Final COP-Section 1

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Safety and Technical Training
On
GAS Distribution
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Mahanagar Gas Limited

MGLHouse, (Opposite ICICI Building), Bandra Kurla Complex,
Bandra (E), Mumbai 400 051.
1
CONTENTS
SerialNo.SubjectPage
1.0IntroductiontoMGL3
2.0MGLAreaandOperation4
3.0MGLHealth,Safety&EnvironmentPolicy7
4.0MGLQualityPolicy8
5.0MGLLifeSavers9
6.0ThirdPartyEngineerRoles&Responsibility18
7.0MGLGasDistributionNetwork&Process26
8.0PEPipeDistributionNetwork34
9.0PropertiesofNaturalGas40
10.0GeneralSafety42
11.0 GeneralHSSEContractclauses52
12.0TechnicalInformation
12.1SpecificSafetyrequirement67
12.2Medicalfirstaid&Safetyguard68
12.3Excavationwork69
12.4PolyethyleneMain&servicelaying 74
12.5Riser&Lateral 77
12.6Emergencyhandling(dealingwithreportedgasescape)80
2
MAHANAGAR GAS LIMITED
VISION
To be a leading consumer-friendly gas company.

To provide safe, efficient & reliable energy.
To contribute significantly for a pollution free environment.
COMPANY PROFILE
Mahanagar Gas Limited (MGL) is one of Indias leading natural gas distribution
companies Established in 1995, MGL, a joint venture between GAIL (India) Ltd,
British Gas, U.K. and the Government of Maharashtra. MGL today is an ISO
9001:2008,ISO14001:2004&OHSA18001:2007certifiedorganization.Significantly
MGL has already connected over 5.6lakh household & more than 1500 small
commercial & Industrial establishments. It also supplies CNG to over 2.4lakh
vehicles,whichincludesmorethan1.4lakhautorickshaw&over94000taxi/carsin
Mumbai, Thane, MiraBhayander & Navi Mumbai areas, Besides this, over3500
BEST/TMT/MSRTC/NMMT buses, above 4320 LCVs/Tempos/Trucks/Private buses
are plying on CNG supplied by MGL through a wide network of over300kms of
steel and more than 3000kms of MDPE pipeline system, around 151 CNG filling
stationsover750dispensingpoints
3
AREA&OPERATION
Being a City Gas Distribution Company (CGD) MGLs operations are subject to the downstream
regulatingauthorityi.e.Petroleum&NaturalGasRegulatoryBoard(PNGRB)oftheGovt.ofIndia.
Figure below illustrates the basic steel grid network and gasified area in Mumbai and adjoining
areaslikeThane,MiraRoadandNaviMumbai.
4
At present MGL receives gas at Two City Gate Stations (CGS) CGS1 at Wadala in Mumbai and
CGS2 at Mahape in Navi Mumbai. These are the custody transfer points between MGL and its
transporter GAIL Ltd. At CGSs the Pressure regulation, filtration & Odorisation activities are
carriedoutbeforedispatchingNaturalGasintotheMGLnetworkat19barpressure.
5
Figure below represents the MGL-Gas Supply chain
19 Network)
The Gas Distribution Chain (PNG Bar Steel Network
City Gate Station CNG Station DRS

4 Bar PE
Network
100
mbar PE
21 mbar CU Network
Network
Domestic Kitchen Service Regulator

GI Installation

6

Health,SafetyandEnvironmentPolicy
StatementofPrinciple
Outstanding business performance requires outstanding HSE performance. This means the
protection of the health and safety of our people and of those affected by our business, the
protectionofourphysicalassetsandreputationandtheprotectionortheenvironment.
Webelievethatallinjuriestopeoplearepreventable.Ourgoaliszeroinjuries.Weconductour
business in a responsible manner and go beyond compliance with local regulation to meet
internationallyacceptedgoodpracticeinhealth,safetyandenvironmentalprotection.
WerecognizethatHSEiseveryonesresponsibilityandthatweeachhaveadutytointerveneto
prevent unsafe action and to reinforce good behaviors. The safe delivery of projects and
operationoffacilitiesisacriticalsuccessfactoritisnotjusttheendresultthatmatters,wecare
abouthowwegetthere.WeaimtobeanindustryleaderinHSEperformance.
Implementation
Wewill:
EnsurethatallmanagementdecisionsreflectourHSEIntention:
EnsureallemployeesunderstandtheirHSEaccountabilitiesanddemonstratevisibleHSE
leadership;
EnsurethatourHSEmanagementsystemsreflectbestindustrypracticeandareproperly
resourced.Wewillcontinuallyimprovebyensuringthatlesionsarealwayslearned;
Provide direction, education, training and supervision to ensure that all employees
understandtherequiredbehaviorsandtheconsequencesofnoncompliance,GoodHSE
performanceisessentialforcareeradvancement;
EnsurethatourcontractorsunderstandtheirHSEresponsibilities&
Accountabilitiesandrequiredbehaviorsshareouraspirationsandareaware
Ofnoncompliance.Wewilllearncontinuallyfromeachothersexperience;
Developariskbasedmanagementsystemforeffectivemonitoringand
ControlofHSEperformance;
Take account of stakeholder HSE performance so that work related ill health and
incidents are reduced and so that environmental emissions, waste and the use of
energyarereducedrelativetoactivity.
Comply with this policy and drive HSE improvements by setting expectations and
objectivesandreviewing,monitoringandauditingperformance.
PubliclyreportonKeyHSEobjectivesandperformance,fullycooperatewithrelevant
GovernmentagenciesandworkwiththeindustrytoimproveHSEpractices;
Regularlyreviewthispolicy
7
MAHANAGAR GAS LTD
Corporate office : MGL House Block No G- 33 Bandra Kurla
Complex, Opposite ICICI Tower, Bandra (E) Mumbai - 400051
QUALITY POLICY
WeinMAHANAGARGASLTDarecommittedtoprovidequality
servicesforsupplyingsafeanduninterruptedNaturalGastoour
valuedCustomers.
Toachievethis,weshalldiligentlymaintainallequipmentsand
systemstofunctionsafelyandefficientlyandthroughour
continualimprovementeffortsensurethatwesatisfythe
enhancedexpectationsandneedsofourCustomers.
8
MGLLIFESAVERS
Basictoavoidanyinjury:
FollowingaretheareawhicharebeingcoveredbyLifeSavers
1.DrivingSafety
Allcategoriesofvehicleincludingselfpropelledmobileplantmustnotbeoperated
unless:
Vehicleisfitforpurpose,inspectedandconfirmedtobeinsafeworkingorder.
Numberofpassengersdoesnotexceedmanufacturesdesignspecificationforthe
vehicle
Loadsaresecureanddonotexceedmanufacturesdesignspecificationsorlegallimitfor
theVehicle
Seatbeltsareinstalledandwornbyalloccupants.
Safetyhelmetarewornbyridersandpassengersofmotorcycles,bicycles.
Planyourjourneyinadvanceby:
Checkingfuel,oillevel,lightsandtyreensuringthevehiclehasbeen
maintainedandhasvalid.Certificatesplanningforadverseweather/road
conditions&takingappropriateduecare
Ensureyourdrivercomplieswiththeserules.
Drivermustnotbeauthorizedtooperatethevehicleunless:
Theyaretrainedcertifiedandmedicallyfittooperatetheclassofvehicle
Theyarenotundertheinfluenceofalcoholordrugandarenotsufferingfromfatigue.
Theydonotusecellphoned&radioswhiledriving(bestpracticetoswitchoff.
Ensureyourdrivercomplieswithallthismeasures.

2. SafeSystemofWork
Noworkistoproceedunlessariskassessmenthasbeencarriedoutandanappropriate
,
Emergencyplanhasbeenestablished,testedandemergencyequipmentpositioned
BeforecommencingworkcheckifapermittoWork(PTW)isrequired
ThePTWmusthavedetailedscopeofwork,clearlyidentifyhazards,associatedrisksand
9
Controlmeasures
Beforeworkingonisolatedfacilities,checkthatallelectrical,processandmechanical
isolationhavebeencompletedbytheappropriateauthorizedperson
Ifunsureaboutthetaskofyourabilitytoperformsafely,stopthejobanddiscusswith
yoursupervisorfirst.
Changetoplantandequipmentorproceduresmustbecarriedoutthroughanapproved
ManagementofChange(MOC)procedure
3. EnergyIsolation
Anyisolationofenergysystems,mechanical,electricalprocess,hydraulicandotherscannot
proceedunless:
Themethodofisolationanddischarged.
Asystemoflocksandtagsisutilizedatisolationpoints.
Atestisconductedtoensuretheisolationiseffective
Isolationeffectivenessisperiodicallymonitored.
4. GroundExcavation.
Workthatinvolvesamanmadecut,cavity,trenchordepressionintheearthssurfaceformed
byearthremovalcannotproceedunless:

Planandagreedesignofexcavationtakingintoconsiderationheavyequipmentuse
Ahazardassessmentoftheworksiteiscompletedbythecompetentperson(S)
Allundergroundhazards,i.e.pipelines,electriccablesetc.havebeenidentified,located
andifnecessary,isolated.
Wherepersonsaretoenteranexcavation:
Aconfinedspaceentrypermitmustbeissuediftheentrymeetstheconfinedspace
definition.
Groundmovementmustbecontrolledandcollapsepreventedbysystematically
shoring/sloping/benchingetc.asaappropriate.
Groundandenvironmentalconditionsmustbecontinuouslymentionedforchange.
5. WorkingatHeight
Workingatheightsof2meter(6feet)orhigherabovethegroundcannotproceedunless:
Allotheroptionshavebeenruledout
Afixedplatformisusedwithguardorhandrails,verifiedbyacompetentperson,or
Fallarrestequipmentisusedthathas:
Syntheticfiberlanyards
Petzl
Shockabsorber
Fallarrestequipmentwilllimitfreetometers(6feet)orless.
Avisualinspectionofthefallarrestequipmentandsystemiscompletedandany
equipmentthatisperson(s)iscompetenttoperformthework.

10

6. ConfinedSpaceEntry
Allotheroptionshavebeenruledout
Permitisissuedwithauthorizationbyaresponsibleperson(s)
Permitiscommunicatedtoallaffectedpersonnelandposted,asrequired.
Securelinesofcommunicationareestablished
Allpersoninvolvedarecompetenttodothework.
Allsourcesofenergyaffectionthespacehavebeenisolated.
Testingofatmospheresisconducted/verifiedandrepeatedasoftenasdefinebythe
riskassessment
Standbypersonisstationed
Unauthorizedentryisprevented.
IfrequiredaircylinderofselfcontainedBreathingapparatus(SCBA)used

7. LiftingOperation
Liftsutilizingcranes,hoistsorothermechanicalliftingdeviceswillnotcommenceunless:
Anassessmentofthelifthasbeencompletedandtheliftmethodandequipmenthasbeen
determinedbeenacompetentperson(s)
Operatorsofpoweredliftingdevicesaretrainedandcertifiedfortheequipment.
Riggingoftheloadiscarriedoutbyacompetentperson(S)
Liftingdevicesandequipmenthavebeencertifiedforusewithinthelast12Months(ata
minimum)
Loaddoesnotexceeddynamicand/ofstaticcapacitiesoftheliftingequipment.
AnySafetydevicesinstalledonliftingequipmentareoperational.
Theriskofdroppedobjectshasbeenassessed/mitigated.
Allliftingdevicesandequipmenthavebeenvisuallyexaminedbeforeeachliftbya
competentperson(s)
Personnel&publicarekeptclearofthelift
11

ExecutionofPictogramatMGLworksite
BasedonMGLLifeSaverthePictogramsaredesignedwhichdescribethesafeworking
procedure:
1) Ground Excavation
2) Working at Height
12
3) Lifting Operations
4) Electrical Safety
WithrespecttoalltheaboveLifeSaverthereisonemorewhichisapplicabletoallworksitei.e.
SafeSystemofWorkwhichhastobeimplementedincombinationwithaboveall.
13

5) Safe System of Work
ThesepictogramscanbeprintedinvarioussizesonPVCsheets,aluminumsheetsandstickerswith
properarrangementtodisplayatsites.Thesizescanbe:
1) PVCSheets410x450mm
2) AluminumSheets294x178mm
3) Stickers240x420mm
14
LIFESAVER INSPECTION CHECKLIST - GROUND EXCAVATION / CONFINED SPACE /
WORK ATHEIGHT / LIFTING OPERATION / ELECTRICAL SYSTEM
MGLLifeSaversAudit PE
SteelProject CNGProject Facilities Planning O&M
of Project
Audit
Contractor Activity Date
by
AIC SubContr Zone Time
Project
Unplanned NoAddress
TPE Planned
S.
LIFESAVERSMANDATORYREQUIREMENTS COMPLIANCE
No.
COMMON REQUIREMENTS FOR ALL LIFE SAVERS (SAFE SYSTEM OF
A Y N NA
WORK)
IstheRiskassessmentinOHSASformatcompletedandavailableatsitefor
1
dailyreview?
2 Allprobablehazardsareidentifiedandallcontrolmeasuresimplemented?
AnynewhazardidentifiedinHIRAlikeloosesoil,orwaterlogging,WAHand
3
findplaceinToolBoxtalk?
4 IsToolBoxTalkconducteddaily?
Arealldisplayboards(NoSmoking,Emergencynumberdisplay,Workin
5
progress)available?
Isthedrinkingwaterfacilityprovided20ltsforSteeland10ltsforPE&O&M
6
Site?
7 IsthereplenishedFirstaidboxavailableatsite?
8 ArecontinuousBarricadingprovided?
9 AretheFireExtinguishersofrequiredcapacitiesavailableatsite?
10 ArethepersonnelinvolvedintheactivityareSTCtrained?
AreproperPPE(HandGloves,EarPlug,HardHat,Shoes,Goggle,respiratory
11
protection)usedasperPPEmatrix?
IsproperCaretakenforuseofheavyequipmentnearexcavationandtraffic
12
movement?
Emergencyandrescueplanavailableandtestedbeforeworkstarts(check
13 forLadder,Rope,Topslineemergencynumberandawarenessinpeople
aboutrescue)
AreNecessaryequipmentsinspectedbeforeworkcommencesandrecord
14 available?(Fullbodyharnessinspectionreport,Liftingequipments,JCB,DG
Setetc.)
15 Aretherelevantpictogramsdisplayedatsites?
16 Hasdailysiteinspectioncarriedout&reportrevealsfollowingthings:
16.1 IsSIMOPconsideredwhileplanningtheactivities?
16.2 Areisolations(process/mechanical)placedandlockouttagoutapplied?
SCORE (A)
B EXCAVATIONS/ DEEP EXCAVATIONS/CONFINED SPACE ENTRY (CSE) Y N NA
IsSiteinspectionreportavailableandtypeofground,natureofsoiletc
1
identified?
15
Anypreviousexcavationdoneovertrench,siteidentified&mentionedin
2
thereport?
3 IstheExcavationinspecteddailybeforestartofworkandrecordsavailable?
4 Isaccessandegressprovided(likeladders)?
Iftrenchis>1.5mand<2m,whetherjointriskassessmentwithHSSEcarried
5
outforagreeingontrenchprotection(Ifnowriteinremarks).
6 Iftrenchis>2mthen(Nallahcrossing,Valvechamberworketc)
6.1 IstheCSEpermitraised?
IstheotherConfinedspaceworkpermitrequirementsfullycompliedwith
6.2
nodeviation?
6.3 IsTrenchprotectionprovidedirrespectiveofsoilquality?
AreWAHPrecautiontakenfordeepexcavations(properLadder,Harness
6.4
andrope)?
7 Isthesoilstored300mmawayfromtheedgeofthetrench?
8 Arethepersonnelinvolvedintheexcavationactivitytrained?
IstheinspectionofBreaker&CompressorcarriedoutandWhipCheckSling
9
providedforeachjoint?
10 Ispedestriancrossoverplateprovidedatevery50meter?
Incaseofroadcrossing,crossoverplateforvehicleswithoverlapofmin2m
11
oneithersideoftrenchedgeprovided.
12 AretheCrowBarsproperlyinsulated?
Arethelegalforms&operatorslicenseavailableforheavyequipments(Like
13
JCB,HYDRACRANE)?
SCORE (B)
C WORKING AT HEIGHT Y N NA
1 IsSafetyPermitforWorkatHeightissued?
IsPetzlworkatHeightsystem,AscenderZumar,IDdescender,podium
2
availableatsite?
3 IscompletePetzlWAHsysteminspectedbeforeuse?
IsIDdescenderisinstalledonrightropei.e.workinglineandASAPfall
4
arrestorisinstalledonleftropei.e.secondlineofsafety.
Riskofdroppedobjectsiseliminatedbypropertoolbag,istheworkarea
5
properlybarricadedwithchainbarricadesalongwithsafetycones
Hastheinspectionoffallarrestequipmentforautomaticlockingincaseof
6
fallcarriedout?
7 IstheIDpermanentlockcheckedbeforeuse?
Arebothropes(ID&ASAP)withropeprotectortiedtoapermanent
8
structurewithBowline/Kuwaknotwithangle45to60degree?
9 Arebothropestouchingtogroundandhavingsimpleorfigureof8knot?
10 Isropeprotectorusedonsharpedges?
11 Istheminimum10.5mmdiameterropeused?
Isfullbodyharnessusedbyhelperprovidedwithsingle/doublelanyardand
12 anchoredtosupportstructure?(Doublelanyardmandatoryonlyforworking
onscaffoldingordeepexcavationactivity)
Istheplumbertrainedandapproved/certifiedbyPetzltousetheWAH
13
equipment?
SCORE (C)
D LIFTING OPERATIONS Y N NA
1 Islifting/Riggingplaninplace?
16
2 IsCraneinspectionchecklistfilled?
3 SWLismarkedoncraneanditisnotexceeded.
Liftingtackles(Sling,Rope)andmachinesareexaminedandtested,statutory
4
papersavailableatsiteforcraneandslings.
5 Firmfoundationisensured.
6 CompetentCraneoperator,BanksManprovided.
7 Liftingareaisbarricadedandwarningconesprovidedtoalerttraffic.
8 Lineofcommunicationbetweenbanksmanandcraneoperatormaintained.
SCORE (D)
E ELECTRICAL SYSTEM Y N NA
1 IsProvisionofearthleakagecircuitbreaker(ELCB)onelectricalsystem?
2 PositiveisolationofenergywithProperlockoutandTagoutsystemisdone.
3 AreCableslaidproperlytoavoidslip,trip&fall?
4 Isundamaged/testedelectricalequipmentatsitebeingused?
Industrialqualityfittings/distributionboxesareavailableatsitewith
5
continuouswireandthreepinplugandcoveredinsocket.
IsElectricalisolationcertificate/safetypermitavailableforworkonelectrical
6
system?
SCORE (E)
TOTAL SCORE (A+B+C+D+E)
REMARK:
Action Taken
SIGN AS APPLICABLE
HSSETPE ProjectTPE ContractorSupervisor HSSERepresentative
17
THIRDPARTYENGINEER(TPE)ROLESANDRESPONSIBILITY
ThefollowingaretheTPERoles&Responsibilitytoensureallactivitiestobeexecutedaccording
toCodeofpractice(COP)&TechnicalstandardofMGL
Sr.No Description Responsibility

