INDEX

Sr. No. 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. Contents Table of Visited Industries Safety in Industry Essar Refinery Jamnagar Refinery ONGC WSS Hazira LNG & Port Gujarat Gas ONGC Hazira GSPC Niko GSPL GSPC Gas Page No. 1 2 3 8 16 18 24 26 28 33 36

Visits
Sr. No. 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. Date of Visit 14/12/2009 15/12/2009 16/12/2009 17/12/2009 18/12/2009 18/12/2009 19/12/2009 20/12/2009 20/10/2009 21/12/2009 Industry Visited Essar oil Reliance Industries Limited (RIL) ONGC WSS ONGC Cambay Hazira LNG & Port Gujarat Gas Company Limited (GGCL) ONGC Hazira GSPC Niko Gujarat State Petronet Limited (GSPL) GSPC Gas Place Jamnagar Jamnagar Kalol Khambhat Hazira Hazira Hazira Hazira Hazira Hazira

Safety at Industry
Industry Safety, Health, Environment and Social Programs (SHESP) are intended to ensure their activities do not compromise the well being of their employees, contractors, communities or the environment in which they operate. They will ensure that recognized safety, health, environment and social standards and legal requirements are met through the provision of adequate facilities, equipment, procedures, training and management systems. Safety is an integral part of their day to day activities and an essential employment skill. They expect their staff and contractors to exercise the right and responsibility to refuse to do work when unsafe conditions exist. By conducting their operations and activities in a safe manner, they are not only protecting their staff but also their friends, families, the public and the environment. They will ensure the safety of their activities through diligent implementation of its Safety, Health and Environment Management System (SHEMS). Protection of the environment is, and shall always be an important consideration in any activity we undertake. To accomplish this they will comply with all applicable environmental laws and regulations, implement and keep current their SHEMS and adopt industry best practices. It requires that all of their activities are carried out in a socially and culturally responsible and respectful manner. Further, at such time as corporate profitability allows it, they will form time to time undertake benevolent environmental and social action in cooperation with local communities. They will set measurable Safety, Health, Environmental and Social Program (SHESP) performance objectives and monitor their suggestions on a regular basis. All employees and contractors are accountable for following SHESP policies rules and procedures as well as all applicable laws and regulations. Through cooperation, teamwork and knowledge we can achieve our primary SHESP goal of no harm to people and assets, minimal impact on the environment and constructive relations with potentially affected individuals and communities.

Essar Refinery
About Essar:
Essar Global Limited is a diversified business corporation Essar has manufacturing & service portfolios in sectors like Steel, Energy, Power, Communications, Shipping Ports & Logistics, and Construction. Essar has offices in Asia, Africa, Europe and the Americas. Essar has been focusing on global expansion with projects/investments in Canada, USA, Africa, the Middle East, the Caribbean and South East Asia. With Forward and backward integration, state-of-the-art technologies, in-house research and innovation have made Essar Global a leading player in most of its businesses. Essars philosophy is to be a low cost, high quality, technology driven group with innovative customer offerings. Essar was setup in the year 1969 & since then has earned lots of laurels for itself Essar Oil is a fully integrated oil company. Its assets include o Development rights in exploration blocks o A 12 MTPA refinery in the west coast of India at Jamnagar o Over 1,000 oil retail stations across India. Future Plans are o To increase its exploration acreage in various parts of the globe o Expand its refinery capacity to 34 MTPA o Over 5000 retail outlets

Introduction:
Essar's oil refinery at Vadinar in Jamnagar, Gujarat, is ideally located on India's West Coast in close proximity to the crude rich Gulf States. Vadinar is an all-weather deep-draft natural port. About 70 per cent of India's crude imports land in and around this region. Besides, the refinery's location enables access to the fast growing markets in the north and western region of India through product pipelines. The eastern and southern parts of India will be serviced through the coastal route circling the country. This world-class 10.5 million ton or 210,000 bpd refinery (operating at 280,000 bpd) produces fuels compliant with latest emission standards, and is being progressively expanded to 16 million tons (320,000 bpd) and to 34 million tons (680,000 bpd).
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The refinery has been built with state of the art technology with technical and project assistance from the world's leading consultants and equipment suppliers in the field. It is designed to handle a diverse range of crude mixes. The world-class refinery produces middle distillates like aviation turbine fuel, kerosene oil and highspeed diesel, as well as LPG and transport fuels conforming to Euro III and Euro IV product quality standards. Post expansion, the refinery will have a Nelson Complexity of 12.8 with capability of processing tougher crudes and producing petroleum products of very high quality, meeting Euro V standards. The refinery is fully integrated with its own dedicated 120MW co-generation power plant, port and terminal facilities. It includes rail car and truck loading facilities and a Single Point Mooring (SPM) capable of handling vessels up to 350,000 dwt with a marine product dispatch capacity of 14mtpa. The refinery has built-in environment friendly technologies for pollution management. A selfsustainable, 700-acre greenbelt, with over three lakh saplings, has been developed to ensure a green corridor around the entire refinery complex. In Mombassa, Kenya, we have a 50 per cent stake in an 80,000 bpd refinery run by the Kenya Petroleum Refineries Ltd (KPRL); the remaining 50 percent is owned by the Kenyan government.

Production Process Flow:

The Plant is divided into 3 parts Jetty, Storage Tank, & Processing Area

Jetty:
The Jetty area is used to load & unload crude from the tankers arriving at the jetty platform. From the larger ships the crude is unloaded by SPM (Single Point Mooring) where the ship is unloaded in mid sea as they cannot come to the docking area due to the depth of the sea being too less. The arms at docking area unload the crude & store it in COT (Crude Oil Tank). This tank is also used to store the substance to be loaded into the ships. The crude is brought or is taken from this tank to the storage area.

