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Measures adopted for safe transportation of petroleum products through pipelines
19th June 2018
R.K.Acharya,
GM(HSE), WRPL, Rajkot
India is the 4th largest consumer of Oil Equivalentafter China, US & Russia.
Oil Industry plays a vital role in providing energysecurity and contributes towards the overall growthof the country.
Oil Pipelines & Installations operate at high pressure& complex operation; handles highly hazardous &inflammable HCs.
Therefore, preservation and safety of these vital Nationalassets are of paramount importance.
Hydrocarbon industry in India
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Pipelines – an Introduction
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Cross Country Pipelines are used for transportationof many commodities.
Crude oil and petroleum products are perhaps themost common commodities transported bypipelines.
Apart from being most reliable andeconomic means, it is also superior to other modesof transportation viz. rail and road from the angle of
Safety Flexibility Environmental Pollution Product loss during transit etc.
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The pipeline industry set its foot in India about 110 years back.Digboi oil field to Digboi Refinery
During 1960-62, first trunk crude oil pipeline laid by Oil IndiaLimitedNahorkatiya and Moran Oil field to Guwahati & Barauni
Refinery of 1156 Km
The first cross-country productPipeline was laid during 1962-64Guwahati Refinery to Siliguri of 435 Km
Pipelines in India-Historical Back ground
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Typical Pipeline network
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Pipelines Network In India
Presently India is having more than 26,856 Km ofcross country pipeline for transportation of crudeoil, Petroleum products & Gas
49%
18%
12%
7%8% 4% 2%
Approximate % of length of pipeline being operated by Major oil & Gas companies in
India
IOCLHPCLBPCLOILGAILONGCCAIRN
Vadinar
Chaksu
Mundra
Guwahati
BongaigaonSiliguri
Digboi
Tinsukia
Jalandhar
Meerut
Tundla
NajibabadRoorkee
Ambala
Mathura
Kot
Jodhpur
MohanpuraAjmer
Dahej
Chittaurgarh
Koyali
BhatindaSangrur
PanipatRewari
Haldia
BarauniKanpur
Lucknow
Mourigram
Rajbandh/ Durgapur
Ennore
Sankari
Asanur
Trichy
Madurai
CBR
BangaloreBangalore AFS
Paradip
Ratlam
Chennai AFS
Hazira
Bharatpur
Ahmedabad
SidhpurViramgam
Raipur
RanchiKorba
MotihariBaitalpur
Kolkata AFS
BerhampurVizag
RajahmundryVijaywada
Hyderabad
Kandla
Muzaffarpur
Patna
Raxaul
Amlekhgunj, NepalDadri
LegendExisting Crude Oil Pipeline
Ongoing Crude Oil Pipeline
Existing Product Pipeline
Ongoing Product Pipeline
Existing LPG Pipeline
Ongoing LPG Pipeline
Existing Gas Pipeline
Ongoing Gas Pipeline
Refinery
BetkuchiHasimara
Jatni
PipelineExisting Length
(km)
Ongoing Length
(km)
Total Length
(km)
Product 7518 5544 13,062
Crude 5301 0 5301
LPG 432 2141 2575
R-LNG 140 1707 1847
Total 13,391 9,392 22,785
Navagam
M’ SaraiAllahabad
Existing/Ongoing Pipelines Networkof IOCL
Manmad
Ahmednagar
Solapur
Una
Jasidih
Chennai
Delhi
RamanathapuramTuticorin
Dhamra
Puducherry
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Majors for safe transportation petroleum through cross
country Pipeline
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Major Components of a Cross Country Pipeline System
MainlineMainline pipes.
Coating and wrapping on mainline. Cathodic Protection System.
Telecommunication and Telesupervisory System
Telecommunication System.Telesupervisory system/ SCADA
Pumping/ Intermediate Delivery/Terminal StationsMainline pumping units.
Instrumentation and control system.Fire fighting facilities.
Cross CountryPipeline System
PEOPLE PROCESSES
Safety Tripod
DesignPeople
Systems & procedures
Pipeline Safety Management
All 3 legs of Safety Tripod should be secured10
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Design and maintain all systems according tointernational standards.
