limited health, safety and environmental services safety

Bureau Veritas Industrial Services (I) Pvt. Limited Health, Safety and Environmental Services Bureau Veritas Industrial Services (I) Pvt. Limited Health, Safety and Environmental Services 72 Business Park, 8th Floor, Opp: Seepz Gate no. 02,Marol Industrial Area, MIDC Cross Road “C”Andheri, (East) Mumbai: 400 093 Tel: + 91 22 6274 2000 Fax: + 91 22 22 6274 2008 E-Mail: [email protected]

[email protected] www.bureauveritas.co.in

VISIT CONTACTS Narayan Chaudhari AVP (S&OR)

Satya Srinivas Area Manager, CS -02

Confidential

Safety Audit Report

COMPRESSOR STATION - 02 PIL PIPELINE

Vil.Koppaka, Mandal.Pedavegi, Dist. W. Godavari, Andhra Pradesh

Pipeline Infrastructure Limited. Maker Maxity, 4th North Avenue, 2nd Floor, Kala Nagar, Bandra Kurla Complex, Bandra (East), Mumbai 400051

Visit Dates: 01 August 2019

(Final Report) 00

24/09/2019 Surender Maniktala

Sunil Gonsalves

(Draft Report) 00

03/09/2019 Surender Maniktala

Sunil Gonsalves

Revision Date of Issue Prepared by Reviewed by

Disclaimer: This report includes the findings of the Safety Audit of the Compressor station- 02 on the PIL Pipeline of Pipeline Infrastructure Limited (PIL), Mumbai, located at Koppaka village in West Godawari district of Andhra Pradesh. This report is issued within the scope of contract, documents submitted and does not perpetuate into compliance to any statutory regulations and / or codes of any country/region. The discussion of facts, as determined by the investigator, and the views expressed in the report do not assume and are not intended to establish the existence of any duty at law on the part of PIL, its employees or agents, contractors, their employees or agents, or any other party. This report neither determines nor implies liability.

Safety Audit Report Compressor Station– 02

Vil. Koppaka, Dist. West Godawari, Andhra Pradesh. Pipeline Infrastructure Ltd., Mumbai Report No. PIPL/MUM/ML4/66100047- 02

Page | 3 IND.M.43.19.0635- HSE www.bureauveritas.co.in

ACKNOWLEDGEMENT

We are thankful to the management and employees of Pipeline Infrastructure Limited, Mumbai and the Compressor Station-02 located at Koppaka village in West Godawari district of Andhra Pradesh on its PIL Pipeline for their kind co-operation during the Safety audit of the said compressor station and appreciate the courtesy and cordiality extended to the Bureau Veritas auditor.

- Bureau Veritas Industrial Services (I) Pvt. Ltd.




Part-1 Executive Summary 06 Part-2 Preamble 2.1 Introduction 13 2.2 Scope 13 2.3 Objectives 13 2.4 Methodology 14 2.5 Brief Process Description 16 Part-3 Health & Safety Management 3.1 Health & Safety Policy 18 3.2 Safety Organization 18 3.3 Safety Budget 21 3.4 Annual Safety Action Plan 21 3.5 Safety Promotion & Motivation 21 3.6 Safety Education & Training 22 3.7 Safety Inspection 24 3.8 Safety Audit 24 3.9 Safety of Contractor Workers 25 3.10 Standard Operating Procedures 26 3.11 HSE Procedures 27 3.12 Work Permit System 27 3.13 Accident Reporting, Investigation & Analysis 27 3.14 Personal Protective Equipment 27 3.15 First-Aid 28 3.16 Plant Security 28 Part-4 Fire Prevention and Protection 4.1 Portable Fire Extinguishers 30 4.2 Training 30 4.3 Fire Hydrant System 31 4.4 Fire & Gas Detection and Fire Suppression System 31 4.5 Manual Fire Call Points 32 4.6 Fire Proximity Suits

33

Part-5 Electrical Safety

CONTENTS




5.1 General 34 5.2 First-aid 34 5.3 Hazardous Area Classification 34 5.4 Electrical Maintenance 35 5.5 Earthing Systems 36 5.6 Lightning Protection 37 5.7 Other Observations

37

Part-6 Process Safety 6.1 Material Safety Data Sheets 38 6.2 Process Parameters 38 6.3 Process Interlocks 38 6.4 Management of Change 38 6.5 Pressure Vessels & Safety Relief Valves 39 6.6 Pipelines (Intra-Station) 40 Part-7 Emergency Planning & Preparedness 7.1 Emergency Action Plan 42 7.2 Hazard Analysis 43 7.3 Emergency Drills 43 7.4 Emergency Sirens 43 7.5 Exits 43 7.6 Other Measures 43 Part-8 Other Physical Hazards & Control Measures 8.1 Storage of Materials 45 8.2 Material Handling 45 8.3 Compressed Gas Cylinders 46 8.4 Machine Guarding 46 8.5 Safe Access 46 8.6 Work Environment 46 8.7 Environment Protection 46 8.8 Video Display Terminals 47 8.9 Occupational Health 47 8.10 Other Observations 48 Distribution 49

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At the request of Pipeline Infrastructure Limited (PIL), Mumbai, Bureau Veritas (BV) conducted safety audit of the Compressor Station-02 and the associated Main Line Valves (MLV) - 03 and MLV-04 on its PIL Pipeline located at Koppaka village in West Godawari district of Andhra Pradesh. The safety audit was conducted on 01 August 2019. The main objectives of the audit were to particularly examine Health & Safety (H&S) systems prevalent in the compressor station and the associated MLV stations, identify potential H & S hazards and suggest corrective actions, wherever necessary.

The information presented in the report is based on perusal of various documents and internal records pertaining to H & S, a sample inspection of the Compressor Station-02 station, associated MLV-03 and MLV-04 discussions held with various personnel deputed at the compressor station and management representatives. The recommendations made herein in the report, are based on the conditions and systems prevalent in the Compressor Station-02and hence applicable only to the said station or mentioned otherwise. The PIL may however, replicate these recommendations in its other such other compressor stations after studying their implications depending on the conditions and systems prevalent therein. Due care has been exercised while framing the recommendations to make them simple, practical, feasible and thereby workable. The key findings of the safety audit are summarized in the following paragraphs:

• The PIL has declared a written policy statement with respect to the health and safety of employees at work and the organization and the commitments to achieve the objective of the policy is also prescribed. The HSE Policy demonstrates top management’s commitment and interest to manage its H&S responsibilities. The policy was displayed in three languages i.e. in English, Hindi and also in Telagu at prominent locations. The policy was reviewed in 9 May 2019 and also was endorsed by Mr. Mihir Nerukar to demonstrate commitment of top management.

• Well organized sophisticated control systems are provided for in order to manage the natural gas that

enters the pipeline, and to ensure that all customers receive timely delivery of their portion of this gas and to monitor the gas as it travels through all sections of lengthy pipeline network. To accomplish this task of monitoring and controlling the natural gas that is traveling through the pipeline, centralized gas control stations collect, assimilate, and manage data received from monitoring and compressor stations all along the pipe.

