ACKNOWLEDGEMENT

After the completion of my in plant training I intend to thank all the staff of GAIL (INDIA) Ltd.
who directly or indirectly was responsible for making mystay(during the training period) fruitful.
I am very grateful to the staff of GAIL who cooperated with me during the entire training period.
First and foremost, I would like to thank Mr. P.K. Jain Chief Manager (training) for making it
possible for me to come to GAIL and undergo the training.
The people of IOP&S Unit( where we were deputed) deserve special mention. I extend my
sincere gratitude to
Mr. A.K. Nashkar, HOD(IOP&S)
Mrs. Sweta Rani, Dy Manager( PC Operation), (IOP&S)
Finally, I would like to thank the field Engineers& GAIL family, who were in some way or
other related to our successful training.

1 | Page

ABSTRACT

In plant training is a vital part in the progress of fledgling engineers. For me this was the first
rendezvous of practical knowledge with the theoretical concepts acquired during the years in
college. I am very fortunate that I got the opportunity of undergoing training in one of the most
sophisticated and modern petrochemical plant, GAIL. The experience gained during the short
stay here was fascinating to say the least. It was tremendous feeling to see the practical operation
of different equipment and processes, which until now existed for me only in books. I was
deputed in IOP&S unit for my training. I was overwhelmed by the sheer size and complexity of
the plant. What still fascinates me, how such a big unit is being monitored and operated with the
desired results.
In this short stay it was possible for me to wholly decipher the detailed functioning of the
plants; but still I was fortunate enough to get a sound overview of the unit.
Thanks

2 | Page

CONTENT

CERTIFICATE
ABSTRACT
ACKNOWLEDGEMENT
LIST OF FIGURES
LIST OF TABLES

1. Inroduction to gas industry

1.1 Exploration
1.2 Production
1.3 Consumption
2. Introduction to GAIL
2.1 Project configuration
3. GAIL, (PATA) Project
3.1 Upstream operation
3.1.A gas sweetening unit
3.1.B gas processing unit
3.1.C LPG unit
3.1.D Gas cracking unit
3.2 Downstream operation
3.2.A Petrochemical
3.2.B Linear low density polyethylene
3.2.C High density polyethylene
4. IOP&S UNIT
4.1 Introduction to iop&s
4.2 Storage vessels
4.3 D m plant
4.4 Cooling tower and cooling tower efficiency
4.5 Raw water
5. References
6. Remarks

3 | Page

5-6
5-6
6
6
7-8
9
10-18
10-15
10-12
13
14
15
16-18
16
17
18
19-42
19
19-24
25-31
32-37
38-42
43

INTRODUCTION TO GAS INDUSTRY

fig 1.1
Gas demand in india is dominated by the power and fertilizer sectors which account for
66 per cent of the current consumption. In 2006, the total gas demand was around 152
MSCMD. The gas demand is expected to increase to 320 MSCMD, according to a report
by Ernst & Young. Significantly, the share of natural gas in the overall fuel mix is
expected to increase from 8 per cent in 2006 to 20 per cent by 2025.
Reliance industries plans to invest between US$ 5.45 billion to US$ 6.54 billion over the
next three years to lay a 10,000 km pipeline.

Exploration and production:

Exploration:
Exploration for and production of natural gas are the first steps in delivering gasoline to
your car, heat to your home, raw material to business and industry, fertilizer to farmers
fields and for many other aspects of daily life. Many people are unaware of the important
role that gas exploration and production play in their daily lives. Without successful
exploration and continued production, our nations energy security and the economic
prosperity that goes along with it will be compromised.

Production:

4 | Page

1.

Domestic production of crude oil has increased to 34.11 MT in 2007-08 from

33.98MT in 2006-07

2. The production of petroleum products went up to 144.93 MT in 2007-08 from 135.26

MT in 2006-07
3. The production of natural gas went up to 32.27 billion cubic meters tones in 2007-08
from 31.74 BCM in 2006-07
4. The projected production of crude oil during the 11th five year plan(2007-12) is
206.76 MMT while that of natural gas is 255.27 BCM
5. Production of gas from Reliance industries eastern offshore KG D-6 fields, with a life
of 11 years , started on april 1 and will increase to 80 million standard cubic meters
per day(MSCMD) by the end of the year. Production will help save US$ 9 billion in
oil import.
6. Cairn india will commence the commercial production of crude oil from its rajasthan
fields from September 2009. It is expecting a production of 175,000 barrels per day

Consumption:
Indias domestic demand for oil and gas is on the rise . As per the Ministry of Petroleum,
demand for oil and gas is likely to increase from 176.40 million tons of oil equivalent
( mmton ) in 2007-08 to 233.58( mmton ) in 2011-12

INTRODUCTION TO GAIL
GAS AUTHORITY OF INDIA LTD. (GAIL) is one of the outstanding public enterprises
within the country today. It is one of the MAHARATNA Company in INDIA.
The setting up GAIL(India) LTD., in august 1984, heralded a new era of natural gas in
the country. GAIL is now 29 glorious years of service to the nation.
5 | Page

Since 1984, GAIL has made significant contribution to the nations economy by supplying
natural gas through its pipeline network for
1. Generation of over 87,000 MW of power
2. Production of over 145 million tons of urea
3. Production of LPG for over 7 cr. households in the country
4. Over 5.7 lakhs vehicles in the country today running on CNG supplied by GAIL and
over 7 lakhs households on piped natural gas(PNG) in the country.
5. Production of petrochemicals of around 4 lakhs mts which is used in the plastic
industry.
The natural gas infrastructure of around 7,000 km. accounting for over 82% of total
pipeline infrastructure in india , set up so far by gail has contributed enormously to the
economically and socially critical sectors such as fertilizers and power.
GAIL has the distinction of pioneering the clean fuel revolution for transport sector in the
country with the introduction of CNG in Delhi and Mumbai which has significantly
helped in reducing pollution levels in these two cities.
It provides ready market access to the domestic gas producers, making gas available to
the customers including those remotely located and devoid of market access. It has
provided cheaper, environment friendly alternative fuel and has reduced import
dependency as natural gas has substituted liquid fuel such as naphtha, fuel oil, etc.
GAILs pipeline network to the gas consumers in the states of:
1. Gujarat
2. Maharashtra
3. Rajasthan
4. Madhya Pradesh
5. Delhi
6. Haryana
7. Uttar Pradesh
8. Andhra Pradesh
9. Tamilnadu
10. Assam
11. Tripura
In addition to supplying natural gas to various consumers, GAIL has also setup 7 LPG
plants and a petrochemical plant to extract value added products from gas. Gail today
handles about 95% of natural gas business in India , through its 3900km of pipelines in
country. Gail is also one of the largest LPG producers in India with a liquid hydrocarbon
production. It produces around 1.35 MMTPA of liquid hydrocarbon including LPG for
domestic consumption. It has emerged as the no. 1 gas company in India. It has won the
excellent performance award for past several years, as well as safety award. It has
ISO 900 certificate for its pipeline system and also ISO 14001 for HVJ pipeline.
6 | Page

Entering into the field of petrochemical, GAIL has set up petrochemical complex at
PATA(UP).
The natural gas to the complex is coming from vijaipur through HVJ pipeline for
producing petrochemical conversion of ethane, propane& LPG from natural gas. The
ethane& propane are recovered from natural gas in GPU & set to gas company unit to
produce ethylene& propylene while LPG is recovered in LPG is recovered in LPG
recovery unit. Ethylene is converted to final products HDPE& LLDPE.

