Another failure, another mess
Tuesday, 7 April 2009
Engr Khondkar Abdus Saleque
AT a time when Bangladesh is suffering from severe energy crisis due to gas deficit, Petrobangla /GTCL's impudent action has created another undesirable mess.
Petrobangla's action for evacuating the trapped 70 mmcfd from Jalalabad Gas Field in Sylhet through constructing a new spur line did not work. The Gas pressure at Khatihata off-take of North-South Transmission Corridor obviously developed higher than desired pressure to allow off-take from Titas gas field location 5 into the system. This as reported in media caused panic among the now-novice Petrobangla gas bosses .Gas supply from Titas field to N-S system was stopped causing gas draught in national grid and obvious tripping of some pressure-sensitive units down the line. At this stage of serious energy crisis principally due to gas shortage, this kind of unimaginative unplanned action of Petrobangla /GTCL deserves stern punitive action. The key functionaries of Petrobangla should be asked to explain what the parastatal gained from adding another cost element for recovery by Chevron here. Some persons should be held responsible for the loss triggered by failures of gas system. The withdrawal of 220-230 mmcfd gas from Jalalabad field was possible in 2004. It did not require additional spur line if downstream evacuation and pressure could be adjusted. Keeping high flow from Bibiyana, Jalalabad can never deliver the expected gas at Golapgonj intake point which also takes gas from Kailashtilla and Beanibazar gas fields. GTCL has gas network simulation computer programme. It has SCAA system which can monitor live pressure and flow from all gas fields. Everyone knows that NS corridor cannot handle any additional gas without Gas Compressor or loop lines. Still some impudent bosses to impress new government tried this adventure which, unfortunately, could not be managed professionally.
In what follows are some frustrating media reports.
"Upbeat about tapping the maximum output from the newly installed Jalalabad spur line, but later getting disappointed, Petrobangla stopped gas supply from Titas Gas Field's North-South (N-S) Gas Pipeline.
Failing to reach its target of adding 60 mmcf gas through this much-talked-about pipeline, Petrobangla instructed Gas Transmission Company Limited (GTCL) to stop the gas flow, which ultimately reduced gas pressure in different pockets at Demra and Amin Bazar gate in greater Dhaka.
Many believed that if Chevron, the US based operator, were allowed to install this spur line then it would add 60 mmcf gas to the network. Petrobangla and Chevron have successfully commissioned a spur line and commissioned it from March 26, but failed to add any gas. "We have completed the work, but unfortunately, it did not yield the output as we desired. The Chevron and GTCL people are working on the project and we assume the situation will improve in the shortest possible time," a high official of Petrobangla, told an English daily.
The Petrobangla official said the GTCL people found out that if the spur line extracted a large quantity of gas then it would create serious pressure anomalies in the line, as the pressure levels of Kaylashtila and Bibiyana gas fields do not match that of Jalalabad gas field. As a result, they suggested Petrobangla to stop the gas flow from North-South Gas Pipeline of Titas Gas Field, he added.
According to sources in Petrobangla, it is now being pondered, if there are any big consumers in the area, then it may add the desired amount.
If that is the issue then why Petrobangla has spread the word that the spur line would add huge quantity of gas," a top official asked. It was learnt that before starting operation of this 'spur-line', Jalalabad gas field was producing about 143 mmcfd of gas. But it is now producing 100 to 110 mmcf of gas.
The chairman of Petrobangla earlier told reporters that the pipeline would enhance gas supply by 40 mmcfd to the national gas network, which would finally lead to an additional supply to the gas-starved power plants and other industries.
As had been viewed by some gas experts, the persisting bleak power situation was expected to improve slightly from the end of this month with the commissioning of a 'spur-line' aiming at boosting gas supply from Jalalabad gas field.
Due to lack of gas supplies, different gas-fired power plants in the country cannot generate around 660 megawatt (MW) power. It was believed that commissioning of the new spur line would add 60 to 70 mmcfd gas, which could help Power Development Board (PDB) generate around another 300 MW power.