1 L.P.Planningdrawings
Coordinationwithsurveyagency&physicalsurveyif
necessary.
Basedonhandsketchdevelopedbysurveyteam,designing ToAssistAICin
a
oftheloop&Glsizing. physicalsurvey
ForwardingofhandsketchanddesigndataforAutoCAD
drawingpreparationtoagency.
2 BMC/NMMC/TMT,RTO,CFOrelatedactivities
Beforestartofconstructionseasonbasicproposal
preparation&forwardingtoBMC/MCGM/TMT/RTO/CFO. ToAssistAICin
a physicalsurvey
DetailedhandsketchespreparationdulyidentifyingM.P.

stretchesonpriorityaspernewguidelines.
FollowupwithBMCdirectly/throughLiaison/through ToassistAICin
b contractorforjointinspectionofsiteandintimationtoLead jointinspectionofsite
Engineerafterinspection
3 ActivityrelatedtoM.P.laying
Coordinateeffortfororganizingandensuringmanpower,
a
materialresourceatsite
AtleastdailymonitoringofMPsitesinviewoflimitedtime Continuousmonitoringof
b span,stringentBMCguidelinesdulyadheringtoHSS&E MPsitewithdedicated
compliances. TPE
Carrying out of Precommissioning audit and follow up for ToassistAICinpre
c PrecommissioningauditbyO&Mdept commissioningAudit.
d CommissioningoflineinpresenceofO&Mpersonnel
4 ISOdocumentationcompliance
Startswithjoborderendswithcommissioning/conversion
a
asthecasemaybe
5 Visit/inspection/auditatsite.
Atleastdailyvisitstoallsites.Planning.Monitoringof IndividualTPEtovisitsite
a activitieswithTPE&contractorspersonnel.Carryingout &monitorjobentrusted
inspection/audit tohim
6 HSS&E
a Safetybriefing,dailyToolBoxTalkatSite Safetybriefing
b Safetyaudits
18
c NearMiss,InjuryReportedtoAIC,Ifnot,Then'Why?
7 L.P./G.I./Cu.Meterjob
Atleastdailysitevisittoensurerightworkmanshipand
a
qualityofjob.
Onlinejobclosemonitoring DedicatedTPEforeach&
8
everyonlinejob
9 L.P.commissioning
Carryingoutofprecommissioningauditandensuring
a
properdocumentationfollowedbytesting/commissioning
10 WeeklyplanningofProjectactivities
Basedontheimmediatefrontavailabilitypreparationof
a weeklyschedule(jointlywithcontractor).Followupfor
executionofthesame
Highrisebuildingsandbuildercategoryjobswhichneed
11
specialattention
Propercoordinationwithconcernedandensuring
a availabilityofadequateandrightmanpower,material
resource.Executionwithduesafetycompliances
12 Contractorsstoresrecord
Contractorsstoresrequiredtobemaintainedinproper
a
orderandregularfollowupisnecessary
13 Onlinejob
a SpecialattentionforonlineJob
14 Customercomplaints
Toresolvecustomer
complaintreceived
AttendingcustomercomplaintsreflectedinCRMmodule&
a directlyatsiteandalsoto
receiveddirectlyontelephoneetc.
assistAICincustomer
dealing.
15 AslaidDrawingschecking
16 Contractclosure
a Inputs
Continuousobservation
17 HSS&Ecompliance(MP,LP,GI,Cume&Conversion)
onnoncompliance
19
TPE DAILY SITE ACTIVITY CHECK LIST- PE
PE Daily Checklist - MP / LP Works

Name Of Road / Building : Date :
Area : DRS :
Contractor:
Sr.
Parameter Y N Remarks
No.
A Before Laying
1 IssueOfJobOrder(RecordNoPECRE010)
a)Start&Completiondatetobementioned
b)AvailabilityofPlanningDrawingtobechecked
c)Requirementofstatutorypermissiontobe
checked,forsocietypermission(PECRE020)tobe
obtainedincaseofLP
CheckSupervisors,Technicians,CivilLabourfor
2
STCCard,PPE
a)ValidityofSTCcard
b)PhotoIdentity
c)SafetyShoes/GumBoots
d)SafetyHelmets
e)HighVisibilityJackets
f)InsulatedCrowBars
g)HandGloves
h)Form13forcompressoroperationavailability
&validity
i)BoilerSuit,electricalhandgloves,Ear
Defenders/plugs,SafetyGlovesforoperatorsof
PneumaticJackHammers(compressoroperation)
j)Checkthepipingandfittingsofcompressorfor
anylooseendsandwhetherjointsareproperly
fitted.
k)Drinkingwater
3 FirstAidBox
a)AllItemsasperFirstAidList
4 FireExtinguisher
a)Live10KgDCP/ABC2Nos
b)Validityperiod
20
5 UtilityMapping/CableLocationandcoordination
a)Allutilitieslocationrecorded
b)Anyexcavationprogramofotherutilitiesrecord
available
c)Anynotificationofutilitiesavailable
a)Trialpitsatanintervalof25m
6 Barricading
a)Asperspecification(Wooden/Steel)
Painted,LightsandBoxperMGLspecification
7 Emergencyarrangementdisplayedonsite
a)MGLContractor'sName
b)WorkDescription
c)ResponsiblepersonwithContactNo.
d)MGLEmergencyTollFreeNo.1800229944
(e)Topslineno1252
8 CheckAvailabilityof
a)Steelplatesforheavytraffic20mmthickplate
d)Plateforpedestriancrossing(gates)
9 Debris
a)Anydebrisbalance
b)Compaction(Waterflooding)
B During Laying
10 Depth
a)Minimum1meterTopCover
b)HDPESleeveof1.5meteroncrimp
11 TrenchBed
a)Nostones,rocks,foreignmatter,treerootsin
trench
b)Minimum300mmspacingfromotherutilities
12 BottomSandpadding
c)Compaction
13 PipeMaterial&VisualInspection
a)MGLSupply
b)Pipeendsealed
c)Checkthatabrasion/damagelessthan10%of
wallthickness
14 PipeFittingsformakingjoints
a)MGLsupply
b)Packedinplasticbag
c)Fusion&coolingtimeindicatedonfitting
recorded
15 Clampsformakingjoints
21
a)Ensurecorrecttools&clampsTopteeclamp,
alignmentclampsforcouplers,tees,elbow,etc
16 PipeCutting,Scrapping&Marking
a)Pipeendsshouldbecutsquare
d)Bothendsofpipeinrestraining/alignment
clamp
17 Electrofusion
a)Calibration
b)VoltagestabilizationwhileusingGenerators
5KVAonly
c)CheckforBarewires
d)Checkforpropersupply
e)Correctfusiontimingissetontimer
f)Fusiontimefullyelapsed
g)Indicatorshaverisen
h)Terminalcapsonfittingpins
i)Nomovementinfitting
j)Coolingtimehasfullyelapsed
18 VisualinspectionofJointsafterElectrofusion
19 PipeEnd
a)Notopen,Endcapburiedat1.0m
20 IfMP&LPareinsametrench
a)MPRedcolour1.2mtopcover
b)LPGreen1.0mtopcover
21 Protection,ifanydeviations
a)Protectionasperapproveddeviation
b)RCCTiles/UBlock,asperspecification
c)CountnumberofRCCtiles/UBlockinstalled
22 Proximitytootherutilities
a)Minimum300mm
23 Topcover
a)1.0mtrwithRCCTilesonroads
b)1.5mtrwithRCCHumepipeatRoadcrossings
24 Finefilling
a).Excavatedmaterial/Softgradesoilfromother
place
25 Pipelinedatarecording
a)Pipelocationfrompermanentstructure
b).Topcoverofpipe
c)Utilitieslocated
26 Nallah/DrainCrossing
a)1.0mbelowbottomslabofnallah
b)NP4Humepipeprotection
c)NeopreneRubberseal
27 TechnicalDeviations(RecordNoPECRE012)
a)TobeapprovedbyCompetentAuthority
22
AfterLaying
28 ExcavatedMaterialBackfilling
a)1.5mmHDPEsheetfortrencheswithin0.5mof
theedgeofCCRoad
b)Nobigstonesorboulders
c)NoWaterLogginginTrenches
d)LayerwiseCompaction
e)Matchingsurfacetotheexistingsurface
29 Tilesprotection
a)RCCTiles/UBlock,asapplicable
b)CountnumberofRCCtiles/UBlockinstalled
30 WarningTape
a)600mmdeepfromRoadlevel
BackfillingCompletionreport(RecordNoPECRE
31
011(MP)/PECRE021(LP)
a)Pipelocationfrompermanentstructure
b)Topcoverofpipe
c)Utilitieslocated
d)Alldetailsfilled
e)Signature
32 DebrisRemoval
33 Reinstatementinsidesociety(satisfaction)
34 MarkerpostonAuthorityroadevery100mter
AllfittingsandStopoffvalve(ifany)arelocated
35
andChainagemarkedindrawings
What is unsafe act? Why & What causes?
Corrective & Preventive action -
Contractor Representative Third Party Engineer
TPE DAILY SITE ACTIVITY CHECK LIST- GI

23
PE Daily Checklist - GI Works
Name Of Building : Date :
Area : DRS :
Contractor:
Sr.
Parameter Y N Remarks
No.
A Before installation
1 IssueOfJobOrder(RecordNoPECRE010)
a)Start&Completiondatetobementioned
b)AvailabilityofPlanningDrawingtobechecked
c)Checkedworkatheightpermit(PECRE030)
FireNOCforHighriseBldgi.e.morethanseven
floor&above
d)Anyotherremarks,notices
CheckSupervisors,Plumber,HelperforSTC
2
Card,PPE
a)ValidityofSTCcard
b)PhotoIdentity
c)SafetyShoes
d)SafetyHelmets
e)HighVisibilityJackets
f)ConditionofDrillMachine,&allcableshould
bewithoutjoint,Threepinplug&coveredwith
socket
g)HandGloves,earplug
h)Drinkingwater
i)Handgloves,safetygoggle
3 FirstAidBox
a)AllItemsasperFirstAidList
4 FireExtinguisher
a)FireExtinguisher/ABCType
b)Validityperiod
5 Petzl
a)AscenderZumar,IDdescender,Podium
availableatsite
b)Fallarresterequipmentforautomaticlocking
incaseoffallcarriedout
c)Minimum10.5mmdiaropetobeused
d)Riskofdropobjectiseliminatedbyproper
toolbag
6 Barricading
a)AsperMGLspecification
24
7 Emergencyarrangementdisplayedonsite
a)MGLContractor'sName
b)WorkDescription
c)ResponsiblepersonwithContactNo.
d)MGLEmergencyTollFreeNo.1800229944
e)TelephonenoofLocalhospital
f)Topslineno1252
8 TechnicalDeviations(RecordNoPECRE012)
a)TobeapprovedbyCompetentAuthority
B During Installation
Properventilationisavailablewherepipeis
9
beinginstalled(open/Duct)
a)Pipematerial
b)DistancefromElectriccable&otherutilities
c)ProvideTee&firstMCVforeveryPotential
customer
b)Minimum300mmdistancefromcable
MCVinstalledinPluggedconditionwithmale
10
femaleelbow
a)CheckpresleeveHolepiece&condition/GI
holepiecewithPVCsleevewherePresleeve
lengthisnotmatching.
C Welded Riser (7th Floor & above)
11 PipeMaterial&VisualInspection(ERWPipe)
a)WeldingMachine&Weldingelectrode
approvedbyMGL(2.5mm,12Gauge)
b)Weldinghelmetwithglass
c)Welderqualification
d)Anacondafitting
12 Testing&purgingofGIinstallation
13 ProperlocationofMeter&copperinstallation
a)Copperfittingmustbepresoldered
b)LacomakeFluxmustbeused
c)Blowlampcondition
d)Pressuregaugecondition
14 Customersatisfactionreport
What is unsafe act? Why & What causes?
Corrective & Preventive action -
Contractor Representative Third Party Engineer
25
MGL Gas Distribution Process
MGLreceivesitsgassupplyatCityGateStations,Wadala(Sion)inMumbaiandMahapeinNavi
Mumbai.AtWadalaCGSgasissourcedfromONGCUran,throughtheGAILterminalatTrombay.
At Mahape CGS in Navi Mumbai, gas is sourced either from GAIL / Reliance Industries Limited
throughDahejUrannationalGasgridtrunkpipeline.ThepressureoftheGasreceivedatWadala
CGS is up to 35 Bar and that at Mahape CGS is up to 80 bar. The two city gate stations are
connectedthroughthe19barsteelnetwork.
GasissuppliedintotheMGL19barsteelpipelinenetworkfordistributionin&aroundGreater
Mumbai. To provide security of supply of gas, MGL has, where possible, designed its steel grid
networkinloopscomprisingCentral&Southernloopssothatrequiredsectionsofnetworkcanbe
isolatedwithoutdisruptingthesupplyofgas.Theloopingofpipelinenetwork&Citygatestations
ensuresuninterruptedgassupply.
City Gate Station:
TheGasisreceivedbyMGLattheCityGateStation,wherecustodytransfertakesplacebetween
GAILandMGL.ItisattheCGSwherethenaturalgasceasestobetheresponsibilityofsupplier/
TransportCompanyandtransferstoMGL.
The following activities are carried out by at the City Gate Station: Gas filtration, Metering,
Pressure regulation & Odorisation. Accordingly the CGS facility comprises of: Filters, Knock out
drums,Pressureregulators,Safetyvalves,Gasflowmeters,ControlinstrumentationandOdorizing
system.
Thefiltrationisdonewiththeobjectiveofeliminatingdustandsolidmatterfromthegasreceived,
metering is to measure the quantity of gas received from the suppliers, Pressure regulation
ensuresasteadydownstreampressurewhileOdorisationimpartsthecharacteristicsmelltothe
gassoastomakeitdetectabletohumannoseincaseofaleakage.EthylMercaptan(C2H5SH)is
usedforOdorisationnormallyinadosageof15to30PPM.
City Gate Station terminal at Wadala with twin stream system for reliability
26
Odorizing Unit:
The odorization system comprises of a storage tank, a dosing pump with pneumatic action, a
reserve pump, instrumentation, filters, tubing & fittings etc. All this equipment is installed and
operated in a selfcarrying Skid Mounted compact unit so as to facilitate its installation,
operation&maintenance.
SalientfeaturesofOdorizingunitareasfollow.
Odorizinginjectionrate,13to15ppm
.2pumps(inautomode,1inmanual)
.TwoOdorantstoragetanks(200&500liter)
.Inlet/OutletandDrainvalves.
.Visuallevelindicator
.Ystrainerattheoutlet
.LevelTransmitter:Indicates0to100%oftankLevel
.PLCprogramming
.CurrentMGLFlowsignal
.APressureswitchtogivealarmforexcesspressure
.Apressurereliefvalveforexcesspressure
.IncaseofanyfailurealarmwillbedisplayedintheControlRoom

