1

GAIL (INDIA) LIMITED

Presentation on

SAFETY
In
Natural gas Processing Installations

By :
S.P.GARG, DGM (F&S)
CORPORATE O&M DEPARTMENT
( sp.garg@gail.co.in )
 GAIL (INDIA) LIMITED -
ESTABLISHED ON
2

16TH AUGUST 1984

GAIL - ACROSS THE GAS VALUE CHAIN

Power
Power

City
City Gas
Gas

LNG
LNG Marketing
Marketing &
& Gas
Gas processing
processing Petrochemical
Petrochemical
Import
Import Transmission
Transmission
E
E&&P
P
Telecom
Telecom

MARKET SHARES : 79% Gas Transmission

70% Gas Marketing
HUMAN RESOURCE : 3,700 +
 PHYSICAL ASSETS 3

GAS PIPELINES
Length : 7,000 KMS
Capacity : 142 MMSCMD
Spread : 11 STATES

RAJASTHAN LPG PIPELINE

PL Length : 1900 KMS
JL PATA LAKWA
Capacity : 3.8 MMTPA
L
VP VIJAIPUR
VJ
, D Spread : 6 states
H TRIPURA
AR
NDH VAGHODIA GAS PROCESSING
GA

USAR
No. : 7 PLANTS
VSPL Capacity : 1.35 MMTPA LPG
KG BASIN
NATURAL GAS PIPELINE Spread : 5 states
LPG PIPELINE PETROCHEMICALS
LPG PLANT
4,40,000 TPA ETHYLENE
PETROCHEM PLANT
CAUVERY 4,10,000 TPA POLYETHYLENE
BASIN
 DIVERSIFICATION 4

OFC CONNECTIVITY 13,000 KMS

E&P 27 BLOCKS
(3 - OVERSEAS)

LNG PLL, DAHEJ

RGPPL, DABHOL
(10 MMTPA)

GAS RETAILING IGL, MGL, BGL,

TNGCL, CUGL,
GGL, AGL, MNGL
POWER 156 MW
OFC CONNECTIVITY
E&P BLOCKS
Major Investments planned across the MYANMAR BLOCK
DAHEJ LNG TERMINAL
gas value chain in the next few years CITYGAS
 SAFETY INTEGRAL PART OF 5

CORPORATE HSE POLICY

CORPORATE HSE POLICY

GAIL has a well established Health, Safety & Environment
HSE POLICY

SALIENT FEATURES:
Aims to establish & implement a HSE management system,
Ensure safety of public, employees, plant & equipment,
Ensure compliance with all statutory rules and regulations,
Provide structured training to its employees,
Delegate powers to employees for fulfilling HSE responsibilities,
Set tangible and measurable targets for monitoring HSE
performance and
Promote eco-friendly activities.
 SAFETY FEATURES 6

IN PROCESS PLANTS
All internal roads at higher elevation then the plant floor
level.

All electrical equipments are installed as per the area

classification.

Earthing and bonding in place and their continuity being

checked periodically.

Inert gas blanketing inside the inflammable tanks storages.

Dyke wall around storage tanks.

LPG & propane stored in mounded storages .
 SAFETY FEATURES 7

IN PROCESS PLANTS

Loading of tankers with automatic earthing/continuity check

system.

Water curtain system around cracker furnaces.

Well laid out public address system with connection to

intercom telephones.

High expansion foam system installed to cover pipe-yard

area in case of emergency.

Safe distances between various units, storage tanks.

 OPERATIONAL SAFETY 8

PSVs and TSVs installed to avoid over pressurization.

PSV connected to flare.

PSVs & TSVs calibrated as per schedule.

Load testing of EOTs, tools & tackles as per statutory norms.

Auto emergency shut down interlock.

All systems having failsafe configuration.

 OPERATIONAL SAFETY 9

Safety interlock bypass only by authorised persons.

NDT of equipments as per schedule

Environment monitoring as per statutory requirements.

 PHYSICAL SAFETY MEASURES 10

9No vehicle movement without spark arrestor & road

movement permit clearance .
9Wearing of cotton dress is compulsory.
9Display of assembly points and provision of emergency siren.
9Use of walki talki by field operators and Fire & Safety
personnel.
9Radio paging system in place.
9Display of electronic safety boards.
9Display of Health, Safety and Environment policy.
9Rehearsal of on site emergency plan on half yearly basis.
 PHYSICAL SAFETY MEASURES 11

9Establishment of emergency control centre within the

complex.

9Process trip bypass records.

