GAIL (INDIA) LIMITEDGAIL TRAINING INSTITUTE- JAIPUR

INDUSTRIAL TRAINING PRESENTATION

ONOPERATION & MAINTENANCE

ofJAMNAGAR-LONI LPG PIPELINE

SYSTEMAt IPS Mansarampura

Submitted By – Kapil Soni

GAIL TRAINING INSTITUTE(GTI)

• NOIDA• JAIPUR

History :

• GAIL Limited is the largest state-owned natural gas processing and distribution company in India declared by Govt. Of India.

• It is headquartered in New Delhi.• It has six segments: Transmission services of natural gas &

liquefied petroleum gas(LPG)• Natural gas trading, Petrochemicals, LPG • Liquid hydrocarbon• GAILTEL • and others.

Gas authority of India Limited

• The gas sector infrastructure of gail is as follows:•  • 1984 - The Birth of GAIL• 1987 - HAZIRA VIJAIPUR JAGDISHPUR P/L commissioned• 1990 - Entry in LPG Processing• 1997 - Achieved youngest Navratan Status• 1997 - Entered in CNG Network• 1999 - Entry Petrochemical Processing• 2001 - Commissioned world largest LPG P/L • 2004 - Import of LPG• 2008 - Augmentation of Gas P/L Net work• 2011 - Declared world No. 1 Co. in DS operation• 2011 - MNC deal for Gas Contracts• 2012 - New P/L dedication up to Bhatinda• 2013 - P/L expansion in Uttrakhand• 2013 - Declared Youngest MAHARATAN Co. • (Top 5) by Govt. of India•  

Number of projects undertaken :-

• Study the CATHODIC PROTECTION OF PIPELINE .

• Study the working of PIGGING SYSTEM, Types of PIG And Pigging.

• List all the Mechanical Equipments with their specification.

1. LPG is a liquid under pressure but a gas at ambient conditions.

2. Vapour LPG is twice as heavy as air.3. Liquid LPG is half as heavy as water.4. LPG is colorless.5. LPG has a low boiling point of - 6°C6. LPG has a narrow flammability range between 1.8 to 9.5%

in air.7. Flash point of LPG is -60°C.8. The approximate minimum ignition temperature of LPG is

in the range 410°C to 580°C.

Properties of LPG

9) LPG is odourless.10) Ethyl Mercaptan is added as an odourant to

detect LPG in case of leaks. 11) LPG is non-toxic.12) It is lightly anaesthetic and can cause

suffocation, if present in sufficiently high concentrations.

13) Liquid LPG can cause severe cold burns to the skin owing to rapid vapourisation and the consequent lowering of temperature.

Requirment of LPG pipeline

•Cost Benefit•Continous flow•Easy transportation•Avoid delay in supply•To reduce traffic on Road•Prevent accident on Road

•In 2001, GAIL commissioned world’s longest and India’s first Cross Country LPG •Transmission Pipeline from Jamnagar to Loni .•JAMNAGAR – LONI LPG PIPELINE, the world’s longest exclusive LPG pipeline (1355 Km) & inaugurated for the commencement LPG supply to oil companies on 24/12/2000. •JLPL is the longest pipeline network in the world of 1335 km long, where main line is 1244 km and spur line is 91 km. •The pipeline is design to carry LPG and the capacity is 2.5 MMTPA. •JLPL is used for LPG transportation.

JLPL pipeline

JLPL PIPELINE

State wise pipeline length :-

Gujarat- 578 KMRajasthan- 686 KMHaryana- 98 KMDelhi- 5 KMUP- 48 KM

Total- 1414 KM

Size wise pipeline length :-

• 16” - 578.1 KM• 14” - 166.7 KM• 12” - 439.0 KM• 10” - 58.67 KM• 8” - 114.3 KM• 6” - 43.3 KM• 4” - 13.6 KM Total - 1414 KM

This pipeline mainly comprises of:-

A. 4 Intermediate Pumping Station(IPS) - Which are responsible for increasing the pressure to a limit so that it can be on the next pumping station and further-

1. SAMAKHALI2. ABUROAD3. NASIRABAD4. MANSARAMPURA

B. Receiving Terminal(RT) - Places which we tap the LPG so that it can be supplied to various oil companies-

•IOCL - 4•BPCL - 4•HPCL – 2

Most of the Terminals are having the arrangements for:-1. Filtration Facilities2. Temperature Control Facilities3. Pressure Control Facilities4. Measurement System 5. Pigging arrangement as per need6. Fire fighting Network7. Tap off arrangement

