A PROJECT REPORT

ON
SAFETY REQUIREMENTS IN CITY GAS
DISTRIBUTION
AT
Mahanagar Gas Limited; Mumbai

SUBMITTED IN PARTIAL FULFILLMENT OF

ADVANCE DIPLOMA IN INDUSTRIAL SAFETY

Year 2013-2014

AS PRESCRIBED BY
MAHARASHTRA STATE BOARD OF TECHNICAL EDUCATION,
MUMBAI.

COURSE CONDUCTED BY

THANE BELAPUR INDUSTRIES ASSOCIATION

RABALE, NAVI MUMBAI

Submitted By
HARESH PARAB
 FORWARD

Mahanagar Gas Limited (MGL), a pioneering initiative to bring clean,

safe efficient and affordable Piped Natural Gas, direct to over
6,00,000 homes in Mumbai. Presently MGL has connected to more
than 4,83,283 households in Mumbai. The MGL project, which
started in 1995 from Chembur, has covered major parts of Mumbai
through its distribution network i.e. from Dadar to Mira Road and
from Sion to Mulund. MGL has already started work in South
Mumbai areas like Prabhadevi, Worli, Colaba etc. From cooking
stoves to geysers and air-conditioners, this versatile gas has today
become the preferred choice for the residents of Mumbai.

Fulfilling the promise of a Clean Mumbai, MGL's Compressed Natural

Gas (CNG) powers 49,254 taxis, 1,39,268 auto rickshaws and 2827
BEST buses across the city through it's network of 148 CNG stations,
thus contributing to more than 900 tonnes reduction of pollutants
every day in Mumbai.

MGL has always emphasized on Health, Safety, Security and

Environment (HSS&E). In this endeavor we have in place systems
and processes that match up with the best in the world. Besides
monitoring our system on a daily basis we have also our Customer
Service Cell with a customer care number 1917, to give you access to
us at all times to answer all your queries, thereby providing greater
convenience and better services to Mumbaikars.

Any accident or mishap is very costly affair. The loss in production or

damage to equipment can be over come at a cost exorbitant to the
nation, but injury to human beings or loss of life is irreparable.

So it is necessary that all people working in industry engaged in

operation and maintenance adopt safe practice and don't take any
short cut measures, which compromises the safety requirements.

2
 ACKNOWLEDGEMENT

It gives me great pleasure in presenting the Project Report on “Safety

Requirements in Pipe Line Lying” undergone at M/s. Mahanagar Gas
Ltd. Mumbai. The success of any project depends on the efforts of the
team; moreover it heavily depends on the guidance and co-ordination
of the team. I would like to acknowledge the support and efforts of
many people who made significant contribution to this study.

I avail this opportunity to express my wholehearted thanks and

sincere to Mr. Appaso Nalawade (Manager-HSSE), Mr. Ullhas Patil
(Asst.Manager-HSSE). who gave me the opportunity to undergo
project report study in MGL.

I acknowledge my thanks to Mr. Ajit Diwadkar Project Guide who

gave me opportunity to undergo industrial project under his
guidance.

I would also like to express my deepest gratitude to Dr. S.L.Patil

(Principal), College Faculty Memebers and Mr. Anil Chougule
(course coordinator) ADIS (Thane Belapur Industries Association)
for their kind and consistent guidance.

HARESH PARAB

3
 SUBMISSION

This Project report has been prepared and submitted in partial

fulfilment of the requirement of “Advance Diploma in Industrial
Safety” course for the academic year 2013 -2014 of the Thane
Belapur Industries Association, Rabale, Navi Mumbai. Topic of report
is “Safety Requirement in City Gas Distribution” in M/s. Mahanagar
Gas Ltd. Mumbai.

The organization set up is studied Safety aspects in details. Accident

data is analyzed from January 2011 to Dec.2011 according to IS
3786-1983 and guidelines provided by the faculty members of TBIA.

After detailed study of the status, an attempt is made to suggest the

ways and means for improvement in Safety management System.

Signature

Internal Examiner

4
 INDEX
Sr. Description Page No.
No
1 Preface 6
2 Scope of the Project. 7
3 Objective 8
4 Methodology 9
5 Organization Profile 10
6 HSE Policy 14
7 Safety Organization: Safety Management System & 16
Safety Committee
8 Safety Training : Employees, Contractors, Visitors 19
Rules, Manuals, Classroom etc
9 Safety Promotion: Safety Day / Week, Contests, 25
Awards, Posters, Suggestions, Coordinators etc.
Awards won by organization
10 Nearmiss/Hazards Statistics (calendar years) 30
11 Housekeeping : Plant Layout, Roads, Location of 32
Machines Ventilation, Noise, Illumination
12 Ergonomics 34
13 P.P.E : Availability, Use, Training, Comfort 40
14 Risk Assessment : HAZOP, JSA, Audit, Inspection 42
HIRA etc
15 Work Permit Systems 45
16 Fire Prevention / Control : Extinguishers, Hydrants, 48
Training Sprinklers
17 Emergency Preparedness : Plan, Training, Mock drill 51
18 Safety of Contractors / Visitors 55
19 Findings & Recommendations 56
20 Conclusion 58
21 Annexures 59

5
 CHAPTER 1

PREFACE

Industries are inevitable in modern society to fulfil human needs and

requirements. Therefore place of Industries is ahead, vital & most
desirable. We can not eliminate industry only its hazards are to be
eliminated. Major problem commonly face by all industries is an
accident at work. Which have been on increase with rapid
industrialization? Last two decades clearly indicates that the
accidents are gone up by manifold due to following reasons.

 Inadequate enforcement of safety regulations in the industries.

 Inadequate knowledge of hazards associated with the new
technologies, new machines and process involved.

To protect the human being from industrial hazards direct & indirect
cost of accidents death & injuries, pain & various social losses the
need of accident prevention & safety at work place is increasing.

Safety being the human instinct & basic need of man kind, it is not
true that industry always bring hazard. The science of safety is also
increased & modern scientific control measures are always trying to
decrease accident and injuries. We have to study this aspect in much
detail, because it is only use full subject to avoid accidents and
increase safety.

Safety is a way of life, let us always maintain safety and solve our
problems in safe atmosphere only. Lets us perform this safety duty
first, enjoy the right. This is the only good motivating force to mould
the human behaviour to maintain safety.

In engineering, industries noise, vibration, hot process, use of toxic,

poisonous, flammable, explosive chemical & gases which pose to
serious threat to safety and health of employees, people living in the
vicinity and environment. This small and simple work is an attempt
to highlight to importance of safety in engineering industry.
I have prepared this project report as a part for the partial fulfilment
of the course of “Advance Diploma in Industrial Safety”.
6
 CHAPTER 2

SCOPE OF THE PROJECT

Prevention of human and property losses is integral to the

management of any industry. This may be achieved through the
selection of a technology that is inherently safe. Alternatively safety of
plant design and/or operation can be audited by the application of
hazard identification and risk assessment techniques, and adopting
measures suggested by the assessment.

This approach constituent the fire and safety requirements, the code
of practice describes specific techniques that can help in attaining
such objectives. The overall methodology presented in this code
allows systematic identification of hazard as well as qualification of
the risk associated with the processes or activities. Applied with due
expertise and rigor the prescribed methodology can help the user
understand the relative level of hazards and risk potential in the
process. This aids the selection and prioritization of necessary
strategies for accident prevention and limiting their consequences.

7
 CHAPTER 3

OBJECTIVES
The project on Safety in City Gas Distribution has been carried out at
Mahanagar Gas Ltd. located at Mumbai. This company specially chosen
for project due to the risk involved in its operations. The organisations
infrastructure is spread across the city passing through the public places.
All these involved variety of hazards that needs careful attention secondly
company has well established safety department and hence interaction
with it is surely helpful.

Our objectives for working on this project are as follows:

 This project was selected to identify the potential hazards in

industry and understand the practical aspects of fire and safety
requirements

 To study safety organization and safety performance of the

factory

 To analyze the safety procedure systems and practices

 To find out the existing risk inside the industry along with their
corrective measures and check its adequacy.

 To take all possible steps safeguarding life and property by

accurate hazards identification and efficient risk assessment.

 To study cause of accident with example and suggest possible

improvement on organization & procedural aspect as well as
control of cause of accident in health and better working condition.

 To further recommend enhanced measures to minimize the risks

involved in the activity and suggest ways to reduce the probability
of occurrence of any hazards.
8
 CHAPTER 4

METHODOLOGY

1. Study of City Gas Distribution process, Hazardous Chemical

storage system, handling & transportation of Hazardous chemical
and safety measure incorporated there in.

2. Study of Safety manual & Practices of MGL.

3. Study of Personnel protective Equipment & its Specifications

4. work permit system in MGL

5. Accident reporting culture and techniques adapted for

investigation by Safety department.

