no. t^ · of “eme ited the by a team 16 british safety ants & re” by isors. ( hr ) &m...

GAIL (India) LimitedCorporate HSE Department

IOM

Ref-. No. GAIL/NOIDA/CO-HSBl2l20l6-17

1. HVJ and Non HVJ Gas Pipeline Installations.2. LPG Pipeline Installations.3. Process Plants.

Overall HSE Score stands at92. l6 for the month of May, 2016.

General Manager (HSE)

To : All OICs (as per the mailing list)

CC: fbr favor of infbrmation to:

. C&MD

. Director (MarketingiBD/Finance/HR/Project)

'' ED ( PD/CRO )lED (O&M-CR)/ED(0&M-CO)/ED(0IC-Pata)/ ED(IA)/ ED(pC)/ED(E&P)/ ED(HR/I{RD)/GM(SR)

Dated: T^

June, 2016

SUB: MONTHLY HSE scoRE REPORT - Mav 2016

HSE Score Report for the month of May 2016 containingfor the following Installations / Plants is sent herewith forinformation please.

inter alia HSE Scoreyour kind perusal &

1. GSM

2. LPi

3. E&C

4. Atp

5. BJ

6. AhR

7. JC

8. ID

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Page 1 of 14

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1 1 1 1 1 1 0 0 1 0 1 0 1 1 1 1 1 0 1 1 1 1 1 1 0 0 1 0 0 1 1 1

2

(b) 2 2 2 2 2 2 2 1 1 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 1 2 2 2

(c) 2 2 2 2 2 2 2 2 2 2 2 1 2 2 2 2 2 2 2 2 2 2 2 2 2 1 2 2 2 2 2 2

3

(a) 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0

(b) 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0

4

(a) 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1

(b) 1 1 1 1 1 1 1 1 1 1 1 1 0 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1

(c) 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 0 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1

5

(a) 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0

6

(a) 1 1 1 1 1 0 1 1 1 0 1 0 0 0 0 0 1 1 1 0 0 1 1 1 1 1 1 1 0 1 1 1

7

(a) 1 1 1 1 1 1 1 1 1 1 1 1 1 0 1 1 1 1 1 1 1 0 1 1 1 1 1 1 1 1 0 1

(b) 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1

8 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2

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(a) 2 2 0 0 2 2 2 2 2 2 2 2 2 0 2 2 0 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2

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Facility Design, construction & pre-start up review

Control of defeat and reliability of critical system and devices

Display of critical SOP

Risk analysis and management

Risk analysis

Process safety information

HAZOP study

Pre-start up review

Display of MSDs

Display of Electrical area classification

1

HSE SCORE AT A GLANCE FOR THE MONTH OF May 2016

Category ---> Process Plants L P G P/L Stations

Chh

ains

a

HVJ NG P/L Stations Regional NG P/L Stations

Koc

hi

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ELEMENTS

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(a) Safety Suggestion from Employee

1 1 1

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Jam

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NC

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HSE Leadership and Commitment (M)

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Sl

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11 1 1 1 1 1

Safety Committee meeting(Q)

1 1 1 1 1 11 1 1 1 11 1 1

Third Paty Services

Safety Rule Violation

Monthly HSE briefing Undertaken by OIC/WIC

Unsafe condition/Act reported by employees

11 1 11 1 1

Review of HSE policy (Y)

Work Permit System

Job safety analysis

Personal Safety

Workplace monitoring

Availability of PPEs

Page 3 of 14

Viz

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(b) 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 0 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2

10

(a) 1 1 1 1 1 0 1 1 1 1 1 1 1 1 1 1 1 1 1 1 0 1 1 1 1 1 1 0 1 1 1 1

(b) 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3

(c) 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 1 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3

(d) 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3

(e) 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1

(f) 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 2 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3