Project configuration:
S.no
1
2
3
4
5
6
7

unit
Gas cracker unit
Gas sweetening
agent
C2/C3 Recovery
LLDPE
HDPE 1& 2
LPG&
PROPANE
BUTENE
PLANT

capacity
licencor
4,00,000 TPA
U.S.A.
12.66 MMSCMD TOTAL
FINAEIF
4,00,800 TPA
E.I.L.
2,10,000 TPA
NOVACOR
1,00,000 TPA
MITSUI,JAPAN
2,98,480 TPA
E.I.L
10,000 TPA

I.F.P., FRANCE

Various utilities and offsite facilities have been provided in the complex. These include
raw water, cooling tower, compressed air, DM water, nitrogen flare, storage system are
provided.

GAIL, PATA PROJECT

GAS
Rich gas from
SWEETNING
UNIT LIC: TOTAL
FINAEIF
7 | Page

LLDPE/ HDPE
SWING UNIT LIC:
NOVACOR

vijaipur

C2/C3
GAS
CRACKING
UNIT LIC:
USA

GAS
PROCESSING
UNIT

HDPE UNIT LIC:

MITSUI, JAPAN

LPG UNIT
LIC: E.I.L.

BUTENE 1 LIC:
I.F.P., FRANCE
PROPYLENE

LPG
PROPANE

UPSTREAM OPERATION
GAS SWEETENING UNIT

Amine gas treating also known as gas sweetening and acid gas removal, refers to a group of
processes that use aqueous solutions of various alkyl amines( commonly referred to simply as
amines) to remove hydrogen sulfides and carbon dioxide from gases. It is a common unit process
used in refineries and is also used in petrochemical plants, natural gas processing plants and
other industries.
Processes within oil refineries or chemical processing plants that remove hydrogen sulfides or
mercaptans are commonly referred to as sweetening processes because they result in products
which no longer have the sour, foul odour of mercaptan and hydrogen sulfide.
8 | Page

There are many different amines used in gas treating:

1. Monoethanolamine (MEA)
2. Diethanolamine(DEA)
3. Methyldiethanolamine(MDEA)
4. Diisopropylamine(DIPA)
5. Aminoethoxyethanol ( Diglycolamine) (DGA)
The most commonly used amines in industrial plants are the alkanolamines MEA, DEA, and
MDEA.
Amines are also used in many oil refineries to remove sour gases from liquid hydrocarbon such
as LPG.

Description of a typical amine treater

Gases containing H2S or both H2S and CO2 are commonly referred to as sour gases or acid
gases in the hydrocarbon processing industries.The chemistryinvolved in the amine treating of
such gases varies somewhat with the particular amine being used. For one of the more common
amines,monoethanolamine (MEA) denoted as RNH2, the chemistry may beexpressed as:
RNH2 + H2S

RNH3 + SH-

A typical amine gas treating process (as shown in the flow diagram below)
includesan absorber unit and a regenerator unit as well as accessory equipment. In theabsorber,
the downflowing amine solution absorbs H2S and CO2 from the upflowing sour gas to produce a
sweetened gas stream (i.e., a gas free of hydrogen sulfide and carbon dioxide) as a product andan
amine solution rich in the absorbed acid gases. The resultant "rich" amine is then routed into the
regenerator (a stripper with a reboiler) to produce regenerated or "lean" amine that is recycled for
reuse in the absorber. The stripped overhead gas from the regenerator is concentrated H2S and
CO2. In oil refineries, that stripped gas is mostly H2S, much of which often comes from a sulfur9 | Page

removing process called hydrodesulfurization. This H2S-rich stripped gas stream is then usually
routed into a Claus processto convert it into elemental sulfur. In fact, the vast majority of the
64,000,000 metric tons of sulfur produced worldwide in 2005 was byproduct sulfur
fromrefineries and other hydrocarbon processing plants. Another sulfur-removing process is
the WSA Process which recovers sulfur in any form as concentrated sulfuric acid. In some
plants, more than one amine absorber unit may share a common regenerator unit.

fig 1.2
Process flow diagram of a typical amine treating process used in petroleum refineries, natural
gas processing plants and other industrial facilities.
The amine concentration in the absorbent aqueous solution is an important parameter in the
design and operation of an amine gas treating process. Depending on which one of the
following four amines the unit was designed to use and what gases it was designed to
remove, these are some typical amine concentrations, expressed as weight percent of pure
amine in the aqueous solution:

Monoethanolamine: About 20 % for removing H2S and CO2, and about 32 % for
removing only CO2.

Diethanolamine: About 20 to 25 % for removing H2S and CO2

Methyldiethanolamine: About 30 to 55% % for removing H2S and CO2

Diglycolamine: About 50 % for removing H2S and CO2

10 | P a g e

The choice of amine concentration in the circulating aqueous solution depends upon a
number of factors and may be quite arbitrary. It is usually made simply on the basis of
experience. The factors involved include whether the amine unit is treating raw natural
gas or petroleum refinery by-product gases that contain relatively low concentrations of
both H2S and CO2 or whether the unit is treating gases with a high percentageofCO2 such
as the offgas from the steam reforming process used in ammonia production or theflue
gases from power plants. Both H2S and CO2 are acid gases and hence corrosive to carbon
steel. However, in an amine treating unit, CO2 is the stronger acid of the two. H2S formsa
film of iron sulfide on the surface of the steel that acts to protect the steel. When treating
gases with a high percentage of CO2, corrosion inhibitors are often used and that permits
the use of higher concentrations of amine in the circulating solution. Another factor
involved in choosing an amine concentration is the relative solubility of H2S and CO2 in
the selected amine. For more information about selecting the amine concentration, the
reader is referred to Kohl and Nielsen's book.
The choice of the type of amine will affect the required circulation rate of amine
solution, the energy consumption for the regeneration and the ability to selectively
remove either H2S alone or CO2 alone if desired.
The current emphasis on removing CO2 from the flue gases emitted by fossil fuel power
plants has led to much interest in using amines for that purpose.
In the specific case of the industrial synthesis of ammonia, for the steam
reforming process of hydrocarbons to produce gaseous hydrogen, amine treating is one
of the commonly used processes for removing excess carbon dioxide in the final
purification of the gaseous hydrogen

Gas Processing Unit

GAIL is marketing gas processing units (GPU) products namely LPG, Propane, Pentane,
Naphtha and by products of polymer plant namely MFO, Propylene & Hydrogenated C4 mix.
LPG is being sold exclusively to PSU Oil Marketing Companies ( omcs) while other products
are sold directly to customers in retail segment.
GAIL is Indias major producer of propane, popularly known as GAIL propane. It is an eco
friendly fuel and provides an effective way of reducing pollution and increasing productivity.
GAIL produces and markets Pentane. It is primarily being used for reprocessing into iso, normal
and commercial pentane used in EPS , PU and lab industry.
11 | P a g e

