The document provides information about GAIL (India) Limited and their Jamnagar-Loni LPG Pipeline system (JLPL). It discusses that JLPL is the world's longest exclusive LPG pipeline at 1,355 km long. It transports LPG from Jamnagar to Loni and has a capacity of 2.5 MMTPA. The pipeline consists of intermediate pumping stations, receiving terminals, sectionalizing valves, and pigging stations to facilitate the transportation of LPG. Cathodic protection and pigging systems are used to maintain pipeline integrity and cleanliness.

1. GAIL (INDIA) LIMITED
GAIL TRAINING INSTITUTE- JAIPUR
INDUSTRIAL TRAINING PRESENTATION
ON
OPERATION & MAINTENANCE
of
JAMNAGAR-LONI LPG PIPELINE
SYSTEM
At IPS Mansarampura
Submitted By – Kapil Soni

2. GAIL TRAINING INSTITUTE(GTI)
• NOIDA
• JAIPUR

3. • GAIL Limited is the largest state-owned natural gas processing
and distribution company in India declared by Govt. Of India.
• It is headquartered in New Delhi.
• It has six segments: Transmission services of natural gas &
liquefied petroleum gas(LPG)
• Natural gas trading, Petrochemicals, LPG
• Liquid hydrocarbon
• GAILTEL
• and others.
Gas authority of India Limited

4. • The gas sector infrastructure of gail is as follows:
•
• 1984 - The Birth of GAIL
• 1987 - HAZIRA VIJAIPUR JAGDISHPUR P/L
commissioned
• 1990 - Entry in LPG Processing
• 1997 - Achieved youngest Navratan Status
• 1997 - Entered in CNG Network
• 1999 - Entry Petrochemical Processing
• 2001 - Commissioned world largest LPG P/L
• 2004 - Import of LPG
• 2008 - Augmentation of Gas P/L Net work
• 2011 - Declared world No. 1 Co. in DS operation
• 2011 - MNC deal for Gas Contracts
• 2012 - New P/L dedication up to Bhatinda
• 2013 - P/L expansion in Uttrakhand
• 2013 - Declared Youngest MAHARATAN Co.
• (Top 5) by Govt. of India
•

5. Number of projects undertaken :-
• Study the CATHODIC PROTECTION OF
PIPELINE .
• Study the working of PIGGING SYSTEM, Types
of PIG And Pigging.
• List all the Mechanical Equipments with their
specification.

6. 1. LPG is a liquid under pressure but a gas at ambient
conditions.
2. Vapour LPG is twice as heavy as air.
3. Liquid LPG is half as heavy as water.
4. LPG is colorless.
5. LPG has a low boiling point of - 6°C
6. LPG has a narrow flammability range between 1.8 to 9.5%
in air.
7. Flash point of LPG is -60°C.
8. The approximate minimum ignition temperature of LPG is
in the range 410°C to 580°C.
Properties of LPG

7. 9) LPG is odourless.
10) Ethyl Mercaptan is added as an odourant to
detect LPG in case of leaks.
11) LPG is non-toxic.
12) It is lightly anaesthetic and can cause
suffocation, if present in sufficiently high
concentrations.
13) Liquid LPG can cause severe cold burns to the
skin owing to rapid vapourisation and the
consequent lowering of temperature.

8. Requirment of LPG pipeline
•Cost Benefit
•Continous flow
•Easy transportation
•Avoid delay in supply
•To reduce traffic on Road
•Prevent accident on Road

9. •In 2001, GAIL commissioned world’s longest and India’s first Cross
Country LPG
•Transmission Pipeline from Jamnagar to Loni .
•JAMNAGAR – LONI LPG PIPELINE, the world’s longest exclusive LPG
pipeline (1355 Km) & inaugurated for the commencement LPG
supply to oil companies on 24/12/2000.
•JLPL is the longest pipeline network in the world of 1335 km long,
where main line is 1244 km and spur line is 91 km.
•The pipeline is design to carry LPG and the capacity is 2.5 MMTPA.
•JLPL is used for LPG transportation.
JLPL pipeline

10. JLPL PIPELINE

11. State wise pipeline length :-
Gujarat- 578 KM
Rajasthan- 686 KM
Haryana- 98 KM
Delhi- 5 KM
UP- 48 KM
Total- 1414 KM

12. Size wise pipeline length :-
• 16” - 578.1 KM
• 14” - 166.7 KM
• 12” - 439.0 KM
• 10” - 58.67 KM
• 8” - 114.3 KM
• 6” - 43.3 KM
• 4” - 13.6 KM
Total - 1414 KM

13. This pipeline mainly comprises of:-
A. 4 Intermediate Pumping Station(IPS) - Which are
responsible for increasing the pressure to a limit so
that it can be on the next pumping station and
further-
1. SAMAKHALI
2. ABUROAD
3. NASIRABAD
4. MANSARAMPURA