Storage Tank Area:

Storage area is used to store the crude from the ships the plant processes 36 different crudes. So each crude present at the moment is stored in a different tanker. According to the requirement they are blended to get specific gravity in different tanks they are done in the blending tanks. The

blending is done in the tank to acquire a certain type of crude at some specific gravity (usually sp. Gravity = 0.867). From the tanks it goes to the processing unit.
The tank area is as shown in figure

Crude Oil Tanks

Future Tanks

Crude Oil Tanks

Blending Tanks

Process Area:
The various different processing units & their capacities are given below: Unit / Facility Capacity (MMTPA) CDU / VDU/ SGU 10.5 Amine Wash & Regeneration 400 T/D* Visbreaker 1.9 CCR 0.9 Naphtha Hydrotreater 1.36 Diesel Hydrotreater 3.3 FCCU / UGS 2.9 Kerosene Treating Unit 0.63 Gasoline Treating Unit 0.5 Saturated LPG Treating Unit 0.28 UNSAT. LPG Treating Unit 0.29 FCC FGD Sulphur Recovery Unit 2x220 T/D Sour Water Stripper Unit 166 M3/hr

Technical Details:
The plants occurring in order are CDU(Crude Distillation Unit)/VDU (Vacuum Distillation Unit)/SGU(Seperator Gas Unit) VVU /treators CCR (Continuous Catalytic Reformer) &NHT (Naptha Hydro Treators) Hydrogenation Plant FCCU (Fluidised Cracking Catalytic Unit)/ FGD (Fuel Gas Distillation) DHDS (De-Hydrogenation De-Sulphonisation) SRU(Sulphur Recovery Unit)/ ARU (Aeromatic Recovery Unit)/SWS (Sour Water Stripper) PIT Area LPG/Hydrogen Unit Dispatch area o Truck Loading o Rail Loading o Tanker loading It also has utilities like Sea water treatment plant Cooling Tower Distillation tower PFO tank Power Plant & Switch Yard The working of the plant can be shown by the figure

Labs:
There are different labs in the plant for various testing they can be given by following diagram

The control Unit is like all the other control units & the reaction valve time is approx 45 seconds for complete closure.

Reliance Refinery
About RIL:
Reliance industries needs no introduction since it is the largest multinational company of India and 1st private Indian company to be listed into the fortune 500 list which has turnover of 29.7Billion US$ and the Net profit is US $ 5 Billion. The importance of Reliance in Indian market ortance o 3% of Indias GDP o 13.4% of Indias export o 4.9% of Indias direct & indirect tax revenue o 7% Profit of the entire corporate sector It is a backward integrated company unlike most companies it has started producing the end product 1st & then gone to producing & refining the raw material
The backward integration of the company

Motto:Think Big, Think Long Term, Think Growth.

Introduction:
Reliance's Jamnagar complex represents the largest industrial project ever implemented by anyone agar from the Indian corporate sector. The Jamnagar complex is a fully integrated manufacturing facility,
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with a petroleum refinery complex, an aromatics/petrochemical complex, a power generation complex and a port and terminal complex that provides access to a pipeline network. The high degree of integration at the Jamnagar complex allows for feedstock and product linkages that continue to lead to higher efficiencies and enhanced value addition.

Some facts:
It is the largest refinery in India. 3rd largest in the world but with the sanctioning & starting of the new refinery it will become the undisputed leader It is even today the largest grass root refinery in the world It was built in a record time of 36 months with a mammoth investment of US $6.6 Billion The sanctioning of all the 40 units including the petrochemical complex were done in the span of 5 months The refinery can refine up to 660 K bbl/day & with the new refinery sanctioning the capacity will be increased by 580 kbbl/day This is far more than any other refinery in the world. The plant also has its own 450 MW power plant The plant also has a fully functioning Jetty
The figure shows the old & new refinery respectively

Production process flow flow:

The refinery complex at Jamnagar has more than 50 process units, which together process the basic feedstock, crude oil, to obtain various finished products deploying the following major refining processes: e Crude oil distillation (Atmospheric as well as vacuum distillation) Catalytic cracking (Fluidised Catalytic Cracker) Catalytic reforming (Platforming) Delayed Coking

Processes & Working:

The following simplified schematic diagram shows how crude oil is refined to obtain various finished products.

The CDU unit: CDU has a 2 stage desalter to reach salt content PTB of crude & 2 kerosene drums for heavy & light kerosene respectively. Hydro treatment Unit: It removes sulphur & nitrogen and converts Olefins /Aeromatics to saturated compounds. Oxygenation unit is also a part of this unit. VGO (Vacuum Gas Oil)Hydrotreatment: il)Hydrotreatment: This is a different unit here which increases parafinity of crude oil as it is favourable for cracking. It pressurises gas to 105 kg/m3 . DHT (Digital Hydro Treatment) plant reatment) plant:

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It is equipment which helps in treatment of high quantity of crude. The hydrogen partial pressure increases the treatment is higher. FCC: Unit here is the largest with capacity is 205 KBPSD. Coker: It is a larger form of VBU Unit and thermal cracking is done here to break larger molecules into small molecules. Cracking is done under high pressure & High residence line. For cracking purpose Merox (merkapton oxide) are used as catalyst. There are 3 types of Merox used at different stages 1. Gasoline Merox 2. LPG Merox 3. Cero Merox TAME (Tertiary Amyl Methyl Ethane) is produced by this unit so is SKO/tame Hydrogen Unit: To meet requirements of hydrogenated hydrocarbons because now a days Hydrocarbons with less carbon & more hydrogen are required. Sulphur Unit: CBA(Cold Bed Absorption) of Sulphur is done and Glaus reaction is used to remove Sulphur . Aeromatic Plant: Designed to produce Para- & ortho- Xylenes from naptha feed to obtain mixed xylenes (C7+C9=C8 this reaction is used) There are also Utilities like Water, Air & off-set system.

