Annual Report 2014-15 Corporate HSE Page 1

Corporate HSE Department Noida

Annual Performance Report 2014-15

Annual Report 2014-15 Corporate HSE Page 2

Table of Contents

SN Topic Page No.

1. Highlights for the year 3-8

2. Targets vs Achievement 9

3. HSE Index & Score 10

4. External Safety Audits 11

5. Pre-Commissioning Safety Audits 12

6. Inter Unit Safety Audits 12

7. HSE Checks 13

8. Life Saver Schemes 14

9. Awards &Accolades 15

10. Way Forward 16

Annual Report 2014-15 Corporate HSE Page 3

Behaviour Based Safety in GAIL

Behaviour Based Safety was conceived in GAIL

during the Annual HSE Workshop 2012,

wherein, the management deliberated that in

spite of the Best People, Processes & Systems

in place, random, isolated incidences do take

place from time to time. It was also felt that to

build strong safety culture one needs to

imbibe safety in all activities of the

organization right from design stage to

construction, commissioning, operation &

maintenance. It is with this deep desire to

eliminate incidences, GAIL (India) Limited

embarked upon a Journey of Behaviour Based

Safety to address the human element and

improvise on the existing processes.

In view of above, BBS journey was started in

November 2013. Corporate steering

Committee and task force were constituted at

corporate level to oversee the BBS

implementation. Site steering committee &

functional committees and lead trainers were

developed to further drive BBS at respective

sites of GAIL. Accordingly, Behaviour Based

Safety (BBS) was rolled out successfully

across all GAIL installations on 12th March

2015.

Sustaining “Behaviour Based Safety” drive

implementation is a big challenge.

Understanding this Challenge, following

actions have been taken to drive/sustain BBS

at respective sites:

Development of web based BBS Centralized Portal to facilitate the observation feedback process and smooth implementation of BBS across all GAIL installations.

Steering committee headed by OICs and functional committees headed by respective HODs have been constituted to drive further BBS at their respective sites.

119 Nos. Lead Trainers have been developed at sites for further transformation of safety culture at their respective sites.

Bi-monthly visits being made to all the sites to review the progress of BBS with the assistance of our consultant.

Effective Implementation of Behavioural Based safety at all locations and for all employees working at Site through awareness workshops, training and sensitization.

Nos. of Workshops : 50 Total Participants : 1086 Total Lead Trainers : 119 Site Steering Committee : 13Nos. Site Functional Committee : 58 Nos.

Highlights

Annual Report 2014-15 Corporate HSE Page 4

06 Corporate Steering Committee

Meetings were organized to review the implementation of Behaviour Based Safety in GAIL.

Observance of Monthly Safety Day

Concept of observance Safety Day on 10th of Every Month commenced.

All site OICs devote exclusive half day on 10th of each month as a Safety Day to review all the safety related aspects of their installations under their jurisdiction.

All pending points related to Audits like OISD, PNGRB T4S, other external and Internal Audits points being reviewed and taken action for fast liquidation of points.

Exception Report on Monthly Safety

Day is being reviewed jointly by Director (HR) and Director (Projects).

Emergency Planning & Response

Review and improvement of the existing Crisis management system and Emergency Response & Disaster Management Plan (ERDMP) and de-briefing to all concerned through various modes.

Incident reporting system & Disaster Management Plan of GAIL has been revised to improve the reporting structure & incorporate changes due to various communications of the ministry.

Annual Report 2014-15 Corporate HSE Page 5

For faster response during emergency, IT and Mobile technology have been further developed using Voice Telephony and SMS and implementing easy Toll Free (15101) numbers for First Responders at site.

Declaration of National Gas Management Center (NGMC) as the nodal control room for handling any emergency situations.

Emergency Response and Disaster Management Plan (ERDMP) of Chainsa, Kailaras, Banguluru, Kochi and NCR have been prepared and accredited by third party agency certified by PNGRB.

ERDMP of Chainsa, Kailaras, Banguluru, Kochi and NCR were submitted to PNGRB after due approval of Board of Directors.

