BSC IMS ISO 9001 OISD AWARD ISO 14001

BSC IMS ISO 9001 OISD AWARD ISO 14001 OHSAS 18001 FIVE STAR SWORD OF HONOR By : Sukant Ku. Singh, Manager(F&S), GAIL- Vijaipur, MP. SARVASHRESHTA SAFETY AWARD

GAIL (India) Limited, India’s Principal Gas transmission and Marketing company, own and operates Country’s largest Natural Gas Transmission network. GAS PIPELINES Length : 10, 000 KMS Capacity : 157 MMSCMD Spread : 11 STATES LPG PIPELINE RAJASTHAN Length : 1922 KMS PL JL PATA L J, GA AR N DH HV P DV LAKWA Spread : 6 states VIJAIPUR TRIPURA VAGHODIA GAS PROCESSING No. : 7 PLANTS Capacity : 1. 2 MMTPA LPG USAR VSPL KG BASIN NATURAL GAS PIPELINE LPG PLANT 2 Capacity : 3. 8 MMTPA PETROCHEM PLANT CAUVERY BASIN Spread : 5 states COMPRESSOR STATION No. : 08 PETROCHEMICALS No. : 01

OPERATIONS AT GAIL-VIJAIPUR Pipe Line v O&M Headquarter of HVJ pipeline system comprising of HVJ, GREP, DVPL & VDBPL Pipelines v Operates HVJ pipeline compressor station having 14 nos. compressors discharging flow of 450 - 500 KSCM//hr. Compressor Station v This is the largest single gas grid of GAIL & 100% uninterrupted gas availability to its customers since last 27 Years This is Chapter-3(Applicability) as per Notification of PNGRB for ERDMP

OPERATIONS AT GAIL-VIJAIPUR Operates two LPG recovery units having the production capacity : LPG : 406000 TPA Propane : 130000 TPA Pentane : 42000 TPA Naphtha : 24000 TPA Gas Processing Unit Consumer Terminals Which is equivalent to more than one lakh LPG cylinders per day in the domestic circle. This is Chapter-3(applicability) as per Notification of PNGRB for ERDMP

OBJECTIVES & TARGETS ACHIEVED 2007 TO 2011 By GAIL-Vijaipur TARGET ACHIEVED OBJECTIVES TARGETS SET FATAL ACCIDENTS 2007 2008 2009 2010 2011 ZERO ZERO REPORTABLE ACCIDENTS ZERO ZERO HSE INDEX 98% 100% 100% LEGAL COMPLIANCES 100% 100% FIRE INCIDENTS – MAJOR ZERO ZERO INTERNAL SAFETY AUDIT 04 PER YEAR 4 4 4 EXTERNAL SAFETY AUDIT 01 PER YEAR 1 1 1 LPG 04 PER YEAR 4 4 4 HVJ 04 PER YEAR 4 4 4 4 4 100% 100% 100% SAFETY COMMITTEE MEETING MOCK DRILL DISTRIBUTION OF SAFETY KITS 100 % GAIL EMPLOYEES HSE INTERNAL TRAINING 100 % EMPLOYEES This is as per Chapter-4. 2(Intent) as per Notification of PNGRB for ERDMP

SAFETY MANAGEMENT SYSTEM HSE TRAINING- 05 HSE LEADERSHIP & COMMITMENT- 12 RISK ANALYSIS & MANAGEMENT - 01 INCIDENT REPORTING, INVESTIGATION & ANALYSIS- 15 EMPLOYEE PARTICIPATION (NEAR MISS & SAFETY SUGGESTION) - 05 INSPECTION & MAINTENANCE - 04 ENVIRONMENT MONITORING -05 HSE INDEX 100 Marks CONTROL OF DEFEATS & RELIABILITY OF CRITICAL SYSTEM & DEVICES-03 PROCESS SAFETY INFORMATION 05 OCCUPATIONALHEAL TH MONITORING -10 COMPLIANCE AUDIT (EXTERNAL & INTERNAL HSE AUDIT) - 15 OPERATION & MAINTENANCE (FIRE APPLIANCES, FIRE WATER BASED & NON WATER BASED SYSTEM, CALIBRATION STATUS OF PSV, FIRE DETECTION & ALARM SYSTEM) -15 EMERGENCY PLANNING & RESPONSE – 05 This is mainly as per Chapter-8( Consequences of default or non-compliance) as per Notification of PNGRB for ERDMP

Chapter-12. 2( Training) as per Notification of PNGRB for ERDMP

TRAINING FACILITIES AT GAIL, VIJAIPUR More than 15 nos Training models are available. (SIMULATION OF BLEVE)