Jetty:
The jetty is used to load & unload marerial on the ships. The ships have to wait at a point in the sea before they are allowed; a survey is done then via pilot ship it is brought at the jetty are along a single path (this path is lighted by red light in left & green light on the right at night). This is done so that the ship can come in if the ship drifts from the path it will get stuck up. Once it is brought to the area it is unloaded or loaded according to the requirement. The jetty area is divided into 3 main sections: 1. Platforms: This is used to unload & load the solid materials There are 3 platforms A- lower, B-Middle , C- Higher loading & unloading decks Some times for heavy loads crane is also used 2. Jetty The jetty area is used to load & unload the liquid components The ship is brought by the pilot boats & is anchored & held close to the docking area by Mooring & Breastling dolphins There are 4 docking areas Alpha, Bravo , Charlie, Delta.
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Alpha has 2 arms while other 3 areas have 3 arms The crude to be loaded or is unloaded first goesto the COT before it goes to its various directions When more than one component is used in a single pipe than purging is done with the next material used till our material comes out 3. SPM(Single Point Mooring) This is used to unload large ships as they cannot come inside the docking area. So SPM is used The SPM has a rubber pipe & a 360 for easy attachment with ship This is so that the pipe does not break because of constant moving of the ship A-Elephant is used for testing There are 5 SPMs & 1 in spare The component is brought to the jetty area via 2 black pipelines This is all controlled by control unit at the jetty area this is all very efficient & automatically controlled.

Refining Processes:
Alkylation:
Alkylation is a process for chemically combining isobutane with light olefinic hydrocarbons, typically C3 and C4 olefins, (e.g.propylene, butylene) in the presence of an acid catalyst, usually sulphuric acid or hydrofluoric acid. The product, alkylate (an isoparaffin) has a high-octane value and is blended into motor and aviation gasoline to improve the antiknock value of the fuel. The light olefins are most commonly available from the Catalytic crackers. Alkylate is one of the best gasoline blending components because it is a clean burning, very low sulphur component, with no olefinic or aromatic compounds and with high octane and low vapour pressure characteristics. The Indian scenario is unique, in that on the one hand, the relative gasoline consumption is much lower vis a vis the developed counter parts, on the other hand, the C3 and C4 components, which are otherwise used in alkylation as a feedstock, offer much higher value alternative, i.e. LPG.

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LPG is in large deficits in India, and to meet its demand, Reliance's configuration is designed to maximize the production of LPG. Hence the processing scheme currently does not include Alkylation.

Bottom of the Barrel Processing:

"Bottom of the barrel" is a term used to refer Vacuum residue (VR) boiling above 5650C. It is produced from bottom of the Vacuum Distillation Column. Traditionally this material, high in sulphur, asphaltenes and metals has been blended into heavy or industrial fuel oil. Outlets for high sulfur fuel oil are becoming increasingly scarce, with stringent emission norms for SOx and NOx . In the most parts of the world, increasing switch over from heavy fuel oil to clean combustion natural gas for power generation is already evident. The process of displacing high sulfur fuel oil is expected to gather further momentum as further switching from fuel gas to natural gas takes place for environmental and availability reasons. There are several options for the bottom-of-the barrel processing including Delayed Coking, Visbreaking and Resid Desulfurization. Reliance has selected Delayed Coking for upgrading the "bottom of barrel".

Catalytic Cracking:
Catalytic cracking is a process which breaks down the larger, heavier, and more complex hydrocarbon molecules into simpler and lighter molecules by the action of heat and aided by the presence of a catalyst but without the addition of hydrogen. In this way, heavy oils (fuel oil components) can be converted into lighter and more valuable products (notably LPG, gasoline and middle distillate components). The catalytic cracking unit is known as the Fluidized Catalytic Cracking or FCC. The FCC is the most widely used secondary conversion process in the refinery industry. Traditionally, the FCC units have been operated on either the maximum gasoline mode or the maximum distillate mode, dependent largely on the seasonal product demand pattern. Of late, a third mode is gaining importance, that of a maximum olefin mode which maximizes LPG, propylene and butylene. In India, FCC in the max olefin mode is suitable for maximum value addition because LPG and propylene are among the highest value petroleum products. Reliance operates the Jamnagar FCC in the max olefin mode, to maximize LPG and propylene. FCC in the max olefins mode also produces isobutylene which can be used for MTBE, isobutane and butylene which can be processed into alkylate and isoamylene which can be used for TAME. MTBE, Alkylate and TAME are principal gasoline additives used to improve gasoline quality. Reliance utilizes the isoamylene from the FCC as a feedstock to produce TAME in the Jamnagar Refinery.

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The FCC feed is also known as vacuum gas oil (VGO) because it is generally a product from the Vacuum Distillation Column. The FCC feed can be of three types:

VGO Hydrotreated VGO VGO mixed with VR (Process is known as Resid FCC or RFCC).

The VGO material for the FCC feed is generated from the Vacuum Distillation Column in the CDU/VDU and from the Coker.

Delayed Coking:
Delayed Coking is a high severity "Bottom of the barrel processing" scheme by which heavy crude oil fractions can be thermally decomposed under conditions or elevated temperatures to produce a mixture of lighter oils and petroleum coke. The light oils can be processed further in other refinery units or blended into products. The coke can be used either as a fuel or in other metallurgical applications such as the manufacturing of steel or aluminum. The Delayed Coking process achieves approximately 70% of residue conversion to lighter products compared to only about 30% in Visbreaking. Reliance has selected Delayed Coker to maximize conversion to higher products. Reliance, with a large Delayed Coker to handle 100% of Vacuum Residue, is able to achieve much higher value addition and "zero fuel oil production".

Distillation (Atmospheric and Vacuum):

This is the first stage in the refining for separating crude oil components at atmospheric pressure by heating, and subsequent condensing, of the fractions (unfinished petroleum products) by cooling. Distillation under reduced pressure (less than atmospheric) i.e. Vacuum Distillation lowers the boiling temperature of the liquid being distilled permitting the production of distillates at lower temperature than would be necessary in atmospheric distillation, thus avoiding coke formation. The Jamnagar Refinery has a combined Crude Distillation Unit / Vacuum Distillation Unit (CDU / VDU) to separate the crude oil into primarily fractions of LPG, Naphtha, Kerosene, Gasoil, Vacuum Gas Oil and Vacuum Residue. The combined CDU/VDU maximizes energy integration to minimize the energy required for primary separation.

Hydrotreating:
Hydrotreating is used for treating petroleum fractions in the presence of catalysts and substantial quantities of hydrogen. Hydrotreating results in desulphurisation, (removal of sulphur), denitrification (removal of nitrogen compounds) and conversion of olefins to paraffins.

