by NSC, Mumbai.
Suraksha Puraskar Award from National Safety Council, Mumbai for HVJ Compressor station, Vijaipur
5 Greentech Gold Award-2009 on HSE Management by Greentech Foundation, Mumbai.
Sarvashreshta HSE Award-2009 to GPU, Vijaipur by NSC-MP Chapter.
Safety Innovation Award-2011From Institution of Engineers (India) – Delhi to GAIL Vijaipur Complex.
6 Safety Innovation Award-2009 by Institutes of Engineers-India.
Sarvashreshta HSE Award-2009 to HVJ Compressor Station, Vijaipur by NSC-MP
Chapter.
CMD Trophy for best HSE Performance, Winner 2010-2011 for Gas processing Unit, Vijaipur.
7 CMD Trophy for best HSE Performance to GPU GAIL, Vijaipur.
Greentech Gold Award-2010 on HSE Management by Greentech Foundation,
Mumbai.
CMD Trophy for best HSE Performance, Winner 2010-2011, for HVJ Compressor station
8 CMD Trophy for best HSE Performance to HVJ Compressor Station, Vijaipur.
CMD Trophy for best HSE Performance to GPU GAIL, Vijaipur.
Green Tech Environment Award (Gold) for the year -2011, for GAIL Vijaipur Complex. Received on 21.10.2011.
9 International Safety Award-2009 from British Safety Council,UK.
CMD Trophy for best HSE Performance to HVJ Compressor Station, Vijaipur.
Sarvashreshta HSE Award-2011 to GPU, Vijaipur by NSC-MP Chapter.
10 Safety Innovation Award-2010 by Institutes of
Engineers-India.Sarvashreshta HSE Award-2011 to HVJ,
Vijaipur by NSC-MP Chapter.
LIST OF AWARDS & ACCOLADES BY GAIL-VIJAIPURLIST OF AWARDS & ACCOLADES BY GAIL-VIJAIPUR
HVJ Cross country HVJ Cross country pipeline & LPG pipeline & LPG Recovery Plant, Recovery Plant, Vijaipur conferred Vijaipur conferred prestigious OISD prestigious OISD Safety Award: Safety Award: 2010-112010-11
• 88thth Time for GPU Time for GPU• 1515thth Time for HVJ Time for HVJ
GAIL(India)Limited, Vijaipur
Received
HVJ Compressor Station & LPG Recovery Plant From
For
Shreshtha Suraksha Puraskar -2010from National Safety Council, Mumbai
HVJ Compressor station & LPG Recovery plant Of GAIL