summer training report at gail dibiyapur

1. SUBMITTED BY:
AAYUSHI LAL
EI-FINAL YR
SUMMER TRAINING REPORT
AT
GAIL COPMRESSOR STATION,DIBYAPUR

2. 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)

3. 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.

4. Gas Consumers of GAIL
Fertilizer Plant:
 Vijaipur
 Jagdishpur
 Shahjahanpur
 Babrala
 Phulpur
Power & LPG PLant
 Kawas
 Anta
 Auraiya
 Vijaipur
 Usar
 Lakawa
 Aonla

6. 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.

8. 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.

10. 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.

12. 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.

14. 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

15. 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.

16. 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.

17. 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.

18. BLOCK DIAGRAM OF GC

19. GC oven Thermal conductivity
detector(TCD)

20. 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.

21. 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.