(g) 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2

(h) 2 2 2 0 2 2 2 2 2 2 2 2 2 0 2 2 2 2 2 2 2 2 2 2 2 2 2 0 2 2 0 2

11

(a) 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2

(b) 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1

(c) 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2

(d) 2 2 2 2 2 0 0 2 0 2 2 2 0 2 2 2 2 2 2 0 2 0 2 2 2 2 2 2 2 2 2 2

(e) 3 1 3 3 3 1 0 3 0 1 0 3 3 3 3 2 2 3 3 1 3 3 1 3 3 3 3 3 3 3 3 3

12 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1

13 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5

14

(a) 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2

(b) 18 18 18 18 18 18 18 18 18 18 18 18 18 18 18 18 18 18 18 18 18 18 12 18 18 18 18 18 18 18 18 18

(c) 2 2 2 0 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2

15

(a) 4 0 4 4 0 4 0 4 0 4 0 0 4 0 0 0 4 0 0 0 0 0 4 4 0 4 0 0 4 0 4 4

Training:Health,Safety and Environment

Management of Change

Calibration/Resetting

Incident Investigation and analysis

Incident Reporting

Operation and Maintenance (Procedure)

Safety Toolbox Talk

Fire & Safety Manpower

Fire Detection & Alarm System

Fire Water-Based System & Non-Water based system

Fire Fighting Appliances

Fire Fighting Chemicals

Critical Instruments

Communication System

Near miss Incidents

Pipeline Thickness

Pressure Vessels

Portable equipments

Load bearing Installed equipment

Safe Operating Procedures

Inspection and Maintenance

Incident Reporting, Investigation and analysis

Health Monitoring

Occupational Health

Page 4 of 14

Viz

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(b) 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0

16

(a) 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1

(b) 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1

(c) 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2

(d) 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1

17 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2

18

(a) 8 7 8 7 4 8 7 4 4 8 3 7 8 3 8 8 5 5 2 8 6 7 0 7 1 8 7 7 7 8 8 8

(b) 4 3 4 4 4 4 4 3.5 3.5 4 2.5 3.5 1.5 4 4 4 4 4 4 4 4 4 4 4 2.5 4 4 4 4 4 3.5 4

100 92 98 93 92 94 89 93.5 85.5 96 86.5 91.5 93.5 85 95 90 92 92 90 91 92 92 84 99 86.5 98 95 91 96 96 96.5 10019 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0

92.00 98.00 93.00 92.00 94.00 89.00 93.50 85.50 96.00 86.50 91.50 93.50 85.00 95.00 90.00 92.00 92.00 90.00 91.00 92.00 92.00 84.00 99.00 86.50 98.00 95.00 91.00 96.00 96.00 96.50 #####

Excel Excel Excel Excel Excel VG Excel VG Excel VG Excel Excel VG Excel Excel Excel Excel Excel Excel Excel Excel VG Excel VG Excel Excel Excel Excel Excel Excel Excel

Sl

1

2345

Environment related accident/incident

≥70 & <80 GOOD ≥60 & <70 FAIR Below 60 POOR

RATING

90 - 100 EXCELLENT

≥80 & <90 V. GOOD

91.40 94.20

Overall HSE Score 92.16

92.56 90.50

HSE Score Achieved

Rating

Groupwise HSE Score

Internal HSE audit (Including IUSA) observations & Compliance

Environment Management

Occupational Health Facility

Hazardous waste

Environment audit by external agencies

Environment Monitoring

External HSE audit Observations & Compliance

Compliance audit

Emergency planning and Response:Onsite Mock Drill

TotalScore Deduction on NC

Page 5 of 14

of 14

Highlights of HSE Activities for the Month - May, 2016

Highlights of HSE Activities at Work Centres are summarized below:

1. Behavior Based Safety (BBS):

BBS schedule meetings of functional committee and Steering Committee organised at various sites.

BBS follow up visit by representatives from M/S Obul Consultancy at Abu Road, Agartala, Hazira, Jamnagar, Mumbai, Nasirabad, Samakhiali.

2. Emergency Response and Disaster Management Plan (ERDMP) / Mock Drill:

Quarterly On-Site Mock Drill organised at Pata for Leakage scenario.

