GAIL (India) Limited Team Vaghodia

Rohit Ram Manager (Inst )

Vikash Kumar SE (Elect.)

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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 Stations & 02 nos. are under construction.

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

GAIL at a Glance

IPCL o

HAZIRA (10+2)

VAGHODIA (3)

KASARBADI o

JHABUA (7+3+3) DUDHMAL o

DEVGARHBARIA oo SHERPURA

o VEMARJHAGADIYA o o SAMNI

MOHANKOT o

o JAMBUDI

JAGOTI o

GORKHPURA o

JAISINGHPURA o

DHATARWADA o

DESU

AURAIYA (3+2)

SON

IPAT

SIWALI

BAHA

DURG

ARH

G’ BADDADRI

BAJHERA o

o FARIDABADo N

AWADIA

GURGAON o

SHAHJAHANPUR o o PI

PRAULA

o MATHURA

Schematic Diagram of HVJ/GREP/DV Pipeline

AGRA CGS

FIROZABAD

DAHEJ

MAKARWAN o

ANTA o

CHHABRA o ATTRU o

o BORERIo CFCL G’PAN

SAMACORE

o BAJRANGGARHo NAISARAI

KAMAD o

o PIRONTH

KHERI o

BHAUNTI oDUNGARWAHA o

o CHITARAMIANPUR o

KHARAUWA o

o GORABHUPKA NTPC

o S

ACHE

NDI

o A

CHAL

GAN

J

o M

AURW

AN

o T

HULE

NDI

JETH

WAD

A o

INDOGULF

o JA

GDI

SHPU

R

PHU

LPU

R o

IFFCO

N

ARAY

ANPU

R o

o MALA

KPUR

JIGNIS o BANDHMAU o

CHAINSA(2)

o BABRALATCL

o M

UNDER

KSFL

o AONLAIFFCO

NTPC

IOCL

SKBAD

o KHORDAR

o BURDHAo MARA

o SONE KA GURJA

BAMNIKALAN o

o SIHANAo JATAULI

SBAD

o S’WASA

MARUTI

IGL

NTPC

NTPC

KOSAMBA o

o ANKOT VAGHODIA o

MANAGEMENT CONTROL CENTRE

o MALANPUR

KAILARAS (2) o GWALIORo

NFL o

o IBRAHIMPUR DHAULPUR o

IDPL 10”x33 KMS

RRVNL

DEWAS

PITHAMPUR

o INDORE

NGMC NOIDA

GANDHAR

UPPC PATA

KHERA (3)

o KACHACHIBARODA

o KARANPUR

o H

ISAR

SFCL KOTA

BHILWADA o

o JALALPURA

o SANDWATA

BHA

WAN

A

HVJ Pipeline :1211 KM

DVPL-I Pipeline : 610 KM

GREP Pipeline : 499 KM

VDPL Pipeline : 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 : 67 / 23 / 116

Consumers :

VIJAIPUR (5+3+3+3)

o RUDRAPUR

o MORADABAD

(3) + (2)

HAZIRA

JHABUA

DIBIYAPUR

VIJAIPUR

FROM ONGC

ANTA

IPCL

DELHI

JAGDISHPUR

DADRI

18.2 33.4 MMSCMD

PHULPUR

VAGHODIA

KHERA

(3)

(3)

ORIGINAL HVJ PIPELINE (1915KM):CAPACITY : 18.2 MMSCMDNO OF COMPRESSOR STN : 4

UPGRADED HVJ PIPELINE (GREP)-497 KM :CAPACITY : 33.4 MMSCMDNO OF COMPRESSOR STN :

UPGRADED : 2NEW : 2

DVPL (611 KM) :PIPELINE CAPCITY : 23.9 MMSCMDLINE SIZE : 42”COMPRESSOR STN : VJPR (3 CMP)

Total Existing Capacity : 56.9 MMSCMD

DAHEJ

KOTA

Malanpur

INDORE

Regional Pipelines added with HVJAdded : 483 Km

(5+3) + (3)

(7) + (3)

