IMS ISO 9001 ISO 14001 OHSAS 18001 FIVE STAR BSC SWORD OF HONOR SARVASHRESHTA SAFETY AWARD OISD AWARD By : Sukant Ku. Singh, Manager(F&S), GAIL- Vijaipur,

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