Outside fire call was attended by the Fire & Safety deptt at G Kondruru, Nasirabad, Pata, Vaghodia & Vijaipur.

3. External Safety Audit

External Safety Audit conducted by M/s CEIL at Abu Road & Nasirabad.

T4S audit as per PNGRB Regulation of Khera & Mumbai ( Maharashtra ) region

pipeline system has been conducted by M/s Intertek Moody International Private Limited.

4. OISD Audit

Audit for Dabhol Panvel Pipeline (DPPL) region has been conducted by OISD team

Delhi from 10-14th May 2016.

5. Other Highlights

02 nos of LPG pipeline awareness program conducted under Loni Region for villagers and district administration.

Pipeline Representative from Vaghodia attended meeting of Local Crisis Group, Vaghodia at Mamlatdar Office Vaghodia.

Safety Awareness Program conducted at village Narvalia in District Jhabua..

of 14

Community Awareness program on Natural Gas Pipelines safety and Dos & Don’ts in case of leakage are being conducting by hiring local focus group and arranging in PL ROU Villages. In 2nd phase 150 villages covered so far.

Pig launching & receiving activities carried out at Agartala, Cherlapalli, G Kondruru & Hazira.

*****

of 14

Near-miss Incidents Reported by Work Centres:

Near miss incidents have been reported from various sites in the month of May 2016. Notable near-miss incidents are summarized as below:

Abu Road: On 28.05.16 at 15:50 hrs, Pig receiver line modification job was under progress. Before performing cutting and welding the line was purged with nitrogen. One nitrogen cylinder was kept at site, during movement one worker was struck with cylinder and cylinder got tilted. It was observed that the cylinder was tied up with a structure using a thin rope at middle of the cylinder. Cherlapally: On 21.05.2016, Job of foundation breaking was under progress at the FWPH using Tractor mounted Air Compressor, when suddenly the boiling radiator water of the tractor started gushing out of the radiator. Fireman on standby immediately informed to the tractor breaker operator and operator in turn immediately stopped the tractor and the job. As the hot water splashed when no person was in close proximity, no person was injured. As the tractor was stopped just in time, further heating of the tractor & further consequences were avoided. Chhainsa: On 24.05.2016 at 1630 hrs, Installation of tin sheets was being done on the iron angle frame structure around GTC-A stack by contract worker of M/s Venture Engg. While working, a piece of iron angle and tin sheets were lying on top of the shed. Due to sudden change in the weather, strong wind started blowing and forcing the worker to stop the job. But, before he could collect his tools and other small leftover pieces of angle & sheets, the wind moved a cut section of the sheet and thereby making an iron piece placed on it to fly in the air. The piece straight away came to the ground. Luckily, it didn’t injure anyone as the area was barricaded to limit the movement of persons below the working level. Gandhar: On 05.05.2016 at 10:30 hrs, Mr. Raj Ilyas I, while on plant round near main control room his head strikes with dense bushes of tree which were hanging on the roadside. Luckily nothing untoward happened. It has a potential to cause injury if someone passed from that area during night hours. On receipt of information immediately information given to horticulture dept. for removing the trees dense bushes which are obstructing the pathway to avoid such incidents in future. Khera: On 28.05.2016, worker involved in the construction of drain near new FWPH slipped from the edge of the under construction drain. Fortunately he did not suffer injury. Loni: On 24.05.2016 at 20:00 hrs, Mr. Om Prakash, Foot Patroller was on his way for LPG pipeline foot patrolling. When he reached at SV- 65, he hears some unusual sound from the process area. After going near to the process area with security person on duty, he observed that there was small LPG leakage from the flange of TE- SV- 65. They immediately informed the Madanpur Khadar Control Room regarding the same. As per instructions of C/r they isolated the TE and thus leakage got stopped. Maintenance team reached at the site and replaced the damaged gasket of the leaking flange. Had Mr. Om Prakash not noticed the leakage in time, it would be a major incident. NCR: On 16.05.2016, during the pigging activity at Dadri terminal, it was observed that at BNPL Launcher site as there is no space for movement around launcher tray & height is also