C. Sectionalizing Valves (SV) Stations-

1) Responsible for isolating the PL in case of emergency.2) JLPL project has a total of 73 SV stations.3) Responsible for isolating the p/ L case of emergency .4) SV’s are installed at an average distance of 20 km all

along the pipeline

D. Crossing-1) Rail -272) Road -1983) Water bodies-1494) HT-1255) Foreign PL -113

E. 4 Intermediate Pigging Station:-

1) IP 1 ( Between Samakhali – Abu Road P/L Section)2) IP 2 ( Between Abu Road – Nasirabad p/L Section)3) IP 3 ( At Mansarampura)4) IP 4 ( Between Mansarampura – Loni P/L Section)

Project cost : RS 1250 Crores

PIPELINE SECTION THROUGHPUT MMPTA

FLOW RATE TONS/HR

KANDLA TO SMK 0.5 63.33

SAMAKHIALI TO ABU ROAD 2.5 316.65

ABU ROAD TO NASIRABAD 2.5 316.65

NASIRABAD TO MANSARAMPURA 2.2 278.65

MANSARAMPURA TO LONI 2.0 253.32

FLOW RATE

Mechanical equipment used at IPS MANSARAMPURA

• Booster pump/centrifugal pump• Basket filter• Mass flow meter• Main jockey• Main fire water pump• Fire water tank• Diesel storage tank• Diesel transfer pump• Scraper receiver• Scraper launcher

Centrifugal Pump

• Centrifugal pump is basically a machine which is intended to raise the pressure of an incompressible liquid from an external source.

• Its purpose is to convert energy of a prime mover (a electric motor or turbine) first into kinetic energy and then into pressure energy of a fluid that is being pumped

• The energy changes occur by virtue of two main parts of the pump, the impeller and the volute or diffuser.

• The impeller is the rotating part that converts driver energy into the kinetic energy. Diffuser is the stationary part that converts the kinetic energy into pressure energy..

Cenrifugal pump

Specification of Cenrifugal pump

• Pump manufacturer - DAVID BROWN • Pump size - 6*8*10.5 B• Model -DB 36 Multi stg. Centifugal Pump• Number of stages – 10 • Suction pressure – 21 kg/cm2• Discharge pressure – 70 to80kg/cm2• Pumping temperature – 15 C normal 25 C max.• Head – 1180m• Capacity (normal/ rated) – 177/195 m3/hr• Rated speed – 3420 rpm

• There are no drive seals, therefore the risk of leaks is completely eradicated.

• Less heat transfer from the motor—the pump chamber is separated from the motor by an air gap; this provides a thermal barrier.

• Reduced friction

• Complete separation of the liquid means that liquid cannot seep into the motor from the pump.

Advantages

Introduction to Pigging system:

1) Pigging refers to the practice of using pipeline inspection gauges or 'pigs' to perform various maintenance operations on a pipeline.

2) This is done without stopping the flow of the product in the pipeline.

3) These operations include cleaning and inspecting of the pipeline.

Working of PIGGING System:-

1) This is accomplished by inserting the pig into a 'pig launcher' (or 'launching station')

2) The launcher / launching station is then closed and the pressure-driven flow of the product in the pipeline is used to push it along down the pipe until it reaches the receiving trap – the 'pig catcher' (or receiving station).

The launcher & Receiving area:

TYPES OF PIG Pigs can be broadly divided into four categories:1) Foam pigs: which is used to remove moisture,

condensate etc.. this is a type of pig by which, it is analysis that whether the pipe is thoroughly cleaned or not.

2) Brush and Magnetic Pigs: which are used to clean magnetic impurities from pipes. in case when form pig fails to protect pipeline from unwanted dirt, dust etc., then brush pigs are used.

3) Gauge pigs: which is used to check whether it is applicable for intelligent pigging. 4 ) Magnetic Flux Leakage: which is used for intelligent pigging .In the IPS use in determining the thickness, anomalies, holes etc. in pipelines.

Types of PIGGING:-

1) Cleaning Pigging- In this pigging Foam pig of respective pipe diameter is launched directly into the pipes who serve normal cleaning of pipes.

2) Intelligent Pigging- In this pigging process a special types of pigs equipped with various sensors to detect the various conditions of pipe eg. Thickness of pipe range, ultrasonic sensing, bend, and accumulation of sludge.

Some of the pigs after pigging :-

CATHODIC PROTECTION OF PIPELINES

CORROSION

• WHAT IS CORROSION.• DEGRADATION OF MATERIAL THRU

ENVIORMENTAL INTERACTION.• FOCUS ON CORROSION OF CARBON STEEL

USED IN UNDERGROUND PIPELINES.• WHEN IRON IS PLACED IN SOIL/WATER.

