Upload
others
View
23
Download
5
Embed Size (px)
Citation preview
GAIL (India) Limited
Vaghodia
INTEGRATED MANAGEMENT
SYSTEMS MANUAL
IN LINE WITH REQUIREMENTS OF
ISO 9001:2008, OHSAS 18001:2007 & ISO 14001: 2004
DOC NO : AM01
ISSUE NO.: 02; DATE : 01.05.2012
REV. NO. : 04; DATE : 01.06.2016
AUTHORISED HOLDER:
COPY No.:
GAIL (India) Ltd.,
GIDC INDUSTRIAL ESTATE VAGHODIA, DISTRICT VADODARA-391760
GUJARAT
REG. OFFICE : 16, BHIKAIJI CAMA PLACE, R. K. PURAM, NEW DELHI 110 066
======================================================================
NO PART OF THIS DOCUMENT IS TO BE REPRODUCED IN ANY OR BY ANY MEANS,
FOR ANY PURPOSE, WITHOUT THE EXPRESS WRITTEN PERMISSION OF GAIL
===========================================================
GAIL (India) Ltd. Vaghodia. INTEGRATED MANAGEMENT SYSTEM MANUAL
TITLE: CONTENTS
DOC. No.: CH AM01.1 REV. NO.: 02 REV. DATE: 26.09.2014 PAGE NO. 1
Sl. No.
Document Ref. No.
ISO 9001:2008 Clause No.
ISO 14001: 2004
Clause No.
OHSAS 18001:2007 Clause No.
TITLE No. of Pg.’s
Rev. Status
01 CH AM01.1 Contents 03 02
02 CH AM01.2 Abbreviations 01 00
03 CH AM01.3 Approval &
Issue 01 00
04 CH AM01.4 Amendment
History 02 04
05 CH AM01.5 Authorized
Holders 01 00
06 CH AM01.6 Company
Profile 07 01
07 CH AM01.7 1 1 1 Scope 01 00
QSHE Management System Requirements
08 CH AM01.8
4.1 4.1 4.1 General Requirements
09 CH AM01.9 5.3, 5.1 4.2 4.2 Policy
5.4 4.3 4.3 Planning
10 CH AM01.10
- 4.3.1 - Environmental Aspects
11
CH AM01.11
- - 4.3.1
Planning for Hazard Identification, Risk Assessment & Control
12
CH AM01.12
5.2,7.2.1 4.3.2 4.3.2 Legal and other Requirements
13
CH AM01.13 5.4.1, 5.4.2, 8.5.1
4.3.3 4.3.3 Objectives and Targets and Programme(s)
7.0 4.4 4.4 Implementation and Operation
14
CH AM01.14 5.1, 5.2, 5.5.1, 5.5.2, 6.1, 6.3,6.4
4.4.1 4.4.1
Resources, roles, responsibility and authority
15
CH AM01.15 6.2.1, 6.2.2
4.4.2 4.4.2 Training, Awareness & Competence
GAIL (India) Ltd. Vaghodia. INTEGRATED MANAGEMENT SYSTEM MANUAL
TITLE: CONTENTS
DOC. No.: CH AM01.1 REV. NO.: 02 REV. DATE: 26.09.2014 PAGE NO. 2
Sl. No.
Document Ref. No.
ISO 9001:2008 Clause No.
ISO 14001: 2004
Clause No.
OHSAS 18001:2007 Clause No.
TITLE No. of Pg.’s
Rev. Status
16 CH AM01.16 5.5.3,
7.2.3 4.4.3 4.4.3
Communication
17 CH AM01.17 4.2.1 4.4.4 4.4.4 Documentation
18 CH AM01.18
4.2.3 4.4.5 4.4.5 Documentation Control
19
CH AM01.19
7.1 4.4.6 4.4.6 Operational Control
20
CH AM01.20
8.3 4.4.7 4.4.7 Emergency Preparedness & Response
8.0 4.5 4.5 Checking and Corrective Action
21 CH AM01.21 7.6, 8.2.3, 8.2.4, 8.4
4.5.1 4.5.1 Monitoring and Measurement/ Performance/ Measurement and Monitoring
22 CHAM01.22 8.2.3, 8.2.4
4.5.2 4.5.2 Evaluation of Compliance
23 CH AM01.23 8.3,8.4, 8.5.2, 8.5.3
4.5.3 4.5.3.2 Non Conformance & Corrective & Preventive Action
24 CH AM01.24 4.2.4 4.5.4 4.5.4 Control of Records
25 CH AM01.25 8.2.2 4.5.5 4.5.5 Internal Audit
26 CH AM01.26 5.1,5.6, 5.6.1, 5.6.2, 5.6.3, 8.5.1
4.6. 4.6 Management Review
27 CH AM01.27 7.1 4.4.6 4.4.6 Planning of Product realization
28 CH AM01.28 5.2,7.2, 7.2.1, 7.2.2
- - Customer related Processes
GAIL (India) Ltd. Vaghodia. INTEGRATED MANAGEMENT SYSTEM MANUAL
TITLE: CONTENTS
DOC. No.: CH AM01.1 REV. NO.: 02 REV. DATE: 26.09.2014 PAGE NO. 3
Sl. No.
Document Ref. No.
ISO 9001:2008 Clause No.
ISO 14001: 2004
Clause No.
OHSAS 18001:2007 Clause No.
TITLE No. of Pg.’s
Rev. Status
29 CH AM01.29 7.4.1, 7.4.2, 7.4.3
- - Purchasing Process
30 CH AM01.30 7.5, 7.5.1, 7.5.5
- - Production and Service Provision
Approved by: (Management Representative)
GAIL (India) Ltd. Vaghodia. INTEGRATED MANAGEMENT SYSTEM MANUAL
TITLE: ABBREVIATIONS
DOC. No.: CH AM01.2 REV. NO.: 00 REV. DATE: 01.10.2011 PAGE NO.4
BLEVE : Boiling Liquid Expansion Vapour Explosion
BPCL : Bharat Petroleum Corporation Limited
E & Q : Environment and Quality
ELEC. : Electrical
IMS : Integrated Management Systems
EMS : Environmental Management System
QMS : Quality management Systems
OHSMS : Occupational Health & Safety Management Systems
ESP : Environmental System Procedure
ETP : Effluent Treatment Plant
F & S : Fire and Safety
GAIL : GAIL (India) Limited
GIDC : Gujarat Industrial Development Corporation
GNFC : Gujarat Narmada Fertilizer Company
GPCB : Gujarat Pollution Control Board
GT : Gas Turbine
HBJ : Hazira-Bijaipur- Jagdishpur
HC : Hydrocarbon
HDPE : High Density Poly Ethylene
HOD : Head of the Department
IGT : Institute of Gas Technology
INST. : Instrument
GAIL (India) Ltd. Vaghodia. INTEGRATED MANAGEMENT SYSTEM MANUAL
TITLE: ABBREVIATIONS
DOC. No.: CH AM01.2 REV. NO.: 00 REV. DATE: 01.10.2011 PAGE NO.5
IOC : Indian Oil Company
IPCL : Indian Petrochemical Company Limited
LLDPE : Linear Low Density Poly Ethylene
LNG : Liquefied Natural Gas
MGL : Mahanagar Gas Limited
MMSCM : Mega Metric Standard Cubic Meter
MMSCMD : Million Metric Standard Cubic Meters per Day
MMTPA : Mega Metric Tonne Per Annum
MOEF : Ministry of Environment and Forest
MR : Management Representative
MT : Metric Tonne
NTGG : Natural Gas Liquid to Gas & Gasoline
DGM (O&M) : Officer In-Charge
ONGCL : Oil & Natural Gas Corporation Limited.
OPS : Operation
PARC : Petroleum and Research Center
PSV : Pressure Safety valve
RG : Regeneration Gas
SBP : Special Boiling Point liquid
SMP : Sustaining Membership Programme
WI : Work Instruction / Operation Control Procedure
WWTP : Waste Water Treatment Plant
GAIL (India) Ltd. Vaghodia. INTEGRATED MANAGEMENT SYSTEM MANUAL
TITLE: APPROVAL & ISSUE
DOC. No.: CH AM01.3 REV. NO.: 03 REV. DATE: 26.09.2014 PAGE NO.6
THE INTEGRATED MANAGEMENT SYSTEMS MANUAL
DOCUMENT NO. AM01 WHICH IS IN CONFORMANCE TO THE
REQUIREMENTS OF ISO 9001:2008 QUALITY MANAGEMENT
SYSTEM STANDARDS, ISO: 14001:2004 INTERNATIONAL
ENVIRONMENT SYSTEM STANDARDS, AND OHSAS 18001:2007
OCCUPATIONAL HEALTH AND SAFETY MANAGEMENT
SYSTEMS SPECIFICATION IS HEREBY APPROVED AND
ISSUED TO ALL THE AUTHORIZED HOLDERS FOR ITS
IMPLEMENTATION.
ALL THE AUTHORIZED HOLDERS ARE REQUESTED TO
ENSURE ITS COMPLIANCE IN THEIR RESPECTIVE AREAS AND
TO UPDATE IT AS AND WHEN AMENDMENTS ARE ISSUED TO
THIS DOCUMENT.
THE CHANGE MANAGEMENT OF THIS MANUAL SHALL
FOLLOW THE REQUIREMENTS OF DOCUMENT & DATA
CONTROL PROCEDURE IN THIS MANUAL.
Prepared & Reviewed By Approved By (Management Representative) (Officer in Charge / DGM (O&M)
GAIL (India) Ltd. Vaghodia. INTEGRATED MANAGEMENT SYSTEM MANUAL
TITLE: AMENDMENT HISTORY
DOC. No.: CH AM01.4 REV. NO.: 04 REV. DATE: 26.09.2014 PAGE NO. 7
Amdt
No.
Amdt.
date
Discard
Nature of change
Insert
Sign.
Issue
Control
ler
Chap. No. Page.
No. Chap. No.
Page
No.
Rev
01 01.05.2012 AM01.09 21 Change of Designation AM01.9 21 01
02 01.05.2012 AM01.09 22 Omission of Word
Occupier AM01.09 22
01
03 01.05.2012 AM01.14 44 Word Occupier replaced
by Factory Manager AM01.14 44
01
04 01.05.2012 AM01.14 49 Word Occupier replaced
by Factory Manager AM01.14 49
01
05 01.05.2012 AM01.16 56 Change of Designation AM01.16 56 01
06 01.05.2012 AM01.30 92 MFO replaced with
Naphtha AM01.30 92
01
07 01.05.2012 AM01.04A 96 Target Dates Review AM01.04A 96 01
08 01.05.2012 AM01.04B 97 Target Dates Review AM01.04B 97 01
09 01.05.2012 AM01.04C 98 Target Dates Review AM01.04C 98 01
10 01.05.2012 AXM01.05 99 Change in Organogram AXM01.05 99 01
11 23.04.13 AXM01.05 99 Change in Organogram AXM01.05 99 02
12 08.01.2014 AM01.04A 95 Target Dates Review AM01.04A 96 02
13 08.01.2014 AM01.04B 96 Target Dates Review AM01.04B 97 02
14 08.01.2014 AM01.04C 97 Target Dates Review AM01.04C 98 02
15 09.07.2014 CHAM01.1 1-3 Approver CHAM01.1 1-3 01
16 09.07.2014 CHAM01.3 6 Approver CHAM01.3 6 01
17 09.07.2014 CHAM01.4 7 Change in Amnd History CHAM01.4 7 03
18 09.07.2014 AXAM01.03 94 Change in HSE policy AXAM01.03 94 01
19 09.07.2014 AXAM01.04A 95 Target Dates Review AXAM01.04A 95 03
20 09.07.2014 AXAM01.04B 96 Target Dates Review AXAM01.04B 96 03
21 09.07.2014 AXAM01.04
C 97 Target Dates Review AXAM01.04C 97 03
22 09.07.2014 AXAM01.05 98 Change in Organogram AXAM01.05 98 03
23
26.09.2014 CH AM 01.6 09-17
Change in Company
profile details CH AM 01.6 09-17
01
GAIL (India) Ltd. Vaghodia. INTEGRATED MANAGEMENT SYSTEM MANUAL
TITLE: AMENDMENT HISTORY
DOC. No.: CH AM01.4 REV. NO.: 04 REV. DATE: 19.10.2015 PAGE NO. 7 A
Amdt
No.
Amdt.
date
Discard
Nature of change
Insert
Sign.
Issue
Control
ler
Chap. No. Page.
No. Chap. No.
Page
No.
Rev
24
26.09.2014 CHAM01.1 1-3 Change of approver CHAM01.1 1-3 01
25
26.09.2014 CHAM01.3 6 Change of approver CHAM01.3 6 01
26
26.09.2014 CHAM01.4 7 Change in Amnd History CHAM01.4 7 &
7A
03
27
26.09.2014 CH AM 01.7 18 Change in Scope CH AM 01.7 18
01
28
26.09.2014 CH AM 01.13 30-39
Change in Objective,
Targets & Programs CH AM 01.13 30-39
01
29 26.09.2014
AXAM01.04A 95 Target Dates Review AXAM01.04A 95 03
30 26.09.2014 AXAM01.04B 96 Target Dates Review AXAM01.04B 96 03
31 26.09.2014 AXAM01.04C 97 Target Dates Review AXAM01.04C 97 03
32 01.06.2015 AXAM01.04A 95 Target Dates Review AXAM01.04A 95 04
33 01.06.2015 AXAM01.04B 96 Target Dates Review AXAM01.04B 96 04
34 01.06.2015 AXAM01.04C 97 Target Dates Review AXAM01.04C 97 04
35 19.10.2015 CH AM01.26 81-83 Title Change CH AM01.26 81-83 01
GAIL (India) Ltd. Vaghodia. INTEGRATED MANAGEMENT SYSTEM MANUAL
TITLE: AUTHORIZED HOLDERS
DOC. No.: CH AM01.5 REV. NO.: 00 REV. DATE: 01.10.2011 PAGE NO. 8
SR.
NO. AUTHORISED HOLDER COPY NO.
1 MR cum AUDITOR’S COPY -
MASTER COPY
(HARD COPY)
01
2 GAIL VAGHODIA – LOCAL
INTRANET (SOFT COPY)
Not
Applicable
Note:
i. Copy Nos. 01 is issued to the Auditors (internal / external), for the duration of
the audit, and are withdrawn once the audit is completed. These are maintained
with the MR.
ii. Soft Copy of manuals (Read Only) is a controlled copy available in the local
server for reference of interested parties / employees and is amended by the
DCO with necessary approval of MR. from time to time as and when required.
GAIL (India) Ltd. Vaghodia. INTEGRATED MANAGEMENT SYSTEMS MANUAL
TITLE: COMPANY PROFILE (GAIL, Vaghodia)
DOC. No.: CH AM01.6 REV. NO.: 01 REV. DATE: 26.09.2014 PAGE NO. 9
MAIN FUNCTION
GAIL (India) Limited was established by the Government of India in August
1984 for handling post exploration activities relating to natural gas with the
objective of accelerating and optimizing the effective and economic use of natural
gas and its fractions to the benefit of national economy. GAIL was established
with the authorized and paid up capital of Rs.1000 Crores and Rs. 845.65 Crores,
respectively.
Within a period of 26 years, GAIL has emerged as a Gas Major of India and
maintained its position as the No. 1 Gas Company in India. GAIL, in the last two
decades of its existence, has created a sizeable natural gas market in the country.
GAIL handles around 157 MMSCMD of Natural Gas through its Transmission
Network, and holds around 90% share in Natural Gas Transmission business.
It has won the Excellent MOU Performance Award for the past 7 years
consecutively, and particularly in the year 2003-04, it secured 1st place amongst
PSEs with a perfect score of 1.00. It has also maintained its Navratna Status right
since it was granted the same.
On International front, GAIL has been declared by PLATTS, as 1st amongst
Global Gas Utilities based on Return on Invested Capital (ROIC) in its
Worldwide Survey of Top 250 Energy Companies (2002). GAIL also joined Top
10 Club of Global Energy Companies based on Return on Invested Capital
(ROIC) in Platts Worldwide Survey of Top 250 Energy Companies (2002). In the
FORBES 2000 (2005), GAIL has been ranked 12th amongst the list of Indian
Companies with the Global Rank of 1250.
It has also received several prestigious awards like NPMP, SCOPE (Institutional
category), GREENTECH, and GOLDEN PEACOCK for CORPORATE
GOVERNANCE, GOLDEN PEACOCK for Innovation Management,
GHEWITT-CNBC, The PetroFed oil & Gas pipeline Transportation - Company
of the Year for 2007-2008 Award, and HT POWERJOBS in the field of HR
MANAGEMENT, ICWAI, NATIONAL and INTERNATIONAL SAFETY
AWARDS from BRITISH SAFETY COUNCIL, OISD, PCRA etc.
In its two-decade long journey, GAIL has integrated across the GAS-VALUE
CHAIN, and has transformed itself from purely Gas Transmission and Marketing
GAIL (India) Ltd. Vaghodia. INTEGRATED MANAGEMENT SYSTEMS MANUAL
TITLE: COMPANY PROFILE (GAIL, Vaghodia)
DOC. No.: CH AM01.6 REV. NO.: 01 REV. DATE: 26.09.2014 PAGE NO. 10
Company to an Integrated Gas Major in India, with an entry into the Global
Market.
From a Transmission Company, GAIL has expanded downstream into Gas
Processing – LPG and other Value-Added Liquid Hydrocarbon Products and Gas-
based Petrochemicals. It has also leveraged its Core Competence by way of
setting-up world’s largest Jamnagar-Loni Liquefied Petroleum Gas (LPG)
Transmission Pipeline and further leveraged its Natural Gas and LPG
Transmission Network Infrastructures for Telecommunications business.
To ensure long-term gas-supply security from multiple natural gas sources, the
company has also ventured into Liquefied Natural Gas Re-gasification and
Exploration and Production through Joint Ventures / Equity Participation routes.
In fact, GAIL played a lead and pivotal role in sourcing R-LNG from Ras Gas,
Qatar and developing R-LNG market in a market which was regulated with
Administered Gas Price, around 1/3rd
of the price of R-LNG.
GAIL has also realized the downstream natural gas business potential in terms of
Gas-Power Convergence and Natural Gas Retailing, and hence ventured into
these areas by way of Joint Ventures / Equity Participation.
Today, GAIL is the owner and operator of:
India's largest Gas Transmission Networks (7847 kms)
World's longest exclusive Jamnagar-Loni LPG pipeline (1269 kms) and
another one Vizag-Secunderabad LPG pipeline (653 kms.)
Seven Gas Processing facilities with a capacity of more than 1.2 MMTPA of
LPG
India's largest gas-based Petrochemicals Complex with an installed capacity
of 410,000 TPA of Polyethylene (HDPE, LDPE, LLDPE).
Optic Fibre Cable Network of more than 13,000 Kms to offer bandwidth as a
Carrier's Carrier in the Telecom sector
GAIL has financial exposure in following ventures in the form of Joint Ventures /
Equity Participation, in India and abroad:
GAIL (India) Ltd. Vaghodia. INTEGRATED MANAGEMENT SYSTEMS MANUAL
TITLE: COMPANY PROFILE (GAIL, Vaghodia)
DOC. No.: CH AM01.6 REV. NO.: 01 REV. DATE: 26.09.2014 PAGE NO. 11
Exploration and Production – Varied equity participation, ranging from 10%
- 80% in 14 blocks. Out of these, one block in Myanmar having huge gas
reserve and would become potential supply source for Indian markets.