of 14

around more than a meter. After pushing of pig in launcher barrel, Push rod of 4” dia pipe around 4 meters length and more than 100 kg weight is to be removed from tray by two persons. One person was on platform around tray and another person jumped from platform of one meter height because there are no steps to come down from platform. After jumping both persons fell and very narrowly escaped from injury. Pata: On 16.05.2016 at 08:44 hrs, Mr. Sooraj Pal Singh Manager (GPU Opns.) reported that the newly erected pipe rack of pc-2 near GPU C/R and between GPU/GCU plant has cable tray at the top this cable tray is covered with GI sheets, .during heavy wind these sheets (size around 3x8 feet) are being detached from cable tray and fell down on roadside and in plant area. If someone crossing the road during heavy wind may get injured fatally by flying metal sheet. Rajahmundry: On 11.05.2016 at 11:15 hrs, the construction job of modification of KKD-1 old PCV line 14”/ 6” reducer cutting and bewailing was under progress at Tatipaka Terminal Process Area. Simultaneously another job of opening the 14” Ball Valve flange of the same line was also being done at a distance of 10 meters. While removing the flange, suddenly condensate of approx. 2-3 Litres was gushed out from the line and spread out nearly 1-2 meters radius. Without expecting and noticing the same by the cutting and bewailing team, they tried to continue the grinding job. On seeing the sparks from grinding job, the Fireman at the site immediately responded and operated the DCP Extinguishers on the condensate spread area and successfully prevented to catch the fire. Otherwise the grinding sparks have potential to ignite fire on condensate. Vadodara: On 28.05.2016 at 11:30 hrs, during monthly maintenance of fire -fighting equipment a Contract Fire man who was approaching the terminal, narrowly missed by the flying spark generated inside factory into his eyes. Vaghodia: On 03.05.2016 at 2300 hrs, live burning flying lamp (Chinese flying Lamp) was dragging and descending with air draft and fell near the NTGG Plant area. Mr. Ratnakar Wagh was on safety round and notice descending burning flying lamp, when the lamp touched the ground near the NTGG Plant it was still burning. Immediately he responds with nearby fire extinguishers and burning flying lamp extinguishers. Vijaipur: On 26.05.2016, Crane was engaged for calibration of DVPL-C machine discharge line PSV by HVJ Instr. While removing PSV, smoke observed from crane control panel. Also On-Off switch of crane was also found non-functioning but anyhow operator managed to switch-off the crane by cutting its control wiring. As crane was operating in hazardous area & looking into high potential risk in the area, incident should be investigated. Vizag: On 11.05.2016, as the air conditioning system inside the conference hall of technical building was not effective Electrical Dept. personnel placing Stand Fans inside the conference hall. While placing the stand, the fan portion got loose at stand stem top threaded joint. The fan was not electrically connected at that time. The stem & the fan were made connected properly before charging & starting of the fan.

of 14

Details of Deduction of Marks in the Month of May 2016

Sl. No.

Name of Installation Marks Deducted

Element No.

Reason for Mark Deduction

1.

HV

J N

G P

/L S

TA

TIO

NS

Hazira

2 11 ( e ) PSV monitoring / testing not done as due

4 15 (a ) 100% manpower not covered for health check up

1 18 (a) Pending ESA (OISD June 2014) points

1 18 (b) Pending IUSA (26.11.2013) points

2. Jhabua 2 9 ( a ) JSA not done 100%

3. Khera

2 9 ( a ) JSA not done 100%

2 10 ( h ) SOP not reviewed as due

2 14 ( c ) Incident dt 08.01.2016 recommendations

1 18 (a) Pending ESA (CEIL July 2014) points

4. Vijaipur, CS

4 15 ( a ) 100% manpower not covered for health check up

4 18 ( a ) Pending T4S Audit points 28.07.2011

5. Vaghodia, CS

1 6 Safety violation by contract employees

1 10 (a) Available Staff+ Outsourced <95% of Std. Requirement

2 11 ( d ) Thickness testing not done as due

2 11 ( e ) PSV monitoring /testing not done as due

6. Dibiyapur

1 1 HSE policy not reviewed as due

2 11 ( d ) Pipeline thickness survey not done as due

3 11(e) PSV/LEL monitoring /testing not done as due

4 15 ( e ) 100% manpower not covered for health check up

1 18 ( a ) Pending OISD ( Aug 2014 ) point

7. Kailaras


1 2 ( b ) 95% of previous Safety Committee meetings not complied

4 18 ( a ) Pending T4S audit (16.08.2011) points

of 14

Sl. No.


