Overview
iFluids Engineering completed the external safety audit for multiple GAIL (India) Limited installations. This extensive safety assessment covered critical sites across GAIL’s pipeline networks, gas processing units, and associated infrastructure, ensuring compliance with statutory norms and reinforcing operational safety standards. The team conducted detailed inspections, reviewed safety management systems, and provided actionable recommendations to mitigate risks and improve overall safety performance. The audit fully aligned with GAIL’s expectations and national regulatory frameworks.
Audit Methodology
The process followed a structured approach:
- Kick-off Meetings with site personnel
- Site Inspection & Document Review
- Risk Assessment & Hazard Identification
- Closeout Meetings & Presentations
- Submission of Draft and Final Reports
Visit Safety Audit for Refineries for detailed Methodology
Scope of Work
- The audit scope included annual safety assessments (for FY 2018–19 and 2019–20) of eight major natural gas compressor stations—Hazira, Vaghodia, Jhabua, Khera, Vijaipur, Dibiyapur, Kailaras, and Chainsa, along with associated infrastructure such as mainlines, spur lines, sectionalizing valve (SV) stations, intermediate pumping stations (IPS), intermediate pigging stations (IP), and tap-off terminals (TOT). The audits also extended to the natural gas pipeline network under the Vadodara jurisdiction, ensuring end-to-end coverage of critical transmission and distribution assets.
- The Safety audit was carried out as per National/International audit methodologies and also covered GAIL’s HSE Management System
- The safety audit evaluated the adequacy and implementation of the Site’s safety management systems against Industry best practices, referencing national and international standards such as OISD guidelines, PNGRB regulations, Indian Standards (IS codes), and NFPA standards. The audit covered safety management and technical aspects, including hazard identification and control, reliability of utilities and critical equipment, emergency preparedness, fire and mechanical hazard controls, PPE practices, safety interlocks, operating and maintenance procedures, contractor safety, chemical handling and storage, and compliance with statutory regulations.
- The audit team is composed of a Fire Safety auditor, a Chemical Safety auditor, an Electrical Safety auditor Instrumentation Safety auditor, and a Mechanical Safety auditor, with experience in the natural gas/petrochemical/refinery sector
Codes and Standards Referenced
The safety audit framework was designed in compliance with:
- OISD Guidelines (Oil Industry Safety Directorate)
- PNGRB Regulations (Petroleum and Natural Gas Regulatory Board)
- Indian Standards (IS Codes)
- NFPA (National Fire Protection Association) Standards
- Factories Act, Petroleum Act, Explosives Act, MSIHC Rules, and Environment Protection Act
Deliverables
- A draft safety audit report for 8 stations
- A final report for 8 stations
- Supporting documents and guidelines were issued to implement the recommendations effectively.