Transcript Slide 1

GAIL (India) Limited
Team Vaghodia
Rohit Ram Manager (Inst )
Vikash Kumar SE (Elect.)
2
2
GAIL at a Glance
 Existing pipeline network of GAIL is around 10,000 Kilometers.
 Around 8,000 Km of Natural Gas pipeline.
 1,900 Km of LPG transmission pipelines.
 Presently supplying around 130 MMSCMD of Natural Gas & RLNG.
 06 nos. of existing Compressor
construction.
Stations & 02 nos. are under
 07 nos. of Gas Processing Plants
 01. no. Petrochemical complex
 5000 Km of additional pipelines will be added by the year 2011-12 at an
estimated cost of 14,500 Cr.
3
IOCL
o MATHURA
AGRA CGS
BAJHERA o
FIROZABAD
BAMNIKALAN o
UPPC
RRVNL
o IBRAHIMPUR
DHAULPUR o
o SONE KA GURJA
IDPL 10”x33 KMS
o MALANPUR
BHILWADA o
o MARA
o BURDHA
SAMACORE
o
NTPC
o KHORDAR
CFCL G’PAN
ANTA o
o
BORERI
o CHITARA
o S’WASA
ATTRU o
CHHABRA o
AURAIYA (3+2)
NTPC
o GORABHUPKA
KHERI o
KHARAUWA o
KAMAD o
DUNGARWAHA o
BHAUNTI o
MIANPUR o
o
o
GWALIOR
KAILARAS (2)
SFCL KOTA
PATA
NFL o
o PIRONTH
o NAISARAI
o BAJRANGGARH
MANAGEMENT CONTROL CENTRE
JAISINGHPURA o
VIJAIPUR (5+3+3+3)
o JALALPURA
GORKHPURA o
o SANDWATA
DHATARWADA o
KHERA (3)
JAGOTI o
MAKARWAN o
o KACHACHIBARODA
KASARBADI o
MOHANKOT o
DEWAS
o INDORE
PITHAMPUR
HVJ Pipeline
:1211 KM
DVPL-I Pipeline
: 610 KM
GREP Pipeline
DUDHMAL o
DEVGARHBARIA o
o SHERPURA
o
JAMBUDI
IPCL o
VAGHODIA o
DAHEJ
JHAGADIYA o
KOSAMBA o
HAZIRA (10+2)
JHABUA (7+3+3)
VDPL Pipeline
: 499 KM
: 499 KM
DVPl-II Pipeline : 611 KM
CGJH Pipeline : 454 KM
DBNL Pipeline ; 700 KM
Compressor Stn.
: 8 no.
LPG Plant
: 4 no.
RR/IP/SV Station
116
: 67 / 23 /
Consumers
:
VAGHODIA (3)
o VEMAR
GANDHAR
Schematic Diagram of HVJ/GREP/DV Pipeline
INDOGULF
IFFCO
PHULPUR o
SHAHJAHANPUR o
KSFL
BANDHMAU o
JIGNIS o
o SIHANA
NGMC
NOIDA
o JAGDISHPUR
MARUTI
JETHWADA o
o JATAULI
NARAYANPUR o
o FARIDABAD NTPC
GURGAON o
o THULENDI
IFFCO
o AONLA
o MAURWAN
o MORADABAD
CHAINSA(2)
IGL
BAHADURGARH
TCL
o BABRALA
SIWALI
o ACHALGANJ
NTPC
DADRI
o SACHENDI
BHAWANA
SONIPAT
o HISAR
o RUDRAPUR
G’ BAD
SKBAD
SBAD
DESU
Phases of HVJ & DVPL Pipeline Network
ORIGINAL HVJ PIPELINE (1915KM):
CAPACITY
NO OF COMPRESSOR STN : 4
: 18.2 MMSCMD
DADRI
DELHI
JAGDISHPUR
UPGRADED HVJ PIPELINE (GREP)-497 KM :
CAPACITY
: 33.4 MMSCMD
NO OF COMPRESSOR STN :
UPGRADED : 2
NEW
:2
Malanpur
DIBIYAPUR
Added : 483 Km
ANTA
INDORE
VIJAIPUR
KHERA
JHABUA
VAGHODIA
20 MMSCMD
(3)
DAHEJ
HAZIRA (10) + (2)
FROM ONGC
18.2
33.4 MMSCMD
(3) + (2)
Regional Pipelines
added with HVJ
KOTA
IPCL
PHULPUR
(5+3) + (3)
(3)
(7) + (3)
DVPL (611 KM) :
PIPELINE CAPCITY
LINE SIZE
COMPRESSOR STN
: 23.9 MMSCMD
: 42”
: VJPR (3 CMP)
Total Existing Capacity
: 56.9 MMSCMD
UNITS
• LPG PLANT
• GREP COMPRESSOR STATION
• NTGG PLANT
• HRSG PLANT
PROCESS FLOW DIAGRAM - VAGHODIA COMPLEX
FROM HAZIRA
TO JHABUA
GTC
IP-2
LNG
FEED GAS line 10”
FUEL LINE
Zero Pt
LPG PLANT BYPASS
GSFC
UNDERA
GIPCL
LEAN GAS 12”
LPG PLANT
LPG TO STORAGE
IPCL
NGL
LPG
IOCL
MFO Product
LPG PLANT
Design Capacity
GAS PROCESSING
: 2.5 MMSCMD
LPG PRODUCTION
: 73000 TPA
NGL PRODUCTION
:10600 TPA
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PROCESS DESCRIPTION
Turbo expander based cryogenic process
Feed Gas received from GREP Compressor discharge
Drying and filtration of Feed Gas
Dry Feed Gas is chilled in Feed Gas Chiller
Feed Gas is liquefied in two separators
Liquefied heavier components of NG is sent to LEF Column
Methane/Ethane / Nitrogen / CO2 etc are removed from LEF
Column
Remaining liquid is sent to LPG Column.
