24 February 2012

A Navaratna Company

1

to Presentation

on

Natural gas available from its oil and gas fields

OIL’s LPG plant is based on turbo-expansion process 24 February 2012 2

LPG Recovery Plant produces LPG & Condensate from-

LPG department has two installations - LPG Recovery Plant LPG Filling Plant Various Sections at LPG Dept - Recovery Plant Operation, Filling Plant Operation, Mechanical & General Maintenance , Electrical, Instrumentation, Quality Control, Safety, Planning & Administration

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LPG Department – an overview

By DNV 24 February 2012 4

is accredited with- LPG Department

1. ISO-9001:2008 For Quality Management System 2. ISO-14001:2004 For Environmental Management System 3. OHSAS 18001:2007 For Occupational Health and Safety Assessment Series

Gas processing capacity - 2.21 MMSCMD (80 MMSCFD)

LPG production - 55,000 MT / year

Condensate production - 25,000 MT / year

DESIGN : The Randal Corporation, USA

CONSTRUCTION : Industrial Consulting Bureau

DESIGN : Kosan Crisplant a/s, Denmark

COMMISSION : August, 1982

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LPG Recovery Plant

LPG Filling Plant

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Produces LPG and Condensate Storage facility for LPG and Condensate Maintenance facilities for Mechanical, Electrical, Instrumentation

LPG Recovery Plant

LPG Filling Plant

LPG Cylinder filling facility Road Tanker filling facility for LPG & Condensate Maintenance facilities

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Marketing of LPG is done by IOCL

No. of LPG cylinders filled per day is about 7000

On an average 12 road tankers are filled daily

On an average per month – 1800 tons of LPG is filled in cylinders

2400 tons of LPG is filled in road tankers

Product Dispatch

Natural gas @ 80 MMSCFD (at design) from LPG Off-take Point of Production Gas Department is received at LPG Recovery Plant. The natural gas is processed in LPG Recovery Plant to produce -- LPG

-- Condensate (NGL-natural gasoline) The remaining natural gas called residue gas @ 76 MMSCFD (at

design) is returned back to LPG Off-take point. Assam Gas Company Limited (AGCL) acts as a supplier of OIL’s

natural gas to various consumers viz., The residue gas is supplied to Power House, domestic use, some tea gardens, BVFCL (Namrup), APL (Namrup), NTPC (Namrup), NEEPCO (Kathalguri) etc..

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Salient features of LPG plant-

LPG is a mixture of certain light hydrocarbons, derived from petroleum, which are –

gaseous at ambient temperature and atmospheric pressure but may be condensed to liquid state at ambient temperature by the application of moderate pressure liquefaction is accompanied by a considerable decrease in the volume, thus the liquid formed requires much less storage space of many gaseous hydrocarbons, only propane & butane have got the qualities required for LPG that makes it especially useful

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What is LPG ?

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COMPONENT DESIGN PRESENT N2 0.26 0.44 CO2 1.10 1.15 C1 86.80 88.99 C2 6.50 4.31 C3 3.30 2.39 i- C4 0.72 0.56 n-C4 0.86 0.83 i- C5 0.18 0.31 n-C5 0.13 0.26 C6 + 0.15 0.77

Natural Gas Composition

SPECIFICATIONS IS 4576- 1999 1. Vapour Pressure at 1050 max. 40 ºC , Kpa.

2. Volatility, ºC 2.0 max.

3. Total Volatile Sulphur, 0.02 max. % Mass (150 ppm)

4. Hydrogen Sulphide Absent

5. Dryness No Free Water

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Quality Control of LPG

RESIDUE GAS

LPG

CONDENSATE

INLET GAS COMPR.