27
Smallbulkcontainermethod(SBC)hasbeenadoptedsothattheodorantisprocured,transported
and unloaded directly into the odorant tank. With this initiative, need for storage of Ethyl
Mercaptaninbarrelsanddisposalofemptybarrels(ahazardousactivity)&ahazardouswastehas
beeneliminated.
Basic Steel Grid network
Thebasicsteelgridpipelinenetworkislaidfortransporting&distributingGasfromtheCityGate
StationstovariousplacesofconsumptionlikeDRS,MRS&CNGCompressors.Thesteelnetwork
pipelinesarebuiltincarbonsteelandnormallyoperateat19barpressure.
Inmostofthecasesthe19barpressureofthetrunklinesistoohighfordirectcustomerusage
therebynecessitatingthestepsofPressureRegulationataDistrictRegulatingStation,toreduce
&maintainthepressureat4bartosupplyintothemediumpressurenetworks.
IndustriesandCNGstationsarehoweverdirectlyconnectedto19barlinepressure.Thevarious
pressureregimesselectedforatypicalMGLCityGasDistributionsystemareexplainedinsketch
below:
28
The steel grid network along with isolation valve assemblies and above ground installations like
DRS,MRSareconstructedinconformancetotheASMEB31.8andrelevantIGEstandards.
Steelpipelinesofdifferentsizesvaryingfromdia4to18conformtoAPI5LGradeB.Theseare
laidundergroundwithatopcovergenerallyinexcessof1.0meter.Wherethedepthofcovercan
notbeachieved,deviationshavetobeapprovedthrutheMGLMOCprocedureSCO01.
In each Sectionalizing Valve Assembly, vent valves have been installed both on the upstream as
wellasdownstreamtoenablepromptdepressurizationoftheaffectedsectionintheeventofany
untowardincidentsresultingintogasescapes.Thisfeatureeffectivelyminimizesthedurationof
uncontrolledescapeofgasandisincompliancewiththerequirementsofASMEB31.8.
Route markers have been installed at regular intervals along the entire pipeline route and are
distinctlymarkedwithpipelinewarning,emergencycontactTelephonenumberinformationetc.
MGLhasadoptedthreelayersPEcoatingonthesteelpipelineandheatshrinkablePEsleeveson
theweldjointsandfittingslikebends.
To supplement the passive corrosion protection system, MGL has installed active cathodic
protectionsystemusingtheknowntemporaryandpermanentsystematvariousstages.Induced
Current Cathodic protection (ICCP) system takes care of the corrosion control management. A
totalof27nos.ofTransformerRectifierUnitsareutilizedforthepurposeinstalledatappropriate
29
locations. The CP current concentration is monitored thru a series of Test Lead points (TLPs),
totalingtoinexcessof600,atanintervalof0.5Km.acrosstheentiresteelpipeline.
The inspection of materials, pipeline laying activities and testing of pipeline is carried out by
reputedThirdPartyInspectionagenciesappointedbyMGL
CNG STATION LAYOUT
Typical CNG station layout
240 Bar
19 Bar
240Bar
Convenient Economical Safe Eco-friendly
IncaseofCNGstationstheGasreceivedisfurtherpressurizedinstepsthroughcompressorsupto
apressureofaround250bars,necessaryforsupplyingtotheautomobiles.AtypicalCNGstation
comprisesofreciprocatingCompressor(s)ofacapacityof750/1200SCMH,CNGstoragecascade(s)
anddispensers.Thegasisreceivedfrom19barsteelpipeline,compresseddispensedintotheCNG
vehicles so as to have a final fill pressure of around 200 bar. Depending upon the location &
expected load the CNG station is designed with the right size & number of compressors &
dispensers.
30
Compressor:
TheCNGcompressorsconformstoAPI618/API11P&otherrelevantInternationalStandards.All
compressoraremountedinsideaweatherproof(protectionlevelequivalenttoIP44asdefinedin
AS1939)acousticenclosuretolimitthenoisetoamaximumof65DBAatadistanceof1meter.
Allelectricaldevices,controlpanel,instrumentsetcareselectedfortherelevanthazardousarea
classification i.e. class I, Div I, Group D as per NEC or ZoneI, Group IIA/IIB as per IS/IEC
specificationsorequivalentspecifications.Gasdetectionsystemconsistingof2nos.Infraredtype
LEL detectors are provided inside each compressor enclosure for automatic shut down of the
compressorintheeventofgasleakage.
Dispenser:
TheCNGdispensersconformtoNFPA52,NZS5425,OilIndustrySafetyDirectorate(OISD)179/
relevant international standards. All the electrical and electronic components are mounted in
flame/explosionproofhousingsuitableforhazardousareaclassificationofClassI,Div1,GroupD
asperNECorZone1,GroupIIA/IIBasperIS/IECspecifications.Dispensersarehousedinweather
proof cabinet of robust construction and stainless steel (SS 304) material with a tamper proof
locking arrangement. Dispensing units have overfilled protection through electronically
programmed microprocessors with 2 nos. of pressure limiting device per filling line. Dispensers
refueling hoses are provided with return vent line hose for safe venting of gas. Dispensers are
providedwitheasilyaccessibleemergencyshutoffvalveoneachfillingline
31
Cascade:
Construction,licensing&inspection,markings,fitment,handling,storageandallotherrelevant
aspectsofcylindersandfittingsareasperTheGasCylinderRulesandareapprovedbyChief
ControllerofExplosives(CCOE).Cylindersaremountedonarobustframestructurewhichdoes
notallowlateral/rotatingmovementofcascadeinanycondition.Allcylindersaresubjecttoa
hydraulicstretchtestataminimumpressureof422barortopressureasdeterminedand
approvedbyCCOEandasrequiredunderrules39to42ofGasCylinderRules,1981(India).All
cylindersareprovidedwithsafetyreliefdeviceconsistingoffusibleburstdiscassemblyas
approvedbyChiefControllerofExplosives(CCOE).Theburstdiscdischargeismanifoldtoa
commonheaderforsafeventing.Allcylindersareperiodicallyexamined&hydrotestedeveryfive
yearsasperGasCylinderRules.
District Regulating Station:

MGLhasDistrictRegulatingStationswhosefunctionistoreduceandregulatethepressure19bar
ofgassuppliedfromthesteelgridnetworkintotheMediumpressurePEnetworkat4bar.ADRS
alsofiltersanyimpuritiessuchasdustthatmaybepresentinthegas.Theprincipalcomponentsof
atypicalDRSaredescribedasfollows:
a) Inlet isolation: The inlet section to DRS comprises insulation joint & an isolation valve. The
inlet thereafter bifurcates into two separate streams each provided with inlet as well outlet
isolations.
b) Filtration: Thefiltrationofincominggasisthroughthefilterofaratingadequateforthetypes
ofequipmentinstalleddownstreamsuchaspressureregulators,reliefvalves,slamsetc.
c) Slam Shut-off: UpstreamofthepressureregulatorisfittedtheOverpressureshutoff(OPSO)

valveswiththeaimofshuttingoftheGasflowintheeventtheoutletpressureexceedstheset
values.OPSOprotectsthefacilities&equipmentdownstreamoftheDRS.DRSisalsofittedwith
Underpressureslamshutoff(UPSO)valvestoprotectthesystemincasethepressuredropsto
extremelylowvalues(lowerthanthepredefinedvaluesi.e.outsidethesafeoperatingenvelope)
d) Pressure Regulating: TwopressureregulatorsareinstalledinseriesformingtheMonitor&

Active configuration with the one taking over the other in case of malfunction. This system
ensures uninterrupted supply of Gas by automatic switching between the two regulators in the
eventoftheActivesufferingamalfunction.Themodels&ratingsofboththeregulatorsarethe
samewithonlyarequiredvariationintheirpressuresettings.
e) Safety Relieving: ASafetyReliefValveisinstalledDownstreamoftheregulatorforrelieving

ofexcesspressurebuildupscausedbythesuchthingsastheregulatorvalvesnotfullysealingat
lockup,suddendropofconsumptionoranyotherfluctuationscausinganupsurgeinpressure.
f) Outlet Isolation: TheoutletoftheDRSisprovidedwithanisolationvalvethroughwhichGas

passesintothedownstreamMediumpressurePEnetwork.TypicalDRSinternallayoutandits
installationatsiteareshowninpicturebelow.
32
In built safety in DRS.
Twinstreamconfiguration,online&standby,soastoensurecontinuityofgassupply
incaseoffailureofonestream.Active&monitorconfigurationwithinastream.Slamshutvalves
providedineachstreamtoprotectagainstOverpressureofthedownstream.Someunitshave
Underpressureshutofftooforprotecttheupstreamincasesoflowinletpressure.Reliefvalve
providedineachstreamtoprotectagainstdownstreamoverpressureintheeventofregulator
malfunctioning.
33
PE PIPE DISTRUBTION NETWORK
TheMediumPressurePEDistributionNetworkstartsfromdownstreamIsolationvalveofDistrict
RegulatingStations.TheLocalDistributionNetworkisconstructedofPolyethylenepipesvarying
fromdia20mmto180mm.ThesepipesaremadeofPE80materialwithSDRas11.Thenetwork
has been designed as per IGE/TD/3 (Institution of Gas Engineers UK Transmission and
Distribution requirement), ASME B31.8 and is operated at a maximum pressure of 4 bar. The
Potential Gas Supply area, which is fed by a DRS is called as a DRS area. Each DRS caters for to
specific load of Domestic, Commercial and Industrial customers in the respective DRS area. The
DRSsareloopedtoeachothertoprovidereliability&continuityofsupply.
Thepressureisreducedfrom19Barto4bar(g)attheDRSfromwherethegasisfedintothePE
network. The DRS has twin stream system with Under Pressure Shut off (UPSO), Over Pressure
Shutoff(OPSO)&SafetyRelief(SRV)devices.The4barPEsystemiscalledasMediumPressure
(MP)Network&ismadeupofMediumDensityPolyEthylene(MDPE)pipe.
PE network utilizes lengths of MDPE pipes which are supplied either in coils or straight lengths
(dependingupondia);electrofusionprocessconformingtoStandardsBG/PL2Part4/ISO8085
Partiii / EN 1555PartIV is employed for jointing of these pipes which ensures 100% leak proof
joints.TappingTeesareutilizedfordrawingfreshbranchesoutoftheLivePEnetworkwithout
affectingtheGassupply.Boththeelectrofusion&OnlineTappingprocedurescanbedonewithin
a very short period with adequate safety & ease. PE has strong advantages for usage as under
groundnetwork.
AdvantageofPEpipe:
Resistanttocorrosion Easilyrepairable
Squeezable Flexible
Easyhandling Easilyidentifiable
Highlifeperiod(Designlife50years)Lowcost
PE PIPE AND PE FITTING

PE Pipe & Properties
Material Medium density PE 80
Colour Yellow
Sizes 20mm,32mm,63mm,90mm,125mm,180mm
Rating SDR11
Length 6mtr minimum in straight & 50mtr
minimum in coil
Operating temp -10 to 40c
Operating 4 bar
pressure
34
PE PIPE
Fittings
Type: electro fusion
Sizes: 20, 32, 63, 90,125,180mm OD
Fittings Marking on fittings:
Stopper
Fusion indicator
Name of manufacturer
90oElbows Fusion time
45oElbows Cooling time
Material PE80
Fitting size & type (e.g.
coupler, elbow etc.)
Note:
Must have see the fusion and cooling time as it may
change for same fittings.
35
Fittings
Type: electro fusion
Sizes: 20, 32, 63, 90,125,180mm OD
Fittings Marking on fittings:
Stopper
Fusion indicator
Name of manufacturer
Tapping tee Fusion time
Cooling time
Material PE80
Fitting size & type (e.g.
coupler, elbow etc.)
Note:
Must have see the fusion and cooling time as it may
change for same fittings.
Service Regulator:
AServiceregulatorhasbothOverpressure(160mbar)andUnderpressureSlamshut
devices(40to65mbar).Theoverpressuresdeviceprotectsthedownstreamfromover
pressurizationandtheunderpressurizationdeviceprotectstheupstreamfromairingressandto
maintainapositivegaspressure.
ServiceregulatorisalsoincorporatedwithcreepreliefvalvetoprotectagainstdownstreamOver
pressureintheeventofregulatormalfunctioning
Service Regulators (SR) & Metering and Regulating Stations (MRS) are installed at appropriate
locationswithinrespectivecustomerspremises.TheSRregulatesthepressurefrom4Barto100
Mbar,whichisfurtherdistributedthroughsmallerdiaPEpipesi.e.sizeof20,32,63mmforming
theLPnetwork,whileanMRSfeedsanIndustrial/commercialcustomerattherequiredpressure,
normallyabout500mbar.TheMRS&SRtohaveUPSO,OPSO&pressurereliefsafetydevices.
GalvanizedIron(GI)pipesareinstalledontheexternalwallsofthebuildingwithanentryinto
everyregisteredcustomerskitcheninthebuilding.Onceinsidethekitchenthepressureisfurther
reducedto21mbarbyanotherregulator,knownastheMeterRegulator.Themeterisinstalledto
measurethegasconsumptionforeachcustomer.
ThepipeworkinsidethedomestickitchenisthatofCopperpipeofdia..12mm.Twovalves
MeterControlValve(MCV)andApplianceValve(AV)areinstalledinsidekitchenattheentryas
wellasattheendpointofthepipingsoastofurtherenhancecontrol&safety.
Meter Regulator:
Themeterregulatorfurtherregulatesthe100mbarpressureto21mbarpressure.Italsohasthe
followingfeatures:
36
Gasflowratesupto2.5m3/hInbuiltwithLowpressurecutoffdevice,whichshutsoffthesupply
throughtheregulatorwhentheinletpressurefallstoaslowas11.0to15.0mbar
Lockuppressureis30mbar,whichhelpsinprotectingthedownstreampipingandapparatusfrom
overpressurization.
Regulatorsshallbeprovidedwithanadjustablespringloadingdevicetoregulatetheoutlet
pressure.Repressurizationsafetydevicefittedinregulator,whichpreventstheregulatorfrom
reopeningwhentheinletpressureisrestored,unlessthereisdownstreambackpressure,i.e.all
connectedapplianceshavebeenturnedoff/attended
Domestic Gas Meter:
Positivedisplacementdiaphragmgasmetersof2.5m3/hrcapacityforusewithnaturalgas,having
specificgravityof0.61,normalworkingpressureof21mbar(g),maximumflowrateof2.5m3/hr,
andRangeabilityof1:150orbetter,suitabletowithstandamaximumpressureof200500mbar.
The meters shall be approved and manufactured in accordance with the requirements of BS EN
1359:1999,orequivalent
Commercial / Industrial Consumers:
Thelargecommercial/industrialconsumersaresuppliedbymeansofSpurlinesoriginatingfrom
thehighormediumpressurenetworks,asapplicable.Thegassupplyisreceivedbythese
customersattheMetering&Regulatingstation(MRS)thatperformthefunctionofregulatingthe
pressureasperthecontractedrequirementsaswellasthemeasurementofthevolumeofGas
delivered/consumed
Common Used Meter & regulator for I&C connection:
Tentative Meter Regulator Regulator type Operating

Load(SCMH) Size(SCMH) Size(SCMH) Pressure(mbar)
Upto2.5 2.5 2.5 Domestic 21
2.56 6 10 Modular/Riser 100
610 10 10 Modular/Riser 100
1025 25 25 Modular/Riser 100
2540 40 40 Riser 100
4065 65 65 Riser 100
Above65 Combinationof Combinationof Modular/Riser 100
above above
Above65 Customized Customized MRS 100500
37
Categories of Commercial Customers
On Basis Of Consumption Patterns
COMMERCIAL INDUSTRIAL
(Consumptiontill1000SCMD)* (Consumptionabove1000SCMD)
COMMERCIALA COMMERCIALB *COMMERCIALC COMMERCIALAC

(Between2001000SCMD) (Above 1000SCMD)
CapacityMinimum200TR
NORMAL SMALL
(ConsumptionTill200SCMD (PeakLoadUpto2.5SCMH CONCESSIONARY
Classification On Basis Of
Type Of Consumers
COMMERCIAL INDUSTRIAL
COMMERCIALA COMMERCIALB
(Smallscalecommercialestablishment/Industries)
COMMERCIALAC(AIRCONDITIONING)
COMMERCIALC
Bighotels/Hospitals/Commercialestablishments BigHotels/Hospitals/Commercialestablishments
NORMAL SMALL CONCESSIONARY

