Module 2
Module 2
O&M MANUAL
CHAPTER – 2
POLICY AND ORGANISATION
2.1 Philosophy
2.2 Policy & Objectives
2.3 Operation & Maintenance Plan
2.4 Organization, Role & Responsibility
2.5 Competency & Training
Module 2 of 9
Block - 15, 2nd Floor, Udyog Bhavan, Sector - 11, Gandhinagar – 382 011.
2.1 Philosophy
GSPC GAS believes that, apart from achieving the desired intent, Good O&M
management can also minimize the loss in production and property resulting from
accidental occurrences.
Well designed O&M management is one aspect of the company’s main policy, and is
the direct responsibility of line management and contractors. All management
functions, and contractors, will comply with ‘GSPC GAS’ requirements applicable to
the operation and maintenance. When conformity with any of these requirements is
not practicable or cost effective, an amendment to such a requirement will be
considered.
Reviews for compliance with this policy will be performed on a selective basis.
• Deployment of Contractor.
The company will engage the competent contractor for O&M management of
city gas distribution system to ensure safe operations, integrity of network and
protection of those involved, protection of environment and public at large.
The contractor selection will be solely based on experience in the similar job
and have required resources and capabilities.
• Inspection
Inspections to detect and correct unsafe practices and conditions will be
conducted periodically by GSPC GAS and / or contractor.
• Job Placement
The company will ensure that contractor and employees will only be assigned
tasks that are consistent with their capacities and job skills; this enable
employees / contractor to work safely and effectively.
• Accountability
Contractor and all his employees shall be held accountable for personal and
functional O&M performance. An important factor in a contractor and
employee's overall job performance valuation will be, how well the contractor /
employee meets his skill and safety responsibilities.
• Compliance Reviews
On a selective basis, compliance reviews will be conducted by teams that
include people with related expertise to determine compliance with this policy.
In order to ensure the credibility and effectiveness of the review, the team
members must be detached from the operation being reviewed.
2.3 Operation & Maintenance Plan
General Information :
The Annual Operation and Maintenance Plan for City Gas Distribution system shall
cover all component of assets and activities to ensure safe & uninterrupted gas
supply along with integrity of network & complying the various statutory requirements
and local / international standards / codes. It shall be prepared with specific detail
based on asset data, own experience, knowledge of facilities and its conditions of
operation. The plan should also cover periodic audit, inspection and performance
reporting. It should be dynamic, flexible and reviewed periodically to ensure
effectiveness and capable of meeting ever growing demand of natural gas and
complexity of latest technology and safety.
Competent trained staff should be deployed and they should be equipped with
required resources for effective implantation of plan.
O&M Contractor of City Gas distribution shall develop an Annual Operating and
Maintenance Plan based on O&M Manual provided by GSPC Gas and based on
O&M guidelines of latest addition of ASME B 31.8 for City Gas Distribution.
Contractor shall also comply time to time with guidelines / standard published by
Petroleum and Natural Gas Regulatory Board (PNGRB), “Bureau of Indian Standard”
(BIS) and or Oil Industry Safety Directorate (OISD) on City Gas Distribution
LOCATION : Year :
DEPARTMENT :
J F M A M J J A S O N D
Sr.
Description Unit Frequency Responsibility A E A P A U U U E C O E Total
No.
