Gas Detectors Zoning Study for Sachal Gas Processing Complex at MPCL

Project Overview

The Gas Detectors Zoning Study for the Sachal Gas Processing Complex at MPCL aims to assess and establish appropriate zoning for gas detectors to ensure safety and effective monitoring of potential hazards at the facility

The Sachal Gas Processing Complex (SGPC) managed by MPCL includes two primary processing facilities: the Gas Process Facility for TIPU and the Gas Process Facility for GORU. This study focuses on ensuring the optimal placement and efficiency of flammable gas detectors across the complex, ensuring the early detection and mitigation of hydrocarbon gas leaks.

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Facilities at Sachal Gas Processing Complex

• TIPU Facility
  • Process Overview:
    • Multiphase well fluid from Tipu 1 and 2 wellheads is directed to a three-phase intake separator. Key operations include:
    • Gas Measurement: Sales gas is metered at the 2-stage membrane unit, while HP raw gas is measured before further processing.
    • Hydrocarbon Condensate Management: Condensate is stored in tanks after passing through a degasser.
    • Produced Water Treatment: Water from the separator flows through degassing and CPI units into ponds.
• GORU Facility
  • Process Overview:
    • Goru wellheads fluid undergoes separation and pretreatment to reduce CO2 levels before processing through amine sweetening and glycol dehydration units. Key operations include:
      • Gas Integration: Mixed with TIPU-treated gas and metered.
      • Condensate Handling: Similar to TIPU, condensate is degassed and stored.
      • Produced Water Management: Directed through CPI systems into ponds.
• HRL Facility
  • Process Overview:
    • Gas from HRL wells is compressed and routed for further processing, either through Goru Membranes Pretreatment Skids or ASU Units, enabling seamless sales and operations.

Scope

The scope of this study is to ensure the flammable gas detection are in place to check early detection of HC Gas leaks/accumulation/migration.,

Fire and Gas Mapping Study (F&G)

Objectives

In Fire and Gas mapping study (F&G) the goal of the gas detection study is to make sure that gas detectors are installed in accordance with the project's gas detection philosophy based on gas detector layouts, to find any gaps based on the study, and to offer suggestions where necessary regarding the quantity and positioning of the different detectors.

Fire & Gas detection:

Rapid early detection of an emerging gas leak is a key factor in the effectiveness of a fire protection system, and a rapid response can minimise the potential for an escalation. In order to limit the impact of releases on personnel, the environment, assets, and reputation, a good fire and gas detection system provides detection provisions that are in line with the threats prevalent throughout the site. Detection can be performed using personnel or protective equipment, equipment detection systems include:

• A manual call point that staff members use to issue a warning
• Gas detection, which provides a warning on gas leaks. (Flammable)

Methodology

• Step 1: Hazardous Area Identification
  • Hazardous Area Identification Based on the facility plot design and process simulation report, the Sachal Gas Processing Complex will be subjected to a thorough desktop assessment in order to identify hazardous regions with flammable gas hazards. These areas will then be divided into various hazardous detection or mapping areas.
• Step 2: Hazardous Area Characterization
  • On the basis of the aforementioned identification, a desktop study will be conducted to characterize great risks for accidents, considering fluid properties and release quantities using PIDs and the Process Simulation Report. Additionally, using the plot plan and 3D model, locations that are likely to accumulate flammable gases will be classified as open, crowded, or confined.
• Step 3: Determination of Risk Volume / characteristic cloud for detection
  • Risk volume characterized as the volume within which the accumulation of hydrocarbon gas may result in a potential explosion or flash fire, causing significant harm to personnel and assets. Typically, it is determined based on the guidelines outlined in Shell DEP 32.30.20.11, considering the area characterization, such as open, congested, or confined, and is often expressed in terms of diameter.
• Step 4: Modelling.
  • The 3D geometry file is imported into the software and the gas detectors are placed based on the provisional layout for gas detector at the dangerous zone.
• Step 5: Coverage Mapping
  • The preliminary evaluation of coverage to achieve the specified target will be conducted by utilizing the existing detectors position. If any limitations are identified, further steps will be taken, including the installation of new detectors or relocating existing ones, to ensure that the detectors are appropriately positioned to sense and detect potential gas dispersion in that area.
• Step 6: Optimization/Detector Layout Definition
  • Redo the above procedures for all loss of containment scheme. Optimize the detector position height or modify the detector position to accommodate hydrocarbon release dispersion coverage if detectors prove inadequate to detect or observe the dispersion.

Executive Summary

Gas Detection Study for this project has been performed using the appropriate software and the results were presented in the below table format.

Based on the zone-wise study, a considerable No of detectors have been relocated within their respective zones. Furthermore, a considerable No. of detectors have been removed from their respective zones. Additionally, the required no of detectors, and point-type gas detectors have been added to their corresponding zones prior to the existing detectors after relocation.