EMERGENCY CONTROL CENTERE(ECC) At GAIL, VIJAIPUR, MP There is a vital importance of emergency control room in case of any emergency situation arises in the factory premises. The various coordinators are required to report in the emergency control room during emergency for coordination purpose. Keeping in view the same, the emergency control room is shifted at Fire station building which is located a safe distance (as per QRA study). FACILITIES AVAILABLE 1. 2. 3. 4. 5. 6. Satellite phone. P&T Phone. 3. HVJ Phone. Public Address system. Projectors & PC Flow chart of Communication system. 7. On site EAP. 8. Off site EAP. 9. Roles & Responsibility Manual. 10. All P&ID Diagram. 11. All Standards. 12. Telephone list. 13. Copy of ERDMP of GPU. 14. Copy of ERDMP of HVJ. 15. MSDS. Dr U D Choubey, C&MD, GAIL inaugurated the ECC Chapter-15. 1( for ECC) as per Notification of PNGRB for ERDMP

EMERGENCY PREPAREDENESS There are two types of Emergency Action Plan at GAIL, Vijaipur: ON SITE EMERGENCY ACTION PLAN: -This On-Site Emergency Action Plan is based on the Disaster Management Plan, which was prepared on the basis of Risk analysis and consequence analysis, and meets the requirement of the Indian Factories Act, 1948, and also complies with the requirement of ERDMP. OFF SITE EMERGENCY ACTION PLAN: - Plan has been approved by district administration i. e. Collector. Chapter-16( Declaration of On site & off site emergency) as per Notification of PNGRB for ERDMP

ON-SITE EAP GPU Chapter-14( Emergency Organization & Responsibility, Organization Chart ) as per Notification of PNGRB for ERDMP

ON-SITE EAP HVJ

EMERGENCY SIREN CODE AS PER OISD STD 116 SMALL FIRE: No siren MAJOR FIRE: A wailing siren for two minutes. Sirens will be sounded three times for thirty seconds with an interval of fifteen second in between. DISASTER: Same type of siren as in case of Major Fire but the same will be sounded for three times at the interval of one minutes. ON ON OFF 30 SEC 15 SEC ON Disaster 2 MIN ON OFF 30 SEC 15 SEC ON ON OFF 1 MIN Disaster 2 MIN 30 SEC OFF 1 MIN Disaster 2 MIN ALL CLEAR (For fire): Straight run siren for two minutes. TEST: Straight run siren for two minutes on Friday at 7 PM to 7. 15 PM. EMERGENCY CONTROL CENTRE IS IN FIRE STATION FIRST FLOOR ROOM NO. 10, HVJ NO- 1444, 2443, 2444, 274250 Chapter-14. 2. 5. 9 ( Siren Code) as per Notification of PNGRB for ERDMP

GAIL(India) Limited, Vijaipur, MP CISF gate/Colony NFL Gate HVJ MCR Gate CISF gate C 2 C 3 Project Fire Station LPG C/R EIL Building C 2 C 3 Project C&P Store Assembly Points Way To Emergency Exit First Aid center Hospital 1 -EIL Building 2 -LPG C/R / Lab Bldg. 3 -Fire station. 4 -LPG C&P Store. 5 -HVJ MCR gate 6 -C 2 C 3 Project site. Chapter -13( Zoning & Maps), Chapter-15. 2( Assembly point), as per Notification of PNGRB for ERDMP

COMMUNICATION SYSTEM TYPES OF COMMUNICATION SYSTEM RANGE HVJ Phone - Walkie Talkie 1 KM range NOS OF COMMUNICATION SYSTEM Every where available as per req. 04(Fire Stn. ) Siren electric motor 10 KM All plants, offsite, loading, storage, etc 05 nos Manual Siren 1 KM 01(Fire Stn. ) Mobile phone - 01 BGU/ MCPs - 67(LPG) & 53(HVJ) Satellite phone (INMARSET TEL. ) World Wide 05 Paging system(PA) Chapter-14. 2. 5. 8 ( Communication Services) as per Notification of PNGRB for ERDMP

MUTUAL AID SYSTEM (MAS) SL NO NOS OF INDUSTRIES WRITTEN DETAILS OF WITH MAS & NAME AGREEMENT SYSTEMS UNDER EXISTS OR MAS: NOT M/S NATIONAL FERTILIZER YES i. LIMITED, VIJAIPUR 01 ii. RESCUE FIRE FIGHTING iii. LOGISTICS iv. ENGG SUPPORT & v. OTHER HELP. 02 M/S INDIAN OIL LTD. YES DONGER, VIJAIPUR i. FIRE FIGHTING. ii. RESCUE. iii. ENGG SUPPORT & iv. OTHER HELP. Chapter-12. 3( Mutual Aid) as per Notification of PNGRB for ERDMP