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Reliance has the highest Hydrotreating Capacity relative to crude distillation which enables it to produce world class products and high value addition.

Oxygenates:
Oxygenates are ethers which are used as gasoline additives to improve the gasoline. Two principal oxygenates are Methyl Tertiary Butyl Ether (MTBE) and Tertiary Amyl Methyl Ether (TAME).

Reforming:
Reforming Process rearranges hydrocarbon molecules in the naphtha (or naphtha type) feed, thereby converting paraffinic and naphthenic type hydrocarbons into aromatic type hydrocarbons, suitable for blending into finished gasoline. Since its product, reformate, is richer in aromatics than its feed, naphtha, this process is also used to produce aromatic petrochemicals (Benzene, Toluene and Xylene). The Reforming process requires high temperature and catalyst to facilitate the reaction. The Reforming catalyst contains Platinum. The Platinum based catalyst has to be protected and hence reformer feed has to be sulphur free.

Thermal Cracking:
In this process, heat and pressure are used to break down, rearrange, or combine hydrocarbon molecules. Thermal cracking includes vis-breaking, delayed coking, fluid coking, and other similar processes.

Vis-breaking:
Vis-breaking is a relatively mild thermal cracking process in which heavy atmospheric or vacuumdistillation bottoms are cracked at moderate temperatures to make light products and produce a lower viscosity residue than the initial feed to the unit. Vis-breaking process achieves about 30% of residue conversion to lighter products. Vis-breaking is one of the least costly upgrading processes, and is common where there is still a relatively large use of heavy fuel oil. But with the problems of fuel oil compounding the world over, the importance of this process is expected to decline. Sweetening the petroleum products should be free of mercaptans (a form of sulphur compound) because otherwise it emits foul odour on burning. Sweetening is a process of mercaptan removal by oxidation. This sweetening process is also better known by the patented process name of Merox or mercaptan oxidation. Reliance has 4 sweetening units to remove mercaptans from Saturated LPG, Unsaturated LPG, Gasoline and Kerosene.

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ONGC WSS
Introduction:
In well production stage if the well gets depleted by any reason, it results in low pressure of formation conditions of that well. Thus WSS methods are used for enhancement of productivity of the well. The WSS technique to be applied depends on reservoir history and formation characteristics.

Process Involved:
There are different processes which we can include in WSS are Hydraulic Fracture, Acid Treatment, Sand Control, Nitrogen Injection and Coiled Tubing Unit.

Hydraulic Fracturing:
A tube of smaller diameter like 1, 1 has been inserted into the drilled well for stimulation. We make a special gel and slurry which can be inserted into the well to open the chocked production casing. Depending on pressure, temperature and depth we should make these things. By inserting the gel into the cracks we remove the blockage and hence create a path to let the hydrocarbon flow. After it we remove gel from the production pipe and again we got the normal production or production of hydrocarbon fluid with some reduced pressure.

Acid Treatment:
When damage in formation occurs we do Acid Treatment for remove the damaged part and its used for deeper where the well bore is away from the formation region. We pressurized the annuals and then acid is pumped into the well and this way we can open the production path for the hydrocarbon fluid.

Sand Control:
when in unconsolidated part the sand collapse occur sand control methods uses to protect the wall. And hence we can isolate the system.

Nitrogen Injection:
In Nitrogen Injection is we convert the liquid nitrogen into hot nitrogen gas and inject into the well so that blockage of sand and other particles has been removed and the clear path is made to flow the hydrocarbon fluid.

CTU (Coiled Tubing Unit):

Its a two tubing operation for removal of sand from the Formation. Used to avoid installation of a particular rig for particular well. Process Carried out by lowering coiled tube inside production tubing and clear obstruction that reduces flow. Also known as foam treatment.

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Hot oil circulation:

Hot oil with temp around 82 degree centigrade is circulated through the well to clear wax and sand formations from the tubing.

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Introduction:
Hazira (Surat) Port, is a deep-water, all-weather, multi-cargo port, which will be a significant infrastructure asset to the state of Gujarat. Hazira ( Surat) Port is designed as a deepwater, all weather and direct berthing port. It is situated in the state of Gujarat on the west coast of India, is about 25 km from Surat and 120 nautical miles north of Mumbai. It is built with a harbour design with additional waterfront for development of non-LNG cargo handling terminals. Hazira (Surat) Port is planned as a Gateway Port to serve the hinterlands of North, West & Central India. It has the added advantage of possessing a highly industrialized immediate hinterland, where the container traffic is expected to grow at over 13% Hazira (Surat) Port has an approach channel of about 1000 m, turning radius of 600 m and dredged depth of (-12) m chart datum with a capacity to accommodate larger vessels using tidal variance. The expansion of the functionality of the port to handle Containers as well as bulk cargo will involve additional investments potentially up to another Rs 3000 crore.

What is LNG?
Liquefied Natural Gas, or LNG, is a clear, colourless liquid that forms when natural gas has been cooled to -162C. It is odourless, non-toxic and non-corrosive. In its liquid form, natural gas is more efficiently stored and is economic to transport in dedicated LNG carriers overseas to receiving terminals. Indeed, converting natural gas into LNG is the only viable way to transport natural gas to places that are beyond the reach of pipeline systems. In liquid form, natural gas takes up 600 times less space than it does as a gas.It is like shrinking the volume of a beach ball to that of a ping-pong ball. LNG is warmed into a gas again where needed (known as regassification) and introduced into the existing natural gas pipelines. From there it has residential uses (e.g. heating homes, cooking); commercial uses (e.g. heating buildings, providing fuel for natural gas transport); and industrial uses (e.g. as a fuel for turbines that produce electricity).As the world searches for greener forms of energy, demand for natural gas the cleanest-burning hydrocarbon is expected to double over the next two decades. Power made from natural gas transported as LNG typically emits about half as much carbon as coal, even with the extra energy needed for liquefying and shipping.Natural gas liquefaction dates back to the 19th century when the first practical compressor and refrigeration machine was built in Germany in 1873. Although the first LNG plant began operation in 1917 in the USA, significant commercialization did not get underway before 1941, when the first commercial liquefaction plant was built. LNG is already a growing part of the worlds energy supply and is produced in many countries that have abundant natural gas reserves and facilities to produce LNG for export. These facilities include:
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Storage facilities: used for keeping a reliable supply of natural gas close to consumers Export terminals: used for liquefying and transporting LNG from production regions Receiving Terminals: used to regasify natural gas for delivery to consumers.