• Pipeline control stations in all compressor station including in CS -02 are provided with Supervisory

Control and Data Acquisition (SCADA) systems that takes measurements and collects data along the pipeline (in metering or compressor stations and valves) and transmits it to the PIL centralized control station. Flow rate through the pipeline, operational status, pressure, and temperature readings are used to assess the status of the pipeline at any one time. These systems work in real time, that there is little lag time between the measurements taken along the pipeline and their transmission to the control station. The data is relayed to the PIL centralized control station, allowing pipeline

1. EXECUTIVE SUMMARY




engineers to know exactly what is happening along the pipeline at all times. This enables quick reactions to equipment malfunctions, leaks, or any other unusual activity along the pipeline.

• The fire protection system consisting active and passive fire protection, such as, Fire Hydrant,

Portable fire extinguishers, Dry chemical powder and carbon dioxide have been deployed at various locations in the station.

• The whole station is adequately covered by the fire water hydrants. Hydrant points are provided with

hose box enclosing branch pipe and hose reel. Water monitor is also installed for extinguishing water at 360 degree. Deluge system was provided for the gas turbine.

• The fire and gas detection system including smoke detector, heat detector, gas detector (Point IR,

Ultra sonic & Open path) and flame detector is in place at the critical field locations of the station including the control room, compressor room, battery room, (including the battery room in associated MLV stations) stores, etc.

• Manual call points are installed at critical manned areas to activate and detect the location at the time

of emergency. Both Detection system and MCPs are controlled by intelligent fire alarm panel/mimic panel.

• At select locations including compressor room, battery room, etc. the fire & gas detection system is

coupled with FM 200 flooding to extinguish the fire. Battery rooms are equipped with hydrogen gas detector also.

• The gas turbine enclosure of each of the gas compressors has been provided with CO2 flooding

system. It was provided with flame detectors for detection of any flame and heat detectors for detection of temperature more than 260 degree. Emergency shutdown switch and visual alarm was also installed for it. There is manual activation and abort is provided outside the gas bank.

• Safety organization is well established headed by AVP (S&OR), clearly defining the roles, duties,

accountabilities and responsibilities of every individual of the organization. The HSE affairs of the Region I comprising 5 compressor stations including CS -02 are coordinated by a Regional HSE Engineer. In addition, there is an exclusive Compressor Station HSE Coordinator for CS -02.

• Safety management system has been developed, implemented and is being monitored on a regular

basis. A management framework with defined structures, roles and responsibilities, guidelines, audits and training has been instituted.

• Process safety is also given top priority, well documented standards, management responsibility, and

standardized process as to achieve higher employee participation in the safety management process.

• OMS (Operating Management System) to enhance the level of safety, compliance and reliability is being implemented in phase manner across the PIL compressor stations.




• PIL has set up a Safety Committee consisting of equal number of representatives of workers and

management to promote co-operation between the workers and the management in maintaining proper safety and health at work and to review periodically the measures taken in that behalf. There are Safety Committees at three different levels for the whole Pipeline System covering all the ten compressor stations and the associated MLVs i. e. Apex Safety Committee for the whole Pipeline System covering all the ten compressor stations and the associated MLVs, Regional Safety Committee for each of the two regions and Station Safety Committee for each of the 10 compressor stations including the CS -02. Periodic meetings of the said committees are conducted regularly.

• There is a practice of preparing corporate annual safety action plan listing all the major safety activities to be undertaken and annual HSE budget indicating funds required for such activities. H&S performance of the managerial employees is considered for career advancement.

• The O&M personnel posted at the compressor station have been trained in safety procedures, fire safety and first-aid. Safety induction training is being imparted to contractor employees prior to their entry in the compressor station. Other safety trainings for specific hazards were also imparted to respective employees, contractors and labors.

• PIL ensures preventive health care through pre-employment and also periodic medical examinations

of all employees. Contractor workers undergo routine medical check-up arranged by the contractors. The compressor station- 02 has first aiders and first aid kit for first aid treatment at control room and emergency kit for pipeline is kept in maintenance building.

• The maintenance system of the plant was well organized and documented. The inspection / maintenance procedures in the form of checklists have been developed for major equipment and necessary safety aspects of respective equipment are covered in these procedures/ checklists. Besides external audit, PIL has a well-developed ‘internal safety audit' system.

• Safe work practices were followed so that all works are carried out safely and risks of injury to workers and damage to the equipments are minimized. Standard operating and maintenance procedures including shut-down and start-up procedures have been developed and well documented. The Work Permit System is in place at the compressor station.

• Accident reporting and investigation system is in place. Activity-wise and location-wise PPE needs have been identified and documented.IM (Incident Management) portal is being implemented across PIL to report and keep track of incidents online.

• The compressor stations are manned over 24 hours and the associated MLV and M&R stations are

guarded for 24 hours.

• The path of the underground electric and instrument cables has been marked in the station by erecting adequately spaced indicators. Rubber mats conforming to IS 15652:2006 – Insulating mats for




Electrical Purposes - Rubber mats for electrical purposes are provided in front of control panels and switchgears.

• Flameproof electrical equipment and fittings are provided at the station each station in gas handling areas. Lockout & Tag out system is in practice. Major electrical equipments were provided with double earth connections and earth pit tests are being conducted half yearly. Lightning arrestor has been installed on the Compressor Room.

• The process parameters such as pressure, temperature & flow rate are continuously controlled and monitored from the control room by the operating personnel who are well aware of these process parameters.

• Piping and Instrumentation (P&I) diagrams of the stations are available on Reliance Enterprise Information Management System (REIMS). There is a procedure and a system for management of change to review the modifications made in the specifications of piping, equipment, process engineering, instrumentation, etc. Necessary process interlocks provided in the station. Each of the pressure vessels is equipped with a safety relief valve and the valves are tested once in two years. Ultrasonic thickness measurement test of pressure vessels is being carried out.

• The pipelines were found properly painted conforming to IS 2379. Cathodic protection is provided for underground section of the pipelines. Ultrasonic thickness measurement of pipelines has been conducted and records are also maintained. The resistance between two adjacent flanges of the pipelines has been measured and the records are also kept.

• An emergency response plan for CS -02 and the associated remote and manually operated MLVs is in place. The plan describes the anticipated emergency scenarios, notification procedures, the duties and responsibilities of the personnel in the event of emergency and important contacts. Emergency mock drills are carried out at the station and records are also kept. An emergency response support system is in use. As per the said system, in the event of any emergency, the emergency response team members and management team members are expected to receive the notification of emergency.

• The company has Emergency Response and Disaster Management Plan in place and dedicated Emergency Response Vehicles equipped with essential equipment have been deployed to manage any eventuality or incident. All operations and maintenance employees and contactor workers are trained in emergency response procedures, periodic emergency mock drills are conducted, Pipeline Operations Centre working on 24 hours a day, 7 days a week 365 days a year basis act as a nodal point for emergency notification, communication and coordination.

• Periodic stack monitoring and ambient air monitoring are carried out through an external agency.

Hazardous waste is disposed of through an MoEF-approved agency. In its pursuit of sustainable development, PIL has integrated its safety and environment performance in the overall business plan and strategy.