Naphtha is primarily used by power, fertilizer, steel and petrochemical units. In power and steel
it is used as a fuel, whereas in petrochemical , chemical, fertilizer units it is used as a feedstock.
GAIL is presently operating 7 GPU located at Vijaipur (2 units), Auraiya, Vaghodia, Usar, Lakwa
& Gandhar plant for production of main products viz. LPG & Polymer through GPU/GCU
except usar, the following by products liquid hydrocarbons (LHC) are produced:

Plants

byproducts

Vijaipur

propane, pentane, naphtha

Auraiya

propane, pentane, naphtha, MFO,

Hydrogenated c4 mix, propylene, slop oil

Vaghodia

naphtha

Gandhar

pentane, naphtha

Lakwa

solvex GL, naphtha

Liquefied Petroleum gas unit(LPG)

GAIL is the company in India to own and operate pipelines for LPG transmission . . It has 1900
km LPG pipeline network, 1300 km of which connects the western and northern part of India
and 600 km is in southern part of country connecting eastern coast. The LPG transmission
system has the capacity to transport 3.8mmtpa LPG . LPG transmission through pipelines was
3337 TMT in year 2010-11.
GAIL has a share of about 10% Indian LPG market in LPG production and 7% in LPG sales.
Gail produces LPG through fractionation in GPU, Known as straight run LPG. Gails LPG is an
eco friendly fuel and provides a cheaper and effective means of reducing pollution and
increasing productivity.
12 | P a g e

Characteristics of Gail LPG:

1. Processed for natural gas
2. Has a high vapour pressure
3. Vapourizes at atmospheric temp. and pressure
4. Clean fuel with almost nil unsaturated compound
5. Has a high calorific value than refinerys LPG
6. Its homogenous composition results in more efficient combustion
7. The air fuel ratio need not to be changed in each branch
8. No impurities like sulphur, CO2 traces on N2
9. Has nil moisture content
In auraiya PATA plant it produces 258250 MT/annum
Application of LPG
Domestic: for use in household
Auto: for use as fuel in automobiles

Gas cracking unit(GCU)

A gas cracker is any device that splits the molecules in a gas or liquid usually by electrolysis,
into atoms. The end product is usually a gas. A hydro cracker is an example of a gas cracker. In
nature, molecules are split often, such as in food digestion and microbial digestion activity. A gas
cracker device splits the molecules at a rate much greater than that normally found in nature. In
science and industry, gas cracker are used to separate two or more elements in a molecule. For
example, liquid water or h20 is separated into hydrogen and oxygen gases.
This is not to be confused with the splitting of the nucleus( nucleus power).
Gas cracker: Petrochemical are usually manufactured in large scale from petroleum feed
stocks.Naphtha , natural gas, refinery off gas from cookers and thermal crackers are good
13 | P a g e

sources. Thus natural gas is one of the most wanted feed stocks for petrochemical production.
The thermal cracking of natural gas proceeds at very high temp. resulting in olefins( mostly
ethylene/propylene). The temp. in a gas cracker exceeds 1000 degree C. For
ultimatedecomposition of gas into elements more than 1500 degree C is required. Thus ,
acetylene/carbon black production encounters such high temperatures. Usually oxy combustion
methods are used for attaining such high temp.. BASF burners/kellogs burners are available in
market

fig 1.3

Downstream operation

Petrochemicals
Gails the countrys premier natural gas marketer& transporter, diversified into the
manufacturing and marketing of downstream HDPE& LLDPE from natural gas cracking at its
pata unit from 19th april 1999. The beginning was with a name plate capacity of 2,60,000 MTPA
of HDPE & LLDPE. In FY 2009-10, the petrochemical business portfolio contributed over 28%
of the segment gross profit.

14 | P a g e

Gail is the only HDPE/ LLDPE plant operating in northern India and has a dominant market
share in north India. The primary thrust markets for the polymer had been western India, but with
the entry of Gail in the HDPE&LLDPE market verticals, today north India has also witnessed a
rapid and significant growth in the polymer downstream processing verticals. In a successful
span of about a decades of establishing and marketing its grades under the brand names Glex&
Glene, Gail has alongside augmented its name plate capacity of HDPE&LLDPE to 4,10,000
MTPA by adding another dedicated HDPE downstream polymerization unit of 1,00,000 MTPA.
GAIL has two trains of dedicated HDPE units of the Mitsui slurry technology license( capacity
2* 1,00,000 MTPA) and marketing the grades under the brand name of G lex and one train of the
HDPE&LLDPE swing plant under the NOVACOR solution based technology license( capacity
2,10,000 MTPA).
Further by adding 6th furnace & de bottlenecking of the plant, the Gails pata plant capacity will
reach to 5,00,000 mts of ethylene & 5,00,000 MTs of HDPE&LLDPE producing capacity by
FY 2011-12.
GAIL has also formed a joint venture company by the name of M/s Bhramaputra cracker and
petrochemicals ltd.( BCPL) to accelerate the GoIs only authorized petrochemical project in the
north east of India( at Assam ,India). The bcpl is a JV between the government of Assam , GAIL
INDIA ltd. OIL INDIA ltd.& NRL.
Further Gail has plans to augment the installed capacity further by putting up new plants of
HDPE/LLDPE by 500 KTA at pata, which is targeted to the operational by FY 2013-14

Linear low density polyethylene(LLDPE)

This is the only LLDPE plant in North India. The plant installed new generation multi reactor
spheriline process. The technology used is termed as Swing technology owing to its flexibility
of producing both HDPE and LLDPE.
Different sections:
1. Monomer purification unit
2. Polymerization section
3. Catalyst, co catalyst handling and metering
15 | P a g e

4. Prepolymerization
5. Polymer drying
6. Extrusion
7. Product homogenization
8. Product storage and bagging

High density polyethylene(HDPE)

This is a MITSUI low pressure, bimodal, twin reactor slurry process. This plant is designed to
produce HDPE and has two trains of equal capacity. The main feeds of this plant are ethylene, co
monomer(1-butene and propylene) and hydrogen. Each train of the unit is capable of running in
both parallel and series mode.

Different section:
1. Catalyst, co catalyst handling and metering
2. Polymerization
16 | P a g e

3. Separation and drying

4. Extrusion and pelletization
5. Product homogenization
6. Product storage and bagging

fig 1.4

Integrated offset plant& storage(IOP&S)

It is the midstream unit. It is required for different purposes:
1. Storage vessels
2. Nitrogen plant
3. DM plant
4. Cooling tower
5. Raw water
17 | P a g e

Storage vessels:
TYPES OF STORAGE VESSELS IN IOP&S:
Following are the types of vessels used in Storage area :
1.) Cylindrical vessels
2.) Spherical vessels (HORTON SPHERES)
3.) Double Walled Ethylene tanks
4.) Bullets
5.) Mounded Bullets
Spherical Vessels are generally preferred as its ratio of volume to surface area is less . Therefore
large amount of material can be stored in less space. There are 14 Horton Spheres, 9 cylindrical
storage vessels and 2 double walled ethylene tanks. Horton spheres present in storage area are of
different fixed designed diameters such as 11.5m, 13m and 15m. There are 8 spheres of diameter
equal to 15 m to store C2/C3 having their tag no. from TS - 101 to TS - 108 . Fire coating of
thermolag is required in these C2/C3 storage vessels as temp conditions are very low. There are 2
Horton spheres of diameter equal to 11.5 m to store Propylene with their tag no. as TS 109 and
TS 110 . There are 2 Horton spheres of diameter 13m to store Butene -1 having tag no. TS
112 and TS 113 . And there is a Horton sphere each for C4 mix ( tag no. TS - 111) and
ethylene (TS -114) as well. Likewise C2/C3 Horton sphere, insulation is required in ethylene
sphere also as its temp conditions are very low.
There are 2 Double walled Ethylene tanks to store ethylene ( from GCU ) at -104c and 0.7-0.8
kg/cm2. As temp conditions are very low so insulation with perlite is done in the annular space.
There are 9 cylindrical vessels in storage area . one for xylene , one for wash oil, one for hexane ,
one for cyclohexane , two for mixed fuel oil and two for SBP.
There are 7 mounded storage bullets to store LPG as it is heavier than air. And there are 2
mounded bullets for storage of propane also.
There are 2 storage bullets to store hydrogen also.

