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.
***
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