Under Crisis Management Plan, Emergency Preparedness Exercise was conducted at Gandhar, Vijaipur, Vaghodia & Lakwa to check effectiveness of Crisis Management Plan.

Sub Committee Meeting

Sustainable Development Sub-Committee meetings were organized on 11.07.2014, 27.08.2014 & 25.02.2015 to review emergency preparedness of GAIL installations and HSE Management System implementation, besides other issues.

HSE Workshop on “Safety Leadership”

HSE Workshop on the theme “Safety Leadership” was organized on 28th January 2015. It was inaugurated by CMD through video conferencing.

Eminent faculty from OISD, Dupont & Other reputed institutions were invited to deliver lecture on subject of “Safety Leadership”.

Annual Report 2014-15 Corporate HSE Page 6

Various Incidents/Accidents case studies were presented by GAIL Executives as part of learning exercise.

Life Saver Scheme

With a view to focus on saving precious human lives at GAIL installations and continual learning, an analysis of past incidents was done to arrive at major causes of incidents.

The major causes identified were taken as focused campaign topic and were launched under “Life Saver Scheme” from January 2015.

Life Savers Topic: 2015

Proper Maintenance – Increased

Productivity

Timely Inspection – Safety with

Perfection

Know SOP – Get to Work

Use Specified Material – Prevent Failures

Occupational Health

04 Nos. Corporate Occupational Health Committee Meetings were organized to discuss the issues related with Occupational Health.

Occupational Health Audit of Process Plants at Usar and Gandhar was carried out by team of Occupational Health Committee members to review the Occupational Health procedures, infrastructure & facilities.

Occupational Health Guidelines of GAIL have been prepared. Those are under review by various stakeholders.

Environment Management

Green House Gas (GHG) Accounting of Chainsa and Kailaras was done in-house. Report prepared and shared with sites.

Quarterly follow up with Vijaipur site carried out for compliance of recommendations for Global Methane Initiatives (GMI)

Environmental Audit of GAIL Vijaipur carried out by Corporate HSE Team to review implementation of Environment Management System.

HSE Signature of GAIL

GAIL has zeroed in on formulation of its HSE Signature with respect to each of the element of HSE i.e. Health, Safety and Environment.

In view of this, the HSE Signature that has been chosen from each of the elements Health, Safety and Environment are:

Annual Report 2014-15 Corporate HSE Page 7

Health : ‘Body Mass Index (BMI)’ Safety : ‘One Safety Training per employee

per year’ Environment : ‘Plantation of one tree per

employee per year’

HSE Signature Drive was launched by Director (HR) on 14th January 2015.

Safety Performance & Monitoring

By reviewing prevailing best practices

in the industry “HSE Score” has been

devised containing 18 measurable

parameters against each element of the

HSE Management System.

This new “HSE Score” system for

measuring the HSE performance which

is more comprehensive, more

elaborate, having better penetration

and detailing was approved by the SD

Subcommittee of the Board in their

meeting held on 27.08.2014.

Overall HSE Score of GAIL which is

compiled based on the evaluation of HSE Score of O&M installations is 90.23 for FY 2014-15 (September’ 14 – March’ 15).

EHS Module functionality on Incident/Accident and Safety Audit was made live for effective monitoring.

20 Nos. of External Safety Audits including OISD Audit of GAIL Installations were coordinated by Corporate HSE Department during the year.

08 Nos. of Inter Unit Safety Audits (IUSA) of GAIL Installations were coordinated by Corporate HSE Department during the year.

HSE Check of 06 Nos. installations have been carried out by Corporate HSE Officials.

Annual Report 2014-15 Corporate HSE Page 8

Special Safety Audit of C2-C3, Vijaipur was coordinated by Corporate HSE Department.

Pre-Commissioning Audit of C2-C3, Vijaipur & PC-II, Pata was carried out by OISD.

Revision of Technical Specification of Personal Protective Equipment carried out for uniform implementation across the GAIL.