6. Fire and safety rule manuals.

7. Fire prevention and protection system.

8. Study of safety performance report

9. Study of Maharashtra factory Act 1948, latest edition.

10. Discussion with management, union, safety committee.

11. Visit all departments of MGL and the gas terminal.

12. Safety audit reports and qualitative risk analysis report.

9
 CHAPTER 5

ORGANISATION PROFILE
Mahanagar Gas Limited (MGL) incorporated on 8th May 1995 is engaged in the
distribution of Natural Gas in the city of Mumbai. It is a Joint Venture with Gas
Authority of India Limited (GAIL), a Navratna Public Sector Undertaking, BG Plc.
(Formerly British Gas), a leading International Gas Distribution Company and
Government of Maharashtra.
MGL is engaged in distribution of Natural Gas, a clean and alternative source of
energy through safe, efficient and cost effective means. 1.5 MMSCMD of Natural
Gas has been allocated to Mumbai city to meet the energy requirements covering
Domestic, Commercial, Transport (CNG) & Industrial sectors.
The main objective of the company is to substitute other fuels with Natural Gas
in accordance with internationally recognized standards of practice. MGL
supplies gas to Domestic consumers and Commercial / Industrial consumers
plus compressed Natural Gas to Vehicles.
Natural Gas can be used by all Industries which at present use fuel, oils, LPG,
Electricity, coal etc. Natural Gas is not only economical but it also considerably
reduces the pollution in the city.
Natural Gas is also used as a fuel for automobiles in both private vehicles and
public transport. This considerably reduces the pollution in the city of Mumbai.

Nature of Business:

Mahanagar Gas limited is into transmission & distribution of natural gas to the
city of Mumbai & adjoining areas.

The Gas Distribution Process:

Natural Gas produced from Mumbai High offshore is transported to MGL’s City
Gate Station in Wadala after processing, from where MGL distributes the gas
through its vast network of steel and medium density polyethylene pipelines all
over the city of Mumbai.

10
Flow Process Diagram:

11
PNG- Piped Natural Gas:

Piped Natural Gas (which consists of 80 - 90% Methane) is safe, uninterrupted,

convenient, economical, versatile and eco-friendly. The gas comes from Bombay
High via Uran and is brought to the city through Steel pipe lines laid by GAIL.
MGL receives the gas at its City Gate Station (CGS), Sion, Mumbai.

PNG today is widely recognized as being the preferred fuel for domestic,
commercial and industrial applications. It offers the convenience of gas on tap
with no storage and refilling requirements. PNG is economical when compared to
LPG. A versatile gas, the use of PNG can range from cooking to geysers to air
conditioners and other household equipment.

CNG – Compressed Natural Gas:

The benefits of Compressed Natural Gas over other automobile fuels are well
known. It not only has the lowest environmental emissions, but is also cost
effective. CNG is good for both, the business and the environment

Typical Layout of CNG Station

CNG as a fuel is provided through filling stations to all the vehicles running in
the city of Mumbai. At present 105 filling stations are catering this services of
providing this environment friendly natural gas to vehicles in the city of Mumbai

12
Potential Hazards:
MGL Risk exposure is categorized into to
 Asset Integrity hazards
 Occupational Health & Safety Hazards

Asset Integrity Hazards:

Following are the hazards related to the infrastructure

 Natural Events: Flood, Earthquake, lightning, severe wind,

 Spontaneous failure: Design, corrosion, erosion, mechanical, electrical,
fatigue, communication.
 Abnormal Operation: Under or over pressurization of the network by
system out of balances, i.e. supply and demand mismatch.
 Third Party Interference: Impact damage, vandalism and terrorism, war,
attack by aircraft etc.
 Other Extraneous events – Fire and explosion, thermal radiation,
uncontrolled vapor cloud or catastrophic explosion

Occupational Health & Safety Hazards:

The following are the highest risk activities in CGD distribution:
 Confined Space entry
 Electrical Work
 Work at height
 Ground Excavation
 Lifting Operations
 Driving
 Odorant transfer

Workers in the CGD business are exposed to risk of harm due to various hazards
which are inherent in carrying out above activities

13
 CHAPTER NO 6

MGL believes that outstanding business performance requires outstanding HSE

performance in the protection of the health and safety of our people, those
affected by our operations, our physical assets, our reputation and the
environment.

Our Goal is zero injuries because we believe they are all preventable. We conduct
our business in a responsible manner and to internationally accepted good
practice. HSE performance is everyone’s responsibility and we each have a duty
to intervene to prevent unsafe actions and to reinforce good behaviours through
demonstrating HSE leadership. Safety in all our operations is a critical success
factor for our business.

In implementing this policy we will ensure that:

 Management decisions reflect our HSE intentions
 Our HSE management system reflects best industry practice and is properly
resourced
 Ensure & Maintain compliance to all the Legal and other Requirement to
operate our Business
 Provide direction, education, training and supervision to ensure all
employees are competent and understand their accountabilities, the required
behaviours and the consequences of non compliance
 Ensure that our contractors and suppliers understand their HSE
accountabilities and required behaviours, share our aspirations and are
aware of the consequences of non compliance. We will share and learn from
each other’s experiences
 Work with our partners to achieve internationally accepted good practice in
HSE and learn continually from each other’s experiences
 Adopt a risk based approach to the design, construction and operation of our
facilities across their life cycles
 Involve and consult all our Stakeholders and take into account their
concerns on HSE
 Continually improve our performance by acting on lessons learned to avoid
work related ill health, accidents and incidents and so that environmental
emissions, waste and energy use are minimized

14
  Report on our HSE objectives together with our performance and work with
industry and government agencies to improve HSE practices

Observation:
 The policy reflects the clear intension towards occupational health safety
environment by providing training, implementation by providing
education, condition monitoring and assigns at various levels of hierarchy
to all statutory obligation.
 This Policy reflects the Desire Management, Organisation set up and
Arrangement.

Recommendation:
 This Policy should be widely published in all employees.
 Make available appropriate resources to implement this policy.
 This policy has also been displayed at prominent locations make the policy
available to visitors, suppliers, customers.

15
 CHAPTER 7

SAFETY ORGANISATION
HSSE Management System has been established to ensure that the MGL HSE
risk exposure is well below the ALARP. The occupier is the accountable person
for the safety of the organisation. To ensure the safety of employees, safety of the
people who are affected by MGL operations, and to protect the environment, MGL
has established its HSSE management system for the effective implementation of
its safety programme. The HSE Management is underpinned by the integrated
framework of responsibilities and functions driven from top management down to
operational levels, covering all aspects of risk, most notably OHS risk, equipment
failure and operational risk (including legal, regulatory, and human resources
risk).

Safety has always been the top most priority at MGL. In keeping with standards
that are best in the world, MGL has adapted and implemented a robust Health,
Safety Security & Environment (HSS&E) management system with risk control
system and operator instruction in place. The system insures continual
improvement in HSS&E performance.

This apart, MGL has also taken several pro-active measures to further
strengthen safety and security and provide uninterrupted supply of PNG and
CNG to consumers.

16
These include,
A toll-free number for consumers, in case of any emergency, offering 24 x 7
service.
A network of 18 offices around Mumbai, who ensure that help is just and arm’s
length away.
A team of fully equipped emergency vans having an impeccable record of
reaching any site under 30 minutes that is available 365 days a year, 24 x 7.
MGL’s initiatives in areas of health, safety and environment have been recognized
by renowned institutions like BG Group, CII and the Greentech foundation.

Safety Management System:

MGL has already set up a Safety Management System in accordance with OHSAS
18001:2007, an Environmental Management System in accordance with ISO
14001:2004 and Quality Management System in accordance with ISO
9001:2008. These Management Systems have been audited by a third party
Certification Body viz D N V and found to conform to the requirements of the
respective standards mentioned above. The success of the system has been due
to the commitment from all levels and functions of the organization, and
especially from top management.

MGL Adopts A Behavior Based Safety Approach For Employees:

Behavior based safety (BBS) emphasizes that employees need to take an

ownership of their safe as well as unsafe behaviors. If they behave unsafe, they
are not punished, instead they are repeatedly told to correct; and when they
behave safe, they are encouraged. Both unsafe and safe behaviors are counted
and displayed. BBS also discusses the unsafe conditions that influence unsafe
behaviors.

BBS is a data driven decision-making process. BBS believes that what gets
measured gets done and each employee can make a difference in organizational
safety. Employees are the basic source of expertise of behavioral change (observe
and correct). BBS begins by briefing sessions for all work areas and depts. BBS
is a teamwork; it is company wide and people driven. BBS purpose is not to
enforce safety rules, force change, gossip about others, reporting to boss. Its
purpose is to identify safe and at- risk behaviors, identify possibility for injury,
communicating the risk and helping to identify safer solutions. An
implementation team or BBS steering committee monitors its progress.
Essentially BBS is not a management driven tool for safety. It’s an employee
driven approach with management support.

In MGL BBS Checklist is being filled by the employees

17
Safety Committee:

MGL has established its HSE management system to meet organization’s safety
goal i.e. Zero injury. As a part of the system several initiatives have been taken.
Some of the initiatives are much beyond the legal/ statutory requirements. Top
management along with the Heads of the departments as well as union
representatives reviews the effectiveness of the safety programs and takes
corrective actions which include ensuring adequate resource.

Observation:

 MGL has its HSE management system who takes initiative to arrange
safety programs.

 MGL Safety committee review effectiveness of safety programs, also take

corrective action.

Recommendation:

 MGL safety committee members should take safety programs in

contractor’s employee (project manager, supervisors, workers) also, it gives
opportunity for employee to meet and have face to face discussion.

18
 CHAPTER 8

SAFETY TRAINING
MGL has established HSSE Training Framework has been approved by the
HSS&E Steering Group, and has been published under the authority of MGL for
use throughout the existing and expanding geographical limits of the Company.

