1

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

2

Pipelines – an Introduction

3

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.

4

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

5

Typical Pipeline network

6

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

7

Majors for safe transportation petroleum through cross

country Pipeline

8

9

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

11

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

12

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

14

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.

15

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

17

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

20

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

22

CSR Synergy & Trust Building

Village need assessment

IOCL expectation

from Villagers

Motivation

CSR : Mediator between

Villagers & IOCL

Corporate Social Responsibilities

Understanding Village Problems

23

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.

24

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

25