N B R R Y N L G P T V C
1.3 Leak check of all joints on CGS Nos. Twice in a Year O&M Shift
1.6 House Keeping of CGS Facility Nos. Twice in a Year O&M Shift
6 SERVICE REGULATOR
6.1 Monitoring of Pressure (Inlet / Outlet) Nos. Need Base
6.2 Testing of OPSO / UPSO Nos. Yearly
House Keeping in and around Fenced
6.3 Nos. Twice in a Year
Area
General maintenance of whole
6.4 Nos. Once in Two Year
installation including painting
7 DOMESTIC CONNECTION
Attending Gas Leak / Gas Smell
7.1 Nos. As & When Required
Complaints
7.2 Attending Stove Flame Complaints Nos. As & When Required
8 INDUSTRIAL CONNECTION
Monitoring of Pressure (Inlet / Outlet),
8.1 Nos. Daily
Flow and Volume
9 ODOURANT SYSTEM
Monitoring of Odorant Level /
9.1 Nos. Daily
consumption at CGS
9.2 Monitoring of Odorant Smell Nos. Daily
9.3 Odorant Transfer from barrel to tank Nos. As & When Required
Monitoring / Inspection of Odorant
9.4 Nos. Twice in a Year
Storage Area
11.3 G E B Requirements
11.3.1 Approval / Agreement for Power Nos. Once
11.3.2 Approval for D G Nos. Once
Annual Inspection / Energy Audit of
11.3.3 Nos. Yearly
Electrical installation
Reporting of Electric Accidents and As & when electrical
11.3.4 Nos.
Inquiries accident occurs.
11.5 INSURANCE
11.5.1 Third Party Public Liability Insurance Nos. Yearly
11.5.2 Man Power Insurance Nos. Yearly
11.5.3 Asset Insurance Nos. Yearly
12 REPORTS
12.1 Daily Activity Report Nos. Daily
Monthly Report (Review for current
12.2 Nos. Monthly
month and Plan for next month)
12.3 Gas Smell Monitoring Report Nos. Monthly
12.4 Complaint Analysis Report Nos. Monthly
12.5 TR Monitoring Report Nos. Monthly
12.6 CPRS, DRS Monitoring Report Nos. Monthly
Reconnection / Disconnection (RC DC
12.7 Nos. Monthly
) Report
12.8 Network health and integrity report Nos. Monthly
As and when S/D
12.9 Shut Down Report Nos.
taken
As and when B/D
12.10 Break Down Report Nos.
occurs
As & When
12.11 Activity Report Nos.
Conducted
As & When
12.12 Awareness / Training Report Nos.
Conducted
General Information :
The contractor should ensure that adequate training and education to all members,
covering technical knowledge, network knowledge, safe work procedures and
practices, customer dealing, complaints handling, fire, safety, and emergency
handling, are given before engaging them on job.
Proposed Manpower:
Sr. Shift
Manpower Qualification Experience Total
No General Ist IInd IIIrd
BE/DE
O&M
1 (Mech./ 3 / 5 Years 01 01
In-charge
Elec.)
Billing B.com /
2 1 / 2 Years 01 01
Officer Graduate
DE / ITI
Shift
3 (Mech. / 2 / 3 Years 01* 01 01 01 04
Engineer
Elec.)
ITI
4 Technician (Mech./ 2 / 3 Years 01 01 01 03
Fitter)
ITI
5 Technician 1 / 3 Years 01* 01
(Draftsman)
SSC /
7 Driver 3 / 5 Years 01 01 01 03
Literate
Helper cum
8 Literate 01 01 01 01 04
Labour
Proposed Organization Chart
Contractor
O&M In-charge
General Shift
Shift Timings:
Shift -General 09:00 to 17:30 Hours Shift -Ist 06:00 to 14:00 Hours
Shift -IInd 14:00 to 22:00 Hours Shift -IIIrd 22:00 to 06:00 Hours
Note:
General shift persons will be given weekly off on Sunday
Shift persons will get weekly off after 6 working days, as per shift schedule.
On public holidays general shift persons will be given holiday, shift persons will be
working and paid extra wages.
Persons not attending given duty hours / day will be considered as absent and wages
will be deducted proportionally.
Person working extra hours / day will be paid proportionally.
Duty change or take over, handover of duty should be carried out in control room
premises only, after exchange of verbal, written information.
Duties of O&M In-charge:
1. O&M In-charge shall be over all O&M In-charge.
2. He should be qualified engineer with relevant experience and posses the
leadership, qualities, managerial skills, safety consciousness, good listening
skill and analytical mind.