The LNG Chain

LNG Chain is shown in figure

Production Process Flow & Details:

The Shell Hazira Plant does the Re-gasification of LNG. The gas supply to the national grid after doing pressure maintenance.

Processes:
1st a Carrier ship of LNG is boarded on the jetty 1 carrier ship carries approximately 75,000 to 1,45,000 m3 of LNG in their cryogenic

Cryogenic tank is the storage tank in the carrier ship & the breastling & manoovering dolphins are used to attatch the ship to the jetty

The breastling & manoovering dolphins are used for attaching & docking the carrier ship on the jetty docking area After the ship is docked the 3 arms in the header are attached to the cryogenic tank to take out the LNG The arms joint to the cryogenic tank with joints called swivel joints

The arms are The 3 central structures in figure

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The middle one is the vapour arm & the other 2 are the liquid arms

The flench size of the arm is according to international standards so that it fits on the hole of the Carrier ship f The LNG is pumped out by carbon pumps at the speed of 10,000 m3/hr There is also a gang way tower is used to go to the ship The vapour arm is used to supply some amount of gas back to the ship so that vacuum is not developed inside the tank The pumped out LNG is taken to tanks via pipes of special material so that cryogenic temperature is maintained The pipe is connected with the arm with the choke manifold
The schematic diagram is shown in figure

The pipe caries the LNG to the tank. The tank is specially made to store the LNG

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The tank is as shown

The bottom of the tank there is the slab heater so that it absorbs the heat of the ground The Annular space is between the inner tank & the outer tank it is filled with perlite as it is an insulator There are 2 storage tanks at shell hazira plant. Their configurations are Design standard of steel -- PPI620 Approximated capacity Outer surface diameter Inner tank diameter -- 1,60,000m3 -- 72 80 m -35 40 m

The LNG from the tank goes to the Recondensor as the LNG when travels in pipes it losses pressure & temperature so to maintain them & help in the formation of CNG it is recondenssed & recompressed\ While the BOG(Boil Off Gas):-The gas which is formed from LNG in the tank .Some of it goes to the vapour arm & the other part is treated & then again goes to the BOG condenser & then send to the recondensor & then to the vapourisers If less amount of consumers are there then the BOG is passed through the MSO(Min Sent Off) where it is compressed to the 80kg/m3 level The gas obtained from the vaporizer is also of 80kg/m3 level The outlet of the tank are from the top this is because if it is taken from the bottom two main types of errors occur 1. Stratification :- In the LNG terminal different kinds of LNG come via different kinds of station so if top inlet then the LNG with higher density that comes slowly will be at the top & as it moves down homogeneity is achieved but if at

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bottom den strata of LNG is formed this is called stratification. This leads to another problem called roll over 2. Roll Over :- Due to stratification the heat absorbed is not equal so higher density fluid at bottom absorbs more heat expands & moves up leading to Roll over this leads to more BOG & thus leads to more heat generation & cracking of the tanks. Thus the top entry & top leave mechanism is preferred in tanks & recondenssors

The recondenssor

The LNG from the recondenssor flows to the Vaporizers ORV(Open Rack Vaporizer):-In this vaporizer sea water is pumped up & is made 1. to flow around the LNG pipe. As the water is at room temperature &the LNG at -160C so the temperature increases & gas is gormed this gas is compressed as it is directly obtained from LNG

The fig of ORV is as shown

2.

SCV(Submerged Combustion Vaporizer):-In it some of the gas is burnt to heat the container of water & the LNG pipe is passed through it so its converted to gas
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This system is costly so it is used as a backup system

The fig of SCV is as shown

After the vapourizer the gas is compressed to the required amount before send off Before send off gas Chromatography is done to know the calorific value of gas & to get actual worth of gas that is being sent

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Gujarat Gas
Introduction:
Gujarat Gas Company Limited (GGCL) holds the distinction of being Indias largest private sector player in the natural gas transmission and distribution business. Incorporated in 1980, with the primary objective to procure, distribute and utilize natural gas and allied technology, GGCL pioneered the concept of combined natural gas distribution to the industrial, commercial and domestic customers. Today, it supplies gas to more than 265000 domestic, commercial and industrial customers and serves over 100000 Compressed Natural Gas (CNG) users. GGCLs pipeline network is spread over 3000 kms. The corporate office of GGCL is in Ahmedabad and its area of operations is spread across various districts of Gujarat, including Surat, Bharuch and Valsad. In 1989, the company began its operations in the industrial hotspots of Ankleshwar and Bharuch in South Gujarat. In the year 1991, GGCL expanded its operations to Surat, the diamond and textile powerhouse of India. Its CNG operations started in 1992. The first CNG station of India was setup in Surat. The company has been a part of the BG Group portfolio since 1997. BG Group has a 65.12% controlling stake in GGCL. FIs, FIIs and public hold the remaining 34.88% of shares. However, GGCL plant at Hazira which we visited is CGS (City Gas Station). The gas is distributed from the plant to the nearby industries and to LDZs (Local Distribution Zones). The distribution is done through Hazira Ankleshwar pipeline. The plant has capacity of transporting 3500000 SCMD (Standard Cubic Meters per Day) of gas. The major sources of Gas input to the plants are PMT, GAIL, Niko, Cairn etc. while main Customers are GFCL, ESSAR steel, Gujarat Glass and LDZs.

Production Process Flow:

GGCL has a wide network of underground pipe lines, approximately 2700 kms. These comprises of mild steel (MS) and polyethylene (PE). Through these lines gas is supplied to Residential, Commercial and Industrial customers. At present GGCL has a base of approximately 230,000 PNG customers. Gas is supplied to these customers through pressure reduction stations which are called as IPRS (Industrial pressure reduction) or DPRS. Majority of the gas sales happen through long term contracts signed between GGCL and customers, there are very few instances where sales is done on spot basis.