Initiated as part of a move by Petrobangla and Gas Transmission Company Ltd (GTCL) to overcome problems arising out of various bottlenecks in their gas pipeline system -- the 750-metre long and 12-inch diameter pipeline -- has been declared ready for commissioning. It was to facilitate an approximately 50 per cent increase in gas production from Jalalabad field by the end of this year.
Jalalabad field now produces around 150 mmcfd gas.
To commission the spur line, the operator of Jalalabad field -- Chevron, was to stop gas production from Jalalabad for three days. The process of commissioning involved shifting the measuring meters from Kailastila to Jalalabad."
When the thoughts of constructing spur line came to our notice, we felt a bit confused. We could not make out how this additional gas from Jalalabad would be transported through a supersaturated transmission system without adjusting off-take pressure at several locations. Yes, it could be transported adjusting the delivery and delivery pressure from different downstream gas fields like Habiganj, Titas and accepting lower pressure at Ashuganj Manifold station. The gas demand in the entire system was to be monitored. Someone having hands-on knowledge of national gas grid should have taken the lead. The communication system at all load intake and off-take points should have been established. One wonders if the system demand was enough for additional withdrawal at that time? As it appears now, GTCL was not tasked with proper homework. Two GTCL senior executives Engr Jameel A Aleem and Engr Sanwar Hussian Chowdhury commissioned several transmission systems in my team. Whether they were involved is a matter of guess! Gas system operation cannot be the piece of cake of every Tom, Dick or Harry.
Anyone who has basic knowledge of natural gas and hydraulics is aware that gas unlike water is a compressible fluid. It is driven by pressure difference. Any gas transmission pipeline is designed to handle a maximum allowable operating pressure. Twenty four inches O.D, 175 km-long ANSI# 600 North-South Pipeline from Gooloogonj Sylhet to Ashuganj, Brahmanbaria at MAOP 1076 PSIG can carry 420MMCFD gas. In an ideal situation, the terminal pressure at Ashuganj Gas Manifold station used to drop down to 800PSIG. But gas delivery into that pipeline is staggered -- gas is injected at various intakes along the line. Before construction of Rashipoor -- Ashuganj Loop line, the staggered nature of gas intake facilitated transportation of 500MMCFD+ through N-S pipeline to meet increased gas demand downstream of Ashuganj Gas Manifold station.
This writer was GTCL Project Manager of Rashidpoor-Ashuganj Gas Transmission Loop-line and later worked at Director (Operation) GTCL. At this critical stage, it is now considered as a 'religious obligation' to deal with the situation. Prior to the design of Rashidpoor Ashuganj Loop line, we carried out extensive gas transmission system simulation utilising the win flow simulation system borrowed from UNOCAL. In many permutations and combinations, it appeared that a 30-inche OD, 82 km loop line, looped at Muchai, Shajibazar, Madhadpoor, Khatihata and Ashuganj with North -- South Pipeline, would facilitate addition of 800mmcfd gas to N-S corridor. This, together with 500 mvcfd of N-S pipeline, created a total capacity of 1300mcfd. But the demand downstream kept on increasing. The downstream capacity was subsequently enhanced upon construction of Ashuganj-Monohardi and Dhanua-Savar Pipelines.
In this situation, prior to development of Maulavibazar and Bibiyana Gas fields in 2004, the author took initiative to acquire computer software through Cairn for GTCL to carry out network simulation. We found that to evacuate additional gas from Bibiyana beyond 2008 (Bibiyana was projected to produce 600mmcfd+) we had two options:
a.) build a second loop line from Muchai to Ashuganj,
b). Set up Pipeline Compressor Stations at Muchai and Ashuganj.
We had to step beyond our shoes on occasions to convince Petrobangla bosses that pipeline compressor stations were the better choice. Ultimately, the Asian Development Bank (ADB) had to engage consultant to convince Petrobangla of pipeline compressor stations.