3. O&M In charge should assist contractor in recruitment of qualified / experience
persons for various posts and should arrange induction / refresher training for
all O&M personnel for developing and maintaining job competency to ensure
the safe and uninterrupted gas supply to customers, safe handling of various
emergencies like gas leak, fire, explosion and integrity of the network.
4. He should ensure the availability of or prepare the written procedure, work
instruction and safe practices for all routine maintenance and emergency
handling and to ensure that the activities are carried out as per documented
procedures, instructions and safe practices.
5. He will work as coordinator to interact / interface with GSPC Gas / its
representative.
6. O&M In-charge will be responsible for planning, organizing, administration and
required supervision and technical, safety guidance for execution of all works,
starting from establishing and manning of control room, preparation and
execution of GSPC Gas approved Annual Operation Maintenance Plan,
covering scheduled monitoring, operation, maintenance, statutory compliance,
audit and inspection, and preparation, maintenance and submission of various
reports.
7. O&M In-charge should plan and organize activities related to, meter reading,
Billing & Payments in scheduled time for all customers.
8. He will be responsible for gas reconciliation from purchase to sales including
payment realization to GSPC Gas.
9. He will be responsible for inventory management, especially for essential
spares / assets management.
10. While carrying out any business activity, He should take care of the health,
safety, security and environment protection (HSSE) for his men, machines,
network and equipments,
11. He should motivate his subordinates for compliance to various requirements of
HSSE, by his leadership in the role.
12. He should make all efforts to ensure incident free operations; He should take all
action as per ERP to control / mitigate the consequences, in case of accident,
and will assist in accident investigation.
Apart from specific job related responsibilities and requirements, there are certain
general rule and regulations that must be followed by all working with O&M team.
1. Smoking is strictly prohibited and use of any match, lighter or other means of
producing, flames, spark or articles of similar nature is prohibited, at terminal,
control room, everywhere on gas network and installations of GSPC Gas.
2. Report promptly any situation affecting the safety of self or fellow employees or
property and public in general.
3. Employees should train themselves to be on the lock out for regulatory safety
signs and should observe them all the time.
4. Any person sustaining an injury on the job, no matter how small, should report
for treatment.
5. Horseplay or fooling around while on duty is strictly forbidden.
6. Jumping on or off the trucks, automobiles or other vehicles are prohibited.
Employees should wait until vehicles stop before attempting to board or alight.
7. Employees must stay within their working zone and shall not roam around the
other installation of or any other area.
8. Running, jumping or throwing material on job site is prohibited.
9. Where walkways are provided use them. Don’t use short cuts or make
pathways through equipment.
10. Drive cautiously near the gas installation and gas rich area. Stick to speed
limits and other instructions, e.g. No parking, Vehicle Entry Prohibited, etc.
Vehicles shall be parked in parking places only.
11. Employee should never use compressed air to clean the clothing they are
wearing.
12. Personnel doing hot job or working near open fire shall not wear clothes made
of highly combustible synthetic fibers such as nylons, teryline, etc.
13. Wearing of jewelry ornaments should be avoided while working at site.
14. Only authorized persons may turn valves or operate any equipment or
machinery on any installation.
15. No employees should interfere with, remove, displace, damage or destroy any
safety devices or other appliances installed for protection of personnel and
plant equipment.
16. Cleanliness is necessary for a safe plant. Wastage lie used papers, plastic etc.,
should be deposited in proper receptacles.
17. Every employee should study safety orders thoroughly and make proper use of
all safety devices and equipment furnished for his protection and the protection
of others.
18. Every employee must familiarize himself with location and usage of safety
devices a fire fighting system.
19. Be sure you understand emergency instructions. Anticipate what you will do in
case of emergency. Above all, be clam and alert for instructions.
20. Report on work incurred injuries or illnesses immediately to your supervisor and
to safety department.