LNG Re-Gasification – 12.5% in Petronet LNG Limited
Gas based Power – 12.85% in GSEG in Gujarat
City Gas Distribution and CNG/PNG – Participation in India and abroad:
Indraprastha Gas Limited in Delhi – 22.5%
Mahanagar Gas Ltd. in Mumbai – 49.75%
Bhagyanagar Gas Limited in Hyderabad – 25%
Central UP Gas Ltd. in Kanpur – 22.5%
Tripura Natural Gas Co.Ltd.- 29%
Fayum Gas Co., Egypt – 19%
NatGas, Egypt – 15%
SHELL CNG, Egypt – 22%
China Gas Holdings Co. Ltd – 9%.
Project RGPPL – Ratnagiri Gas and Power Limited (Dabhol) with equity
contribution of Rs.500 Crores. To play a role of sourcing LNG and operating
LNG Re-gasification terminal.
GAIL has taken several major business initiatives in order to to have its
sustainable long-term “Industry Leadership in Indian Natural Gas Market”, which
are as follows:
Sourcing of additional 2.5 – 5 MMTPA LNG from Ras Gas, Qatar
Sourcing of 5 MMTPA LNG from Iran and negotiating for another 2.5
MMTPA
Sourcing of LNG from other countries like Australia, Malasiya and other
Middle-East countries
Acquiring stakes in other E and P blocks in Mynamar. Also, bidding for
blocks in other countries like Indonesia, Libya, African and Middle-East
countries for “Oil for Gas”.
GAIL (India) Ltd. Vaghodia. INTEGRATED MANAGEMENT SYSTEMS MANUAL
TITLE: COMPANY PROFILE (GAIL, Vaghodia)
DOC. No.: CH AM01.6 REV. NO.: 01 REV. DATE: 26.09.2014 PAGE NO. 12
Nodal role in import of gas through proposed Iran-India and Myanmar-India
cross-border pipelines
Developed Blueprint of National Gas Grid that would integrate existing and
potential sources of Natural Gas with existing and potential markets under a
common infrastructure across the country. It would benefit the end-
consumers in terms of uninterrupted gas supply at optimum delivered price.
Above all, natural gas is an environment friendly and comparatively efficient
fuel.
GAIL has more than 60 major work centers in the form of modern assets and
marketing network throughout India and is efficiently managing its business
operations with less than 3400 employees.
GAIL's Vision: “Be the leading company in Natural Gas and Beyond, with
Global Focus, Committed to Customer Care, Value Creation for all
Stakeholders and Environmental Responsibility”.
Corporate Mission: "Accelerating and optimizing the effective and economic
use of Natural Gas and its fractions to the benefit of
national economy"
GAIL-VAGHODIA
1. Brief Description
GAIL (India) Limited- Vaghodia is located in GIDC Industrial Estate –
Vaghodia, which is at a distance of approx. 35 KM from Vadodara city. With
respect to the plant operations carried out in Vaghodia, GAIL-Vaghodia is
divided into mainly following four units:
Unit-I : LPG recovery Plant (also known as Gas Processing Unit)
Unit-II : Compressor Station (also known as GREP)
Unit-III : Naphtha Plant
Unit-IV : Heat Recovery Steam Generation (HRSG)
GAIL (India) Ltd. Vaghodia. INTEGRATED MANAGEMENT SYSTEMS MANUAL
TITLE: COMPANY PROFILE (GAIL, Vaghodia)
DOC. No.: CH AM01.6 REV. NO.: 01 REV. DATE: 26.09.2014 PAGE NO. 13
Unit-I: Gas Processing Unit
The Gas Processing Plant was set up at a project cost of Rs 50 Crores in January
1993 for extraction of LPG from (sweetened, dehydrated and dew point
depressed) Natural Gas coming from M/s ONGC’s Hazira gas processing
complex through HVJ pipeline. The main product of this plant is LPG. NGL
(Natural Gas Liquids) is also obtained after extraction of LPG which is further
fractionated to produce Naphtha. The lean gas is supplied to downstream
customers (M/s IOCL, M/s GSFC, M/s GIPCL and M/s RIL) through GAIL’s gas
terminal located at Undera in Vadodara. All LPG and Naphtha produced at
Vaghodia plant is sold to M/s BPCL and M/s RIL respectively. The transportation
of products LPG & Naphtha from our premises through tankers are carried out by
M/s BPCL and M/s RIL.
The LPG Recovery plant consists of the following sections:
a) Gas receiving and drying.
b) Chilldown, Expansion and Re-compression
c) Regeneration
d) Fractionation
Unit-II: Compressor Station
The compressors are located adjacent to LPG Recovery Plant within plant
premises. It was commissioned in 1998 for boosting pressure of Natural Gas
coming from Hazira through HVJ pipeline from suction pressure 50kgf/cm2 to
discharge pressure 90 Kg/Cm2 and Natural Gas after boosting pressure is again
fed to HVJ line which goes to Jhabua for onward transmission. There are three
centrifugal compressors driven by gas turbines, two in running mode and one in
standby mode. The salient parameters are as under:-
No. of compressors : 3 Nos.
Inlet pressure : 50 Kg/Cm2
Outlet pressure : 93 Kg/Cm2
BHP : 17995 KW
Capacity of each compressor : 15.8 MMSCMD
In addition to the above 01 No gas engine generator (GEG) of capacity 2.25 MW
is installed for power generation. A diesel engine generator of 1500 KVA has
GAIL (India) Ltd. Vaghodia. INTEGRATED MANAGEMENT SYSTEMS MANUAL
TITLE: COMPANY PROFILE (GAIL, Vaghodia)
DOC. No.: CH AM01.6 REV. NO.: 01 REV. DATE: 26.09.2014 PAGE NO. 14
been provided for meeting the power needs of emergencies and it starts
automatically if power fails.
Unit-III: Naphtha plant
Naphtha plant was set up as R&D project to process Heavy Hydrocarbons
(bottom stream of LPG column in LPG Recovery plant) into value added
products. HHCs from LPG plant are fed to packed bed Debutanizer column after
being sent to feed surge drum. Naphtha produced from Naphtha plant is sent to
Naphtha storage system and further sold to M/s RIL.
Unit-IV: Heat Recover Steam Generation
HRSG was commissioned in August’2012 to generate super-heated steam to the
tune of 52 MT/ Hr, at 30 kg/cm2, 325oC. The HRSG System utilizes the flue gas
energy from exhaust gases from Rolls Royce RB211 Gas turbines that drives their
respective compressors in open cycle, for generation of steam. After the
installation of HRSG unit, the temperature of flue gas has been reduced from
450°C to about 140-150°C. The HP Steam generated in HRSG is supplied to M/s
Apollo tyres.
2. Critical Business Information
The organization has identified critical success factors as competitive
factors. GAIL (India) Limited, Vaghodia has adopted the following efficient
and effective control system as a critical success factors in this competitive
world:
Maintain the quality of the product as per the guidelines issued by the BIS
and the quality laboratory is accredited by NABL.
To keep the healthy relationship with the customer.
Safe and healthy working environment in the transportation of Natural Gas
and Production of LPG from Natural gas.
Effectively monitor and control all environmental conditions to the
protection from accidental loss.
Prevention of pollution and conserve Natural resources.
GAIL (India) Ltd. Vaghodia. INTEGRATED MANAGEMENT SYSTEMS MANUAL
TITLE: COMPANY PROFILE (GAIL, Vaghodia)
DOC. No.: CH AM01.6 REV. NO.: 01 REV. DATE: 26.09.2014 PAGE NO. 15
Responsibility / Accountability fixed at all levels to prevent physical injury,
risk to health and damage to environment.
Continually update its technology / systems to improve the health, safety
and environment conditions.
All the routine and non-routine jobs are identified and their risk assessment
done. Management programme are made to reduce the high risk to low risk
in various jobs.
Adopting National as well as international HSE auditing system.
Different awards related to Health, safety and environment from different
organizations like OISD, BSC, GSC, Greentech etc. gives an additional
weightage towards recognition.
3. Market And Customer of the Company
Major Market : National
M/s Bharat Petroleum Corporation Limited (BPCL) is the only customer
for LPG which is produced at Vaghodia. The product dispatched to the
BPCL bottling plants through road tankers. The Naphtha plant products are
purchased by private companies / parties from different areas / location
across India.
Natural gas is transported through underground pipe line and distributed to
the online customer viz. IOCL, GSFC, IPCL, APOLLO TYRES, SGPL
etc.
4. Disaster Control Plan
GAIL-Vaghodia is having its own On-Site Disaster Control Plan to enhance
our efficiency for handling any kind of emergency. Conducting mock drills
once in a quarter religiously practiced in line with our onsite Disaster
Control Plan. The same plan has been practiced / in action since
construction of this plant. The above mentioned plan has been verified up to
the satisfaction of various Statutory Authorities like representatives of Oil
GAIL (India) Ltd. Vaghodia. INTEGRATED MANAGEMENT SYSTEMS MANUAL
TITLE: COMPANY PROFILE (GAIL, Vaghodia)
DOC. No.: CH AM01.6 REV. NO.: 01 REV. DATE: 26.09.2014 PAGE NO. 16
Industry Safety Directorate, Factory Inspectorate, Govt. of India and District
Authorities etc. The above plan clearly defines the category of hazards and
mitigation methods and thus the role and responsibilities of all levels of
personnel involved. A procedure is being established for preventing and
mitigating the hazards which may have direct / indirect impact on
environment and all kinds of emergency situations.
There are 2 nos. of emergency fire tenders, 1 no of Ambulance and fire
trained personnel on round the clock basis, auxiliary fire-fighting squad, first
aiders in every shift and various types of fire protection and safety
equipment to handle any kind of emergency at LPG Plant & Compressor
station Vaghodia.
An OFF SITE DISASTER CONTROL PLAN has also been drawn up and
practiced by the district administration in consultation with the Factory
Inspectorate and necessary inputs from GAIL have already been submitted.
Latest copy of OFF SITE DISASTER CONTROL PLAN has been received
from Factory Inspectorate (DISH, Govt. of Gujarat).
4.0 Social and Welfare Development
Competitions for children of nearby Villages, Schools are motivated for
thinking the theme of “OIL and FUEL CONSERVATION and
ENVIRONMENT PROTECTION” on the eve of Oil Conservation
fortnight and Environment day.
5.0 Mission
Accelerating and optimizing the effective and economic use of Natural Gas and its fractions to the benefit of national economy.
GAIL was established by the Government of India for handling diverse
post-exploration and production activities relating to Natural Gas viz.
transportation, processing, distribution and marketing of gas and its
fractions and byproducts. The company has a corporate mission to:
GAIL (India) Ltd. Vaghodia. INTEGRATED MANAGEMENT SYSTEMS MANUAL
TITLE: COMPANY PROFILE (GAIL, Vaghodia)
DOC. No.: CH AM01.6 REV. NO.: 01 REV. DATE: 26.09.2014 PAGE NO. 17
6.0 VISION:
Be the leading company in Natural Gas and Beyond, with Global Focus, Committed to Customer Care, Value Creation for all Stakeholders and
Environmental Responsibility
GAIL (India) Ltd. Vaghodia. INTEGRATED MANAGEMENT SYSTEMS MANUAL
TITLE: SCOPE
DOC. No.: CH AM01.7 REV. NO.: 01 REV. DATE: 26.09.2014 PAGE NO. 18
SCOPE:
Integrated Management System covers the Quality Management systems, Environmental,
Occupational Health & Safety requirements of GAIL, Vaghodia and follows the specification
set by:
ISO 9001:2008 Quality Management system- Specifications with guidance for use
ISO 14001:2004 Environmental Management Systems – Specifications with guidance
OHSAS 18001:2007 Occupational Health and Safety Management Systems Specifications
Scope:
“ Processing of Natural Gas for Recovery and Supply of LPG and Naphtha”
The system is applicable to all the activities / product and service at GAIL, Vaghodia, for
production and supply of its Products.
Exclusions
This system is not applicable to the following clauses:
1. Compressor Station is excluded from the scope of Integration as Compressor Station is an
integral part of HVJ pipe line, responsible for gas transmission across the pipe line, for
which ISO-9001:2008, ISO-14001:2004 and OHSAS:18001:2007 Certification is obtained
separately and operated centrally by GAIL-Vijaipur work centre.
2. Clause Number 7.3 – Design and Development under ISO 9001:2008
The business process carried out by GAIL, Vaghodia does not call for design and
development of the product. It is affirmed that these exclusion does not affect our ability or
responsibility to provide product that meets customer and applicable regulatory
requirements.
3. Clause Number 7.5.2 – Validation of Processes under ISO 9001:2008
Validation of Processes is not required as the unit is not involved in any process that can be
validated through further testing and monitoring.
GAIL (India) Ltd. Vaghodia. INTEGRATED MANAGEMENT SYSTEMS MANUAL
TITLE: GENERAL REQUIREMENTS
DOC. No.: CH AM01.8 REV. NO.: 00 REV. DATE: 01.10.2011 PAGE NO. 19
1.0 PURPOSE : To establish and maintain an Integrated Management
System based on the Quality Management Systems
as per ISO 9001:2008, Environment Management
Systems Specification with Guidance for use ISO
14001: 2004, and Occupational Health & Safety
Management Systems as per OHSAS 18001:2007
for all its processes, activities, products and services
2.0 SCOPE : Applicable to all processes, activities, product and
services of GAIL, Vaghodia.
3.0 RESPONSIBILITY : All employees
4.0 SYSTEM REQUIREMENTS:
1. To establish an Integrated Management Systems by addressing all the Requirements of
ISO 9001:2008, ISO-14001: 2004, and OHSAS 18001:2007 For easy Understanding and
effective implementation supporting activities include:
a) To bring about awareness of IMS to all employees.
b) To organize Initial QSHE Review
c) To aid in identification of environmental aspects and associated impacts
d) To aid in identification of hazards and associated risks.
e) To take into account the following in design, implementation and maintenance of the IMS
Environmental Aspects & Associated impacts identified through IER
Hazards and associated risks identification
Company Environmental, Quality and Safety policy.
Applicable EHS Legislation
Internal / external communication records.
f) To co-ordinate IMS related activities
2. Identified the processes needed for the Integrated Management System and their
application throughout the organization as given in AXAM01.01(Master list of processes).
These are for the existing range of products offered based on the understanding of current
requirements of customers.
3. Determined the sequence and interaction of these processes as depicted schematically in
AXAM01.02( Site Organogram ).
4. Determined the criteria and methods needed to ensure that both the operation and control
of these processes needed are effective. (Ref. Section 7 and 8).
5. Ensured the availability of resources and information necessary to support the operation
GAIL (India) Ltd. Vaghodia. INTEGRATED MANAGEMENT SYSTEMS MANUAL
TITLE: GENERAL REQUIREMENTS
DOC. No.: CH AM01.8 REV. NO.: 00 REV. DATE: 01.10.2011 PAGE NO. 20
and monitoring of these processes and periodically reviews them.
6. Established and implemented the system for monitoring, measuring and analyzing these
processes.
7. Established and implemented the system of implementing actions necessary to achieve
planned results and continual improvement of these processes
8. The analysis of the process data/information is used for initiating corrective and preventive
action for continual improvement of the integrated management system.
9. To assist in enhancing the QSHE performance though demonstrating continual
improvement, improvement Measures in Processes. Products and services which interact
with the quality, safety, health and environment aspects of our organization.
10. To cross link different documents of the IMS with existing documented production /
maintenance & other specified practices.
11. To organize periodic Integrated Management System review with the top management
5.0 REFERENCE:
AXAM01.01 Master List of all the Processes
AXAM01.02 Sequence and Interaction of these processes
P MM01.02 Procedure for Control of Document
P MM01.04 Procedure for Quality & Environmental Records
GAIL (India) Ltd. Vaghodia. INTEGRATED MANAGEMENT SYSTEMS MANUAL
TITLE: QUALITY AND SHE POLICY
DOC. No.: CH AM01.9 REV. NO.: 01 REV. DATE: 01.05.2012 PAGE NO. 21
1.0 PURPOSE:
To define the QSHE Policy of GAIL (India) Ltd, Vaghodia.
2.0 SCOPE:
Applicable to the Gas Processing Unit of GAIL (India) Limited, Vaghodia.
3.0 RESPONSIBILITY:
The DGM (O&M) is responsible for defining the Quality, Safety, Health &
Environment policy, updating it to meet he requirement of the time.
The responsibility of providing the policy to public on demand lies with Management
Representative.
4.0 SYSTEM REQUIREMENT:
The policy will be appropriate to the customer requirements, management
commitment, nature, scale and environmental impacts, occupational health and
safety associated risks of all the process, activities, products or services of GPU,
GAIL-Vaghodia
The policy will include commitment to continual improvement, customer
satisfaction and prevention of pollution and OHS Risks.
Commitment to comply with all the relevant legislation and regulations and
industry specific guidelines of Oil Industry Safety Directorate (OISD) as
applicable and to which GAIL subscribes.
The top management ensures that employees at all levels within the organization
understand the goals and objectives of the organization and its integrated
management system. This is achieved through regular meetings and conduct of
training programs.
GAIL (India) Ltd. Vaghodia. INTEGRATED MANAGEMENT SYSTEMS MANUAL
TITLE: QUALITY AND SHE POLICY
DOC. No.: CH AM01.9 REV. NO.: 01 REV. DATE: 01.05.2012 PAGE NO. 22
The top management conducts management reviews and discusses the
importance of the following:
i. Customer requirements.
ii. Quality, Environment and Occupational Health and Safety objectives.
iii. Statutory, legal, and regulatory requirements.
iv. Continual improvement goals.
The top management has established Quality, Safety, Health & Environment
policy and quality, environment and SHE objectives, which is made known to
all the personnel.
The top management conducts periodic management review.
The top management has provided adequate resources for carrying out the
activities as per requirement given in chapter CHAM01.4.1 of this manual.
The top management carries out the activities relating to monitoring,
measurement, analysis and improvement as described in chapter CHAM01.8.0
of this manual.
Communicating to the organization the importance of meeting customer as
well as statutory and regulatory requirements as defined in the “Procedure for
Legal and Regulatory Requirements” P-MM01-10
The organization has defined and documented its policy for quality, Safety, Health and
Environment as per AXAM01.03
The quality, Safety, health and environment policy has been signed by the OIC
Vaghodia showing commitment at the highest level. It is appropriate to the purpose of
the organization as this is in line with the Vision and Mission of the Organization.
Future business opportunities are identified based on the market trend / requirements,
present capabilities and customer requirements.
It is ensured that the Quality, Safety, Occupational Health and Environment, Policy are
understood by all the employees of the Organization. The policy is made known to
employees through discussions, training programmes, handouts, display boards and any
other means felt appropriate.
The Quality, Safety ,Health and Environment Policy is reviewed for continuing
suitability during the Management Review meeting every six months and necessary
actions will be taken.
GAIL (India) Ltd. Vaghodia. INTEGRATED MANAGEMENT SYSTEMS MANUAL
TITLE: QUALITY AND SHE POLICY
DOC. No.: CH AM01.9 REV. NO.: 01 REV. DATE: 01.05.2012 PAGE NO. 23
5.0 QUALITY, ENVIRONMENTAL AND OCCUPATIONAL HEALTH AND
SAFETY POLICY OF GAIL, VAGHODIA.