PROPYLENE STORAGE
18 | P a g e

In UPPC propylene will be produced in the Gas Cracker as a product. For storing this propylene,
two Horton spheres 44-TS-00-109/110 have been provided in the Offsite area. The spheres are
11.5m diameter and elevated by 5.5 m to cater to the transfer pump NPSH requirement.

Propylene product sphere

Tag No.

44-TS-00-109/110

Number of spheres

Two

Op. Pr. Kg/Cm2g 7 to 17

Op. Temp.

C 9.4 to 40

Design Pr. Kg/Cm2g 9.4 to 40

Design Temp.
Diameter

C -40/+55

M 11.5

Stored Capacity M3 650

MOC

Killed Carbon Steel

Insulation

Fire Protection Paint

C2C3 STORAGE SYSTEM

INTRODUCTION:
The complex receives natural gas as its feedstock from Pipelines. This gas is first sweetened to
remove CO2 and then sent to Gas Separation Unit for recovery of C2C3 which is mainly an
ethane rich stream (70-84% ethane). When the gas comes through the LPG plant at Vijapur, the
ethane percentage is high i.e. 84%. Otherwise when it is bypassed, the ethane percentage is low

19 | P a g e

i.e. 70%. Similarly propane percentage is low in the former case (15%) than the latter case
(26%). This is the feed stock to the Gas Cracker.
The C2C3 comes through a 8 line from the C 2C3 plant for storage at Offsites. Eight spheres each
of 1500M3 capacity (15 M diameter) have been provided for this storage. This storage capacity
is equivalent to 3 days production of C2C3 corresponding to 4,10,000 TPA ethylene production.
Under normal conditions cracker will receive C2C3 directly from C2C3 plant and a small slip ream
of 7 T/hr will be diverted to the offsite storage. Three pumps (41-PA-CF-004 A/B/C) of 100
M3/hr capacity each are provided to transfer C 2C3 to GCU. Under normal condition (when C 2C3
plant is running) this 7 T/hr will be pumped out of the storage spheres and is routed to join the
main C2C3 rundown line leading to the GCU. Thus the entire system is kept chilled at a
temperature of -2 to 5 0C. This is to ensure that the system can be taken in line immediately
whenever required. The sphere is provided with facility to measure average temperature of the
fluid by the probe mounted with servo type level transmitter on sphere top. C 2C3 will be stored in
the sphere at a temperature of -20C to 50C and a pressure of 22.5 Kg/cm2g.

fig 1.5

HORTONS SPHERE

20 | P a g e

fig 1.6
STORAGE TANK
HYDROGEN STORAGE AND TRANSFER
Receipt & Storage:
Hydrogen is used as a chain terminator in polymeric reactions. So a continuous supply of H 2 has
to be ensured for the safe running of the polymer plants. Under normal conditions, Hydrogen
coming from the PSA unit at GCU (at 19 Kg/cm2g) will be compressed by a MP compressor
(41-KA RP-001) to 50Kg/cm2g and will be routed to the consumer. The balance hydrogen will
be compressed in a HP compressor (41-KA-RP-002) up to 137 Kg/cm2g and stored in two H2
bullets (41-VV-00-118 A/B) of 70M3 capacity each. These bullets store H2 at a pressure of 137
Kg/cm2g. These will be in use when H2 is not available from GCU-PSA. The HP compressor
can also be used as a standby of the MP compressor whenever required. PCV-2103 has been
provided to let down HP hydrogen pressure to MP level for consumption. Provision is also there
to evacuate the bullets by the same compressor whenever required.

Hydrogen Bullets Tag No. 41-VV-00-118 A/B

Number of Bullets

21 | P a g e

Two

Dia of Bullets M 2.5

Length of Bullet M 13.2
(Excluding Heads)
Op. Pr. Kg/cm2g 137
Op. Temp

Ambient

Design Pr. Kg/cm2g 149

Design Temp

C 55

Stored Capacity M3 70
MOC

Carbon Steel

Insulation

Nil

Each bullet is provided with the following instruments:- One pressure transmitter
- One temperature gauge
- One pressure gauge
- Two safety valves (one in operation + one spare) Designed for fire case.
Each bullet is provided with two process line, one fill-in and one line grouted to the consumer.
All the process lines are provided with remote operated valve for isolation in case of any
emergency i.e. fire, leakage, etc. Thus on closure of these valves, the bullet gets isolated from
rest of the system. Both open and close push buttons and status indications of these ROVs are
available in the control room. Each bullet is protected with a pair of safety valves (one operating
+ one standby) designed for fire case discharge capacity.

SAFETY IN STORAGE VESSELS

22 | P a g e

FIRE:

Spheres are protected against external fire by a layer of fire proofing paint which can
stand fire for 2 hrs. Apart from this over this layer, there are networks of thermal fuses
and water spray. Thermal fuses are small glass bulbs filled with a liquid set to break when
it gets heated upto 790C and are located at the tip of an instrument air network. Thermal
fuses seal the network thus pressurizing the entire network to level of instrument air
pressure. The second network is that of fie water with a spray on the tips. Water is
supplied to this network through a solenoid operated valve which normally remains
closed. When the bulb breaks instrument air leaks out causing a drop in air pressure. A
low pressure switch located on instrument air line to each sphere is actuated when
pressure falls to 2.5 Kg/cm2g. This in turn actuates solenoid valves thereby closing
ROVs of respective sphere and simultaneously opening solenoid operated valve on fire
water line to the sphere. The sprays will drench the sphere at a rate of 10 LPM/M2 of
sphere surface area. Instrument air is supplied through a restriction orifice so that when a
bulb breaks only PSL of the affected sphere is actuated while instrument air network on
other two spheres remain pressurized. ROVs on hydrocarbon lines and those on fire
water lines are operate as described for the case of propylene storage. Instrument air to
only bottom ROV is supplied through a volume bottle with capacity sufficient for two
operations

In the event of fire in the sphere area, the sphere is provided with security system to
isolated the affected sphere from the others. All the spheres are provided with two nos. of
safety valves sized for fire case (1+1). This safety valve will be protecting the sphere
from over pressure by dumping the vapour generated due to fire.

High expansion foam can also be applied on the ethylene tank. Around 5000 lpm of foam
solution can be applied on the tank

All the ROVs of the spheres are provided with close facility from field.

The deluge valves on fire water sprinkler lines for adjacent tanks in the dyke shall get
opened.

The transfer pumps shall get tripped.