(Restaurants/Caterers/SSI/Cafeterias) OfficeKitchen
(Temples/Trust/Govt.Inst.)
38
Commercial customer:
25 SCMH Riser - Meter Installation.
6/27/2012 18
40SCMH RISER REGULATOR METER INSTALLATION
39
PROPERTIES OF NATURAL GAS
Natural Gas
Naturalgas,oil,&coalarecollectivelyknownashydrocarbon.Naturalgasisconstitutedofa
mixtureofhydrocarbonswithsmallamountsofotherchemicalcompoundsthatarefoundinthe
gaseousorliquid/particulatestatealongwiththecrudeoilinnaturalundergroundreservoirs.
Thelowerthenumberofcarbonmolecules,thelighterthecompound,&themorelikelythe
hydrocarbonwillbefoundinthegaseousphase.Crudeoilcontainlongerchainofcarbon
molecules&areheavierthangas,theyaremorelikelytobefoundinliquidphase.Coalisusually
foundinthesolidphase&containsevenlongerchainsofcarbonmolecules.
Principal characteristics and physical-chemical properties

Thehydrocarbonspresentinthenaturalgasarethelightercompoundsoftheseriesofthe
paraffin(saturatedhydrocarbons),havingmethane(CH4)asitsmajorconstituent(80to90%),the
restbeingethane(C2H6),propane(C3H8),butane(C4H10),hexane(C6H14)andsmallquantities
ofheavierhydrocarbons,apartfromsomeNonhydrocarboncomponentssuchascarbondioxide
(CO2),Hydrogensulphide(H2S),Nitrogen,hydrogen,helium,&argon.Thecarbondioxide(CO2)
&Hydrogensulphide(H2S)mustberemovedfromnaturalgasstreampriortosale.Gaswithhigh
levelofHydrogensulphide(H2S)iscalledsourgas&GaswithlowleveloftheHydrogen
sulphide(H2S)istermedassweetgas.Sweetgascanbedirectlysoldtoconsumer.Sourgasusually
requiredtreatmenttoremovedsulpherpriortosale.
NaturalGasexhibitsadequatecharacteristicsatambienttemperatureandatmosphericpressure
tobeusedasfuelindomestic,industrial,commercial,vehicularapplicationsandasrawmaterialin
chemical,steelandfertilizerindustries.Thedensityofthenaturalgasislessthanthatofair(SG
approx.0.6),facilitatingitsdispersionintotheatmosphereintheeventoflossofcontainment.
The natural gas causes asphyxiation by the suppression of oxygen in confined spaces. Asphyxia
occurs when any gas occupies the space of the atmospheric air at the height of the human
breathing.
Theexplosivelimit(byvolumeinair)forNaturalgasis5%to15%.
AnExplosionisaprocessofspontaneouscombustionofveryhighintensityreleasinghugeamount
ofenergyinthefractionofasecond.
40
Specifications of Natural Gas:
METHOD
CHARACTERISTIC UNIT LIMIT
ASTM ISO
Calorificvalue Kcal/m3 8500kcal/m3 D3588 6976
WobbeIndex kJ/m 46.500a52.500 6976

Methane,min. %vol. 90 D1945 6974
Ethane,max. %vol. 5.3
Propane,max. %vol. 1
Butaneandheavier,max. %vol. 0.4
CO2 %vol. 0.6
Nitrogen&mix %vol. 2.7
mg/m3 70 D5504 63262
TotalSulfur,max.
63265
HydrogenSulphide(H2S), 10.0 D5504 63262
mg/m3
max. 63265
Dewpointofwaterat
C 45 D5454
1atm,max.
CalorificValueItisthenumberofheatunitwhichcanbeobtainedfromameasured
VolumeofGas.ThecalorificvalueofNaturalgasis8500kcal/m3.
LPGItcontain30%to50%propane&Butane&withsmallquantityofEthane,ethylene,Pentane.
DensityofLPGvaporis1.7timesthatofair.TheexplosivelimitforLPGis2%to10%.TheCalorific
valueofLPGis11400Kcal/Kg.
Liquefied Natural gas (LNG):

Methaneisthemostcommoncomponenttransportedbypipelinesandconvertedtoliquefied
naturalgas(LNG).LNGistheliquidproductproducedbycoolingMethane(CH4)gasto161.5c
whosevolumeisapproximately600timeslessthantheequivalentvolumeofmethanegas.LNGis
usuallystoredandmovedatcoldtemperaturesandatlowpressure.GasconvertedtoLNGcanbe
transportedbyshipoverlongdistanceswherepipelinesareneithereconomicnorfeasible.
41
GENERAL SAFETY
Safe Leadership Toolkit
Interventions
Hazard,Nearmiss,accidentreporting
RiskAssessments
Toolboxtalks
Intervention:
An intervention is when anyone intervenes to STOP a task or any activity because the feel or
believethatitisunsafeoritdoesnotmeettherequiredLifesaverstandard.
Aninterventionshouldtakeplaceimmediatelywhen:
WhenataskoractivityisnotcompliedwiththeMGLLifesavers
Whenanyactthatcouldleadtoinjuryistakingplace
Whenpeoplearecreatingorworkinginunsafeconditions
Whenariskassessmenthasnotbeencarriedout
Anytimesomeonehasasafetyconcern
Hazard, Near miss/accident reporting:
ThepurposeofreportingNearmiss&hazardistoaddressanoccurrencewhichhasapotentialfor
injury or property loss. The reporting of Near miss & hazard helps in analyzing the way to
overcomethesessituationbyproperrootcauseanalysis,correctiveaction&sharingoflessonsso
thatfutureaccidentscanbeavoided.
YoucanreportnearmissorHazardoneofthethreeways:
Completeanearmissreport&returnitthroughAICtotheHSSEdepartment
Send an email to the HSSE department with title Near miss report to
hsse@mahanagargas.com
CallitintoHSSEassistanton02224031720
42
BirdsTriangle:
Fatality & Loss time injury
(1)
Intermediate injuries
(10)
Minor injuries (First aid
cases)
(30)
Property damage
(600)
No loss
incident
(Nearmisses,
hazarads)
Health&safetymanagementmethodsaremeasuredonBirdstriangle.ThebirdsTriangleratioof
11030600showstheno.ofaccident&incidentreported.
We know how incidents are caused & means if we can measure our control & measure their
impactonbehavior&orhazardsthenwecanuseleadingsafeindicatorstoprovideamoredirect
controloversafety&wecanreducethenumberofunsafeacts,conditions&reducethenumber
ofseriousaccidents.
ThemostcommonrepeatedlosttimeindustriesinjuriesareassociatedwiththeBack.
Accident Causation:
Wecanidentifythepotentialforanincidentthroughobservingeverydaypracticesorexamining
near misses to identify the potential root causes of incidents. Through proper investigation it
thereforebecomespossibletoidentifythesesproblemsandpreventincidentsfromoccurring
Some of Past incident/Accident in MGL to identify the potential root causes of incident
& prevent incidents from occurring:
(a) Flash Fire during conversion:

On 5th Dec 2011 at 1410 hrs. aflashfireoccurredinjuring4personswhentheMGLcontractor
M/SDineshEngg`sworkforcewasundertakingaconversiontoNGofadomesticflat602Neelam
Society,Charkop,Mumbai.Uponfittingthemeterandcookerhotplatetheynoticedthatthegas
supplypressurewaslow.Theteam,consistingoftwogasplumbers,Contractorssupervisor,MGL
TPE and an MGL Trainee TPE, decided to investigate and rectify the blockage by removal of the
MeterControlValveandupstreampipeworkinsidethekitchenwithoutisolatingexternally.When
the blockage was freed gas was allowed to flow unrestricted into the confined space of the
kitchen,theconcentrationbuildinguptoanexplosivemixture.
Thegasaccumulatedinsidethekitchen&gotignitionfromeitheranelectricallamporrefrigerator
thatwerepresentintheroom.Thecustomer,gasplumber,traineeTPEandcontractorsupervisor
receivedburninjuries.Allweretakentonearbyhospitalsandhavesincebeendischarged
43

TheincidentwasinvestigatedbyMGLandthefindingsoftheteamwerethat:
1) Theteamdidnotseekadvice/permissionfromtheMGLwhenanplannedeventoccurred
2) The team did not follow MGL Procedures by not isolating the incoming gas supply or
connectingapurgehosetotheservicepipetoventthegasexternally.
Root Causes:
1.NottakinginstructionfromMGLwhenanunplannedeventoccurred
2IgnoringMGLproceduresbyventinggasinsidepropertyandnotisolatingtheincominggas
supplybeforeremovaloftheMCV.
3)Competency/DiligenceofMGLTPEandContractorsGasPlumber
Actions to Prevent Recurrence:

1. ApplicationofMGLAccountabilityMatrix
2. ShareincidentwithallMGLOperationalpersonnelandcontractors(GasPlumbers,
TPEs,Contractors)
3. ReviewofMGLTrainingProcess
(b)Safety Alert trench collapse:
On 17th January 2011 atapprox1715atrenchwasbeingexcavatedtolaya12DiaSteelpipe

underaNallah.Paralleltothetrenchawaterpipelinehadpreviouslybeenlaidandbackfilledwith
loose noncohesive soil. The trench walls had not been shuttered or benched or tapered to
prevent collapse. As a result the top part of the trench wall (surrounding the water pipe)
collapsed.Atthetimeoftheincidentheavyvehicleswerepassingneartothetrenchedgecausing
vibrationandadditionalloadingtothetrenchwall.Thepersoninthetrenchreceivedsuperficial
bruisesandFirstAidwasprovidedatsite,howeverhewastakentohospitalforexaminationand
resumedtheworkthatday.
Allteammembershadreceivedbasicsafetytraining.

Where possible use mechanical excavation for excavation including deep trenches thereby
minimizingtheexposuretopeople.
Site specific risk assessments to be undertaken for all activities and reviewed on a daily
basis
Fortrenchdepthsbetween1.2meters&2.0metersaformalsitespecificriskassessment
mustbeundertakentodeterminethetypeoftrenchprotectionrequired.TheEngineerIn
chargeandarepresentativefromtheHSEdepartmentwillundertaketheRiskassessment
andagreetheshuttering/trenchprotectionrequirementbasedontheRiskAssessment.
TheRAandmitigationplanmustberecordedinwritingbeforeworkcommences.
Allexcavationsregardlessofsoilconditionsbelow2metersMUSThaveshuttering/trench
protectionandwillrequireConfinedEntryProcedurecompliance.
AllsitemanagementpersonnelincludingcontractorsmustbecompetentintheMGLcodes
ofPracticefortheworktheyareundertaking
44
(c)Minor Burn Injury to Helper of Emergency team due to ignition of gas flash fire:
Description of Incident: A flash incident occurred on 19th August, 2008 at 1250 hrs at MGL
Domestic Customers premises at Flat No D 31, Yayati CHS, Sector 2, Srushti Complex , Mira
Road. The incident occurred while the Emergency team was attending the CRM complaint
regarding Escape at Meter. After visiting the flat, Mira Road Emergency Technician found that
therewasgasleakagefromcoppertubefromtheoutletofmeter.Thetechnicianclosedthemeter
control valve and remaining line gas was vented to atmosphere through appliance valve.
TechnicianinstructedthehelpertoperformtheskilledjobofsolderingtheCUtubingforwhichhe
wasnottrained.Asthebrazingtorchwaslightedbythehelpertosolderthecoppertube,within1
minute flash fire occurred which caused burns on the hands & face of the helper. The flash fire
resultedfromignitionofaccumulatedgas(fromtheleakagethatwastrappedinvoidabovethe
meter) ignited by the flame of the Brazing Torch. Gas accumulated due to the leakage from the
15mmCupipe
Actions to prevent recurrence:
Need to check for presence of gas with Gascoseeker and ventilate prior to undertaking
work.
Systemtobeinplaceforallthehelpers&techniciansemployedbythecontractorsonMGL
dutytoundergobasictrainingofuseofGascoseeker,Gasproperties&Emergencyhandling
Develop the training module for helpers of MGL emergency vans and provide them with
competencycertificateforthehelpersjobs.Themoduletocontaintheriskassessmentand
controls,sequenceofjobandcommunicationprotocol.
Strict enforcement of MGL PPE requirement (full coveralls, Goggles/ face shields, gloves,
safetyshoes.
Root Causes and Failed Barriers

TheMGLprocedurewasnotfollowedbythetechnicianbynotcheckingthepresenceof
thegas
Themeterwasnotlocatedinawellventilatedplace.Thegasleakingfromthedamaged
coppertubingaccumulatedintheloft&betweenmeter&roof.Thewindowiswellbelow
meter.
Nosystemsoftrainingthehelpersoftheemergencyvans
(d) Safety Alert Use of Hydra:
Description of Incident in 2009:

Acontractor'slabourerMrKishorPatelwaswalking&occasionallyridingonthehydrawhenhe
fell under the front wheel of the hydra, whilst transporting a PE pipe coil about 5 kilometer
distancefromastoretocontractor'ssite.MrPatelreceivedfatalinjuriesasthewheelpassedover
his legs and up to waist crushing him. The other helper and a trafficconstable rushed him in a
threewheelertonearbyhospital&thentoShivajihospitalatRabalewherehewasdeclareddead
onadmittancetothehospital.
45
To avoid such type of incidents, the following must be adhered to:
HydraMUSTNOTbeusedfortransportingmaterialincludingpipesandfittings
Allpipe,fittingsandequipmentmustbetransportedinavehicleregardlessofdistance
AllpersonnelmustbeSTCtrainedpriortocommencingworkonanMGLsite
AlloperationsmusthaveaRiskassessment
Arrangementsforemergencytreatmentmustbeknownbyallsitepersonnelandcontact
telephonenumbersdisplayedonsite.

(e)Flash Fire inside the kitchen:
On22ndMarch2012,inGaneshCHS,Worli;(DRS30),onlineconnectionworkwasgoingonasper
theplan.MeterInstallationfinishedandCopperpipeinstallationwasinprocess.Whilesoldering
of Cu pipe with outlet fitting, there was sudden flash fire leading to superficial burn injuries to
plumber on face and hand. Injured Plumber was then shifted immediately to Hospital for
treatment.

TheincidentwasinvestigatedbyMGLandthefindingsoftheteamwere:
1) SolderingjobwasgoingonatthemezzaninefloorofkitchenwiththehelpofBlowlamp
(containingbutanegas).
2) Mezzaninefloorishavingasmallopeningabovewhichmeterwasfixed(confinedspace).
3) IgnitionsourceLightingofblowlampwiththehelpofmatchandbutanegasleakinthe
confinedspaceofmezzaninefloorwhichleadstofire.
4) Blowlampnotinspectedpriertothestartofthesolderingjob
5) Plumbernotwearinggloves
Root cause
1.Meterfixingatconfinedspaceofmezzaninefloorwheresolderingbyblowlampwasbeing
used
Twopossiblecauses
a)Loosesealofblowlampmayhavecausedbutanegasleakage
b)DelayinlightingBlowlampmayhavecausedgasaccumulationintheconfinedspaceforming
anexplosivemixtureignitedbymatchwhenBlowlampwaslit.
1. InspectionofBlowlampconditionbeforestartofsolderingjobisrequired.
2. Solderinginconfinedspacesshouldnotbeallowed.
3. ShareincidentwithallMGLOperationalpersonnelandcontractors(GasPlumbers,
TPEs,Contractors)
4. Blowlamphazardsanditssafeoperationtobeincludedinthetrainingmodules.
5. Plumbertoweargloves
Safety Checklist
1) Checktheblowlampcondition(freeofdamagesandtampering)
2) Checkforcorrectfittingofcartridgewithtorch
3) Checkforgascartridgecollarnotchisingoodconditionandnotdamaged
4) NodelayinlightingthetorchLightmatchbeforeopeningthevalveoftheBlowlamp
46
5) Noworkinconfinedspaces
Manufacturers warnings-
1) Protectfromdirectsunlight
2) Donotexposetotemperatureexceeding50C
3) Keepoutofreachofchildren
4) Storeincoolanddryplace
5) Changing the cartridge perform this operation in well ventilated area free from ignition
sources
6) Closethecartridgevalveafteruse
7) Removethecartridgefromapplianceafteruse
8) Replacetheconnectionsealifitisdamaged
9) Donotpuncture/pierceorincinerateafteruse
10) Aligngascartridgecollarnotchwithlocatortabontheregulatorofstove

(f) Fatality CAT 01 INCIDENT
WhiletakingaUturnaLightCommercialVehicle(LCV)usedfortransportingCNGhitanauto
rickshawthatwasparkedatthelefthandsideoftheroadtoalightapassenger.Theautowas
crushedbetweentheLCVandanothervehicleparkedinfront,fatallyinjuringtheautodriver.The
LCVcontinuedforwardtoparkhisvehicleandindoingsoranoverapedestrianwhowascrossing
theroadinfrontofhim.
Description of Incident: OnThursday19/05/2010atabout1420hrsaMGLContractLCVwas
travelingonJuhuTararoadtowardsSantacruzfillingmotherstationafterdecantingCNGatthe
daughterboosterstation(JuhuAutoStation).WhileattemptingaUturntheLCVhittherearof
anautorickshawwhichwasparkedatleftsideonroadtoalightapassenger.TheAutorickshaw
hadstoppedneartotheUturnforthepassengertogetoutandpaytheirfare.Theautohad
parkedbehindacommercialvehiclethatwasdeliveringicecreamnearby.Asaresultofthe
impacttheAutorickshawanddriverwerecrushedbetweentheLCV&icecreamdeliveryvehicle.
AftertheimpacttheLCVdrivercontinuedaheadtoparkhisvehicleanddidnotnoticea
pedestrianwhowaswalkingontheroadinfrontusingamobilephone.TheLCVranoverthe
pedestrianinjuringhimfatally.Bothinjuredpersonsweretakentohospitalbythepoliceandlater
diedasaresultoftheirinjuries.
Actions to prevent recurrence:

MGLHSSEtoraiseawarenessonMGLLifeSaverDrivingrequirementsbysharingthis
incidentacrossMGL
IncreaseDefensivedrivingtrainingtoalldriverstotwiceinayear
EstablishaMandatoryyearlymedicalcheckupforLCVdrivers,
InitiatebreathtestsamplingtoensurethatdriversofVehiclesarenotunderalcohol
influencewhilstonduty.
LCV`stohaveattendant/helpertoassistdriver
Tointroducedailyvehiclehealthchecklist,andoperationchecklistforhandoveroverby
drivers,
ReviewtheexistingLCVoperationprocedureandincludedocumentationonHandovertake
overduringshiftchange,toincludeassurancethatkeyisproperlyhandedoverandnext
shiftdriverisfittodrivevehicle(atleastvisuallyseemsokaytofirstshiftdriver)
47
ShareMGLAccountabilityBehavioranalysistoallconcernedtoemphasisSafebehaviors
andactionswhiledealingwithMGLoperationsasperMGLSafebehaviors,standardsand
LifeSavers
IntroduceSTOP,LookthendriveifsafeCampaignforLCV&EmergencyVehicledrivers
acrossMGLoperationsforsuchtypeofUturns.
Investigatevehicleproximitysensorstowarndriverinsuchsituationsofproximitytofront
orrearthirdpartyvehicles,sothathestopsatsuchplacesortakesappropriatestepsto
avoidcollisions.
ConvertDaughterCNGstationstoonlinestationstoremovethenodfortransportingCNG
insuchamanner.
Root Causes and Failed Barriers:
Defensive driving skills not followed by LCV driver
Driverdidntfollow2secondruleandkeepproperdistancebetweenhisvehicleand
autoinfront.
Driverdidnotpayproperattentiontotheparkedautoinfront,wasmoreattentive
totrafficfrombacksideonhisrightaswastryingtotakeUturn.Hemisjudgedthe
positionoftheauto.
2. Lack of sufficient awareness about MGL procedures
Thereneedstobehandovertakeoverworkinstructionfordriverstoensurethat
safetyischeckedintheoperations,asthefirstshiftdriverkeptkeyinignitionslot
andwentaway.
SecondshiftdriverMr.Someshwardidnttalkwithfirstshiftdriverandstarted
vehicleanddroveaway.
3. Lack of Sufficient Resources.DuetothetrafficsituationinMumbaiandtheuseofU
Turnsthevehiclecouldhavehadanassistanttoassistthedriveratsuchcriticalspots/
maneuvers.
(g) Gas leak inside the Kitchen
Incident Summary:
GasLeakageoccurredon21stJune2011atapprox.1807hrsinanunoccupiedflat1202Aat
SambhavnathTower,Ghatkopar(E).Mumbai.TheServicewasfoundwithouttheinternalplugged
MeterControlValve.
Description of Incident:
On21stJune2011at18:07hrsacallfromtheSambhavnathTower,Ghatkopar(E),was
receivedintheMGLEmergencyControlroomaboutagassmellin&aroundFlatnumber1202A.
AccordinglytheEmergencycrewwereimmediatelydispatchedandrecordedGaskoseekar
readingsofgasconcentrationat70%.Theyimmediatelyopenedthewindowsanddoorstoallow
naturalventilation.Anopenendedservicepipewasfoundinstalledinthekitchenhoweverthe
externalisolationvalvehadbeenturnedoffbeforethearrivaloftheMGLcrew&hencetherewas
nofurtherleakage.Theemergencyteamthensealedtheopenend.
Itappearsthatatthetimeofconstructionsometwoyearspreviousaservicepipehadbeenlaid
intotheproperty.Atthetappingofftheriseranexternalisolationvalvehadbeenfitted,the
servicelateralextendedintothekitchenbutaninternalMetercontrolvalvehadnotbeenfitted.
Atthetimeoftheincidentbuilderswereworkingontheflataboveanditisbelievedthey
accidentallyknocked/turnedontheexternalisolationvalveallowinggastoenterthepremises.
Havingrealizedwhattheyhaddonethebuilderturnedofftheexternalisolationvalve..
48
Root Causes:
Deviation from of MGL standard Practice of not fitting an internal plugged MCV
where the piped entered the kitchen.
Inadequate supervision & site control.
Toavoidsuchtypeofincidents,thefollowingmustbeadhered:
RemindallConstructionpersonneloftheneedtofollowMGLCofP.
CirculationofIncidentInvestigationReporttoallconcernedtogetherwithlessonslearnt
andcorrectpracticestobefollowed.
Ifthecustomerisnotconvertedwithin12monthsoftheconnectionthenthegassupplymustbe
isolatedexternallyortheMCVlocked
(h)Tapteegasleakage
Incident Summary:
A4barPEleakagewasobservedon22ndAugust2012oppositeIIPS,Deonar,Chembur,froma
90 x 32 mm top tee joint. The leakage was discovered by our Patrolman at 17.45 hrs on his
Patrolling when he stopped at the location spotting an MTNL crew doing some excavation
personnel&feltsomegassmell.
AftertherepairstheaffectedTapTeewascutout&broughttoCGSforobservation&analysis.
Followingfindingsweredrawnfromtheinvestigation:
1) Improper fusion, as the joint could be easily peeled off although fusion indicators found
completelyrisen.
2)Externalimpactimpressionobservedononeoftheribsofthefitting.
MostProbablerootCause(s):
1.0 Non usage or usage of a Tap Tee clamp with uncalibrated spring providing inadequate top
load.2.0Contaminatedfitting&pipesurfacespreventingeffectivefusionprocess.
Actionstopreventrecurrence:
1.0EnsurethattheTapTeeClampsareused&calibratedperiodically,atleastonceayear.
2.0ProperassemblyofTapTeeduringfusion
3.0DonottakePEfittingsoutoftheProtectivePlasticcoversuntilactualusage.
4.0Ensureadequatescrapping&cleanlinessofpipesurfacetobefused.
5.0 Allow correct fusion, cooling durations and fusion Eqpt (eg 5KVA genset is needed for
180mm)
6.0Generatespecifiedrecordsforallfusionjoints.
7.0EnsuredisseminationofthisLLBtoallrelevantpersonneli.e.Mgrs/AICs/TPIs/Techniciansetc.
49

(I)FullboreGasleakinsidetheKitchen
AcaseofNaturalGasleakagecumaccumulationinsidekitchenoccurredon22ndAugust2012,at
1845hrs,inMalad(e)areaatFlat102Bwing,Harishchandrasocietyduetoanunplugged/open
ended GI wall piece arising out of partially completed PNG connection. On noticing the hissing
sound & gas smell the customer intimated the MGL emergency control room at 1925, the
emergencycrewpromptlyrushed,reachingthesiteataround2000hrs&attendedtheleakageby
closingtheMCV&leavingthekitcheninstallationsafebypluggingtheopenpipeend.
Theincidentwasinvestigatedasahighpotentialnearmiss&Followingfindingsweredrawn:
1) TheholepiecewasfoundwithoutMCVfittedontotoit.
2) Riser testing and commissioning was done without check for open ends and incomplete
pipework.
3) ThepersonnelundertakingthejobdidnothavevalidSTC.
4) Inadequatesupervision&control
Rootcause:
Risertestingandcommissioningdonewithoutpropertesting&withoutensuringallMCVs
ontherelevantrisertobeinopen&pluggedpositionasperrequirementsofMGLcodeof
Practice.
Plumber&TPInotfollowingMGLcodeofPractice
Recommendationstopreventrecurrence:
PipeworkMUSTNOTbecommissioneduntilasuccessfulsoundnesstestisundertaken.
BriefingacrossentirePEprojectsteam,TPIsandContractorspersonnelonthisincident,
thelessons
learnt&correctpracticestobefollowed.
Adaptation to the practice of issuing & usage of only PreMCV fitted & plugged wall
pieces.
Fillingup&signing(byTPI)ofthetestreportsatsiteassoonasthetestingisperformed&
successfullycompleted.
Thorough counseling, retraining & strict reassessment of the Plumber & TPI before
redeployment,ifany.Counselingofrelevantprojectpersonnel.
Periodic audits & checks on various testing activities & commissioning activities and
relevantrecords&documentsfortheirextentofcompleteness,especiallyintermsof
criticaldetailssuchasTestPressure,Permit,dates,etc.
KeepingtrackonvalidityofSTCcardsofallpersonnelatsite.
RegularcommunicationofSTCstatusviaintranet/emailonanongoingbasis& wellin
advanceoftheexpirydatesoastoenableneedfulaction.
50

Riskassessment:RiskassessmentstartswithHazardidentification.Hazardsofhow
Peoplecouldbeharmedforeachsubactivity,intermsofsafety,humaninjuryorillhealth.
Fourquestionsenablehazardidentification:
a)Isthereasourceofharm?
b)Who(orwhat)couldbeharmed?
c)Howcouldharmoccur?
d)Whatistheseverityoftheharm?
e)Havingidentifiedthehazards,riskisevaluatedwiththehelpofsoftwarebasedonparameterslik
eLikelihood,Exposure
Permit to work process

Apermittoworkisrequiredwherethereisanobviousriskexpectedatplantortopersonneland
wherespecialsafeguardisrequired.InMGLPTWisrequiredforfollowingactivities:
1.Entryintoconfinedspacesi.e.Valvechambers,deepexcavations,
2.Hotwork
3.WorkingatHeight
4.Workingonlivesteelnetwork
5.Maintenanceactivitiesonpipeline&inCNG&Compressorstations.
PTWcontainsSitedetails,TypeofworkforwhichPTWisissued,Name&Designationofthecomp
etentperson,Emergencycontacts,Hazardidentificationandcontrolmeasuresdetails,Simultaneo
usactivitiesdetails,DetailsofAuthorizationofactivity,continuationofwork,Workcompletion,
availabilityofPPEs,Firefightingequipmentetc.
Tool Box Talks:

Atoolboxtalkisconductedatthestartofworkingdayorjustbeforeanactivityisabouttostart.
Theseareopportunitiestomakesafetyexpectationknowndirectlytotheworkgroup.Thefirst
thingtopdowhenconductingatoolboxtalkistoensurethateveryonewhoneedstobethereis
presentfortoolboxtalk.Thesecondthingthatshouldbedoneistocheckthatpeoplehavethe
rightPPE&toolsforthejob.Thethirdthingistoensurethatyouhavepreplannedtheecontentof
yourtoolboxtalk.
51
General HSSE Contract Clauses
HSS&E Clauses MP/LP Work/GI/CU/ Conversion/Rectification
1) Contractor shall make Basic safety Health Environment Plan containing topics such as
Basic Safety Health Plan

ContractorNo
ContractorName
ProjectName
1 ProjectHighlights
iTitleofthecontents
iiContractorNumber
iiiBriefScopeofWork
ivLocationMap/KeyPlan
vPeriodoftheproject
2 HSSEPolicy
3 SiteOrganizationChart
ChartindicatingreportingofHSSEpersonnel
4 Roles&Responsibility
Individualresponsibilityofthe
iProjectManager
iiiConstructionSupervisor
ivHSSECommitteeMembers
vHSSEincharge
viSiteEngineers
viiFirstLineSupervisor
viiiSubcontractors
5 HSSETraining
6 HSSEInspection
5 HSSEAudit
8 AccidentInvestigationandReportingProcedures
9 OccupationalHealthMeasures
7 LabourWelfaremeasures
11 Riskassessmentandmitigationprocedures
12 SafeWorkProcedures
iWorkatHeight
iiWelding,CuttingandBracing
iiiLiftingappliances
ivWorkPermitsystem
52
vElectricalEquipments
viMechanicalEquipment
viiExcavation
viiiFirePrevention
13 WorkPermitsystem
14 ListofstandardjobspecificPPEstobeusedinthesite
15 Maintenance Regime for construction Equipment and
Machinery
16 TrafficManagement
15 Housekeeping
18 EnvironmentManagement
19 EmergencyManagement
2)ContractorshallcomplywithMGLLifeSaversrequirement
3)ContractormustprovidecontinuousSteel/woodenbarricadesonboththesidesofthe
trench.
4) LinkedbarrierswithlinkchainsmustbeusedforcrooningthetrenchofLPsite(insidesociety).
5) Linkedbarrierswithlinkchainsmustbeprovidedbythecontractorforcordoningtheareaat
groundlevel,duringGIwork.
6) Ataspecificdistance(min100mtrs)thecontractorshouldprovidewoodenboards/foot
boards/steelplatesforthesafeaccessofpedestrians/societyresidents.
7) Allbarricadesshallbeconspicuouslyseeninthedark/nighttimebytheroaduserssothatno
vehiclehitsthebarricade.Visibilityshallbeensuredbyaffixingretroreflectivestripesof
requiredsizeandshapeatappropriateangleatthebottomandmiddleportionofthe
barricadeataminimumgapof1Minadditionminimumoneredlightorredlightblinker
shouldbeplacedatthetopofeachbarricade.
8) ForworkatHeight:Contractorshallprovideladder/Petzl/Platform/Scaffolding.
9) Onlytrainedplumberundergonepracticaltrainingonworkatheightshallonlybedeployed
10)AnyworkingatheightrelatedactivityhastobecarriedoutwithPermittoSystem.(Permitfor
WorkingatHeight).PermitwillbeissuedtoAICsbyHSS&Edepartment.
11)Activityfollowingsafetyprecautionismandatorybythecontractor
TheactivitymustbecarriedoutinpresenceofMGLRepresentativeonly

a) Nonakedflamedallowedinthevicinity.
b) Areahastobarricadeasapplicable.
53

c) CalibratedGascoseekershouldbemadeavailableduringthework.
d) Uncontrolled release of gas/purging should not be allowed. Vent pipe of sufficient

height(morethan3meter)withflamearrestor.
e) Fortappingfromexistinglinecontractorshallinformtotheresidence/society.
f) Aftercommissioningsiteshouldbemadesecuredbycheckinggasreading/coveringof
theendpipe.
g) All proper /relevant PPE including fire retardant clothing must be used by the
personnelinvolvedinlivegasoperationonMPLine.
h) Calibrationcertificateforalldigitalpressuregaugesmustbeavailableatsite.
i) IncaseoffireorgasleakinformcontrolroomandrespectiveAICImmediately.
12)Contractorsupervisor/EngineermustbealwayspresentonthesitewithvalidSTCcard.
13) Contractor PE technicians/supervisors/Engineers/helpers & labors must have valid STC

card.NOSTCNOWORKpolicyshouldbeimplementedonsite.
14)ContractorshallreturnSTCcardbacktotheHSSEDepartment,ifanypersonalleavethe
organizationandforreviewtraining
15)STCtraining&cardsforPlumber,Supervisor&PEtechnicianwillbeprovidedbyHSS&E
department.MGLhasdeputedM/sMakwana&Pentsafefortraining&issuingSTCcard.
16)STCforlabors&helperswillbearrangedatthenearestemergencydistrictoffice.
17)Useofinsulatedcrowbarsshouldbethereatsite.(AScrappiece[1Meter]ofPEpipeshas
tobeusedforinsulationpurpose.Theupperendofcrowbarhastobeendcapped.)Use
insulatedcrowbarsatsite.
18)Beforecarryingoutexcavation,theundergroundcableshouldbedetectedwiththehelp
ofcablelocatorandsameshouldbemarkedonthedrawingaswellasontheroadwiththe
helpwhitepaint/chalkpowder.
19)Theexcavatedsoilmustbestackedatleast300mmawayfromthetrench.
20)ThecontractorshallprovideFirstAidBoxatallsitesContentasperattachment.
a) Thecontentsofthekitshallincludethefollowingitemsasmentionedbelow:
54

Contents of First Aid Box
Sr.
Quantity Description Use of the item
No.
Rollerbandagefll7.5cmsx3mts
1 4Pcs usedforlargercuts/wounds
(Hand&FeetDressing)
1mtx1mt.AbsorbentGauzefllFor
2 1Pkt usedfordressing
DressingWound
usedforcleaningwound/applying
3 6Pcsx20Gms AbsorbentCottonWoolI.P.
withbandage
5 1x100mls AntisepticSolutionSavlon/Dettol Forcleaningwoundarea.
6 1x15gms VellosulphPowder Usedforpowderingwounds.