MGL has adopted “NO STC NO WORK” policy. It is the responsibility of every
Manager of the respective department to ensure that every person is STC (Safety
Technical Competency) trained and possesses valid STC Card.
MGL requires that all personnel who are required to undertake work on gas
supply network, throughout lifecycle of Design, Construction, Operation,
Maintenance and Disposal must be competent to undertake the tasks.
HSSE Training wing of MGL facilitates every individual who works in MGL
business process in developing his competency. Broadly there exist two areas
one is all MGL direct employees and other is all Contract Employees.
For all MGL direct employees (except personnel and finance dept) competency
levels O, E & M will be developed based on job responsibilities, competency
matrix and competency assessment as described in MGL Competency
Framework.
For all Contract employees, specific activity based or risk based training will be
imparted through in-house training programs or through external agency. They
will be assessed to ensure their competency.
Random surveillance will be carried out to assess training and competency
effectiveness so as to enable improvement in this HSSE Training Framework.
Goal of HSSE training is to inculcate safety consciousness in every direct and
indirect employee. It develops awareness of hazard which is the first step
towards accident prevention efforts. It educates them safe procedure and
practices and in a way make them eligible to work safely

Following departments are in scope of this Training framework

 Steel Construction
 CNG Construction
 PE/GI-Cu Construction
 Planning
 O&M
 Asset Integrity
 HSSE

19
Safety And Technical Competency (STC) Training Program:
In accordance with “NO STC TRAINING NO WORK” policy of MGL, concerned
department shall ensure that everyone in the department (MGL + Contract
Worker) must undergo safety & competency training (STC) prior to starting any
work. To facilitate this policy following program is planned.

Induction to new employees and third party inspectors (TPI):

HSSE Induction training is provided to every MGL employee and TPI immediately
after joining the organization. This training is provided by HSSE department.
HSSE Induction to the Contractor management is provided at the time of
contract kick-off meetings

All MGL Employees:

Training coordinator from each dept will conduct training need assessment with
the help of MGL competency framework. From the training needs assessment
training module/program will be developed which will incorporate risk focus area
and competency area as stipulated in Appendix 1 and 2 of the competency
framework. STC Card/Certificate will be provided to the employee by HSSE Dept.

MGL and Contractor Employees:

 First Aid Training to all concerned
 Fire fighting practical training to all concerned
 Work at height and Rescue:- Practical training to all concerned
 Excavation practical training to all concerned
 CNG Compressor Operators
 CNG Dispenser Operators
 Defensive driving LCV, Emergency Vans and Patrolmen
 HazChem Training to LCV drivers
 All O&M Contractors including owner and management of the contractor
 Steel Contractors including owner and management of the contractor
 PE Contractors including owner and management of the contractor
 CNG Project: All Civil, Steel Fabrication Contractors
 Planning: All Civil, Steel Fabrication Contractors
 Defensive driving pool vehicles
 Migrant labours

20
Evaluation Of Training Effectiveness:

It is ensured that all training programs are measured and reviewed for their
effectiveness through the following:
Assessing the quality of training and training facility during training session by
HSS&E representative on sampling basis.
Obtaining feedback from the participants observing and periodically assessing
safe work practices after training at sites by AIC’s as well as HSS&E
representatives.

Audit Of Training Facilities:

Audit of training facility shall be carried out by team of HSSE and Departmental
Training Coordinator. This audit shall be carried out every six months.

Observation:
 MGL conducts safety training for every workers i.e. MGL employee as well
as contractor employee for safety consciousness.
 MGL adopt one policy that ‘NO STC NO WORK’ which help in organisation
to give better result in safety.

Recommendation:
 MGL should posses some new training method like audio visual film, use
of working model, transparencies slides etc.
 Give first aid and fire fighting training to all site representatives and
workers.

21
Safety & Technical Competence Training Process for PNG:

Request for STC from Contractor / AIC

Related to PE / GI / CU/conversion
Training

HSSE  IOM (List of Candidates, Date &

Type of Training)

Outsourced
Fail
Training
(Theory / Practical)
Assessment by AIC

Pass

Permanent Card issued

Fit For Carrying out his Job with MGL

After One Year

22
Safety & Technical Competence Training Process for Steel Project:

Request for STC from AIC Related to

Steel Laying

IOM (List of Candidates, Date & Type

Of Training)

Internal Training at
Fail
CGS Training Hall
Assessment by AIC

Pass

Permanent Card issued

Fit for Carrying out his Job with MGL

After One Year

23
Safety & Technical Competence Training Process for Labour briefings:

Arrival of labours at site

AIC informs to HSSE Dept for STC

Training Van moves site for

the briefing on first call first
visit basis

STC Briefing completes. If Training Van is, busy at

Verbal assessment is carried other site then or additional
out by asking questions mobilization of labors,
randomly to any labor in the AIC shall brief the labor as
group. per predefined training
module and mark their STC
on daily Tool Box Talk

At next opportunity
Renewal after one year Training van visits the site
and brief them and issues
STC card

Briefing provided by the AIC is deemed to be at par with (STC) Safety

& Technical Competency Card

24
 CHAPTER 9

SAFETY PROMOTION

Enhancing safety in the every facet of MGL business operation is top priority for
MGL. Educating the organisation, MGL is actively involved with safety education
across the organisation for promoting safety
Safety must be sold to everyone in the chain of command, from the Top
management down to the migrant labors working with contractors. MGL
approached three pronged approach for safety promotion.

 Mandatory STC process

 Safety reminders by pictograms and signage display at point of
risk
 Safety events like: lifesaver campaigns safety week, stepping
forward day etc

STC process:
STC process gives a consistent approach to educate all the direct employees and
contractor employees with respective to safety. Below photograph shows safety
training for the contractor employees as well as MGL employees.

Safety Technical Competency

Training by Mobile Training Van for
Contract Labours at Site

25
 Safety Training for Employees
by External Faculty

Safety Reminders:

MGL uses posters are a passive training method to remind workers of a

hazard, precaution, or idea. MGL ensures that posters are current and have
a message applicable to the audience. These posters also get changed
frequently so they don’t become part of the bulkhead
Posters uses both pictures and words to convey a safety message for
workers with poor reading skills, posters are more effective than
lengthy written text. MGL posters are Eye-catching, colourful pictures
which is important to the effectiveness of a poster as clever text.
Pictograms have been developed to prompt contractors and employees at
the point of risk
The crew room posters are been put up in the office areas and the
contractor site offices for visibility.

26
Following are the some examples of posters and pictograms.

Excavation Pictogram display at site

27
Safety Events:

As a part of safety promotion MGL conducts several safety events like

stepping forward day, lifesaver campaign, and migrant labour safety
awareness sessions. MGL celebrates National Safety Day / Week every year
from 4th – 10th March to commemorate the foundation of the National
Safety Council in India since 1966.
In MGL the Campaign is aimed at renewing the commitment of employees,
contractors and our customers to be safe throughout the year. The
ultimate objective of the Campaign is to ensure integration of Health,
Safety and Environment (HSE) in work culture and life style. For the past
several years Safety Week is one of a variety of means being used by MGL
for promoting and disseminating useful information on the HSSE topics.
During safety week various competitions/activities are planned and
communicated to all the MGL Employees, contractors via email & intranet.
The Functions are grand success by full hearted support & good number of
participation from all MGL employees, their families, contract workers etc.

Following were the various activities scheduled during the safety week of
2013.
4th March – Safety Pledge Administration
5th March – CNG Safety Awareness program for BEST Drivers & Mockdrill at
CNG outlet
6th March – Awareness session on Pictogram
7th March – Health Checkup Camp for Migrant Labor
8th March – Rangoli Competition for employees & families
9th March – Rewards by Senior Management & Safety Quiz

28
 National Safety Week Celebration

Safety Awareness Competitions for Employees

Awards & recognition:

MGL won the First prize in the Service (Large) category in Confederation of
Indian Industry (CII) Western Zone Safety, Health and Environment Award
2009 competition. Also in 2011 MGL won the “BG Chairman” Award for
excellence in implementation of VTS system.

29
 CHAPTER 10
Near miss/Hazards Statistics
As a part of MGL HSSE management system, employee and contractor
employee’s suggestions are sought and technically feasible suggestions are
implemented. Employee suggestions reports are monitored. Providing
suggestions are the part of employees Key performance indicators.

Closeout Status

Apr'11 May'11 Jun'11 July'11 Aug'11 Sept'11 Oct'11 Nov'11 Dec'11

YEAR Repo close Repo close Repo close Repo Close Repo close Repo close Repo close Repo close Repo close
2011 rted d rted d rted d rted d rted d rted d rted d rted d rted d

30
Near
miss 7 6 11 10 6 5 9 9 6 5 4 4 7 4 7 5 8 6
Hazards
Reported 6 6 4 2 5 4 5 5 1 0 4 4 7 2 8 2 2 0
Rubber
Tube
Damage
Complain
ts 4 4 13 13 8 8 0 0 0 0 5 5 6 6 14 14 14 14
100 mbar
damages 53 53 28 28 32 32 40 40 18 18 28 28 28 28 22 22 23 23
Site
Hazard(
MGL TPI
&
Contract
or
Related) 1929 1929 2501 2501 2827 2827 3093 3093 3326 3326 3721 3721 3995 3995 4058 4058 4173 4173

Observation:

 From above table it is observed that maximum number of hazards and

injuries are due to unsafe act, unsafe condition, improper material
handling, careless working, no use of PPE etc.

Recommendation:

 Every worker should follow safety rules and regulation.

 Handle material with proper procedure.
 Working area need to be kept clean.
 Proper training should be provided to the worker.
 Workers do their work carefully, concentrately, attentively.
 Use proper PPE.
 Good housekeeping.

Above all recommendations follow by everyone will minimize the accident, hazard
in the working area.