GAIL has issued separate corporate Quality policy and separate corporate Environment,
Health and Safety Policy. The Quality, Safety, Health & Environment policy of GAIL,
Vaghodia is extracted from the corporate Quality policy and Corporate Health, Safety
and Environment Policy with specific process inputs of Vaghodia .
6.0 REFERENCE:
Corporate Environment, Health and Safety Policy of GAIL (India ) Limited.
Corporate Quality policy of GAIL ( India ) limited.
P MM01.01 Procedure for Management Review
GAIL (India) Ltd. Vaghodia. INTEGRATED MANAGEMENT SYSTEMS MANUAL
TITLE: ENVIRONMENTAL ASPECTS
DOC. No.: CH AM01.10 REV. NO.: 00 REV. DATE: 01.10.2011 PAGE NO. 24
1.0 PURPOSE:
To identify and periodically update the environmental aspects of activities, products or
services of GPU, GAIL, Vaghodia that it can control and over which it can be expected
to have an influence. Environmental aspects are identified in order to determine those,
which have or can have significant impacts on the environment.
2.0 SCOPE:
Applicable to all the activities carried out at GPU, GAIL- Vaghodia.
3.0 RESPONSIBILITY:
The overall responsibility for establishing, documenting and updating this system lies
with Management Representative.
The responsibility for identifying and periodically updating the environmental aspects
related to a department, lies with the concerned departmental heads.
4.0 SYSTEM REQUIREMENT:
GAIL, Vaghodia has established its position with regard to its commitment to
environment by means of an environmental review carried through direct inspection and
measurement of
- Legislative and regulatory requirements.
- Identification of significant environmental aspects.
“Procedure for Identification of Significant Environmental Aspects” will be
implemented, established and maintained to identify the environmental aspects of
activities, products or services which have or can have significant impact on the
environment.
The following points will be taken into account during the process of determining
significance of environmental aspects:
a. Inputs (including, use of raw materials and natural resources) and outputs (including
emissions to air, releases to water, waste management, contamination of land).
- associated with current, relevant past and, reasonably foreseeable, i.e. future (such as
plant modifications, new product introductions, new or planned developments)
activities, products and services.
- During normal operating, shut down / start up conditions and emergency situations.
b. Local environmental and community issues.
GAIL (India) Ltd. Vaghodia. INTEGRATED MANAGEMENT SYSTEMS MANUAL
TITLE: ENVIRONMENTAL ASPECTS
DOC. No.: CH AM01.10 REV. NO.: 00 REV. DATE: 01.10.2011 PAGE NO. 25
c. Each product, component or raw material input may not be considered. Categories of
products, components or raw materials may be selected to identify those aspects most
likely to have significant impact.
It will be ensured that wherever possible the aspects related to the identified
significant impacts are considered in setting environmental objectives.
The information on the identified environmental aspects will be kept up to date
by periodically reviewing once a year, in cases of emergency situations and/ or
plant modifications.
5.0 REFERENCE:
“Procedure for Identification of Significant Environmental Aspects” P MM01.13
6.0 RECORDS:
The records mentioned in the above procedure will be maintained.
GAIL (India) Ltd. Vaghodia. INTEGRATED MANAGEMENT SYSTEMS MANUAL
TITLE: PLANNING FOR HAZARD IDENTIFICATION,
RISK ASSESSMENT & CONTROL
DOC. No.: CH AM01.11 REV. NO.:
01 REV. DATE: 26.09.2014 PAGE NO. 26
PURPOSE:
To identify and periodically update the OHS Hazards and associated risks of
activities, products or services of GAIL, Vaghodia that it can control and over which
it can be expected to have an influence. OHS hazards are identified in order to
determine those, which have or can have non tolerable risks.
2.0 SCOPE:
Applicable to all the activities carried out at GPU, GAIL-Vaghodia.
3.0 RESPONSIBILITY:
The overall responsibility for establishing, documenting and updating this system
lies with Management Representative.
The responsibility for identifying and periodically updating the OHS hazards related
to a department, lies with the concerned departmental heads.
4.0 SYSTEM REQUIREMENT:
GAIL, Vaghodia has established its position with regard to its commitment to
Occupational health and safety by means of an OHS review carried through direct
inspection and measurement of
- Legislative and regulatory requirements.
- Identification of unacceptable risks.
The organization has identified the hazards associated with all its activities and
products especially the ones which have or can have significant bearing on the
Occupational Health & Safety and Environment. The identification of OHS risks is
an on-going process that determines the status of the already identified risks and any
potential new risks arising due to ongoing or new activities, products and services.
The risks have been identified based on the routine and non-routine activities of the
organization including the activities of the personnel having access to the work place
including contractors and visitors and the use of facilities / resources at the work
place. A register of OHS Hazards and Risks (RR-01) has been established on the
basis of an Status Review undertaken for all the plant activities by the core group to
establish the current position with regard to the OHS using risk assessment criteria
based on likelyhood and severity of the potential event. A procedure [P MM01.16] has also been established to identity the hazards and
assess the associated risks of various activities which have or can have significant
impact on the Occupational Health & Safety.
5.0 REFERENCE:
GAIL (India) Ltd. Vaghodia. INTEGRATED MANAGEMENT SYSTEMS MANUAL
TITLE: PLANNING FOR HAZARD IDENTIFICATION,
RISK ASSESSMENT & CONTROL
DOC. No.: CH AM01.11 REV. NO.:
01 REV. DATE: 26.09.2014 PAGE NO. 27
“Procedure for Identification of OHS hazards and associated non tolerable
Risks P MM01.16
6.0 RECORDS:
The records mentioned in the above procedure will be maintained.
GAIL (India) Ltd. Vaghodia. INTEGRATED MANAGEMENT SYSTEMS MANUAL
TITLE: LEGAL AND OTHER REQUIREMENTS
DOC. No.: CH AM01.12 REV. NO.: 00 REV. DATE: 01.10.2011 PAGE NO. 28
1.0 PURPOSE:
To identify and have access to legal and other requirements to which the organization
subscribes.
2.0 SCOPE:
Applicable to legal and other requirements concerning the Customer requirements,
Process, environmental aspects and OHS hazards and associated risks of GAIL,
Vaghodia’s activities, products or services.
3.0 RESPONSIBILITY:
The overall responsibility for establishing, documenting and updating the system lies
with the Management Representative.
Key responsibility for ensuring applicable legal compliance lies with the respective user
departments.
4.0 SYSTEM REQUIREMENT:
“Procedure for Legal and Regulatory requirements” will be established,
implemented and maintained to identify and have access to
- Applicable EHS laws and regulations
- Relevant regulatory authorities
- Applicable EHS legal and other environmental requirements to which
organization subscribes are considered in developing, implementing and
maintaining IMS.
The top management ensures that customer requirements are determined and are
met (Ref. CHAM01.5.2) with the aim of enhancing customer satisfaction) the top
management also ensures through Management Representative and other means the
promotion of awareness of customer requirement throughout the organization.
They will facilitate in the understanding of customer requirements with the aim of
enhancing customer satisfaction.
The system will be modified if required to ensure product/service delivery in line with
the requirements.
The Quality specifications of Products are informed to the Customer and we are having
a procedure for Handling of Customer Complaints (PMM01. 12).
The procedure will also define how to track compliance to these laws. To ensure
access to the latest applicable laws, regulations and updates, the respective user
departments will keep themselves abreast by liaising / being informed through
regulatory bodies such as Pollution Control Board, MOEF etc.
GAIL (India) Ltd. Vaghodia. INTEGRATED MANAGEMENT SYSTEMS MANUAL
TITLE: LEGAL AND OTHER REQUIREMENTS
DOC. No.: CH AM01.12 REV. NO.: 00 REV. DATE: 01.10.2011 PAGE NO. 29
It will be ensured the latest revision of the applicable laws and regulations are
followed.
GAIL, Vaghodia will also be informed about the changes in QSHE law by the
QSHE auditors.
An up-to-date list of Acts and Rules will be prepared and maintained by
concerned HOD.
5.0 REFERENCE:
“Procedure for Legal and Regulatory Requirements” P MM01.10
6.0 RECORDS:
All the records mentioned in the above-mentioned Procedure will be maintained.
GAIL (India) Ltd. Vaghodia. INTEGRATED MANAGEMENT SYSTEMS MANUAL
OBJECTIVES, TARGETS & PROGRAMME(S)
DOC. No.: CH AM01.13 REV. NO.: 01 REV. DATE: 26.09.2014 PAGE NO. 30
1.0 PURPOSE:
To establish and maintain documented Quality, Safety Health and Environmental
objectives and targets.
2.0 SCOPE:
Applicable to each relevant function and level within the organization involved with
processes, activities, products or services of GAIL, Vaghodia, developed in line with the
ISO 9001;2008, ISO 14001:2004, and OHSAS 18001:2007 standard.
3.0 RESPONSIBILITY:
The overall responsibility for establishing, documenting, implementing and updating the
system related to QSHE objectives, targets and programme(s) lies with the Management
Representative.
The overall responsibility for establishing, documenting, implementing and updating the
objectives and targets lies with the Management Representative at organization level with
the approval of top management.
The overall responsibility for establishing, documenting, implementing and updating the
departmental targets in line with organizational objectives lies with the respective
Departmental Heads in consultation with the Management Representative.
4.0 SYSTEM REQUIREMENT:
The organization has established specific current organizational QSHE objectives in
line with the Quality, Safety, Health and Environmental policy.
The Organizations’ objectives, targets and programmes (which includes commitment
to prevention of pollution), are described as per “Procedure for Establishing and
Updating Objectives and Targets”, “Procedure for Environmental Management
Programme”.
The organization has established and is maintaining documented occupational health
and safety objectives, at each relevant function and level within the organization. The
procedure is described in P MM01.17: Setting/ maintaining / reviewing OHS
objectives & targets and prepare OHS management programme.
Quality Objectives (as stated in AXAM01.04) have been established based on the
framework provided by the Quality Policy. Organizational Objectives department’s
levels and functions are appropriately assigned within the organization. Where
required additional Departmental objectives may be framed based on the
organizational objectives. This is detailed in the “Procedure for establishing and
updating of Objectives and targets” PMM01.08.
The process objectives for various processes, where appropriate, have been established in
line with the quality objectives. They are in terms of performance measures and measured
& analyzed for improvement as described in CHAM01.4.5.1.
GAIL (India) Ltd. Vaghodia. INTEGRATED MANAGEMENT SYSTEMS MANUAL
OBJECTIVES, TARGETS & PROGRAMME(S)
DOC. No.: CH AM01.13 REV. NO.: 01 REV. DATE: 26.09.2014 PAGE NO. 31
While establishing and reviewing the current organizational environmental and OHS
objectives, the following details will be kept in consideration:
Legal and other requirements.
Significant environmental aspects and non tolerable OHS Risks.
Technological options. Where practical, use of best available technology if
economically viable, cost effective and judged appropriate.
Financial, operational and business requirements such as desired growth rate.
Views of interested parties such as the neighboring community, villagers.
Where appropriate, preventive measures shall be taken into account.
Based on the organizational objectives, measurable organization wide targets shall
be established wherever practicable.
Based on the organizational objectives and targets, measurable targets will be framed
department wise, wherever possible.
The performance with respect to the departmental targets will be monitored at
departmental level every three months.
The environmental and OHS management programme will include
o Designation of responsibility for achieving objectives and targets at each
relevant function and level of the organization.
o Means and the time frame by which they are to be achieved, which will take
care of procurement of material, shutdown and availability of resources.
Whenever new projects / plant modifications are initiated or any other new or
modified activities, products or services are introduced, the Environmental and OHS
Management Programme will be amended, where relevant, to ensure that it applies to
such activities.
For construction of civil and other structures the programme may address planning,
design, construction, commissioning, operation and decommissioning, if required.
After completion of an Environmental and OHS Management Programme, its
performance will be monitored and after satisfactory performance, it will be
incorporated into the system as a procedure or work instruction.
The Environmental and OHS Objectives, Targets and Programme(s) (organizational /
departmental) will also be reviewed during Management Review meeting once in six
months for their performance or changes, if any.
THE OHS Management Programmes are described in the OHS Management
Programme Register (OMP01) wherein it details the sequence of actions to be carried
out, resources required or allocated, the responsibility & authority and time frame by
which the objectives and targets are to be achieved.
GAIL (India) Ltd. Vaghodia. INTEGRATED MANAGEMENT SYSTEMS MANUAL
OBJECTIVES, TARGETS & PROGRAMME(S)
DOC. No.: CH AM01.13 REV. NO.: 01 REV. DATE: 26.09.2014 PAGE NO. 32
The procedure for preparing OHS Management Programme is described in P
MM01.17: Setting/ maintaining / reviewing OHS objectives & targets and prepare
OHS management programme.
GAIL, Vaghodia management will provide all resources to meet the objectives, targets
and programmes.
5.0 REFERENCE
“for Establishing and Updating Objectives and Targets” P MM01.08
“Procedure for Environmental Management Programme” P MM01.14
“Procedure for preparing OHS Management Programme “P MM01.17
6.0 RECORDS
All the records mentioned in the above-mentioned Procedure will be maintained.
GAIL (India) Ltd. Vaghodia. INTEGRATED MANAGEMENT SYSTEMS MANUAL
OBJECTIVES, TARGETS & PROGRAMME(S)
DOC. No.: CH AM01.13 REV. NO.: 02 REV. DATE: 01.06.2015 PAGE NO. 33
OBJECTIVES TARGETS AND PROGRAMS WITH RESPECT TO ISO:
9001, ISO: 14001 & OHSAS: 18001
SL
NO
DETAILS OF OBJECTIVE STANDARD TARGET REMARKS
1 CONTINUAL MOTIVATION AND
UPDATING OF SKILLS OF
PERSONNEL THROUGH HRD
ACTIVITIES
ISO:9001 2015-16 Details as per
ANNEXURE:
AX AM 01.04A
2 STRICT ADHERENCE TO QUALITY
MAINTENANCE PROGRAMME
USING MODERN MAINTENANCE
(MANAGEMENT) TECHNIQUE
ISO: 9001 2015-16 Details as per
ANNEXURE:
AX AM 01.04A
3 OPERATING PLANT AND PROCESS
RELIABLY AT OPTIMUM ENERGY
LEVEL
ISO:9001 2015-16 Details as per
ANNEXURE:
AX AM 01.04A
4 REDUCTION IN ELECTRICAL
ENERGY CONSUMPTION
ISO:9001 &
ISO:140001
2015-16 Under progress as per Management program Reference: ANNEXURE:
AX AM 01.04B
5 DEVELOPMENT OF GREENERY IN
& AROUND PLANT AREA
ISO:14001 2015-16 Under progress as per Management program Reference: ANNEXURE:
AX AM 01.04B 6 ENVIRONMENTAL AWARENESS
FOR EMPLOYEES &
CONTRACTORS
ISO:14001 2015-16 Under progress as per Management program Reference: ANNEXURE:
AX AM 01.04B 7 REDUCTION OF WATER
CONSUMPTION WITH RESPECT
TO PREVIOUS YEAR
ISO:14001 2015-16 Under progress as per Management program Reference: ANNEXURE:
AX AM 01.04B 8 EMERGENCY AWARENESS AND
MAINTAINING SAFETY FOR
EMPLOYEES & CONTRACTORS
OHSAS:18001 2015-16 Under progress as per Management program Reference: ANNEXURE:
AX AM 01.04C 9 CATEGORISATION AND
MONITORING OF HEALTH LEVEL
OF EMPLOYEES
OHSAS:18001
2015-16 Under progress as per Management program Reference: ANNEXURE:
AX AM 01.04C
GAIL (India) Ltd. Vaghodia. INTEGRATED MANAGEMENT SYSTEMS MANUAL
OBJECTIVES, TARGETS & PROGRAMME(S)
DOC. No.: CH AM01.13 REV. NO.: 02 REV. DATE: 01.06.2015 PAGE NO. 34
MANAGEMENT PROGRAM FOR OBJECTIVE AND TARGETS FOR ISO: 14001
TITLE: REDUCTION IN ELECTRICAL ENERGY CONSUMPTION
1. SCOPE : GPU, Vaghodia
2. OBJECTIVE: To reduce fixed electrical energy consumption.
3. TARGET: To reduce the electrical consumption by 0.5% in FY 2015-16
4. PERFORMANCE CRITERIA: Daily electrical energy consumption.
5. RESPONSIBILITY: HoD (Ops.) & HoD (Elect.)
6. ACTIVITIES:
Sr.
No. Description Period
Responsibili
ty
6.1 Study of present electrical consumption of fixed loads
(minimum electrical energy required for utility services.) June 2015
HoD
(Elect.)
6.2
Explore the possibilities for suitable modification in the
present process system so as to achieve savings in
electrical consumption of fixed loads. Aug 2015
HoD
(Ops.)
6.3 Implementation of any modification scheme.
Oct. 2015 HoD
(Ops.)
6.4 Monitoring of electrical energy consumption for next three
months for record. Jan. 2016
HoD
(Elect.)
6.5 Records are maintained in Energy Conservation Record file
Continuous HoD
(Elect.)
7. REVIEW: MR and Document Control Officer will monitor and review the progress.
8. RECORDS: Energy Conservation Record file available with HOD(Elect).
GAIL (India) Ltd. Vaghodia. INTEGRATED MANAGEMENT SYSTEMS MANUAL
OBJECTIVES, TARGETS & PROGRAMME(S)
DOC. No.: CH AM01.13 REV. NO.: 02 REV. DATE: 01.06.2015 PAGE NO. 35
MANAGEMENT PROGRAM FOR OBJECTIVE AND TARGETS FOR ISO: 14001
Title: DEVELOPMENT OF GREENERY IN & AROUND PLANT AREA
1. SCOPE: GPU, Vaghodia.
2. OBJECTIVE: Plantation of trees in & around plant area.
3. TARGET: To plant 50 trees in & around plant in FY 2015-16
4. PERFORMANCE CRITERIA: Nos. of trees planted & survival rate.
5. RESPONSIBILITY: HoD (CIVIL)
6. ACTIVITIES:
Sr. No. Description Period Responsibility
6.1 Tree plantation of 50 saplings of trees shall be
planted in the FY
Apr-15 to
Mar-16 HoD (Civil)
6.2 Identify location for plantation of trees. May 2015 HoD (Civil)
6.3 Study of plants which will help for pollution
control and Suitable for Hydrocarbon processing
industry. June 2015
HoD (Civil)
6.4 Budgetary and Administrative approval for
implementation of the scheme. July 2015 HoD (Civil)
6.5 Sapling shall be obtained from any Forest/Social
Forestry/Horticulture nursery. Nov. 2015 HoD (Civil)
6.6 Extension of existing treated effluent water line, if
required. Dec. 2016 HoD (Civil)
6.7 Survey for the trees growth/ survival rate Mar.2016 HoD (Civil)
7. REVIEW: HoD (Civil), MR and Document Control Officer will monitor and
review the progress.
8. RECORDS: Available with HOD (Civil).
MANAGEMENT PROGRAM FOR OBJECTIVE AND TARGETS FOR ISO: 14001
GAIL (India) Ltd. Vaghodia. INTEGRATED MANAGEMENT SYSTEMS MANUAL
OBJECTIVES, TARGETS & PROGRAMME(S)
DOC. No.: CH AM01.13 REV. NO.: 02 REV. DATE: 01.06.2015 PAGE NO. 36
MANAGEMENT PROGRAM FOR OBJECTIVE AND TARGETS FOR ISO: 14001
TITLE: ENVIRONMENTAL AWARENESS FOR EMPLOYEES & CONTRACTORS
1. SCOPE: Employees and Contractor providing services at GAIL, Vaghodia.
2. OBJECTIVE: To bring environmental awareness to all Employees & Contractors.
3. TARGET: To complete 80% employees training by March 2016.
4. PERFORMANCE CRITERIA: Nos. of employees trained under awareness training.
5. RESPONSIBILITY: MR is responsible for deciding the topics to be covered in the
programme & the Faculty and informing HoD (HR) and Training In-Charge are responsible for
organizing the awareness programme for the employees. Respective HoDs are responsible for
conducting awareness programme for contractors and their employees.
