Transcript Slide 1

BSC
OISD AWARD
IMS
ISO 9001
ISO 14001
OHSAS 18001
FIVE STAR
SWORD OF
HONOR
By : Sukant Ku. Singh, Manager(F&S), GAIL- Vijaipur, MP.
SARVASHRESHTA
SAFETY AWARD
GAIL (India) Limited, India’s Principal Gas transmission and
Marketing company, own and operates Country’s
largest Natural Gas Transmission network.
GAS PIPELINES
Length
: 10,000 KMS
Capacity : 157 MMSCMD
Spread
: 11 STATES
LPG PIPELINE
RAJASTHAN
Length
PATA
LAKWA
: 1922 KMS
Capacity : 3.8 MMTPA
Spread
: 6 states
VIJAIPUR
TRIPURA
VAGHODIA
GAS PROCESSING
No.
: 7 PLANTS
Capacity : 1.2 MMTPA LPG
USAR
VSPL
KG BASIN
NATURAL GAS PIPELINE
Spread
: 5 states
COMPRESSOR STATION
LPG PIPELINE
LPG PLANT
2
PETROCHEM PLANT
CAUVERY
BASIN
No.
: 08
PETROCHEMICALS
No.
: 01
OPERATIONS AT GAIL-VIJAIPUR
Pipe Line
 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.
Compressor Station
 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
OPERATIONS AT GAIL-VIJAIPUR
Operates two LPG recovery
units having the production
capacity :
LPG
: 406000 TPA
Propane
: 130000 TPA
Gas Processing Unit
Pentane : 42000 TPA
Naphtha
: 24000 TPA
Consumer Terminals
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 & TARGETS ACHIEVED
2007 TO 2011 By GAIL-Vijaipur
TARGET ACHIEVED
OBJECTIVES
TARGETS SET
FATAL ACCIDENTS
2007
2008
2009
2010
2011
ZERO
ZERO
ZERO
ZERO
ZERO
ZERO
REPORTABLE ACCIDENTS
ZERO
ZERO
ZERO
ZERO
ZERO
ZERO
HSE INDEX
98%
100%
100%
100%
100%
100%
LEGAL COMPLIANCES
100%
100%
100%
100%
100%
100%
FIRE INCIDENTS – MAJOR
ZERO
ZERO
ZERO
ZERO
ZERO
ZERO
INTERNAL SAFETY AUDIT
04 PER YEAR
4
4
4
4
4
EXTERNAL SAFETY AUDIT
01 PER YEAR
1
1
1
1
1
LPG
04 PER YEAR
4
4
4
4
4
HVJ
04 PER YEAR
4
4
4
4
4
04 PER YEAR
4
4
4
4
4
100%
100%
100%
100%
100%
100%
100%
100%
100%
100%
SAFETY COMMITTEE
MEETING
MOCK DRILL
DISTRIBUTION OF SAFETY
KITS
100 % GAIL
EMPLOYEES
HSE INTERNAL TRAINING
100 %
EMPLOYEES
This is as per Chapter-4.2(Intent) as per Notification of PNGRB for ERDMP
SAFETY MANAGEMENT SYSTEM
HSE TRAINING- 05
HSE LEADERSHIP &
COMMITMENT- 12
RISK ANALYSIS &
MANAGEMENT - 01
INCIDENT
REPORTING,
INVESTIGATION &
ANALYSIS- 15
EMPLOYEE
PARTICIPATION (NEAR
MISS & SAFETY
SUGGESTION) - 05
INSPECTION &
MAINTENANCE - 04
ENVIRONMENT
MONITORING -05
HSE INDEX
100 Marks
CONTROL OF DEFEATS &
RELIABILITY OF CRITICAL
SYSTEM & DEVICES-03
PROCESS SAFETY
INFORMATION 05
OCCUPATIONALHEAL
TH MONITORING -10
COMPLIANCE AUDIT
(EXTERNAL &
INTERNAL HSE
AUDIT) - 15
OPERATION & MAINTENANCE
(FIRE APPLIANCES,FIRE WATER
BASED & NON WATER BASED
SYSTEM, CALIBRATION STATUS
OF PSV, FIRE DETECTION &
ALARM SYSTEM) -15
EMERGENCY
PLANNING &
RESPONSE – 05
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
TRAINING FACILITIES AT GAIL, VIJAIPUR
More than 15nos Training models are available.
