GAIL (India) Limited

Team Vaghodia
Rohit Ram Manager (Inst )
Vikash Kumar SE (Elect.)
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 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 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.

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 BHAWANA
o HISAR
o RUDRAPUR

SONIPAT
G’ BAD NTPC
SKBAD SIWALI TCL
SBAD DADRI o MORADABAD
o BABRALA
DESU
IFFCO

o JAGDISHPUR
IGL CHAINSA(2)
o AONLA
o FARIDABAD NTPC

o MAURWAN
o ACHALGANJ

o THULENDI
GURGAON o

BAHADURGARH

o SACHENDI
o JATAULI
MARUTI o SIHANA SHAHJAHANPUR o
NGMC IOCL KSFL
NOIDA o MATHURA INDOGULF
BANDHMAU o
AGRA CGS JIGNIS o IFFCO
BAJHERA o

NARAYANPUR o

JETHWADA o

PHULPUR o
FIROZABAD
BAMNIKALAN o UPPC PATA AURAIYA (3+2)
RRVNL o IBRAHIMPUR
BHILWADA o NTPC
DHAULPUR o o SONE KA GURJA
IDPL 10”x33 KMS o MALANPUR o GORABHUPKA
o KHERI o
KAILARAS (2) GWALIOR
o
KHARAUWA o
SFCL KOTA o MARA
o BURDHA KAMAD o
SAMACORE DUNGARWAHA o
o CFCL G’PAN o KHORDAR BHAUNTI o
ANTA o MIANPUR o
o BORERI o CHITARA
NTPC o PIRONTH
ATTRU o o S’WASA
NFL o o NAISARAI
CHHABRA o o BAJRANGGARH
MANAGEMENT CONTROL CENTRE
JAISINGHPURA o VIJAIPUR (5+3+3+3)
o JALALPURA
GORKHPURA o
o SANDWATA
DHATARWADA o

JAGOTI o
KHERA (3)
MAKARWAN o DEWAS
o INDORE
o KACHACHIBARODA
KASARBADI o HVJ Pipeline :1211 KM
PITHAMPUR
MOHANKOT o DVPL-I Pipeline : 610 KM
GREP Pipeline : 499 KM
DUDHMAL o JHABUA (7+3+3) VDPL Pipeline : 499 KM
DEVGARHBARIA o DVPl-II Pipeline : 611 KM

o SHERPURA CGJH Pipeline : 454 KM

o JAMBUDI DBNL Pipeline ; 700 KM

IPCL o
Compressor Stn. : 8 no.
VAGHODIA o VAGHODIA (3)
DAHEJ LPG Plant : 4 no.
o VEMAR
JHAGADIYA o RR/IP/SV Station : 67 / 23 /
KOSAMBA o GANDHAR 116

Consumers :

HAZIRA (10+2)
Schematic Diagram of HVJ/GREP/DV Pipeline
 Phases of HVJ & DVPL Pipeline Network

ORIGINAL HVJ PIPELINE (1915KM):

CAPACITY : 18.2 MMSCMD
DADRI
NO OF COMPRESSOR STN : 4 DELHI

JAGDISHPUR
UPGRADED HVJ PIPELINE (GREP)-497 KM : PHULPUR
CAPACITY : 33.4 MMSCMD
NO OF COMPRESSOR STN :
Malanpur DIBIYAPUR (3) + (2)
UPGRADED : 2
NEW :2
KOTA Regional Pipelines
added with HVJ

ANTA Added : 483 Km

INDORE
VIJAIPUR (5+3) + (3)
KHERA (3)

IPCL JHABUA (7) + (3)

VAGHODIA (3)
DVPL (611 KM) :
20 MMSCMD DAHEJ PIPELINE CAPCITY : 23.9 MMSCMD
HAZIRA (10) + (2) LINE SIZE : 42”
COMPRESSOR STN : VJPR (3 CMP)

FROM ONGC Total Existing Capacity : 56.9 MMSCMD

18.2 33.4 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 LPG PLANT BYPASS Zero Pt

GSFC

UNDERA
GIPCL
LPG PLANT
LEAN GAS 12”
IPCL LPG TO STORAGE

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

Cooler Fuel gas

NGL Cooler
from
LPG
Reactor
Plant 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 TPD
MFO ( GASOLINE + HEAVY END) : 11.89 TPD
FUEL GAS : Balance

NAPHTHA MODE

NGL PROCESSING CAPACITY : 28 TPD

NAPHTHA : 26 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-1010
AV-1001 AV-1002

K-01A
AV-1009
AV-1003 AV-1004
AV-1007
K-01B

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

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) – 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

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

 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

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 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 25
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

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 DISASTER
PREVENTION / PREPAREDNESS
SYSTEM
FOLLOWED IN GAIL

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 PARAMETERS FOR HSE INDEX EVALUATION
LEADERSHIP & HSE TRAINING- 05
COMMITMENT- 10

ENVIRONMENT
INCIDENT
MONITORING -05
REPORTING- 20

NEAR MISS INCIDENT - HSE INDEX HEALTH

5 100 Marks MONITORING -10

FIRE APPLIANCES,FIRE WATER

BASED & NON WATER BASED INTERNAL SAFETY AUDIT
SYSTEM, CALIBRATION STATUS
OF PSV, FIRE DETECTION &
OBSERVATIONS &
ALARM SYSTEM -20 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 Flooding system

Smoke detection system

Gas detection system

Automatic Water spray system

Fire water network
 COMMUNICATION SYSTEM

TYPES OF NOS OF
COMMUNICATION SYSTEM RANGE 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, 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.