7 12Pcs SafetyPins fortyingbandage
DressingScissors12cmsStainless
8 1 forcuttingbandage
Steel
9 1x20gms BoricAcidI.P. forapplyingonwound
10 1x20gms BurnOintment/(Burnol) forfirstdegreeburninjury
11 1x20gms SoframycinOintment Foruseasantiseptic.
Forcleaningwoundarea.Another
12 1x15gms ProvidonIodineOintment
disinfectant.
5Nos.
13 BandAidStrips foruseonverysmallcuts
Waterproof
1No.2.5cmx foruseonwoundfortaping
14 AdhesiveTapeUSP
5mt purpose
foruseforbackache/body
15 1Nos.X35GMS. PainReliefSprayMoov ache/musclepain/sprainorjoint
pain
Ayurvediceyedropsforremoving
16 1 Itoneeyedrops
dustparticlesfromeyes.
17 1Nos.X35GMS. Iodex/Zhandubalm ForCold&Otherbodypain
55
Personnel Protective
Equipments (PPE)
while carrying out the work all tools should be tied to tie
line
check required PPE like hard hat, safety goggles etc,
Standard Salient Feature

Sr. /Inspect
Item
No. ion
Criteria
IS5852-77
For steel
Safety shoe with injection molded PVC / nitrile rubber
toe
sole, collar cushion, fully leather lined with steel toe cap
1 Safety Shoe IS 10667-
as per BIS. Shoe sole to be anti skid and provide
83 Guide
adequate insulation. No nails are used on sole.
for
selection
IS 12254- Full size (up to Knee height ) Molded foot wear made up
2 Gum Boot WITH
1993 of PVC and cotton fabric with Fiber toe cap
Made of high density polyethylene thermoplastic with
Safety IS2925- radium Should have head harness and chin strapped for
3
helmet 84 fixing Polyester fiber reinforced polycarbonate /polyester
fiber glass material shall also be considered.
Hand Gloves
Cotton IS6994(P Should be PVC dotted for grip
4
T 1)-73
56
Sr. /Inspect
Item
No. ion
Criteria
Rubber
(Elect
Resistant)
Leather
(welding)
IS6994-73 Suitable for 11 KV Working potential
Overall /
5 dangri/ Boiler IS8519-77 One piece apparel of cotton material.
Suit
Leather Apron
6 IS6153-71 Full skirt type
(Welder)
Safety
goggles
Impact resistant & thermally toughened glass, suitable
IS7524
X: For Drilling to be worn over normal spectacles.
7
& Grinding
Thermally resistant & protection from radiation
IS1176-76
Y: Welding
screen
Noise protection should be made of high impact
Ear muff with
8 IS6229-80 polypropylene for rugged use. No metal parts to be
head band-
used. Should attenuate sound level by 30 to 30 db.
Moisture & heat resistant. Should be made of soft
9 Ear plug IS9167-79 pliable, non allergic rubber should reduce sound level by
minimum 17 db.
10 Gas mask IS8318-77
11 Escape mask IS8318-77

The vest of jacket shall be made of net type cloth and m
made of dual colour, vertically to give more visibility and t
bed reflective fabric mounted on fluorescent organic fabric
the vertical band of each shoulder and horizontally tape
the chest and back to create 360 degree visibility as
High Visibility
12 EN 471
Jackets
Cross belt 2 inch Glass Bead EN 471 reflective tape

cross at back & two vertical bands in front having Velcro
57
Sr. /Inspect
Item
No. ion
Criteria
both sides.
Industrial coverall, 4.5 Oz / yd2 Nomex IIIA, Flame

resistance fabric with imported reflective Tape- 3m
make, Sizing recommendation : Work rite two extra
deep front inset pockets, and two rear patch pockets,
Nomex two large double stitched chest pockets one with flap
Flame
retardant reinforced tool pocket on right leg, pass through
13 retardant
suit To inner clothing. Deep "action Black" style for
clothing
Ease of movement. Solid brass breakaway zipper.
Double stitched seams for enhanced durability. Roomy
Leg cut to fit over boots. Elastic waists, French style
Collar, snap wrist closures, In navy royal blue.
1 ListoftheApprovedmanufacturerforsupplyingPPEisasunder.Thecontractorsshallprocure
allrequiredPPEsofapprovedmanufactureronly:
Sr. No. Name of the Approved Manufacturers
1 UnicareEmergencyEquipmentPvt.Limited
LeslicoHouse,Dadar(W),Mumbai28.Telephone24227198
2 JosephLeslie&Company
LeslicoHouse,Dadar(W),Mumbai28Telephone24221880
3 P.N.SafetechPvt.Limited
E001,SanpadaRailwayStationComplex,Sanpada(E)
Mumbai400705Telephone56117768/27613553
4 InternationalSafetyProducts
117,1stFloor,AWingKanaraBusinessCentre,BehindEverest
Garden,Ghatkopar(E),Mumbai75Telephone55551161/62
ShreeLalita
5 PlotNO:7C,LaxmiAshsihIndustrial,NewLinkRoad,
Mumbai53Telephone55023356/57
6 SafetyProjectsPvt.Limited
68/70,NagdeviStreet,2ndFloor,
Mumbai400003
PhoneNo.23450573
FaxNumbers23112097
58
7 JosephLeslieDraggerManufacturingPvt.Ltd.
LeslicoHouse,4thFlr.Office87CProf.V.S.AgasheRd.Bhavani
ShankerRoadDadarWestIndia,
TelePhoneNo02224221878
Fax24306044
ContactPersonMr.J.SChauhan
8 JaycoSafetyProductPvt.Ltd
82/84,MasjidVBunderroad,2ndfloorNearSatkarHotel,
Mumbai3
Tel:28709989/90/39525323
1) AfulltimequalifiedsafetyofficershallbeavailablewiththecontractorwithvalidSTC(Safety
andTechnicalCompetency)card.
Qualification:B.E.with2yearsExperienceandwithoneyearDiplomainInd.Safetyor3Years
DiplomainEngineeringwithoneyearDiplomainInd.Safetyandthreeyearsexperiencewillonly
beacceptedasSafetyOfficerforeachWorkorder.Anyothergraduateor+12withDiplomainFire
&SafetywillnotbetreatedasQualified.
The Safety officer should attend the monthly meeting of the Safety Officers at respective Zonal
officealongwiththeTPEmentoringsessions
2)Equipmentlistincludingaircompressor/liftingtools&tacklesmustbemadeavailabletoAICs
and HSS&E dept. and the equipments must be certified for safety as per the requirements of
MaharashtraFactoryAct.
a) Inspection certificate- Tool and Tackles should be calibrated from HSSE approved vendor
only.
List of Tools & Tackles:
Item Inspection/Calibration Date

PETZL OnceinSixMonth
RopeGrabFallarrestor OnceinSixMonth
FirstAidBox OnceinMonth
FireExtinguishers(10KgABC) OnceinYear
O2Meter OnceinSixMonth
Gascoseeker OnceinSixMonth
CableLocator OnceinDay
Extensionboard(Without TobecheckedbyHSSEdept.3
cablejointwithsocket)with monthly
circuitbreaker
DigitalPressuregauges& OnceinSixMonth
fusionmachine
Compressor OnceinYear
Nylontielinefortools OnceinDay
59
TOOLS AND EQUIPMENTS
Squeezer Temporary stopping-
off the flow of gas in
pipe.

Toe End To pull the pipe
60
P. E. Pipe Use to cut the PE
Cutter pipe diametrically.
61
TOOLS AND EQUIPMENTS contd.
Leak Temporarily stopping the

Clamp gas from leak position
Georg Fischer WAGA Repair Clamps

Indigenous made

contd.
Parallel To hold the pipe
Clamp firmly during Fusion
62
Top Tee Clamp: To hold the pipe & Fitting firmly during fusion
Small Tap-tee spring load 500 Nm

Big Tap-tee spring load 15000 for dia 32/20 mm
Nm for dia >32 mm
Note: No tap is drilled unless a time period of 2 hour after cooling

Squeezer:When using a hydraulic squeeze-off tool the locking pins must be used
immediately the squeeze-off has been applied.
GBE/PL2:part .
Gas Business
Engineering
Technical
Specification
specifies
requirements
for squeeze-off
equipment
for PE sys.16mm -
400mm
63
Electro fusion machine
Type: MSA 200
Mains Voltage :180-264V

Fusion Voltage :39.5VAC
Operating temperature :-5 to +45 C
Weight :approx. 19kg(with
cables)
Fusion cable :3m length
Pin adopter size : 4.7mm dia.
Note:
Machine should be calibrated.
In case of M/c failure do not open it.
Keep it in dry condition.
Cable locator-
Procedure
TO DETERMINE DEPTH Hold the pace trace over
the Mark made (as above) Turn gain control until
indicator registers exactly 10. then move unit left or
Right if direction of Cables until the indicator ceases to
fall towards Zero (0) Mark this point. The distance
between the two marks is approximately equal to the
depth below ground level.
MAKE SURE TEST BATTERY
Switch on Unit but do not turn up Gain Control. Press
Battery Test button. The indicator should read
between 7 and 10 if the reading is below 7. Renew
Battery (Fit a new PP3-9V battery) Test again if reading
is still below 7 (Contact Supply)
In Heavy Traffic use meter indication of Signal rather
than bleeper unless it is safe to wear headphones plug
into the side and the Control box.
After use ensure unit is switch off. Remove battery if
unit to be stored for more than one week.
Wearing- The Pace trace is only on indicator and in
Freak conditions may be unable to detect a Live Cable
Therefore always proceeds with Caution.
64
Gascoseeker
Photo of MK-I &
Leak Surveyor
b)AtleastoneGascoseekershouldbeavailablewiththecontractor.(Itshouldhavetagonit
indicatingitscalibrationstatus&allcalibrationcertificates.Equipmenthastobecalibrated
twiceayear)
c)DigitalPressuregauges&fusionmachineavailableatsitemustbeingoodworkingcondition
& valid calibration certificate must be available with contractor. (It should have tag on it
indicatingitscalibrationstatus&allcalibrationcertificates.Equipmenthastobecalibrated
twiceayear)
d)ListofApprovedvendorfortestingpurpose
o M/SIndsafEngineeringConsultancyServices,SwastikIndustrialEstate,Mumbai98
TelephoneNo:9821658137

o United Phosphorus Limited, Ready money Terrace, Worli, Mumbai18 Telephone
No:24930681

65
o AltopcalibrationServices,A4,JaySukhSagarCoop.Hsg.Kandivali(W)Mumbai67
o Tritech,121VeenaIndustrialEstate,LBSMarg,Vikhroli(W),Mumbai83,Telephone
25777288,55969990
e)Contractorshalldisplayatleastthefollowingsafetysignboards/hoardings(each)
persitelike:
Inconveniencetomembersofpublicregretted/Workinprogress.
NosmokingSign
Nameofthecontractor&contactdetails
EmergencyDisplayBoardshowingthedetailsofTOPSLINE,MGLEmergencyTollFreeNo&
nearestFireStationNo.
f) 10 kg ABC (Stored Pressure) type fire extinguishers must be made available prior to start of
workoneachMPsite.(Extinguishershouldhavetagonitindicatingtesting&expirydate
onit.)
Note: Contractor has to maintain the file (records of refilling/hydro testing) in a

format provided by HSSE dept.
1. Drilling machine used by contractors should in good work conditions. Electric wire used for
machineshouldnothavejoints.
2.Adequatelightingarrangementstobeprovidedwhileworkingduringnighttime
3. Hygiene requirements must be met on site by providing fresh drinking water of minimum 20
Litersateachsite.
4.Ifthecontractoremploysfemaleworkersthenaprovisionofcrchefortheirchildrensmustbe
doneateachsite.
5.Undernocircumstances,thecontractorshouldemployminor(below18yrs.)attheirsite.
6. All the safety equipments like PPEs, Gascoseeker Mark II (GMI Make), self locking body
harness,cabledetectorsshouldbeprocuredaftergettingNOCfromsafetydept.
7.ContractorProjectMangerandSafetyOfficershouldattainZonalSiteSafetymeetingsat
respectiveZonalOfficeswhenevercalledupon
66
SPECIFIC SAFETY REQUIREMENTS
1.AvoidElectricityCables

Beforestartingwork:
Obtainallavailableinformationonundergroundcables&otherservices.
Usecablelocatorbeforeexcavatingorstrikingpinningequipmentintotheground.
Markoutindicatedcableroutesonthesurfaceusingplants&acablelocator.

Atalltimes:
Workwithcareascablemaybefoundatanydepth.
Treatallcableasliveunlessotherwiseconfirmed.
Whenindoubt,stopdigging&askforadvice.
Ceaseworkifacableishit&reporttheincidenttoyourmanager.

Asworkproceed:
Makefurthercheckwithacablelocatorpertcurlyiftheproposedpiperouteisaltered.
Donotusemechanicalplatorpowertoolswithin0.5mofthededicatedlineofanycable.
Haveatleasttwo10kgpowderfireextinguisheronsiteduringtheprogressofwork.
AvoidInjuryfromElectricalEquipment
Beforeconnecting,disconnectingorreplacingcable,connector,electrofusioncontrol
boxes&otherelectricalequipment,makesurethattheelectricalsupplytothemisdead.
Donottrytorepairelectricalequipmentorreplacepartifyouhavenotreceivedproper
training.

2. Routine Fire precaution
Ensurethatanosmokingsignisdisplayed.
Ensurethattherearenonakedflamesinthevicinityofthework.
Keepallsourceofignitione.g.Electrofusionboxesatleast5mawayfromthework&
upwind.
Intheeventofaunforeseenreleaseofgaswhichcannotbecontrolledquickly,keepthe
generalpublic&vehicleatleast5mawayfromtheescapinggas.

3. During purging operation
Ensurethatventpipesareproperlyearthed
Donotuseplasticpieforventinggas.
Donotdischargegasathighvelocity.
4. Dealing with fire
Decidewhichisthegreaterhazardthefireortheescapinggasifthefireisextinguished.
Ifthefireisallowedtoburn,attendthefireatalltimeuntilthematerialrequiredfor
sealingthepipeareavailableorthegassupplyisturnedoff.
Keeppedestrianawayuntilthefirehasbeenextinguished&sitemadefree.
Placesign,barrierfencingetc.aroundallexcavation
67

MEDICAL FIRST AID AND SAFEGUARD

First Aid
Intheeventofinjurytopersonnel:
Protectthecausalityfromfurtherdangerorinjury.
Laythecasualtyonhis/herside&keepwarm&dry.
Trytostopanybleedingbyapplyingdirectpressureatthebleedingpoint.
Ifyouknowhow,&theneedisevident,giveartificialresuscitation.
Whenworkinginsoilorinthevicinityofsewerorstagnantwater,coveranycutsor
abrasionswithwaterproofingdressingwearprotectivegloves.

Reporting accidents
ReportanyaccidentsassoonaspossibletoyourAICorManager
Emergency Situation Immediate actions/remedies

a) Do nottouch the casualty.
ElectricShock b) Breaktheelectricalcontactbyswitchingoffatthemains,or
removingtheplugfromitssocketoutlet,orwrenchingthecable
free.
a) Temporarily protect the wound with a sterile swab
(or clean
Handkerchief) and clean the skin around the wound, wiping
away, nottowardsthewound.Dabitgentlytodry.
b) Ifbleedingiscontinuous,applydirectpressuretostemtheflow
Bleeding ofbloodand,ifpossible,raisetheinjuredlimbtoreducethe
flowofblood.
c) Dress the wound.A small cut can be dressed with a plaster
or smallbandage;inthecaseofalargerwoundapplyasterile
dressingorclean
Pad and bandage firmly.
a) Placetheinjuredpartunderslowcoldrunningwater,or
Burnsandscalds immerseitinaContainerofcoldwater.
b) Donotapplyanadhesivedressingoranylotions,ointments,
fatsoroilstotheinjury.Donotinterferewiththeinjuredpart.
c) Seekmedicalattention.
a) Askthecasualtytoclosetheinjuredeyeifpossible.
b) Covertheinjuredeyewithaneyepadorsteriledressing.
Holdthisinplacewithabandageorstickytape.
Eyeinjuries c) Onnoaccountattempttoremoveaforeignbodyfromaneye;
leavethistosomeonewhoknowswhattheyaredoing.
d) Seekurgentmedicalattention.
Hazardoussubstance a) Ifpractical,washtheeyeoutwithcoldrunningwateror,
inaneye preferably,aproprietaryeyewashsolution.
b) Seekurgentmedicalattention.