• PIL is statutory compliant in the area of environment. Necessary mitigation measures are incorporated. Some of the key features incorporated in PIL assets are:

• Dry Low Emission (DLE) mapping of all Gas Turbine Compressors and LENOX mapping of all Gas

Engine generators except CS-1, are performed to minimize the air pollution with optimal efficiency.

• To decrease ozone depletion, HFC-227ea, an environment friendly gas is being used instead of Chlorofluorocarbons (CFC) for extinguishing the fire.

• Rain water harvesting facility is provided at compressor stations except CS-1, for ground water re-charge. Minimum 25% of the total constructed area at each compressor station is being developed as green belt and local species of saplings are being planted.

• PIL has taken proactive measure for safe disposal of hazardous waste such as used oil and condensates are sold only to the Central Government approved recyclers and, Non-hazardous wastes such as metallic, wooden scrap, plastic material are sold to local scrap dealers.

• One Reliance-Common Portal-Pipeline Asset Management Group is being established to maintain all HSE related documentation. This is accessible to all PIL employees.

• A mock drill was conducted on July 2019, for testing the effectiveness of On-site emergency

management, response, preparedness, and resources, are found very satisfactory.

• “Test Potential” and safe Working Potential “were found not marked on the Electrical insulating rubber hand gloves meant for repair and maintenance of electrical installations. It is marked on the gloves.

• Gate of the Transformer fencing of MLV-04 was not locked. Transformer fencing gate should always kept locked and a notice saying entry restricted to authorized persons only should be displayed in local language. Authorized person has been displayed.

• 47 PR Valves (including spare valves in the stores) were tested between 16.08.2017 and 19.08.2017 and next due date of testing is 18.08.2019 Report of testing is available but relief valve setting pressure is not mentioned in the report as well as not marked on the body of the vessel. As per SMPV Rule No.18 (2) vi nd vi (a) - (vi) safety relief valves on any vessel shall be set to start-to-discharge at a pressure not in excess of 110 per cent of the design pressure of the vessel and shall have a total relieving capacity sufficient to prevent the maximum pressure in the vessel of more than 120 per cent of the design pressure; [(via) In case of cryogenic pressure vessel, the safety relief devices shall be set to discharge in such a manner that at least one such device shall be set at a pressure not higher than the maximum allowable working pressure and the other device may be set at a pressure not higher than 110% of the maximum allowable working pressure;]. So this should be set as per this rule and marked on the vessel with due date of testing. Set pressure has been mentioned on the name plate.




• Fall arrestors are installed in GTC and Office building in CS-02. The usage of fall arrestor should not be allowed during cloudy or rainy weather. Fall arrestor has been tested and warning has been provided.

• Blow down area platform was found cracked all around a separated from main platform. The Platform has been repaired.

• Receiver and Launcher or Scrubber pipeline support is welded to the pipeline is provided with studs for axial movement of the pipelines at the bottom of the support. Holes in the support are oval shaped to facilitate axial movement of pipeline. This may not allow proper axial movement as well as restrict the axial movement of the pipeline when the pipeline gets pressurized and expands under high temperature or contracts when temperature/pressure falls. This may also break the support or put strain over a section of the pipeline. It is recommended to use a roller support just below the pipeline properly anchored and support below should be fixed to take care of the axial or lateral movement of the pipeline. The recommendation has been closed.

While appreciating the above systems and measures already in practice in the compressor station, key areas identified for improvement in H&S systems are listed below:

Health & Safety Management

• In view of Change in Management, Health, Safety and Environment Policy of PIL has been displayed in

A4 size papers in CS-02, MLV-03 and MLV-04. A board displaying the HSE Policy in English, Hindi and Telgu in visible font should be installed in CS-02, MLV-03 and MLV-4 as per Factory Act 1948.

• Prohibited place board is not displayed outside the CS-02, MLV-03 and MLV-04. It should be displayed

outside the gates of CS-02.all MLVs and M&Rs as per Indian Stamp Act 1923.

Electrical Safety

• Most of the earth pits are due to resistance checking. So false results are expected due wet season. It is recommended to plan to carry out the earth resistance testing between April-May and Oct-Dec which is normally a dry season

• In MLV-04, sand has lumps in the buckets. Fine sand should be kept in the buckets.

Process Safety • The wire mesh of vents in GTC Fuel gas skid (or where rain hood is fitted, it should be below the rain

hood) should be cleaned every quarter for dust or clogging with the dust. If these are damaged, they should be replaced with double wire mesh of fine copper or brass or Stainless steel or non- corrodible metal.




• Painting in GTC Fuel Gas skid is faded. Painting in pipelines is incomplete. • 6 No pilots in GTC fuel Gas skid are not serviced. They should be serviced immediately. • Portable ladder (L/D/P19) - have not been tested. They should be tested and test date should be mentioned

on the ladder.

Fire & Gas Detection and Fire Suppression System

• Hydro testing of FM 200 Cylinders have expired on 18.2.18. (CS-02 and MLV-04). As per Rule26 and 35 of Gas Cylinders Rules 2018, unless the cylinders are examined and hydro tested, they shall not be transported or filled. So it is recommended that these cylinders should be examined and hydro tested as per IS: 15975. Also exemption from PESO should be sought for extending the period of hydro testing as per the Rule 66 of Chapter VII of Gas Cylinder Rules.

Other Physical Hazards

• In MLV-03 (Chinna Tadepalli): There is drain on two sides of the security cabin. Entry into the cabin is on the back of, wherein a Security Guard has to cross the drain on either side. This may cause a slip and trip or fall. The drain should be covered (preferably provide a pipeline of equal dia of the width of drain and cover the pipeline up to the top of the edges of the drains), to avoid slip, trip or fall.

The audit findings including the observations and recommendations are detailed in the ensuing report.




2.1 INTRODUCTION: This report presents the findings and recommendations of the safety audit the Compressor Station-02and associated MLV& M&R stations on the PIL Pipeline of Pipeline Infrastructure Limited (PIL), Mumbai, located at Koppaka village in West Godawari district of Andhra Pradesh conducted on 6th December 2018 by Bureau Veritas Industrial Services (I) Pvt. Ltd. (BV). The main objectives of the audit were to particularly examine Health & Safety (H & S) systems prevalent in the compressor station and the associated MLV stations, identify potential H & S hazards and suggest corrective actions, wherever necessary.

The information presented in the report is based on perusal of various documents and internal records pertaining to H & S, a sample inspection of the Compressor Station-02, MLV-3 & MLV-4 and discussions held with various personnel deputed at the compressor station and management representatives. The recommendations made herein in the report, are based on the conditions and systems prevalent in the Compressor Station-02and hence applicable only to the said station or mentioned otherwise. The PIL may however, replicate these recommendations in its other such other compressor stations after studying their implications depending on the conditions and systems prevalent therein. Due care has been exercised while framing the recommendations to make them simple, practical, feasible and thereby workable. 2.2 SCOPE: The safety audit was carried out as per IS: 14489 and OISD-145 “Code of practice on Occupational Safety and Health Audit” The broad areas covered in the safety audit are as under:

• Health and Safety (H&S) management

• Process safety

• Fire prevention and protection

• Electrical safety

• Emergency planning and preparedness

• Other physical hazards and control.

