OBSERVATIONS & RECOMMENDATIONS FOR THE IMS SITE AUDIT OF IOCL-Aurangabad,

Kaimur & Rohtas GA FROM 21.11.2022 TO 23.11.2022

SI No. Observation/Recommendation Remarks

(A) GENERAL:
1. Risk registers with risk identification, risk scoring & mitigation plan etc are Recommendation
not available specific to GA. The risk register covering all threats as per
schedule-6 in the IMS manual needs to be prepared. The risk register shall
be updated and maintained regularly. Periodic analysis to be carried out
to determine the level of risks to assets. Risk officer need to be nominated
to update risk register periodically in coordination with other dept.
2. Response & Mitigation Tracker Sheet is not maintained specific to GA in Recommendation
line with Appendix V of the PNGRB Regulations 2020. The same may be
complied.
3. Integrity assessment of, Surge Diverter, insulating joint, Anode Bed to be Observation
covered in the IMS document and carried out regularly.
4. ICDA has not been included in IMS manual which may be included as Observation
internal corrosion is one of the major threats in CGD network. The pipeline
is not pig gable however There is no provision for monitoring of internal
corrosion. Corrosion Coupon and ER Probes are not provided in the Gas
pipeline at CGS. ICDA needs to be implemented to ascertain internal
health of the pipeline.
5. Pipe Book for 6" mainline (Joint no. KM00MJ02 TO KM00MJ26) has been Recommendation
checked and a sample radiography report with welders' qualification has
also been checked and found in order. Presently the pipe book is in loose
paper stacked in a folder and report is not aligned with chainage number.
The entity should ensure availability of pipe book for in hard bound form
with chainage number.
6. Periodic thickness assessment for above ground piping and pressure Recommendation
vessels along with comparison to baseline values is not available.
Thickness assessment needs to be done once a year as per schedule 5 :
IMS regulations.
7. Gas quality is an important to assess internal corrosion of pipeline. Gas Recommendation
analysis sent by GAIL contains gas composition, calorific value only
however IOCL needs report from supplier for analyzer report of absence
of corrosive items such as moisture, H2S, S02 else it shall conduct gas
analysis to ensure quality of gas w rt impurities.
8. The pipeline is under TCP, CP adequacy survey (CIPL, DCVG etc.) has not Recommendation
been done yet. The same needs to be done.
9. Field instrument calibration is not done annually. The same needs to be Recommendation
done with display of calibration tags.
10. AC/ DC Interference Survey has not been carried out till date. AC/ DC Recommendation
Interference Survey needs to be carried out as there are EHV/HT lines ,:

crossing.
11. GIS area mapping has been done for charged network, however Recommendation
additional data feedinq/mappinQ is in proi:iress.
SI No. Observation/Recommendation Remarks
12. Certificatio n for electrical installation from Electrical inspector are to Recommendation
be obtained for all installation s.
13. Odorants smell Survey at the farthest point is not being carried out in line Recommendation
with Appendix II of the List of Critical Activities of the PNGRB Regulations
2020. The Odorization is in manual mode. Odorization to be kept in auto
mode
14. Integrity inspection system for GI riser piping forming part of tertiary Recommendation
network and the last mile connectivity is not bE!ing carried out at present
in line with Appendix II of the List of Critical Activities of the PNGRB
Regulations 2013. Same may be carried out regularly.
15. Entity must develop, implement, and maintain a written training plan to Recommendation
instruct all CNG station personnel in native language with respect to the
matters specified in paragraphs 19.2.1 to 19.3.
16. First aid training is yet to be provided to all employees and staff. Recommendation
17. Functional check record for a. flame and leak detection for CNG Recommendation
compressor b. automatic CO2 flooding unit c. Active and monitor
regulator of DRS to be carried out periodically.
18. Illumination Survey to be carried out regularly at all locations Recommendation
19. QRA report (Doc no. TSC-IOCL/TE-013554-QRA-Ol) has been reviewed. Recommendation
Recommendations were given at cl no. 9.0 under conclusion and risk
reduction measures. Mitigation and tracker sheet need to be developed
for monitor implementation status.
20. HAZOP report no. TSC-IOCI-TEPL-P.013554-HAZOP-01 dated 03.02.2021 Observation
has been reviewed. Recommendations were given at Cl no. 13.0 under
summary of recommendations under Table 2: Recommendation table.
The entity confirmed that action has been taken as per HAZOP study
action and response sheet for most of recommendations, Balance
recommendations will be taken in due course of time as and when
required .
21. 66 KMs steel pipeline has been laid starting from august ' 2019. 46 KMs Recommendation
steel pipeline has already been commissioned. Presently, steel line is
protected by TCP and TCP design life is 2 years. Action needs to be initiated
for providing Permanent Cathodic Protection on urgent basis .
22. Patrolling of Steel pipeline is being done daily and Patrolling of MOPE Recommend ation
pipeline is being done daily through bike monitored by third party APP.
Periodic foot patrolling should also be done as per Regulation
23. PSP level measured at TLP at CGS, Sasaram are found as (-) 1.045V Recommendation
(protected) and(-) 0.580Vacross insulating joint which is in order however
PSP measured for zinc anode is found as(-) 0.8.96 V.
As per PSP MONITORING REPORT, DTD 20.6.22 PSP LEVEL OF many
Magnesium and Zinc anodes are found to be low as remarked. Anode
condition needs to be reviewed to take approp'riate action.
AC induced voltage records are not included PSP monit oring report which
needs to be included.
24. TLP no., chainage no., TLP type, and circuit diagram are not available in Recommendation
TLP. These need to be inco porated in TLP.
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SI No. - Observation/Recommendation Remarks
25. Due date of hydrotest of st ationary cascade cylinder at Golden RO will be Recommendation
expired in Dec 2022. Action for hydrotesting needs to be taken for
hydrotest of all such cylinders.
26. Hydrotest history records such as cylinder/vessel number/ due date/ date Recommendat ion
of testing etc. of all cylinders and vessels need to be maintained.
27. PESO approval has not been taken for the Steel Pipeline. The same needs Recommendation
to be taken at the earliest.
28:. IMS policy and head of Integrity management are not available presently Recommendat ion
in IMS manual and the same needs to be incorporated.
29. Earth pits to be provided in line with IS-3043 and Earthing Layout drawing Recommendation
shall be available at all locations. Earthing layout to be displayed at all
locations.
30. Gas Reconciliation on volume basis has been carried out on monthly basis. Observation
Checked the report and found in order.
31. Odorization is in manual mode. Odorization to be kept in auto mode in Recommendation
line with Append ix-I of PNGRB T4S Regulations 2008
32. Management of change procedure has been prepared. The document is Recommendation
good, however, approving authority etc to be added in the procedure .
(A) CITY GATE STATION and CNG Mother station, Gotpa (DT-21.11.2022).(AL1 )"(l7)'!o-. ~J (2.l• l\ -ut, J
33. Flow direction, Pipe dia., Grade, Wall Thickness, Design Pressure to be Observation
displayed at all locations, wherever aboveground piping syst em exists.
34. MSDS of Spotleak has not been displayed. MSDS of Natural Gas is not as Recommendation
per revised regulation.
35. SOP, Do's and Don'ts and spill management for odoriser unit is not Recommendation
displayed. Spill kit quantity needs to be checked for adequacy.
36. Eye wash shower near odorizing system is not available. Recommendation
37. CNG Compressor Area: Recommendation
I. Compressor enclosure has single earthing
11. Door limit switch was available, however interlocking has been
by-passed.
111. Almost 90% of allen bolts for FLP control panel inside
compressor enclosure are found missing.
IV. One of the door hinge and door lat ch of compressor enclosure
found broken .
V. Door gasket is found to be damaged.
VI. Lot of oil spillage is found inside compressor.
VII. Vent line of compressor has 90-degree bend and not of yellow
color.
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Corrective actions for above points need to be taken.
38. Earth resistivity measurement for EP-03 and EP-12 was checked and Recommendation
,, verified. Readings are: ❖