21. It is prohibited to light agarbatti in office.
22. Report immediately to control room or safety department, if there is any
abnormal burning smell from A.C. system or electrical system.
2.5 Competency & Training
The term competency is synonyms to capability, ability. Similarly the training is the
teaching, giving guidance, instructions and exercises, either in classroom, or in-plant,
by oration, written test or simulation is carried out to develop the competency. Thus
both the terms are interrelated. Every job in a business is carried out to get some
specific end result, in scheduled time with safety and quality requirements. Hence the
person who is to perform this job must have certain qualifying requirements in terms of
qualification. Knowledge, skill, behavior to achieve the job end results. After recruiting
the new person for proposed job / duty, he should be trained, educated, tested,
certified and made and declared competent to perform the job effectively, in
scheduled time with safety, quality and statutory compliances.
Competency training and test should be regularly conducted to ensure that the
certified person still posses the required competency to perform the job with specific
requirements as with the lapse of time the sense of the human gets weaker due to
aging effect or sometimes the sense gets affected before age, due to ill health or
wrong life style. There is a direct effect of human senses on his / her competency for
job performance.
The training may be in-house or out-house and it starts with the induction, for new
recruits, and refresher or need based training for existing employees, to check,
maintain their competency level. The training may be in class room for understanding
theory and in plant training or simulation for practical purpose.
Competency training needs for employees are identified considering the following
factors;
In operation maintenance, of city gas distribution system, many activities are critical as
the persons are working on highly flammable natural gas charged installation and
network. Critical activities need more stringent competency. Here for our
understanding, main activities which are also repetitive in nature are selected for
competency development criteria, based on job evaluation. They are (1) Handling gas
escape / fire and explosion in upstream and downstream of service control valve (2)
odorant handling.
Competency Requirement for Handling gas escape / fire and explosion in upstream
and downstream of service control valve
O&M In-charge
Knowledge
⇒ Basic properties of natural gas and hazards associated
⇒ Gas distribution system, PE distribution network, Service regulator, Domestic
connection
⇒ Knowledge of safe procedure for gas leak / escape handling as well as for fire
& explosion due to gas leak
⇒ Knowledge of safe working for excavation, road side work
⇒ Knowledge of equipment and instrument for gas leak detection and repair
rectification
⇒ Knowledge of emergency response plan and emergency escalation
⇒ Fire prevention and control
⇒ Applicable standards, codes and statutory requirements
Skill
⇒ Development of safe procedure for gas leak handling
⇒ Leading people to work as per safe work practice
⇒ Identification of risk and control measures
⇒ Coordination with other utility agencies
⇒ Emergency coordination and communication
⇒ Emergency handling as a ERT member
Behavior
⇒ No tolerance for violation of codes / safe practices.
⇒ Attitude for full Compliance with safe work procedure and HSSE requirements
Evaluation Method
⇒ Written test
⇒ Simulation test, Case Study
⇒ Practical test
Shift In Charge
Knowledge
⇒ Basic properties of natural gas and hazards associated
⇒ Gas distribution system, PE distribution network, Service regulator, Domestic
connection
⇒ Knowledge of safe procedure for gas leak / escape handling as well as for fire
& explosion due to gas leak
⇒ Knowledge of safe working for excavation, road side work
⇒ Knowledge of equipment and instrument for gas leak detection and repair
rectification
⇒ Knowledge of type of emergency, communication and escalation
⇒ Applicable standards, codes and statutory requirements
Skill
⇒ Development of safe procedure for gas leak handling
⇒ Supervising people to ensure work as per safe work procedure & practice
⇒ Identification of risk and control measures
⇒ Reading of network drawing
⇒ Site evacuation and cordoning / barricading
⇒ Fire prevention and control
⇒ Emergency coordination and communication
⇒ Emergency handling as a site in charge
Behavior
⇒ No tolerance for violation of codes / safe practices.