2.3 OBJECTIVES:

2. PREAMBLE




• Identify design deficiencies and weaknesses, if any, that might have cropped up during

modifications / additions of facilities.

• Examine the existing operating/maintenance and other work practices, safety systems, fire protection facilities and control measures which might have degraded over the time.

• Identify potential Health & Safety (H&S) hazards not covered by the existing control

procedures.

• Recommend improvements for better effectiveness of the existing procedures, systems and

control measures for H & S hazards.

• Recommend procedures, systems and control measures for the hazards identified.

• Study compliance with critical statutory provisions and relevant codes of practice and

recommend actions to be taken wherever there is non-compliance.

2.4 METHODOLOGY:

• Study and analyze preliminary information provided by the compressor station

management in the format sent by the BV.

• Opening Meeting with concerned officials of the compressor station.

• Carry out sample inspection of the compressor station.

• Discuss with key personnel in group and individually as required to know their views, suggestions or to verify existence of the systems/procedures.

• Study important documents and records.

• Closing meeting with the senior personnel of the compressor station to present important observations and recommendations.

• Submission of the draft report to PIL to peter out factual errors/discrepancies in

observations, if any.




• Submission of the final Safety Audit Report to PIL. 2.4.1 Opening Meeting: As intimated in advance by the BV, the compressor station management of PIL arranged an opening meeting on 01 August 2019 at 09.30 hrs. The meeting was attended by the concerned officials of the compressor station involved in operation, maintenance and management of the compressor station. During the meeting, the concept of safety audit was explained to PIL officials. The safety audit team members made the following points:- The Safety Audit is being conducted at the request of the Management of the PIL and hence shows its keenness and determination to improve the safety performance and thereby to make the workplace safer. As the Management of the PIL is represented by the officials present at the meeting, their involvement and co-operation are essential and important in carrying out the safety audit successfully. The safety audit is not the inspection of each and every activity/piece of equipment, but a sample inspection of the workplace and study of key documents and records. The scope of the safety audit will be limited to the field visit of areas planned to be made available by the compressor station management for inspection, information provided to the safety audit team and documents & records produced for verification. The safety audit is not a fault-finding but a fact-finding exercise and aims at identification of areas for improvement in the safety performance based on observations, discussions at various levels and reference to the records & documents made available for verification. The safety audit report would be a confidential document between and BV and PIL. 2.4.2 Field Inspections: The field inspections were undertaken with a view to focusing on key areas of safety. In order to help maintaining uniformity and speeding up collection of information, inspections were facilitated by using a pre-designed checklist covering various elements of safety audit. The checklist was prepared by pooling the expertise and hands-on experience of BV, besides reference to relevant Indian standards & codes of practice. Inspections were carried out in presence of the O&M personnel associated with the respective departments of the compressor station. 2.4.3 Discussions:




Information was also gathered through discussions with senior management personnel and compressor station personnel at various levels from respective disciplines such as operation, maintenance, electrical, instrumentation, etc. The auditor also interacted with the personnel involved in the operation and maintenance of the compressor station. 2.4.4 Study of Documents In order to check and assess the status of the H & S management system prevalent in the various PIL compressor stations/facilities/sections, many documents such as safety policy, work permit system, operating & maintenance procedures, inspection schedules & reports, previous safety audit reports, calibration reports, records of testing of critical compressor station equipment, earthing systems, fire extinguishers, etc. were perused. 2.4.5 Concluding Meeting: The audit team presented important observations and recommendations in a meeting with key officials of the Compressor Station-02 on 01 August 2019. 2.5 BRIEF PROCESS DISCRIPTION: Pipeline Infrastructure Ltd. (PIL) has been implemented to transport gas from Kakinada (Andhra Pradesh) to Bharuch (Gujarat) including various spurs and interconnects on the way. PIL traverses through the states of Andhra Pradesh, Karnataka, Telangana, Maharashtra and Gujarat. PIL has been authorized as a common carrier pipeline. PIL is a 48 inch uniform diameter (API 5L Grade X-70) pipeline across the entire trunk length of around 1375 km with wall thicknesses 17.2, 20.7 and 25.4 mm depending on the code requirement. The pipeline is 3LPE (three layer polyethylene) coated; internally epoxy lined, helically spiral submerged arc welded (for 17.2 mm) and longitudinal submerged arc welded (for 20.7 mm and 25.4 mm). Impressed current cathodic protection system has been provided to supplement the coating system for protection against external corrosion. Maximum Allowable Operating Pressure (MAOP) of the pipeline is 98.0 bar (g). The pipeline has been designed and engineered in accordance with the requirement of applicable codes and standard (ASME B 31.8) and conforming to the Oil Industry Safety Directorate's (OISD) standards 138 and 141 and other rules and regulations. PIL Pipeline system broadly comprises of a trunk pipeline, spurs lines and feeder lines, and associated mainline block valves, tap-off points, compressor stations, metering and regulating (M&R) stations, cathodic protection system, Supervisory Control And Data Acquisition (SCADA)




system and a dedicated optical fiber cable based telecommunication system. Eleven compressor stations (CS) have been installed along the length of pipeline for transporting design capacity of 80 MMSCMD of natural gas. Main facilities provided at a CS comprise of gas turbine driven compressors (GTCs), gas after-coolers, scrubber, fuel gas conditioning system, scraper traps, gas blow-down system, fire alarm and fire-fighting system, instrumentation and control system, gas engine generators (GEGs), emergency diesel engine generator (DG), buildings and other utilities. The compressor stations on the Pipeline Infrastructure Limited (PIL) Gas Pipeline (PIL) are designed to boost the gas pressure to the pipeline MAOP limit of 98 barg. Each compressor station has three compressor units (approximate site rating of 33 MW each). CS-1 is located inside Reliance’s Onshore Terminal (OT) and shares some utility systems with them. Stations CS-2 to CS-9 is located along the 1375 km pipeline at approximately even intervals, with all utilities generated at the station itself.

The main pipeline has approximately 37 Mainline Valves (MLV’s) to isolate sections of the pipeline in case of a leak or for maintenance. Mainline block valves (MLVs) have been provided en-route the pipeline at regular interval conforming to code requirements. Provision for tap-off is made at each valve location. Selected MLVs have been provided with remote operation service. 24 Remote MLV’s and 13 Manual MLV’s are remotely operated and monitored are remotely operated and monitored. The balance is locally operated and is not monitored by SCADA. A Metering & Regulating Station monitored by SCADA is provided at the end of each spurline for custody transfer metering of delivered gas. Interconnects / spur lines have been installed for delivering gas to the customers either directly or through third party networks. Cumulative length of interconnects / spur lines is approximately 85 km. All tie-ins / terminals have been provided with ultrasonic type of metering system along with pressure regulation/control and gas quality measurement system. PIL System is remotely operated and controlled with the help of State-of-the-art Supervisory Control and Data Acquisition (SCADA) system. Optical fiber cable (OFC) based telecommunication system is provided for effective long distance communication. Pipeline Application Software (PAS) comprises of leak detection and location, operation optimization, line pack calculations and survival analysis, pig tracking and look-ahead modules. Security Automation System is provided for monitoring and access control. Pipeline Operations Centre of PIL is located at Gadimoga Kakinada near OT and backup operations centre is located at Mumbai, called GPOC and MPOC respectively.