(SIMULATION OF BLEVE)
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).
FACILITIES AVAILABLE
1.
2.
3.
4.
5.
6.
Satellite phone.
P&T Phone.
3. HVJ Phone.
Public Address system.
Projectors & PC
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.
Dr U D Choubey, C&MD, GAIL inaugurated the ECC
Chapter-15.1( for ECC) as per Notification of PNGRB for ERDMP
EMERGENCY PREPAREDENESS
There are two types of Emergency Action Plan at
GAIL, Vijaipur:
ON SITE EMERGENCY ACTION PLAN:-This On-Site
Emergency Action Plan is based on the Disaster
Management Plan, which was prepared on the basis of Risk
analysis and consequence analysis, and meets the
requirement of the Indian Factories Act, 1948, and also
complies with the requirement of ERDMP.
OFF SITE EMERGENCY ACTION PLAN:- Plan has
been approved by district administration i.e. Collector.
Chapter-16( Declaration of On site & off site emergency) as per Notification of PNGRB for ERDMP
ON-SITE EAP GPU
Chapter-14( Emergency Organization & Responsibility, Organization Chart ) as per Notification of PNGRB for ERDMP
ON-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.
ON
ON
OFF
30 SEC
15 SEC
ON
Disaster
2 MIN
ON
OFF
30 SEC
15 SEC
ON
ON
OFF
1MIN
Disaster
2 MIN
30 SEC
OFF
1 MIN
Disaster
2 MIN
ALL CLEAR (For fire): Straight
run siren for two minutes.
TEST: Straight run siren for two minutes on Friday at 7PM to 7.15PM.
EMERGENCY CONTROL CENTRE IS IN FIRE STATION FIRST FLOOR ROOM NO.10, HVJ NO- 1444, 2443, 2444, 274250
Chapter-14.2.5.9 ( Siren Code) as per Notification of PNGRB for ERDMP
GAIL(India) Limited, Vijaipur, MP
CISF gate/Colony
NFL Gate
HVJ MCR Gate
CISF gate C2C3 Project
Fire Station
LPG C/R
EIL Building
C2C3 Project
C&P Store
Assembly Points
Way To Emergency Exit
First Aid center
Hospital
1-EIL Building
2-LPG C/R / Lab Bldg.
3-Fire station.
4-LPG C&P Store.
5-HVJ MCR gate
6-C2C3 Project site.
Chapter -13( Zoning & Maps), Chapter-15.2( Assembly point), as per Notification of PNGRB for ERDMP
COMMUNICATION SYSTEM
TYPES OF
COMMUNICATION SYSTEM
RANGE
HVJ Phone
-
Walkie Talkie
1 KM range
NOS OF
COMMUNICATION
SYSTEM
Every where available
as per req.
04(Fire Stn.)
Siren electric motor
10KM
All plants, offsite,
loading, storage, etc
05nos
Manual Siren
1KM
01(Fire Stn.)
Mobile phone
-
01
BGU/ MCPs
-
67(LPG) & 53(HVJ)
Satellite phone
(INMARSET TEL.)
World Wide
05
Paging system(PA)
Chapter-14.2.5.8 ( Communication Services) as per Notification of PNGRB for ERDMP
MUTUAL AID SYSTEM (MAS)
SL NO
NOS OF INDUSTRIES
WRITTEN
DETAILS OF
WITH MAS & NAME
AGREEMENT
SYSTEMS UNDER
EXISTS OR
MAS:
NOT
01
M/S
NATIONAL
FERTILIZER
YES
LIMITED, VIJAIPUR
i.
FIRE FIGHTING
ii. RESCUE
iii. LOGISTICS
iv. ENGG SUPPORT &
v. OTHER HELP.
02
M/S INDIAN OIL LTD.
YES
DONGER, VIJAIPUR
i.
FIRE FIGHTING.
ii. RESCUE.
iii. ENGG SUPPORT &
iv. OTHER HELP.
Chapter-12.3( Mutual Aid) as per Notification of PNGRB for ERDMP
CLASSIFICATION OF EMERGENCY
 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).
