1. Rohit Ram Manager (Inst ) Vikash Kumar SE (Elect.)
GAIL (India) Limited
Team Vaghodia
Rohit Ram Manager (Inst )
Vikash Kumar SE (Elect.)

2. 2

3. 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 at an estimated cost of 14,500 Cr.

4. 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 ( )
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)

5. 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 : MMSCMD
LINE SIZE : 42”
COMPRESSOR STN : VJPR (3 CMP)
Total Existing Capacity : MMSCMD
20 MMSCMD
DAHEJ
HAZIRA
(10) + (2)
FROM ONGC
18.2
33.4 MMSCMD

6. UNITS
LPG PLANT
GREP COMPRESSOR STATION
NTGG PLANT
HRSG PLANT

7. 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

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

11. 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

12. NTGG PLANT DESIGN CAPACITY NGL PROCESSING CAPACITY : 25.00 TPD
LPG RICH STREAM : TPD
GASOLINE : TPD
HEAVY END : TPD
MFO ( GASOLINE + HEAVY END) : TPD
FUEL GAS : Balance

13. 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

14. NTGG PLANT NTGG MODE NGL PROCESSING CAPACITY : 25.00 TPD
LPG RICH STREAM : TPD
GASOLINE : TPD
HEAVY END : TPD
MFO ( GASOLINE + HEAVY END) : TPD
FUEL GAS : Balance
NAPHTHA MODE
NGL PROCESSING CAPACITY : 28 TPD
NAPHTHA : 26 TPD

15. 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

16. 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

17. 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)

18. 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 MWh annually

19. Existing Compressor Station
PROCESS FLOW DIAGRAM FOR HRSG
Existing Compressor Station
HRSG Boiler
Gas Turbine

20. GAIL (India) Limited, Vaghodia (Govt. of India Undertaking)
ISO 9001:2008, ISO 14001:2004 & OHSAS 18001:2007

21. Focus Point for Emergency Response & Disaster Management Plan
GAS PROCESSING UNIT

22. 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

24. 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.

25. Fire Due to Pipeline Gas Leakage

26. BLEVE IN A LPG STORAGE FACILITY

27. Disaster in
Petro China Plant
Disaster in Moscow
Due to Gas Leakage
Disaster in Washington
Due to Gas Leakage

30. 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.

31. DISASTERS

32. PREVENTION / PREPAREDNESS
DISASTER
PREVENTION / PREPAREDNESS
SYSTEM
FOLLOWED IN GAIL

33. 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

34. (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

35. SAFETY FOR CONTRACT EMPLOYEES
PPE FOR EVERYONE
USE OF PPE’S BY CONTRACT PERSONS
TRAINING BEFORE STARTING THE JOB

36. 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

37. FIRE PROTECTION FACILITIES
PROTECTION SYSTEM
Automatic Flooding system
Smoke detection system
Gas detection system
Automatic Water spray system
Fire water network

38. 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.)

39. 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.

40. 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.