31
 CHAPTER 11

House Keeping
MGL believes good housekeeping is one of the surest ways to identify a safe
workplace. One can tell how workers feel about safety just by looking at their
housekeeping practices. Good housekeeping is not the result of cleaning up once
a week or even once a day. Its the result of keeping cleaned-up all the time. It’s
an essential factor in a good safety program, promoting safety, health,
production, and morale.

At MGL housekeeping is responsibility of every ones. Clean work areas and aisles
help eliminate tripping hazards. Respecting "wet floor" signs and immediately
cleaning up spills prevents slipping injuries. Keeping storage areas uncluttered
reduces the chances of disease and fire as well as slips, trips, and falls.
Accumulated debris can cause fires, and clutter slows movement of personnel
and equipment during fires. MGL ensures good house keeping practices by
considering all the above factors.

In fact the MGL facilities are designed with good layout and this is also helping in
maintaining good house keeping practices.

MGL also follows other housekeeping practices include keeping tools and
equipment clean and in good shape or keeping hoses and cables or wires
bundled when not in use. MGL advises its employees that be aware of open
cabinet drawers, electric wires, sharp corners or protruding nails. To ensure good
hose keeping hazard reporting practice is in place. Either correct the unsafe
condition if you are able and it is safe to do so, or notify the person responsible
for overall maintenance that something should be done.

32
How a workplace looks makes an impression on employees and visitors alike. A
visitor’s first impression of a business is important because that image affects
the amount of business it does. Good housekeeping goes hand-in-hand with good
public relations. It projects order, care, and pride.

Besides preventing accidents and injuries, good housekeeping saves space, time,
and materials. When a workplace is clean, orderly, and free of obstruction; work
can get done safely and properly. Workers feel better, think better, do better
work, and increase the quantity and quality of their work

Photo graph showing neat & clean premises and pedestrian path at on of
the MGL facilities showing good layout and house keeping.

Machines:

At MGL machinery means the compressors and the dispensers. As explained

MGL receives natural gas through pipelines and distributes through pipelines to
its domestic/commercial/industrial customers. It also provides CNG to transport
vehicles. MGL has about 150 retail outlets. Gas is compressed to 250 bar with
the help of compressors and dispensed to vehicle cylinders through 3-stage
cascade cylinders. Entire compression section is properly isolated from the
vehicle passage area and categorised as hazardous zone. Compressor is driven by
an electric motor (300 to 500KW) placed inside acoustic enclosure. Adequate
ventilation provisions are made for the compressor kiosk.

Noise:

The acoustic enclosures are good enough to bring down the noise levels as low as
ambient level. MGL conducts noise monitoring monthly at all CGS (City Gas

33
Station) and MGL offices @ 60-65 db. Noise measurement is carried out at the
0.5m distance from the fence of the retail outlet. It was observed that noise level
are well below the norms.

Illumination:

MGL periodically conducts illumination study to ensure that employees work

area is comfortable and have adequate work place lighting.

CHAPTER 12

Ergonomics
The term "ergonomics" is derived from two Greek words: "ergon," meaning work,
and "nomoi," meaning natural laws.
Ergonomists aim to provide working conditions which are well above the
minimum required to ensure health and safety of the workforce. Thus, in
achieving a comfortable, productive and satisfying office environment, any
musculoskeletal complaints would also be minimized. To design such an
environment, it is necessary to consider not only furniture and equipment, but
also the job designs, lighting, noise, air quality, office landscaping and personal
space. This paper concentrates on furniture and equipment which both have a
strong influence on postures.

In office work, discomfort and pain are most likely to be caused by

constrained postures, and hence static muscle loads which lead to early fatigue.
Constrained postures which are often troublesome are:

 Forward flexion of the neck;

 Twisting of the neck;
 Elevation of the shoulders;
 Twisting of the trunk;
 Forward reaching of the upper arm;
 Abduction of the upper arm;
Seat Height:
Seat heights are measured after loading the seat with the British Standard seat
plate and compression weights, which simulate the compression resulting from a
person sitting on the seat (see BS 5940: Part 1: 1980).Consider the height of the
seat above the floor for a fixed height chair such as a visitor's chair.

34
 Figure. Some critical dimensions for chair design.

Seat Width:
The checklists recommend a minimum width of 450mm. This gives a little extra
space above the 97.5th percentile hip width for British women of 445mm. The
97.5th percentile hip width for British males is less than this (417mm).

Seat Slope:
Related to seat height is the slope from front to back of the seat. Since the seat
height should be selected to minimize pressure on the thighs, the backward slope
should be minimized, and the front edge well rounded. The option of making the
slope adjustable is increasingly available on adjustable office chairs.
Unfortunately, this results in the possibility of the slope being left at a setting
where there is a substantial backward slope. This could lead to excessive
pressure on the thighs and an impairment of blood circulation to the legs. For
this reason, a maximum backward slope of 5 degrees is recommended.

In recent years, ergonomics have attempted to define postures which minimize

unnecessary static work and reduce the forces acting on the body. All of us could
significantly reduce our risk of injury if we could adhere to the following
ergonomic principles:

 All work activities should permit the worker to adopt several different, but
equally healthy and safe postures.
 Where muscular force has to be exerted it should be done by the largest
appropriate muscle groups available.
 Work activities should be performed with the joints at about mid-point of
their range of movement. This applies particularly to the head, trunk, and
upper limbs.

35
Office Ergonomics:

Office Ergonomics is the utmost thing to be considered for maintaining good

ergonomics at the office. An example of Office Ergonomics is to have a better view
of the monitor and see the images clearly if you take good care in selecting the
right level of illumination and place it appropriately.
Normally, brighter lighting or sources that cause glare on the monitor lead to
eyestrain or headaches which enforce work in awkward postures (Ergonomic
Seating) to have a better view of the screen.
The comfort of the user and hence his productivity is related to the aeration and
moisture levels in the Office Ergonomic environment. Lighting, Glare &
ventilation are the three factors that affect the workstation environment.

Feasible Solutions of Office Ergonomics Disorders:

1. Try to vary the tasks and Office Ergonomics, so that you get ample time
to recover from the outcome of your activity. Different ways are being
practiced to provide recovery time for overused muscles.
2. Office design should be in such a way that can easily change the working
postures according to the convenience. It is always safe to select adjustable
furniture for the workstation that allows shift to different seated postures.
This helps different muscle groups to provide support while others rest.
3. Work area should be spacious enough to use the mouse with either hand
alternately. Thus the tendons and muscles of the free hand get enough
relaxation.
4. Reduce dependences on the mouse and use more of shortcut keys. For
example, use Ctrl+S to save, Ctrl+P to print etc. Certain jobs do require
more dependence on the mouse. Users in such professions should learn to
use more shortcut keys.
5. Jobs that involve more repeated tasks or prolonged static postures leads to
muscular strain. The users should forcefully take several short breaks or
relaxed pauses. The users should stand, stretch, and move around during
such breaks. This increases blood circulation and gives enough time for
the muscles to relax.
6. Computer tasks and non-computer tasks should be mixed alternately in all
possible situations. This encourages the movement of different parts of the
body by using different muscle groups.
7. Everybody who uses computers should acquire training on general Office
Ergonomics awareness.
8. training should be on the aspects related to all the computer components
exclusively, that generally increase discomfort or risk of injury

36
 9. Employees should be made aware of the different signs and symptoms of
all kinds of discomforts caused by continuous computer usage so that they
can identify these from the beginning and treat with appropriate
medications.
10. Training on the methods of using and adjusting all the computer
components correctly as well as the environmental factors should be
imparted.

Ventilation Ergonomics:

Ventilation Ergonomics is to be followed at a workstation otherwise it may lead to

discomfort to the workers of the workplace

Ventilation Ergonomic - Probable Risks:

1. If the ventilation system is poorly designed or not functioning properly, the
user may experience discomfort. For instance, air conditioners or heaters
that directly "dump" air on users are bad for health.
2. Eyes tend to get dried easily due to the dry air, especially while wearing
contact lenses.
3. If the air circulation in the room is poor, it can result in stuffy or stagnant
conditions.
4. Comfort and hence the productivity is affected if the temperatures are
above or below standard comfort levels.

Feasible Solutions:

1. If the air conditioning vents are not designed to redirect the flow of air
away from the underneath areas of the vents, desks, chairs, and other
office furniture in these areas should not b placed.
2. Diffusers or blocks should be used in order to redirect and mix airflows
from ventilation systems.
3. Airflow rates must be maintained within three and six inches per second
(7.5 and 15 centimeters per second). In fact, these airflow rates are barely
noticeable or not noticeable at all.
4. The relative humidity of the air should be maintained between 30% and
60%.
5. During hot season, maintain the ambient indoor temperature between 68°
and 74° F (20° and 23.5° C). During cold season, the recommended
temperature is between 73° and 78° F (23° and 26° C).

37
Probable Risks:

The users will have discomfort and several health problems if they are exposed to
chemicals, volatile organic compounds (VOCs), ozone, and other particles from
computers and their peripherals (say, laser printers).

Feasible Solutions:

1. Before purchasing a computer and its components, do investigate about its

potential to emit air ventilation diffuser pollutants. The components that are
identified to emit pollutants should be placed in well-ventilated areas in your
office.
2. It is good to ensure sufficient supply of fresh air to maintain proper ventilation
in the office room.
3. Before installing the new equipments, allow the "air out" in a well-ventilated
area.
4. Pollution Control : Analysis, Monitoring, ETP, Hazardous Wastes Disposal
System

All the industries which are covered under the provisions of Water (Prevention &
control of Pollution) Act, 1974 and Air (Prevention & control of Pollution) Act,
1981 are required to obtain ‘consent to establish’ for establishment of any new
unit or before commencing construction / laying of pipelines and ‘ Consent to
Operate’ before commencing supplies of the products in the public premises.

