Alok Sharma

WELCOME to the presentation On Safety in CNG / PNG Operations
INDRAPRASTHA GAS LIMITED

August 12th, 2010
CNG for Clean & Green Environment
OVERVIEW
1 2 3 4 5 ABOUT IGL NATURAL GAS : COMPRESSED NATURAL GAS SAFETY IN CNG OPERATIONS SAFETY IN PNG OPERATIONS IGL INITIATIVES
INDRAPRASTHA GAS LIMITED (IGL)

Incorporated on 23rd December 1998 for supply of natural gas to domestic, commercial and
Institutional 16.54% Govt. of Delhi 5.00% Body Corporate 5.32% FII 17.87% BPCL 22.50% Individuals 10.27% GAIL 22.50%
automobile sectors (CNG). Immediate target -
implementation of Supreme Court order
DESU/Delhi/MARUTI
DADRI
NTPC DADRI
FARIDABAD TCL-BABRALA
CHAINSA
HVJ PIPELINE
DESIGN CAPACITY:33.4 MMSCMD DESIGN PRESSURE:92 KG/SQ CM LENGHTH:2800 KMS
MATHURA
(IFFCO) AONLA
SHAHJAHANPUR
(OFCL)
AGRA/FEROZ
NTPC AUR
JAGDISHPUR
CFCL
AURAIYA
BORERI ANTA
VIJAIPUR
DAHEJ KHERA
42*610 km
Hazira
VAGHODIA
HBJ ting JHABUA E xi s km 6 40 36 *
Additional Compression
EXISTING LINE NEW LINE
AT PRESENT IGL IS OPERATING MORE THAN 3000 KMS OF PIPELINE NETWORK IN DELHI & NCR
Geographical Spread in Delhi
1 2 3 4 5
ABOUT IGL NATURAL GAS : COMPRESSED NATURAL GAS SAFETY IN CNG OPERATIONS SAFETY IN PNG OPERATIONS IGL INITIATIVES
NATURAL GAS
A MIXURE OF HYDROCARBONS TYPICAL COMPOSITION FOR NG METHANE (CH4) ETHANE (C2H6) PROPANE (C3H8) CARBON DI-OXIDE OTHERS SPECIFIC GRAVITY: CALORIFIC VALUE (net) : : : : : : : 85-90% 5-7% 2% 3-5% 1% 0.65 (Approx) 8300 KCAL/SCM
7
Compressed Natural Gas (CNG)

Natural gas is compressed to 250 Kg/cmg through reciprocating compressors installed at Mother and On-Line CNG Stations for use as automotive fuel. CNG is dispensed to vehicles at maximum 200 Kg/cmg pressure. CNG is artificially odorized(Ethyl Mercaptan) Physical Properties of CNG: Colourless Non-toxic Lighter than air Non-corrosive
COMPARATIVE PROPERTIES OF AVAILABLE FUELS

PROPERTIES
CALORIFIC VALUE RELATIVE DENSITY AUTOIGNITION TEMPERATURE FLAMMABILITY LIMIT FLAME TEMPARATURE
UNIT
KCAL/KG AIR=1 C % IN AIR C
PETROL
11200 3.4 232-282 1-8 1977
DIESEL
10850 3.9 225 0.6-5.5 2054
CNG 10600 0.65 540 5-15 1790
CNG : AN INHERENTLY CLEAN & SAFE FUEL

CNG for Clean & Green Environment 9
CNG SUPPLY CHAIN

STEEL PIPELINE NATURAL GAS CARRIER
19-22 Kg/cm2g CNG Compressor 19-22 Kg/cm2g CNG Compressor Mobile Cascade Mobile Cascade 250 Kg/cm2g Storage Cascade
250 Kg/cm2g
Storage Cascade
MOTHER STATION
Dispenser
<=200 Kg/cm2g
Dispenser
ONLINE STATION
<=200 Kg/cm2g
CNG Vehicle
Mobile Cascade Mobile Cascade
CNG Vehicle
DAUGHTER STATION
Dispenser
<=200 Kg/cm2g
Booster
Dispenser
DAUGHTER BOOSTER STATION
<=200 Kg/cm2g
CNG Vehicle
CNG Vehicle
10
CNG PROJECT OF DELHI & NCR STATUS