14. B. Receiving Terminal(RT) - Places which we tap the LPG
so that it can be supplied to various oil companies-
•IOCL - 4
•BPCL - 4
•HPCL – 2
Most of the Terminals are having the arrangements for:-
1. Filtration Facilities
2. Temperature Control Facilities
3. Pressure Control Facilities
4. Measurement System
5. Pigging arrangement as per need
6. Fire fighting Network
7. Tap off arrangement

15. C. Sectionalizing Valves (SV) Stations-
1) Responsible for isolating the PL in case of emergency.
2) JLPL project has a total of 73 SV stations.
3) Responsible for isolating the p/ L case of emergency .
4) SV’s are installed at an average distance of 20 km all
along the pipeline
D. Crossing-
1) Rail -27
2) Road -198
3) Water bodies-149
4) HT-125
5) Foreign PL -113

16. E. 4 Intermediate Pigging Station:-
1) IP 1 ( Between Samakhali – Abu Road P/L Section)
2) IP 2 ( Between Abu Road – Nasirabad p/L Section)
3) IP 3 ( At Mansarampura)
4) IP 4 ( Between Mansarampura – Loni P/L Section)
Project cost : RS 1250 Crores

17. PIPELINE SECTION THROUGHPUT
MMPTA
FLOW RATE
TONS/HR
KANDLA TO SMK 0.5 63.33
SAMAKHIALI TO ABU ROAD 2.5 316.65
ABU ROAD TO NASIRABAD 2.5 316.65
NASIRABAD TO MANSARAMPURA 2.2 278.65
MANSARAMPURA TO LONI 2.0 253.32
FLOW RATE

18. Mechanical equipment used at IPS
MANSARAMPURA
• Booster pump/centrifugal pump
• Basket filter
• Mass flow meter
• Main jockey
• Main fire water pump
• Fire water tank
• Diesel storage tank
• Diesel transfer pump
• Scraper receiver
• Scraper launcher

19. Centrifugal Pump
• Centrifugal pump is basically a machine which is intended to
raise the pressure of an incompressible liquid from an
external source.
• Its purpose is to convert energy of a prime mover (a electric
motor or turbine) first into kinetic energy and then into
pressure energy of a fluid that is being pumped
• The energy changes occur by virtue of two main parts of the
pump, the impeller and the volute or diffuser.
• The impeller is the rotating part that converts driver energy
into the kinetic energy. Diffuser is the stationary part that
converts the kinetic energy into pressure energy..

20. Cenrifugal pump

21. Specification of Cenrifugal pump
• Pump manufacturer - DAVID BROWN
• Pump size - 6*8*10.5 B
• Model -DB 36 Multi stg. Centifugal Pump
• Number of stages – 10
• Suction pressure – 21 kg/cm2
• Discharge pressure – 70 to80kg/cm2
• Pumping temperature – 15 C normal 25 C max.
• Head – 1180m
• Capacity (normal/ rated) – 177/195 m3/hr
• Rated speed – 3420 rpm

22. • There are no drive seals, therefore the risk of leaks is
completely eradicated.
• Less heat transfer from the motor—
the pump chamber is separated from the motor by
an air gap; this provides a thermal barrier.
• Reduced friction
• Complete separation of the liquid means that liquid
cannot seep into the motor from the pump.
Advantages

23. Introduction to Pigging system
1) Pigging refers to the practice of using pipeline
inspection gauges or 'pigs' to perform various
maintenance operations on a pipeline.
2) This is done without stopping the flow of the product
in the pipeline.
3) These operations include cleaning and inspecting of
the pipeline.

24. Working of PIGGING System:-
1) This is accomplished by inserting the pig into a
'pig launcher' (or 'launching station')
2) The launcher / launching station is then closed
and the pressure-driven flow of the product in
the pipeline is used to push it along down the
pipe until it reaches the receiving trap – the 'pig
catcher' (or receiving station).

25. Thelauncher& Receivingarea:

28. TYPES OF PIG
Pigs can be broadly divided into four categories:
1) Foam pigs: which is used to remove moisture,
condensate etc.. this is a type of pig by which, it is
analysis that whether the pipe is thoroughly
cleaned or not.

29. 2) Brush and Magnetic Pigs: which are used to clean
magnetic impurities from pipes. in case when form
pig fails to protect pipeline from unwanted dirt, dust
etc., then brush pigs are used.

30. 3) Gauge pigs: which is used to check whether it
is applicable for intelligent pigging.
4 ) Magnetic Flux Leakage: which is used for
intelligent pigging .In the IPS use in determining the
thickness, anomalies, holes etc. in pipelines.

31. Types of PIGGING:-
1) Cleaning Pigging- In this pigging Foam pig
of respective pipe diameter is launched
directly into the pipes who serve normal
cleaning of pipes.
2) Intelligent Pigging- In this pigging process a
special types of pigs equipped with various
sensors to detect the various conditions of pipe
eg. Thickness of pipe range, ultrasonic sensing,
bend, and accumulation of sludge.

32. Some of the pigs after pigging :-

33. CATHODIC PROTECTION OF
PIPELINES

34. CORROSION
• WHAT IS CORROSION.
• DEGRADATION OF MATERIAL THRU
ENVIORMENTAL INTERACTION.
• FOCUS ON CORROSION OF CARBON STEEL
USED IN UNDERGROUND PIPELINES.
• WHEN IRON IS PLACED IN SOIL/WATER.