GAS- GAS EXCHANGER

GAS - LIQUID EXCHANGER

TURBO-EXPANDER

EXPANDER SEPARATOR

DE-ETHANIZER DE-BUTANIZER

BOOSTER COMPRESSOR FEED

GAS

COLD SEPARATOR

DEHYDRATOR

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Simplified flow Diagram

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Storage

LPG VESSEL TYPE NOS. WATER CAPACITY MOUNDED BULLET 3 830 CU.M. (EACH) (UNDER CONSTRUCTION) HORTON SPHERE 2 2000 CU.M. (EACH)

CONDENSATE HORIZONTAL TANK 2 150 CU.M. (EACH)

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LPG PRODUCTION TARGETS Vs ACHIEVEMENTS

YEAR TARGET ACHIEVEMENT (Tonnes) (Tonnes) 1991-92 49,000 49,270 1992-93 50,000 51,700 1993-94 50,000 50,417 1994-95 50,000 50,760 1995-96 50,000 55,780 1996-97 50,000 52,670 1997-98 50,000 52,720 1998-99 53,000 54,610 1999-00 52,500 51,390 2000-01 50,000 51,470 2001-02 50,500 50,950 2002-03 50,000 54,320 2003-04 50,000 51,510 2004-05 50,000 49,500 2005-06 50,000 48,320 2006-07 45,000 43,750 2007-08 45,000 48,165 2008-09 43,600 47,610 2009-10 43,600 44,950 2010-11 43,600 45,010

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LPG is a colourless liquid which readily evaporates into a gas

It has no smell, although it will normally have an odour (because of the addition of mercaptans) to help detect leaks

It can burn or explode when it is mixed with air and meets a source of ignition

It is heavier than air, so it tends to sink towards the ground

It can flow for long distances along the ground, and can collect in drains, gullies and cellars

LPG liquid can cause cold burns to the skin

Properties

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FLASH POINT : (-) 1050C AIR VAPOUR MIXTURE HIGHLY EXPLOSIVE FLAMMABLE LIMITS : 1.8% LEL - 9.5% UEL

Approx. 10900 KCAL/KG OF ENERGY YIELDS 3 – 4 TIMES CO2 OF ITS OWN VOLUME AUTO IGNITION TEMP : 410 - 5800C

LPG VAPOUR 1.8% to

9.5%

Air/O2 90.5%

to 98.2%

Spark FIRE

3 to 4 times CO2

10900KCAL/KG of ENERGY

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LIQUID TO VAPOUR PHASE – EXPANDS 270 TIMES

HEAVIER THAN AIR - SETTLE DOWN AT GROUND LEVEL

LOW VISCOSITY - HENCE CAN LEAK WHEN OTHER PETROLEUM PRODUCTS NORMALLY CAN NOT

LIQUID CONTACT CAUSES TO FROST BITE (COLD BURN)

INHALATION CAUSES NAUSEA, BREATHLESS AND HEADACHE

LPG VAPOUR

270 Times Liquid LPG

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Because of its relatively fewer components, it is easy to achieve the correct fuel to air mix ratio that allows the complete combustion of the product. This gives LPG its clean burning characteristics.

Both Propane and Butane are easily liquefied and stored in pressure containers. These properties make the fuel highly portable, and hence, can be easily transported in cylinders or tanks to end-users.

Advantages of LPG

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LPG is a good substitute for petrol in spark ignition engines. Its clean burning properties, in a properly tuned engine, give reduced exhaust emissions, extended lubrication and spark plug life. The clean burning properties and portability of LPG provide a substitute for traditional fuels such as wood, coal, and other organic matter. This provides a solution to de-forestation and the reduction of particulate matter in the atmosphere (haze), caused by burning the traditional fuels.

Advantages of LPG…. contd

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24 Point Cylinder filling carousel : 01 NO. Road Tanker Filling Point : 05 NOS. Tanker Evacuation Point : 01 NO. Pumps for Cylinder & Tanker Filling : 03 NOS.

Dispatch facilities at LPG Filling plant-

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CHECK SCALE

PROPER WEIGHT CYLINDER +

OVERFILLED CYLINDERS WITH MARKER

UNLOADING OF EMPTY CYLINDERS

REJECTED UNSERVICABLE CYLINDERS

UNCAPING OF EMPTY CYLINDERS

WASING UNIT

TARE WEIGHT MARKING

CAROUSEL FILLING MACHINE

VISUAL CHECK

ACCEPTED SERVICABLE CYLINDERS

CHECK SCALE UNDERFILLED

CYLINDERS

FILLING GUN

COMPACT VALVE TEST MACHINE

LEAK TEST BATH

ACCEPTABLE CYLINDERS

LEAKY & OVERFILLED CYLINDERS

SEALING & CAPPING OF CYLINDERS

CYLINDER EVACUATION UNIT

LOADING OF CYLINDERS &

DESPATCH

REJECTED CYLINDERS HANDED OVER TO IOCL

BLOCK DIAGRAM OF LPG CYLINDER FILLING

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Various Safety Measures available at LPG plant