PILOT PHASE PRESENT FUTURE
(END 98) (July10) (July
(till 2012)
NO. OF STATIONS MOTHER ONLINE DAUGHTER DAUGHTER BOOSTER TOTAL COMPRESSION CAPACITY (MILLION SCM/DAY) NOS. OF CNG VEHICLES (APPROXIMATELY) AVERAGE CNG SALE, (MILLION SCM/DAY) : : : : : : : 1 3 5 9 0.02 1200 88 58 01 47 195 3.11 244 4.25
0.35 million
0.003
1.95
2.3 11
Delhi-CNG Infrastructure
Buses
14,764 1,10,245
100% 100% 100% 10%
Auto
RTVs 17,474 & Taxis Private 2,11,313 Cars
The present infrastructure caters to more than 3,50,000 vehicles from NCT Of Delhi and NCR. This includes the largest fleet Of CNG buses operated in any single city in the world
Growth / Projection of CNG Stations

21 7 24
2006-07 250
200
No. of CNG Stations
150
100
50
0 2007-08 2008-09 2009-10 2010-11 2011-12
15
16
17 9
19 4
13
1 2 3 4 5
14
DESIGN & OPERATIONAL SAFETY OF CNG STATIONS
15
The CNG Stations are designed as per Best National & International Codes and Standards.
16
SALIENT FEATURES OF COMPRESSORS

TYPE CAPACITY DISCHARGE PRSSURE DESIGN CODE RECIPROCATING. 250 1200 SCM/HR. 255 KGS./CM2G API-11P, OISD 179, NFPA-37, ANSI, ASTM, NEC, NEMA, INDIAN ELECTRICITY RULES AND INDIAN EXPLOSIVE ACT. GAS ENGINE / ELECTRIC MOTOR PLC CONTROL WITH ALL SAFETY INTERLOCKS, CO2 FLOODING SYSTEM, LEL DETECTORS, UV/INFRARED FLAME DETECTORS AND ESD SYSYTEM
17
PRIME MOVER SAFETY FEATURES
PLC CONTROL
The unit is designed for fully automated, unattended operation. Auto start, auto stop, alarm & trip on development of abnormal condition through PLC control. The unit goes into a safe mode in case of any fault.
18
SAFETY INTERLOCKS
Safety interlocks are provided in the PLC system to give Audio-Visual alarm & trip the unit whenever any of these parameter crosses the High/Low limits :
High Discharge Pressure : Each stage Low Pressure : Suction, Engine Lube Oil, Compressor Oil High Temperature : Each stage, Lube Oil, Coolant Gas Leakage in the Package Flame Low Level : Lube Oil, Coolant High Vibration
19
LEL & FLAME DETECTORS

2 Nos of L.E.L. Detectors in each partition of the package provided to sense gas leakage 2 Nos of UV / IR flame detectors provided in each partition of the package to sense Flame. The signals of each of these sensors are continuously monitored by the PLC system. Upon sensing presence of Gas or Flame, the PLC trips the unit, and isolates it from suction line, CNG dispensers & the cascades. In case a flame is sensed, the CO2 Flooding system is activated to immediately extinguish the fire.
20
GAS DETECTOR INSIDE CNG COMPRESSOR
21
FLAME DETECTOR INSIDE CNG COMPRESSOR
22
CO2 FLOODING SYSTEM

The compressor package is provided with a CO2 flooding system, which is triggered by signal from the UV/IR flame detectors.
On detection of flame, CO2 is Discharged to extinguish the fire.
23
IGNITION SYSTEM
The Natural Gas Engine is provided with a Breakerless Ignition system. There is no distributor in the system, which might be a potential source of spark. All the wiring harness of the Ignition system are enclosed in grounded, metal shielded flexible conduits, thus any leakage current does not generate spark. The Ignition transformers are mounted on the spark plug, avoiding any high tension cable. Engine Silencer is Residential / Hospital type with Exhaust Flame trap and Spool type Flexible Connector.
ESD SYSTEM
The CNG compressor packages are provided with an Emergency Shut Down System. The ESD system is activated by pushing a Mushroom Head type Emergency switch mounted in a safe & accessible location. The ESD system, when activated, Brings the unit to an immediate halt. Isolates the unit from Gas Suction Line. Closes all the output priority valves, thus isolating the Compressor, Cascades & Dispensers from each other.
25
ELECTRICAL CONNECTIONS
All the Cables are terminated with compression Explosion - proof glands. Double
The Electric Motors are Explosion Proof, with Motor Protection relays, with Multiple safety features.
26
INTRINSICALLY SAFE
All the instruments / sensors are intrinsically safe, suitable for hazardous area application. Any Loose Wiring / Failure of any sensor / instrument takes the PLC to fail safe mode.
27
SALIENT FEATURES OF CASCADES