In order to prevent corrosion there are coating used like iron is coated by zinc or simply grease, paint, plastic is used. In many cases there are cathode protection used where a noble metal is connected to a less noble and potential applied

FOUR COMPONENTS FOR CORROSION CELL

• THERE MUST BE AN ANODE• THERE MUST BE A CATHODE.• THERE MUST BE A ELECTRICAL PATH

(PIPELINE ITSELF)• THERE MUST BE A CONDUCTIVE

ELECTROLYTE (WATER/SOIL)

CATHODIC PROTECTION

• WE HAD SEEN THAT• CORROSION TAKES PLACE AT ANODES.• NO CORROSION AT CATHODES.• DIFFERENT CORROSION CELLS ON PIPELINE.

WHAT WILL HAPPEN , IF WE MAKE

-THE WHOLE PIPELINE AS CATHODE.

NO CORROSION WILL TAKE PLACE..

HOW WE CAN MAKE-BY MAKING IT CATHODE W.R.T. OTHER METAL--BY MAKING IT TO COLLECT CURRENT FROM ANODE.-WHEN WE MAKE ANY PIPELINE/STRUCTURE AS A CATHODE W.R.T SOME METAL/ANODE-IT IS CALLED CATHODIC PROTECTION.

CATHODIC PROTECTION- HOW IT WORKS

• PRINCIPLE– DIRECT CURRENT IS MADE TO FLOW FROM EXTERNAL

SOURCE TO P/L– THE PIPELINE IS MADE TO COLLECT CURRENT BY MAKING

IT CATHODE– THE EXTERNAL CURRENT IS ADUSTED TO OVERPOWER THE

CORROSION CURRENT.– RESULTING IN A NET FLOW OF CURRENT ONTO PIPELINE .– ENTIRE P/L SURFACE BECOMES CATHODIC AND

PROTECTION COMPLETED.

GROUND BED

+IVE

-VETR UNIT/C.P

SOURCE

BURRIED PIPELINE

CURRENTFLOW

ELECTROLYTE/SOIL

FIG : BASIC CATHODIC PROTECTION INSTALLATION

TYPES OF CP SYSTEM

• SACRIFICIAL ANODE SYSTEM

• IMPRESSED CURRENT SYSTEM

Sacrificial CP System

Sacrificial Anode Pipeline

Current

Practical Galvanic Series for Metals in Neutral Soil and Water METAL POTENTIAL V (CSE)

Mill Scale On Steel - 0.2Mild Steel In Concrete - 0.2Lead 0.5Mild Steel (Rusted) - 0.5Mild Steel (Clean and Shiny) - 0.5 to - 0.8Aluminum Alloy (5% Zinc) - 1.05Zinc - 1.1Magnesium Alloy (6% Al, 3% Zn, 0.15% Mn)

- 1.6

Commercially Pure Magnesium

-1.75

Impressed Current CP System

Impressed current Anode Pipeline

Current

DC PowerSource+ -

ENVIRONMENT CURRENT DENSITY IN mA/m2

WELL-AERATED NEUTRAL SOIL 21.5 – 32.3

DRY, WELL-AERATED SOIL 5.4 – 16.1

WET, SOIL, MODERATE/SEVERE CONDITIONS

26.9 – 64.6

HIGHLY ACID SOIL 53.8 – 161.4

STATIONARY FRESH WATER 53.8

MOVING FRESH WATER 53.8 – 64.6

WELL COATED PIPELINE IN SOILS

0.01

CURRENT REQUIREMENTS FOR STEEL

TYPES OF ANODE BEDS

• HORIZONTAL ANODE BED

• VERTICAL ANODE BED

• DEEP WELL ANODE BED

Horizontal Anode Bed

3m 6m 0.4m

Ground Level

Anode cable Coke1.1m 0.75m Section

Vertical Anode Bed

6m 0.4m

1.1m 0.75mAnode cable Coke Section

Deep well Anode Bed

10 m

1.0 m

1.0mAnode cable

Coke

Section

0.3 m

O&M Base Jurisdiction: IPS, Mansarampura

Scheduled activities of LPG Pipeline as per Maintenance policy

Guidelines.

Normal PIGGING : Frequency – Yearly INTELLIGENT PIGGING: Frequency – 10

Years Helicopter / Aerial Surveillance- Monthly Foot Patrolling: Foot Patrolling by Security Agency

personnel: Daily Yearly foot patrolling by GAIL officials

after monsoon 4) Coating Integrity Survey : Quaterly 5) Thickness Measurement Survey : 2

times in a year 6) IDENTIFICATION AND MONITORING OF

VULNERABLE LOCATIONS: Monthly

THANK YOU

ANY QUERIES ??