9Installation of acoustic telephone booths.

9Use of mobiles with in the battery limit of the complex is

strictly prohibited.

9Availability of all types of portable fire extinguishers at easily

accessible locations

9Installation of wind socks at strategic locations.

 PHYSICAL SAFETY MEASURES 12

9No smoking inside the plant premises.

9Emergency action plan displayed at strategic locations.

9Installation of HVLR monitor for gas dispersion at strategic

locations.

9Patrolling in storage area by operation, Fire & Safety and

Security personnel.

9CCTV for flare & LPG tanker loading area monitoring.

 PHYSICAL SAFETY MEASURES 13

9Compulsory use of basic personal protective equipments

like safety helmet & safety shoes.

9Use of special safety gadgets e.g. Breathing apparatus, gas

masks, fire proximity suit, PVC suit are mandatory based on
nature of hazards involved in the job.

9Emergency lighting in field and control rooms.

9Use of bi-cycle for internal movement of the operation &

maintenance personnel.

9Safety showers installed at strategic locations in all plants

 PHYSICAL SAFETY MEASURES 14

9Siren installed to alert all personnel during emergency.

9Different kinds of fire protection and safety equipment

placed in the plants.

9Regular maintenance as per the declared schedule.

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FIRE PROTECTION SYSTEM

Round the clock manning.

Mutual aid agreement with neighboring industries.
Mock Drills are rehearsed on Quarterly basis as per OISD
recommendation.
Control rooms have been made blast proof and automatic
fire protection system has been provided.
Below false floor co2 flooding system provided inside
control rooms.
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FIRE PROTECTION SYSTEM

All the process pumps covered by water spray system.

All the hydrocarbon storages provided with automatic
water spray system.
Hydrocarbon leak detection system installed all over the
plant areas.
Intelligent fire alarm system (microprocessor based)
provided.
Panels in respective control rooms and fire control room.
 SAFETY AND ENVIRONMENTAL INITIATIVE

LPG transportation through pipelines; 2.444

million MT in year 2009-10, nearly equal to
17.2 crore cylinders.

Developing a healthy and green

environment in and around its work
stations. More than 50 % of plant area is
covered with water bodies & Green Belt.
 BEST SAFETY RACTICES IN GAIL 18

Incentive on Near Miss Reporting

HSE is important agenda point in Management Review
Meetings, including Board of Directors Meeting
Monthly Critical safety Campaigns at Sites
EHS Module of SAP implemented
No safety interlock bypass without written authorization
Counter signing of safety officer in all Work Permits
 BEST SAFETY PRACTICES IN GAIL 19

Safety talk to employees on daily basis before starting of

job.
Task Risk Assessment by Committee consisting of
various discipline to access the risk and recommend the
precautions to carry out job safety in hazardous area.
Structured HSE Training to O&M employees. Regular
training is imparted to contractors, tanker drivers &
nearby villagers.
Extensive use of Bicycles within plant premises.
 BEST SAFETY PRACTICES IN GAIL 20

Internal safety audit and its review for compliance of

each plant/section are being conducted on quarterly
basis.
External safety audit of the complex is being conducted
on annual basis.
Monthly compliance of audits is being reviewed by OIC.
Safe operating and maintenance procedure & Safety
Manual have been developed, documented and
followed.
Material Safety Data Sheet of all plant chemicals
prepared and made available on LAN
 BEST SAFETY PRACTICES IN GAIL 21

Safety guidelines to be followed in various

activities being carried out by contractors
were issued for strict compliance.

In case of non compliance of safety

recommendations in spite of repetitive
advise punitive fines are being imposed
with the consent of competent authority.
 Assessment of SAFETY Performance 22

HSE Policy states GAIL accords highest priority to set

tangible and measurable targets for monitoring the
performance on HSE.

HSE index is the yardstick for evaluating HSE

performance of all 28 O&M work centers. HSE index is
calculated based on 9 measurable parameters which are
allotted weightage out of maximum 100 percentage
according to their importance.
 ANNUAL CMD TROPHY FOR 23

BEST INSTALLATION
GAIL Management has formulated Annual HSE Award
Scheme to reward the Best in Class work center for the
best HSE Performance.
All O&M installations have been categorized in the following three
classes for this award scheme.
Gas Processing Plants
Gas Compressor Stations & LPG Pumping Stations
Natural Gas & LPG Despatch Terminals

The HSE Performance of the work centers are evaluated

on monthly basis for each financial year and scores
averaged for assessing the yearly performance.
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THANK YOU