***

Annual Report 2014-15 Corporate HSE Page 9

Targets vs. Achievement 2014-15

SN Parameter Unit Performance Levels

Actual Achievement

Excellent

1 a) HSE Index (April 2014 - August 2014)

% 98.5 97.97

b) HSE Score (Sept. 2014 - Mar 2015) 90 90.23

2 Inter Unit Safety Audit Nos. 8 8

3 Organising External Safety Audit at sites

Nos. 20 20

4 OISD External Safety Audit Compliance

% Compliance

92 60%

5 Organising Workshops for BBS implementation at Pipelines and Petrochemical Pata

Nos. 30 30

6 Organizing Annual HSE Workshop Date 31.01.2015 28.01.2015

8 Review of Occupational Health Management System in GAIL

Nos. 4 4

9 GHG Accounting at 02 Sites of GAIL Nos. 2 2

10 Organising Corp. Occ. Health Committee visit to Occ. Health Centre of two process plants other than Pata & Vijaipur.

Nos. 2 2

11 Revision of PPEs Specification Nos. 31.08.2014 Prepared & approved

12 Revision of Incident reporting System Date 15.02.2015 21.10.2014

13 Publication of "Safety First" Magazine Nos. 2 1

14 Organizing Steering Committee Meetings of BBS

Nos. 6 6

16 Implementing EHS Module in SAP Date 31.01.2015 09.09.2014

18 Quarterly Review of Implementation of Global Methane Initiatives (GMI) recommendations

Nos. 4 4

Annual Report 2014-15 Corporate HSE Page 10

HSE Index

a) Overall HSE Index of GAIL which is compiled based on the evaluation of HSE Index of O&M

installations is 97.97 for FY 2014-15.

HSE Score

b) Overall HSE Score of GAIL which is compiled based on the evaluation of HSE Score of O&M

installations is 90.23 for FY 2014-15. Trend of HSE Score for last 7 months is indicated

below.

Annual Report 2014-15 Corporate HSE Page 11

External Safety Audits 2014-15

External Safety Audits of 20 O&M installations were carried out during FY 2014-15.

S. No. GAIL Installation Audit Dates Auditing Agency

From To

1 Mumbai 01.05.2014 03.05.2014 CEIL, Mumbai

2 Dahej Uran Pipeline 16.06.2014 20.06.2014 OISD, New Delhi

3 Agra 18.06.2014 20.06.2014 CEIL, Mumbai

4 GPU, Gandhar 02.07.2014 04.07.2014 CEIL, Mumbai

5 GPU, Vijaipur 24.07.2014 26.07.2014 CEIL, Mumbai

6 Khera 21.07.2014 23.07.2014 CEIL, Mumbai

7 JLPL NCR 31.07.2014 01.08.2014 OISD, New Delhi

8 Auraiya Delhi Pipeline 04.08.2014 09.08.2014 OISD, New Delhi

9 Pata 25.08.2014 29.08.2014 CEIL, Mumbai

10 Auraiya Phulpur Pipeline 02.09.2014 06.09.2014 OISD, New Delhi

11 Gandhar Dhuwran Dabka Pipeline, Vadodara 22.09.2014 24.09.2014 OISD, New Delhi

12 Hazira 18.09.2014 20.09.2014 CEIL, Mumbai

13 Vijaipur 15.10.2014 17.10.2014 CEIL, Mumbai

14 GPU Vaghodia 10.11.2014 12.11.2014 CEIL, Mumbai

15 GPU Usar 15.12.2014 17.12.2014 CEIL, Mumbai

16 VSPL 01.11.2014 01.11.2014 CEIL, Mumbai

17 JLPL 10.11.2014 19.11.2014 CEIL, Mumbai

18 Rajahmundry 25.11.2014 28.11.2014 CEIL, Mumbai

19 Vijaipur C2-C3 20.01.2015 22.01.2015 OISD, New Delhi

20 Pata PC II 16.02.2015 19.02.2015 OISD, New Delhi

Annual Report 2014-15 Corporate HSE Page 12

Pre Commissioning Safety Audits: 2014-15

S. No.

GAIL

Installation

Audit Dates Auditing Agency

From To

1. Vijaipur C2-C3 20.01.2015 22.01.2015 OISD, New Delhi

2. Pata PC II 16.02.2015 19.02.2015 OISD, New Delhi

Inter Unit Safety Audits: 2014-15

Inter Unit Safety Audits of 08 GAIL installations were carried out during FY 2014-15.