The units after establishment are required to obtain ‘consent to operate’ before
commencing commercial production and supplies. Consent to operate is also
required for all the existing units which are covered under the provisions of
Water (Prevention & control of Pollution) Act, 1974 and Air (Prevention & control
of Pollution) Act, 1981. Consent to establish is one time and required only at the
time of establishment of new unit or before carrying out expansion
/modernization in the existing unit whereas consent to operate is granted for a
specific period and needs to be got renewed every time after expiry.

For obtaining NOC from MPCB, the organizations are required to apply in
prescribed application form and also required to attach some documents as
prescribed by the MPCB

After detailed scrutiny of the applications by the regional offices of the MPCB the
application is forwarded to head quarter of the MPCB wherein deliberations are
held in the clearance committee meeting (normally held once in three months)
and the proposal is either cleared or rejected. Once the proposal is cleared
initially Consent to Establish is granted to the industry which is valid for a period

38
of three years and within these three years the organization has to initiate the
construction of the project. Once the construction phase is complete, before
starting actual supplies of the product the industry has to obtain Consent to
operate in a similar fashion following the steps as in case of Consent to
Establish.

MGL is accredited with ISO 14001 certificate since Nov. 2003. As per the
Hazardous waste (Management & Handling) rules 1989 as amended in May 2003
vide notification dated 20th May, 2003 by Ministry of Environment and Forests,
New Delhi, the following waste is considered under hazardous waste category:
 Empty Ethyl Mercaptan Drums
 Used Filters from Compressors
 Activated Carbon.
 Cotton waste containing waste oil
Hazardous wastes generated are mandatory to be stored, treated, transported
and disposed as per the Manufacturing Storage & Import of Hazardous
Chemicals
At MGL also Hazardous waste are stored in the designated area. Generating dept
files in the relevant form for storing the hazardous material. At the time of
disposal of Hazardous waste to M/s Mumbai Waste Management form 13 is filled
and copy is sent to MPCB also.

 Occupational Health & Hygiene : Medical Officer, First Aid, Ambulance,

OHC, Periodical Check-ups

 Storages and Warehousing : Tank Farms, Bullet Yard, Godowns, FLP

Fittings, Earthing / Blending, Earth Pits, Sprinklers

39
 CHAPTER 13

P.P.E: Availability, Use, Training, Comfort

Mahanagar Gas Limited (MGL), a pioneering in business of Piped Natural Gas

distribution, therefore steel and PE pipe line laying is main project activities for
supply of gas to customer, so during construction job there are several hazards
which can not eliminated through engineering and /or administrative controls,
PPE must be used to protect the eyes, face, head, feet, hands, arms, body, ears,
and lungs.

PPE should always be regarded as the ‘last resort’ to protect against risks to
safety and health; engineering controls and safe systems of work should always
be considered first.

Personal Protective Equipment is required when there is a reasonable probability

of injury that could be prevented by the use of such equipment

Following listed PPEs suitably categorized for standardization and

understanding:

Head Protection - Hard hats (Safety helmets)

Safety Footwear – Safety shoes / boots
Hearing Protection – Ear plugs / Ear muffs
Face Protection - Eye protection (Safety glasses/goggles), Face shield
Protection - Gloves
Respirators
Fall Protection
Special Clothing

The Annexure I attached which provides guidance on selection of various

PPE’s based on type of usage.

40
Real situation at site:

MGL project work constituent Steel, PE Pipeline laying underground at BMC

roads, private roads and society premises also. It includes Excavation work, by
manually using crowbar, compressor-breaker machine, JCB etc. Many other
operations like lifting of pipe, laying of pipe in trench, Steel pipe welding, PE pipe
jointing by using fusion machine. Sometimes confined space entry permit should
also require for this work. (i.e. below 1.8mtr depth). So Workers, Supervisor, Site
Engineer used PPE like Safety Helmet, Safety Shoes, Gloves, Ear Plugs, Safety
Goggles, Face Shield, etc.

MGL also install G.I, ERW pipes on buildings, towers for domestic connections.
In that process manually handling of pipes, threading, welding, clamping etc
processes involved. For installation of these pipes on buildings & towers, work at
height permit should have been issued by authorised person at site. In this
process PETZL life saver equipment, permanent structure at building terrace,
electrical equipment, PPE like Safety Helmet, Safety Shoes, Gloves, Ear Plugs,
Safety Goggles etc, proper barricades, First aid box, Fire extinguisher, Water
bottle should be checked by site supervisor and site engineer at site. After
inspecting all these equipment work should start.

After laying and installing of Steel, P.E, and G.I./ERW pipe lines, it should
commissioned & tested by site engineer and then charged. After charging the gas
in building our team of workers, supervisor and engineer go to customer house
for installation of meter & copper pipe. In This process bending & soldering of
copper pipe should be done. So they should have to take safety precaution like
wear PPE, cut off gas supply, only skill person should do work etc. After this take
testing of copper pipe, meter, regulator by water manometer. Then only connect
the rubber tube to appliance. After completion of work, supervisor give demo to
customer of using/handling the gas and make them satisfied

41
 CHAPTER 14

Risk Assessment: HAZOP, JSA, Audit,

Inspection HIRA etc.
HIRA:
HAZARD: Hazard is defined as a characteristic or group of characteristics that
provide the potential for a loss.
Flammability or toxicity are examples of such characteristics.
It is Source, situation, or act with a potential for harm in terms of human injury
or ill health or a combination of these
MGL’s methodology for hazard identification and risk assessment has been
defined with respect to its scope, nature and timing to ensure it is proactive
rather than reactive and it also provides for the identification, severity,
prioritization and documentation of risks, and the application of controls, as
appropriate
Each department has identified their activities minutely at each work place
which could cause harm to the people and surroundings and then the risk
assessment has been done based on these activities to calculate the criticality of
the risk. The risk is calculated by taking into account the existing control
measures associated with the activity.
The activities are classified based on:
 routine and non-routine activities (like start up/shut down & emergency
situations);
 any applicable legal concerns / obligations relating to risk assessment and
implementation of necessary controls;
 activities of personnel having access to the workplace (like contractors and
visitors);
 Human behavior, capabilities and other human factors.
 identified hazards originating outside the workplace capable of adversely
affecting the health and safety of persons under the control of MGL within
the workplace;

42
  hazards created in the vicinity of the workplace by work-related activities
under the control of MGL;
 infrastructure, equipment and materials at the workplace, whether
provided by M G L or others;
 changes or proposed changes in M G L, its activities, or materials;
 modifications to the OH&S management system, including temporary
changes, and their impacts on operations, processes, and activities;
 the design of work areas, processes, installations, machinery/equipment,
operating procedures and work organization, including their adaptation to
human capabilities

Risk assessment is done by using a 5*5 matrix for Impact Vs Severity. The
ratings range from 1 to 5 the impacts & severity and is described in the table
below:

Risk Rating Card

Table 1 - Impact or Consequence criteria (I)

Impact Category Extent Of Injury Extent of Damage Legal

Occupational illness
 Significant Loss  Non compliance with  Permanent total
Severe 5  Multiple Fatalities Outside premises legal or certification disability to more than
effecting public requirement one person
 Single Fatality
Permanent total Disability
Major 4  Permanent Total --- --
to a person
Disability
 Major or serious
Injury
Serious 3  Permanent Partial ---- -- Permanent partial disability
Disability
 Lost Time Injury
 Restricted Work Day Temporary Impairment
Medium 2 ---- --
 Medical Treatment
 No potential violation
Minor 1  First Aid Treatment  Inside premises with legal or certification Not Recognized
requirements

Table 2: Likelihood or Probability criteria (P)

Likelihood Category Criteria

The event is expected to occur in most circumstances, incident could happen daily to
Almost certain 5
weekly

The event will probably occur in most circumstances, incident could happen weekly to
Most likely 4
monthly

The event will probably should occur at some time, incident could happen monthly to
Likely 3
yearly

Moderate 2 The event may occur only in exceptional circumstances

Unlikely 1 The event is not likely to occur

43
All such unacceptable risks are controlled by applying the principles given
below:

 Prioritize the risks and first control those, which have a major
risk impact on MGL
 Deal with Major risks in a structured and systematic manner so
that the actions taken are legally defensible
 Complicated systems are avoided when drawing up control
measures. Pragmatism is kept in mind
 Staff is invariably involved, in order to make sure that what is
proposed will work in practice and will not introduce any new
hazards

The hazards posing legal concern are assumed to be not acceptable and hence
the corresponding control measures in the form of all the necessary compliance
of legal aspects is maintained thoroughly for e.g. Periodic Testing of Cascades
etc…and all such activities bearing legal concerns.
When determining controls, or considering changes to existing controls,
consideration is given to reduce the risks according to the following hierarchy:

a) Elimination;

b) Substitution;

c) Engineering controls;

d) signage/warnings and/or administrative controls;

e) Personal protective equipment.

Within the hierarchy use of Personal Protective Equipment {PPE) is always

regarded as the last resort.