LPG is received from column top
LPG Column bottom is sent to NTGG Plant
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NTGG PLANT
DESIGN CAPACITY
NGL PROCESSING CAPACITY
: 25.00
TPD
LPG RICH STREAM
: 10.82
TPD
GASOLINE
: 10.75
TPD
HEAVY END
: 1.14
TPD
MFO ( GASOLINE + HEAVY END)
: 11.89
TPD
FUEL GAS
: Balance
NTGG (NGL TO GAS & GASOLINE) PROCESS
LPG to
LPG Plant
Heater
Condenser
Fuel gas
Cooler
NGL
from
LPG
Plant
Cooler
Reactor
Gasoline
Separator
HEF
Column
De-Butaniser
Column
Cooler
Heavy Ends
NTGG PLANT
NTGG MODE
NGL PROCESSING CAPACITY
: 25.00
TPD
LPG RICH STREAM
: 10.82
TPD
GASOLINE
: 10.75
TPD
HEAVY END
: 1.14
MFO ( GASOLINE + HEAVY END)
: 11.89
FUEL GAS
TPD
TPD
: Balance
NAPHTHA MODE
NGL PROCESSING CAPACITY
NAPHTHA
: 28
: 26
TPD
TPD
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COMPRESSOR STATION
DESIGN CAPACITY
No. of compressors
: 3 ( 2+1 )
Suction Pr.(Kg/Cm2a)
: 50
Discharge Pr.(Kg/Cm2a)
: 93
Capacity of each Compressor : 15.8 MMSCMD
Total Capacity
: 31.6 MMSCMD
Make
: Rolls Royce
Model
: RB211
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Compressor Station-Vaghodia
AV-1807
AV-1805
AV-1809
From Hazira
AV-1008
To Jhabua
AV-1001
AV-1010
AV-1002
K-01A
AV-1009
AV-1003
AV-1004
AV-1007
AV-1806
AV-1005
K-01B
AV-1808
AV-1006
K-01C
Vaghodia Suction
50 Kg/ cm2a
Vaghodia Discharge
90 Kg/ cm2a
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RAW MATERIAL & PRODUCTS
•
Unit I – LPG Recovery Plant (Turbo Expander Process)
•
Unit II – NTGG Unit (R&D Project with IIP)
•
Unit III – Compressor Station (Cross Country Pipeline)
•
Raw material used:
1. Natural Gas
•
Products:
1. LPG (Liquefied Petroleum Gas)
2. Naphtha
3. Natural Gas Transmission
– Unit I (LPG Plant)
– Unit II (NTGG Plant)
– Unit III (Compressor
Station)
Heat Recovery Steam Generation (HRSG)
• HRSG project is to be set up for recovery of Heat from exhaust of Gas
Turbine Compressor to produce steam
• The HRSG is unfired, natural circulation, and Horizontal Heat Recovery
Steam Generator which is installed in the exhaust of each gas turbine
• The Capacity of Steam generation is proposed to be 60 tons/hour
• The steam shall be supplied to M/s. Apollo Tyres Limited and the D. M.
water required for the generation of same shall be supplied by M/s.
Apollo Tyres Limited
• Apart from reduction of thermal load on the environment, the Heat
Recovery Steam Generation Project will also save an energy equivalent of
446350 MWh annually
PROCESS FLOW DIAGRAM FOR HRSG
Existing
Compressor
Station
HRSG Boiler
Gas Turbine
GAIL (India) Limited, Vaghodia
(Govt. of India Undertaking)
ISO 9001:2008, ISO 14001:2004 & OHSAS 18001:2007
Focus Point
for
Emergency Response & Disaster Management Plan
• GAS PROCESSING UNIT
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EMERGENCY SCENARIOS











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Fire / explosion
Major release of flammable/toxic chemical
Cyclonic Storm / Hurricane
Earthquake
Floods
War
Bomb Threat
Industrial Unrest
Transportation Accident involving Hazardous Material
Accident during tanker filling
Gas leakage in pipeline
NEAR MISS REPORTING
NEAR MISS REPORTING
 NEAR MISS INCIDENT ARE REPORTED BY THE EMPLOYEES AS &
WHEN HAPPENED IN THE PRESCRIBED FORMAT.
 FORMAT IS AVAILABLE ON LAN.