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3. HEALTH & SAFETY MANAGEMENT

3.1 HEALTH & SAFETY POLICY 3.1.1 PIL has declared its ‘Health, Safety and

Environment (HSE) Policy at the Corporate Level. The Policy in its English and Telugu version has been displayed conspicuous locations of the Station and also at the associated MLVs. The Policy has also been signed by the Occupier of the Factory (Compressor Station) who has overall control on the affairs of PIL.

This is a good practice. Management's vision is reflected in PIL HSE policy statement. In declaring the Policy, the PIL has sent a clear message that it has a vision for H&S management within the whole organization.

3.1.2 In view of Change in Management, Health, Safety and Environment Policy of PIL has been displayed in A4 size papers in CS-02, MLV-03 and MLV-04.

A board displaying the HSE Policy in English, Hindi and Telgu in visible font should be installed in CS-21, MLV-03 and MLV-4 as per Factory Act 1948.

3.1.3 Prohibited place board is not displayed outside the Cs-02, MLV-03 and MLV-04 and as per Indian Stamp Act 1923.

It should be displayed outside the gate of CS-03 and all MLVs and M&R stations.

3.2 SAFETY ORGANISATION 3.2.1 HSE Department PIL has an HSE Dept. headed by AVP

(S&OR) at the corporate level, who reports to Senior Vice President. All the 10 compressor stations and associated MLV stations are grouped into 2 regions, namely region 1

This is satisfactory.




comprising CS-01 to CS-05 and region 2 comprising CS-06 to CS-10 including the CS -02 and their associated MLVs. The HSE affairs of each of the two regions are coordinated by an HSE Engineer and both the HSE Engineers functionally report to AVP (S&OR). The HSE Engineers possess necessary educational qualifications and experience. In addition, the HSE Engineers visit every station located in the respective regions at least once in a month. In addition, there is a HSE Coordinator for every Compressor Station.

3.2.2 Safety Committee There are Safety Committees at three

different levels for the whole Pipeline System covering all the ten compressor stations and the associated MLVs i. e. Apex Safety Committee for the whole Pipeline System covering all the ten compressor stations and the associated MLVs, Regional Safety Committee for each of the two regions and Station Safety Committee for each of the 10 compressor stations including the CS -02. The Apex Safety Committee at the corporate level is chaired by the Senior Vice President who is the in-charge of the whole pipeline system and the AVP (S&OR) as a secretary.

This is satisfactory and should be continued. This would certainly help achieve employees’ participation and active involvement in raising safety standards of the station.




Similarly, the Regional Safety Committees at the regional level are chaired by the respective Regional Managers who are responsible for the operation & maintenance of the pipeline sections and the associated MLVs in that respective region and the respective HSE Engineer is the secretary. The Safety Committee for the Compressor Station - 02 is chaired by the Area manager who is responsible for the operation & maintenance of the pipeline section and the MLVs associated with CS -02 and the Compressor Station HSE coordinator is the secretary. The meetings of the Apex Safety Committee and the Regional Safety Committees are conducted once in three months whereas the meetings of the Compressor Station-level Safety Committees including the Safety Committee for CS -02 are conducted once in every month. The contractors’ representatives are also invited in the meeting of the safety committees at the station and regional level. The minutes of the meetings of the Safety committee at the CS level are recorded and are available on the Common portal– Pipeline Asset Management Group (O&M).




In addition to the issued discussed the suggestion put forth by the employees or workers are also discussed for implementation, if applicable. The issues discussed in the meetings, decisions taken, the responsibility for implementation of decisions and recommendations and the deadlines for their implementation were found recorded in the minutes.

3.2.3

Safety committee minutes of meeting not displayed on notice board.

Safety committee meeting minutes of meeting must be displayed on the notice board

3.3 SAFETY BUDGET There is a practice of providing an

annual HSE budget at the corporate level to take care of HSE activities including external safety audit, Safety training, PPE, employees’ health check-up, safety promotional material, fire extinguishers, etc. For the current year, the HSE budget has been prepared by the corporate HSE Dept. and the same has been distributed among the compressor stations.

This demonstrates corporate management’s commitment to H&S.

3.4 ANNUAL SAFETY ACTION PLAN There is a practice of preparing Annual

HSE Action Plan at the corporate level and at the station level. The progress status of the safety action plan is monitored and is reported in the Monthly HSE Report.





3.5 SAFETY PROMOTION AND MOTIVATION 3.5.1 Display of Safety Posters Safety posters and signages were seen

displayed at various locations at the compressor station and they were commensurate with the nature of activities carried out at and the hazards associated with the stations.

This is a good practice.

3.5.2 HSE Campaigns It was reported that the HSE campaigns such as Fire Service Week, World Environment Day and National Safety Day were observed in the current year by involving all employees, associates and contractors’ workmen. As per the records many awards with reference to the safety are given to the employees to encourage the awareness in safety.

This is a good practice and shall be continued. HSE campaigns are the effective tools to remind employees of their commitment to safety throughout the year and its observance should be continued.

3.5.3 Safety Suggestions Scheme

It was reported that every employee can forward safety suggestion HSE portal, Monthly Safety Committee Meetings or through direct contact with Area Manager.


3.5.4 The Pipeline System participated in Safety Award Competitions operated by OISD and received award for year 2012-13.





3.5.5 There is practice of evaluating H&S performance of the employees and the same be considered for career advancement.

This is a good practice and should be continued.

3.5.6 Display of Accident-free Period The accident-free period has been conspicuously displayed at the entrance of the station.

This is a good practice which reflects the commitment towards safety and should be continued.

3.6 SAFETY EDUCATION & TRAINING 3.6.1 The station has a conference room

equipped with video conferencing facility and requisite training facilities. The said conference is used as training centre for conducting the training courses.

PIL deserves appreciation for instituting such a good training and conferencing facility.

3.6.2 It was reported that safety training

courses are organized by the corporate HSE Dept. for all the O&M personnel of CS -02 making them aware of safety procedures for CS and pipeline.


3.6.3 It was informed that one-day first-aid

training, firefighting training, ERDMP Training and job-specific trainings has been imparted to majority of O&M personnel of the station.

It was reported that all the station personnel including the security personnel have been trained in the fire fighting training including use of portable fire extinguishers, operation of fire hydrant system, etc.





3.6.4 It was also reported that safety induction training is being imparted to contractor employees prior to their entry in the station.

Management’s efforts to train contractors workers too, are praiseworthy

3.6.5 At present, there is a system for

evaluation of safety training

programmes in terms of their overall effectiveness towards attainment of course objectives and changes necessary for improvement.


3.6.6 For the purpose of induction training of

the contractor employees, PIL has also a video film depicting the hazards associated with compressor station and the associated MLVs and M&Rs and the control measures and procedures in place and the safety precautions to be taken to counter the hazards.


3.6.7 Records of Safety Training Records of training are be maintained in

a comprehensive manner in respect of every employee indicating the type and the period of training programmes attended by him. If such relevant information is readily available, safety training needs of every employee can easily be assessed.