6. ACTIVITIES: Sr. No. Description Period Responsibility
6.1 Prepare a detail report of employees and
contractors to be trained on EMS.
June
2015
Training In
Charge
6.2
Decide on EMS awareness programme for
senior/middle level management and inform HoD
(HR).
Sep.
2015
MR &
HoD (HR)
6.3 Organize the programme to cover all employees.
Nov-
Feb
2015
MR &
HoD (HR)
6.4
Observe the effectiveness of the programme by
obtaining feed back from employees in case of
external training.
After
each
training
Training
In
Charge
6.5
In case the programme is not held as per schedule,
the same is to be reviewed in one month and new
dates will be intimated. - HoD (HR)
6.6 Reorganize the programme, after one year. - HoD (HR)
7. REVIEW: MR and Document Control Officer will monitor and review the progress in
organizing training programme.
8. RECORDS: TRAINING RECORD AND SCHEDULE.
GAIL (India) Ltd. Vaghodia. INTEGRATED MANAGEMENT SYSTEMS MANUAL
OBJECTIVES, TARGETS & PROGRAMME(S)
DOC. No.: CH AM01.13 REV. NO.: 02 REV. DATE: 01.06.2015 PAGE NO. 37
MANAGEMENT PROGRAM FOR OBJECTIVE AND TARGETS FOR ISO: 14001
Title: REDUCTION OF WATER CONSUMPTION IN FY 2014-15 WITH
COMPARED TO PREVIOUS YEAR
1. SCOPE: GPU, Vaghodia.
2. OBJECTIVE: Reduction in water consumption at GAIL, Vaghodia.
3. TARGET: 0.5% reduction in water consumption for the FY 2015-16.
4. PERFORMANCE CRITERIA: As per above targets.
5. RESPONSIBILITY: HOD (GPU - OPS.)
6. ACTIVITIES:
Sr. No. Description Period Responsibility
6.1
0.5% reduction in water consumption
for the year 2014-15 wrt previous
years
2015-2016 HoD (GPU-OPS.) /
HoD (Mech.)
6.2 Study of the entire water consumption
scheme. Apr. 2015 HoD (GPU-OPS.)
6.3 Preparation of various water
consumption outlets. May 2015 HoD (GPU-OPS.)
6.4 Identification of possible source of
water loss. July 2015 HoD (GPU-OPS.)
6.5 Exploring the possibility of recycling of
used water. Sep 2015
HoD (GPU-OPS.) &
HoD (Civil.)
6.6 Budgetary and Administrative approval
for implementation of the scheme, Nov. 2015
HoD (GPU-OPS.) /
(F&S)/(Mech.)
6.7 Execution of scheme. Mar-2016 HoD (Mech.)
6.8 Evaluation of performance Apr-2016 HoD (T.S.)
6.9
Preparation of performance Report and
reporting to GPCB by September every
year.
every year
by
September
HoD (T.S.)
7. REVIEW: MR and Document Control Officer will monitor and review the progress.
8. RECORDS: AVAILABLE WITH HOD (T/S) & HOD (OPS)
GAIL (India) Ltd. Vaghodia. INTEGRATED MANAGEMENT SYSTEMS MANUAL
OBJECTIVES, TARGETS & PROGRAMME(S)
DOC. No.: CH AM01.13 REV. NO.: 02 REV. DATE: 01.06.2015 PAGE NO. 38
MANAGEMENT PROGRAM FOR OBJECTIVE AND TARGETS FOR ISO: 18001
TITLE: EMERGENCY AWARENESS AND MAINTAINING SAFETY FOR
EMPLOYEES & CONTRACTORS
1. SCOPE: Employees and Contractor providing services at GAIL, Vaghodia.
2. OBJECTIVE: To bring emergency awareness to all Employees & Contractors.
3. TARGET: To impart refresher training to 80% employees every year.
4. PERFORMANCE CRITERIA: Nos. of employees trained under awareness programme.
5. RESPONSIBILITY: HoD (F & S) is responsible for deciding the topics to be
covered in the programme and faculty and informing all HoDs. HoD (F&S) is responsible
for organizing the emergency awareness programme for the employees. Respective HoDs
are responsible for ensuring the participation of the employees working
under them
6. ACTIVITIES: Sr. No. Description Period Responsibility
6.1
Prepare a detail report of employees and
contractors to be trained on emergency
preparedness.
June.
2015 HoD (F & S)
6.2
Decide on emergency preparedness awareness
programme for senior/middle level management
and inform HoD (HR) w.r.t. the collection of
feed back from employees.
Sep.
2015
MR
&
HoD (F & S)
6.3 Organize the programme to cover all
employees.
Nov.
2015 MR &HoD (F &S)
6.4
Observe the effectiveness of the programme by
obtaining feed back from employees in case of
external training.
After
each
training
Training In
Charge
6.5
In case the programme is not held as per
schedule, the same is to be reviewed in one
Month and new dates will be intimated.
- HoD (F & S)
6.6 Reorganize the programme, after one year. - HoD (F & S)
7. REVIEW: MR and Document Control Officer will monitor and review the progress in
organizing training programme
8. RECORDS: Training Record and Schedule.
GAIL (India) Ltd. Vaghodia. INTEGRATED MANAGEMENT SYSTEMS MANUAL
OBJECTIVES, TARGETS & PROGRAMME(S)
DOC. No.: CH AM01.13 REV. NO.: 02 REV. DATE: 01.06.2015 PAGE NO. 39
MANAGEMENT PROGRAM FOR OBJECTIVE AND TARGETS FOR OHSAS-18001
TITLE: CATEGORISATION AND MONITORING OF HEALTH LEVEL OF
EMPLOYEES
1. SCOPE: GPU, Vaghodia.
2. OBJECTIVE: Categorization and monitoring of health level of employees.
3. TARGET: Categorization of different employees as per annual health check & subsequent
monitoring / counseling of employees in the year 2014-15.
4. PERFORMANCE CRITERIA: As per above target
5. RESPONSIBILITY: HoD (HR) & HOD ( F&S )
6. ACTIVITIES:
7. REVIEW: MR will monitor and review the progress in organizing occupational health
checkup program.
8. RECORDS: Health Check-Up Register/Record.
Sr. No. Description Period Responsibility
5.1 HEALTH CHECK UP 2015-2016 HoD (GPU-OPS
& Mech )
CATEGORISATION AND MONITORING OF HEALTH LEVEL OF EMPLOYEES
5.2 Preparation of List of employees July 2015 HoD (HR)
5.3 Preparation of health parameters for health
check up Aug 2015
HoD
(HR/HOD(F&S)
5.4 Budgetary and Administrative approval for
implementation of the scheme. Sept 2015 HoD (HR)
5.5 Preparation of Tender document Oct 2015 HoD (HR)
5.6 Awarding of Contract Nov 2015 HoD (C &P)
5.7 Schedule of employees given to hospital Nov 2015 HoD (HR)
5.8 Completion of the Health checkup scheme by
target date Dec 2015
HoD (HR)/
HOD(F&S)
5.9 Submission of report by hospital Jan -2016 HOD(HR)
6.0 Evaluation of Health status of employees Jan -2016 HOD(F&S)
6.1 Preparation of categorization of employees as
per disease etc Jan -2016 HOD(F&S)
6.2 Preparation of performance Report Feb -2016 HOD(F&S)
6.3 Counseling by Doctor to employees Mar -2016 HOD(F&S)
GAIL (India) Ltd. Vaghodia. INTEGRATED MANAGEMENT SYSTEMS MANUAL
TITLE: RESOURCES, ROLES, RESPONSIBILITY AND
AUTHORITY
DOC. No.: CH AM01.14 REV. NO.: 01 REV. DATE: 01.10.2012 PAGE NO. 40
1.0 PURPOSE:
To ensure that
Roles, Responsibility and Authority in establishing, implementing, maintaining
and improving the IMS are defined, documented and communicated.
Resources and infrastructure essential to the implementation and control of the
IMS are provided
Defining organization structure as well as ensuring proper Work Environment
2.0 SCOPE:
Applicable to GAIL, Vaghodia covered under the IMS established in line with ISO
9001:2008, ISO 14001:2004 and OHSAS 18001:2007 standards.
3.0 RESPONSIBILITY:
The Overall responsibility for ensuring that IMS is established in line with the
Organizational goals lies with the OIC,Vaghodia.
4.0 SYSTEM REQUIREMENTS:
GAIL shall define the roles, responsibility and authority in a systematic manner. Overall
responsibility of Integrated Management System is with top management, which shall
provide necessary technical, human & financial resources for effective implementation
and maintenance of IMS. Organogram of GAIL Vaghodia complex shall be developed
and maintained with reporting relation. GAIL top management shall also appoint MR
with responsibility and authority for implementing and maintaining IMS. MR shall be
responsible for coordinating with HODs & top management. MR shall report the
performance of IMS including audit findings to the top management.
HODs are assigned the responsibility and authority of maintaining the IMS within their
areas. Detailed responsibilities shall be prepared, documented and communicated to all
concerned. GAIL Environment Policy also makes aware all the employees for their
responsibilities towards prevention of pollution. The detailed organogram of the GAIL
Vaghodia complex is developed & enclosed in AXAM01.01. Responsibilities are also
defined for achieving objectives, targets, EMP’s and OHSMP’s, procedures, internal
audits & action plan of management reviews.
GAIL (India) Ltd. Vaghodia. INTEGRATED MANAGEMENT SYSTEMS MANUAL
TITLE: RESOURCES, ROLES, RESPONSIBILITY AND
AUTHORITY
DOC. No.: CH AM01.14 REV. NO.: 01 REV. DATE: 01.10.2012 PAGE NO. 41
PROVISION OF RESOURCES
The resources needed to implement and maintain the integrated management
system and continually improve its effectiveness, and to enhance customer satisfaction
by meeting customer requirements shall be determined by the Head of Department and
communicated to the relevant authority. These resource requirements shall be reviewed
(especially during management reviews) and shall be provided by appropriate means as
described below.
The organization has determined and provided necessary resources needed
To establish and maintain the quality management system, and improve its
effectiveness.
to enhance customer satisfaction by meeting their requirements
HUMAN RESOURCES
The organization selects and assigns personnel performing work affecting product
quality, or involved in activities with significant environmental aspects and non
tolerable OHS risks on the basis of appropriate education, skills and experience. The
organization has also a system to assess the competence of its personnel on periodic
basis (Performance Appraisal and Development Report) to identify gap in the
performance, if any, as well as assess their training needs to bridge the gap.
INFRASTRUCTURE
Resources requirement in terms of plant, machinery, tools, instruments and personnel
have been identified and provided.
GAIL has gone for the best technology available in the world for the recovery of LPG
from Natural Gas. Building & equipments were provided as per the recommendations of
EIL. Further a well-equipped Lab with facility for assuring the quality of products is
provided along with competent personnel.
These are being maintained in order to achieve conformity to product requirements and
reviewed from time to time for suitability and further improvement.
The infrastructure needed for effective functioning of the IMS in terms of workspace
requirements, equipment needed, the other support facilities required shall be assessed
by the H.R for current work requirements and by the Head of Department for future
growth. The requirement for infrastructure shall be reviewed during management
reviews and meetings or at times when required. The required infrastructure shall be
provided after assessing the cost- benefit implications. Material resources where
required are procured as per the “Procedure for Purchase-PM07.01”
GAIL (India) Ltd. Vaghodia. INTEGRATED MANAGEMENT SYSTEMS MANUAL
TITLE: RESOURCES, ROLES, RESPONSIBILITY AND
AUTHORITY
DOC. No.: CH AM01.14 REV. NO.: 01 REV. DATE: 01.10.2012 PAGE NO. 42
WORK ENVIRONMENT
The organization has determined and is maintaining the necessary work environment
needed to achieve a positive influence on motivation, satisfaction and performance of
people to enhance the overall performance of the organization and achieve
uninterrupted supply of products to its customers.
This includes:
a. Environmental Legislation and guidelines.
b. Safety rules and guidance Adherence to safety rules and guidance, including use
of protective equipment like helmets, Safety Belts, gloves, shoes, raincoats
during rains.
b Work instructions, which define the operating work environment conditions for
achieving desired production
c Facilities for people in the organization such as DCS, Computers etc., for
producing and checking
d Hygiene, cleanliness etc.
Maintenance department ensures that the plant and the machinery are suitable to
achieve the product conformity as detailed in the respective department Manual.
These have been documented in the respective procedures wherever needed to achieve
conformity to product requirements.
5.0 ROLES OF EACH FUNCTION
5.1 D.G.M (O&M)/OIC,Vaghodia:
1. Providing necessary resources to implement IMS by arranging manpower and
budgetary support and overall IMS implementation.
2. External / Internal Communication.
3. Chairperson of Management Review Committee & responsible for reviewing the
suitability and effective implementation of IMS.
4. Approving Policy and Objectives.
5. He shall assist Director (Projects) in ensuring that the Quality Policy and Objectives
of the Organization as defined and documented by him shall be understood,
implemented and maintained at all levels of the Organization.
6. He shall also nominate a Management Representative with adequate responsibility
and authority as per the requirement of the international Quality System Standard
ISO - 9001: 2008, Environment Management Systems ISO 14001:2004 and
GAIL (India) Ltd. Vaghodia. INTEGRATED MANAGEMENT SYSTEMS MANUAL
TITLE: RESOURCES, ROLES, RESPONSIBILITY AND
AUTHORITY
DOC. No.: CH AM01.14 REV. NO.: 01 REV. DATE: 01.10.2012 PAGE NO. 43
Occupational Health and Safety Management Systems OHSAS 18001:2007 for
LPG Recovery Plant.
7. He shall responsible for Contract Review. He has been provided with adequate
responsibility and authority for carrying out the above activities. In carrying out
these tasks he shall be assisted by a team of officers and staff under him. 8. He is designated as Factory Manager and as per Gujarat Factory rules, and has all
the responsibility of an Factory Manager and he shall ensure the health, safety and
welfare of all workers while they are at work in the factory, includes:
Provision and Maintenance of plant and system of work in the factory that are
safe and without risks to health.
Arrangement in the factory for ensuring safety and absence of risks to health in
connection the use, handling, storage and transport of articles and substances.
The provision of such information, instruction, training and supervision as are
necessary to ensure the health and safety of all workers at work.
The maintenance of all places of work in the factory in a condition that is safe
and without risks to health and he provision and maintenance of such means of
access to, and egress from, such places as are safe and without such risks.
The provision, maintenance or monitoring of such working environment in the
factory for the workers that is safe, without risk to health and adequate as
regards facilities and arrangements for their welfare at work.
Prepare a written statement of general policy with respect to health and safety of
workers at work and organization and make arrangements for carrying out this
policy; also responsible to bring the statement and any revision there of to the
notice of all the workers. 5.2 MR:
1. MR has the responsibility for establishing & ensuring effective implementation &
maintenance of IMS and reporting performance to the top Management.
2. Internal Audits and Management Review Meetings.
3. Follow up of action plan related to objective and targets.
4. Corrective/Preventive actions after Internal Audit.
5. External / Internal Communication. 6. Ensuring that processes needed for the IMS are established implemented and
maintained.
7. Reporting on the performance of the Environment, safety , Health and Quality
System including internal and external quality audit reports to the management in
the Management Review meetings for review, corrective actions and for its
continual improvement;
8. Analyzing the customer’s feedback
9. Ensuring the promotion of awareness of customer requirements through meetings,
trainings, discussions or any other means as appropriate.
10. Liaison with external agencies on matters relating to ISO-9001, ISO 14001 and
OHSAS 18001 Management System.
GAIL (India) Ltd. Vaghodia. INTEGRATED MANAGEMENT SYSTEMS MANUAL
TITLE: RESOURCES, ROLES, RESPONSIBILITY AND
AUTHORITY
DOC. No.: CH AM01.14 REV. NO.: 01 REV. DATE: 01.10.2012 PAGE NO. 44
5.3 HOD (Operations-LPG):
1. Achieving objectives & targets related to the department.
2. Communication to other departments.
3. Aspect identification, hazard identification and risk assessment, impact evaluation
and operational control related to department.
4. Control of IMS documentation and records related to the department.
5. Training identification of the department.
6. Ensuring process control for smooth Plant operation as per established procedures
and quality plan / specifications.
7. Maintaining Controlled Environment for Processing.
8. Authorization for release of final products to the customer.
9. Ensuring compliance to all Safety and regulatory requirements in plant operation.
10. To ensure availability of plant / machinery / equipment for maintenance purpose.
11. He is fully responsible for process safety and safe operation of plant including
compliance to all OHS safety and statutory / mandatory regulation in the plant
operations. He is also responsible for
12. Training identification of the department
In carrying out the above tasks he shall be assisted by a team of officers and staff
under him.
5.4 HOD (Operations-HVJ): 1. Achieving objectives & targets related to the department.
2. Communication to other departments.
3. Aspect identification, hazard identification and risk assessment, impact evaluation
and operational control related to department.
4. Control of IMS documentation and records related to the department.
5. Training identification of the department.
6. Ensuring process control for smooth Plant operation as per established procedures
and quality plan / specifications.
7. Maintaining Controlled Environment for Processing.
8. Authorization for release of final products to the customer.
9. Ensuring compliance to all Safety and regulatory requirements in plant operation.
10. To ensure availability of plant / machinery / equipment for maintenance purpose.
11. He is fully responsible for process safety and safe operation of plant including
compliance to all OHS safety and statutory / mandatory regulation in the plant
operations. He is also responsible for
12. Training identification of the department
In carrying out the above tasks he shall be assisted by a team of officers and staff
under him.
GAIL (India) Ltd. Vaghodia. INTEGRATED MANAGEMENT SYSTEMS MANUAL
TITLE: RESOURCES, ROLES, RESPONSIBILITY AND
AUTHORITY
DOC. No.: CH AM01.14 REV. NO.: 01 REV. DATE: 01.10.2012 PAGE NO. 45
5.5 HOD (TS)/ ISO CO-ORDINATOR:
HOD (TS) is responsible for following activities:
1. To perform pollution control activities.
2. Meeting Legal & regulatory requirements:
a) Factories Act
b) Water Act
c) Air Act
d) EPA Act etc.
3. Control of EMS documentation and records related to the department.
4. Communication to other departments.
5. Responsible for issue, updation, amendments, coordination & recall of all
“CONTROLLED” documents.
6. Identification of training need for the departmental.
7. To conduct testing and monitoring of Air and Water quality.
8. HOD (TS) is authorized to perform his responsibility for the above activities
5.6 HOD (F&S): 1. Implementation of legal rules related to department.
2. Achieving objectives & targets related to the department.
3. Communication to other departments.
4. Aspect identification, Hazard identification and risk assessment, Impact evaluation
and operational control related to department activities.
5. Control of IMS documentation and records related to the department.
6. Training identification of the department.
7. Review, revise and distribute on site Disaster Control Plan.
8. Conducting mock drills, safety audits and fire fighting training.
9. Maintenance of fire fighting equipment and emergency response system of GAIL,
Vaghodia.
