Vaghodia Compressor Stn.pptx

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

8

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 11

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 14

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 15

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 16

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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 27

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

32

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.