3.7 SAFETY INSPECTION A well-documented maintenance

system is at place. As part of preventive maintenance the major and critical equipment are inspected. It was reported that housekeeping and environment inspection was conducted once in a month.





3.8 SAFETY AUDIT 3.8.1 PIL has initiated external safety audit

system. The whole PIL including the CS -02 and its associated MLVs was subjected to OISD Audit in year 2013. This audit covered Safety aspects too besides the technical aspects.

Conscious efforts of the management and site personnel in instituting such a system of conducting external and internal safety audits are appreciable.

Besides external audit, PIL has a well-developed ‘internal safety audit' system. Internal audits are also being carried out by the O&M personnel of other stations at least once in a year i. e. two audits per year – one by the intra-region O&M personnel and the other by the inter-region O&M personnel.

An exhaustive checklist has been developed and is being used for conducting the internal safety audits.

3.8.2 Action plans in respect of the internal

and external safety audit reports are being prepared allocating the clearly assigning the responsibility for implementation of recommendations. There is a proper channel and system to communicate findings of the internal and external audits and their implementation status to the management. Reasons for delay in implementation were also found documented with reasons. The reports of internal safety audits and





external safety audit and also the PNGRB technical audit were available on HSE portal for monitoring the status of implementation.

3.9 SAFETY OF CONTRACTOR WORKERS 3.9.1 Most of the maintenance work is done

by the contractors’ workmen but is supervised by the RTGIL engineers and technicians posted at the station. Presently PPEs to contractor workmen are provided by PIL except safety shoe.


It was reported that the contractor induction/refresher training is carried out at least once in a year. The necessary PPE and other safety appliances are provided to the contractor workmen by PIL. Safety shoes are provided by contractor.

3.9.2 It was informed that specific safety

precautions to be taken by the contractors' workmen are normally included in the contract agreement. It was also reported that safety performance of the contractors in respect of their earlier work contracts is assessed while evaluating the contract bids and lowest quotation is not considered as the sole criterion for offering work contract to the contractors.


3.10 STANDARD OPERATING AND MAINTENANCE PROCEDURES Standard operating and maintenance This is satisfactory




procedures including shut-down and start-up procedures have been developed and well documented.

3.11 HSE PROCEDURES Common ‘HSE Procedures’ prepared by

the PIL at corporate level were available at the compressor station.


3.12 WORK PERMIT SYSTEM The Work Permit System coupled with

LOTO (Lock-Out and Tag-Out) is in place at the station. Three types of work permits are issued as follows –

Cold Work,

Hot Work

Confined Space/Vessel Entry The work permit is issued through SAP system.


3.13 ACCIDENT REPORTING AND INVESTIGATION 3.13.1 Accident Reporting A written accident reporting and

investigation procedure and format for reporting accidents is available in HSE manual and HSE Portal. Besides accidents, near-miss accidents are also reported.

This is a satisfactory and should be continued.

3.14 PERSONAL PROTECTIVE EQUIPMENT 3.14.1 Personal Protective Equipment (PPE) This is satisfactory




such as safety shoes and helmets earmuffs / earplugs conforming to relevant Indian standards are provided to every plant personnel posted at the station. The electrical gloves were also found available at the station. The PPE were found conforming to relevant Indian Standards. Notices with color coding regarding use of ear protection in high noise areas have been displayed. Ambu bag was provided in the electrical substation and the battery room

3.14.2 PPEs to contractors’ workers are given by

the contractors. It was reported that the safety clause in the contract document requires contractors to provide PPEs to their employees.


3.15 FIRST- AID 3.15.1 Well-equipped first-aid box were found

in the security control room. This is satisfactory.

3.15.2

Some selected employees have attended first-aid training. Refresher training has been organized alternate year. Employees involved in electrical activities also undergone first aid training.


3.16 PLANT SECURITY 3.16.1 The compressor station and the

associated MLV & M&R stations are This is a good practice.




manned over 24 hours. The visitors are allowed to visit the station or MLVs only if they are accompanied by PIL employee. The PIL employees are provided with an access card. No trespasser can enter the station premises without valid access card.

3.16.2 Smoking and use of mobile phones are

prohibited inside the station and instructions in this respect have been displayed on the hoardings/boards installed at the gates.


3.16.3 A leaflet listing the key safety

instructions has been prepared by the corporate HSE Dept. and is handed over to the visitors prior to their entry in the station.


3.16.4 3.16.5

As a normal safety practice the vehicles are allowed to enter the station only after equipping it with a spark arrestor. About 10 mufflers were found available at the security gate. Visitors are shown safety video with respect to the plant layout, awareness, hazards, evacuation layout, mandatory safety instructions both in English and local languages.

This is satisfactory. This is a good practice.

*****




4. FIRE PREVENTION & PROTECTION

The potential fire hazards in the stations are due to natural gas which is a flammable gas. The vulnerable leakage points are pipeline flanges, valves, compressors and other such equipment. The probable ignition sources are electrical equipment involving short circuit, frayed wires etc., static electricity and hot work. Further, the cooling oil used in the GTC is also a major potential fire threat.

4.1 PORTABLE FIRE EXTINGUISHERS 4.1.1 ABC/CO2 portable fire extinguishers of

have been deployed at various locations in the station as well as control rooms. Locations of the portable fire extinguishers were found marked and numbered.


4.1.2 Periodic inspection and maintenance of the fire extinguishers at the station is carried out through an external agency and the records of inspection and maintenance are maintained. The inspection tags including the metal tag indicating the date of inspection and due date of inspection were also found on the extinguishers.


4.2 TRAINING

4.2.1 The security guards and operating personnel including the contractor personnel manning the stations and MLVs have received training in the use of portable fire extinguishers and they were found capable of the using extinguishers confidently.


4.3 FIRE HYDRANT SYSTEM




4.3.1

The whole station is adequately covered by the firewater hydrant or monitor system. Fire hose boxes are provided at all the stations where fire hydrant system is at place. The fire hydrant water is supported with a main fire water pump and 2 jockey pumps and a diesel driven pump and 2 fire water storage tanks. The diesel required for operation of the diesel pump is stored in a tank and its level is monitored locally. In case of low level than the pre-set value, an alarm is raised. The fire hydrant system is being maintained at 8.5 bar pressure and it is always kept on auto mode.


4.4

FIRE & GAS DETECTION AND FIRE SUPPRESSION SYSTEM

4.4.1 The fire and gas detection system is in place at the critical locations of the station including the control room, compressor room, battery room, (including the battery room in associated MLV stations) stores, etc. Locations of concern like compressor room, battery room, etc. the fire & gas detection system is coupled with FM 200 flooding to extinguish the fire without damaging the facilities. The system is designed to raise an alarm prior to FM 200 flooding for warning the station personnel to leave the room.





4.4.1

The fire & gas detection system is inspected periodically through an external agency to ensure its functional reliability and the records are also maintained.

4.4.2 The FM 200 activation control panel is kept on “auto” mode to ensure that the system will get automatically actuated in case of any fire or gas leakage. Warning notices have also been displayed at the entrance of such rooms to instruct all the plant personnel to keep the FM 200 activation control panel on “manual” mode prior to entering the rooms or premises where the fire & gas detection system is coupled with FM 200 flooding.