CLASSIFICATION OF EMERGENCY q FIRE DRILL ON MONTHLY BASIS(Level 1) q MAJOR MOCK DRILL / ON SITE EMERGENCY PLAN DRILL ON QUARTERLY BASIS(Level-2). q OFF SITE DRILL- ONCE IN A YEAR BY DISTRICT ADMINISTRATION INVOLVING MUTUAL AID MEMBERS(Level-3). FIRE DRILL-(Level-1) ON SITE DRILL(Level-II) OFF SITE DRILL(Level-III_ Chapter-6 ( Classification of emergency) as per Notification of PNGRB for ERDMP

This is as per Schedule-IV( Resource Mobilization)

PLC Based Fire Control Room PUMP INDICATION LOCATIONIOD MANUAL CALL POINTS AUTOMATIC TURN OUT SLIP INDICATION OF FIRE WATER TANKS

PLC Based Fire Control Room PLC control Fire station having facilities of Real Time data of followings, v Wind Speed. v Wind Direction v Ambient Air Temperature v Relative Humidity v Rainfall v Solar Radiation, etc.

Fire Water Line Above Ground (KM) Under Ground(KM) Total LINE SIZE 4’’ To 24’’ 26. 259 Kms 6. 225 Kms 32. 484 Kms FIRE WATER NETWORK AT HVJ & LPG PLANT WITH INDICATION OF ISOLATION VALVES, MONITORS, HYDRANTS

DP-A DP-B DP-E DP-C DP-F DP-D EP-C JP-A NEW FIRE WATER PUMP HOUSE LPG JP-B EP-A EP-B OLD FIRE WATER PUMP HOUSE LPG JP-C DP-G EP-D FWPH IN HVJ AREA EP-E LEGEND DP- Diesel driven pump EP –Electric driven pump

FIRE APPLIANCE AVAILABLE AT GAIL, VIJAIPUR Technical Data Registration No. of the Fire Tender 2 MP 08 A 1493 Fire Tender -2 Fire Tender- Emergency 2 Rescue Tender MP 08 D 0821 MP 08 GA 0703 Mobile Flare Unit Chassis Make/Details TATA 1210 TATA ASHOK LEYLEND 1616 High Mast Flooding Light Water Tank Capacity 1000 Lit. 2000 Lit 4000 Lit Cutter/ Spreader Foam Tank Capacity 1200 Lit. 500 Lit 1000 Lit Lifting tools 1000 Kg- Monex & 1000 Kg Olfex 500 Kg of Monex & 500 Kg Olfex. Gen. Set Dry chemical powder Vessel No. of EXP. Gas /Nitrogen cylinders 1000 Kg Monex 4 in main Line and 4 in standby. 4 in main line 2 in main line and 2 and 4 in standby. Chlorine Kit *Throw range of DCP monitor 50 m horizontally & 25 m in Verical 50 m horizontally Fire Fighting equip. Discharge of DCP monitor Selective (15, 25 & 40 Kg/sec. ) -- Selective (15, 25 & 40 Kg/sec. ) PPEs Delivery outlet for Hose 4 Nos. X 63 mm dia. Portable Pump with double head Chapter-17( Resource for Controlling Emergency) as per Notification of PNGRB for ERDMP

FIRE PROTECTION SYSTEM q FIRE WATER NETWORK WITH WATER HYDRANTS AND WATER MONITORS. q AUTOMATIC WATER SPRAY SYSTEM THROUGH ROV q LONG RANGE HIGH VOLUME / STANDARD WATER MONITORS. q HOSE BOXES & HOSE REEL. q WET RISER FOR MAIN CONTROL ROOM AND SUB-STATIONS q WATER CURTAINS. q FOAM POURER & FOAM TROLLEY q CO 2/ FM-200 TOTAL FLOODING SYSTEM IN GTC , GTG & C/R. q 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 v Gas detection installed in GTG and GTC. v LEL detectors & PLC monitors in controls room. v Heat detectors and U-V detectors in GTG and GTC. v Smoke detectors in control building(UV & Optical Detectors). v Fire bells connected with alarm system followed by PLC C/R. v Break glass type fire alarm system(MCPs) connected with emergency siren at control room and fie station C/R. v CCTV Camera for critical areas.