Domestic Customers
These are also called as residential customers. This set of customers primarily use gas for cooking purpose and also for heating water through gas geysers. Growth of this segment is expected at a rate of approx 20% per annum. This is majorly being adopted as an attractive alternate for LPG.

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Commercial Customers
These customers are grouped into majorly 3 segments - Commercial, Non commercial and YHS. Commercial customers comprises of Hotels, restaurants, dairies, bakeries, educational institute etc. Customers like temples, NGOs are covered under non commercial category. GGCL has 2 years back launched a specific application for yarn heating; customers using gas for this specific purpose are grouped as YHS. Majority of the operational processes are common to domestic category.

Industrial customers
These customers are large volume customers spread across various segments of business like textile, pharmaceuticals, glass, chemical, ceramic, dyes and intermediates, agrochemicals, pulp & paper. They constituent the major portion of the total gas sales. There are approx 1000 small to large industrial customers across Surat and Bharuch district. Gas is used by these set of customers for applications like

Heating - Boiler, Thermic fluid heater, Furnace Cooling - Absorption chiller Power - Gas engine, Gas turbine Process - Direct firing of Stenters (Textiles), Dryers, Furnace, Ovens, Feedstock for Fertilizer plants...

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ONGC Hazira
About ONGC:
ONGC (Oil & Natural Gas Corporation of India) deals with exploration & production with reserves of approx. 1 billion tones is under exploration. It produces approx. 1.1 billion bbl/day of oil and 8.8 MMTPD of gas. It has a pipeline on land of approx 22000 Km. & sub sea of 4500 Km. It has 39 projects & 74 existing on-shore projects with 70 Off-shore & Approx 68-70 work over rigs. Its annual turnover for the last year was 872 crores.

Introduction:
ONGC Hazira is situated on the banks of the river Tap and site extends upto 705 hector with 30% green belt. Refining of crude & gas is its main work. Its major products are Natural Gas, Naptha/NGL, Sulphur, SKO (Superior Kerosene Oil), HSD (High Speed Diesel), ATF (Aviation Turbine Fuel). ATF is there main product & also most unique & best quality in India. It is the only plant to produce ATF from condensate. It also generates power via gas turbines. Approx 67 MW of electric power is generated. The plant generates a revenue of 18-19 crores/day = 1.3 lakh/hour

Production process flow:

Gas Reception Terminal (GT) :- To receive gas & condensate & distribute it to the various units Gas Sweetening Unit (GSU) :- Sweetens the gas i.e. removes excess H2S Gas Dehydration Unit (GDU) :- Removes water & other liquid components Dew Point Depression Unit (DPDU) :- Removes Liquid hydro-carbons for effective transport Sulphur Recovery Unit (SRU) :- Converts H2S to non-toxic components by removing sulphur Sour Condensate Processing Unit :- This unit is used to remove H2S from the condensate Condensate Fractionig Unit (CFU):- Seperates the components of the condensate according to boiling points L.P.G Unit :- To get various gaseous products from LPG Kerosene Recovery Unit (KRU) :- This is where all the kerosene products like SKO, ATF, HSD are produced

Technical Details:
Working & Outline:
The gas comes from the field of Vassai (earlier Bassein ) which is located 80 km North- West (NW) of Mumbai the well there is 30 km deep Here the gas comes via two lines there are two lines for different roots & different pressure 1. 36 inch diameter pipe -231 Km long 2. 42 inch diameter pipe -244 Km long
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This gas goes to the gas terminal After this the procedure is as shown:

There are 3 GSU units & similar no. of GDU & DPDU units LPG from CWU goes to the LPG storage tank these tanks are circular in shape because it has minimum stress While as in figure the gas goes to the HBJ (Hazira Bijapur Jagdishpur) pipeline The Dispatch modes for the other products are road, rail wagon & pipe line.

Products and Its Quantities Produced:

LPG >3000 m3 /day Naptha >5000 m3 /day SKO/ATF >600 m3 /day ARN(Aeromatic Rich Naptha) > 16500 m3 /day Propane >200 m3 /day HSD/Diesel >60 m3 /day (this is not for sale it is for internal use only)

Control Unit:
There is a separate Control Unit for Gas & Condensate & for LPG/Naptha/ATF All the main valves can be controlled from these control centres The valves can be controlled centrally & localy Each movement & pressure change can be measured & kept under control by these valves The pressure, temperature, flow & other important readings can be observed on the screen then the valves can be controlled automatically manually by the computer or physically on the site spot itself. The reaction response is directly but the valves take time to close In case of emergency shut down the whole plant can be shut down in the time of 2.5 min
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GSPC Niko
Introduction:
Hazira is a 50 sq. km. gas field located 35 kms south-west of Surat city, Gujarat. Two-third of this field lies offshore in water depths of 20 meters. While taking over, the field was estimated with reserves of 50 million m of gas with one well drilled by the national oil company. After taking over, GSPC-Niko commenced production in July 1995 after workover of Hazira well #1. Thereafter, 5 onland wells were drilled, which upgraded the in-place reserves to more than 20 BCM. Since the reserves extended up to shallow offshore, a unique 100 sq. m. Land Based Drilling Platform (Ratnakar), the first of its kind in India, was constructed in water depth of 10 to 12 meters. The land based drilling platform is connected to land by a 1.5 km long causeway, which facilitated movement of land rigs, men and materials. Seventeen wells were drilled from the LBDP. Thereafter, to probe further offshore, an offshore platform was constructed about 4 km away from coast in water depths of 20 meters. Out of sixteen wells required to be drilled from the platform, 6 wells have been drilled so far. At present, production from Hazira field is 4 MMSCMD which is likely to go up to 5.5 MMSCMD after drilling all wells from the platform. GSPC - NIKO has also finalised a plan to drill oil well for offshore platform and produce oil at the rate of approximately 2000 BOPD.

