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

Schematic Diagram of HVJ/GREP/DV Pipeline o HISAR o RUDRAPUR SONIPAT BHAWANA G’ BAD SKBAD NTPC SIWALI TCL SBAD DADRI o BABRALA o KARANPUR o MORADABAD DESU CHAINSA(2) IFFCO IGL o AONLA o NAWADIA NTPC o PIPRAULA o JAGDISHPUR o FARIDABAD GURGAON o o MUNDER o MALAKPUR o ACHALGANJ o JATAULI o SACHENDI o MAURWAN o THULENDI BAHADURGARH MARUTI o SIHANA SHAHJAHANPUR o NGMC NOIDA IOCL KSFL o MATHURA UPPC PATA BANDHMAU o INDOGULF AGRA CGS BAJHERA o JIGNIS o IFFCO BAMNIKALAN o FIROZABAD NARAYANPUR o JETHWADA o AURAIYA (3+2) PHULPUR o RRVNL o IBRAHIMPUR BHILWADA o NTPC DHAULPUR o o SONE KA GURJA IDPL 10”x33 KMS o MALANPUR o GORABHUPKA KAILARAS (2) o GWALIOR KHERI o SFCL KOTA o MARA o KHARAUWA o o BURDHA KAMAD o SAMACORE DUNGARWAHA o o CFCL G’PAN o KHORDAR BHAUNTI o ANTA o MIANPUR o o BORERI o CHITARA NTPC ATTRU o o S’WASA o PIRONTH CHHABRA o NFL o 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 DEWAS o KACHACHIBARODA o INDORE KASARBADI o 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 : PITHAMPUR MOHANKOT o DUDHMAL o JHABUA (7+3+3) DEVGARHBARIA o o SHERPURA IPCL o o JAMBUDI o ANKOT VAGHODIA o VAGHODIA (3) DAHEJ o SAMNI o VEMAR JHAGADIYA o GANDHAR KOSAMBA o Schematic Diagram of HVJ/GREP/DV Pipeline HAZIRA (10+2)

Phases of HVJ & DVPL Pipeline Network ORIGINAL HVJ PIPELINE (1915KM): CAPACITY : 18.2 MMSCMD NO OF COMPRESSOR STN : 4 DADRI DELHI JAGDISHPUR UPGRADED HVJ PIPELINE (GREP)-497 KM : CAPACITY : 33.4 MMSCMD NO OF COMPRESSOR STN : UPGRADED : 2 NEW : 2 PHULPUR Malanpur DIBIYAPUR (3) + (2) KOTA Regional Pipelines added with HVJ Added : 483 Km ANTA INDORE VIJAIPUR (5+3) + (3) KHERA (3) (7) + (3) IPCL JHABUA VAGHODIA (3) DVPL (611 KM) : PIPELINE CAPCITY : 23.9 MMSCMD LINE SIZE : 42” COMPRESSOR STN : VJPR (3 CMP) Total Existing Capacity : 56.9 MMSCMD 20 MMSCMD DAHEJ HAZIRA (10) + (2) FROM ONGC 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” Zero Pt FUEL LINE LPG PLANT BYPASS GSFC UNDERA GIPCL LPG PLANT LEAN GAS 12” IPCL LPG TO STORAGE NGL LPG IOCL MFO Product NTGG

LPG PLANT Design Capacity GAS PROCESSING : 2.5 MMSCMD LPG PRODUCTION : 73000 TPA NGL PRODUCTION :10600 TPA

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

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 TPD MFO ( GASOLINE + HEAVY END) : 11.89 TPD FUEL GAS : Balance NAPHTHA MODE NGL PROCESSING CAPACITY : 28 TPD NAPHTHA : 26 TPD

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

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 16

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: Natural Gas Products: LPG (Liquefied Petroleum Gas) – Unit I (LPG Plant) Naphtha – Unit II (NTGG Plant) 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

Existing Compressor Station 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

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

NEAR MISS REPORTING NEAR MISS REPORTING FORMAT IS AVAILABLE ON LAN. 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

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

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

PREVENTION / PREPAREDNESS DISASTER PREVENTION / PREPAREDNESS SYSTEM FOLLOWED IN GAIL

PARAMETERS FOR HSE INDEX EVALUATION LEADERSHIP & COMMITMENT- 10 HSE TRAINING- 05 ENVIRONMENT MONITORING -05 INCIDENT REPORTING- 20 HSE INDEX 100 Marks NEAR MISS INCIDENT - 5 HEALTH MONITORING -10 FIRE APPLIANCES,FIRE WATER BASED & NON WATER BASED SYSTEM, CALIBRATION STATUS OF PSV, FIRE DETECTION & ALARM SYSTEM -20 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 PROTECTION FACILITIES FIRE WATER PUMP HOUSE Diesel pump 4 Nos. Electric driven pump 2 Nos. Jockey pump 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 system Fire water network

COMMUNICATION SYSTEM TYPES OF COMMUNICATION SYSTEM RANGE 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, 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.