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NUMALIGARH- SILIGURI PIPELINE OPERATION

MANUAL (Volume I)

Document No: OIL/NSPL/2010/001

OIL INDIA LIMITED PIPLELINE DEPARTMENT

Revision Status

Rev Date

0 01.08.10

__________ __________ __________ PREPARED BY REVIEWED BY APPROVED BY Shri P.J. Sarma,CEPL(PLM) H(PL-OPS) GM (PLS) &All Sectional Heads

PREFACE This manual contains the supervisory operating guidelines for Numaligarh-Siliguri Multiproduct Pipeline of OIL India Limited (OIL).It consists of process description, supervisory instructions for normal operation, pipeline start-up and of various equipment. This manual also provides general guidelines for preparing the facilities for start-up and on safety aspects. The instructions have been prepared for the purpose of facilitating the start-up and subsequent operations. The operating procedures and conditions given herein may have to be modified from time to time for improving operations of the pipeline based on site constraints or as a result of experience gained in operating the facilities. Detailed operating and maintenance instructions for equipment are not included in this manual, for which manufacturers / vendor’s manual may be referred to. In event of any discrepancy between this manual and manufacturer’s recommendation, the latter is deemed final.

653 KM

TABLE OF CONTENTS INDEX SECTION NO. PAGE SECTION A GENERAL SECTION A.1 OPERATIONAL Organogram SECTION A.2 Schematic Diagram of Pipeline Installations SECTION-A.3 GENERAL INFORMATION OF THE PIPELINE A.3.1 INTRODUCTION A.3.2 BASIC PARAMETERS A.3.3 PIPELINE PARAMETERS A.3.4 PUMPING FACILITIES A.3.5 BATTERY LIMITS A.3.6 DESPATCH STATION PARAMETERS A.3.7 INSTRUMENTATION A.3.8 METERING SYSTEM A.3.9 SCADA SYSTEM A.3.10 FIRE PROTECTION SYSTEM A.3.11 EQUIPMENT NUMBER AND DRAWING A.3.12 PIPELINE ROUTE FEATURES SECTION B OPERATIONS SECTION-B.1 DESCRIPTION OF FACILITIES B.1.1 INTRODUCTION B.1.2 DESCRIPTION OF FACILITIES B.1.3 INSTRUMENTATION, SCADA & LEAK DETECTION SECTION –B.2 CONTROL PHILOSOPHY B.2.1 GENERAL B.2.2 NUMALIGARH DESPATCH STATION B.2.3 SEKONI INTERMEDIATE PIGGING STATION B.2.4 NOONMATI INTERMEDIATE PIGGING STATION B.2.5 BONGAIGAON INTERMEDIATE PIGGING STATION B.2.6 MADARIHAT INTERMEDIATE PIGGING STATION B.2.7 SILIGURI RECEIPT STATION B.2.8 SECTIONALISING VALVES B.2.9 LEAK DETECTION B.2.10 CORROSION MONITORING SYSTEM B.2.11 EMERGENCY / NORMAL SHUTDOWN

SECTION – B.3 NORMAL OPERATION B.3.1 GENERAL B.3.2 NORMAL OPERATION OF NSPL B.3.3 OPERATION OF NUMALIGARH DESPATCH TERMINAL B.3.4 PUMPING OF A BATCH B.3.5 BATCH CHANGING B.3.6 INTERFACE STORAGE AND HANDLING B.3.7 STATION PRESSURE CONTROL B.3.8 DOWNSTREAM/BACK PRESSURE CONTROL B.3.9 SECTIONALIZING & MAINLINE STATION INLET/OULET VALVES OPERATION B.3.10 ROUTINE CHECKS B.3.11 LIST OF ALARMS AND SET POINTS B.3.12 SHUTDOWN B.3.13 OPERATION OF CENTRIFUGAL PUMPS SECTION—B.4 OIL MOVEMENT B.4.1 FUNCTION AND SCOPE B.4.2. RESPONSIBILITY B.4.3 CUSTODY TRANSFER B.4.4 DOCUMENTATION B.4.5 TANKAGE SECTION- B.5 EMERGENCY CONDITION AND PROCEDURE B.5.1 EMERGENCY CONDITIONS B.5.2 EMERGENCY PROCEDURE SECTION- B.6 FIRE FIGHTING INSTALLATION SECTION – C INSPECTION, MAINTENANCE AND DOCUMENTATION SECTION C.1 PIPELINE C.1.1 Ground Patrol and Leak Survey Inspection C.1.2 Inspection of Submerged River Crossings C.1.3 Aerial Patrol Inspection C.1.4 Inspection of Identification Facilities C.1.5 Operating Pipe Defects and Facilities C.1.6 Pipe Line Maintenance Procedures C.1.7 Corrosion Control Inspections C.1.8 Valve Inspection C.1.9 Pigging and Line Scraping

