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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.
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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
Consumers :
HAZIRA (10+2)
Schematic Diagram of HVJ/GREP/DV Pipeline
Phases of HVJ & DVPL Pipeline Network
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
INDORE
VIJAIPUR (5+3) + (3)
KHERA (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)
• LPG PLANT
• NTGG PLANT
• HRSG PLANT
PROCESS FLOW DIAGRAM - VAGHODIA COMPLEX
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
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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
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
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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
K-01C
• 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)
Existing
Compressor
Station
HRSG Boiler
Gas Turbine
GAIL (India) Limited, Vaghodia
(Govt. of India Undertaking)
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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
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
TYPES OF NOS OF
COMMUNICATION SYSTEM RANGE COMMUNICATION
SYSTEM