TYPE NO OF BANKS DESIGN CODE CYLINDERS VALVES SAFETY DEVICES OPERATING PRESSURE TEST PRESSURE 3000 WATER LITRE CAPACITY 2200 WATER LITRE CAPACITY 3 OR 1 GAS CYLINDER RULES & IS: 7285 IS: 3224 IS: 5903 255 BAR 435 BAR
28
SALIENT FEATURES OF CASCADES

SAFETY FEATURES
PRESSURE RELIEF DEVICES ARE PROVIDED IN THE FORM OF BURST DISCS WITH FUSIBLE PLUG, TO RELEIVE THE EXCESS PRESSURE. THE VENT OF RELEIF DEVICES OF INDIVIDUAL CYLINDERS IS COMBINED INTO A COMMON MANIFOLD & RELEASED TO ATMOSPHERE AT A SAFE LOCATION. CNG CYLINDERS ARE HYDROTESTED EVERY 5 YEARS.
29
SALIENT FEATURES OF DISPENSERS

CAR DISPENSERS
TYPE NO OF ARMS FLOW RANGE DESIGN CODE FAST FILL 2 0-15 KG/MIN NFPA 52, NGV 4.2/A.G.A. 1-93, ANSI/NGV1,NGV 4/A.G.A., AG901, IS 5572, IS 5571, OISD 179 AND OISD 113 OVER FILL PROTECTION, ESD MANUAL VALVES, BREAK-AWAY COUPLING WITH EXCEEDING 200 KG/CM2.
SAFETY FEATURES AUTO CUT-OFF DEVICE
30
SALIENT FEATURES OF DISPENSERS

BUS DISPENSERS
TYPE NO OF ARMS FLOW RANGE DESIGN CODE ULTRA FAST FILL 1 0-75 KG/MIN NFPA 52, NGV 4.2/A.G.A. 1-93, ANSI/NGV1, NGV 4/A.G.A., AG901, IS 5572, IS 5571, OISD 179 AND OISD 113 OVER FILL PROTECTION, ESD MANUAL VALVES, BREAK-AWAY COUPLING WITH AUTO CUT-OFF DEVICE.
SAFETY FEATURES
31
CONDUCTIVE HOSES & EARTHING
The filling Hoses of CNG Dispensers are Electrically Conductive & designed as per ANSI / NGV 4.2 Static charge is carried to dispenser body, and does not produce spark during engagement and disengagement of Filling nozzle with Vehicle receptacle. The dispensers are Earthed to dissipate the Static Charge, and leakage current if any.
32
STATION TUBING & FITTINGS

All the High Pressure Tubing at CNG stations is made of Stainless Steel, which does not corrode. All the tubing Connections are Double Ferrule type. All tubing & fittings are internationally reputed vendors. procured from
33
INTER DISTANCES
(FROM BUILDINGS AND OUTER BOUNDARIES TO GAS STORAGE)
TABLE-1
S.NO. TOTAL CAPACITY OF GAS STORAGE UNITS (IN LTRS.) UPTO 4500 4500-10000 10000-100000 MINMUM DISTANCE FROM BUILDINGS AND BOUNDARIES (IN MTRS.) 2.5 4.0 10.0
1 2 3
SOURCE: OISD - 179

INTER DISTANCES
(BETWEEN VARIOUS FACILITIES)
TABLE-2
S. NO. 1 2 3 4 5 6 7 DISTANCE FROM (IN MTRS.) CNG COMPRESSOR CNG DISPENSING UNIT STORAGE CASCADES OUTER BOUNDARY WALL/CLF MS/HSD DISPENSER VENT OF MS/HSD U/G STORAGE TANKS FILLING POINT OF MS/HSD 1 3 2 3 6 6 2 3 2 4 6 4 3 2 2 T-1 T-1 (MIN-6) T-1 (MIN-4) 4 3 4 T-1 6 4 5 6 6 T-1 (MIN-6) 6 6 6 6 4 T-1 (MIN-4) 4 6 6 7 T-1 (MIN3) -DO-DO-DO-DO6 -
------------------T-1 (MIN-3)-------------------
T-1 STANDS FOR TABLE-1
SOURCE: OISD - 179 35
FIRE PROTECTION SYSTEM AT CNG STATIONS

A) FIRE FIGHTING ARRANGEMENTS AS PER OISD-179: EQUIPMENT COMPRESSOR DISPENSER CASCADE LCV POINT ELECTRICAL PANEL DCP-75KG. 1
(online & mother)
DCP-10 KG. 1 1 1 1 -
CO2- 4.5 KG. 1
36
FIRE PROTECTION SYSTEM AT CNG STATIONS

B) AS PER CCOE GUIDELINES:
6 NOS. FIRE BUCKETS AT EACH CNG STATION.
C) ADDITIONAL SAFETY MEASURES BY IGL: CO2 FLOODING SYSTEMS FOR COMPRESSORS ARE INSTALLED AS STANDARD SAFETY MEASURE.
37
SAFETY PRACTICES IN O&M

Preventive Maintenance of Equipment Regular Testing and Calibration CNG is odorized for easy detection in case of leakage Portable & fixed Gas Detectors for Checking Leaks Compressor Area Fenced Installation of Safety Guards for Dispensers Safety & Operational Training to all staff Safety Manual with all safety & emergency information. Safety Work Permit System followed.
SAFETY PRACTICES O&M contd.

