Gail mansarampura

summer training ppt on GAIL MANSARAMPURA on OPERATION & MAINTENANCE

1. Contents-: INTRODUCTION INTRODUCTION TO JLPL FIRE AND SAFETY ELECTRICAL CORROSION INSTRUMENTATION MECHANICAL PIGGING SYSTEM CONTROL SYSTEM

2. INTRODUCTION   GAIL (India) Limited is a Navratna PSU and India’s Flagship Natural Gas Company, integrating all aspects of the Natural Gas value chain (including Exploration & Production, Processing, Transmission, Distribution and Marketing) and its related services. At Jaipur, GAIL has the Headquarter of its Jamnagar- Loni LPG Pipeline which is the World’s longest exclusive LPG Pipeline starting from Jamnagar & Kandla (Gujarat) to Loni (UP). This pipeline is fulfilling the LPG requirement of the Northern Zone of our country. GAIL Jaipur is also the Marketing Office for the state of Rajasthan. At, Mansarampura , GAIL has a Intermediate Pumping Station of its JLPL Pipeline. IPS is the pumping station on the JLPL system where the line pressure of the gas is boosted to the required level so as to provide the supply to the downstream station as per requirement of LPG. From upstream, LPG is received at 16-20 kg/cm2 & is pumped to the next stations at 60-80 kg/cm2 with 3 mainline pumps. Facilities like pig launching & receiving, filtration, metering, instrumentation, control, interlocks, power, fire & safety are provided for safe startup and shut down operation of LPG pumps.

3. INTRODUCTION TO JLPL   4 Intermediate Pumping Station(IPS)- which are responsible for increasing the pressure to a limit so that LPG can be transported to next pumping station and further- Samakhali Aburoad Nasirabad Mansarampura 2. Receiving Terminal (RT)- Places where we tap the LPG so that it can be supplied to various oil companies. IOCL-5 BPCL-4 HPCL-2

4. 3. Sectionalizing Valves (SV) Stations- responsible for isolating the pipeline in case of emergency. JLPL has a total of 73 SV stations. SVs are installed at an average distance of 20 km all along the pipeline. The stations have the facility for isolation of the line as well as venting of the gas in case of emergency. Mainline valves, of all bore gate type, are installed for isolating different sections of pipeline in case of leak/burst etc. At manual SV stations, pressure gauge and temperature gauges are installed to monitor pressure and temperature respectively. 4. Crossings- Rail-27 Road-198 Water bodies-149 HT-125 Creek-1 Foreign Pipeline-1

5. 5. Intermediate Pigging station(IP)- IP 1 (Between Samakhali – Aburoad P/L Section) IP 2 (Between Aburoad – Nasirabad P/L Section) IP 3 (At Mansarampura ) IP 4 (Between Mansarampura – Loni P/L Section) Pigging stations are installation designed and established to facilitate the pigging operation. These stations do have all the arrangements for launching and receiving of pigs for cleaning and monitoring the health of pipelines. Pig is a cylindrical device fitted with wire brushes all along its periphery and used for internal cleaning of pipeline. There are lot many varieties of pigs used for cleaning, gauging and checking the health of pipelines.

6. Fire and Safety Fire is the rapid oxidation of a material in the exothermic chemical process of combustion, releasing heat, light, and various reaction products. Slower oxidative processes like rusting or digestion are not included in this definition. There are four classes of Fire: Choosing Fire Extinguishers Class A: SOLIDS such as paper, wood, plastic etc Class B: FLAMMABLE LIQUIDS such as paraffin, petrol, oil etc Class C: FLAMMABLE GASES such as propane, butane, methane etc Class D: METALS such as aluminium, magnesium, titanium etc