10. Ensuring complete safety in construction, operation and maintenance for men,
materials and equipment.
11. Ensuring the damage control with fire extinguisher of any fire or gas leakage
situation.
12. Ensuring complete accident prevention, reporting and investigation measures are
taken care off.
13. Ensuring that the relevant requirement of OISD norms on fire & safety are
complied with and properly maintained.
14. Identifications and requirement of regular F&S training
15. Liasoning with OISD, LPA, NSC, Insurance and Statutory Authorities.
16. Impart minimum Fire & Safety measure / awareness training to all the employees of
LPG Recovery Plant and also to the contractors.
17. Convening of safety committee meeting and follow up.
18. Planning and processing for procurement of F&S equipment and PPEs.
19. Compliance as regard to internal and external safety audits requirements.
GAIL (India) Ltd. Vaghodia. INTEGRATED MANAGEMENT SYSTEMS MANUAL
TITLE: RESOURCES, ROLES, RESPONSIBILITY AND
AUTHORITY
DOC. No.: CH AM01.14 REV. NO.: 01 REV. DATE: 01.10.2012 PAGE NO. 46
5.7 HOD (Mech.):
1. Achieving objectives & targets related to the department.
2. Communication to other departments.
3. Aspect identification, Hazard identification and risk assessment, Impact evaluation
and operational control related to department.
4. Control of IMS documentation and records related to the department.
5. Training identification of the department.
6. Planning and implementing preventive maintenance with view to achieve high
availability of Mechanical equipment.
7. Carrying out routine and break down maintenance of mechanical equipment.
8. To prepare specifications / material requisition / technical evaluation of various
contracts, purchase requirements and various annual maintenance contracts.
9. Availability of spare parts to ensure low down time.
In carrying out the above tasks, he shall be assisted by a team of officers and staff
under him.
5.8 HOD (Electrical): 1. Implementation of Legal rules related to department.
a) Indian Electricity Rules. b) Battery Rule
2. Achieving objectives & targets related to the department.
3. Communication to other departments.
4. Aspect identification, Hazard identification and risks assessment, Impact evaluation
and operational control related to department.
5. Control of IMS documentation and records related to the department.
6. Training identification of the department.
7. Planning and implementing preventive maintenance with a view to achieve high
availability of Electrical equipment.
8. Carrying out routine and break down maintenance.
9. Spares parts planning to ensure low down time.
10. O & M. of electrical sub-stations ensuring electrical safety aspects in plant.
11. To prepare specifications for various contracts required for above-mentioned
activities.
In carrying out the above tasks he shall be assisted by a team of officers and staff
under him.
5.9 HOD (Instrumentation): 1. Implementation of Legal rules related to department. Indian explosive act (SMPV
rules) especially pressure safety valves etc.
2. Achieving objectives & targets related to the department.
3. Communication to other departments.
4. Aspect identification, Hazard identification and Risks assessment, Impact evaluation
and operational control related to department.
GAIL (India) Ltd. Vaghodia. INTEGRATED MANAGEMENT SYSTEMS MANUAL
TITLE: RESOURCES, ROLES, RESPONSIBILITY AND
AUTHORITY
DOC. No.: CH AM01.14 REV. NO.: 01 REV. DATE: 01.10.2012 PAGE NO. 47
5. Control of IMS documentation and records related to the department.
6. Training identification of the department.
7. Planning and implementing preventive maintenance with a view to achieve high
availability of Instruments.
8. Carry out modifications as per process requirement.
9. Carrying out predictive and break down maintenance.
10. Calibration of test and measurement instrument.
11. Spares parts planning to ensure low down time.
In carrying out the above tasks he shall be assisted by a team of officers and staff
under him.
6.0 In Charge (HR):
1. Implementation of Legal rules related to department. Labour laws.
2. Achieving objectives & targets related to the department.
3. Communication to other departments.
4. Aspect identification, Hazard identification and Risks assessment, Impact evaluation
and operational control related to department.
5. Control of IMS documentation and records related to the department.
6. Training identification of the department.
7. Training records and competency check.
8. Organizing training for employees.
9. For arranging In-house and External training for all employees as per approved
TNA / Training planner.
10. Arranging and recording the training feed back obtained from the participants for
assessing the effectiveness of the training.
11. For maintaining an updated training records of all personnel.
12. Necessary coordination with concerned HOD`s and the MR for identifying and
approving the training requirements.
In carrying out the above tasks he shall be assisted by a team of officers and staff
under him.
6.1 HOD (C & P): 1. Achieving objectives & targets related to the department.
2. Communication to other departments & vendors.
3. Aspect identification, Hazard identification and Risks assessment, Impact evaluation
and operational control related to department.
4. Control of IMS documentation and records related to the department.
5. Training identification of the department.
6. Responsible for ensuring that all the planned material supplies are made timely to
enable plant facilities do not face operational interruption / upset due to non-
availability of material thus causing an impact on the environment.
GAIL (India) Ltd. Vaghodia. INTEGRATED MANAGEMENT SYSTEMS MANUAL
TITLE: RESOURCES, ROLES, RESPONSIBILITY AND
AUTHORITY
DOC. No.: CH AM01.14 REV. NO.: 01 REV. DATE: 01.10.2012 PAGE NO. 48
7. Procurement of Quality Spares, Consumables, Lab Chemicals, Capital Items and
others as per the Specified Quality requirements as per C&P procedure of GAIL.
8. Works contracts except Civil Jobs
9. Identification & Disposal of Scrap and obsolete items.
10. Approval of subcontractors, and updation of the list.
11. The approval of purchasing data (PO) after review.
12. Verification of Purchased Product.
13. Maintenance & Operation of main stores.
14. Regular monitoring of the stored items.
In carrying out the above tasks he shall be assisted by a team of officers and staff
under him.
6.2 HOD (CIVIL): 1. Achieving objectives & targets related to the department.
2. Communication to other departments & contractors.
3. Aspect identification, Hazard identification and Risks assessment, Impact evaluation
and operational control related to department.
4. Green belt management.
5. Horticulture development and maintenance.
6. Control of IMS documentation and records related to the department.
7. Training identification of the department.
8. Record keeping and value addition for environment related jobs.
6.3 IN CHARGE (LABORATORY)
1. Achieving objectives & targets related to the department.
2. To mange quality control activities
3. Overall functioning of laboratory as per established procedures.
4. Overall responsible for maintaining the certified material or chemicals and other
tests and measuring equipments used in laboratory.
5. Responsible for maintaining quality standards as per NABL accreditation
6. Training identification of the department
7. Record keeping and value addition for Quality Control and Laboratory.
6.4 FACTORY MANAGER
He is responsible for compulsory disclosure of information as per Factories
Act, 1948 which includes:
He discloses in the manner prescribed all information regarding danger,
including health hazards and the measures to overcome such hazards arising
from such exposure or handling of materials/substances in the manufacture,
transportation, storage and other processes to the workers employed in the
GAIL (India) Ltd. Vaghodia. INTEGRATED MANAGEMENT SYSTEMS MANUAL
TITLE: RESOURCES, ROLES, RESPONSIBILITY AND
AUTHORITY
DOC. No.: CH AM01.14 REV. NO.: 01 REV. DATE: 01.10.2012 PAGE NO. 49
factory, Chief Inspector, Local authority within whose jurisdiction the factory is
situated and the general public in the vicinity.
The information includes accurate information to the quantity, specifications and
other characteristics of wastes and the manner of disposal.
Drawing up & revision of on site Emergency Plan and detailed disaster
controlled measure with the approval of Chief factory Inspector; Informing
workers and general public in the vicinity of factory.
The safety measures required to be taken in the event of an accident taking
place.
Laying down measures for the handling, usage, transportation, storage of
hazardous substances outside the factory premises and publicize among the
worker and general public in the vicinity.
Informing person outside the site either directly or through district emergency
authority, the areas which may be affected by major accident along with nature
of the accident and safety measures, do’s & don’ts to be adopted.
Be a part of local crisis group and taking appropriate actions as per Chemical
Accident Rules, 1996.
In the case of emergency the roles and responsibilities are as given in Onsite / Offsite
emergency plan.
The organizational structure is given in AXAM01.05.
Whenever personnel responsible for specific quality functions are not available, the
immediate superior shall re-delegate their responsibilities.
Designations/ Roles specified are minimum required to carry out an activity. A higher-
level person in the organization structure also can carry out the same task.
Key roles and responsibilities of personnel shown in the organization chart are as
mentioned in AXAM01.05.
COMMON RESPONSIBILITIES, AUTHORITIES & ACCOUNTABILITY OF
ALL HODs
1. Accountable to all processes related to the concerned Departmental Activities.
2. To define functional responsibility and authority of the personnel reporting to
them.
3. Approval / Maintenance / Updation of the procedures relevant to their work
areas.
4. To maintain identification and tractability as per established procedures in their
work area.
GAIL (India) Ltd. Vaghodia. INTEGRATED MANAGEMENT SYSTEMS MANUAL
TITLE: RESOURCES, ROLES, RESPONSIBILITY AND
AUTHORITY
DOC. No.: CH AM01.14 REV. NO.: 01 REV. DATE: 01.10.2012 PAGE NO. 50
5. To control non conformities including the non conforming products in their
respective work area.
6. To implement corrective / preventive action for any nonconformities including
the audit observations in their area.
7. To control records related to their work areas.
8. To identify and impart training to the personnel reporting to them.
9. To implement applicable (if any) statistical techniques identified in their work
area.
10. The detailed responsibilities and authorities are defined in the relevant
procedures. These have been communicated within the organization through
departmental manuals. The responsibilities and authorities of all personnel in the
organization have been defined and are maintained in the form of organ gram by
the respective HODs in their respective manuals and communicated by them to
the concerned personnel.
11. The specific responsibility and authority of all HODs in addition to common
responsibilities given above are as under.
Coordinator & Document Control Officer (DCO)
The Document Control Officer has the following responsibility and authority;
1. To control all document as per established procedure.
2. To maintain the master list of controlled documents.
3. To keep issue records of all controlled documents.
4. To identify / withdraw and preserve obsolete documents to avoid unintended
use.
5. To incorporate changes in documents as per established procedure.
For authority of key personnel please refer Book of delegated Power issued by GAIL
corporate office.
The detailed responsibilities and authorities are defined in the relevant procedures. These
have been communicated within the organization through departmental manuals. The
responsibilities and authorities of all personnel in the organization have been defined and
are maintained in the form of organogram by the respective HODs in their respective
manuals and are communicated by them to the concerned personnel.
6.0 REFERENCE:
Procedure for Emergency Handling (PMM01.11) PM06.01
GAIL (India) Ltd. Vaghodia. INTEGRATED MANAGEMENT SYSTEMS MANUAL
TITLE: TRAINING, AWARENESS & COMPETENCE
DOC. No.: CH AM01.15 REV. NO.: 00 REV. DATE: 01.05.2011 PAGE NO. 51
1.0 PURPOSE:
To identify training needs and ensure that all personnel who is working for or on behalf
of the organizations and whose work may create a significant impact upon the
environment or non tolerable risks associated with his work or affect the quality of the
product have received appropriate training.
2.0 SCOPE:
Applicable to training provided to all employees/subcontractors involved directly in all
the activities of GAIL, Vaghodia who is working for or on behalf of the organization
and whose work may create a significant impact upon the environment.
3.0 RESPONSIBILITY:
The overall responsibility for establishing, implementing and updating the system lies
with the Management representative.
Responsibility for maintaining and updating the training related documentation lies with
the HOD, HR.
The responsibility for identifying needs and additional responsibility for supporting
training of their personnel lies with the respective Department Heads.
4.0 SYSTEM REQUIREMENTS:
“Procedure for Training” will be established and maintained by Human Resources
Department to make the employees or members or any persons working for, or on
behalf, the organization at each relevant functions and level aware of
a) The importance of conformance with the quality, safety and occupational health
and environmental policy and procedures and with the requirements of the
integrated management system.
b) The significant environmental impacts, non tolerable risks, actual or potential, of
their work activities and the environmental, quality and occupational health and
safety benefits of improved personal performance.
c) Their roles and responsibilities, in achieving conformance with the quality,
safety , health and environmental policy, procedures and with the requirements of
the integrated management system, including emergency preparedness of response
requirements.
d) The potential consequences of departure from the specified operating procedures.
GAIL (India) Ltd. Vaghodia. INTEGRATED MANAGEMENT SYSTEMS MANUAL
TITLE: TRAINING, AWARENESS & COMPETENCE
DOC. No.: CH AM01.15 REV. NO.: 00 REV. DATE: 01.05.2011 PAGE NO. 52
Personnel performing the tasks which can cause significant environmental impacts
and non tolerable risks or affect the quality of the product will be competent on the
basis of appropriate education, training and/or experience.
GAIL, Vaghodia will also require that contractors working at site / in transportation
on its behalf are able to demonstrate that their employees have the requisite training
/ awareness so that they comply with the quality, safety, health and environmental
policy and procedures of GAIL e.g. training on proper operation of vehicles, diesel
engines, statutory requirement of vehicular emissions etc.
Management will determine the level of experience, competence and training
necessary to ensure the capability of personnel, especially those carrying out
specialized environmental as well as integrated management functions e.g.
operating LPG Plant.
Training programmes will be planned and imparted to employee and contract
workers whether in-house or external.
Effectiveness of training will be reviewed from time to time.
Competency of each employee is monitored as per human resources management
system of GAIL, Vaghodia.
The organization has determined the necessary competence for personnel
performing work affecting product quality and is available with HR Department.
The organization has established “Procedure for Training-PM08.01” for identifying
training needs and provides training to personnel as per identified needs. The
effectiveness of training is also evaluated.
The training process entails the following:
a) Provision of training to satisfy competence needs of personnel identified.
b) Evaluate the effectiveness of the actions taken i.e. the training imparted
c) Ensure that the personnel are aware of the relevance and importance of their
activities and how they contribute to the achievement of the quality,
environment, safety and health objectives
d) Maintenance of appropriate records of education, training, skills and
experience
Fire & Safety Training shall be given to all GAIL Employees as well as to
Contract employees from time to time.
GAIL (India) Ltd. Vaghodia. INTEGRATED MANAGEMENT SYSTEMS MANUAL
TITLE: TRAINING, AWARENESS & COMPETENCE
DOC. No.: CH AM01.15 REV. NO.: 00 REV. DATE: 01.05.2011 PAGE NO. 53
5.0 REFERENCE:
“Procedure for Training” in Human Resource Department Manual P M08.01
6.0 RECORDS:
All the records in the above mentioned procedure will be maintained.
GAIL (India) Ltd. Vaghodia. INTEGRATED MANAGEMENT SYSTEMS MANUAL
TITLE: COMMUNICATION
DOC. No.: CH AM01.16 REV. NO.: 01 REV. DATE: 01.05.2012 PAGE NO. 54
1.0 PURPOSE:
To receive, document and respond to relevant information and requests from- & to-
interested parties, both internal and external.
2.0 SCOPE:
Applicable to communications regarding significant environmental aspects, non
tolerable risks and environmental, quality as well as OHS issues concerning GAIL,
Vaghodia with interested parties, this can be both internal and external.
3.0 RESPONSIBILITY:
The overall responsibility for establishing, documenting, updating the system lies with
the Management Representative.
The responsibility for implementing the system lies with the HODs.
4.0 SYSTEM REQUIREMENTS:
With regard to its environmental aspects, OHS hazards and non tolerable risks,
quality of product and integrated management system, GAIL, Vaghodia will
establish and maintain Procedure for Internal and External Communication
a) Internal communication regarding quality, OHS and environmental issues
between the various levels and functions of the organization through memos,
meetings, circulars, training, and sign boards, cards, etc.
b) Establishing any method for external communication about GAIL, Vaghodia’s
significant environmental aspects will be decided in Management Review
Meeting.
c) Receiving, documenting and responding to relevant communication from external
interested parties such as PCB, public bodies/individuals, the court, investors,
MOEF etc. Other responses to interested external parties concerns will include
relevant information/discussions about the environmental impacts associated with
the organization’s operations.
d) Legal communication on EHS issues will be done by respective HOD’S of GAIL,
Vaghodia.
e) Communication related to legal cases if any will be done by HR department of
GAIL, Vaghodia.
f) Necessary communications with public authorities regarding emergency planning
and other relevant issues will be made.
External communication on EHS issues will be recorded and tracked.
The Quality, Environmental, Safety and Health policy and objectives and targets are
communicated to all employees through discussions, training programmes, hand
GAIL (India) Ltd. Vaghodia. INTEGRATED MANAGEMENT SYSTEMS MANUAL
TITLE: COMMUNICATION
DOC. No.: CH AM01.16 REV. NO.: 01 REV. DATE: 01.05.2012 PAGE NO. 55
outs, display boards and any other means as appropriate. Achievement of the
quality, environment, safety and health policy and objectives are reviewed in the
management review meetings.
The communication regarding the effectiveness of the integrated management
system is done through the management reviews, meetings and any other avenues as
felt appropriate. It is ensured that all the employees are communicated the relevant
issues discussed in such meetings by the respective department/ functional heads.
The communication between management and employees is through notice boards,
e-mail, suggestion schemes, and meetings and through HODs.
The senior management conducts meetings of HODs for communicating with
employees as well as reviewing the working of the plant.
The organization has got its own dedicated telecom network, which facilitates easy
transmission of voice and data throughout GAIL Vaghodia.
5.0 REFERENCE: Procedure for Internal and External Communication P MM01.06
6.0 RECORDS:
All the records in the above mentioned procedure will be maintained.
GAIL (India) Ltd. Vaghodia. INTEGRATED MANAGEMENT SYSTEMS MANUAL
TITLE: DOCUMENTATION
DOC. No.: CH AM01.17 REV. NO.: 00 REV. DATE: 01.05.2011 PAGE NO. 56
1.0 PURPOSE:
To ensure the documentation of IMS is established.
1.0 SCOPE:
Applicable to all the documents of GAIL, Vaghodia covered under IMS established in
line with ISO 9001:2008 , ISO 14001:2004 and OHSAS 18001:2007 standards.
2.0 RESPONSIBILITY:
The overall responsibility for establishing, documenting, updating IMS documentation
lies with the Management Representative in consultation with top Management and
with the HODs for the concerned departments.
3.0 STRUCTURE OF DOCUMENTATION:
Documents are structured in four layers as follows:-
Apex Manual - Level 1
Procedures - Level 2
Work Instructions - Level 3
Formats - Level 4
The Documents are typically grouped as
a) Apex Manuals and
b) Departmental Manuals
The numbering of the manuals is as follows:-
Sr.
No.
Level of
Document Document Name
Manual
No.