35. In order to prevent corrosion there are
coating used like iron is coated by zinc or
simply grease, paint, plastic is used. In
many cases there are cathode protection
used where a noble metal is connected to
a less noble and potential applied

36. FOUR COMPONENTS FOR CORROSION
CELL
• THERE MUST BE AN ANODE
• THERE MUST BE A CATHODE.
• THERE MUST BE A ELECTRICAL PATH
(PIPELINE ITSELF)
• THERE MUST BE A CONDUCTIVE
ELECTROLYTE (WATER/SOIL)

37. CATHODIC PROTECTION
• WE HAD SEEN THAT
• CORROSION TAKES PLACE AT ANODES.
• NO CORROSION AT CATHODES.
• DIFFERENT CORROSION CELLS ON PIPELINE.

38. WHAT WILL HAPPEN , IF WE MAKE
-THE WHOLE PIPELINE AS CATHODE.
NO CORROSION WILL TAKE PLACE..
HOW WE CAN MAKE
-BY MAKING IT CATHODE W.R.T. OTHER METAL
--BY MAKING IT TO COLLECT CURRENT FROM ANODE.
-WHEN WE MAKE ANY PIPELINE/STRUCTURE AS A
CATHODE W.R.T SOME METAL/ANODE
-IT IS CALLED CATHODIC PROTECTION.

39. CATHODIC PROTECTION- HOW IT WORKS
• PRINCIPLE
– DIRECT CURRENT IS MADE TO FLOW FROM EXTERNAL
SOURCE TO P/L
– THE PIPELINE IS MADE TO COLLECT CURRENT BY MAKING
IT CATHODE
– THE EXTERNAL CURRENT IS ADUSTED TO OVERPOWER THE
CORROSION CURRENT.
– RESULTING IN A NET FLOW OF CURRENT ONTO PIPELINE .
– ENTIRE P/L SURFACE BECOMES CATHODIC AND
PROTECTION COMPLETED.

40. GROUND BED
+IVE
-VE
TR UNIT/C.P
SOURCE
BURRIED PIPELINE
CURRENT
FLOW
ELECTROLYTE/
SOIL
FIG : BASIC CATHODIC PROTECTION INSTALLATION

41. TYPES OF CP SYSTEM
• SACRIFICIAL ANODE SYSTEM
• IMPRESSED CURRENT SYSTEM

42. Sacrificial CP System
Sacrificial Anode Pipeline
Current

43. Practical Galvanic Series for Metals in Neutral
Soil and WaterMETAL POTENTIAL V (CSE)
Mill Scale On Steel - 0.2
Mild Steel In Concrete - 0.2
Lead 0.5
Mild Steel (Rusted) - 0.5
Mild Steel (Clean and Shiny) - 0.5 to - 0.8
Aluminum Alloy (5% Zinc) - 1.05
Zinc - 1.1
Magnesium Alloy (6% Al, 3%
Zn, 0.15% Mn)
- 1.6
Commercially Pure
Magnesium
-1.75

44. Impressed Current CP System
Impressed current Anode Pipeline
Current
DC Power
Source+ -

45. ENVIRONMENT CURRENT DENSITY IN
mA/m2
WELL-AERATED NEUTRAL SOIL 21.5 – 32.3
DRY, WELL-AERATED SOIL 5.4 – 16.1
WET, SOIL, MODERATE/SEVERE
CONDITIONS
26.9 – 64.6
HIGHLY ACID SOIL 53.8 – 161.4
STATIONARY FRESH WATER 53.8
MOVING FRESH WATER 53.8 – 64.6
WELL COATED PIPELINE IN
SOILS
0.01
CURRENT REQUIREMENTS FOR STEEL

46. TYPES OF ANODE BEDS
• HORIZONTAL ANODE BED
• VERTICAL ANODE BED
• DEEP WELL ANODE BED

47. Horizontal Anode Bed
3m 6m 0.4m
Ground Level
Anode cable Coke
1.1m 0.75m Section

48. Vertical Anode Bed
6m 0.4m
1.1m 0.75m
Anode cable Coke Section

49. Deep well Anode
Bed
10 m
1.0 m
1.0m
Anode cable
Coke
Section
0.3 m

50. O&M Base Jurisdiction:
IPS, Mansarampura
Scheduled activities of LPG Pipeline
as per Maintenance policy
Guidelines.

51.  Normal PIGGING : Frequency – Yearly
 INTELLIGENT PIGGING: Frequency – 10 Years
 Helicopter / Aerial Surveillance- Monthly
Foot Patrolling:
 Foot Patrolling by Security Agency personnel: Daily
 Yearly foot patrolling by GAIL officials after
monsoon
 4) Coating Integrity Survey : Quaterly
 5) Thickness Measurement Survey : 2 times in a year
 6) IDENTIFICATION AND MONITORING OF
VULNERABLE LOCATIONS: Monthly

52. ANY QUERIES ??