 ON RECEIPT OF NEAR MISS REPORT, AN INDIVIDUAL IS
MOTIVATED WITH APPRECIATION LETTER AND TOKEN GIFT TO GET
MORE RESPONSE IN FUTURE FOR REPORTING THE NEAR MISS
INCIDENT.
Fire Due to Pipeline Gas Leakage
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BLEVE IN A LPG STORAGE FACILITY
Disaster in
Petro China Plant
Disaster in Moscow
Due to Gas Leakage
Disaster in Washington
Due to Gas Leakage
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OBJECTIVES OF ON-SITE EMERGENCY
MANAGEMENT PLAN AT GAIL,VAGHODIA
 To define and assess emergencies, including risk and environmental impact
assessment.
 To contain and control emergency incidents.
 To safeguard employees and people in vicinity.
 To provide maximum possible safety for the emergency response personnel.
 To minimize damage to the environment.
 To minimize damage to company installations and public property.
 To inform employees, the general public and the authority about the hazards /
risk assessed
 Mutual Aid.
 To effect rescue and treatment of casualties. To count injured.
 To identify and list any fatalities. To inform and help relatives.
 To secure the safe rehabilitation of affected areas / people and to restore
normalcy.
 To provide authentic information to the news media.
 To dovetail properly to a similar plan of the local government for an offsite
emergency arising out of an on-site emergency.
 Ensure business continuity following an emergency event.
 Minimize the effects of the emergency event on the company image.
DISASTERS
31
DISASTER
PREVENTION / PREPAREDNESS
SYSTEM
FOLLOWED IN GAIL
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PARAMETERS FOR HSE INDEX EVALUATION
LEADERSHIP &
COMMITMENT- 10
HSE TRAINING- 05
ENVIRONMENT
MONITORING -05
INCIDENT
REPORTING- 20
NEAR MISS INCIDENT 5
HSE INDEX
100 Marks
FIRE APPLIANCES,FIRE WATER
BASED & NON WATER BASED
SYSTEM, CALIBRATION STATUS
OF PSV, FIRE DETECTION &
ALARM SYSTEM -20
HEALTH
MONITORING -10
INTERNAL SAFETY AUDIT
OBSERVATIONS &
COMPLIANCE- 10
EXTERNAL SAFETY AUDIT
OBSERVATIONS &
COMPLIANCE- 15
(WORK PERMIT SYSTEM IS FOLLOWED AS PER
OISD GDN NO 105)
TYPES OF WORK PERMIT
Hot Work Permit
 Excavation Permit
 Vessel Entry Permit
 Vehicle Entry Permit
 Work At Height
 Cold Work Permit
 Electrical Lockout Permit

SAFETY FOR CONTRACT EMPLOYEES
PPE FOR EVERYONE
USE OF PPE’S BY CONTRACT PERSONS
TRAINING BEFORE STARTING THE JOB
FIRE WATER PUMP HOUSE
Diesel pump
4 Nos.
Electric driven pump
2 Nos.
Jockey pump
2 Nos.
Normal water pressure in fire water network is around 8 Kg/cm^2
PROTECTION SYSTEM
Automatic
Smoke
Gas
Flooding system
detection system
detection system
Automatic
Fire
Water spray system
water network
COMMUNICATION SYSTEM
TYPES OF
COMMUNICATION SYSTEM
RANGE
HVJ Phone
-
Every where available
as per req.
Walkie Talkie
1 KM range
04(Fire Stn.)
Paging system(PA)
NOS OF
COMMUNICATION
SYSTEM
All plants, offsite,
loading, storage, etc
Siren electric motor
10KM
05nos
Manual Siren
1KM
01(Fire Stn.)
Evaluation for Activity Standards for
ERDMP
– Organization and Administration of Safety, Health
and Environment.
– Industrial hazards Control
– Fire control and Industrial hygiene
– Supervisory and Workman participation,
Motivation and training.
– Accident investigation analysis, reporting and
follow up action.
– Additional areas of performance rating as may be
felt.
EMERGENCY RESPONSE AND DISASTER
MANAGEMENT PLAN
 SYSTEMATIC AND CRITICAL EXAMINATION OF
INDUSTRIAL
OPERATION IN ITS ENTIRETY TO IDENTIFY POTENTIAL HAZARDS
AND LEVEL OF RISKS/ DISASTER.
 TO MOBILIZE ALL THE TECHNICAL & MANPOWER RESOURCES TO
INVESTIGATE THE CAUSES AND MEANS OF PREVENTIONS
 FOR FORESEEING HAZARDS AND RISKS AND PREVENTING THEM
BEFORE THE OCCURRENCE.
 REGULATORY, MORAL AND ECONOMIC NECESSITY.
 SAFETY AND PRODUCTIVITY ARE CLOSELY LINKED AND SOUND
PRODUCTIVITY PRACTICES ARE LINKED WITH THE SOUND SAFETY
PRACTICES.
 INVESTMENTS IN SAFETY PAYS BACK IN SHORT PERIOD AND ARE
THUS AN ECONOMIC NECESSITY.
 ENHANCES THE MORALE OF THE WORK FORCE AND ADD TO
PRODUCTIVITY IN TURN.