01 Level 1 Apex Manual – Integrated Management
Systems Manual AM01
02 Level 2 to
Level 4
Operations Department Manual (LPG) M3.1
Operations Department Manual (GREP) P4
Mechanical Department Manual M3.2
Electrical Department Manual M3.3
Instrumentation Department Manual M3.4
Fire & Safety Department Manual M3.5
GAIL (India) Ltd. Vaghodia. INTEGRATED MANAGEMENT SYSTEMS MANUAL
TITLE: DOCUMENTATION
DOC. No.: CH AM01.17 REV. NO.: 00 REV. DATE: 01.05.2011 PAGE NO. 57
Civil Department Manual M3.6
Contract & Procurement Department Manual M3.7
H R Department Manual M3.8
Quality Control Laboratory M3.1L
M R Department Manual – Generic processes
applicable across Organization/ applicable to M
R’s Department
MM01
The documents Level 3 and Level 4 are numbered as,
X.YYY.ZZ
Where, X – Type of Document
X Type of Document
P Procedure
WI Work Instruction
F Format
YYY – Manual No. and
ZZ – 01,02,…….., Serial Number of document for the given manual
4.1 INTEGRATED SYSTEM MANUAL (AM 01):
It is the policy level document, which indicates that all requirements of EMS, QMS and
OHSMS standard as per ISO 9001:2008, ISO 14001:2004 and OHSAS 18001:2007
have been addressed, outlines the organization structure and includes responsibility of
key personnel. It also provides reference and directions to all the related procedures. It
is numbered as CH AM01.XXX where XXX = serial number.
4.2 INTEGRATED SYSTEM PROCEDURES (MM 01): Integrated System Procedures are given in MR Department Manual (MM 01). These
procedures define the steps towards meeting the ISO 9001:2008, ISO 14001:2004, and
OHSAS 18001:2007 standards requirements.
In this Manual the elements of ISO 9001, ISO-14001, and OHSAS 18001 are addressed
in detail. ISP covers all the procedures referred in Integrated Management System
Manual (AM01). These are generic procedures applicable across GAIL, Vaghodia.
The Environmental, Quality and Occupational Health and Safety documentation
System are integrated wherever specified and applicable.
GAIL (India) Ltd. Vaghodia. INTEGRATED MANAGEMENT SYSTEMS MANUAL
TITLE: DOCUMENTATION
DOC. No.: CH AM01.17 REV. NO.: 00 REV. DATE: 01.05.2011 PAGE NO. 58
4.3 DEPARTMENTAL PROCEDURES/WORK INSTRUCTIONS MANUAL /
OPERATION CONTROL PROCEDURE MANUAL:
These contain detailed instructions for carrying out those operations, which have
significant environmental impacts, non tolerable risks and quality requirements and
include external reference documents, where applicable. Operational control procedures
/ work instructions have been integrated with the requirements of IMS.
5.0 RECORDS:
The effective implementation of IMS is demonstrated by records. List of other records
pertaining to integrated management at GAIL Vaghodia is also integrated with the
implementation of EMS, QMS and OHSMS Policy and procedures. The records will
contain all NCR’s, CAR’s & observations etc.
The records of EMS, QMS and OHSMS are integrated wherever specified and
applicable.
6.0 REFERENCE:
“Procedure for Document Control” P MM01.02
GAIL (India) Ltd. Vaghodia. INTEGRATED MANAGEMENT SYSTEMS MANUAL
TITLE: DOCUMENTATION CONTROL
DOC. No.: CH AM01.18 REV. NO.: 00 REV. DATE: 01.10.2011 PAGE NO. 59
1.0 PURPOSE:
To ensure all documents are controlled.
2.0 SCOPE:
Applicable to all the documents of GAIL, Vaghodia covered under IMS, established in
line with ISO 9001:2008, ISO 14001:2004 and OHSAS 18001:2007 standard.
3.0 RESPONSIBILITY:
The overall responsibility for establishing, documenting and updating and document
control lies with the Management Representative and with the HOD’s for the concerned
departments.
4.0 SYSTEM REQUIREMENTS:
4.1 Procedure for Control of Documents will be established to ensure that
documents can be located
Periodically reviewed, revised as necessary and approved for adequacy by the
appraising authority.
Document of external origin shall also be controlled.
Current versions of documents are available at all locations where operations
essential to the effective functioning of IMS.
Obsolete documents are properly removed from all points of issue and points of use
Obsolete documents are retained by DCO for knowledge purpose
4.2 DCO is responsible to ensure that:
1. Documents are legible, maintained in orderly manner and retained for a specified
period.
2. Proper distribution as per copy No. and authorized holder's list.
3. Provision for review/approval signatures and a means of indicating the latest
document revision level.
4. A register to indicate the document/copy number and the names and locations of
all holders of controlled documents.
5.0 REFERENCE: “Procedure for Control of Documents” P MM01.02
GAIL (India) Ltd. Vaghodia. INTEGRATED MANAGEMENT SYSTEMS MANUAL
TITLE: OPERATIONAL CONTROL
DOC. No.: CH AM01.19 REV. NO.: 00 REV. DATE: 01.10.2011 PAGE NO. 60
1.0 PURPOSE:
To identify the various operations and activities of GAIL, Vaghodia, including
maintenance, to ensure that they are carried out under specified conditions.
2.0 SCOPE:
Applicable to all the departments of GAIL, Vaghodia covered under IMS, established in
line with ISO 9001, ISO 14001, and OHSAS 18001 standards.
3.0 RESPONSIBILITY:
The overall responsibility for establishing, documenting, implementing and updating
the system lies with the respective Department Heads.
4.0 SYSTEM REQUIREMENTS:
Documented procedure and Operation control procedure will be established and
maintained to cover situations where their absence could lead to deviations from the
quality, safety and health and environmental policy and their objectives and targets,
by the respective department in their department manual or other operating manuals.
Procedures / Work Instructions / Operation control procedure / will be documented /
integrated with existing documents and implemented on the following:
a) Waste management which defines the process of identification, collection,
handling storage and disposal of wastes.
b) Identification, handling, storage and disposal of hazardous materials.
c) Optimum utilization and maintenance of equipment.
d) Emergency preparedness and response, safety.
e) Housekeeping.
Where practicable operating criteria shall be specified in the procedures and/or work
instructions.
5.0 REFERENCE:
MM01 - M R Department Manual
M3.1 - Operations Department Manual (LPG)
P4 - Operations Department Manual (GREP)
M3.2 - Mechanical Department
M3.3 - Electrical Department
M3.4 - Instrument Department
M3.5 - Fire & Safety Department Manual
GAIL (India) Ltd. Vaghodia. INTEGRATED MANAGEMENT SYSTEMS MANUAL
TITLE: OPERATIONAL CONTROL
DOC. No.: CH AM01.19 REV. NO.: 00 REV. DATE: 01.10.2011 PAGE NO. 61
M3.6 - Civil Department
M3.7 - Contract and Procurement
M3.8 - HR
6.0 RECORDS:
All the records as mentioned in the above manuals will be maintained.
GAIL (India) Ltd. Vaghodia. INTEGRATED MANAGEMENT SYSTEMS MANUAL
TITLE: EMERENGENCY PREPAREDNESS & RESPONSE
DOC. No.: CH AM01.20 REV. NO.: 00 REV. DATE: 01.10.2011 PAGE NO. 62
1.0 PURPOSE:
To identify potential for and respond to accidents and emergency situations and prevent
and mitigate the environmental impacts, OHS hazards and associated risks that may be
associated with them.
2.0 SCOPE:
Applicable to all activities, products and services of GAIL, Vaghodia, covered under
the scope of ISO 14001:2004, ISO 9001:2008 and OHSAS 18001:2007
3.0 RESPONSIBILITY:
The overall responsibility for establishing, documenting, implementing and updating
the system lies with the HOD (Fire & Safety).
4.0 SYSTEM REQUIREMENTS:
Procedures/Work Instructions for emergency preparedness and response will be
documented and implemented.
It will be ensured that potential emergency situations are identified in all areas.
Internal safety audits will be held once in every four months.
Safety permit system is followed for all works to be conducted in the plant
premises.
Safety instructions will be followed in all areas of operation.
Teams to deal with the above-defined emergency situations will be formed and
trained to act in an emergency.
Equipment to deal with emergency such as fire extinguishers will be maintained and
inspected at periodic intervals.
First aid training and Fire & Safety training will be imparted.
List of emergency telephone numbers will be readily available to reduce time in
getting the required help.
The GAIL, Vaghodia will review and revise where necessary, its emergency
preparedness and response procedure, in particular, after the occurrence of accidents
or emergency situations.
Where practicable, such procedures shall be tested (fire mock drills, evacuation
drills etc.).
5.0 REFERENCE:
Procedure for Emergency Handling, PMM01.11
6.0 RECORDS:
Records in the above mentioned procedure will be maintained.
GAIL (India) Ltd. Vaghodia. INTEGRATED MANAGEMENT SYSTEMS MANUAL
TITLE: MONITORING, MEASUREMENT & ANALYSIS
DOC. No.: CH AM01.21 REV. NO.: 00 REV. DATE: 01.10.2011 PAGE NO. 63
1.0 PURPOSE:
To monitor , measure and analysis on a regular basis the key characteristics of its
operation and activities that can have an effect on quality of the product, significant
impact on the environment and OHS hazards associated non tolerable risks.
2.0 SCOPE:
Applicable to all those departments of GAIL, Vaghodia who carry out the
environmental monitoring as well as monitoring of quality and OHS performance and
analysis of data.
3.0 RESPONSIBILITY:
The overall responsibility for establishing, documenting, updating this system for all the
departments lies with the Management Representative.
4.0 SYSTEM REQUIREMENTS:
Documented procedure for monitoring and measurement activities will be
established, implemented and maintained by the concerned departments to track the
key characteristics of its operations. Procedures/Work Instructions/Operation
control procedure for management and tracking of waste generated of
environmental procedure will be established and maintained.
Information will be recorded to track performance, relevant operational controls and
conformance with the organization’s environmental objectives and targets as
defined in “Procedure for Establishing and Updating Objectives and Targets”.
Monitoring equipment will be calibrated and maintained. Records to this effect will
be retained.
Legal compliance will be regularly tracked.
Control of Monitoring and Measuring Devices
GAIL has determined the monitoring and measurement requirements and the devices
required to show the evidence of the conformity of the product. Masters are used to
calibrate the equipments wherever calibration is done in house. Requirements of
various monitoring and measuring devices have been identified. Details regarding the
calibration of monitoring devices are available in “Procedure for Calibration- PM05.05
& PM02.04”.
GAIL (India) Ltd. Vaghodia. INTEGRATED MANAGEMENT SYSTEMS MANUAL
TITLE: MONITORING, MEASUREMENT & ANALYSIS
DOC. No.: CH AM01.21 REV. NO.: 00 REV. DATE: 01.10.2011 PAGE NO. 64
It shall be ensured that measuring and test-equipment used are capable of making the
required measurements.
Comparative references, wherever used, shall be verified by an appropriate
authority as capable of verifying the acceptability of the product. Such
comparative references shall be rechecked at prescribed frequency, and records
of calibration shall be maintained.
If required contractually or desired by customer specifically, technical data
pertaining to the valid calibration of inspection measuring and test-equipment
shall be made available to the customer/ customer’s representative for verifying
the dimensions and that the instrument is functioning adequately
Control Procedure
For appropriate control, calibration, maintenance and use of inspection, measuring and
test equipment, it shall be ensured that:
a) Instruments are selected such that they shall be capable of measuring the
required dimension with accuracy and precision.
b) All departments using instruments that can affect product/ service quality shall
identify the instruments and prepare a department specific “Master List of
Instruments / Equipment”
c) All instruments mentioned in the list shall be calibrated and adjusted with
reference to the prescribed frequency in the list or prior to use. The calibration
of instrument shall be done against certified instruments having a known valid
traceability to National/ International Standards.
d) The “Master-List of Instruments/ Equipment” prepared by Instrument
department shall give reference to equipment type, (Name of Instrument, Make,
Model) unique identification number, location, frequency of calibration &
reference to self-calibration work instructions (wherever in-house calibration is
proposed).
The instruments shall be accepted based on the calibration/ test certificates
+indicating fitness for use. “List of Master Instruments and Equipment” shall
be maintained which contains a standard list of calibrated instruments/
equipment against which others will be calibrated.
e) The instrument that cannot be calibrated in house shall be sent to external
agencies for calibration.
f) All inspection, measuring and test equipment shall be identified by calibration
tag/sticker Number on instrument or on casing or correlated through unique
identification description/ number to the calibration certificate. The calibration
tags/ certificates indicate the calibration status. Calibration status is obtained by
attaching a tag/ sticker Number on instrument, where practical.
GAIL (India) Ltd. Vaghodia. INTEGRATED MANAGEMENT SYSTEMS MANUAL
TITLE: MONITORING, MEASUREMENT & ANALYSIS
DOC. No.: CH AM01.21 REV. NO.: 00 REV. DATE: 01.10.2011 PAGE NO. 65
In case instruments that are not calibrated/damaged, they are identified by marking
‘NOT IN USE’ on them / on the parted sticker and are segregated.
Note: Where it is impractical to put the sticker / tag on the instrument/ casing, a unique
reference no. is given and calibration is monitored through “Calibration Schedule”
g) Calibration / Test certificates for all instruments/ equipment as mentioned in
“Master-List of Instruments “shall be kept.
h) In case an Inspection, Measuring or Test Equipment is found to be out of required
calibration limits (due to say the instrument being damaged), the products shall be
inspected for validity of previous inspection.
All inspection, measuring and test equipment shall be handled by authorized personnel
in order to ensure that desired fitness for use is maintained.
MEASUREMENT, ANALYSIS AND IMPROVEMENT
GENERAL
The organization has planned and implemented the monitoring, measurement, analysis
and improvement processes needed to
a. Demonstrate conformity of the product
b. Ensure conformity of the integrated management system
c. Continually improve the effectiveness of the integrated management system are
planned and carried out in a controlled manner. This is as stated in the subsequent
sections.
MONITORING AND MEASUREMENT
Customer Satisfaction
As one of the measurements of the performance of the integrated management system,
the organization monitors information relating to customer perception as to whether the
organization has met customer requirements.
For assessing the satisfaction of customers their feedback shall be obtained annually
through customer survey through letters, fax, messages, telephonically, and in-person on
the following factors
Responsiveness
Quantity
GAIL (India) Ltd. Vaghodia. INTEGRATED MANAGEMENT SYSTEMS MANUAL
TITLE: MONITORING, MEASUREMENT & ANALYSIS
DOC. No.: CH AM01.21 REV. NO.: 00 REV. DATE: 01.10.2011 PAGE NO. 66
Quality
Services
Suggestions for improvement.
In case there is feedback from the customer and the area has to be improved the same
shall be communicated to the concerned personnel. The findings shall be analyzed for
the root cause & necessary corrective action will be taken. The potential causes are also
identified and preventive actions are recommended.
Monitoring and Measurement of Processes
Performance measures for the various processes where applicable have been established
and are aligned to measure the process effectiveness and efficiency. These measures are
defined at the end of the processes / procedures where included as Process Measures.
The organization has identified the various processes applicable and procedure for the
measurement of the process is given in various departmental manuals M01 to M09. The
monitoring and measurement of these processes demonstrates their ability to achieve
planned results. When planned results are not achieved, correction and corrective
actions are taken as appropriate.
The verification whether planned results are being attained shall be done through
internal quality audits, apart from the monitoring, described above.
Monitoring and Measurement of Product
The organization monitors and measures the characteristics of the product to verify that
product requirements have been met during receiving, in-process and delivery of the
product.
Inspection and testing shall be carried out in accordance with the Documented
Procedures and the Inspection Plan to ensure the conformance of the product to the
specified requirements.
The documented Procedures and Inspection Plan for final inspection and testing shall
ensure that all previous specified inspection and tests are carried out, and the results
meet the specified requirements.
Natural gas received from ONGCL at Vaghodia is checked for quality in respect of Net
Heating value and Gas Composition. The natural gas after the recovery of LPG, and
MFO going to the customers is also tested for Net Calorific Value & Gas Composition.
The samples of LPG & MFO products from the plants are also tested.
GAIL (India) Ltd. Vaghodia. INTEGRATED MANAGEMENT SYSTEMS MANUAL
TITLE: MONITORING, MEASUREMENT & ANALYSIS
DOC. No.: CH AM01.21 REV. NO.: 00 REV. DATE: 01.10.2011 PAGE NO. 67
Finally the finished products from the storage tanks of LPG & MFO are tested, and if
found OK, as per specifications, released for sales.
The details of the Quality Control Procedures are given in the Procedure for the
Inspection and Testing-PM02.05.
Records are established and maintained to give evidence that the product has been
supplied within defined acceptable criteria. All the relevant records of testing of
various products are duly signed by authorized persons.
ANALYSIS OF DATA
GAIL Vaghodia determines, collects and analyses appropriate data to demonstrate the
suitability and effectiveness of the quality management system and to evaluate where
continual improvement of the effectiveness of the integrated management system can be
made. The analysis of data provides information relating to
a. Customer satisfaction
b. Conformity to product requirements
c. Characteristics and trends of processes and products including opportunities for
preventive action.
Data shall be collected on client feedback by Customer Survey, any deviations, process
measures, status on achievement of quality objectives, audit findings. This would be by
compiling information from records/ information sources as defined in the respective
processes. Job specific data shall be collected from the personnel designated for the
same. Data Analysis is done as per the “Procedure for Data Analysis” P-MM01.07.
The data collected and compiled shall be analyzed by HOD’s using suitable data
analysis techniques such as trend graphs / data to demonstrate the suitability and
effectiveness of the Integrated Management System. The deviations from desired
requirements shall be identified and cause analysis shall be done to determine areas
where corrective and preventive action can be taken for driving continual improvement.
The output from this analysis serves as input to the Management Review Meetings to
evaluate where continual improvement of the Integrated Management System can be
made.
5.0 REFERENCE:
Procedure for establishing and updating of objectives and targets, PMM01.09
Procedure of Calibration, PM02.04 and PM05.05
P MM01.04 - Procedure for Corrective and Preventive Action
Procedure for the Inspection and Testing- PM02.05.
“Procedure for Data Analysis” P-MM01.07.
6.0 RECORDS:
The records mentioned in the above procedures will be maintained.
GAIL (India) Ltd. Vaghodia. INTEGRATED MANAGEMENT SYSTEMS MANUAL
TITLE: EVALUATION OF COMPLIANCE
DOC. No.: CH AM01.22 REV. NO.: 00 REV. DATE: 01.10.2011 PAGE NO. 68
1.0 PURPOSE:
To establish, implement and maintain a procedure for periodically evaluating
compliance with applicable legal requirements and other requirements to which it
subscribes.
2.0 SCOPE:
Applicable to all activities, products and services of GAIL, Vaghodia, covered under
the scope of ISO 9001:2008, ISO 14001:2004 and OHSAS 18001:2007
3.0 RESPONSIBILITY:
Responsibility of reporting nonconformance and taking corrective and preventive action
lies with respective Head of the Department.
4.0 SYSTEM REQUIREMENTS:
1. Identify the rules and regulations applicable to the operations, environmental aspects
/ impacts and OHS hazards and non tolerable risks of process, activities, products and services
of GAIl, Vaghodia. by referring the following:
I. Pollution Control Acts, Rules and Notifications of Central Pollution control boards.
II. Notifications of Ministry of Environment and Forest
III. Information received from local pollution control board, directorate of factories and
boiler, department of explosive etc
2. Consolidate the list of applicable EHS Regulations in the form of Register of
Applicable EHS legislation as applicable to the site or operations.
3. Update the register whenever there is information on new obligations applicable to
the site within two weeks of receipt of such information collected from the above sources and
convey this information to the HOD s of concerned divisions.