FIRE DRILL-(Level-1)
ON SITE DRILL(Level-II)
OFF SITE DRILL(Level-III_
Chapter-6 ( Classification of emergency) as per Notification of PNGRB for ERDMP
This is as per Schedule-IV( Resource Mobilization)
PUMP INDICATION
LOCATIONIOD MANUAL CALL POINTS
AUTOMATIC TURN OUT SLIP
INDICATION OF FIRE WATER TANKS
PLC control Fire station having facilities of Real Time data of followings,
 Wind Speed.
 Wind Direction
 Ambient Air Temperature
 Relative Humidity
 Rainfall
 Solar Radiation, etc.
Fire Water
Line
Above Ground
(KM)
Under
Ground(KM)
Total
LINE SIZE4’’ 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
DP-A
DP-B
DP-E
DP-C
DP-F
DP-D
EP-C
JP-A
NEW FIRE WATER
PUMP HOUSE LPG
JP-B
EP-A
EP-B
OLD FIRE WATER PUMP HOUSE LPG
JP-C
DP-G
EP-D
FWPH IN HVJ AREA
EP-E
LEGEND
DP- Diesel driven pump
EP –Electric driven pump
FIRE APPLIANCE
AVAILABLE AT GAIL, VIJAIPUR
Technical Data
Registration No. of the
Fire Tender
Fire Tender2
MP08A1493
Fire
Tender-2
Fire Tender- Emergency
2
Rescue Tender
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
1000Kg- Monex &
1000Kg Olfex
500Kg of Monex &
500Kg Olfex.
Gen. Set
2 in main line and 2
in standby.
Chlorine Kit
Dry chemical powder
Vessel
No. of EXP. Gas
/Nitrogen cylinders
1000 Kg Monex
4 in main Line and
4 in standby.
4 in main line
and 4 in standby.
*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
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.
FIRE PROTECTION SYSTEM
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.
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.
MANUALS & SOPs
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
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 JAIPUR FIRE INCIDENT
Board Level HSE Sub Committee Members visited GAIL, Vijaipur.
Sh. R.D Goyal (Director-Projects)
Sh. U.K Sen (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, DMIBhopal, 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)
LIST OF AWARDS & ACCOLADES BY GAIL-VIJAIPUR
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.
4
Shreshtha 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
Safety Innovation Award-2011
From Institution of Engineers (India) – Delhi to
GAIL Vijaipur Complex.
5
Greentech Gold Award-2009 on HSE Management
by Greentech Foundation, Mumbai.
Sarvashreshta HSE Award-2009 to GPU,
Vijaipur by NSC-MP Chapter.
6
Safety Innovation Award-2009 by Institutes of
Engineers-India.
Sarvashreshta HSE Award-2009 to HVJ
Compressor Station, Vijaipur by NSC-MP
Chapter.
7
CMD Trophy for best HSE Performance to GPU
GAIL, Vijaipur.
Greentech Gold Award-2010 on HSE
Management by Greentech Foundation,
Mumbai.
8
CMD Trophy for best HSE Performance to HVJ
Compressor Station, Vijaipur.
CMD Trophy for best HSE Performance to GPU
GAIL, Vijaipur.
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.
Safety Innovation Award-2010 by Institutes of
Engineers-India.
Sarvashreshta HSE Award-2011 to HVJ,
Vijaipur by NSC-MP Chapter.
10
CMD Trophy for best HSE Performance,
Winner 2010-2011 for Gas processing Unit,
Vijaipur.
CMD Trophy for best HSE Performance, Winner
2010-2011, for HVJ Compressor station
Green Tech Environment Award (Gold) for the
year -2011, for GAIL Vijaipur Complex.
Received on 21.10.2011.
HVJ Cross country
pipeline & LPG
Recovery Plant,
Vijaipur conferred
prestigious OISD
Safety Award: 201011
•
•
8th Time for GPU
15th Time for HVJ
GAIL(India)Limited, Vijaipur
Received
For
HVJ Compressor Station & LPG Recovery Plant
From
Shreshtha Suraksha Puraskar -2010
from National Safety Council, Mumbai
HVJ Compressor station & LPG Recovery plant Of GAIL