Ultimately installation of pipeline compressor stations were included in ADB-assisted GSDP and these were foreseen to be in operation by 2008 to handle additional gas from North Eastern gas fields. In 2009, gas fields are ready to deliver additional gas, market is hungry for gas but unfortunately the implementation of pipeline compressor stations did not even start.
In this situation, any attempt to add new gas an already saturated transmission system was an act of novice. Moreover when new gas is introduced into a congested system, it has to be done with great care, observing pressure build up and intake-off-take pressure at different points. GTCL has SCADA .It can monitor pressures and flow at all points. So it is not understood why there was panic. Did they work out a comprehensive plan as to how the additional gas from Jalalabad would be introduced? Did they adjust flow from Bibiyna? Keeping Bibiyna at 600+, it was impossible to have additional flow from Jalalabad. Delivery from downstream gas fields like Titas and Habiganj required appropriate adjustment to bring new gas from Jalalabad.
Jalalabad gas field on many occasions, when this writer operated National Gas Grid as Director (Operation), delivered 210-220 mmcfd. Of course, at that time Bibiyana was not on stream. During our time, we did not have Ashuganj- Monohardi loopline. But still we could accommodate 220 mmcfd gas from Jalalabad gas field. After its commissioning, Bibiyna should have kept Jalalabad flowing at 200 mmcfd + and adjust intake from other fields. Bibiyana should not have been allowed access beyond minimum take or pay till its cost recovery was complete. Additional gas evacuation was contingent upon installation of compressor stations at Muchai and Ashuganj which is still at least two years into the future.
It is surprising why Petrobangla/GTCL acted like novice. It is disgraceful for a pipe liner. This writer was thoroughly embarrassed for unimaginative GTCL action which caused another nuisance at a time when nation is suffering due to gas sector failures. We built GTCL reputation with great pains. Novice Petrobangla bosses must own this failure and may be asked to explain.
The writer can be reached at email: saleque123@gmail.com
AT a time when Bangladesh is suffering from severe energy crisis due to gas deficit, Petrobangla /GTCL's impudent action has created another undesirable mess.
Petrobangla's action for evacuating the trapped 70 mmcfd from Jalalabad Gas Field in Sylhet through constructing a new spur line did not work. The Gas pressure at Khatihata off-take of North-South Transmission Corridor obviously developed higher than desired pressure to allow off-take from Titas gas field location 5 into the system. This as reported in media caused panic among the now-novice Petrobangla gas bosses .Gas supply from Titas field to N-S system was stopped causing gas draught in national grid and obvious tripping of some pressure-sensitive units down the line. At this stage of serious energy crisis principally due to gas shortage, this kind of unimaginative unplanned action of Petrobangla /GTCL deserves stern punitive action. The key functionaries of Petrobangla should be asked to explain what the parastatal gained from adding another cost element for recovery by Chevron here. Some persons should be held responsible for the loss triggered by failures of gas system. The withdrawal of 220-230 mmcfd gas from Jalalabad field was possible in 2004. It did not require additional spur line if downstream evacuation and pressure could be adjusted. Keeping high flow from Bibiyana, Jalalabad can never deliver the expected gas at Golapgonj intake point which also takes gas from Kailashtilla and Beanibazar gas fields. GTCL has gas network simulation computer programme. It has SCAA system which can monitor live pressure and flow from all gas fields. Everyone knows that NS corridor cannot handle any additional gas without Gas Compressor or loop lines. Still some impudent bosses to impress new government tried this adventure which, unfortunately, could not be managed professionally.
In what follows are some frustrating media reports.
"Upbeat about tapping the maximum output from the newly installed Jalalabad spur line, but later getting disappointed, Petrobangla stopped gas supply from Titas Gas Field's North-South (N-S) Gas Pipeline.