LEAKAGE/ LINE RUPTURE:

All the ROVs of the spheres are provided with close facility from the local control panel.

23 | P a g e

All the deluge valves for the water sprinkler is provided with push buttons in the control
room to open them manually.

Gas detectors are provided near each ROV and one on the top of the sphere to alert the
operator from gas leakage

Dm plant
INTRODUCTION:
De-mineralized water is required in GAIL, Pata complex to generate steam as well as for process
use for injection, dilution, washing etc. in units like GCU, LLDPE/ HDPE (Swing), HDPE
(Slurry). Treated raw water is fed to DM water plant to produce DM water of required quality.
DM water is distributed to various users from DM water storage tanks (three in number) which
can meet 6 hours normal requirement each. Three DM water pumps (2 Oper + 1 Standby) in D.
M. Plant-1 and two DM water pumps (1 Oper + 1 Standby) in D. M. Plant-2 are provided to feed
DM water to Power plant and process units.
Brief description of DM plant is given in this section. For detailed description of DM plant, start
up and shut down procedure. Vendors manual shall be referred.

DM WATER REQUIREMENT:
The estimated requirement of DM water for GAIL, Pata is given below:

Normal

Maximum

(T/hr)

(T/hr)

20

5.0

10

10

20

Butene 1

Caustic dilution

7.0

GCU
LLDPE/ HDPE
HDPE-I&II

Spent caustic plant

24 | P a g e

3.0

BFW required for steam

120

130

Generation
HRSG

70

TOTAL DM WATER

90

210

275

DM WATER CHARACTERISTICS:

pH

6.5 7.0

Conductivity micromho/cm

0.2

Total Silica as SiO2

0.02

Turbidity

NIL

Iron as Fe

0.005

TDS

0.1

Copper as Cu

<0.005

Hardness

Nil

CAPACITY:
To meet DM water requirement at GAIL, Pata, two chains each capable of producing 125 M3/hr
(2500 m3/day) DM water are provided. One more chain having capacity of 200 M3/hr (4000
M3/day) was installed in 2002 with installation of LPG plant. Chains are run as per D. M. Water
requirement in the plant.

25 | P a g e

QUALITY OF FEED WATER:

The quality or feed water for DM plant is follows:

pH

7.5-8.3

Turbidity

NTU

<2

M alkalinity as CaCO2

mg/l

80

Ca hardness as CaCO3

mg/l

80

Total hardness as CaCO3

mg/l

110

Chloride as Cl

mg/l

20

Sulphate as SO4

mg/l

60

Total Silica as SiO2

mg/l

20

Total Iron as Fe

mg/l

<0.1

Organic matter as KMnO4

mg/l

<65

PROCESS DESCRIPTION:

Refer INDOCAN P&ID

1228-PI-AI-1041/1042/1043/1044/6041/6042/6043
Refer VA TECH WABAG P&ID
3549-P033-B003-01/02/03/04/05/06

Treatment Scheme:
1)
The water as delivered at the de-mineralizing plant is clarified and filtered by other. It has
little turbidity, organic matter (KMnO4 value) free chlorine and iron. The Activated Carbon
26 | P a g e

Filters (ACF) is installed to effectively eliminate these from the de-mineralized water. To
produce de-mineralized water quality specified above, the water is passed through successive
fixed beds of ion exchange resins. The resin columns are arranged serially as follows:
a)

Strong acid cation exchanger

b)

Degasser system (mechanical, non resin)

c)

Weak base anion exchanger

d)

Strong base anion exchanger

e)

Mixed bed

II)

Column Description:

a)

Strong acid cation exchanger (SAC 1 & 2):

i)

This ion exchange resin exchanges the calcium, magnesium, (i.e. hardness) and sodium
ions present in feed water with Hydrogen ions. This exchange is represented as follows:
RH + NaCl R Na + H+ + Cl
where R represents resin. H+ and Na+ (or Ca or Mg) are cations and Cl- (or SO4- or HCO3- etc.) is
anion.
ii)
The water leaving the cation exchanger column will thus contain HCl (Hydrochloric
acid). H2SO4 (Sulphuric acid) and H2CO3 (Carbonic acid) in quantities equivalent to the cations
removed from the water. The decationised water is thus acidic (pH approx. 4).
iii)
The fixed resin bed has finite quantity of H + ions. Once these have been exchanged for
Ca. Mg and Na ions, the treatment is stopped and the resin is regenerated to replenish the H +
ions. This is done by passing a solution of HCl (Hydrochloric acid) through the column. The
exchange is represented as follows:
RNa + HCl RH + NaCl
The exchange process is thus reversible. The strength of the solution passing through the bed
shall be 4-5%.
iv) The strongly acidic cation exchange resin will exchange all the Ca ++ and Mg++ ions in the
water till the bed is exhausted. Howerver, its affinity to Na + ions is not as strong and therefore
decationized water is hardness free but contains Na+ ions as leakage.
v) The sodium ion leakage is controlled by the quantity of Acid used for regeneration
(Regeneration level). Higher regeneration level reduces Na+ ion leakage.
27 | P a g e

vi) The sodium ion leakage is also regulated by the method of regeneration. Injection of acid in a
direction opposite to the direction of treatment flow (counter current) produces consistently
lower Na+ leakages for the same regeneration level than passing the acid in the direction of
treatment flow. Air pressure from the top is applied to hold the resin without lifting during
counter current regeneration and displacement rinse.
vii) Na+ ion leakage contributes to

viii)

a)
Conductivity of Dematerialized water.
b)
Silica leakage in De-mineralized water and hence must be controlled.
After regeneration, the resin is rinsed with water to waste away the excess acid and the

column can be used again to exchange.

b)

Degasser System:

i) The de cationised water contains strong and weak acids (see (a) ii). The carbonic acid is a
weak acid which is easily driven out of water in the form of carbon di oxide by passing a current
of air through cascading water.
ii) This reduces the exchange load on the following anion exchangers. This is accomplished
mechanically and does not require regenerate chemical.
iii) Water is allowed to fall down in a cylinder filled with raschig rings. The rasching rings
increase the surface area on which water film is formed.
iv) Air is blown into the cylinder from the bottom and passes out at the top with the carbon di
oxide disassociated from the carbonic acid present in the water. Air flow rate is 1080 m3/hr/m2.
v) The water thus stripped of CO2 is collected in a degassed water storage tank and pumped
from there to the anion exchanger.
vi) There is a minimum amount of carbon di oxide retained in the water even after degassing.
This amount is 5.7 mg/ltr as CaCO3 (5ppm as CO2) considered as maximum.

c) Weak Base Anion:

i) This ion exchange resin exchanges, the chlorides and sulphates (equivalent mineral acidity or
EMA) present in the degassed water with Hydroxyl ions (OH -). This exchange is represented as
follows:
ROH + HCl R+ Cl- + H+OHWhere R represents resin. OH- and Cl- (or SO4-) represent Anions.
28 | P a g e

ii) The water leaving the weak base anion column will thus contain only silica and the leakage
CO2 of degasser tower in the form of respective acids along with sodium leakage of cation
exchanger.
iii) As with cation exchanger the fixed resin bed has finite quantity of hydroxyl ions and once
these have been exchanged for chloride and sulphate ions the treatment is stopped and the resin
is regenerated to replenish the OH- ions. This is done by passing a solution of NaOH (sodium
hydroxide) through the column. The exchange process is thus reverse.
iv) The weak base anion resins have very high regeneration efficiency and can be regenerated
with slight excess of caustic soda over the exchanged load. Also weak base resin can be
regenerated with very dilute solutions of caustic soda. Also weak base anion exchanger can
contain up to 1 mg/ltr as CaCO3 of chloride ions as leakage.