Element No.


0.5 18 ( b ) Pending ( IUSA 27.11.2014 ) points

8. NCR

1 2 (b) 95% of previous Safety Committee meetings not complied


3 11(e) LEL detector & PSV monitoring /testing not done as due


4 18 (a) Pending T4S Audit ( 11.08.2011) points

0.5 18( b ) Pending IUSA point of Aug 2014

9. Chhainsa

1 1 HSE policy not reviewed as due 1 6 Safety violation by contract

employees 2 11(e) PSV monitoring /testing not done

as due

10.

RE

GIO

NA

L N

G P

/L S

TA

TIO

NS

Mumbai

3 11 ( e ) PSV monitoring/testing not done as due


5 18 (a) Pending ESA (OISD 06.12.2010) points

1.5 18 (b) Pending IUSA (26.03.2013) points

11. Rajahmundry


1 2 (c) No. of reported unsafe conditions = 2

1 6 Safety violation by contract employees


1 18 (a) Pending ESA ( CEIL Nov., 2014) points

0.5 18 ( b ) Pending ISA ( Feb 2015 ) point

12.

Puducherry

1 4 ( b ) Area classification drawing not displayed at site

1 6 Safety Violation by Contract employees

of 14

Sl. No.


Element No.




13. Vadodara


1 7 ( a ) Workplace monitoring not done




5 18 (a) Pending ESA (CEIL 19.03.2011) points

14. Agartala



15. Kochi

1 4 ( c ) SOP not displayed


2 10 ( c ) Fire pumps availability < 90%

1 10 (f) DCP quantity not 100% available

1 11(e) LEL Det monitoring /testing not done as due


16. Bengaluru


2 9 ( b ) Safety tool box talk not done 100%

1 11(e) LEL Det monitoring /testing not done as due

3 18 (a) Pending T4S audit (31.01.2013) points

17.

PR

OC

ESS

PL

AN

TS

Gandhar




18. Pata 4 15 ( e ) 100% manpower not covered for

health check up

of 14

Sl. No.


Element No.


6 18 (a) Pending ESA ( OISD Feb 2010) points

19. Usar



2 11 ( e ) PSV testing not done as due


20. Vaghodia, GPU





21. Vijaipur, GPU

1 7 ( a ) Work place monitoring not done as due



1 18 (a) Pending ESA( CEIL Oct 2014) points

22.

LP

G P

/L S

TA

TIO

NS

Loni Region

2 11 ( e ) PSV testing not done as due

6 14 ( b ) Non Reportable Incident ( Gas Leakage )

8 18 ( a ) Pending ESA (OISD Nov 2001) points

23. Mansharampura 1 18 (a) Pending ESA (CEIL Nov 2014)

points

24. Nasirabad





25. Abu Road 1 1 HSE policy not reviewed as due

1 2 ( c ) Unsafe Condition given = 4

of 14

Sl. No.


Element No.


26. Samakhiali


1 18 (a) Pending ESA (CEIL Nov 2014) points

27. Jamnagar






28. Kandla


1 2 ( b ) 95% of previous Safety Committee meetings not complied



29. Vizag 4 15 ( e ) 100% manpower not covered for

health check up

30. G Konduru

1 7 ( a ) Work place monitoring not done as due


0.5 18 ( b ) Pending ISA ( Mar 2015) points

31. Cherlapalli NIL

no. t^ · of “eme ited the by a team 16 british safety ants & re” by isors. ( hr ) &m...

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