SUBMITTED BY:

AAYUSHI LAL

EI-FINAL YR

SUMMER TRAINING REPORT AT

GAIL COPMRESSOR STATION,DIBYAPUR

INTRODUCTION

GAIL- Gas Authority of India Limited

GAIL is one of the MAHARATNA enterprises and ranks among PSU public

sector unit in India.

It was establish in 16th of August ,1984.

GAIL is India’s flagship natural gas company, integrating all aspects of

natural gas value chain (including Exploration & Production, Processing,

transmission, distribution and Marketing) and its related services.

GAIL covers its main portion in (HVJ) Hazira-Vijaypur-Jagdishpur line .In

between this three station there are 6 fertilizers companies and 6 power

plant.

It is one of the largest cross –country natural gas pipeline projects in the

world.

• This 1800Km long pipeline was built at the cost of 17 billion rupees(US$280

million)

DIBIYAPUR REGION Dibiyapur Compressor station is in Auraiya district spread in 1089Kms of

pipeline (from 2” TO 30”) of 18MMSCMD supply.

It is a two stage booster station which boost the incoming gas from Vijaipur

up to 90Kg/cm2 for its consumers.

Compressor station consist 2nos gas turbine generators(GTG), 3nos gas

turbine compressors(GTC) , 2nos of European gas turbine(EGT)

Four Power transformers for the eminent operation of the power system.

For Uninterrupted Power Supply (UPS), there is a battery room containing

Ni-Cd Batteries.

Major customers- PATA, NTPC, IGFCL, IFFCO, BHEL, KSFL, CUGL, GGL AND

TCL.

Sale of NG(natural gas) in DIBIYAPUR region is approx 18 MMSCMD.

Gas Consumers of GAIL

Fertilizer Plant:

Vijaipur

Jagdishpur

Shahjahanpur

Babrala

Phulpur

Power & LPG PLant

Kawas

Anta

Auraiya

Vijaipur

Usar

Lakawa

Aonla

Process and Fuel gas flow diagram At Pressure of 58Kg/cm2, received from GAIL Vijaipur, through 30” HVJ

Pipeline.

This total rich natural gas (Feed gas ) is passed to GAIL Pata, where rich

gas is converted into lean gas, which has 98.5% of C1, is received back at

the compressor station from GAIL, Pata, at pressure of 48Kg/cm2.

Approx. 3.2 MMSCMD of this lean gas is supplied through pressure reduction

skid to NTPC, Auraiya.

However , remaining 6.6MMSCMD of lean gas is compressed in two stages

( Primary & Booster compressor) to get discharge pressure of 90Kg/cm2

5.5MMSCMD is transmitted through 18” Jagdishpur line to fulfill the

contractual requirement of end consumers . IFFCO, Phulpur, IGFCL

Jagdishpur & BHEL, besides city gas consumers at Kanpur and Lucknow. The

balance approx. 1.1 MMSCMD of compressed gas is dumped to 24” Aonla

line.

GAS TURBINE COMPRESSOR (GTC)

It is ALLISON GTC also known as primary compressor of 2.7MW. Its

has a capacity of 175 KSM3/Hr. It can compress 48 -68kg/cm2 .

It has an upstream rotating compressor coupled to a downstream

turbine & combustion chamber in -between.

Like an Internal Combustion engine it sucks air from the atmosphere,

compresses it. The fuel is injected and ignited. The gases expand

doing work and finally exhausts outside. Unlike other gas compressor,

it is a mechanical device that increases the pressure of a gas by

reducing its volume.

GAS TURBINE GENERATOR (GTG)

This power generation system has 2nos of GTG of

each 2.7MW.

They have the same capacity as GTC the only

difference is that it generates high power and work as

a source to boost mechanical energy for other

engine and it is controlled by valve through which it

can be shut-down.

The GTGs are single shaft, multi-combustor type

model of Allison.