v) To economize on the consumption of caustic soda for regeneration, the weak base anion is
regenerated in Thoroughfare, with the following strong base anion. This gives the advantage of
passing the total quantity of caustic soda required for both strong base and weak base anion
exchangers through the strong base anion exchanger first and then passing it through the weak
base anion exchanger.
vii) After regeneration the resin is rinsed with degassed water to wash away the excess caustic
soda and the column can be used again to exchange.

d)

Strong Base Anion Exchanger:

i) This ion exchange resin exchanges anions of both strong and weak acids. In the present case,
since the anions of strong acid are exchanged in the preceding weak base anion column the feed
to the strong base exchanger contains mainly silica, carbon dioxide, and chloride in the form of
acids. The later two being leakages from degasser and weak base anion. Besides it contains the
sodium leakage of cation exchanger.
ii) In the strong base anion exchanger, the silica, chlorides and bicarbonates, all anions, are
exchanged with hydroxyl ions. The water leaving the strong base anion exchanger will thus
contain equivalent quantity of NaOH as an exchange product of sodium leakage from cation
exchanger and silica as leakage of the strong base anion exchanger.
iii) The fixed resin bed after being exhausted is regenerated with sodium hydroxide to replenish
the OH ions: the process is thus reversible.
iv) The strong base anion exchanger will exchange all anions but its affinity for silica is not as
strong and therefore the anion treated water will contain some silica as leakage. This leakage is
increased due to the presence of sodium ions in water which is converted into sodium hydroxide.
29 | P a g e

e)

Mixed Bed Exchanger:

I) This ion exchange resin exchanges both Anions as well as Cations. In the present case, the
slippage of Anions from WBA and then SBA and slippage of Cations from SAC is taken care of
by this exchanger.
II) This exchanger consists of Strong Acid Cations resin and Strong Base Anion resin. Both
resins are mixed with each other for the purpose of final polishing of the water.
III) For regeneration of both the resins, both beds are required to be separated. For that the mixed
bed is fluidized by counter current water flow. Both beds are separated with water layer is seen in
between both the beds. Because of difference in specific gravity of both types of resins, Strong
Base Anion resin bed settles at the bottom and Strong Acid Cations settled at the top.
IV) As usual SBA resin is regenerated by 4-5% conc. Solution of NaOH and SAC resin is
regenerated with 4-5% conc. of HCL.
v) After regeneration the resins are mixed by passing a current of air from bottom of the vessel.
After mixing the mixed resins are rinsed and can be put back to exchange.

30 | P a g e

Cooling tower & cooling tower efficiency

A cooling tower is a heat rejection device which extracts waste heat to the atmosphere through
the cooling of a water stream to a lower temperature. Cooling towers may either use
the evaporation of water to remove process heat and cool the working fluid to near the wet-bulb
air temperature or, in the case of closed circuit dry cooling towers, rely solely on air to cool the
working fluid to near the dry-bulb air temperature. Common applications include cooling the
circulating water used in oil refineries, petrochemical and other chemical plants, thermal power
stations and HVAC systems for cooling buildings. The classification is based on the type of air
induction into the tower: the main types of cooling towers are natural draft and induced
draft cooling towers. Cooling towers vary in size from small roof-top units to very
large hyperboloid structures (as in the adjacent image) that can be up to 200 metres (660 ft) tall
and 100 metres (330 ft) in diameter, or rectangular structures that can be over 40 metres (130 ft)
tall and 80 metres (260 ft) long. The hyperboloid cooling towers are often associated
with nuclear power plants,[1] although they are also used to some extent in some large chemical
and other industrial plants. Although these large towers are very prominent, the vast majority of
cooling towers are much smaller, including many units installed on or near buildings to discharge
heat from air conditioning.

History:
Cooling towers originated out of the development in the 19th century of condensers for use with
the steam engine. Condensers use relatively cool water, via various means, to condense the steam
coming out of the pistons or turbines. This reduces the back pressure, which in turn reduces the
steam consumption, and thus the fuel consumption, while at the same time increasing power and
recycling boiler-water. However the condensers require an ample supply of cooling water,
without which they are impracticalthe cost of the water exceeds the savings on fuel. While this
was not an issue with marine engines, it formed a significant limitation for many land-based
systems. By the turn of the 20th century, several evaporative methods of recycling cooling water
were in use in areas without a suitable water supply, such as urban locations relying on municipal
water mains. In areas with available land, the systems took the form of cooling ponds; in areas
with limited land, such as in cities, it took the form of cooling towers. These early towers were
positioned either on the rooftops of buildings or as free-standing structures, supplied with air by
fans or relying on natural airflow. An American engineering textbook from 1911 described one
design as "a circular or rectangular shell of light plate in effect, a chimney stack much
shortened vertically (20 to 40 ft. high) and very much enlarged laterally. At the top is a set of
distributing troughs, to which the water from the condenser must be pumped; from these it

31 | P a g e

trickles down over "mats" made of wooden slats or woven wire screens, which fill the space
within the tower.
A hyperboloid cooling tower was patented by the Dutch engineers Frederik van
Iterson and Gerard Kuypers in 1918.[7] The first hyperboloid cooling towers were built in 1918
near Heerlen. The first ones in the United Kingdom were built prior to 1930 in Liverpool,
England to cool water used at a coal-fired electrical power station

Industrial cooling towers:

Industrial cooling towers for a power plant

Industrial cooling towers can be used to remove heat from various sources such as machinery or
heated process material. The primary use of large, industrial cooling towers is to remove the heat
absorbed in the circulating cooling water systems used in power plants, petroleum
refineries, petrochemical plants, natural gas processing plants, food processing plants, semiconductor plants, and for other industrial facilities such as in condensers of distillation columns,
for cooling liquid in crystallization, etc. The circulation rate of cooling water in a typical 700
MW coal-fired power plant with a cooling tower amounts to about 71,600 cubic metres an hour
(315,000 US gallons per minute) and the circulating water requires a supply water make-up rate
of perhaps 5 percent (i.e., 3,600 cubic metres an hour). If that same plant had no cooling tower
and used once-through cooling water, it would require about 100,000 cubic metres an hour and
that amount of water would have to be continuously returned to the ocean, lake or river from
which it was obtained and continuously re-supplied to the plant. Furthermore, discharging large
amounts of hot water may raise the temperature of the receiving river or lake to an unacceptable
level for the local ecosystem. Elevated water temperatures can kill fish and other aquatic
organisms , or can also cause an increase in undesirable organisms such as invasive species of
Zebra mussels or algae. A cooling tower serves to dissipate the heat into the atmosphere instead
and wind and air diffusion spreads the heat over a much larger area than hot water can distribute
heat in a body of water. Some coal-fired and nuclear power plants located in coastal areas do
32 | P a g e

make use of once-through ocean water. But even there, the offshore discharge water outlet
requires very careful design to avoid environmental problems.
Petroleum refineries also have very large cooling tower systems. A typical large refinery
processing 40,000 metric tonnes of crude oil per day (300,000 barrels (48,000 m3) per day)
circulates about 80,000 cubic metres of water per hour through its cooling tower system.The
world's tallest cooling tower is the 202 metres (663 ft) tall cooling tower of Kalisindh Thermal
Power Plant in Jhalawar, Rajasthan, India.