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Production Process Flow & Details:

Drilling site[LBDP(land based drill points)]:
Drilling site is where the gas is drilled out its an onshore drilling site The drilling site had 4 wells Out of which 3 were straight wells &1 was a slanting well The wells are about 1200 meters deep After the well is drilled the casing is completed then a Well Head or A Christmas Tree as it is called is put on the pipe
A wellhead is as shown

In this structure from the top (1) pressure gauge: which records pressure in the well (2) crown valve :which adjust the pressure (3) 2 wing valves on either side (4) Upper master valve : adverse control valve to control any anomaly in well pressures (5) Lower master valve : First valve to control any anomaly in well pressure (6) Then below & on the side of the structure theres a casing valve & ahead that is casing pressure gauge which helps to control pressure on the casing

Near the production wing valve is the flow line where the oil or gas flows out of the well & just before the flow line is an ESD(Emergency ShutDown valve) which shuts down & ensures that there is no accident caused if the pressure exceeds 40psi

{
1 well has dried out & for further exploration a rig has been placed there The derric of the rig is placed at1 -3 angle so that the pipes & the kelley do not touch or hit it during the drilling process The pipe is attached with a makeup backup tongs to the Hook for drilling

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There is also a blow out preventer(Bop)which if the pressure suddenly increases inside the well it shutdownd the whole system

}
After the oil & gas is removed from the wells it goesd to the KOD (Knock Out Dump) in which the gas is separated from the very little amount of oil & water the other dumps are also removed this is by their densities The KOD contains a SRV(Safety Release Valve) Which helps in controlling the specific amount of pressure in the KOD The KOD also contains an ESDV which shuts down the system if pressure exceeds maximum pressure From the KOD the gas goes to the Test Separator where it is further separated & the Test Separator line in both heat is used to separate gas From this 2 pipes go to the main gas production unit

Gas & oil production unit:

It is the production site from which the oil & gas is produced & distributed to GSPL to distribute it for various purposes The 2 lines each from the onshore wells & off shore well are brought to this site In each of these onshore & off shore There are 2 lines 1. H.P Line : High Pressure Line primarily gas content 2. L.P Line : Low Pressure Line Primarily oil content They pass through the Cathodic valve after this there is an ESDV Then both gas & oil go to separate intake headers Here some amount of extra gas is removed to maintain +ve pressure this gas is called Purge Gas This gas is burnt to avoid air pollution this process is called Flare
Flare is as shown

Now from intake header the path of oil & gas are separated 1) Gas Then the gas flows to 2 headers 1. High Pressure Header(H.P header) [White one] 2. Low Pressure Header(L.P header) [Yellow one] Gas then goes to a gas separator (Noise level 88.3 dB) It is a 3 phase separator From there it flows to the 1st compressor where the gas is reduced to 10-20kg/m3 pressure Then it flows to the
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DPCU(Dew Point Control Unit):-It use propane for chilling so that moisture is removed & glycol is injected to stop the moisture to form ice & clot the flow of gas As water particles are removed pressure decreases so gas is re-compressed in the 2nd compressor Then it is supplied to the users or distributors 2) Oil From the intake header the gas flows to the Oil Header [Black one] This oil is stored in Oil Batteries this will separate some more gas this ensures that no gas is carried into the separator Then it goes to the Oil High Pressure separator (H.P separator) which uses gas valve to push the oil with pressure At the outlet of these separators there are also Mobile Test Separators (M.S.T) these are used for PVT analysis & if some thing wrong (eg more water content) they can divert the flow Then BSW (Bottom Settling Water) is carried out where oil is heated so that the water is removed Then the Oil goes to the Production Tank Then to the Slope Tank where oil is skimmed out This oil goes back to the Production Tank From there it goes to the Shipping Tank from there it goes to the users Safety in this process is necessary .The safety measures are 1. There is a foam tank which contains a balloon filled with chemicals if pressure increases the balloon expands releasing chemicals thus preventing fire 2. There is an Emergency Tank for emergencys like riots strike etc. which stores the oil
The tanks are as shown

There is a control unit which monitors these activities via DCS(Distributer Control System), Flow meter, Moisture meter There is also an Oil loading Plant used to load oil in tankers .It has 2 pressure Loadings are used 1. FTHP->Flow Tubing Head Pressure 2. STHP->Shut Tubing Head Pressure o Before that it goes to the Bullet Tank where it is stored o The oil is then Pumped into the tankers ny Hanger Loading o Here oil is brought to the Hanger loading area via a pump o Water, pressure, mass analysis all are done before loading o LRC meter are used for loading measurement it stops loading when the tanker is full there is always a preset value which when reached the tanker is said to be full o ESDV are fit at all points to shut down immediately if adverse pressure condition is observed

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Earthing is also done to prevent static charge due to some amount of gas inn the pipes This oil & gas then goes to the users via different channels Before the gas goes there gas chromatography is done to get the actual calorific value of the gas Besides this there is also an ETP-> Effluent Treatment Plant :- to treat the water that is used in the plant it contain o Fillent Treatment Plant :- treatment of water to maintain BOD, COD o Tilt Plate Interceptor (T.P.I):- To remove oil species. o Chemical Dosing via Pexol, Pac & Lime is done to maintain POD, COD o Primary Settling Tank (P.S.T):- This is used to remove slug o
The figure of primary settling Tank is shown Below

Tank for storage(Slug is formed here)

Sieve Present that removes the unwanted slug from this region

Control Unit:
There is a control unit which monitors these activities via DCS(Distributer Control System), Flow meter, Moisture meter All this is controlled automatically or manually from the centre This can also be controlled locally by valves at the points All valves are centrally controlled & monitored In case of a leak then first that unit is shut down & not the whole part isolation of the unit can also be done via these valves The reaction time of the valves depends on the conditions But normally a valve closes completely in 1.2 -1.3 minutes of signal given So in case of an emergency the plant can be closed down maximum in 15 minutes

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GSPL
About GSPL:
GSPL, a GSPC subsidiary, has taken a lead in developing energy transportation Infrastructure in Gujarat and connecting major natural gas supply sources and demand markets. Gujarat State Petronet Limited is first company in India to transport natural gas on open access basis and is a Pure Natural Gas Transmission Company.

Gas Transmission Network:

GSPL, a GSPC Group company is a pioneer in developing energy transportation infrastructure and connecting natural gas supply basins and LNG terminals to growing markets. GSPL is continuously expanding its pipeline network in Gujarat to to reach the demand centres by laying gas pipeline network. The company has developed requisite expertise and confidence with proven project management competencies.