EUROPEAN GAS TURBINE

COMPRESSOR(EGT)

There are 2 EGT –A & B, are installed in which EGT-A can only be

operated in booster mode (Series operation with ALLISON GTCs)

& by the time EGT-B is in standby mode

It is a 17 stage compressor which compresses 1Kg of gas into

17Kg, works in parallel /series with earlier compressors .It has a

capacity of 389 KSCM/Hr. It can compress 68-90Kg/cm2. A gas

turbine, also called a combustion turbine.

It also has an upstream rotating compressor coupled to a

downstream turbine like GTC.

EMERGNCY DIESEL GENERATOR The compressor Station is equipped with a 1MW EDG which starts

automatically on failure of normal power supply and the power supply

resumes within 50sec of sensing power loss. It is combination of a diesel

engine with an electric generator to generate electrical energy.

It is used to all critical loads (DEG Auxiliary Motors, UPS AC& DC,

Lighting indoor & Outdoor, Instrument Air Compressors, Jockey Pump,

GTG Auxiliary Motors, ALLISON & EGT machines auxiliaries).

They are used as emergency power-supply if the grid fails, as well as for

more complex application.

Specification of Generator

Manufacturer : Brush Electric Machine

Type : Synchronous, Air Cooled

Power : 2700 KW at 47’C Ambient Temperature

Speed : 1500 R.P.M. Synchronous

METER PROVER

Only GAIL, Dibiyapur is equipped with Turbine Meter Proving System, to provide

efficient flow of gas to its customers.

The gas is transferred through means of pipes which contains turbine to measure its

flow and all necessary data. A turbine meter consists of a practically friction-free

rotor pivoted along the axis of the meter tube and designed in such a way that

the rate of rotation of the rotor is proportional to the rate of flow of gas through

the meter. This rotational speed is sensed by means of an electric pick-off coil

fitted to the outside of the meter housing.

The reference gas can be regulated by adjusting or calibrating with master meter.

It consist of (TT),(PT) & (DPT) on the MUT site.DPT is connected b/w master site and

MUT site. During calibration a MUT is being compared against a master meter. By

comparing and taking the difference in pressure and temperature in the two

meters in the account the flaws of the MUT can be determined.

SEQUENCE OF EVENTS TAKES PLACE

De-pressurize the MUT.

Install the MUT and its

instrumentation is connected.

Pressurize the MUT .

If any leakage, is tested.

Set flow rate through the meter run

to the desired value set by

electrical pickup.

Monitor process until the desired

level of stability in P,T and flow rate

have been achieved.

Measurements are then

performed.

GAS CHROMATOGRAPHY(GC)

The rich gas which is transferred to GAIL PATA they take high carbon

content which when turns into lean gas. That is passed into GC which

shows the exact amount of different gas content.

A small sample gas is injected into the carrier gas flow path of the

column system, which is Micro-packed stainless steel. The column

material is selected to provide ‘partitioning’ of certain gases, such

that separation occurs before the gas exits the column- ‘selective

retardation’.

By gas selector the concentration of each component is then

measured at the end of the column. From the knowledge of the

concentrations of each component, any property of the gas can be

calculated.

Use of (TCD) to measure the concentration of each component. It

senses the changes in the thermal conductivity of the column

effluent and compare it to the reference flow of carrier gas.

BLOCK DIAGRAM OF GC

GC oven Thermal conductivity

detector(TCD)

CONTROL ROOM

It is the controlling area of compressor station with highly sensitive computers.

All the working procedure which is in remote area is controlled through this

room

This room contains several cabinets into which numbers of PLC (Programmable

Logic Controller) is fitted.

It is used for automation of electro-mechanical processes for controlling of

machinery in factory assembly.

They are designed for multiple

I/P & O/P arrangements, extended

temperature ranges, immunity to

electrical noise, and resistance to

vibration and impact. All the data

Signals , transmitters', sensors attached

to different machines sends signal to PLC

,to which PLC convert into a readable

signal through the computers.

CONCLUSION

GAIL has setup a huge pipeline over India with its easy working condition

for the employees and also with their great safety. It has set-up at least

more than one back-up system so that system works with no hazardous

accident.

After summing up all I conclude this report with my utmost privilege in

doing summer training with very cooperative atmosphere.