Heat transfer method:

With respect to the heat transfer mechanism employed, the main types are:

dry cooling towers operate by heat transfer through a surface that separates the working
fluid from ambient air, such as in a tube to air heat exchanger, utilizing convective heat
transfer. They do not use evaporation.

wet cooling towers (or open circuit cooling towers) operate on the principle
of evaporative cooling. The working fluid and the evaporated fluid (usually water) are one
and the same.

fluid coolers (or closed circuit cooling towers) are hybrids that pass the working fluid
through a tube bundle, upon which clean water is sprayed and a fan-induced draft applied.
The resulting heat transfer performance is much closer to that of a wet cooling tower, with
the advantage provided by a dry cooler of protecting the working fluid from environmental
exposure and contamination.

In a wet cooling tower (or open circuit cooling tower), the warm water can be cooled to a
temperature lower than the ambient air dry-bulb temperature, if the air is relatively dry (seedew
point and psychrometrics). As ambient air is drawn past a flow of water, a small portion of the
water evaporates, and the energy required to evaporate that portion of the water is taken from the
remaining mass of water, thus reducing its temperature. Approximately 970 BTU of heat energy
is absorbed for each pound of evaporated water. Evaporation results in saturated air conditions,
lowering the temperature of the water processed by the tower to a value close to wet-bulb
temperature, which is lower than the ambient dry-bulb temperature, the difference determined by
the initial humidity of the ambient air.

33 | P a g e

To achieve better performance (more cooling), a medium called fill is used to increase the
surface area and the time of contact between the air and water flows. Splash fill consists of
material placed to interrupt the water flow causing splashing. Film fill is composed of thin sheets
of material (usually PVC) upon which the water flows. Both methods create increased surface
area and time of contact between the fluid (water) and the gas (air), to improve heat transfer.

Air flow generation method:

With respect to drawing air through the tower, there are three types of cooling towers:

Natural draft Utilizes buoyancy via a tall chimney. Warm, moist air naturally rises
due to the density differential compared to the dry, cooler outside air. Warm moist air is less
dense than drier air at the same pressure. This moist air buoyancy produces an upwards
current of air through the tower.

Mechanical draft Uses power-driven fan motors to force or draw air through the
tower.

Induced draft A mechanical draft tower with a fan at the discharge (at the top)
which pulls air up through the tower. The fan induces hot moist air out the discharge.
This produces low entering and high exiting air velocities, reducing the possibility of
recirculation in which discharged air flows back into the air intake. This fan/fin
arrangement is also known as draw-through.

Forced draft A mechanical draft tower with a blower type fan at the intake.
The fan forces air into the tower, creating high entering and low exiting air velocities.
The low exiting velocity is much more susceptible to recirculation. With the fan on the
air intake, the fan is more susceptible to complications due to freezing conditions.
Another disadvantage is that a forced draft design typically requires more motor
horsepower than an equivalent induced draft design. The benefit of the forced draft
design is its ability to work with high static pressure. Such setups can be installed in
more-confined spaces and even in some indoor situations. This fan/fill geometry is also
known as blow-through.

34 | P a g e

Fan assisted natural draft A hybrid type that appears like a natural draft setup,
though airflow is assisted by a fan.

Hyperboloid (sometimes incorrectly known as hyperbolic) cooling towers have become the
design standard for all natural-draft cooling towers because of their structural strength and
minimum usage of material. The hyperboloid shape also aids in accelerating the
upward convective air flow, improving cooling efficiency. These designs are popularly
associated with nuclear power plants. However, this association is misleading, as the same kind
of cooling towers are often used at large coal-fired power plants as well. Conversely, not all
nuclear power plants have cooling towers, and some instead cool their heat exchangers with lake,
river or ocean water

Cooling tower efficiency:

1 week temp. reading for cooling tower:

temperature

return

Difference b/w temp.

30.98

41.12

10.14

31.42

42.00

10.58

35 | P a g e

31.00

41.98

10.98

31.61

41.24

9.63

29.60

37.62

8.02

29.88

40.17

10.29

31.18

38.46

7.28

For efficiency:
Range= hot water temp. inlet- cold water temp. outlet
Approach= cold water temp. outlet- ambient air wet bulb temp.
Efficiency= range/ hot water temp. inlet- ambient air wet bulb temp.

Efficiency of cooling tower:

WET BULB TEMPERATURE , TB= 28C
GCU RETURN , Ti= 41.12C
GCU SUPPLY , To= 30.98C
EFFICIENCY, = (Ti - To)/(Ti TB)* 100
= (41.12 30.98)/(41.12 28)* 100 = 77.28%
RANGE OF COOLING TOWER:
RANGE = Ti - To = 41.12 30.98 = 10.14C
APPROACH OF COOLING TOWER:
APPROACH = To TB = 30.98 28 = 2.98C
36 | P a g e

HEAT LOAD FOR GCU:

M = GCU SUPPLY FLOW RATE GCU RETURN FLOW RATE
HEAT LOAD = M CP T = (12165 11693) * 995 * 4.2 * 10.14 = 20,001,028.32 kilo joule
So the cooling tower efficiency is around 77.28% in natural conditions it is around 70- 79%.

Cooling tower

RAW WATER
INTR0DUCTION:

37 | P a g e

Raw water is required in GAIL, Pata for the following systems:

Cooling water system
Service water system
Drinking water system
Fire water system
DM plant feed for producing DM water
Raw water requirement in GAIL, PATA is being met from two different sources i.e. Canal
and Tube wells. The maximum amount of water available from canal is 10 Cusecs. This
water is used for DM water make up, drinking water, service water and for blending with
tube well water for using as cooling water makeup. Recycled water of RWTP is used for
firewater make up. Treated water in WWTP is used for horticulture in the plant.
Accordingly the storage system also consists of three independent reservoirs.
DESIGN BASIS:
The requirement of raw water to various systems is as follows:

SYSTEM USING CANAL WATER

QUANTITY M3/Hr
NORMAL

MAXIMUM

A)

DM Water make up

250

450

B)

Cooling Towers Make-up

600

700

B)

Drinking water system

i) Drinking water to plant

20

30

ii) Drinking water to township

43

C)

Service water to Plant

02

03

D)

Miscellaneous Water

25

27

E)

Internal (Filter Backwashing)