Open Access
GSPL is first Pipeline Company in India operating on open access basis and is a pure transmission network. The transmission network of the company envisages development of systematic and seamless pipeline network across Gujarat connecting various suppliers and users. The suppliers of natural gas include traders, producers and LNG terminals. The users comprise industries such as power, fertilizer, steel, chemical plants and local distribution companies.

Highlights of Gas Grid Project

1420 kms of gas pipeline in operation from Hazira-Vadodara-Ahmedabad-KalolHimmatnagar-Mehsana-Rajkot-Morbi-Anjar-Jamnagar. Transports more than 36 MMSCMD of gas currently. 450 kms of gas pipeline under execution. Advanced engineering practices that provide efficient Natural Gas Transportation GSPL gives 4 EOIs to PNGRB for extending its Natural Gas Transmission System across the country Grid Length - 5675 Kms.

Working and Details:

Working:

GSPL is a transporter of gas it takes gas from sender to receiver this is done at various pressure according to the receiver & senders wishes of pressure

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One such gas grid is as shown

Pipelines transferring gas at high pressure are called transmission lines There are 3 types of such lines depending on the user 1. Domestic pipeline: For domestic use; pressure of about 7kg/m3 2. Low pressure pipeline: For small industries; pressure 7 kg/m3 -15 kg/m3 3. High pressure pipelines: For heavy industries; pressure 15 kg/m3 or higher Unlike GAIL ,GSPL works on an Open Carrier Principle:- It works as an open transfer from buyer to end user they do not own the gas but transfer it only. The price of gas id about 10-20$/mm3 The total price earned by GSPL is about % -1% They have a std. Design to allow upto 95 bar pressure While the grid usually carries 60 bar Pressure The 1st pipe line was from Mohra- Hazira for Nikko it was a 14km long & 36 inch wide pipeline .It was Low pressure pipeline At every inlet & outlet points of gas Gas chromatography is done every 5 seconds. This ensures the quality of gas intake from each company & the quality of gas supplied On this billing is done

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The pipeline map is shown below

Loop Line: It used to increase efficiency its parallel to the main pipeline

Risks:
i. ii. iii. iv. Over Run :- If company extracts more than the contract Under Run :- If company extracts less than the contract If under any condition like riots or strike to keep the additional gas inside the problem Gas leakage leading to fire

Prevention & Cure:

1. Taping of pressure & velocity is done at interval stations at every 15 to 20 km by SCADA system o In SCADA system fluctuations , low pressure jerks recorded show leakage 2. Fire does not occur inside the pipes because of lack of oxygen 3. In case of a leak first the customers are in formed 4. Then the leaked gas pipe is isolated by valves & the gas is allowed to flow out from the sides 5. Gas is released in a stop start fashion 6. The reaction of the valves is maximum 30 seconds to the change at the control station. The 36 & 42 inch valves take 30-34 seconds & normal small valves take 15 seconds 7. Carbon steel Pipes are used for less damage.

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GSPC Gas
Introduction:
There can be no doubt that Natural Gas is the fuel of the 21st Century. As a progressive company, Gujarat State Petroleum Corporation (GSPC) has always tried to identify new trends and prepare itself for the future. We at GSPC Group are laying the groundwork and preparing ourselves for the future. The GSPC Groups foray into Gas Distribution in a big way bears testimony to our core philosophy of being A Complete Energy Company. Role: The role of GSPC Gas is envisioned to be complementary to Gujarat State Petronet Ltd. (GSPL). At every location where the GSPL network ends, the GSPC Gas retail network starts. This has resulted in a strong synergy in network management besides ensuring that Gas is adequately available to all retail segments in Gujarat. Segments: GSPC Gas is catering to the Natural Gas requirements of all the retail segments, which comprise of industrial, commercial, transportation and residential customers.

Working & Details:

Natural gas is received directly from Hazira plant Sent out after compression from the plant at 230 240 bar pressure
The general layout of the plant is shown below

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On the left side there is an air compressor & its control unit where the gas is compressed to about 20 21 bar
Its fig. is as shown

From there the gas goes into the compressor via a suction line to the main condenser There are 2 compressors 1. Old compressor: 1kg) 2. New compressor: It use Dresser Rand (D.R) Compressing capacity of 250 scm Compressing capacity of 1200scm (0.73scm=

New compressor :- The new compressor is a 3 stage piston compressor the hydraulic
piston compresses one way & the piston returns back due to inertia the gas compressed is taken to the next stage. After each stage of compression there is water cooling this is because the gas expands slightly which makes it easy & better for compression. So the gas goes from 1st stage compression to cooling then to 2nd stage & then to the 3rd stage from that it goes to the cascade. Now in the compressor there is an oil dropper for proper oiling of the piston this is regulated by the heat of the pistons. So no lubricant is wasted.

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This compressed gas is stored in the CNG STORING CASCADE

There are 40 cylinders Each cylinder has capacity 75 kg There are SOV(Solenoid Operated Valve) which controls the flow of gas going outside the cascade This gas goes to the Priority Panel where the gas is separated into three banks 1. low bank: from pressure 50-160 bar 2. mid bank: from pressure 160-180 bar 3. high bank: from pressure above 200 bar
The fig is as shown

From left the banks are Low bank, mid bank, high bank

From priority panel it goes to the dispenser There are 4 dispensers 2 for trucks, 2 sides for cars, 2 sides for rickshaws

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 Each dispenser has 2 main parts a. hoarse :the pipe through which the gas flows the b. adapter: the part which is attached to the vehicle 78 bar pressure is required for the valve to open When the adapter is inserted into the car it gives signal to the mother board the mother board activates the banks from Low bank, mid bank, high bank respectively. Once the pressure is up to the limit then there is an automatic switched off. This can also be controlled by the control centre
The image of a mother board is as shown below

Inside each dispensor there is

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Low bank, mid bank, high bank

In black cylinders at the bottom are the spring loaded assemblers PNG (Piped Natural Gas )is also distributed at slightly lower pressure to different houses from this station

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