MANUALS & SOPs COMPREHENSIVE MANUALS DEVELOPED v CONTRACTOR SAFETY MANUAL v POCKET SAFETY MANUAL v WORK PERMIT MANUAL v PPE’S MANUAL v CORPORATE HSE MANUAL v FIRE FIGHTING MANUAL v TRAINING MANUAL v HSE TRAINING CALENDER v ROAD SAFETY MANUAL Chapter-21 ( Information to Public) as per Notification of PNGRB for ERDMP

DISSIMINATION OF SAFETY INFORMATION Chapter-21 ( Information to Public) as per Notification of PNGRB for ERDMP

TRANSPORTATION OF HAZARDOUS CHEMICALS o Transportation of LPG, Propane, Pentane and Naphtha is carried out through tankers. (after thorough safety check of tanker as well as documents) o Transportation of LPG is also carried out through Rail wagons as well as underground pipeline Chapter-28 ( ERDMP for Road Transportation) as per Notification of PNGRB for ERDMP

MAJOR STEPS TAKEN BY GAIL AFTER JAIPUR FIRE MAJOR STEPS TAKEN BY GAIL AFTER JAIPUR 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. 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. Drill & Mock drill) as per Notification of PNGRB for ERDMP Chapter-12 ( Emergency

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, DMIBhopal, Sh. Harsh Chaturvedi, Dy. Director (IHS)-Gwalior, Sh. B. S. Negi, Ex-Member, PNGRB and Sh. C M Sharma, Tech Expert, Quality Council of India (QCI) & other senior Chapter-25 ( Termination of Emergency) as per Notification of PNGRB for ERDMP

Emergency Response Disaster Management Plan(ERDMP) of Gas Processing Unit(GPU) & HVJ Compressor Station Certified & Accredited by Disaster Management Institute, Bhopal(an accreditation agency of PNGRB)

LIST OF AWARDS & ACCOLADES BY GAIL-VIJAIPUR 2009 2010 2011 1 Oil Industry Safety Award-2008 -09 to GPU GAIL, Vijaipur for 6 th Times Oil Industry Safety Award-2009 -10 to GPU GAIL, Vijaipur for 7 th Times Oil Industry Safety Award-2010 -10 to GPU GAIL, Vijaipur for 8 th Times 2 Oil Industry Safety Award-2008 -09 to HVJ Pipeline for 13 th Times Oil Industry Safety Award-2009 -10 to HVJ Pipeline for 14 th Times Oil Industry Safety Award-2009 -10 to HVJ Pipeline for 15 th Times 3 Shreshtha Suraksha Puraskar Award to GPU, Vijaipur by National Safety Council, Mumbai. Suraksha Puraskar Award to GPU, Vijaipur by National Safety Council, Mumbai. Shreshtha Suraksha Puraskar Award from National Safety Council, Mumbai for Gas processing Unit, Vijaipur. 4 Shreshtha Suraksha Puraskar Award to HVJ Compressor Station, Vijaipur by National Safety Council, Mumbai. Letter of Appreciation to HVJ Compressor Station, Vijaipur by NSC, Mumbai. Suraksha Puraskar Award from National Safety Council, Mumbai for HVJ Compressor station, Vijaipur 5 Greentech Gold Award-2009 on HSE Management by Greentech Foundation, Mumbai. Sarvashreshta HSE Award-2009 to GPU, Vijaipur by NSC-MP Chapter. Safety Innovation Award-2011 From Institution of Engineers (India) – Delhi to GAIL Vijaipur Complex. 6 Safety Innovation Award-2009 by Institutes of Engineers-India. Sarvashreshta HSE Award-2009 to HVJ Compressor Station, Vijaipur by NSC-MP Chapter. 7 CMD Trophy for best HSE Performance to GPU GAIL, Vijaipur. Greentech Gold Award-2010 on HSE Management by Greentech Foundation, Mumbai. 8 CMD Trophy for best HSE Performance to HVJ Compressor Station, Vijaipur. CMD Trophy for best HSE Performance to GPU GAIL, Vijaipur. 9 International Safety Award-2009 from British Safety Council, UK. CMD Trophy for best HSE Performance to HVJ Compressor Station, Vijaipur. Sarvashreshta HSE Award-2011 to GPU, Vijaipur by NSC-MP Chapter. Safety Innovation Award-2010 by Sarvashreshta HSE Award-2011 to CMD Trophy for best HSE Performance, Winner 2010 -2011 for Gas processing Unit, Vijaipur. CMD Trophy for best HSE Performance, Winner 2010 -2011, for HVJ Compressor station Green Tech Environment Award (Gold) for the year -2011, for GAIL Vijaipur Complex. Received on 21. 10. 2011.

HVJ Cross country pipeline & LPG Recovery Plant, Vijaipur conferred prestigious OISD Safety Award: 201011 • • 8 th Time for GPU 15 th Time for HVJ

Gail(india)limited, vijaipur received For Hvj compressor station & lp. G recovery plant From

Shreshtha Suraksha Puraskar -2010 from National Safety Council, Mumbai HVJ Compressor station & LPG Recovery plant Of GAIL