The additional risk control measures drawn up to reduce the risk are recorded
in a suitable Format. These are set as OH & S Objectives based on which O H
& S Management programmes, Operational Control Procedures and Emergency
plans are drawn up as appropriate to closely monitor the additional control
measures.
Thereafter fresh risk assessment is carried out in the same manner as done
earlier and the controlled level of risk calculated to verify whether the
measures taken have now brought the risk rating within the acceptable limit.

CHAPTER 15
44
 Work Permit Systems
Prior to carrying out any work, the person in charge of the site must carry out a
Risk Assessment to satisfy himself or herself that all reasonable and practicable
precautions have been taken to minimize risks or eradicate any potential
hazards.

A Permit to Work is required where a risk assessment identifies there is

considerable risk either to plant or personnel calling for special safeguards, and
shall be issued for:

 Work in a known asphyxiating atmosphere

 Entry into confined spaces, i.e. valve chambers, deep excavations

 Hot work, e.g. burning, welding, grinding on live or decommissioned

plant

 Hot Work on the live steel network.

 Work in plant containing toxic or hazardous material.

 Work on or near > 415 V electrical system or equipment.

 Working at height.

 Excavation Activities of all nature

 Activities where work on the online gas flow line is required including
maintenance activities on the pipelines and in CNG Compressor
Stations

 Other work where a risk assessment identifies the need for a Permit to
Work.

45
Types of Work Permits Followed in MGL:
1. Confined Space Entry Work permit.
2. Testing Charging and Commissioning.
3. Permit to Work at Height.
4. Hot Work Permit.
5. Permit to Work for Gas / Electrical Isolation for CNG Station.
6. Electrical Work Permit
Ref Annexure II for Formats of above mentioned work permits
The raising, issue and approval of Permits shall be organized such that due time
is available to inform all other (possibly) affected persons, e.g. construction
management, displaying on main and local notice boards.

The Authorizing Person should issue the Permit to Work on site at the location of
the proposed works following a personal inspection.

A permit to Work shall be issued to the Competent Person who must be in

continuous attendance at the site and who is deemed responsible for the works
being undertaken.

The Authorizing Person shall visit site (when issuing a Permit to Work) to confirm
that the conditions of the Permit can be met.

They should brief the Competent Person, advise any other persons (on or off site)
who may be affected accordingly and satisfy themselves that the work can
proceed in a safe manner.

The Permit to Work is not transferable, if the Competent Person is unable to

continue the work (e.g. due to illness) the Authoring Person shall brief and
nominate a new Competent Person and endorse the changes on the Permit.

The initial period of validity of the Permit to Work shall not exceed 7 days, and
the permit will be issued and signed off daily.

Should a Permit to Work be required beyond 7 days, then the site shall be
revisited by the Authorizing Person or their representative to assess and confirm
that the Permit conditions have NOT changed.

The pink copy of the permit will remain with the Competent / Issuing
department / Person.

The yellow copy will be issued to the agency / person carrying out the work and
should be displayed at site at all times

46
The filled in white copy shall remain in the book with the Authorizing Person and
the completed books to be returned to the HSSE department for retention.

The HSSE department shall issue the new book of the work permit only after
receipt of the completed filled in book issued earlier for the purpose.

Simultaneously all the work permit entries are to be made in the WPTS (Work
Permit Tracking System) before the execution of the work.

Issued Permits shall be displayed at the relevant worksite and within the Permit
Office and/or Control Room.

The PTW, certificates and risk assessments are retained at site by the Issuing
Authority for at least 30 days after completion and then archived for a specified
period of two years to enable an effective monitoring and audit process.

Audits and regular monitoring of the Permit to Work procedures shall be carried
out in accordance with MGL’s audit plan.

47
 CHAPTER 16

FIRE PREVENTION / CONTROL:

EXTINGUISHERS, HYDRANTS
At MGL here are areas identified which has chances of potential fire.

 FIRE ON STEEL/PE LINE

 FIRE TO ODARANT (ETHYL MERCAPTAN)
 FIRE IN COMPRESSOR
 FIRE IN D.G SET
 FIRE IN LCV FILLING POINT
 FIRE IN DISPENSING AREA

Various fire prevention and protection equipment provided in MGL various office
and City Gas station

a) Fire Hydrant
b) Fire Alarm system
c) CO2 Flooding system/FM 200 system
d) Fire extinguisher
e) Smoke Detector
f) Emergency Hooter
g) Fire Extinguisher
h) First Aid Box

ACTIONS TO BE TAKEN FIRE ON STEEL/PE LINE:

1. Inform Emergency control room.

2. Emergency control room will inform & take action as per Emergency
Preparedness plan.

3. Onsite Incident controller (responsible person at site) will take following

action.

4. Barricade the affected area

5. Ensure the operational people on site are required with necessary PPE.

6. Assess the situation to see any probable loss to life & property.

7. Isolate the section. Close up-stream downstream valves and all branch
Valves from the section

8. In conjunction with Mumbai Fire Brigade cool the nearby affected area by
spraying water and if required extinguish the fire.

9. Carry out necessary rectification work as per 1.2 & 1.3 procedure

10. Inform Emergency Control room and HOD about the completion of
Emergency.

11. Collect solid wastes and other scraps and deposit it in CGS scrape yard.
Confirm emergency is over/complete and inform it to emergency control
room.

48
ACTIONS TO BE TAKEN IN CASE OF FIRE IN ODARANT (ETHYL MERCAPTAN)
AREA:

1. Inform Emergency control room

2. Emergency control room will inform & take action as per Emergency.

3. Onsite incident controller will take following actions

4. Barricade the affected area.

5. Ensure the operational people on site are required with necessary PPE, and
breathing apparatus.

6. Inform Mumbai Fire Brigade.

7. Use ABC type fire extinguishers & try to extinguish the fire

8. carry out necessary rectification work

9. Send the solid waste to authorized agency for proper disposal

10. Confirm the emergency is over/complete and inform to the incident

control team.

ACTIONS TO BE TAKEN IN CASE OF FIRE IN COMPRESSOR AREA:

1. Inform control room

2. Control room to inform and take action as per emergency response plane.

3. Stop the compressor.

4. Switch off the compressor main supply in electric room.

5. Close the gas inlet valve.

6. Extinguish the fire by using fire extinguishers. (use co2 in case of fire in
electrical panel and use DCP/ABC powder in case of fire in compressor)

7. once the fire is fully extinguished then collect the extinguish powder and
deposit in designated location for disposal

8. Segregate the fire waste in to hazardous and non hazardous waste and store it
accordingly in the demarcated bins.

ACTIONS TO BE TAKEN IN CASE OF FIRE IN D.G SET:

1. Inform control room

2. Control room to inform and take action as per emergency response plane.

3. Stop the d.g.set.

4. switch off the DG set main

5. Extinguish the fire by using fire extinguishers. (use co2 in case of fire in
electrical panel and use DCP/ABC powder in case of fire in d.g.set)

49
6. once the fire is fully extinguished then collect the extinguish powder and
deposit in designated location for disposal

7. Segregate the fire waste in to hazardous and non hazardous waste and store it
accordingly in the demarcated bins.

8. dispose the extinguish powder to Mumbai waste management ltd. and fill form
no. 3,8, & 9 as per hazardous waste management rule 1989

ACTIONS TO BE TAKEN IN CASE OF FIRE AT LCV FILLING POINT:

1 Inform control room.

2 Control room to inform and take action as per emergency response plan.

3 Stop the gas filling.

4 Extinguish the fire by using DCP/ABC type fire extinguishers.

5 Once the fire is fully extinguished then collect the extinguish powder and
deposited in designated location for disposal.

6 Segregate the fire waste in to hazardous and non hazardous waste and store it
accordingly in the demarcated bins.

7 Dispose the extinguish powder to Mumbai waste management ltd. and fill
form no. 3, 8, & 9 as per hazardous waste management rule 1989.

ACTIONS TO BE TAKEN IN CASE OF FIRE IN DISPENSING AREA:

1. Inform control room

2. Control room to inform and take action as per emergency response plan.

3. Stop the gas filling.

4. Switch off dispensing power

5. Extinguish the fire by using DCP/ABC type fire extinguishers. once the fire is
fully extinguished then collect the extinguish powder and deposit in
designated location for disposal

6. Segregate the fire waste in to hazardous and non hazardous waste and store it
accordingly in the demarcated bins.

Dispose the extinguish powder to Mumbai waste management ltd. and fill form
no. 3,8, & 9 as per hazardous waste management rule 1989.

50
 CHAPTER 17

Emergency Response Procedures

An exhaustive Emergency Management Plan to combat emergency situation in
order to effectively make use of available resources. It is designed to identify the
organizational and operational details to effectively combat emergency of any
type and has been planned to delineate functions of various concerned
departments and agencies for the operational responsibilities. It lists among its
objectives, the operational responsibilities, the development of appropriate
system for detection and reporting of leakage and assurance of prompt response
to restore normalcy. Also to be ensured is that complete and accurate records
are maintained of all expenditures to facilitate the recovery of costs

In the event of an incident occurring the immediate action is to respond to the

emergency to safe guard life and property, then to bring the situation under
control followed by any remedial action to repair or restore the situation back to
its original or safe condition.
The procedures that facilitate this are called Emergency Response Plans ERP.

MGL has produced an ERP for all the foreseeable incidents that may occur in
undertaking its operations. Where relevant they are written in English and
Hindi.