7. Equipment used to prevent Fires:   General Fire Fighting Equipment Fire fighting systems and equipment vary depending on the age, size, use and type of need. Fire extinguishers Fire hydrant systems Fire hose reels Automatic sprinkler systems Fire Extinguishers Fire extinguishers are provided for a 'first attack' fire fighting measure generally undertaken by the occupants of the building before the fire service arrive. It is important that occupants are familiar with which extinguisher type to use on which fire. Most fires start as a small fire and may be extinguished if the correct type and amount of extinguishing agent is applied whilst the fire is small and controllable. Fire Hydrant systems Fire hydrant systems are installed in buildings to help firefighters quickly attack the fire. Essentially, a hydrant system is a water reticulation system used to transport water in order to limit the amount of hose that firefighters have to lay; thus speeding up the fire fighting process. Fire hydrants are for the sole use of trained firefighters (which includes factory firefighting teams). Because of the high pressures available serious injury can occur if untrained persons attempt to operate the equipment connected to such installations.

8. Fire Hose Reels Fire hose reels are provided for use by occupants as a 'first attack' firefighting measure but, in some instances, also be used by firefighters. When stowing a fire hose reel, it is important to first attach the nozzle end to the hose reel valve, then close the hose reel valve, then open the nozzle to relieve any pressure in the wound hose, then close the nozzle. Automatic Sprinkler Systems Time is essential in the control of fire. Automatic sprinkler systems are one of the most reliable methods available for controlling fires. Today's automatic fire sprinkler systems offer state of the art protection of life and property from the effects of fire. Sprinkler heads are now available which are twenty times more sensitive to fire than they were ten years ago. A sprinkler head is really an automatic (open once only) tap. The sprinkler head is connected to a pressurized water system. When the fire heats up the sprinkler head, it opens at a preset temperature, thus allowing pressurized water to be sprayed both down onto the fire and also up to cool the hot smoky layer and the building structure above the fire. This spray also wets combustible material in the vicinity of the fire, making it difficult to ignite, thereby slowing down or preventing fire spread and growth. When a sprinkler head operates, the water pressure in the system drops, activating an alarm which often automatically calls the fire brigade via a telephone connection.

9. Electrical

10. Switchgear “The apparatus used for Switching,Controling and Protecting the electrical circuit and equipment” Need of Switchgear Switching during normal operating condition for the purpose of Operation and Maintenance Switching during Faults and Abnormal condition and interruption the fault current Part of Switchgear Switching device Control Circuit Measurement and Display Protection

11. Switching Devices-: Circuit Breaker/Contactors Isolators Earthing Switch Control Switch Tripping and Closing Circuit Spring Charging,anti pumping arrangement Measurement Ammeter,Voltmeter,Energy Meter Protection Relay, CT , PT

12. JVNL Supply-: The Power Supply is being feed through the JVVNL Rjasthan State Electricity Board, it is the primary source Major Electrial Equipment : Transformer 33/6.6Kv , 02 Nos 6.6KV / 415 V – 02 Nos Motor main 630KW for pumping which operate at 600 – 690V through VSD DEG 6.6KV 1475KVA DEG 415 , 200KVA UPS Chargers Battery Banks – 02Nos Utility Motors F&S Eqipments VSD with Transformer

13. Circuit Breaker -: Vacuum Circuit Breaker (VCB)

14. Corrosion   Corrosion is a  natural process , which converts a refined metal to a more stable form, such as its oxide, hydroxide, or sulfide. It is the gradual destruction of materials (usually  metals ) by chemical and/or electrochemical reaction with their environment.  Corrosion engineering  is the field dedicated to controlling and stopping corrosion. Pipeline protection system to prevent External corrosion Cathodic Protection: Cathodic protection (CP) is a technique used to control the  corrosion  of a metal surface by making it the  cathode  of an electrochemical cell . A simple method of protection connects the metal to be protected to a more easily corroded " sacrificial metal " to act as the   anode . The sacrificial metal then corrodes instead of the protected metal. For structures such as long pipelines , where passive galvanic cathodic protection is not adequate, an external DC electrical power source is used to provide sufficient current.