Hazardoussubstance GetthecasualtytotheAccidentandEmergencyDepartmentof
swallowedorinhaled ahospitalimmediately
68
EXCAVATION
Introduction
The in formation contained within this section provides general guidelines on site operations when
excavating&reinstatingopeningformains&services.
1. Route surveys
Surveytheroutetoestablishthemostsuitablelinetakingintoaccountothersurfacefeatures
e.g.Marketplace,Valvecoverboxesetc.
Noteanyvisibledefectinthesurfaceoftheroadorpath&bringthemtotheattentionofthe
appropriateauthority.
Seekadvicebeforeexcavatinginprivatelandtoensurethatthenecessarypermissionhas
beenobtained.
Whereitisnecessarytolaypipelinesincloseproximitytobuildingsorotherstructural,any
structuraldefectsshallbenoted&broughttotheattentionoftheowners.
Obtainplansorotheravailableinformationfromutilitiesregardingtheposition&depthof
theirplant.
Useacablelocationtoconfirmthepositionofcables&otherundergroundplant.
Trailpitmaybeexcavatedatappropriatepointalongthelineoftheproposedroute.
2. Safety in excavations-
Allexcavationover1.2mdeepormadeinunstablegroundconditionshallbesupported.
Toprovideadequateworkingspace&toavoidthedangerofdebrisfallingintothetrench,
sufficientspace(minimum300mm)shallbeleftbetweenthetrenchside&excavated
material..
Wearhighvisibleclothingwhenworkinginornearamainroad.
Maintainminimumclearancesof250mmbetweenthemainorservicebeinginstalled&other
utilitiesplantwherepipesarecrossingotherplant&thiscannotachievedthenprotection
mustbeprovidedconsultyourmanagerasnecessary.
Provisionofsuitableprotectiontopreventpersonfallingintoexcavation
Usealadderwhereitisnoteasytogetin&outoftrench.
Checkthesitedailyfortidiness&safetybeforeworkstartseachday.
ThefollowingtablegivestheTrenchwidths&minimumdepthrequirementformainoperatingupto
4bar&thesemayvarywheresiteconditionisdifferent.&maintain250mmclearancebetweenother
utility.
69

Pipe size Trench Minimum Top
width Cover (mm)
20/32 mm 450 1000
63/90 mm 450 1000
125 mm 500 1000
180 mm 500 1000
3. Digging trenches
Usecablelocatorbefore&duringexcavation.Wherepipesarecrossingorlaidparallel
toanyHTcables&ifclearanceof250mmcantbeachievedthenadequateprotection
likeHumepipeshouldbeprovided.Alltrenchingworkwillbeproceedwithproper
plastic/Woodenbarricadesofareonallside..Excavatedearthetc.willbeproperlyfilled
inemptygunnybagsoremptyplasticbags&neatlystocked.Duringtheexcavationof
trenches,thewaterentrance&openstormwaterdrainswillbeproperlycoveredwith
plasticorgunnybagssoastoensurethatnoexcavatedmaterialfindsitswayinto
stormwaterdrain.
(a) MP Laying on MUNICIPAL CORPORATION roads:
Alllayingofpipelinesshallbelaidat1000mmtopcoverwithprotectiveRCCtiles(of
approx.50mmthick).Incase,wherepipelineispermittedtobelaidwithtopcoverless
than1000mmbutgreaterthanorequalto600mmduetositeconstraintthesameshallbe
specificallyagreedbyEICinwriting,dulyconcurredbythirdpartyinspectorandapproved
byTechnicaldirector(MGL).Insuchcases,UshapeRCCblock/coverprotection(supplied
bythecontractor)shallbeinstalledWhereelectricalcablesareencounteredfromthe
bottomsideofthetrench,RCCbottomslab,tobesuppliedbythecontractor,shallbe
installedbeforeinstallingUshapeRCCblockprotection
(b) Road crossings on MUNICIPAL CORPORATION roads:
Roadcrossingsonprivate/otherthanMUNICIPALCORPORATIONroads:Alltheroad
crossingsshallbecarriedoutwithmaintainingtopcoverofpipeline1500mmfromground
levelthroughRCCHumepipe,

(c)Alldrains/culverts/nallahshouldbecrossedatleast1000mmbelowthebedwith
protection.

(d) Deep Excavation:
Safemethodsofsupportingexcavations:
Supportshallow/mediumtrenchesinarangeofgroundconditionsusingtimber,trench,sheeting&
hydraulicshoring
Propermaintenanceofsideslopesorshoring
Carryoutinspectionofgroundsupportsystemsandcompleterelevantdocumentation
Donotkeepwater,anyotherdisposalwithintwofeetofexcavatedpit
70
Barricadetheareaanddisplaywarningboards
Providestepsorladderifdepthismorethan1200mm
Ifanexcavatedpitiscovered,ensurethatthecoverisproperlysecuredtoavoidfallingof
personnel.

4. MGL Reinstatement Specification:
a) Wheretemporarysurfacereinstatementisrequiredthematerialstobeusedineach
layershallbeasfollows.
Finefillsuitableexcavatedmaterialofgritsizelessthan5mm.
Backfillsuitableexcavatedmaterial
Roadbase/Subbasesuitableexcavatedmaterial,withaggregatesizes40mm
todust&wellgraded.

RunningsurfaceThiswillbematerialbroughtinfromotherplaces,ofaggregatesizes
40mmtodust&wellgraded.
b) WhereaPermanentsurfacereinstatementisrequiredthematerialtobeusedineach
layershallbeasfollows :
Finefillsuitableexcavatedmaterialofgritsizelessthan5mm.
Backfillsuitableexcavatedmaterial
Roadbase/Subbasesuitableexcavatedmaterial,withaggregatesizes40mmto
Dust&Wellgraded.
RunningsurfaceBituminousorconcretematerialasdirectedbyMGL.
5. Guarding of excavations
Excavationwillbeguardedtoprotectandwarnpedestriansandvehiclesthatworkupontheroad
andfootpathistakingplace.
Signsandbarriersand/orroadtapeandpinsshallbeusedaroundtheexcavation(s).
ThespecificrequirementsforeachsitewillbedecidedbytheMGLsiteengineers,however,the
minimumstandardsareasfollows:
Fortrenches,guardingwillbebymeansof1metersteelroadpins,plasticcones,orbollards.These
shallbeplaceat2mintervalsalongthelineoftheedgeofthetrench.Warningtapeorcordshall
connectthepinsorcones,andwillextendacrosseachendofthetrench.Additionally,warning
boards/signsshallbeplacedateachendofthetrenchtoadesignapprovedbyMGL.
71
ExcavationwillbeguardedinaccordancewithanyspecificrequirementsoftheBMCorother
statutoryauthority:
TheseboardswillcontainthefollowinginformationtheprecisewordingwillbeagreedwithMGL:
AnoticethatworksisbeingcarriedoutbyMGLwithanapologyforanyinconvenience.
Thename,addressandtelephonenumberofthecontractorundertakingthework;
T h e MGLemergencyTel.No.1800229944/24012400
TheTOPSLINENO.1252foranyincident/accident
Small hole excavation shall be fenced with pens, and tape as above and a single warning
notice shallbeplacedasdescribedabove,adjacenttotheexcavation.
Excavationshallbeilluminatedatnightwithappropriatewarninglampswherenecessaryand
asdirectedbytheMGLSiteEngineer.

(6)Riskassessmentpriortocarryoutexcavation:

(a)Check for Abnormal conditionsCarry out risk assessment for abnormal conditions
includingworking inrockyterrain,waterloggedarea,andhazardouswastedumpyards, which
willinvolvehazardidentification andmitigationmeasures.

(b) Risk due to Buried Explosives / Chemical Hazards Consultation with local agencies
includingexplosiveauthoritytoobtainanypasthistoryofexplosivesbeingusedin
thevicinityofproposedworks.Makeenquiresfromlocalresidentsconcerningpreviouslanduse
andanypasthistory
.
(c)Incase ofdoubts consult the expertsIdentified special specialist agencies like
state explosive departmentin case of explosiveand state pollutioncontrol
agency in case of hazardous chemicals would be informed for necessary
guidance andclearingupsuchsites

72

Typical Trench/Reinstatement details
G.L
Running 150
Surface
250
Road Base / Sub
Base
Backfill
200
Warning Tape
100
100
HDPE Duct Pipe

Fine Fill / Soft 100 Optional
Soil
RCC Protection Tile 50
75
Fine Fill/Soft Soil
75
Sand PE Pipe
73
POLYETHYLENE MAIN AND SERVICE LAYING
1. Definition
a)AservicepipeisdefinedasapipewhichisusedtosupplygastoasingleBuildingorblockof
flats.
b)Amainisdefinedasapipewhichsuppliesmorethanoneservicepipe
2.General
a) Anyserviceof63mmdiameterorlargershouldbelaid&testedasamain.
b) Pipeendsmustalwaysbesealedwhenlayingatpipeonsitetopreventingressofwaterordebris
alltime.
c) Usemarkertapeoverallmains&services.
d) TheelectrofusionjointingtechniqueisthemethodtobeusedforjoiningPEgaspipeinMGL.

3. Performance requirements for PE pipes governed by:
TheAmericanSocietyforTestingofMaterials(ASTM)establishedASTMD1248.
TypeILDPE0.9100.925gms/cc
TypeIIMDPE0.9260.940
TypeIIIHDPE0.9410.959
TypeIVHDPE0.960andabove
The difference between MDPE pipe & Metal pipe:
CRITERIA MDPE METAL Pipe
Weight/meterofpipeinKg. 0.44 2.50
Flexibility High Low
Standardlength 6m,coil(50300m) 6m
Coilingpossibility Yes No
Surfacefinish Smooth Rough
Environmentalcorrosion Notaffected Yes
Installation Faster Slowasjointatevery6m.
Connection Electrofusion Welded

Onlineconnection possible Notpossible
Workingtemperaturerange 40to600C Weakat400C
74
a) Onlystandardpipe&fittingsuppliedbyMGLshallbeusedfortheconstructionofthe
distributionsystem.
b) PEpipewillbemarkedwiththecompanyname,manufacturersname,&thewordGASat
regularintervalalongitslength.
c) ThestandardsizesusedinMGLare20mm,32mm,63mm,90mm,125mm&180mm.
d) PEpipewillbenormallybesuppliedineithercoilsof50mor100m&straightlengthof6mor
12m.
4. Proximity & depth of cover-

a) WherepossiblePEmains&servicesshouldbelaidwithaclearanceofatleast300mmfrom
otherplant&obstacles.AnMGLengineershouldbeconsultedifthisisnotpossible.
b) PEmains&serviceshouldnotbelaidclosertopropertiesthanstipulatedbelowinTable1
Table1
OperatingPressure Minimumproximity(m)
Upto100mbar 0.25
Upto4bar 3.0
c) Theminimumdepthofcoverfromthetopofthepipetothe
finishedsurfacelevelisgivenbelowinTable2
Table-2
Diameterof Minimum
Pipe(mm) cover(m)
Upto20mm 1
32mm&above 1
d) Anydeviationtotheabovedepthmustbewiththeapprovalofthecompetentauthority.
5) Electro fusion
a) TheElectrofusiontechniqueshallnotbeuseifthereisgasintheatmospheregreaterthan20%
LEL.
b) AllElectrofusioncontrolboxes,Fusionlead&otherassociatedequipmentmustbecompatible
withthesystemusedbyMGL.
c)Inthecaseofanunsuccessfulfusioncutoutthefitting&repeattheprocedureusinganew
fitting.Donotattempttoreheatafailedfitting.

d)Donotadjustorremovetheloadingtoolbeforethefusion&coolingtimehaselapsed
75
Mains that will operate above 100mbar & up to 4bar (MP):
Allmains&servicepipemustbetestedatapressureof6bargauge
Astabilizationperiodmustbeallowedbetweenthestartofpressurization&therecordingofthe
firstpressurereading.Thisenablesthetempoftheairwithinthepipetostabilize&minimized.
Apermissiblepressurelossof6mbarisallowedwhichtakesintoaccountinaccuraciesinpressure
measuringinstruments.
Theonlyacceptabletestmediumiscompressedair.
Medium pressure MDPE (Medium Density Poly Ethylene) pipe laying up to upstream end connection
of Service Regulator (SR)
ServiceRegulatorisadeviceusedtoreducepressurefrom4barto100mbar,whichistheinterface
betweenMediumpressureandLowpressuregasnetwork
.
Main that will operate at 100mbar & below (LP):
Allmains&servicepipemustbepressuretestedatapressureof250mbar.Airisthepreferredtest
medium.
AnLPmainstestissuccessfulifthemaximumpermissiblepressuredropof10mbarisnotexceeded
Purging & commissioning mains-
Purging&commissioningofmainsshallonlybecarriedoutinthepresenceofanMGLAICafter
gettingapprovalofNonroutineOperation(NRO)fromcompetentperson.
Formainsabove63mmdiameterpurging&commissioningshouldbecarriedoutinaccordance
withanapprovedwrittenprocedure.Thisprocedurecontainsanassessmentofthepurge
duration.
Purgingiscompletewhen90%ofgasinair(GIA)isconfirmedwithgascoseeker
76
RISER AND LATERALS
Definition
a) Ariseristheverticalsectionofaservicepipelaidupabuildingwhichsuppliesanumberof
laterals
b) Alateralisanhorizontalofftakefromariser,whichsuppliesasinglecustomer/dwelling

Riser & lateral construction
(a) Differentsizeforpipecombinationi.e.1/2",3/4",1"&1sizeandlengthofGI/ERWpipeusedforGI
riser&lateral.

(b)LayingofPowdercoatedGIpiperiserupto8thfloori.e.24mtr(approx)heightfloorswiththreaded
jointsandanyriserhavinglengthmorethan24mtrheights,i.e.above8thfloorfromthegroundlevel
shouldhaveweldedtypejointforcompletelengthofERWpipelineinplaceofconventionalthreaded
joints.InabovesaidweldedtyperisersContractorsshalluseforgedfittingsasperIS1239Part2and
ERWpipeasperIS1239Part1,Heavyclass.Allforgedfittings&pipesshouldbepurepolyesterpowder
coatedofmin.70micronthickness.

(c)Thereislinearexpansion/contractionofapp.0.2mmpermeterofriserlength,soabove8thfloor
flexibleAnacondafittingshouldbeprovidedoneachlateral.

(d)InstallationofGIpipesaddle/clamps/supports(suppliedbycontractor)atmaximumspacingof1.5
meters.Spacebetweentwopipeclampsshallnotexceed1.5monrisersand1.0monlaterals.

(e)BreakingthroughordrillingofRCC/brickwalls,cuttingofglassforentryintokitchen,marble,granite
tilesetc.andthesubsequentmakinggood.Presleevedholepieces(kitchenentry)shouldbeapplied
whereGIpipepassesthroughthewallsandfloors

(f)Thetapoffjobinvolveslaying,testingandcommissioningtheGI/ERWpipingfromtheexistinggasified
riser starting from the GI tee connection up to the Meter Control Valve. This being a live job on a
GasifiedriserinvolvesproperprecautionstobetakenfordisconnectingthemainriserfromtheRiser
IsolationvalveafterinformingtheindividualGasusersregardingthesame.Adequatemeasureshave
tobetakenforBarricadingtheareabelowtheriser,useofPetzl.
(g) A riser should be constructed with a tee & isolation valve an appropriate for every potential
customer.TheheightofRiserisolationvalvefromthegroundlevelis1meter.Ametercontrolvalve
mustbefittedimmediatelyafteralateralentersaconsumerpremises.
Pneumatic pressure testing
Service riser will be tested at a pressure of 1.5 times the operation pressure. In MGL for GI pipe with
threadedjointstheTestpressureis250mbar.ForERWpipewithweldedjointsthetestpressure
is1bar.
77
Air is the acceptable medium for this test & the pressure must be raised slowly using a hand or foot
pump.Astabilizationperiodof10minutesisrequired.Thetestdurationwillbe5minutes&nopressure
lossispermissible.
Allmetercontrolvalve(MCV)attachedtotheriserwillbesecurelyplugged&leftintheopenposition
duringthetest.
Purging & commissioning of Risers-
Purging & commissioning of riser & lateral shall only take place immediately after a successful
pressuretest.
Purging&commissioningofriser&lateralshallonlybecarriedoutinthepresenceofAICorTPE.
Ventingshallbecarriedoutbyallowingapurgehosetothemetercontrolvalve&ventingthisto
atmosphere.
78
Domestic Installations the pipe work down stream of the meter & Meter regulator, Cu
pipe & Appliance valve.
a)TheinstallationofGasmetershallcomplywiththeGassafetyregulation1984.Thegeneralagreement
oftheowner,MGLofficialshouldbesoughtregardinganacceptablemeterlocation
b) The meter should not be installed in close proximity of any sources of heat, below the sink, in
Bathroom,whereitmightbeliabletomechanicaldamage
c)MeterRegulatorisadeviceinstalledupstreamofmeter,usedtoreducepressurefrom100mbarto21
mbar
d)Domesticinstallationwillbetestedatapressureof32mbar.Airistheonlyacceptablemediumforthis
test.
e)Aperiodof1minuteshallbeallowedforstabilization
f)Thetestshallbefor2minuteswithnopermissiblepressuredrop.
Purging & Commissioning of Domestic Installation

Purging&commissioningofdomesticpipeworkshallonlytakesplaceimmediatelyfollowinga
successfulpressuretest.Purgingiscarriedoutbyattachingapurgehosetotheappliancecontrol
valve&ventingtoatmosphereoutsideproperty.
79

EMERGENCIES DEALING WITH PUBLIC REPORTED GAS ESCAPES
1. Reporting of Gas Escapes
ThecontactpointforreportinggasescapesistheEmergencycontrolroom.Thiswillbethe
controlandcoordinationpointforallemergencyworkandwillbemannedona24hour
basis.
TheEmergencynumberis24012400/Tollfreeno.1800229944
EmergencyTOPSLINENo.1252
ThekeyroleoftheEmergencycontrolroomistoensurethat:
1) Detailsofreportedgasescapesarerecordedaccurately,
2) Safetyadviceisgiventothepersonreportingthegasescape
3) Thegasescapeispassedtotheappropriatepersonforaction.
2. Initial Action
Gasescapesreportedduringnormalworkinghoursshouldbepassedtotheappropriate
emergencytechnician,whowillattendsiteimmediately.Intheeventofamoreserious
incidentbeingreported(i.e.alargenumberofpeopleaffectedbytheemergency)thecallwill
alsobepassedtotheassistantmanagerEmergencywhowillalsoattendsite.Sitepersonnel
mayalsorequesttheassistanceofmoreseniorstaffwhennecessary.
MGLwillattendsiteassoonaspossibleandwithinatargetresponsetimeof30minutesfrom
receiptofthecall.
Thetechnician(s)attendingsitewillneedthenecessarysafetyandemergencyequipment:
theseitemsshouldbeavailableatalltimesintheemergencyvehicleandreplenishedasand
whennecessary.
ThetimeofarrivalofpersonnelonsiteshallberecordedbytheEmergencycellandan
effortshouldbemadetocontactthepersonreportingtheescapetoconfirmdetailsofthe
emergency.
Theprioritieswhendealing withANYgasescapewillalwaysbe:
Safeguardlife
Safeguardproperty
Propertymayneedtobeevacuated
Findandsecuretheescape
Carryoutafinalsiteinvestigation

80
3. Internal Gas Escapes.
Theseescapesarepotentiallythemostserious,particularlyiftheyhavenotbeen
controlledbytheconsumerturningoffthemetercontrolvalve(MCV).