Types of emergency occurrences:

Hazard Particulars

1 Fire & Explosions All types of fires, smoking insulation & auto ignition

Spillage of Ethyl Mercaptan (highly flammable toxic and

2 Major Spillage
Corrosive material

Major collapse of an equipment / building having potential

3 Structure Collapse
to cause severe loss of life & property.

Water logging above 2 feet resulting in machinery / utilities

4 Floods
getting submerged in water.

Natural calamity, having potential to cause severe loss of

5 Earthquake
life & property.

Leakage of gas from flanges due to failure of gaskets or over

6 Natural Gas leak
pressurization.

Bomb threat warning to MGL by written or oral

7 Bomb Threat
communication.

51
 Off site disaster /emergency situations:

Sr.
Hazard Particulars
No.
All types of fires, smoking insulation & auto
1 Fire & Explosions ignition
Leakage of natural gas due to damage to the
Major leakage (4 high pressure Steel line & medium pressure
2
bar & 19 bar) polyethylene line by third party excavation
work.
Rupture of safety
3 Gas release due to rupture of safety disc.
disc.

Pipeline Hazards – Initiating and Contributing Causes

Human Errors Equipment System Or External events

failures procedural
failures
Piping Internal corrosion Inspection Accidental
operations External corrosion Maintenance excavation
Hot tapping Bad welds Communication Earthquake
Slug operation Fatigue Leak Detection subsidence
Repair /
Replacement Failure of cathodic Emergency Avalanche
Of a section of a Protection Temporary repair
line Control system Lightning
Preparation for Failure
Maintenance Brittle fracture Fire
Valve operation Support failure Vandalism /
Construction Sabotage
defects Railroad derailment

Rail / Road crossing

The U.S. Department of Transportation regularly publishes statistics of gas

pipeline failure, which record the type of failure, type of release, and other data. In
Europe, the major gas companies publish failure rate data under the European
Gas Pipeline Incident Data Group. The European oil companies also publish
annual failure rate data under the organization CONCAWE, When considering all
these database together one broad conclusion comes out of the statistics, despite
some variation caused by dissimilarity in the type of data collected – Failures
occur in roughly equal proportions in three broad categories:
 Failure caused by external mechanical interference
 Failure caused by corrosion defects
 Failures caused by miscellaneous factors such as pipe material defects,
natural hazards or operator error.

Outcome Cases and Consequences – General Description:

52
In case of any accidental release of the gas, outflow emerges in the form of a
turbulent free jet, initially with a high momentum. If the jet path is unobstructed
the hydrocarbon-air mixture gets diluted to the Lower Explosive Limit (LEL) within a
relative short distance due to air entrainment by the jet. No adverse consequences
result if un-ignited. If the turbulent free jet ignites, then the outcome is a jet flame.

A jet flame hitting humans will cause fatality due to high thermal radiations and
plant / material can suffer secondary damage due to impinging jet flame. A
colliding jet immediately loses its momentum with loss of air entrainment. The
vapour cloud will then begin to disperse downwind. Te dispersion phenomena
largely depends upon weather stability class and wind speed apart from other
factors such as ground roughness factor, terrain etc. there can therefore be two
outcome cases due to accidental gas release.
 Turbulent free jet (non – colliding)
 Turbulent free jet (colliding) followed by dispersion

The dispersing vapour cloud if ignited will result in a) flash fire b) vapour cloud
explosion with overpressure. Methane or methane rich mixtures have low reactivity.
From experience it is known that the vapour cloud explosion overpressure is not
likely to exceed 0.1 bar for semi – confined explosions.

For over ground mains in the open areas the likelihood is that of turbulent free jet
(non – colliding) will have limited consequences. In case of buried pipelines the
overburden will get undermined in course of time (depending upon the leak size).
Nevertheless an unobstructed jet is unlikely. The entire release will emerge as a
dispersing vapour cloud.

In case of a delayed ignition of the dispersing vapour cloud two outcomes are likely.
In one case the result is a flash fire without overpressure. Everyone in the burning
cloud will die due to extremely high thermal load, though the duration of flash fire
may be a fraction of one second. No adverse outcome occurs outside the cloud. In
the second case a vapour cloud explosion occurs with overpressure. For this to
happen partial confinement in the cloud path is necessary. As mentioned earlier for
methane rich mixture the maximum overpressure that can be generated is 0.1 bar.
At such an overpressure 10% of the buildings are likely to collapse and one in eight
persons in the buildings are likely to suffer fatality. In other words for 0.1 bar
overpressure 1% fatality may result. For various vapour cloud explosion scenarios in
this study 0.1 bar overpressure circles have been plotted. Within the 0.1 bar
overpressure circle people are likely to suffer injuries due to falling debris that would
need rescue and medical treatment services.

53
Mock Drill Plan 2013:

MOCK DRILL PLAN 2013

SR. Scenario Plan Status
1 Spillage of Ethyl Mercaptan at CGS Mahape Jan- Completed on
March 8th March
2013 2013
2 Dispensor hose disconnected (CNG_RO) Jan- Completed on
Tube NMMT Retail Outlet March 8th March
2013 2013
3 Dispensor hose disconnected (CNG_RO) April- Completed on
Tardeo June 8th June 2013
2013
4 Medical emergency at Work at Height PE July-Sept Completed on
site 2013 12th Dec 2013
5 Dispensor hose disconnected (CNG_RO) Oct-Dec Completed on
City Gate 2013 14th Nov 2013

CHAPTER 18

Safety of Contractors/Visitors

54
DO’S:
1) In case of an emergency don’t panic.
2) Assemble near assembly point, back side of driver’s cabin Area floor wardens will
escort you towards the same.
3) Safety shoes, helmet & appropriate PPE in designated areas are mandatory inside
the plant premises excluding the administrative building.
4) Maximum speed limit inside factory premises is 10 km/hr.
5) Report any incident, hazard/near miss or safety suggestion through the ‘SEE
THINK DO’ card.
6) If you discover the fire, sound the alarm-break the glass on the nearest fire alarm
call point. [Every Monday 1030 hours fire alarm testing. Don’t panic.]
7) Follow instruction of the security or floor wardens in case of any emergency.

DONT’S:
1) No smoking in CGS office near CGS premises
2) Switch off the mobile phone when entering the CNG filling area.
3) Do not use lift in case of fire/any emergency use the staircase.
4) Visitors not allowed in the plant area and the CNG compressor area classified as
restricted area. Please do not enter the premises without an escort from MGL.
5) Photography is not permitted inside the plant premises for the visitors without
permission from the plant in charge.
6) Don’t touch any pipeline or equipment without permission.

Above all instructions should be followed by contractor’s personnel and visitors.

CHAPTER 19

Findings & Recommendations

55
FINDINGS:
1. Zhoola used for work at height job which is not quite technical.
2. Communication about rescue method is missing at sites.
3. Nose mask not used during welding activity in trench at steel site & carrying
out welding activity in well ventilated area.
4. Sufficient area information signage not available in City Gas.
5. Workers are not quite comfortable in wearing helmet.

RECOMENDATIONS:
1. Work at height activity is carried out at MGL site for providing the PNG
Supply in the residential area. At present Practice Zhoola is used by the
plumber or worker for working in such condition. Zhoola is a kind of plank
tied with ropes at all the four ends and is then hanged from top of the roof
where is one side of the rope is tied with the permanent structure Though
Zhoola is safe still some alternative source can be opted which is more safer
and economical. Alternative sources could be:
a. Scissor Lift :
b. Mobile Platform
c. Scaffolds etc
2. Onsite awareness session related to rescue methods need to be conducted at
sites also it can be included in the training module which is imparted at all
levels.

a. During Excavation activity trench collapse may occur which can lead to
injury of personal working at site. In such cases site personal must be
aware of the measures to be adopted for rescuing the personnel, he
should know the proper chain of communication to inform about the
incident.

b. During work at height tools may fall on person which lead to any body
injury. In such situation personnel at site should know the right
methods of evacuation from site at safe place.

3. Welding is a fabrication or sculptural process that joins materials, usually

metals or thermoplastics, by causing coalescence. This is often done by melting
the work pieces and adding a filler material to form a pool of molten material
that cools to become a strong joint, Many different energy sources can be used
for welding, including a gas flame, an electric arc, a laser, an electron beam,
friction, and ultrasound. At MGL welding is done mostly in open air and in
confined space. Regardless of location, welding remains dangerous, and
precautions should be taken to avoid burns, electric shock, eye damage,
poisonous fumes, and overexposure to ultraviolet light. Nose mask is respiratory
PPE used for protection of respiratory system, use of nose mask can prevent

56
 from harmful fumes and welding should be carried out in welding hoods which
has good quality of ventilation and exhaust system.

4. An information sign is a very legibly printed and very noticeable placard that
informs people of the purpose of an object, or gives them instruction on the use of
something. Visitors and contract employees visit MGL office premises on day to
day basis as they are new they may not be aware of some of the places like
assembly point and other facilities. Display of various signage’s are helpful to
identify the require location easily.

5. A helmet is a form of protective gear worn on the head to protect it from injuries.
There are various type of hazards present at sites during construction and
process activities, helmet protect form Impact from falling or flying objects, Head
bumping or laceration, Chemical drips or splashes, so use of helmet is mandatory
in MGL premises.Though helmets are being used at MGL sites but it was found
that few workers are not comfortable in working while wearing the helmets.

6. Some modification in Helmet design may be compatible. Ventilation space can be

provided at the side with some cover so that even while working during day time
proper air circulation can help eliminate the sweating problem.

CHAPTER 20

CONCLUSION

57
We have prepared this project after the study of safety requirements in gas
distribution prescribed by various legal agencies have found that gas distribution
industry have lot of scope for the improvement approved on account of various safety
requirement.