Failing to reach its target of adding 60 mmcf gas through this much-talked-about pipeline, Petrobangla instructed Gas Transmission Company Limited (GTCL) to stop the gas flow, which ultimately reduced gas pressure in different pockets at Demra and Amin Bazar gate in greater Dhaka.
Many believed that if Chevron, the US based operator, were allowed to install this spur line then it would add 60 mmcf gas to the network. Petrobangla and Chevron have successfully commissioned a spur line and commissioned it from March 26, but failed to add any gas. "We have completed the work, but unfortunately, it did not yield the output as we desired. The Chevron and GTCL people are working on the project and we assume the situation will improve in the shortest possible time," a high official of Petrobangla, told an English daily.
The Petrobangla official said the GTCL people found out that if the spur line extracted a large quantity of gas then it would create serious pressure anomalies in the line, as the pressure levels of Kaylashtila and Bibiyana gas fields do not match that of Jalalabad gas field. As a result, they suggested Petrobangla to stop the gas flow from North-South Gas Pipeline of Titas Gas Field, he added.
According to sources in Petrobangla, it is now being pondered, if there are any big consumers in the area, then it may add the desired amount.
If that is the issue then why Petrobangla has spread the word that the spur line would add huge quantity of gas," a top official asked. It was learnt that before starting operation of this 'spur-line', Jalalabad gas field was producing about 143 mmcfd of gas. But it is now producing 100 to 110 mmcf of gas.
The chairman of Petrobangla earlier told reporters that the pipeline would enhance gas supply by 40 mmcfd to the national gas network, which would finally lead to an additional supply to the gas-starved power plants and other industries.
As had been viewed by some gas experts, the persisting bleak power situation was expected to improve slightly from the end of this month with the commissioning of a 'spur-line' aiming at boosting gas supply from Jalalabad gas field.
Due to lack of gas supplies, different gas-fired power plants in the country cannot generate around 660 megawatt (MW) power. It was believed that commissioning of the new spur line would add 60 to 70 mmcfd gas, which could help Power Development Board (PDB) generate around another 300 MW power.
Initiated as part of a move by Petrobangla and Gas Transmission Company Ltd (GTCL) to overcome problems arising out of various bottlenecks in their gas pipeline system -- the 750-metre long and 12-inch diameter pipeline -- has been declared ready for commissioning. It was to facilitate an approximately 50 per cent increase in gas production from Jalalabad field by the end of this year.
Jalalabad field now produces around 150 mmcfd gas.
To commission the spur line, the operator of Jalalabad field -- Chevron, was to stop gas production from Jalalabad for three days. The process of commissioning involved shifting the measuring meters from Kailastila to Jalalabad."
When the thoughts of constructing spur line came to our notice, we felt a bit confused. We could not make out how this additional gas from Jalalabad would be transported through a supersaturated transmission system without adjusting off-take pressure at several locations. Yes, it could be transported adjusting the delivery and delivery pressure from different downstream gas fields like Habiganj, Titas and accepting lower pressure at Ashuganj Manifold station. The gas demand in the entire system was to be monitored. Someone having hands-on knowledge of national gas grid should have taken the lead. The communication system at all load intake and off-take points should have been established. One wonders if the system demand was enough for additional withdrawal at that time? As it appears now, GTCL was not tasked with proper homework. Two GTCL senior executives Engr Jameel A Aleem and Engr Sanwar Hussian Chowdhury commissioned several transmission systems in my team. Whether they were involved is a matter of guess! Gas system operation cannot be the piece of cake of every Tom, Dick or Harry.
Anyone who has basic knowledge of natural gas and hydraulics is aware that gas unlike water is a compressible fluid. It is driven by pressure difference. Any gas transmission pipeline is designed to handle a maximum allowable operating pressure. Twenty four inches O.D, 175 km-long ANSI# 600 North-South Pipeline from Gooloogonj Sylhet to Ashuganj, Brahmanbaria at MAOP 1076 PSIG can carry 420MMCFD gas. In an ideal situation, the terminal pressure at Ashuganj Gas Manifold station used to drop down to 800PSIG. But gas delivery into that pipeline is staggered -- gas is injected at various intakes along the line. Before construction of Rashipoor -- Ashuganj Loop line, the staggered nature of gas intake facilitated transportation of 500MMCFD+ through N-S pipeline to meet increased gas demand downstream of Ashuganj Gas Manifold station.