15. Instrumentation   Pressure measurement device: In this pipeline, different types of pressure measurement devices are mounted. Pressure Transmitter - are required for measurement of pressure all along the pipeline & IPS. Highly accurate 2 wire SMART transmitter of make Rosemount ( Model 3051) ABB (600 T) etc. are installed in the field. Differential Pressure Transmitters installed across filters in IPS, DT and RT locations in Pipeline, indicating clogging of filters. Pressure Gauges are used for local indication of pressure are placed in redundant to Pressure transmitters. Most of them have bourdon type pressure sensors.

16. Pressure switches are process switching device having a particular cut off or set point, when process increases or decreases above or below set point, switching happens, it will initiate interlock for as per process requirement. Temperature measurement sensor RTD, Hg filled Temperature gauges, Thermocouples are commonly used temperature measurement equipment in this pipeline,following are detail description regarding this.

17. Gas Detectors A gas detector is a device that detects the presence of  gases  in an area, often as part of a  safety system . This type of equipment is used to detect a  gas leak and interface with a  control system  so a process can be automatically shut down. A gas detector can sound an alarm to operators in the area where the leak is occurring, giving them the opportunity to leave. Gas leak detection is the process of identifying potentially hazardous  gas leaks  by sensors. These sensors usually employ an audible alarm to alert people when a dangerous gas has been detected. Common sensors include  infrared point sensors ,  ultrasonic sensors ,  electrochemical gas sensors , and  semiconductor sensors . Smoke and Heat Detection system A ' heat detector  is a fire alarm device designed to respond when the  convected  thermal energy of a fire increases the temperature of a heat sensitive element. The thermal mass  and conductivity of the element regulate the rate flow of heat into the element. All heat detectors have this  thermal lag . Heat detectors have two main classifications of operation, "rate-of-rise" and "fixed temperature." The Heat detector is use to help in the reduction of damaged property. It is triggered when temperature increases. Fire detectors: Photoelectric smoke detector Leak detection in pipe Infrared gas detectors

18. Mechanical   Mechanical equipment used at IPS Mansarampura : Booster Pump/Centrifugal Pump Basket Filters Mass flow meter Main jockey Fire water pump Fire water tank Diesel storage tank Diesel transfer pump Hvac system Scrapper receiver Scrapper launcher

19. PIGGING SYSTEM Pigging in the context of  pipelines  refers to the practice of using devices known as "pigs" to perform various maintenance operations. This is done without stopping the flow of the product in the pipeline.   Types of Pigs: Foam pigs: which is used to remove moisture, condensate etc. This type of pig is used to determine piggability of pipeline. 2. Brush and Magnetic Pigs: which are used to clean magnetic impurities from pipes. In case when foam pig fails to remove unwanted dirt, dust etc , then brush pigs are used.

20. 3. Gauge Pigs: used to check whether pipeline is capable for undergoing intelligent pigging. 4. Magnetic Flux leakage: used for intelligent pigging. In the IPS it is used in determining thickness, anomalies, holes etc. in pipelines.   Types of Pigging: Cleaning Pigging- In this pigging foam pig of respective pipe diameter is launched directly into pipelines who serve normal cleaning of pipes. Intelligent Pigging- In this pigging process a special types of pigs equipped with various sensors to detect the various conditions of pipes e.g. Thickness of pipe, ultrasonic sensing, bends and accumulation of sludge.

21. The Control System   SCADA based control: Supervisory control and data acquisition system for monitoring & control of all installations from Jamnagar to Loni . A dedicated system links the stations to rest of the Gail installtions through optical fibre cable & satellite links.   All remote operations are carried at MCR only. Start/stop/speed the pumps. Close/open of the sectionalizing valves. Start/stop/reset of TEG at SV stations. Close fuel supply value to TEG’s. Monitoring being carried out at IPS mansarampura & RTs Pipeline parameters- CP related, valve status,Line Pressure and temperature etc. Power source- Health of TEG, voltage, current, Bus voltage. Pumps- Start/stop status and operation parameters. LPG supply/ Reciept status. Building/TEG/Door status.

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