S. No. GAIL Installation Audit Dates

1. NCR Pipeline 19-22 August 2014

2. GPU, Usar 25-27 August 2014

3. Kailaras Compressor Station & Pipelines 24-27 November 2014

4. Viajipur 1-4 December 2014

5. Rajahmundry Pipeline 2-5 February 2015

6. Dabhol Bangalore Pipeline 17-20 March 2015

7. Vadodara Pipelines 17-20 March 2015

8. Jhabua Compressor Station & Pipeline 24-26 March 2015

Annual Report 2014-15 Corporate HSE Page 13

HSE Checks: 2014-15

HSE Checks of 06 GAIL installations were carried out during FY 2014-15.

S. No. GAIL Installation Date of HSE Check

1 Loni 30th October 2014

2 Jamnagar 14th November 2014

3 Kandla 15th – 16th November 2014

4 Puducherry 10th – 11th February 2015

5 G Konduru 10th -11th March 2015

6 Hazira 30th March 2015

Annual Report 2014-15 Corporate HSE Page 14

Life Savers: 2014

With a view to focus on saving precious human lives at GAIL installations, an analysis

of past incidents was done to arrive at major causes of life threatening incidents. The

major causes identified were taken as focussed campaign topic and were launched

under “Life Saver Scheme” from January 2014.

Quarter Life Saver topic

1st Safe Work Supervision

2nd No Permit – No Work

3rd Know SOP – Get to Work

4th Timely Inspection and Maintenance – Safe Operation

Annual Report 2014-15 Corporate HSE Page 15

Awards and Accolades

With its continued focus on HSE across its installations, GAIL has won following awards during the year 2014-15. LPG Recovery Plant, Vijaipur (M.P)

declared winner of “Suraksha Puraskar (Bronze Trophy) Safety Award-2013” by National Safety Council of India, Mumbai.

HVJ Compressor Station, Vijaipur (M.P) declared winner of “Prashansa Patra (Certificate) Safety Award-2013” by National Safety Council of India, Mumbai.

Vizag received Certificate of Appreciation from National Safety Council, Andhra Pradesh Chapter on 28.04.2014, for successful implementation of Occupational Safety & Health.

NCR received International Safety award 2014, by British Safety Council, UK in May 2014.

RT Cherlapalli received certification of appreciation from NSC, AP Chapter in recognition of achieving OHSAS 18001 certification.

Vijaipur declared winner of Golden Peacock Environment Management Award 2014.

NCR bagged Golden Peacock Occupational Health & Safety Award, 2014, by Institute of Directors, New Delhi.

Maharashtra Region Pipeline System, Mumbai has been declared winner of Safety Innovation Award-2014 by the Institution of Engineers (India), Delhi State Centre.

Pata received National Safety Award from DGFASLI for year 2012 on 17th Sept.2014.

Vijaipur bagged NSC Safety Award-2013 as Sarvashreshta from NSC MP-Chapter.

USAR has been awarded with

“Certificate of Merit” for zero accident frequency rate, from National Safety Council Maharashtra Chapter on 20.09.2014.

HVJ Compressor Station-Vijaipur, Khera, Vaghodia & Pata bagged International Safety Award by British Safety Council, UK (London).

Annual Report 2014-15 Corporate HSE Page 16

Way Forward

For the year 2015-16, Corporate HSE

Department has plans to undertake following

new initiatives.

• Measurement of HSE Performance

through “HSE Score”

• Regional Behaviour Based Safety

Workshops

• Handholding of Pipeline Sites for

Behaviour Based Safety

Implementation

• Introduction of new EHSM-SAP

Reporting Safety Observations Reporting Near miss Reporting Incident Accident &

Investigation Management of Change Risk Assessment Worker Safety

• Standardization of technical

specifications of firefighting

equipment.

• Global Methane Initiatives in GAIL.

• Introduction of new approach “Safety

by Heart”.

With the continued support and guidance

of GAIL management, Corporate HSE

department shall continue to serve the

organization in a professional manner to

meet and exceed the stated objectives.

***