This writer was GTCL Project Manager of Rashidpoor-Ashuganj Gas Transmission Loop-line and later worked at Director (Operation) GTCL. At this critical stage, it is now considered as a 'religious obligation' to deal with the situation. Prior to the design of Rashidpoor Ashuganj Loop line, we carried out extensive gas transmission system simulation utilising the win flow simulation system borrowed from UNOCAL. In many permutations and combinations, it appeared that a 30-inche OD, 82 km loop line, looped at Muchai, Shajibazar, Madhadpoor, Khatihata and Ashuganj with North -- South Pipeline, would facilitate addition of 800mmcfd gas to N-S corridor. This, together with 500 mvcfd of N-S pipeline, created a total capacity of 1300mcfd. But the demand downstream kept on increasing. The downstream capacity was subsequently enhanced upon construction of Ashuganj-Monohardi and Dhanua-Savar Pipelines.
In this situation, prior to development of Maulavibazar and Bibiyana Gas fields in 2004, the author took initiative to acquire computer software through Cairn for GTCL to carry out network simulation. We found that to evacuate additional gas from Bibiyana beyond 2008 (Bibiyana was projected to produce 600mmcfd+) we had two options:
a.) build a second loop line from Muchai to Ashuganj,
b). Set up Pipeline Compressor Stations at Muchai and Ashuganj.
We had to step beyond our shoes on occasions to convince Petrobangla bosses that pipeline compressor stations were the better choice. Ultimately, the Asian Development Bank (ADB) had to engage consultant to convince Petrobangla of pipeline compressor stations.
Ultimately installation of pipeline compressor stations were included in ADB-assisted GSDP and these were foreseen to be in operation by 2008 to handle additional gas from North Eastern gas fields. In 2009, gas fields are ready to deliver additional gas, market is hungry for gas but unfortunately the implementation of pipeline compressor stations did not even start.
In this situation, any attempt to add new gas an already saturated transmission system was an act of novice. Moreover when new gas is introduced into a congested system, it has to be done with great care, observing pressure build up and intake-off-take pressure at different points. GTCL has SCADA .It can monitor pressures and flow at all points. So it is not understood why there was panic. Did they work out a comprehensive plan as to how the additional gas from Jalalabad would be introduced? Did they adjust flow from Bibiyna? Keeping Bibiyna at 600+, it was impossible to have additional flow from Jalalabad. Delivery from downstream gas fields like Titas and Habiganj required appropriate adjustment to bring new gas from Jalalabad.
Jalalabad gas field on many occasions, when this writer operated National Gas Grid as Director (Operation), delivered 210-220 mmcfd. Of course, at that time Bibiyana was not on stream. During our time, we did not have Ashuganj- Monohardi loopline. But still we could accommodate 220 mmcfd gas from Jalalabad gas field. After its commissioning, Bibiyna should have kept Jalalabad flowing at 200 mmcfd + and adjust intake from other fields. Bibiyana should not have been allowed access beyond minimum take or pay till its cost recovery was complete. Additional gas evacuation was contingent upon installation of compressor stations at Muchai and Ashuganj which is still at least two years into the future.
It is surprising why Petrobangla/GTCL acted like novice. It is disgraceful for a pipe liner. This writer was thoroughly embarrassed for unimaginative GTCL action which caused another nuisance at a time when nation is suffering due to gas sector failures. We built GTCL reputation with great pains. Novice Petrobangla bosses must own this failure and may be asked to explain.
The writer can be reached at email: saleque123@gmail.com