4.4.3 The alarms of the fire & gas detection

system have been indicated in the local control room as well as the Main control room in Mumbai.


4.4.4 The gas turbine enclosure of each of the

gas compressors has been provided with CO2 flooding system.

This is a good fire safety measure.




4.4.5 Hydro testing of FM 200 Cylinders

have expired on 18.2.18. (CS-02 and

MLV-04).

As perRule26 and 35 of Gas Cylinders

Rules 2018, unless the cylinders are

examined and hydro tested, they shall

not be transported or filled. So it is

recommended that these cylinders

should be examined and hydro tested

as per IS: 15975. Also exemption from

PESO should be sought for extending

the period of hydro testing as per the

Rule 66 of Chapter VII of Gas

Cylinder Rules.

4.5 MANUAL FIRE CALL POINTS 4.5.1 Manual fire call points were found

installed at few places in the station to help in alerting the site personnel and activate the help in event of an emergency as a parallel backup system for fire & gas detection system.


4.6 FIRE PROXIMITY SUITS 4.6.1 Two fire proximity suits were found

available at the station. This is satisfactory.

*****




5. ELECTRICAL SAFETY

5.1.1 GENERAL 5.1.2 The path of the underground electric and

instrument cables has been marked in the station by erecting adequately spaced indicators.

This is a good practice and should be maintained.

5.1.3 Rubber mats conforming to IS 15652:2006 - Insulating Mats are provide in C-02 and MLV-04 For Electrical Purposes —are provided in front of control panels and switchgears.

This is satisfactory

5.2 FIRST – AID

5.2.1 Artificial respiration chart is displayed at the switchgear room to educate the plant personnel about the first-aid to be given to the person who have received electric shock.


5.3 HAZARDOUS AREA CLASSIFICATION

5.3.2

Flameproof electrical equipment and fittings are provided at the station in gas handling areas. It was reported that a full-fledged preventive maintenance programme including maintenance schedules and task lists/checklists for such flameproof electrical equipment and fittings has been devised and integrated with SAP system.


5.4 ELECTRICAL MAINTENANCE




5.4.1 5.4.2

Lockout & Tag out system is in practice. The work permit system being used in the stations requires checking whether the equipment is electrically isolated and tagged before the permit is issued. This system ensures that the concerned persons from maintenance and operation responsible for a particular machine/equipment are intimated about the status of that equipment Most of the maintenance work is done through the contractors under the supervision of the engineer posted at the station. A clause has been incorporated in the contract document to make it obligatory to the contractor to carry out all electrical jobs through authorized electrician(s) as per the Indian Electricity Rules and to declare their name.

This is a good practice This is satisfactory.

5.5 EARTHING SYSTEMS

5.5.1 Major electrical equipment are provided with double earth connections. Earth pits have been provided and connected in grid. All the earth pits have been identified by painting a unique identification number on every individual earth pit.

This is satisfactory and should be maintained.




5.5.2

Earth pit tests are being conducted half yearly i.e. once in pre monsoon and once in post monsoon and records are maintained to ascertain the resistance.


5.5.3 Most of the earth pits are due to resistance checking. So false results are expected due wet season.

It is recommended to plan to carry out the earth resistance testing between April-May and Oct-Dec which is normally a dry season.

5.6 LIGHTNING PROTECTION

5.6.1 The earth pits associated with the lightning arrestors are being tested and records are also maintained as described above.


5.7 OTHER OBSERVATIONS

5.7.1 The transformer oil samples from the transformer installed at MLV stations are being tested at least once in a year and records are also maintained. The test includes Break Down Voltage Value and dissolved gas analysis.


5.7.2 The relays were being found tested at least once in a year.

This satisfactory.

5.7.3 Single Line Diagram was found displayed.


5.7.5

The authorization for energizing the electrical installations required under the Indian Electricity Rules, has been obtained and the copy is available at the station.





5.7.6

Earthing of the portable equipments, flange testing and calibration of electrical instruments were carried out. The documents of the above specified were reviewed and found in order


5.7.7 Test Potential” and safe Working Potential” were found not marked on the Electrical insulating rubber hand gloves meant for repair and maintenance of electrical installations.

It is marked. It is a good practice.

5.7.8 Gate of the Transformer fencing of MLV-04 was not locked.

Fencing gate has been kept locked. This is satisfactory.

5.7.9 In MLV-04, sand has lumps in the buckets.

Fine sand should be kept in the buckets.

******




6. PROCESS SAFETY

6.1 MATERIAL SAFETY DATA SHEETS 6.1.1 Basic information about the NG

outlining its properties, hazards and control measures has been compiled in the form of Material Safety Data Sheet (MSDS) and available at the station. But, It was observed that at some locations like in scrap yard hazardous chemicals are stored where MSDS was not available.


6.2 PROCESS PARAMETERS 6.2.1 The process parameters such as

pressure, temperature & flow rate are continuously controlled and monitored from the control room by the operating personnel who are well aware of these process parameters.


6.3 PROCESS INTERLOCKS 6.3.1 There are a considerable number of

process interlocks provided in the station. The list of the interlocks and the cause and effect logic are available on eDMS.


6.3.2 Select technical personnel have been

authorized for changing the set points of the process interlocks.


6.4 MANAGEMENT OF CHANGE 6.4.1

Piping and Instrumentation (P&I) diagrams of the stations are available on EDMS.





There is a procedure or system for management of change to review the modifications made in the specifications of piping, equipment, process engineering, instrumentation, set points, etc.

6.5 PRESSURE VESSELS & SAFETY RELIEF VALVES 6.5.1 ‘Certificate of Safety’ specifying the

maximum safe working pressure and the tests to which it was subjected to in respect of every pressure vessel, including the instrument air receivers, scrubbers, etc. obtained from the maker of the vessel is available at the station.


6.5.2 Each of the pressure vessels is equipped

with a safety relief valve. An isolation valve is also provided between the safety relief valve and the vessel.


6.5.3 There is a system of testing pressure relief valves at least once in two years for their correct functioning Records of the tests are also being kept.


6.5.4 47 PR Valves (including spare valves in the stores) were tested between 16.08.2017 and 19.08.2017 and next due date of testing is 18.08.2019 Report of testing is available but relief valve setting pressure is not mentioned in the report as well as not marked on the body of the vessel.


6.5.5

The wire mesh of vents in GTC Fuel gas skid (or where rain hood is fitted, it should be below the rain hood) are not been cleaned from depositing of dust or clogging of holes.

The wire mesh of vents in GTC Fuel gas skid (or where rain hood is fitted, it should be below the rain hood) should be cleaned every quarter for dust or clogging. If these are damaged, they should be replaced with double wire mesh of fine copper or brass or Stainless steel or non-corrodible metal.

6.5.6 Painting in GTC Fuel Gas skid is faded. Painting in pipelines is incomplete.




6.5.7 6 No pilots in GTC fuel Gas skid are not

serviced.

They should be serviced immediately.

6.5.8 Portable ladder (L/D/P19) - have not been tested.

This should be tested and test date should be mentioned on the ladder.