75

75

TOTAL

1015

1340

SYSTEMS USING TUBE WELL WATER

38 | P a g e

55

QUANTITY M3/Hr

NORMAL
Fire water make up

MAXIMUM

0-50

Horticulture

100

0-30

30

1.3 CHARACTERISTICS OF RAW WATER:

CANAL WATER

TUBE WELL WATER

pH

7.9-8.6

8.1

Turbidity NTU

20-30

20

Palkalinity as CaCO3, mg/l

Mo alkalinity as CaCO3, mg/l

Cahardness as CaCo.3 mg/l

Total hardness as CaCo3.mg/

0-3

85-95

65-70

90-100

Chloride as Cl.mg/l

82

162

10-12

Sulphate as SO4,mg/l

Silica as SiO2, mg/l

39 | P a g e

310

215

25-30

30-35

167

20

TDS, mg/l

170-190

985

Total iron as Fe,mg/l

0.15-0.2

0.2

KMnO4 value at 100 deg, mg/

Cu, mg/l

Nil

Colloidal SiO2

10

5-10

Nil

--

SYSTEM DESCRIPTION:
RAW WATER RECEIPT AND STORAGE:
Canal water is received in the complex through an open channel and stored in Canal Water
reservoirs. There are three reservoirs having a capacity of 20000 m3 each and one reservoir
having the capacity of 80000 m3. Total design capacity to store canal water is 680000 m3.
However, in year 2007, for using the free board of the dyke of the reservoirs, overflow points
were raised by 20 cm, whereby we can now store up to 750000 m3. For lifting canal water
beyond its canal natural level to uplifted level of reservoirs, two centrifugal pumps having
capacity of 700 m3/hr each were installed in 2007 on feeder channel.
This storage canal water caters to 30 days normal requirement or 25 days of maximum water
requirement of the complex. This water is then sent to Raw Water Treatment Plant RWTP-1 and
RWTP-2 (each having the capacity of 550m3/hr). Here the water is subjected to the following
continuous treatment:

40 | P a g e

Prechlorination @ 0-0.5mg/litre (ppm) based on flow rate

Coagulation with alum 10-15 mg/l based on flow rate during normal period and
@ 30 mg/l based on flow rate during rainy season when turbidity in water is high.
Catfloc-T @ 0.5-1.0 mg/l to be added during rainy season if required.
Clarification
Gravity sand filtration (rapid type)
Post chlorination @ 0.5 mg/l based on flow rate for drinking water

Lime dosing for pH correction if required.

RAW WATER SYSTEM AND TREATMENT PLANT:

P&ID No.: 3346-02-25-Ai-112 Rev. 4
P&ID EIL/3346/PPCL/490/P-02 Rev. 3 of M/s PPCL
P&ID 055/B/09/2000 Rev. 4 of M/s GDCL

RAW WATER TREATMENT PLANT PROCESS DESCRIPTION:

Raw water from the canal water reservoir is pumped into stilling chamber (SC) at the inlet of the
Raw Water Treatment Plant (RWTP-1/2) at a rate of 550 M3/hr. Detention time in the Stilling
Chamber (SC) is 5 minutes. In the stilling chamber the raw water is pre-chlorinated to remove
odour, color (if any) and as an algaecide. Water will flow into the Parshal Flume (PF) from (SC).
Flow measurement will also be recorded through a flow transmitter fitted on the PF by FR-1106
(RWTP-1) & FR-5557 (RWTP-2). A 3.7 M long approach channel after stilling chamber as well
as long outlet channel on downstream of the Flume are provided for getting uniform velocity
distribution. It will flow then into the Flash Mixer (FM). Chemicals viz. Alum (for Coagulation)
& Polyelectrolyte (Coagulant Acid) solution like Cat-Floc T or equivalent will be dosed into the
chamber. If the pH tends to fall below 7.0, lime may also have to be dosed. Alum and Lime
solutions are of 10% strength and Polyelectrolyte solution is of 1% strength.
These chemicals are thoroughly mixed in the flash mixing chamber by means of the agitator
provided. The detention period in the Flash Mixer is minimum 40 Seconds. The chemicals aids
in coagulation / flocculation within the flocculation zone of the clariflocuulator (CLF) into which
the water will flow from the FM. Two Clarifocculators (CF 1 &2) have been provided (both in
RWTP-1 & 2). 30 minutes flocculation has been provided in the flocculation zone at the centre
of the CLF. The flocculator portion is provided with continuous opening at the bottom so that the
flocculated mass of water passes out with significantly low velocity to the clarifier zone. The
clarifier and flocculator are separated by RCC wall. A slow moving flocculator mechanism
accelerates the process of forming flocs in which suspended solids and turbidity get absorbed. It
is driven by 2 HP 1450 RPM motors. The clarifier is designed for an overflow rate of 35
M3/day/M2. The sludge withdrawal from the CLF is controlled by Telescopic valves and
discharged into the SW drains. Vertical paddles have been provided for mechanical aid in
flocculation.Clarified water from clarifocculator unit flocs flows into a 400 mm wide peripheral
outlet launder, owing its travel from the bottom of the flocculation zone to the top near the outlet
launder in the clarification zone all the flocs and suspended matter precipitates at the bottom of
the CLF in the clarification zone. A very slow moving mechanical scraper has been provided,
driven by peripheral geared motor, which scrap the precipitated sludge to the central pocket at
the bottom of the CLF. This sludge flow out through the telescopic bleed pipe to the effluent
sump provided for the purpose. From the top of the CLF through the outlet lauder the clarified
raw water flow out into the battery of rapid sand gravity filter (RSGF) bed (2 nos.) provided.
41 | P a g e

Two are for normal operation and the third will be used as a stand by (275 M3/hr capacity each).
The clarified water from the CLF enter the RSGF through inlet channels provided for the
purpose. From these channels through entry valves at the top the water flow into the RSGF.
Filtration is effective through the granular sand and supporting gravel media in a vertically
downward direction and flow out into the Filtered Water Channel (FWC). In the sand filters, the
turbidity of water is reduced to <2 NTU. During the course of filtration sediments / flocs that
have been carried over from the CLF will deposit on the surface of the RSGH beds and penetrate
upto a certain depth in the sand layers only. With time (may be in 24 hrs.) the rate of filtration
may reduce and there will be head loss within the filter media. This head loss can be read from
the Loss of Head (LOH-1101 A/B/C) gauge provided. When the head loss is sufficiently high it
is an indication that the filters need to be cleaned. After cleaning the filters can be brought back
to normal use. Filter cleaning is done with water backwash from a wash water tank (330 M3
capacity) backwashing is done at the rate of 0.4 M3/min/M2 and air scouring from air
compressor/ blowers (23-BF-1 A/B for RWTP-1 & 35-KA-1005 A/B for RWTP-2) provided for
the purpose. These blowers have a capacity of 1555 M3/hr each and developing a pressure of
0.35 Kg/cm2g. The air scouring rate is 0.9 M3/min/M2. This backwash/ air scouring is done in
the reverse direction to filtration i.e. vertically upwards through the under drain pipes at the
bottom of the RSGF. This filter cleaning generally takes about 10-15 minutes. Once the filters
are cleaned normal operation can be resumed. The RSGF has been designed for a flow of 275
M3/hr/ each. The rate of filtration is 80 LPM/M2. The backwash waste water in RWTP-1 is
collected through a channel into the waste water tank adjacent to the filter beds which is pumped
by Dirty backwash pumps (23-PC-01 A/B) to the sludge lagoons which in turn again pumped
back to the inlet feeder canal channel of raw water reservoir R-3. The Back wash water in
RWTP-2 directly goes to sludge lagoons by gravity. The treated water is now sent to Treated &
Filtered water reservoirs tanks through underground pipe line

References:

1. www.Wikipedia.org
2. www.google.co.in
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3. www. Gail.nic.in
4. www. slideshare.com
5. books and referrences

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