Effective EMP/RA study and optimum/safe pipelineroute selection.
Maintain pipe wall-thickness and spacing betweenValves (SVs) according to population density as perANSI/ASME B 31.8.
Provide good coating (preferably 3LPE) to protectpipeline from external corrosion
Construction Practices
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Providing reliable and efficient CP-system
Maintaining min. 1.2 M ground-cover over buriedpipeline
100% radiographic inspection of welded joints
Hydro testing at 1.25 times design pressure
Caliper and cleaning pigging of pipeline
HDD at river/canal/road/rail crossings
Construction Practices
Tank Farm
Refinery
18m
ROW
River
Pipe Casing
Railway Road/ Highway
2.5m 1.7m 1.2m 1.2m
Pipeline* As per OISD STD 141 & API-1102
Normal Soil
Cathodic protection
Minimum soil cover for various crossings
Anode bed
RCP Stations
Anode bed
Construction PracticesCathodic protection
Close monitoring of operational parameters andprompt action in case of abnormal observations.
Leak detection system (LDS)
Refurbishment of Coating & Wrapping of Pipelines
Pipeline to Soil Potential measurement
Internal Monitoring of Pipeline through Corrosioncoupons & Corrosion probe
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Steps taken to safeguard Pipeline
Intelligent Pigging Survey (IPS)
Use of advance technologies for detection of thirdparty intrusion in ROW.
Deployment of DGR guards/ gunmen in mainline ROWfor Day & Night patrolling.
Monitoring of DGR guards/ gunmen patrolling on Webbased GPS system.
Regular Surprise checks in mainline by IOC officers.
Regular inspection of various crossings & Sectionalizingvalves.
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Steps taken to safeguard pipeline
Surprise integrity test of mainline section preferably innight hours by proper planning.
Joint patrolling in ROW/ adjoining industrial areas atperiodic interval.
Award to best performing Security Guards forenhancing their efficiency.
Close coordination with local police and collection ofdetails of nearby factories/ Go down in sensitivestretches.
Field survey with pipeline locator/ DCVG etc. 16
Steps taken to safeguard pipeline
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Steps taken to safeguard pipeline
Induction of Chief Security officers (retired Dy. SPlevel) at WRPL, Bases.
Liasoning with the Chief Secretary, DGP & otherhigher officials of State administration for briefingabout the pilferage incidents & its consequencesperiodically.
Monthly meeting conducted by Station In Chargeswith respective Superintendent of Police in everydistrict under their jurisdiction.
Onshore Security Coordination Committee (OSCC)meeting.
Meeting with DG & IGP, Govt. of Gujarat
at Gandhinagar
Meeting with Additional Chief
Secretary (Home), Govt. of Gujarat
Interaction with Media at Rajkot on 12.04.2017
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Our Efforts to Connect with People
Village Awareness Program
Cash Reward under Incentive scheme to Informerswho assist in avoiding & identifying pilferageattempts
Conducting Mock Drills involving villagers & localadministration
CSR activities are being done by IOCL as welfaremeasures.
Introduction of Toll Free Number (1800 233 8400)
Award to informers Awards to SOG team
Sensitizing DGR GuardsVillage Awareness programme
Our Efforts to Connect with People
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CSR Synergy & Trust Building
Village need assessment
IOCL expectation
from Villagers
Motivation
CSR : Mediator between
Villagers & IOCL
Corporate Social Responsibilities
Understanding Village Problems
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Conclusion
Pipeline transportation mode will continue to remainleader in the field of oil transportation in the days tocome in the emerging scenario.
With the growing demand of petroleum, therequirement for ensuring safe and environmentfriendly operation, demonstrating compliance tonumber of environmental legislations and otherrelevant statutory requirements is posing newchallenges before the pipeline industry.
Growing industrialization and urbanization hasincreased the probability of occurrence of accidentand the severity of consequence as well.
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The growing awareness of the public/society andincreased activities of NGOs and media withrespect to Safety and Environmental issues, arealso putting continuous pressure on pipelines.
Therefore, a pro-active approach for themanagement of hazards, instead of reactiveapproach, is desirable to reduce/ control harm topeople, damage to property, loss to process andenvironment.
Conclusion
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