The main hazards to deal in a gas distribution industry are Leakage of pressurised
gas, Spillage of ethyl mercaptan, ground excavation, lifting operation, Confines space
job, Work at height and driving.

Thus these are the major hazards carried with distribution of gas; also we come
across various small accidents occurring due to unsafe conditions and unsafe acts.
Thus we should provide safe working conditions and proper training for the
employees and contractor employees to avoid and prevent any incident in the
industry to run the industry with full efficiency.

58
 CHAPTER 21
Annexure – I
PPE Specifications (Guidance)

PERSONNEL PROTECTIVE EQUIPMENT SPECIFICTIONS

PERSONNEL PROTECTIVE
STANDARD DESCRIPTIN TYPES OF USE
EQUIPMENT
a) Plastic or
polycarbonate shell
b) Replaceable, fully
a) Impact from
adjustable harness,
falling or flying
sweat band and
BS EN 397 or objects.
Head textile cradle straps.
1 Hard Hats equivalent b) Head bumping or
Protection c) Slotted accessory
-IS 2925 laceration.
mounting points
c) Chemical drips or
d) Accessories include:
splashes
chin strap, ear
defenders, and face
Shields.
a) Leather top with steel a) Risk of injuries
BS EN 345 or toecaps (200 joules) from falling objects
Safety Boots
equivalent b) Oil Resistant Sole and penetration
And Shoes
- IS:10667 c) Anti-static b) Rough ground
Protective d) Positive grip c) Oily work place
2 Footwear a) PVC or nitrile rubber.
a) Work carried out
b) 200 joules steel toe
BS EN 345 or in wet or slippery
Rubber Boots protection
equivalent conditions
(Wellington) c) Resistant to oil and
- IS:5557 b) Risk of chemical
chemicals
splash
d) Maximum grip sole
3 Protective Coveralls 100% Cotton a) Sleeves: specify long Protection against
Clothing (Including or short cold, wind and
Lining) Non- b) Zip: concealed two- general dirt.
Shrink Fabric way brass zip.
To Weigh 295 G c) Stitching: thread
/ M2. 100% cotton
Blue/Fluoresce d) In case of fire
nt orange retardant ‘numex’
Recommended cloth utilize
Non – Shrink compatible thread
Fabric Of e) Hems double
Nomex Make. stitched.
f) Elasticized belt
section.
g) Pockets: back
trousers, dimensions:
length: 19 cm /
width: 17 cm
(approximately)
h) Front breast,
dimensions:
length: 16 cm /
width: 14 cm
 (approximately)
i) Side trouser,
dimensions:
length: 20 cm /
width: 15 cm
(approximately)
j) Access slot to enable
access to
undergarment
pockets.
k) Collar: double
thickness.
Logo of MGL on left
breast pocket, MGL,
and sample to be
Provided by MGL.
m)Logo of MGL on back
side of coverall sample
l) to be provided by
MGL
PERSONNEL PROTECTIVE EQUIPMENT SPECIFICTIONS
PERSONNEL
STANDARD DESCRIPTIN TYPES OF USE
PROTECTIVE EQUP.
a) Made of waterproof,
durable fabric.
b) Available in either
one or two piece
Wet Weather suits. Protection against
4
Clothing c) Must incorporate a cold or rain.
hood.
Should not be affected by
Protective oil and grease.
Clothing a) One piece, hooded
suits.
BS 7184 or b) Must have good a) Body protection
tearing, cracking and when handling
Chemical equivalent
5 abrasion resistance most oils,
Suits - IS 4501 as well as chemical chemicals and
hold out. acids.
c) PVC coated nylon or
cotton.
a) Natural or synthetic
rubber. a) Protection against
b) Gloves or gauntlets electrical shock.
Rubber BS EN 60903 for extra protection b) Tested to 5 KV for
6 Gloves or equivalent must be marked at working to 650v
(Electrical) – IS 4770 the time of initial or to 15 KV for
testing showing size working to 3.3
Hand
and date of test. KV.
Protection
7 Rubber BS EN 374 or a) Natural rubber, a) Chemical
Gloves equivalent neoprene, nitrile or protection.
(Chemical) – IS 4501 pvc
b) Good wet grip
c) Flexible and
comfortable

60
 BS EN 420 or a) General Use.
a) Leather Palm And/or b) Limited Hand
8 Rigger Gloves equivalent– IS
b) Sturdy Fabric. Protection.
6994 (PART 1)
B.S 7028 / BS
EN 166 - 167 - a) Lens Clear Or Dark.
b) Side Shields.
Eye Safety 168 GRADE 2 a) General Dust
9 c) Replaceable Lenses.
Protection Glasses IMPACT or Protection Only.
d) Adjustable Side
equivalent Arms.
– IS 8520
a) Contoured
B.S 7028 / BS fit /
a) Protection against
EN 166 - 167 - adjustable head
chemical
band.
Safety 168 GRADE 1 splashes.
10 b) Wide vision.
Goggles IMPACT or b) Grinding.
c) Discrete ventilation.
equivalent d) PVC or polycarbonate
– IS 8520 lenses.
PERSONNEL PROTECTIVE EQUIPMENT SPECIFICTIONS
PERSONNEL
PROTECTIVE STANDARD DESCRIPTIN TYPES OF USE
EQUIPMENT
B.S 7028 / BS
EN 166 - 167 – a) Lightweight.
168 GRADE 2 b) Made a) Total Eye and
In Acetate,
Face Protection.
11 Face Shields IMPACT or Polycarbonate
b) Handling
equivalent c) Can Be Secured To
Chemicals.
– IS 8521 Front Of Hard hats
(PART 1)
B.S 1542 a) Fiber-glass shields.
CLEAR LENS b) Hand held or helmet
mounted. a) Welding, cutting
GRADE 1
Welding c) Lens holders and etc.
12 IMPACT or
Shields welding filters are
equivalent supplied depending
- IS 8521 (PART on the job
2) requirement.
13 Hearing Ear Muffs BS EN 352 - 1 a) Consist of 2 rigid a) High level of
Protection or equivalent cups fitted with hearing
– IS 8520 absorbent material. protection.
b) Fit to the head by b) Check the
means of soft rings manufacturer
(ear seals). attenuation chart
c) Seals must be foam for the level of
filled. attenuation and
d) Ear defenders must the standard
be compatible with deviation.
the hard hats in use c) Stated
attenuation will
be achieved only
if equipment
properly fitted
and maintained.

61
 a) Good level of
hearing
a) Foam ear plugs
protection.
which are
b) Check the
compressed in order
manufacturer
to fit into the ear and
attenuation chart
expand to maximize
for the level of
protection.
attenuation and
BS EN 352 - 2 b) Molded pre-shaped
the standard
14 Ear Plugs or equivalent plugs of rubber for
deviation.
– IS 8520 insertion into the ear
c) Stated
canal.
attenuation will
c) May be fitted with a
be achieved only
cord.
if equipment
d) Exist also as ear caps
properly fitted
(plugs fitted with thin
and maintained.
plastic band).

a) Disposable
respirators are made
from filtering
materials and are at
BS EN 149 or a negative pressure.
equivalent b) Half mask respirators a) To be used only if
Respirator – IS 8522 are designed to cover sufficient oxygen
nose and mouth. is present.
y (CHEMICAL
c) Full face piece b) Protection against
15 Protective Respirators CARTRIDGE);
respirators are a range of dust,
Equipmen IS 8523 designed to cover gases and vapors.
t (CANISTER nose, mouth and
TYPE –GAS eyes.
MASKS) d) It is imperative that
the correct filter
medium is used for
the particular
contaminant.
PERSONNEL PROTECTIVE EQUIPMENT SPECIFICTIONS
PERSONNEL
PROTECTIVE STANDARD DESCRIPTIN TYPES OF USE
EQUIPMENT
a) Escape Packs (5
a) It consists of a face to 15 minutes)
piece or a hood by are used only to
BS 4667 / BS which the wearer can leave the work
breathe compressed place in case of
EN 137 / BS
Breathing uncontaminated air. an emergency.
4275 or
Apparatus b) Self contained BA’s b) BA’s with over 30
equivalent include air cylinders minutes capacity
– IS 9623 to be carried on the and/or an airline
back. link may be used
for work or for
rescue purposes.

62
 a) Pole belts comprising
an adjustable body a) Safety belts limit
belt combined with a the distance of
pole strap, which any fall thereby
may be integral or minimizing the
adjustable. risk of injury.
B.S EN 354 or b) General purpose b) It is very
16 Safety Belts equivalent belts which are important that
– IS:3521 provided with a line whenever a safety
or a lanyard to be belt is provided
attached to the there is an
structure allowing a effective mean of
free fall of fixing it to the
respectively 600 mm structure.
and 1.2 m.
a) Safety harness
Fall limits the
Arrestor distance of any
fall thereby
a) Chest harnesses, minimizing the
comprising a chest risk of injury.
belt and shoulders b) It is very
straps fitted with a important that
lanyard, which will whenever a safety
B.S EN 361 or limit the fall to 2 m harness is
Safety
17 equivalent or less. provided there is
Harness b) General purpose an effective
- IS:3521
harness with means of fixing it
shoulder and crutch to the structure.
straps and lanyard c) A safety harness
limiting the fall to 2 gives greater
m or less. protection than a
safety belt in the
event of a fall and
is therefore
preferable.

63
 Annexure – II
Work Permits Formats

64
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