Display of Safety Film on CNG. Use of required Personal Protective Equipment Safety Committee for worker participation. Safety Audit / Safety Inspection conducted. Accident Reporting, Recording, Investigation & Analysis Safety Awareness and Campaign conducted. CNG refueling is done with no passengers in the vehicle Ignition keys of vehicles are removed before refueling
1 2 3 4 5
40
CGD Line Diagram

Steel Pipe Network
Pressure 19 to 26 Bar
City Gas Station Transmission Gas HVJ Pipeline , Pressure - 60 bar
District Regulating Station ( DRS )
Dispensing 200 Bar
CNG
M.D.P.E 4 Bar
Regulating / Metering Kitchen Burner G.I. / Cu Piping 21 mbar
41
AT PRESENT IGL IS OPERATING MORE THAN 3000 KMS OF PIPELINE NETWORK IN DELHI & NCR
Geographical Spread in Delhi
42
PNG Segment (Number of Connections)

Domestic Connections 1,85,300
Commercial Connections 361 Industrial Connections Total PNG Sales 31 0.28 MMSCMD
Planning 3,35,000 domestic connections by 2011-12
43
PNG - A Typical Gas Supply Scheme
44
FEW OF THE SATISFIED CUSTOMERS
AKSHARDHAM TEMPLE
45
Safety Systems & Arrangements for PNG Distribution

Pipeline is laid 1 meter below ground level. Warning tape with emergency contact nos. laid above 250mm the Pipeline. Above ground Pipelines markers with emergency contact nos. is installed. Round the clock Pipeline patrolling is done by Security guards. Isolation valve every 2 kms or at branch of 63mm size pipeline.

Regular Safety Clinics are conducted in the societies for educating consumers. All the PNG contract & IGL employees are imparted with regular Fire & Safety Training with live fire fighting experience of gas fire. Proper Personnel Protective Equipments are provided to the PNG workers for the safe execution of the job. Cautionary instructions and Safety pamphlets bearing emergency contact numbers are distributed regularly along with the bills for enhancing safety awareness to the consumers. Safety Kits and liveries (Safety Clothing, Shoes etc.) are provided to IGL employees as well as contract staff on yearly basis.

Portable gas detectors for monitoring gas leak and First Aid box for staff is provided at the PNG control rooms as per statutory requirements. Calibration and testing of gas detectors is done on half yearly basis. External Safety Audits of all the Small, Medium and Large commercial establishments like restaurants, hotels, hospitals & industries where gas is distributed by IGL, are carried out by Internationally accredited third party or agency and its compliance is ensured. Safety Committee Meetings are held at Control room level with equal participation of executives and non executives, to address all the safety related issues and implementation of safety policies. Central Safety Committee Meetings are conducted on yearly basis. HAZOP and Risk Assessment studies of CNG equipments & installations are carried out from time to time by Internationally accredited third party.
PIPELINE ROUTE MARKERS
CONCRETE MARKER
PLATE MARKER POLE MARKER CNG for Clean & Green Environment
49
Consequences of Gas Leak & Fire at CNG Station due to Consumers Vehicles
50
View of totally damaged CNG Station
51
Cause: Fire due to Safety Disc Failure
52
Failure of Safety Disc of CNG Cylinders results in High Pressure (up to 200 kg/cm2) Gas Leak resulting in damage to vehicles as well as CNG station
(Safety Disc)
53
Unprotected Battery Terminals and Improper Wiring in CNG Vehicles Cause Fire due to Short Circuit
54
Unprotected Battery Terminals and non-standard wiring
55
1 2 3 4 5
56
IGLS INITIATIVE TO MITIGATE INCIDENCES
DCP SYSTEM DESIGNED AND INSTALLED TO AVOID OCCURANCE OF FIRE DUE TO SAFETY DISC FAILURES RESULTING IN MAJOR FIRES.
57
STATIONS EQUIPPED WITH LARGE CAPACITY DCP SYSTEM FOR ATTENDING BUS FIRE AT CNG STATION.
58
TRAINING
Training is given prime importance and regular trainings are imparted to IGL employees, Contract workers, CNG & PNG consumers, Security Guards and Delhi Fire Service personnel.
Multi-discipline Core Safety Groups trained from NEBOSH, UK ensures implementation of Safety Management System in CNG and PNG - O&M.
Fire & Safety Training to IGL Employees
60
Live Fire Fighting Training