(10) + (2)20 MMSCMD

Phases of HVJ & DVPL Pipeline Network

UNITS

• LPG PLANT

• GREP COMPRESSOR STATION

• NTGG PLANT

• HRSG PLANT

FROM HAZIRA TO JHABUA

FEED GAS line 10”FUEL LINE

LEAN GAS 12”LPG PLANT

LPG TO STORAGE

GSFC

IPCL

GIPCL

PROCESS FLOW DIAGRAM - VAGHODIA COMPLEX

LPG PLANT BYPASS

GTC

IOCL

LNG

LPGNGL

MFO Product

IP-2

UNDERA

Zero Pt

8

LPG PLANT

Design Capacity

GAS PROCESSING : 2.5 MMSCMD

LPG PRODUCTION : 73000 TPA

NGL PRODUCTION :10600 TPA

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PROCESS DESCRIPTIONTurbo expander based cryogenic processFeed Gas received from GREP Compressor dischargeDrying and filtration of Feed GasDry Feed Gas is chilled in Feed Gas ChillerFeed Gas is liquefied in two separatorsLiquefied heavier components of NG is sent to LEF ColumnMethane/Ethane / Nitrogen / CO2 etc are removed from LEF ColumnRemaining liquid is sent to LPG Column.LPG is received from column top LPG Column bottom is sent to NTGG Plant

NTGG PLANT

DESIGN CAPACITYNGL 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

NGLfromLPGPlant

Heater

Reactor

Cooler

De-Butaniser Column

Separator

Condenser

Cooler

Cooler

HEF Column

Fuel gas

LPG to LPG Plant

Gasoline

Heavy Ends

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NTGG PLANT

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

NGL PROCESSING CAPACITY : 28 TPDNAPHTHA : 26 TPD

NAPHTHA MODE

NTGG MODE

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COMPRESSOR STATION

DESIGN CAPACITYNo. of compressors : 3 ( 2+1 )Suction Pr.(Kg/Cm2a) : 50 Discharge Pr.(Kg/Cm2a) : 93Capacity of each Compressor : 15.8 MMSCMDTotal Capacity : 31.6 MMSCMDMake : Rolls RoyceModel : RB211

1616

AV-1805

AV-1807

AV-1809

AV-1001 AV-1002

AV-1003 AV-1004

AV-1005 AV-1006AV-1806 AV-1808

AV-1008

AV-1007

AV-1010

AV-1009K-01A

K-01B

K-01C

Compressor Station-Vaghodia

To Jhabua

From Hazira

Vaghodia Suction 50 Kg/ cm2a

Vaghodia Discharge 90 Kg/ cm2a

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) – Unit I (LPG Plant)2. Naphtha – Unit II (NTGG Plant)3. Natural Gas Transmission – 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

HRSG Boiler

Existing Compressor

Station

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

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• GAS PROCESSING UNIT

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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

EMERGENCY SCENARIOS

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.

25 Fire Due to Pipeline Gas Leakage

BLEVE IN A LPG STORAGE FACILITY

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Disaster in MoscowDue to Gas Leakage

Disaster in WashingtonDue to Gas Leakage

Disaster in Petro China Plant

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.

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DISASTERS

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DISASTER PREVENTION / PREPAREDNESS

SYSTEMFOLLOWED IN GAIL

HSE INDEX100 Marks

LEADERSHIP & COMMITMENT- 10

INCIDENT REPORTING- 20

ENVIRONMENT MONITORING -05

HEALTH MONITORING -10

INTERNAL SAFETY AUDIT OBSERVATIONS & COMPLIANCE- 10

EXTERNAL SAFETY AUDIT OBSERVATIONS & COMPLIANCE- 15

NEAR MISS INCIDENT - 5

PARAMETERS FOR HSE INDEX EVALUATION

FIRE APPLIANCES,FIRE WATER BASED & NON WATER BASED SYSTEM, CALIBRATION STATUS

OF PSV, FIRE DETECTION & ALARM SYSTEM -20

HSE TRAINING- 05

(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

USE OF PPE’S BY CONTRACT PERSONS TRAINING BEFORE STARTING THE JOB

PPE FOR EVERYONE

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

FIRE PROTECTION FACILITIES

PROTECTION SYSTEM

Automatic Flooding system

Smoke detection system

Gas detection system

Automatic Water spray systemFire water network

COMMUNICATION SYSTEM

TYPES OF COMMUNICATION

SYSTEMRANGE

NOS OF COMMUNICATION

SYSTEM

HVJ Phone - Every where available as per

req.Walkie Talkie 1 KM range 04(Fire Stn.)

Paging system(PA) All plants, offsite, loading, storage,

etcSiren 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.