6.6 PIPELINES ( INTRA – STATION ) 6.6.1 Overall, the pipelines in the premises of

the station have been adequately supported and a detailed check-list for inspection of pipelines has also been developed.


6.6.2 The pipelines were found properly

painted in the following colour.

NG - Canary yellow Fire water- Fire red Instrument air – Sky blue

This conforms to IS 2379 : 1990 pipelines – identification – colour code and is sufficient to identify the pipelines carrying different contents.

6.6.4 The colour code for pipeline was also

found displayed in the compressor station.


6.6.5 It was reported that it has been decided

to paint the pipelines once in three years. Cathodic protection is provided for underground section of the pipelines.


6.6.7 The resistance between two adjacent flanges of the pipelines has been measured and the records are also kept. Since the values of the resistance between two adjacent flanges are less than 1 ohm, It has been decided that no bonding is needed between two adjacent flanges.





6.6.7 Ultrasonic thickness measurement of

pipelines has been conducted and records are also maintained.

This a good practice in ensuring the mechanical integrity of the pipelines.

****




7. EMERGENCY PLANNING AND PREPAREDNESS

7.1 EMERGENCY ACTION PLAN 7.1.1

PIL has prepared an Emergency Response and Disaster Management plan for CS -02 and the associated remote and manually operated MLVs.

PIL management’s efforts in developing such a detailed and comprehensive Emergency Action Plan are praiseworthy.

7.1.2 The plan describes the anticipated

emergency scenarios, notification procedures, the duties and responsibilities of the personnel in the event of emergency and important contacts. The plan also gives the list of anticipated emergency scenarios.


7.1.3 The emergency plan lists the emergency

equipment such as fire-fighting equipment, protective clothing, self-contained breathing apparatus, etc. available with the stations and the local agencies such as fire brigade, etc. Locations of the emergency equipment are also included in the plan. This would certainly help in knowing whether and where the adequate emergency equipment would be available in the event of emergency.


7.1.4 It was reported that the training of the

station personnel in respect of tackling emergencies was organized covering properties of NG, procedures for reporting emergencies, knowledge of





alarm systems, location & use of firefighting equipment, use of protective equipment, evacuation procedures, etc.

7.2 HAZARD ANALYSIS 7.2.1 The emergency plan has been supported

with a hazard analysis study comprising identification of potential hazards, determining the vulnerability of the geographical area in and around the station to an accidental NG release. The hazard analysis has been carried out considering the plant (station) risk due to probable NG release.


7.3 EMERGENCY DRILLS 7.3.1

Emergency mock drills are being carried out at the CS -02 on quarterly basis records are also kept.


7.4 EMERGENCY SIRENS 7.4.1 Enquires with the compressor station

personnel revealed that the emergency siren installed at the station.

This is satisfactory. Siren code is implemented and tested weekly.

7.6 OTHER MEASURES 7.6.1 A list of important telephone numbers in

case of emergency was found displayed in the station and the associated MLVs.


7.6.2 Wind socks were found provided in the

station and also in MLVs. This is satisfactory.




7.6.3

An emergency response support system is in use. As per the said system, in the event of any emergency, the emergency response team members and management team members are expected to receive the notification of emergency.

The management deserves compliments for introducing such a good emergency communication system

*******




8. OTHER PHYSICAL HAZARDS AND CONTROL MEASURES

8.1 STORAGE OF MATERIALS 8.1.1 Aisles and passageways were found

distinctly marked/painted in the Stores and Maintenance shop. Epoxy coated floor was available in the gangways.

This is satisfactory and should be maintained. It is a good practice

8.2 MATERIAL HANDLING 8.2.1 The material handling equipment used

in the compressor station, include EOT cranes and chain pulley blocks. All the lifting machines and tackles including wire rope slings and D-shackles, are examined and tested by a competent person at least once in every period of 12 months and the certificates received from the competent person in this respect, are maintained as per the Factories Act and the State Factories Rules hereunder.


8.2.2 The Identification Mark and Maximum

safe working load (SWL) was found painted on all the chain pulley blocks and EOT cranes and also the loose lifting tackles.


8.3 COMPRESSED GAS CYLINDERS 8.3.1 Compressed gas cylinders were found with

valve caps. This is satisfactory.

8.4 MACHINE GUARDING




8.4.1 The standard of machine guarding is

satisfactory at the station. All the moving and rotating parts are were found adequately guarded.


8.5 SAFE ACCESS 8.5.1 Fall arrestors are installed in GTC and

Office building in CS-02. The usage of fall arrestor should not be allowed during cloudy or rainy weather. A warning that use of fall arrestors is prohibited during cloudy and rainy season should be put up.

Warning displayed. This is satisfactory.

8.52 In MLV-03 (Chinna Tadepalli): There is drain on two sides of the security cabin. Entry into the cabin is on the back of, wherein a Security Guard has to cross the drain on either side. This may cause a slip and trip or fall.

The drain should be covered (preferably provide a pipeline of equal dia of the width of drain and cover the pipeline up to the top of the edges of the drains), to avoid slip, trip or fall.

8.6 WORK ENVIRONMENT 8.6.1 Noise levels at the high decibel areas are

measured and records are also kept. The noise meter being used for said purpose, was also found calibrated and calibration certificate was available.

This is a good practice. The exposure to high decibel areas should be avoided to the extent possible.

8.6.2 Illumination survey was conducted for

the various premises in the compressor station. The lux meter being used for carrying out the survey was found calibrated and the calibration certificate was also available.





8.7 ENVIRONMENT PROTECTION 8.7.1 Periodic stack monitoring and ambient

air monitoring are also carried out through an external agency to monitor the required parameters indicated in the Consent for Operation obtained for the station.


8.7.2 PIL has obtained authorization for

generating and handling hazardous waste from MoEF. The sources of the hazardous wastes are the waste/spent oil and a small quantity of condensate collected in the condensate tank. PIL has also developed a standard procedure for handling the said hazardous waste at the compressor station before its disposal.


PIL has also tied up with the supplier for

sending the spent batteries back to the supplier.

This is satisfactory and meets the provisions of the Batteries Rules

8.8 VIDEO DISPLAY TERMINALS 8.8.1 DCS control centre of Video Display

Units (VDUs) by the plant personnel posted in control rooms and other departments was witnessed. A training module meant for raising awareness on VDT hazards such as eyestrain, back pain, mental stress etc has been developed and is available for training purpose.


8.9 OCCUPATIONAL HEALTH




8.9.1 Pre-employment have been conducted for all the regular employees (PIL) deputed at the station and the records kept. It was reported that the period of medical examinations of PIL employees deputed at the compressor stations are carried out.


8.10 OTHER OBSERVATIONS 8.10.1 A compressed air line was found

provided in compressor room. A warning notice “Never use compressed air to clean your body” was found displayed nearby in conspicuous manner.


8.10.2 A water line was also found installed in

the compressor room for washing/cleaning purpose. A warning notice “Water not for drinking purpose” was displayed nearby in conspicuous manner.


8.10.3

Blow down area platform was found cracked all around and separated from main platform. This needs to be repaired.

This is repaired. Satisfactory

***




DISTRIBUTION

Narayan Chaudhari AVP (S&OR)

Satya Srinivas

Area Manager, CS –02

***