1. EP-03 - Individual pit= 2.56 ohm and Grid= 1.5 ohm

2. EP-12 - Individual pit= 2.13 ohm and Grid = 1.25 ohm
The earth resistivity of grid is more than 1 ohm. Corrective action needs
l, to be taken. The GI earth electrode do not have meshed f unnel.
SI No. Observation/Recommendation Remarks
39. The following observations pertaining to earthing are as below: Recommendation
I. Cu earthing and GI earthing are found to be connected and
needs to be separated.
11. Compressor unit enclosure is earthed at single point and needs
to be earthed at two separate points.
111. Loose earthing cable were found to be laid on the floor in
battery room. Proper dressing must be done and needs to be
buried.
IV. Earthing looping observed at some panels in electrical room,
entity to ensure that all panels are separately connected to
earthing bus bars at two points.
V. Instrument and electrical earthing are found combined inside
compressor enclosure.
VI. Fence earth continuity along with gate needs to be ensured.
40. SCABA and BA set are not available. Recommendation
41. Air compressor motor and starter panel do not have independent Recommendation
earthing, only base channel has been earthed at single point.
42. Long bolts to be replaced with proper sized bolts at 4" flange joint Recommendation
downstream of GAIL met ering skid under the control of IOCL.
43. DCP, CO2 extinguishers does not have refill ing date, Hydrotest date. Observation
44. Electrical Room: Recommendation
I. Trench cover behind electrical panel is not provided.
II. Ferruling and tagging is not provided to cables.
111. SLD is not displayed.
45. Seven nos. of FLP lights are found not working. Lux level is not maintained. Recommendation
46. LCV Point: Recommendation
I. Crash barrier is not provided.
II. Vent tube upto 3 mtr is not available at vent point.
111. PG is not available at LCV point.
IV. LCV vehicle platform height is 1 mtr from ground. Suitability of
the same may be reviewed in line with PNGRB regulation.
(B) Golden Petrol services (OLS), Sasaram (DT-21.11.2022}
47. Calibration tag of SRVs is not available. Recommendation
48. Compressor enclosure skid is earthed at single point. Recommendation
49. A few allen bolts are found missing on FLP panel box inside compressor Recommendation
enclosure.
so. CNG compressor base frame is not grouted. Recommendation
51. MSDS of Natural Gas is not displayed. Recommendation
52. Door limit switch was available; however, interlocking has been by- Recommendation
passed.
53. Compre:;sor motor is not independently earther at two points. (, Recommendation
54. Air compressor motor and starter panel do not have independent Recommendation
earthing, only base channel has been earthed at single point. Temporary
cover shed is provided.
,, Recommendation
55. Canopy'·is not available a po~ disoenser.

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SI No. 0 bservation/Recommendation Remarks
56. Backup power for emergency lighting is not available through Recommendation
INVERTER/DG SET in CNG stations
57. Stationary cascade: Recommendation
I. Vent pipe provided at stationary cascade is not upto 3 mtr
height. Rain cap is not provided.
11. The Gas cylinder does not have labelling such as "CNG ONLY".
111. Cascade is not anchored at foundation .
58. Gas vent line of compr.essor unit has 90-degree bend without rain cap. The Recor:nmen dation
vent line is of black color which needs to be painted in yellow color.
59. Electrical Room: Recommendation
I. SLD not provided.
11. Earth connections to VFD panel, ACDB were not available.
111. Cable gland is not provided for cable entry exit to main switch
board.
{C) BABBAN MESS (Commercial connection), NMCH (Date - 21.11.2022)
60. Meter regulator unit is installed on wall without any protective Cage. Recommendation
61. Warning Signage and do's and don'ts need to be displayed. Recommendation
62. Rubber tubes used for many gas burners are more than 1 meter length Recommendation
and are not as per IS9573 TYPE II . However the entity has initiated the
replacement of rubber tube on urgent basis.
(D) DRS NO. 1, Golden RO, Sasaram (Date - 21.11.2022)
63. Warning Signage and do's and don't are not displayed. Recommendation
64. Surge diverter is not provided across insulating joint for inlet steel pipeline Recommendation
65. Calibration tag on SRV is not available. Recommendation
66. PF diagram was not present in the DRS. Observation

(G) DOMESTIC CONNECTIONS - NMCH, A BLOCK consumer no.

200000028566, 200000028567, 200000028568, 200000028569,
200000028570 (Date: 22.11.2022) :
67. Sniff test done in the kitchen and found in order. Observation
68. Loose supporting clamps of GI riser needs to be fixed properly. Recommendation
69. SV FOR STEEL/MOPE PIPELINE (date - 21.11.20222)
70. Inspection of Steel pipeline Sectionalizing Valve chamber (SV-1) was Recommendation
carried out. The support channel for Concrete slab is directly laid above
vent pipe.
The support Channel need to be relocated to enable connecting the vent
pipe in future.
71. Sectionalizing valve cbamber 1 for 90mm MOPE pipeline inspected and Observation
found in order . Depth of pipeline found more than 1 metre .

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