Emergency Response Disaster Management Plan BSC IMS ISO 9001 ISO 14001 OHSAS 18001 OISD AWARD SARVASHRESHTA SAFETY AWARD SWORD OF HONOR FIVE STAR By : Sukant Ku. Singh, Manager(F&S), GAIL- Vijaipur, MP.
GAIL (India) Limited, India’s Principal Gas transmission and Marketing company, own and operates Country’s largest Natural Gas Transmission network. RAJASTHAN JLPL PATA LAKWA VIJAIPUR HVJ, DVPL TRIPURA GANDHAR VAGHODIA USAR VSPL KG BASIN NATURAL GAS PIPELINE LPG PIPELINE LPG PLANT PETROCHEM PLANT CAUVERY BASIN 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
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. • This is the largest single gas grid of GAIL & 100% uninterrupted gas availability to its customers since last 27 Years Compressor Station 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 • Pentane : 42000 TPA Naphtha : 24000 TPA • Which is equivalent to more than one lakh LPG cylinders per day in the domestic circle. Gas Processing Unit Consumer Terminals This is Chapter-3(applicability) as per Notification of PNGRB for ERDMP
OBJECTIVES & TARGETS ACHIEVED 2007 TO 2011 By GAIL-Vijaipur This is as per Chapter-4.2(Intent) as per Notification of PNGRB for ERDMP
SAFETY MANAGEMENT SYSTEM HSE LEADERSHIP & COMMITMENT- 12 RISK ANALYSIS & MANAGEMENT - 01 HSE TRAINING- 05 INCIDENT REPORTING, INVESTIGATION & ANALYSIS- 15 INSPECTION & MAINTENANCE - 04 ENVIRONMENT MONITORING -05 HSE INDEX 100 Marks EMPLOYEE PARTICIPATION (NEAR MISS & SAFETY SUGGESTION) - 05 OCCUPATIONALHEALTH MONITORING -10 CONTROL OF DEFEATS & RELIABILITY OF CRITICAL SYSTEM & DEVICES-03 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 PROCESS SAFETY INFORMATION - 05 EMERGENCY PLANNING & RESPONSE – 05 This is mainly as per Chapter-8( Consequences of default or non-compliance) 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 • Satellite phone. • P&T Phone. • 3. HVJ Phone. • Public Address system. • Projectors & PC • Flow chart of Communication system. • On site EAP. • Off site EAP. • Roles & Responsibility Manual. • All P&ID Diagram. • All Standards. • Telephone list. • Copy of ERDMP of GPU. • Copy of ERDMP of HVJ. • 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
GAIL (India) Limited, Vijaipur 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 15 SEC 15 SEC 30 SEC 30 SEC 30 SEC ON ON ON Disaster Disaster Disaster OFF OFF 1MIN 1 MIN 2 MIN 2 MIN 2 MIN 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-18.104.22.168 ( Siren Code) as per Notification of PNGRB for ERDMP
GAIL(India) Limited, Vijaipur, MP Layout of Plant CISF gate/Colony NFL Gate HVJ MCR Gate CISF gate C2C3 Project Fire Station EIL Building LPG C/R C2C3 Project C&P Store Assembly Points 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. Way To Emergency Exit First Aid center Hospital Chapter -13( Zoning & Maps), Chapter-15.2( Assembly point), as per Notification of PNGRB for ERDMP
COMMUNICATION SYSTEM Chapter-22.214.171.124 ( Communication Services) as per Notification of PNGRB for ERDMP
MUTUAL AID SYSTEM (MAS) 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
FIRE PROTECTION SYSTEM AT GAIL, VIJAIPUR This is as per Schedule-IV( Resource Mobilization)
FIRE PROTECTION FACILITIES PLC Based Fire Control Room PUMP INDICATION AUTOMATIC TURN OUT SLIP LOCATIONIOD MANUAL CALL POINTS INDICATION OF FIRE WATER TANKS
FIRE PROTECTION FACILITIES PLC Based Fire Control Room • 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 PROTECTION FACILITIES.... cont'd 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 LEGEND DP- Diesel driven pump EP –Electric driven pump FIRE PROTECTION FACILITIES.... Contd. JP-C DP-G EP-D EP-E FWPH IN HVJ AREA
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.
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.
INNOVATIVE MEASURES IN HSE
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 • Transportation of LPG, Propane, Pentane and Naphtha is carried out through tankers. (after thorough safety check of tanker as well as documents) • 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, 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)
HVJ Cross country pipeline & LPG Recovery Plant, Vijaipur conferred prestigious OISD Safety Award: 2010-11 • 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