4. Check validity of the register and compliance with applicable legislation once in six
months and identify deviations any as per Annexure I of Legal Register (FORMAT FOR
VERFICATION OF LEGAL COMPLIANCE)
5. To communicate the applicable legal requirement as may be applicable in case of new /
amended legislation & ensure compliance action
GAIL (India) Ltd. Vaghodia. INTEGRATED MANAGEMENT SYSTEMS MANUAL
TITLE: EVALUATION OF COMPLIANCE
DOC. No.: CH AM01.22 REV. NO.: 00 REV. DATE: 01.10.2011 PAGE NO. 69
5.0 REFERENCE:
“Procedure for Legal and Regulatory Requirements” P MM01.10
6.0 RECORDS:
Records will be maintained, as per the above-mentioned procedures.
GAIL (India) Ltd. Vaghodia. INTEGRATED MANAGEMENT SYSTEMS MANUAL
TITLE: NONCONFORMANCE & CORRECTIVE AND
PREVENTIVE ACTION
DOC. No.: CH AM01.23 REV. NO.: 00 REV. DATE: 01.10.2011 PAGE NO. 70
1.0 PURPOSE:
To define responsibility and authority for identifying, investigating and analyzing the
non-conformance, taking action to mitigate any impacts caused and for initiating and
completing corrective and preventive actions.
2.0 SCOPE:
Applicable to non-conformities in the Integrated Management System across all
departments of GAIL, Vaghodia.
3.0 RESPONSIBILITY:
The overall responsibility for establishing, documenting, implementing and updating
this system lies with Management Representative.
Responsibility of reporting nonconformance and taking corrective and preventive action
lies with respective Head of the Department
4.0 SYSTEM REQUIREMENTS:
“Procedure for Environmental Non Conformance Control” and “Procedure for
Corrective & Preventive Action” will be established, implemented and maintained
for handling and investigating and determining causes of non-conformance and
implementing corrective and preventive actions.
Nonconformance such as flouting EHS laws, systemic nonconformance, sudden
spillage, wastage, emissions etc. are identified and recorded. The organization has
established a procedure which describes the system for reporting and investigating
all incidents having potential to cause harm to people, damage to property, loss of
process or impact on the environment.
Responsibility and authority for handling and investigating incidents, accidents,
nonconformance, taking corrective action to mitigate any risks and for initiating and
completing corrective and preventive action are described in a variety of sources
including training courses, operating procedures and emergency plans.
The procedure [P MM01.18] is meant for Incident/ Accident reporting and
investigating.
All corrective and preventive actions are reviewed prior to the implementation by
qualified & trained personnel using risk assessment and ensuring that actions are
GAIL (India) Ltd. Vaghodia. INTEGRATED MANAGEMENT SYSTEMS MANUAL
TITLE: NONCONFORMANCE & CORRECTIVE AND
PREVENTIVE ACTION
DOC. No.: CH AM01.23 REV. NO.: 00 REV. DATE: 01.10.2011 PAGE NO. 71
appropriate to the magnitude of problems and commensurate with the OHS impacts
encountered.
All changes in the documented procedures resulting from corrective and preventive
action are recorded. The organization has established procedure P MM01.09 for
Non-conformances and corrective actions.
Appropriate actions will be taken to minimize any impacts caused due to occurrence
of a non conformity through the following means, whichever is most appropriate
such as:
Elimination: complete removal.
Source reduction: avoid production of waste by changes in procedure and
operation.
Recycling: The use, reuse and recycling of wastes for the original or some
other purpose such as input material, material recovery or energy
production.
Treatment: The destruction, detoxification, neutralization of wastes into
less harmful substances.
Disposal: The discharge of wastes to air, water or land in a compliant
manner.
The root cause analysis of non-conformance including potential
nonconformities will be done.
Corrective and preventive actions taken will be to a degree appropriate to the
magnitude of problems and commensurate with the environmental impact
encountered. Corrective and preventive actions may lead to establishment of early
warning system, use of alternate materials, monitoring to ensure prevention of non-
conformity, modification of procedure or work instruction.
The Nonconformance including potential non conformities and their corrective and
preventive actions taken or proposed will be reviewed in the Management Review
Meeting.
CONTROL OF NON-CONFORMING PRODUCT
If any of the products LPG & MFO is not conforming to the requirement; it will be
released only after
Blending
Verifying
a. Correction of the product to meet the intended use.
GAIL (India) Ltd. Vaghodia. INTEGRATED MANAGEMENT SYSTEMS MANUAL
TITLE: NONCONFORMANCE & CORRECTIVE AND
PREVENTIVE ACTION
DOC. No.: CH AM01.23 REV. NO.: 00 REV. DATE: 01.10.2011 PAGE NO. 72
b. By authorizing its use release or acceptance under concession by a relevant
authority and where applicable, by the customers.
Records of nature of non-conformity and subsequent actions taken are maintained.
Where required by contract, for non-conforming products, which do not conform to the
specified requirements, the proposed use or repair of the product shall be reported for
concession to the customer/ customer’s representative. In the case of nonconforming
products, which may affect operations down stream, intimation is sent to the concerned
section for appropriate action.
Corrected products shall be re-inspected as per the procedures for “Inspection &
Testing-PM02.05”.
All non-conforming or related inspection records shall be reviewed and authorized for
appropriate disposition by the concerned Departmental Head.
Corrective and Preventive Action
Documented Procedure for implementing Corrective and Preventive actions is given
in PMM01.03. Additionally for specific corrective actions to be taken for Operations,
relevant Procedure / Work Instructions shall be documented by the concerned
department.
If Corrective and Preventive action requires any change in the documentation, the
same shall be recorded and implemented as per “Procedure for Control of Document-
PMM01.02”.
Corrective Action
The “Procedure of Corrective and Preventive Action” P-MM01- shall include:
a) Effective handling of customer complaints and reports of product non-conformance.
b) Investigation of the causes of non-conformity relating to product, process and quality
system and recording the results of the investigation in “Corrective and Preventive Action
Report”
Effective Customer Complaint Management
Customer complaints are received by way of letters/ faxes/ telephone calls or in person
and are recorded as per the “Procedure for Corrective and Preventive Action"
P-MM01.03
GAIL (India) Ltd. Vaghodia. INTEGRATED MANAGEMENT SYSTEMS MANUAL
TITLE: NONCONFORMANCE & CORRECTIVE AND
PREVENTIVE ACTION
DOC. No.: CH AM01.23 REV. NO.: 00 REV. DATE: 01.10.2011 PAGE NO. 73
The customer shall be informed about the action planned. All customer complaints are
resolved either by
Doing the root cause analysis and taking the necessary corrective
action and or preventive action
Provision of free service, where possible
Sending a ‘Regret Letter’ and explaining relevant reasons
Ensuring that similar errors would not take place in future
Records of all customer complaints and their resolutions along with root clause
Analysis is maintained.
Preventive Action
The “Procedure for Corrective and Preventive Action“for preventive actions shall
include wherever applicable:
a) The appropriate information & analysis from:
i) Audit results
ii) Non-conformity reports
iii) Study of Integrated System Documentation related to the non-conformity
reports.
iv) Customer complaints
b) Identification of an effective preventive action plan. Preventive actions are initiated
by identifying personnel responsible and fixing the target date for completion of the
proposed action.
Closure of Actions:
It shall be ensured that “Corrective Action Report” and “Preventive Action Report”
shall be closed by Departmental Heads / Internal Auditors / Management
Representative as follows
a) IQA findings shall be closed by the Internal Quality Auditor(s)/ Management
Representative, after verifying the position effectiveness of the same.
b) EHS findings will be closed by Internal EHS Auditor(s)/Management
representative.
c) Corrective and Preventive Action Reports for customer complaints/ product non-
conformities/ Improvement, shall be closed by the MR after verifying the
effectiveness.
GAIL (India) Ltd. Vaghodia. INTEGRATED MANAGEMENT SYSTEMS MANUAL
TITLE: NONCONFORMANCE & CORRECTIVE AND
PREVENTIVE ACTION
DOC. No.: CH AM01.23 REV. NO.: 00 REV. DATE: 01.10.2011 PAGE NO. 74
5.0 REFERENCE:
P MM01.04 - Procedure for Environmental and Control
P MM01.03 - Procedure for Corrective and Preventive Action
PMM01.02 - Procedure for Control of Documents
PMM01.09 - Procedure for Inspection and Testing
PMM01.18 - Incident/Accident Reporting
6.0 RECORDS:
Records will be maintained, as per the above-mentioned procedures.
GAIL (India) Ltd. Vaghodia. INTEGRATED MANAGEMENT SYSTEMS MANUAL
TITLE:CONTROL OF RECORDS
DOC. No.: CH AM01.24 REV. NO.: 00 REV. DATE: 01.10.2011 PAGE NO. 75
1.0 PURPOSE:
An effective system for control of environmental, quality and OHS records will be
maintained for demonstrating the conformance to specified requirements and effective
operation of the Integrated Management System through identification, storage,
protection, retrieval, retention, maintenance and disposition of all the environmental,
quality and OHS records.
2.0 SCOPE:
Applicable to all records required for Integrated Management System of GAIL,
Vaghodia which has been developed in line with ISO 9001-2008, ISO 14001-2004 and
OHSAS 18001:2007.
3.0 RESPONSIBILITY:
The overall responsibility for establishing, documenting, implementing and updating
this system lies with Management Representative.
The Departmental Heads will be responsible for ensuring that the nominated personnel
collect, index, provide access, file, and store, retain, retrieve, protect and maintain and
dispose off Departmental Environmental, Quality and OHS Records.
4.0 SYSTEM REQUIREMENTS:
“Procedure for Control of Records” will be established, implemented and
maintained for identification, collection, indexing, access, filing, storage, retention,
retrieval, protection, maintenance and disposal of environmental records. This
procedure will also address those records needed for implementation and operation
of the environmental management system and for recording the extent to which
planned objectives and targets have been met.
Control of Records
General
All the results of activities described in this Manual and associated documents are
recorded and maintained by concerned personnel, to demonstrate the effectiveness of
the quality system. The controls applicable are detailed in the “Procedure for Quality &
Environmental Records” P MM01.04
Identification
Quality, Environment and OHS records required for demonstrating conformance to
specify requirements and the effective operation of the integrated system shall be
GAIL (India) Ltd. Vaghodia. INTEGRATED MANAGEMENT SYSTEMS MANUAL
TITLE:CONTROL OF RECORDS
DOC. No.: CH AM01.24 REV. NO.: 00 REV. DATE: 01.10.2011 PAGE NO. 76
identified. The identification of quality, environment and OHS records shall be at least
by a Title and/or by a Unique Number as mentioned in the Procedures.
Maintenance and Access
The designated person responsible for maintenance of records shall ensure that the
records are legible, suitably stored to prevent damage and/or loss, and are appropriately
collected and filed for easy retrievability.
Indexing and Filing
Records shall be filed appropriately and the records shall be indexed in a structured
manner such as date wise, sequential, alphabetically etc. Suitable partition, where
required shall be made in files. Incase the file becomes too bulky the subsequent records
shall be transferred to another file of the same name.
Record Retention
The records are kept in areas, which provide suitable protection from damage,
deterioration, loss and unauthorized access. For records retention period and locations
are specified in the respective procedures. Electronic records are kept in files / folders
with various extensions based on the type of application. The files shall be organized in
a structured manner being kept in various directories and/or sub directories as specified
in the respective procedures.
Disposition
Once the retention period is over the records are disposed off as defined in the
“Procedure for Quality & Environmental Records” P MM01.04.
Environmental, Quality and OHS records required demonstrating conformance to
the requirements of ISO 9001:2008, ISO 14001:2004 and OHSAS 18001:2007
International Standard, implementation and operation of Integrated Management
System and the extent of achieving planned objectives will be identified.
The identification shall be at least by a Title/Operation procedure control and/or by
a Unique Number as mentioned in the Procedures/Work Instructions. They shall be
legible, identifiable and traceable to the activity, product or service involved.
Pertinent records from the sub-contractors or service providers will also form a part
of the environmental records such as PUC certificate, driving license, wherever
applicable.
The designated person responsible for maintenance of records will ensure that the
records are legible, suitably stored to prevent damage and/or loss, and are readily
retrievable.
Where there is a likelihood of damage to or loss of original data, they will be
photocopied.
GAIL (India) Ltd. Vaghodia. INTEGRATED MANAGEMENT SYSTEMS MANUAL
TITLE:CONTROL OF RECORDS
DOC. No.: CH AM01.24 REV. NO.: 00 REV. DATE: 01.10.2011 PAGE NO. 77
All environmental records will be retained at least for a period specified in the
associated procedures.
Where agreed contractually, environmental, quality and OHS records will be made
available for evaluation by the customer or the customer’s representative for an
agreed period.
The organization has established and is maintaining documented procedures for
identification, collection, indexing, access, filing, storage, maintenance and
disposition of OHS records as described in Procedure P MM01.04.
5.0 REFERENCE:
P MM01.04- Procedure for Control of Quality & Environmental records.
6.0 RECORDS:
Records as defined in the above mentioned procedure will be maintained.
GAIL (India) Ltd. Vaghodia. INTEGRATED MANAGEMENT SYSTEMS MANUAL
TITLE: INTERNAL AUDIT
DOC. No.: CH AM01.25 REV. NO.: 01 REV. DATE: 01.10.2012 PAGE NO. 78
1.0 PURPOSE:
a) To determine whether or not the Integrated Management System.
Conforms to planned arrangements for integrated management including the
requirements of the International Standard and
Has been properly implemented and documented.
b) To provide information on the results of the audit to management.
2.0 SCOPE:
Applicable to all the activities of GAIL, Vaghodia covered by the Integrated
Management System in line with ISO 9001:2008, ISO 14001:2004 and OHSAS
18001:2007
3.0 RESPONSIBILITY:
1. The Management Representative will be responsible for planning, scheduling and
coordinating the internal audit activities.
2. The Management Representative will also be responsible for selecting and assigning
the Internal Auditors and for arranging verification of the effectiveness of the
corrective action.
3. The Management Representative will be responsible for preparing the “Analysis of
Internal Audit Reports” for presentation in the Management Review Meeting.
4. The Internal Environmental, Safety and Quality Auditors will be responsible for
carrying out the audits and preparing the audit reports.
5. The concerned Head of the Department will be responsible for taking corrective and
preventive action and closing the noncompliance of the Audit.
4.0 SYSTEM REQUIREMENTS:
“Procedure for Internal Audit” will be established, implemented and followed.
An “Annual Internal Environmental, Quality and OHS Audit Plan” will be
prepared for the year on the basis of the importance of the activities in various
functional areas and on the environmental, quality of product and OHS results of
the previous audits. It will be conducted at least once in a quarter.
Based on this plan, detailed “Internal Environmental, Quality and OHS Audit
Schedule” will be issued in advance to the respective functional areas.
“Procedure for Internal Audit” will be comprehensive to cover the following:
Audit scope as mentioned in sub clause 2.0 of this procedure.
Frequency once in six months.
GAIL (India) Ltd. Vaghodia. INTEGRATED MANAGEMENT SYSTEMS MANUAL
TITLE: INTERNAL AUDIT
DOC. No.: CH AM01.25 REV. NO.: 01 REV. DATE: 01.10.2012 PAGE NO. 79
Methodologies as well as responsibilities and requirements for
conducting audits i.e. use of audit checklist besides other steps.
Reporting results i.e. Through “Internal Environmental, Quality and
OHS Audit Reports”
Auditor competence.
Suitably trained and approved Internal Auditors will be identified and listed.
Internal Auditors will be selected from this list for carrying out the Internal
Audits as per the schedule ensuring that the selected auditors do not have direct
responsibility for the activity being audited.
In case of observed non-conformities, the “Internal Environmental, Quality and
OHS Audit Reports” will be completed for each nonconformity, for appropriate
corrective and preventive action.
Internal auditors/ Coordinators/ MR will plan the follow up to verify and record
the implementation and effectiveness of the Corrective and Preventive actions
related to the audit findings.
“Analysis of Internal Environmental, Quality and OHS Audit” will be prepared
for each internal audit and will be included in the Management Report, which
will be presented for Management Review Meeting.
GAIL (India) Ltd. Vaghodia. INTEGRATED MANAGEMENT SYSTEMS MANUAL
TITLE: INTERNAL AUDIT
DOC. No.: CH AM01.25 REV. NO.: 01 REV. DATE: 01.10.2012 PAGE NO. 80
5.0 REFERENCE:
P MM01.05 - Procedure for Internal Audits
6.0 RECORDS:
Records will be maintained, as referred in the above-mentioned procedure.
GAIL (India) Ltd. Vaghodia. INTEGRATED MANAGEMENT SYSTEMS MANUAL
TITLE: MANAGEMENT REVIEW
DOC. No.: CH AM01.26 REV. NO.: 01 REV. DATE: 19.10.2015 PAGE NO. 81
1.0 PURPOSE:
To ensure that the top management shall at intervals review the Integrated Management
System to ensure its continuing suitability, adequacy and effectiveness.
2.0 SCOPE:
Applicable to reviews conducted at regular intervals, as decided by the top management
of GAIL, Vaghodia.
3.0 RESPONSIBILITY:
The responsibility for establishing, documenting, implementing and updating the
system lies with the Management Representative.
4.0 SYSTEM REQUIREMENTS:
The Dy. General Manager and in exceptional cases this nominated personnel
will be responsible for the Management Review of the Integrated Management
System for ensuring its continuing suitability and effectiveness in meeting the
requirements of ISO 9001:2008, ISO-14001: 2004 and OHSAS 18001:2007 and
also the Environmental, Quality and OHS Policy and Objectives.
The “Procedure for Management Review” will be established and maintained.
The frequency of the Management Review will be at least twice in a year.
The Management Review will address the possible need for changes to policy,
objectives and other elements of the integrated management system taking into
consideration the environmental, quality and OHS audit results, changing
circumstances and the commitment to continual improvement. The review of
the policy, objectives and procedures will be carried out by the appropriate level
of the Management that defined them.
Review will include the following:
Results of internal audits and evaluations of compliance with legal
requirements and with other requirements to which the organization
subscribes;
Communication(s) from external/ interested parties, including complaints;
The environmental, quality and OHS performance of the Organization;
The extent to which objectives and targets have been met;
Status of corrective and preventive actions;
GAIL (India) Ltd. Vaghodia. INTEGRATED MANAGEMENT SYSTEMS MANUAL
TITLE: MANAGEMENT REVIEW
DOC. No.: CH AM01.26 REV. NO.: 01 REV. DATE: 19.10.2015 PAGE NO. 82
Changing circumstances including developments in legal and other
requirements related to its environmental aspects, quality of product and
customer requirements and non tolerable risks; and
Recommendations for improvement.
The scope of the review will be comprehensive, though not all elements of an
Integrated Management System need to be reviewed at once and the review
process may take place over a period of time.
The top management reviews the organization's integrated management system
at least once in six months to ensure its continuing suitability, adequacy and
effectiveness. This review includes assessing opportunities for improvement and
the need for changes to the integrated management system, including the quality
environmental and OHS policy and objectives. The management review
process is as described in the “Procedure for Management Review” P MM01.01
The review is conducted by a Management Review Committee constituted by the OIC,,
Vaghodia. The committee consists of following:
1. D.G.M (O&M)/ OIC, Vaghodia.
2. Management Representative
3. HOD(TS), ISO Coordinator & DCO
4. HOD (Ops-LPG)
5. HOD (Ops-GREP)
6. HOD (Inst)
7. HOD (Mech)
8. HOD (Elec)
9. HOD (HR)
10. HOD (F&S)
11. HOD (C&P)
12. In Charge (Laboratory)
Review Input
The input to management review includes information on
a. Results of audits
b. Customer feedback
c. Quality, Environment and OHS Objectives.
d. Status of preventive and corrective actions
e. Follow up actions from previous management reviews
f. Changes that could affect the integrated management system
g. Recommendations for improvement
h. MOU targets vis-à-vis actual performance
GAIL (India) Ltd. Vaghodia. INTEGRATED MANAGEMENT SYSTEMS MANUAL
TITLE: MANAGEMENT REVIEW
DOC. No.: CH AM01.26 REV. NO.: 01 REV. DATE: 19.10.2015 PAGE NO. 83
i. Overall system performance for effectiveness
j. Review of Quality and HSE Policy and Objectives
Review Output
The output from the management review includes any decisions and actions related to
a. Improvement of the effectiveness of the integrated management system
b. Improvement of product related to customer requirements and
c. Resource needs.