Alarm and shut- down system ESD Device Safety Relief Valves Fire Drill Inspection of Plant Gas Detection System Fire Alarm System

1. General safety 2. Electrical safety 3. Work Permit System

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Electrical Safety

Earthing system in LPG Recovery & Filling plant - System earthing for current carrying conductor - Equipment earthing for non-current carrying metal work

Special Protection of Electrical Equipments in hazardous areas - Flame proof or explosion proof - Non-sparking - Pressurized –Instrumentation, motor of 3.3 KV, 6.6KV and 33KV

Lightning Protection

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Various Fire Protection facility at LPG plant are-

Water monitors & hydrant points

Medium velocity water spray system

Fire extinguishers and sand bucket

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EQUIPMENT QUANTITY

FIRE WATER PUMPS

JOCKEY PUMPS

HYDRANTS

FIRE ALARM POINTS

GAS DETECTION SYSTEM : % LEL

MONITORS

S.NO.

1

2

4

5

6

3

02

06 (04+02)

28 (21+7)

16 (9+7) + 3

21 (12+9)

25 (17+8)

Fire Safety System

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Name Discharge Head

Pump-1 Hydrant Pump 410 m3/hr 88

Pump-2 Spray pump-A 410 m3/hr 88

Pump-3 Spray pump-B 410 m3/hr 88

Pump-4 Sprinkler pump 275 m3/hr 88

DEFP-1 Engine driven 410 m3/hr 88

DEFP-2 Engine driven 410 m3/hr 88

Jockey Pump-1 20 m3/hr 90

Jockey Pump-2 20 m3/hr 90

N.B. 1) Jockey Pump 1 or 2- auto start 4.6Kg/cm2 and auto stop at 8.4kg/cm2

2) Idle time of Jockey pumps are 12 mins

Fire Water Pump

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PUMP HOUSE

DV DV

FM 2

FM 1

WM 2

WM 14

WM 13

WM 8

WM 1

WM 9

WM 10 H-22

H-20

H-21

H-23

H-24

H-10

H-12

H-18

WM

H-17

H-14

H-15

H-4

H-30

H-3

H-29

H-28 H-27

H : HYDRANT WM : WATER MONITOR FM : FOAM MONITOR DV : DELUGE VALVE

RECOVERY PLANT AREA OFFICE

TO F. PLANT

WATER RESERVOIR

200 NB

400 NB

400 NB

200 NB

200 NB

200 NB

400 NB

100 NB 100 NB 150 NB

100 NB

150 NB 100 NB

100 NB

150 NB

H-2

H-1

H-11 H-13

FIRE PROTECTION SYSTEM

RECOVERY PLANT

HORTON SPHERE

AREA

COND TANKS

WM

DV16

DV 18

DV 17

DV 19

UGV 1

UGV 3

UGV 6

UGV 7 UGV 8

UGV 9

UGV 5 UGV 2

UGV 4

HOSE STORAGE

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H-7

H-8

H-25

H-6 H-5

H-26

H-9

WM-7 WM-6 WM-5 WM-4 WM-3

WM-12

WM-11

EMPTY CYLINDER SHED

FILLED CYLINDER SHED

FROM RECOVERY PLANT

200 NB 100 NB

400 NB

200 NB

400 NB

300 NB 300 NB

200 NB

100 NB

DV 10, 11, 12, 13

DV14 DV15 TANKER FILLING POINTS

UGV 10

UGV 11 UGV 12

UGV 13

DV 6, 7, 8, 9 HOSE STORAGE

FIRE PROTECTION SYSTEM

LPG FILLING PLANT

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GAS DETECTION SYSTEM LOCATION OF DETECTORS: LPG RECOVERY PLANT

RECOVERY PLANT AREA

BULLET AREA

HORTON SPHERE AREA

MCC Room

PUMP HOUSE

CT1 CT2

AIR COMP HOUSE

NEAR GATE

NEAR MCC ROOM

GD-01

NEARFIRE PUMP HOUSE

NEAR AIR COMP. HOUSE

CONDENSATE AREA

TOTAL QUANTITY OF DETECTORS IN RECOVERY PLANT: 19 NOS.