A Demo site has been developed at Rohini Fire Station and live fire fighting training is imparted to IGL Employees, Station Staff and Consumers.
61
Live Fire Fighting Training to DTC staff
62
Fire & Safety Training to Security Guards
63
Fire & Safety Training to CNG Station Workers
64
Station staff is regularly trained and mock drills are conducted
65
CNG Fire Training to Delhi Fire Service Personnel
66
Educating CNG Consumers

Safety Clinics are regularly conducted for Consumers
67
FOR THE SAFETY OF SCHOOL CHILDREN

TRAINING IMPARTED TO BUS DRIVERS AND OPERATORS OF CNG SCHOOL BUSES REGULARLY.
68
69
70
71
Random Safety Checking of Vehicles
The CNG Vehicles are randomly checked for any gas leakage and other statutory compliances and observations are forwarded to concerned departments like DTC and Department of Surface Transport.
72
FREE CHECKUPS OF CNG CARS
73
EDUCATING CONSUMERS Free Service Camps are conducted to check the fitness of CNG vehicles and creating awareness for conservation of gas, among consumers by educating them and pasting cautionary instructions on their vehicles.
74
ACHIEVEMENT
As a result of Management Commitment to Safety, dedicated Team-work and strong Safety Management System, IGL with more than 3000 kms pipeline network in Delhi & NCR, operating 24X7 with more than - 200 CNG stations, 3.5 Lac CNG vehicles and around 2.0 lacs PNG consumers, the company has crossed 60 Million Man Hours without any Reportable Lost Time Accident.
Thanks

Alok Sharma

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WELCOME to the presentation On Safety in CNG / PNG Operations

INDRAPRASTHA GAS LIMITED

CNG for Clean & Green Environment

CNG for Clean & Green Environment

INDRAPRASTHA GAS LIMITED (IGL)

automobile sectors (CNG). Immediate target -

implementation of Supreme Court order

CNG for Clean & Green Environment

HBJ ting JHABUA E xi s km 6 40 36 *

CNG for Clean & Green Environment

Geographical Spread in Delhi

CNG for Clean & Green Environment

CNG for Clean & Green Environment

CNG for Clean & Green Environment

Compressed Natural Gas (CNG)

CNG for Clean & Green Environment

COMPARATIVE PROPERTIES OF AVAILABLE FUELS

CNG 10600 0.65 540 5-15 1790

CNG : AN INHERENTLY CLEAN & SAFE FUEL

CNG SUPPLY CHAIN

DAUGHTER BOOSTER STATION

CNG for Clean & Green Environment

CNG PROJECT OF DELHI & NCR STATUS

CNG for Clean & Green Environment

100% 100% 100% 10%

RTVs 17,474 & Taxis Private 2,11,313 Cars

Growth / Projection of CNG Stations

No. of CNG Stations

0 2007-08 2008-09 2009-10 2010-11 2011-12

CNG for Clean & Green Environment

CNG for Clean & Green Environment

DESIGN & OPERATIONAL SAFETY OF CNG STATIONS

CNG for Clean & Green Environment

CNG for Clean & Green Environment

SALIENT FEATURES OF COMPRESSORS

PRIME MOVER SAFETY FEATURES

CNG for Clean & Green Environment

CNG for Clean & Green Environment

CNG for Clean & Green Environment

LEL & FLAME DETECTORS

CNG for Clean & Green Environment

GAS DETECTOR INSIDE CNG COMPRESSOR

CNG for Clean & Green Environment

FLAME DETECTOR INSIDE CNG COMPRESSOR

CNG for Clean & Green Environment

CO2 FLOODING SYSTEM

On detection of flame, CO2 is Discharged to extinguish the fire.

CNG for Clean & Green Environment

CNG for Clean & Green Environment

CNG for Clean & Green Environment

CNG for Clean & Green Environment

SALIENT FEATURES OF CASCADES

CNG for Clean & Green Environment

SALIENT FEATURES OF CASCADES

CNG for Clean & Green Environment

SALIENT FEATURES OF DISPENSERS

SAFETY FEATURES AUTO CUT-OFF DEVICE

CNG for Clean & Green Environment

SALIENT FEATURES OF DISPENSERS

CNG for Clean & Green Environment

CONDUCTIVE HOSES & EARTHING

CNG for Clean & Green Environment