Time bound action plan and responsibility of its implementation are assigned to
concerned persons while discussing any of the issues listed above. MR is to review the
implementation of the decisions taken in the management review meetings.
Records of meetings (in the form of minutes of meetings) are maintained by MR for a
minimum period of 3 years.
CONTINUAL IMPROVEMENT
GAIL continually improves the effectiveness of the integrated management system
through the use of the quality and HSE policy and objectives, audit results, analysis of
data, corrective and preventive actions and management review.
The effectiveness of the Integrated Management System shall be continually improved
through the following means:
Review of performance vis-à-vis the quality and HSE policy and objectives
Analysis of data as described in the section above (Chapter CHAM01.4.5.1)
Appropriate action shall be taken as per the methodology defined in CHAM01.4.5.3
corrective and preventive actions.
The data on the performance, the analysis done and the status of corrective and preventive
actions shall be discussed during the management reviews to determine the progress on
such improvements being initiated and to provide the necessary support and resources. The
responsibilities for the specific initiative shall be defined depending on the nature of
activities to be carried out.
5.0 REFERENCE:
P MM01.01 - Procedure for Management Review
6.0 RECORDS:
All the records mentioned in the above-mentioned procedures will be maintained.
GAIL (India) Ltd. Vaghodia. INTEGRATED MANAGEMENT SYSTEMS MANUAL
TITLE: PLANNING OF PRODUCT REALIZATION
DOC. No.: CH AM01.27 REV. NO.: 01 REV. DATE: 01.05.2012 PAGE NO. 84
PURPOSE:
To ensure that the processes needed for product realization are planned, developed and
carried out in controlled manner.
2.0 SCOPE:
Applicable to all products offered by GAIL, Vaghodia.
3.0 RESPONSIBILITY:
The overall responsibility for establishing, documenting, implementing and updating
this system lies with the Management Representative.
4.0 SYSTEM REQUIREMENTS
4.1 PLANNING OF PRODUCT REALIZATION
The requirements of the products maintaining high level of productivity and supply of
the products of specified quality to its customers through effective operation and
maintenance of the LPG recovery plant,Vaghodia.
The basic quality objective is to provide the products of specified quality up to the
satisfaction of customers.
The product realization processes along with their interaction have been mapped and
shown in AXAM01.02. The necessary resources required for the product realization
have been provided. (Refer CHAM01.4.4.1).
The product realization processes, wherever necessary, for meeting conformance to
product requirements have been documented.
The required verification, monitoring, inspection and test activities for the product have
been established in the respective processes. Records needed to provide evidence that
realization processes and resulting product meet requirements are being maintained.
GAIL (India) Ltd. Vaghodia. INTEGRATED MANAGEMENT SYSTEMS MANUAL
TITLE: CUSTOMER RELATED PROCESS
DOC. No.: CH AM01.28 REV. NO.: 00 REV. DATE: 01.10.2011 PAGE NO. 85
1.0 PURPOSE:
To ensure that the processes needed for product realization are planned, developed and
carried out in controlled manner.
2.0 SCOPE:
Applicable to all products offered by GAIL, Vaghodia.
3.0 RESPONSIBILITY:
The overall responsibility for establishing, documenting, implementing and updating
this system lies with the Management Representative.
4.0 SYSTEM REQUIREMENTS
Identification of requirements related to the product
The delivery order Products are booked by our Marketing Department at Mumbai and
Baroda. The delivery order contain the name of the party, name of the product, quantity
to be dispatched etc. and it is being E-mailed to us. After fulfilling the various
requirements for loading the product will be dispatched. We will be providing dispatch
(quality) certificate along with the product. We will obtain customer feedback from our
marketing department time to time by fax / E-mail / telephonically / in-person.
Review of Requirements related to the Customer
We are providing dispatch (quality) certificate of our various products to our customers.
The management has reviewed the customer requirements and the Product qualities are
maintained accordingly. However the customer requirements’ regarding the quantity of
the product is obtained through the delivery order.
Amendment to a Contract
Executive Director (Marketing & Planning) is responsible for perusing amendment to a
contract and communicating to the various functional heads upon receipt of
amendments.
Any change or difference in opinion about contract is resolved with the customer by the
Marketing Department.
It shall be ensured that any amendment in the accepted contract is documented and
accepted after doing a capability check. The accepted order amendments shall be
reviewed and correctly transferred to the concerned department. Where an amendment
is desired by GAIL, it shall be ensured that the customer’s approval is taken.
GAIL (India) Ltd. Vaghodia. INTEGRATED MANAGEMENT SYSTEMS MANUAL
TITLE: CUSTOMER RELATED PROCESS
DOC. No.: CH AM01.28 REV. NO.: 00 REV. DATE: 01.10.2011 PAGE NO. 86
The records of result of the reviews and actions arising from the review are maintained.
Customer communication
The organization has determined and implemented effective arrangements for
communication with customers.
a. Product Information: This is provided to clients through “Brochures/Catalogues/IS
Specifications
b. Customer Feedback obtained through customer survey questionnaire. The
questionnaires are analyzed and wherever necessary, corrective/preventive actions are
taken as per “Procedure for Corrective & Preventive Action” PMM01.03 .
The Dispatch department is in constant touch with the customer through telephone and
personal contact regarding Quality, Quantity and services provided by LPG Plant,
Vaghodia.
Customer Satisfaction
As one of the measurements of the performance of the integrated management system,
the organization monitors information relating to customer perception as to whether the
organization has met customer requirements.
For assessing the satisfaction of customers their feedback shall be obtained annually
through customer survey through letters, fax, messages, telephonically, and in-person on
the following factors
Responsiveness
Quantity
Quality
Services
Suggestions for improvement.
In case there is feedback from the customer and the area has to be improved the same
shall be communicated to the concerned personnel. The findings shall be analyzed for
the root cause & necessary corrective action will be taken. The potential causes are also
identified and preventive actions are recommended.
GAIL (India) Ltd. Vaghodia. INTEGRATED MANAGEMENT SYSTEMS MANUAL
TITLE: PURCHASING PROCESS
DOC. No.: CH AM01.29 REV. NO.: 00 REV. DATE: 01.10.2011 PAGE NO. 87
1.0 PURPOSE:
To ensure that the processes needed for purchasing process are planned, developed and
carried out in controlled manner.
2.0 SCOPE:
Applicable to all products offered by GAIL, Vaghodia.
3.0 RESPONSIBILITY:
The overall responsibility for establishing, documenting, implementing and updating
this system lies with the Management Representative.
4.0 SYSTEM REQUIREMENTS:
PURCHASE
Purchasing Process
The basic items purchased are categorized as below:
a) Raw Material – Natural Gas: The purchase of the natural gas is done through the
O & M wing. Inspection and verification of raw materials is done as per inspection
plan given in annexure AXM02A.03.
b) Spares (Indigenous): These spares are purchased by C&P department.
c) Spares (Imported): Imported spares requirement are consolidated and purchased
from our C&P department of Baroda office.
d) Capital items, general stores and consumables: These items are purchased by
C&P department.
As spares of proprietary nature constitute the major portion of purchases, the
performance of vendor is evaluated based on past experience by the indenter.
For other items, which are not likely to affect the quality of end products, no formal
evaluation is done. However, based on the experience, name of the vendors whose
performance is found not up to the desired level with regard to timely delivery, quality
and reliability are deleted from the Data bank.
The list of the vendors is reviewed once in three years to update the same. The activity
involves inclusion of new vendors which are deemed to be registered with GAIL as per
contract & procurement manual of GAIL.
GAIL (India) Ltd. Vaghodia. INTEGRATED MANAGEMENT SYSTEMS MANUAL
TITLE: PURCHASING PROCESS
DOC. No.: CH AM01.29 REV. NO.: 00 REV. DATE: 01.10.2011 PAGE NO. 88
Purchasing Information
Purchasing documents shall contain specifications clearly describing the product
ordered including following, wherever applicable:
a. The type, class, grade, style or other precise identification.
b. The description of the items, specification, drawings, process requirements,
inspection & test requirements etc.
c. Requirements for approval of product, procedures, processes and equipment
d. Requirements for qualification of personnel
e. Quality management system requirements
The concerned C&P executives shall review and approve the purchasing/ sub-
contracting documents prior to issue for adequacy of specified requirements.
Verification of Purchased Product
If required, specifically by contract, the materials to be purchased are verified at source.
The intended verification arrangement and method of release are mentioned in the
purchasing information. The incoming goods, irrespective of verification at source, are
inspected by the user department on receipt, so as to ensure that the product conforms to
required specifications.
For details please refer Procedure for Purchase PM07.01.
GAIL (India) Ltd. Vaghodia. INTEGRATED MANAGEMENT SYSTEMS MANUAL
TITLE: PRODUCTION AND SERVICE PROVISION
DOC. No.: CH AM01.30 REV. NO.: 01 REV. DATE: 01.05.2012 PAGE NO. 89
1.0 PURPOSE:
To ensure that the processes needed for product and service provision are planned,
developed and carried out in controlled manner.
2.0 SCOPE:
Applicable to all products offered by GAIL, Vaghodia.
3.0 RESPONSIBILITY:
The overall responsibility for establishing, documenting, implementing and updating
this system lies with the Management Representative.
4.0 SYSTEM REQUIREMENTS:
Control of Production and Service Provision
a) The characteristics of the product are available in AXM02A.06 / AXM02A.07
/ AXM02A.08.
b) All the processes are carried out in accordance with the documented
procedures, work instructions and vendor manuals.
c) It shall be ensured that processes and equipments used are approved and the
processes are monitored and controlled as defined in the Process Control
sheets/Work Instructions/Quality Plan, as applicable in the respective
functional areas.
d) The products/processes shall be verified using calibrated instruments at
specified stages as defined in the Quality Plan/Quality Control Plan as
applicable in the respective functional areas. The Quality Plan/Quality Control
Plan shall include the acceptance criteria or make reference to the applicable
Standards/Codes/Work Instructions/Method card where these are defined.
e) The equipments required for the processes were procured through EIL who
made the design & development of the plant.
f) Measuring and test equipments are calibrated in accordance with Procedures
for Calibration PM05.05 & PM02.04.
g) Operators are skilled and trained in their respective jobs. Work instructions are
provided to the operators/ technicians to ensure that the job is done as per
specified requirements.
GAIL (India) Ltd. Vaghodia. INTEGRATED MANAGEMENT SYSTEMS MANUAL
TITLE: PRODUCTION AND SERVICE PROVISION
DOC. No.: CH AM01.30 REV. NO.: 01 REV. DATE: 01.05.2012 PAGE NO. 90
h) The release of the products is controlled as given in Procedure for inspection
and testing- PM02.05. The delivery and post delivery activities are as it is
mentioned in manual MM01.
i) Production/Installation machinery and equipments, which require to be
maintained to ensure continuing process capability, shall be maintained as
defined or referenced in relevant department procedure for “Process Control”.
j) LPG recovery plant, Vaghodia has incorporated most modern built-in safety
and security systems during its design development, engineering, construction
and operational phases. Fire protection system provided for LPG Recovery
Plant is maintained by F&S department as given in manual M06.
Validation of Processes for Production and Service Provision
There is no process either for production or service provision where the resulting output
cannot be verified by subsequent monitoring or measurement. Hence this clause is not
applicable. As and when this clause becomes applicable, the same shall be addressed.
Identification and Traceability;
In the product realization process the products status are identified with
a. Identification of In-process Materials: In-process materials shall be suitably
identified by one or more of the methods followed in section 4.1 of this chapter.
Wherever required, the process stage and/or job reference such as job order
number/work order number shall be indicated.
b. Identification of Finished product: Finished products shall be identified, wherever
practicable, as in the case of in-process material to include details of job reference.
c. Identification of Rejected Materials: Rejected materials shall be identified by
rejected tags, stickers, display-boards or similar form of identification or separately kept
in marked area to indicate that these materials are non-conforming.
d. Traceability: Where traceability is a specific requirement, the same shall be indicated.
Records indicating traceability shall be maintained.
The quality specifications of products are informed to the customer and the customer
complaints are handled as per the procedure for handling of customer complaints
(PMM01.11).
Wherever the traceability is a requirement, the identification of the product is controlled
& recorded. However spares and equipment/ instruments etc. are identified with the
help of supplier, tags & nameplate, which gives description of the material.
GAIL (India) Ltd. Vaghodia. INTEGRATED MANAGEMENT SYSTEMS MANUAL
TITLE: PRODUCTION AND SERVICE PROVISION
DOC. No.: CH AM01.30 REV. NO.: 01 REV. DATE: 01.05.2012 PAGE NO. 91
Customer Property
LPG & MFO tankers arranged by the customer is being checked for safety aspects by
representatives of Fire & Safety Department.
The various tank trucks entering the plant will be verified for safety before entry into
plant premises and if any problem is there, same are communicated to the customer. It
is ensured the tank truck is operated inside the plant as per the safety norms.
Customer supplied products shall be verified on receipt and stored, and maintained in a
manner, so as they are fit for use at the time of usage till delivery to the customer.
Customer supplied products, if lost, damaged or otherwise found unsuitable for use
either on receipt or on usage; the same shall be recorded and reported to the customer.
Preservation of Product
During the internal processing as well as storage of the product prior to delivery, the
product requirements are checked and verified by laboratory.
Being a process plant, the products are preserved in their required state by maintaining
appropriate pressure & temperature conditions
GAIL (India) Ltd. Vaghodia. INTEGRATED SYSTEM MANUAL
TITLE: LIST OF MASTER PROCESSES
DOC. No.: AXAM01.01 REV. NO.: 00 REV. DATE: 01.10.2011 PAGE NO. 92
MASTER LIST OF MASTER PROCESSES
i. OPERATION & MAINTENANCE (GAS PROCESSING UNIT)
ii. OPERATION & MAINTENANCE (COMPRESSOR STATION)
iii. CONTRACT & PROCUREMENT
iv. FINANCE & ACCOUNTS
v. HUMAN RESOURCES
vi. SAFETY & FIRE
vii. IT & TELECOM
viii. SECURITY
ix. CIVIL MAINTENANCE
x. ELECTRICAL NAINTENANCE
xi. MECHCANICAL MAINTENANCE
xii. INSTRUMENT MAINTENANCE
xiii. QUALITY CONTROL LAB
xiv. INTERACTION WITH VENDOR/ SUPPLIER/ SERVICE PROVIDERS
GAIL (India) Ltd. Vaghodia. INTEGRATED SYSTEM MANUAL
TITLE: SCHEMATIC OF MASTER PROCESSES
DOC. No.: AXAM01.02 REV. NO.: 00 REV. DATE: 01.10.2011 PAGE NO. 93
CONTRACT &
PROCUREMENT
OPERATION &
MAINTENANCE
(GAS PROCESSING UNIT)
OPERATION &
MAINTENANCE
(COMPRESSOR
STATION)
HUMAN
RESOURCES
FINANCE &
ACCOUNTS
SAFETY & FIRE
SECURITY
TECH.SERVICES
ELECTRICAL
NAINTENANCE
MECHCANICAL
MAINT, IT &TC
INASTRUMENT
MAINTENANCE
CIVIL
MAINTENANCE
QUALITY
CONTROL LAB
VENDOR/ SUPPLIER/
SERVICE PROVIDER
GAIL (India) Ltd. Vaghodia. INTEGRATED SYSTEM MANUAL
TITLE: QSHE POLICY
DOC. No.: AX AM01.03 REV. NO.: 01 REV. DATE: 09.07.2014 PAGE NO. 94
GAIL (India) Ltd. Vaghodia. INTEGRATED SYSTEM MANUAL
TITLE: QUALITY OBJECTIVES AND TARGETS
DOC. No.: AX AM01.04A REV. NO.: 04 REV. DATE: 01.06.2015 PAGE NO. 95
Sr.
No. QUALITY OBJECTIVES
TARGETS
(From 1.4.2015 to 31.3.2016)
1 Continual motivation and
updating of skills of personnel
through HRD activities
1. Minimum One training per
employee.
2. Organizing periodic group
talks among the operation
personnel, emphasizing
amendments in SOP’s & safety
related aspects.
2 Strict adherence to quality
maintenance programmes using
modern maintenance
(management) techniques
100 % adherence to the planned
schedules
3 Operating plant and process
reliably at optimum energy level
1. Achieve plant availability to
340 days in a year.
2. Meet MOU target for the year
GAIL (India) Ltd. Vaghodia. INTEGRATED SYSTEM MANUAL
TITLE: ENVIRONMENTAL OBJECTIVES & TARGETS
DOC. No.: AX AM01.04B REV. NO.: 04 REV. DATE: 01.06.2015 PAGE NO. 96
Sr.
No.
ENVIRONMENTAL
OBJECTIVES
TARGETS
(From 1.4.2015 to 31.3.2016) 1
REDUCTION IN ELECTRICAL
ENERGY CONSUMPTION
a. Reduction in Electrical energy
consumption by 0.5 % as compared to
last year
2 DEVELOPMENT OF
GREENERY IN & AROUND
PLANT AREA
To plant 50 trees in & around plant in FY
2015-16
3 ENVIRONMENTAL
AWARENESS FOR
EMPLOYEES &
CONTRACTORS
a. Celebration of World Environment
Day
b. Celebration of Oil & Natural gas
Conservation fortnight
c. To complete 80% employees training
through environmental awareness
programme
4 REDUCTION OF WATER
CONSUMPTION WITH
RESPECT TO PREVIOUS
YEAR
a. Overall reduction in water consumption
by 0.5 % as compared to last year.
b. Monitoring of water consumption under
different heads
c. To explore the possibility of reduction
in water consumption
GAIL (India) Ltd. Vaghodia. INTEGRATED SYSTEM MANUAL
TITLE: OH & S OBJECTIVES AND TARGETS
DOC. No.: .AXAM01.04.C REV. NO.: 04 REV. DATE: 01.06.2015 PAGE NO. 97
Sr.
No. OH&S OBJECTIVES
TARGETS
(From 1.4.2015 to 31.3.2016)
1 EMERGENCY AWARENESS AND
MAINTAINING SAFETY FOR
EMPLOYEES & CONTRACTORS
1. Zero reportable accident.
2. 400,000 safe man hours
3. To impart refresher training
to 80% employees every
year
2 CATEGORISATION AND
MONITORING OF HEALTH LEVEL OF
EMPLOYEES
1. Annual Health Check up of
all Employees (100%) w.r.t.
vital health parameters as
per factories act.
2. Referal medical check up if
required there off.
3. Providing 100 % PPE’s to
all employees as per GAIL
standard.
4. Ensuring SOP’s & work
permit procedures as
mentioned in Departmental
Procedure Manuals to
safeguard Employees
Health.
5. Improving awareness of
employees by conducting
training programs in the
field of HSEF, Celebration
of National Safety Week,
Fire Services Week etc.