GD-02

GD-03

GD-04

GD-05 GD-21

GD-08

GD-25 GD-26

GD-06

GD-07

GD-22

GD-09

GD-17

GD-18

GD-19

GD-23

GD-24

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EMPTY CYL. SHED FILLING SHED

CAROUSEL

GD-10 GD-11

Cy. Ev. Unit

GD-14

GD-12

GD-13

TANKER FILLING POINTS GD-27 GD-28 GD-29

GAS DETECTION SYSTEM LOCATION OF DETECTORS: LPG FILLING PLANT

TOTAL QUANTITY OF DETECTORS FILLING PLANT: 8 NOS.

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RECOVERY PLANT AREA

BULLET AREA

HORTON SPHERE AREA

FILLING SHED EMPTY CYL. SHED

MCC ROOM

PUMP HOUSE CT1 CT2

AIR COMP HOUSE

NEAR GATE NEAR MCC ROOM

NEAR INLET COMPR.

NEAR EXP-COMP. NEAR FIRE

PUMP HOUSE

NEAR AIR COMP. HOUSE

NEAR COLD SEPARATOR

NEAR HEATER

NEAR PUMP HOUSE

NEAR DV

NEAR MCC ROOM

NEAR DV

NEAR TANKER FILLING POINT

NEAR TK. EV. UNIT NEAR DV

NEAR CYL. EV. UNIT

NEAR CAROUSEL

EMERGENCY/ FIRE ALARM SYSTEM LOCATION OF BREAK-GLASS ALARM POINTS

NEAR CLOSED DRAIN VESSEL

BETWEEN BULLETS AND HORTON SPHERES

NEAR GATE

NEAR OFFICE

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HUMAN SAFETY

PLANT AND EQUIPMENT SAFETY

Safety During Maintenance

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WORKING AT HEIGHT- WEAR SAFETY BELT STRIKE BY OTHER OBJECT/ FALLING OBJECT

FROM HEIGHT-WEAR HELMETS, SAFETY SHOES ETC.

COLD BURN, HOT OIL, HOT LINES- WEAR HANDGLOVES

EXPOSURE TO DUST, INHALATION OF TOXIC SUBSTANCES - WEAR APPROPRIATE MUSKS

SPRINKLING OF ACIDS, HOT OIL ETC.- WEAR GOGGLES

Human Safety

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FOLLOW WORK PERMIT SYSTEM COLD WORK PERMIT

HOT WORK PERMIT

Plant & Equipment Safety

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OBTAIN PROPER WORK PERMIT BEFORE ANY MAINTENANCE JOB

DO POSITIVE ISOLATION OF VESSELS, EQUIPMENTS, LINES

MAINTAIN BLIND REGISTER GAS TESTING SHOULD BE DONE AS & WHEN

REQUIRED WEAR PPES AS & WHEN REQUIRED USE PROPER SIGNAGE/ WARNING

Plant & Equipment Safety

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EQUIPMENT PROPERLY DRAINED, DEPRESSURIZED EQUIPMENT ELECTRICALLY ISOLATED FIREFIGHTING ARRANGEMENT READY SPECIAL ATTENTION REQUIRED IN CASE OF

HOT JOBS USE OF NON-SPARKING TOOLS AS & WHEN

REQUIRED

Plant & Equipment Safety

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SPECIAL ATTENTION SHOULD BE GIVEN WHEN CONTRACT LABOUR IS EMPLOYED FOR MAINTENANCE WORK

IT IS OUR MORAL RESPONSIBILITY TO ARRANGE FOR THEM THE SAME KIND OF SAFETY GEARS WHICH WE USE

ENGINEER AND SUPERVISOR THROUGH RESPECTIVE GROUP LEADERS SHOULD ENSURE USE OF PPE’s BY WCL’s

Contract Labourers

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