Theexplosiverangefornaturalgasisbetween5%and15%GIA(gasinair).

Remembergascanenterpropertiesfromoutsideandcantravellongdistances,usually
followingthelineofleastresistance,e.g.alongsidecables,waterpipes,ductsanddrains.

Thefirstactionstobetakenwillbethebasicsafetyprecautionsinthepropertyaffected for
example:

ShutoffMCVtostopgassupply

Openwindowsanddoorstoprovideventilation

Eliminatepossiblesourcesofignition,e.g.nosmoking,nonakedflames;donot
operateelectricalswitchesorunplugtelephones;donotusedoorbellsandalways
knockondoors;

Donottakepagersormobilephonesintotheproperty;

donotusetorchesinsidetheproperty.

TakeGascoseekerreadingsintheaffectedpropertyathighlevelin2or3locationsineach
room(recheckreadingsandevacuateifnecessary

Recheckandmonitorreadingsevery15minutes.

Ifnoaccesstopropertytakesreadingsthroughdoors,letterboxes,windows,etc.,withprobe.
o InmostcasesinternalgasescapeswillbequicklycontrolledbyturningofftheMCV
readingsshouldstarttodecrease.
o (Wherereadingsdonotreduce,makesimilarchecksinadjacentdwellingswheregas
isdetectedcarryoutthebasicsafetyprecautionsintheaffecteddwelling(s).where
morethanonedwellingisaffectedcheckadjacentblocksandcarryoutbasicsafety
precautionsagainevacuateifnecessary).
Whenthesituationhasbeenmadesafethenextpriorityistolocatethesourceofleakage.
Thestepstotakeintracingescapesoninternalpipeworkareasfollows:
1. CloseappliancetapsandcloseMCVanddisconnecttheappliances
2. Fittestteetoappliancebar.
3. Checkallotherappliancevalvesareclosed.
4. Putinternalpipeworkontest@30mbarbacktoMCV
5. CheckallscrewedjointsdownstreamofMCVwithleakdetectionfluid.
6. Repairleak.
7. Reconnect appliance
8. Reopen MCVand checkjoints notsubjectedtosoundness test(hoseand appliance
connections)

81
Whereanescapeisfoundontheinternalpipework,applianceormeterinstallation,carry
outrepairifpossibleotherwiseleavetheMCVturnedoffandsecureitintheclosed
positionwithawireseal(orfitspincap).
InstructthecustomerthatitmustNOTbeturnedbackonuntilapermanentrepairhasbeen
made.Obtaincustomersignatureintheapprovedformat.
MAKE A FINAL CHECK OF THE PROPERTY BEFORE LEAVING SITE
Wherenoescapeofgascanbetracedontheinternalpipework,orwhereGascoseeker
readingsdonotreduceafterclosingtheMCV,investigatepossibleingressroutesfrom
outsidecableentries,ducts,drains,cracksinfloors,etc.CheckLPGcylindersor
installations.
4. External Gas Escapes
Onarrivalonsite,noteandrecordthetimeofarrivalandtrytocontacttheperson
reportingthegasescapetodeterminetheapproximatelocation.

Alwayscarryoutprioritychecks(safeguardlife;safeguardpropertyandfindandsecurethe
escape).
Wherethecauseoftheescapeisimmediatelyapparent(e.g.aleakingservicejointabove
ground)shutoffthegassupplywherepossible(riserisolationvalveRIV)orquicklymakea
temporaryrepairtostop/slowtheescapinggasbyfittingatemporaryleaklamp.
Oncetheabovehasbeencarriedout,orwheretheleakisnotapparent,thentheactiontaken
shouldbetocheckpropertiesadjacenttothesitetoensurethatgasisnotentering.Follow
proceduresinPart3.WhereaccesscannotbegainedtopropertiesthencheckswithaGasco
seekershouldbecarriedoutthroughwindows,letterboxes,etc.
Wheregasisdetectedinsideproperty,followthebasicsafetyprecautionsinPart3:and
checkadjacentproperties.
Havingcarriedoutthepropertychecks,asurveyforleakageusingaGascoseekershouldbe
conductedoutsidetheproperties.

FirstcheckanyDRS/Serviceregulatorinstallationsinthearea:checkforreliefstacksventing
inthearea.
Checkmanholecovers,pits,ductsetc.testforgasreadingsinallaccessiblelocations.Lift
coverstoventilatewheregasisdetected.
Noteanyvisibleindicationofthepositionofundergroundplant,cables,etc.:carryouta
surveyoftheareawithacablelocator.
Carryoutabarholesurveyonthemainsandservicesintheaffectedarea.Makebarholes
alongthelinesofthemainsandservicesat2mintervalsatadepthof300mmandcheckfor
GIAreadingsusingaGascoseeker.
82
Wherereadingsaredetecteddecideontheareatobeexcavated.
Oncethecauseoftheescapeisfound,makeatemporaryrepairtomakethesituationsafe.
Ifapermanentrepairisnotmadeimmediatelyanotemustbemadeonthecontrollogto
thateffectandthejobrecordedasnotcomplete.
Carryoutapermanentrepairassoonaspossible.
5. Interference Damage Procedures
MostlikelycauseofleakagefromtheMDPEsystemisfromexternalinterferencedamage
fromotherutilitiesworksandcontractors.
Theextentofthedamagecanrangefromarelativelysmallsuperficialpuncture,to
completeseveringofthepipeparticularlywithsmalldiameterservicepipes.
Therewillalsobeaconsiderablygreaterhazardandmuchlargervolumesofgasreleased,
ifdamageissustainedbythe4barsystem.
Theproceduretobefollowedwillthereforebedictatedbythenatureandextentofthe
damage;itslocation,proximitytopropertiesandtheoperatingpressureofthepipe.
Ingeneralthefollowingstepswillbetakenimmediately:
Gettositeasquicklyaspossibleandassessthefactorsdescribedabove.
Inthecaseofseriousdamage(andintheeventofanydamageonthe4barsystem)inform
your
Managerassoonaspossibleaskforassistanceifrequired.
- CheckforPEStopoffvalveanddependingonthenatureofEmergencyshutoffthestopoff
valve.
Thefirsttaskistotryandmakethesiteassafeaspossible.Themeansclearingand
keepingthepublicawayfromthesite,andremovingpotentialsourcesofignition
obtainhelpifrequiredfrompoliceetc.
Dowhateveryoucan,safetyandpracticallytoreducethevolumeofgasescapingfrom
thepipei.e.partiallybackfillingtheexcavation.Ifthedamageistoalowpressuremain
orservice,considerclosingtheinletvalvetotheMPregulator.Ifthisisdone,thesupply
mustnotberecommissionedwithoutconsultingtheMGLEngineerorInspector.
Checkadjacentpropertiesforescapinggasnotethewinddirectiontodecidewhat
propertiestocheckfirst.Evacuateifnecessaryorifindoubt.

Evacuateimmediatelyifthereisdamagetothe4barsystemnearpropertiesandthe
situationcannotbecontrolled.

Assoonasitispractical,reportthesituationtotheEmergencybureauandaskfor
furtherassistanceifnecessary.
83

Wherethedamageistoalowpressuremain,checkthesuppliestotheadjacent
dwellingsandturnofftheMCVifthegaspressureisaffected.
Wherethedamageistoalowpressureservice,turnoffallaffectedMCVs.
Iftheescapinggashasignited,thenfirstshutoffthegassupplybyisolatingthesection
bystopoffvalve.IfDRSareloopedthenshutoffupstream&downstreamvalve.Ifthere
arenostopoffvalvesprovidedthenshutofftheDRS.
Oncethesitehasbeenmadesafe,actiontorepairsthedamagewillneedtobedecided:this
mayinclude
areductioninoperatingpressure;fittingtemporaryleakclamp:considerationtomethodof
flowstopandfittingbypass,ifnecessary.ThiswillbedecidedbytheMGLAsst.Manager.
Oncompletionoftherepairs,furthercheckswillbemadetoensurethatnofurther
damagehasbeencausedelsewheretothemainorservice.
Recorddetailsoftheoffendingcontractorandobtainasmuchinformationregardingthe
causeoftheincident.ThisinformationshouldbepassedtotheManager&DistrictIn
charge.

Whereevacuationisnecessary,informtheMGLEmergencycontrolroomassoonaspossible.
Whenevacuationhastakenplace,ensurethatnounauthorizedpersonreentersthe
buildingandkeeptrafficandpedestriansasfarawayaspossible.
Anevacuatedbuildingshouldnotbereoccupieduntilthesourceofleakagehasbeen
securedortheleakagecontrolledbyexcavatingventholes

ThedecisiontoreoccupyanevacuatedpropertywillrestwiththeMGLEngineer.
.
6.Sources ofignition
Ifyoususpectgasinaproperty,adviseoccupantsnottooperateelectricalapparatus(on
oroff),nottosmokeandtoextinguishallnakedflames.
Donotusedoorbellswhencheckingproperties.
Electricalapparatusmaybeisolatedatitsswitch,ormainsswitch,providingan
atmosphericcheckismadeattheswitchandtheGascoseekerreadingisbelow70%LEL.
Otherpossiblesourcesofignitionare:
Vehicles,compressors,generatorsandmachinery;
Somegasdetectionequipment(Gascoseekerissafe);
Electrofusionequipment;
Streetlighting,beacons,trafficlights,etc.
84

Mobilephonesandtorches.
Noneoftheabovemustbeoperatedinahazardousarea.

7. LPG Escapes
ItispossiblethatMGLwillbecalledtoreportedgasescapeswhichemanatefromLPG
cylindersorothersources.
LPGhasdifferentcharacteristicsandflammabilitylimitstonaturalgas.Themostimportant
differenceisthatitisheavierthanairandthereforeanyescapinggaswillaccumulateat
groundlevelandarounddrainsforexample.
WhentestingforLPGalwaystestsatthelowestlevels.(LPGisheavierthanair)
Ventilatepropertyinthenormalwaybyopeningwindowsanddoorsbutrememberthat
thismayallowthegastomovetoalowerlevel.
ThestandardGascoseekerisnotcalibratedforuseonLPG,however,itcanbeusedasa
meansoflocatingescapesandthereadingobtainedshouldbehalved:buildingsshould
thereforebeevacuatedatastandardGascoseekerreadingof10LEL.

Allotherstandardproceduresfordealingwithgasescapesshouldbefollowed.
Theescapeshouldbemadesafeasquicklyaspossiblebyisolatingthesupplyandthe
customernotifiedofthesituation.
8. CNG Installations
ThereareanumberofretailoutletsinMumbaisupplyingCNG.
UptodatedetailsofCNGoutletsareheldattheCNGcontrolroomatCGS.
Ifagasescapeisreportedwithin100mofaCNGinstallation,carryoutafullsurveyatthe
stationirrespectiveofanyotherfindings:inthesecircumstancescontactCNGControl
Room.

85

Reporting of Emergency Gas Escape Incidents
Anincidentreportshouldbecompletedforanyofthefollowingoccurrences:
Anygasescapefromthe4barsystem.
Anyoverpressurizationofthegassupplysystem
Anyunplannedlossofgassupply.
Anexplosionorfire.
Anyincidentinvolvingemergencyservices,e.g.firebrigadeorpolice.
Anyaccidentinvolvingamemberofstaff,contractorsstafformemberofthepublic
Anyincidentcausingdamagetoproperty.
Anyotherseriousincidentwhichyoubelieveshouldbereported.
AverbalreportshouldbemadetoanMGLEngineerassoonaspossibleatalltimesoftheday.
IftheMGLEngineerisnotavailablethentheinitialreportshouldbetotheTechnicalDirector
duringnormalworkinghoursandtothestandbymanageratallothertimes
AwrittenreportshouldthenbecompletedandsubmittedtotheMGLEngineerwithin24hours
oftheincident,andtotheTechnicalDirectorinhisabsence.Nootherreportsneedtobemade
atthisstage.

86

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=======================================================================

Safety and Technical Training

Mahanagar Gas Limited

To be a leading consumer-friendly gas company.

City Gate Station CNG Station DRS

Domestic Kitchen Service Regulator

5) Safe System of Work

B EXCAVATIONS/ DEEP EXCAVATIONS/CONFINED SPACE ENTRY (CSE) Y N NA

HSSETPE ProjectTPE ContractorSupervisor HSSERepresentative

Sr.No Description Responsibility

PE Daily Checklist - MP / LP Works

Corrective & Preventive action -

Contractor Representative Third Party Engineer

TPE DAILY SITE ACTIVITY CHECK LIST- GI

Corrective & Preventive action -

Contractor Representative Third Party Engineer

City Gate Station:

Basic Steel Grid network

CNG STATION LAYOUT

Typical CNG station layout

Convenient Economical Safe Eco-friendly

District Regulating Station:

c) Slam Shut-off: UpstreamofthepressureregulatorisfittedtheOverpressureshutoff(OPSO)

d) Pressure Regulating: TwopressureregulatorsareinstalledinseriesformingtheMonitor&

e) Safety Relieving: ASafetyReliefValveisinstalledDownstreamoftheregulatorforrelieving

f) Outlet Isolation: TheoutletoftheDRSisprovidedwithanisolationvalvethroughwhichGas

PE PIPE AND PE FITTING

Domestic Gas Meter:

Commercial / Industrial Consumers:

Common Used Meter & regulator for I&C connection:

Tentative Meter Regulator Regulator type Operating

COMMERCIALA COMMERCIALB *COMMERCIALC COMMERCIALAC

NORMAL SMALL CONCESSIONARY

25 SCMH Riser - Meter Installation.

40SCMH RISER REGULATOR METER INSTALLATION

Principal characteristics and physical-chemical properties

WobbeIndex kJ/m 46.500a52.500 6976

Liquefied Natural gas (LNG):

Safe Leadership Toolkit

Hazard, Near miss/accident reporting:

(a) Flash Fire during conversion:

Actions to Prevent Recurrence:

(b)Safety Alert trench collapse:

On 17th January 2011 atapprox1715atrenchwasbeingexcavatedtolaya12DiaSteelpipe

Actions to Prevent Recurrence:

Actions to prevent recurrence:

Root Causes and Failed Barriers

(d) Safety Alert Use of Hydra:

Description of Incident in 2009:

Actions to Prevent Recurrence:

Actions to prevent recurrence:

(g) Gas leak inside the Kitchen

Permit to work process

Tool Box Talks:

HSS&E Clauses MP/LP Work/GI/CU/ Conversion/Rectification

Basic Safety Health Plan

d) Uncontrolled release of gas/purging should not be allowed. Vent pipe of sufficient

13) Contractor PE technicians/supervisors/Engineers/helpers & labors must have valid STC

Contents of First Aid Box

5 1x100mls AntisepticSolutionSavlon/Dettol Forcleaningwoundarea.

6 1x15gms VellosulphPowder Usedforpowderingwounds.

17 1Nos.X35GMS. Iodex/Zhandubalm ForCold&Otherbodypain

check required PPE like hard hat, safety goggles etc,