⇒ Attitude for full Compliance with safe work procedure and HSSE requirements
Evaluation Method
⇒ Written test
⇒ Simulation test, Case Study
⇒ Practical test
Technician Staff
Knowledge
⇒ Basic properties of natural gas and hazards associated
⇒ Hazards of other utilities
⇒ Knowledge of safe procedure for gas leak / escape handling as well as for fire
& explosion due to gas leak
⇒ Knowledge of safe working for excavation, road side work
⇒ Knowledge of equipment and instrument for gas leak detection and repair
rectification
Skill
⇒ Operation of gas leak detection equipment
⇒ Cordoning barricading of site and evacuation
⇒ work as per safe work procedure & practice
⇒ Use of PPEs
⇒ First aid
⇒ Use of fire extinguisher
⇒ PE network / Domestic connection repair / rectification
Behavior
⇒ No tolerance for violation of codes / safe practices.
⇒ Attitude for full Compliance with safe work procedure and HSSE requirements
Evaluation Method
⇒ Written test
⇒ Simulation test, Case Study
⇒ Practical test
O&M In-charge
Knowledge
⇒ Basic properties of odorant & neutralizing agent
⇒ Hazards associated transportation, handling, storage, transfer and injection of
odorant
⇒ Safe Work procedure for transportation, handling, storage, transfer and
injection of odorant
⇒ Knowledge of equipment and instrument of odorant transportation, handling
storage, transfer and injection.
⇒ Applicable standards, codes and statutory requirements for transportation,
handling, storage and transfer of odorant
Skill
⇒ Development of safe operation and maintenance procedure
⇒ Leading people to work as per safe work practice
⇒ Identification of risk and control measures
⇒ Emergency handling as a ERT member
Behavior
⇒ No tolerance for violation of codes / safe practices.
⇒ Attitude for full Compliance with safe work procedure and HSSE requirements
Evaluation Method
⇒ Written test
⇒ Simulation test, Case Study
⇒ Practical test
Shift Engineer
Knowledge
⇒ Basic properties of odorant & neutralizing agent
⇒ Hazards associated transportation, handling, storage, transfer and injection of
odorant
⇒ Safe Work procedure for transportation, handling, storage, transfer and
injection of odorant
⇒ Knowledge of equipment and instrument of odorant transportation, handling
storage, transfer and injection.
⇒ Applicable standards, codes and statutory requirements for transportation,
handling, storage and transfer of odorant
⇒ Use of PPE’s and their maintenance
Skill
⇒ Working as per safe operation and maintenance procedure
⇒ Supervising people to ensure work as per safe work practice
⇒ Identification of hazards, control measures and communication to all
⇒ Fire / Explosion handling
⇒ Emergency handling as a site in charge
Behavior
⇒ No tolerance for violation of codes / safe practices.
⇒ Attitude for full Compliance with safe work procedure and HSSE requirements
Evaluation Method
⇒ Written test
⇒ Simulation test, Case Study
⇒ Practical test
Technician Staff
Knowledge
⇒ Basic properties of odorant & neutralizing agent
⇒ Hazards associated transportation, handling, storage, transfer and injection of
odorant
⇒ Safe Work procedure for transportation, handling, storage, transfer and
injection of odorant
Skill
⇒ Safe loading & unloading of the barrel
⇒ Leakage / vapor Neutralization
⇒ Proper use of PPE
⇒ First aid treatment
⇒ Fire / Explosion handling
⇒ Safe operation of transfer pump / dosing system / barrel neutralizing / smell
monitoring equipments like dragger pump / gas detection
⇒ Proper assembling of piping & associated fittings for safe transfer
⇒ Leak identification & rectification in system.
⇒ Safe storage of hazardous waste
Behavior
⇒ Attitude for HSSE requirements / checklist / instructions
⇒ Self safety & concern for others
⇒ Environment care & concern
Evaluation Method
⇒ Written test
⇒ Simulation test, Case Study
⇒ Practical test