SECTION C.2 PLANT C.2.1 Pumping Equipment C.2.2 Valve Lubrication and Inspection C.2.3 Electrical Plant and Equipment C.2.4 Communications equipments C.2.5 Telemetry & SCADA C.2.6 Instrumentation C.2.7 Fire Fighting Equipment C.2.8 Station House Keeping SECTION D ANNEXURES

1. LEGISLATIONS APPLICABLE TO NSPL OPERATIONS & MAINTENANCE 2. NSPL ELEVATION PROFILE 3. NSPL ELEVATION PROFILE—Sectorwise 4. TYPICAL HYDRAULIC GRADIENT LINE OF NSPL 5. NSPL Process Flow Diagram 6. Process Mimic - Numaligarh Despatch Terminal 7. Process Mimic - IP Stations 8. Process Mimic - Rangapani Receipt Terminal 9. Flow Diagram - Numaligarh Despatch Terminal 10. Flow Diagram - IP Stations 11. Flow Diagram - Rangapani Receipt Terminal 12. Fire Ring main - Numaligarh Despatch Terminal 13. Fire Ring main - IP Stations 14. Fire Ring main - Rangapani Receipt Terminal 15. NSPL ROW/ROU MAP 16. Summery of Scheduled Inspections and Reports

SECTION A

GENERAL

SECTION A1

OPERATIONAL Organogram

to be inserted

SECTION A2 Schematic Diagram of Pipeline Installations

to be inserted

SECTION-A3

GENERAL INFORMATION OF THE PIPELINE A.3.1 INTRODUCTION Oil India Limited owns and operates a 406 mm (16”) cross country multi-product pipeline from Numaligarh Refinery in Assam to Rangapani(Siliguri) in West Bengal for transporting different products of Numaligarh Refinery namely Motor Spirit (MS), High Speed Diesel (HSD) and Superior Kerosene Oil (SKO). The pipeline is designed for a total throughput of 1.721 MMTPA.This 406 mm (16”) pipeline is 653.4 km in length. Product pressure is boosted up at Numaligarh Despatch Terminal. Rangapani Receipt Terminal is the only withdrawal station. There is no intermediate pumping station. Following are the main facilities of the pipeline a) Despatch Terminal at Numaligarh (excluding storage tanks) b) Cross Country Pipeline between Numaligarh Despatch Terminal and Rangapani Receipt Terminal c) Receipt Terminal at Rangapani (excluding storage tanks) d) Four intermediate pigging stations at Sekoni, Noonmati, Bongaigaon and Madarihat e)The pipeline facilities also include the sectionalizing valve stations, HOVs etc. A.3.2 BASIC PARAMETERS Products to be transported a. MS b. SKO c. HSD Design Throughput(MMTPA) a) MS 0.135 b) SKO 0.219 c) HSD 1.367 Total 1.721 ALLOWABLE CONTAMINATION LEVEL IN PRODUCTS (in %)

Contaminants Product

MS SKO HSD

MS -- 1 Nil SKO Nil -- Nil HSD Nil 2 --

A.3.3 PIPELINE PARAMETERS

a) Pipeline throughput : 1.721 MMTPA b) Operating Hours : 8000 Hrs/ Annum c) Pipeline operating life : 35 Years d) Pipeline Length : 653.4 Km (approximate) e) Basis for hydraulic calculation : All the hydraulic calculations are based on

HSD at 25 oC. f) Pipeline Diameter : 406.4mm (16”) g) Design pressure : 84.5 Kg/cm2 h) Max. Operating Pressure: 76 kg/cm2 i) Hydrotesting pressure : 106 Kg/cm2(min.) j) Design consideration : ASME B31.4, OISD 141 k) Pipe grade : 259 Km (converted & existing)- API5LX46/X52-

Pipe thk. - 7.9/11.9 mm : 394Km(new)-API5LX60/X46- Pipe thk. - 6.4/8.7/11.9 mm

l) Pipe Thickness at crossings : Major River crossings : 11.9/8.7mm thk. CTE coated CWC pipe Microtunneling : 8.7mm thk. 3LPE coated HDD : 11.9 mm thk. 3LPE coated Road Crossings : 11.9mm (old) / 8.7mm(new) CTE coated

m) Pipeline roughness : 45 microns n) Material of Construction for Pipeline : Carbon Steel o) Pipeline Corrosion Allowance : 0.5 mm p) Pigging Facilities : Permanent Pigging facilities suitable for "Intelligent Pigs"

provided at IP Stations. q) Subsoil temp. : 31°C(Max), 19°C(Min) throughout the entire length of the

pipeline r) Design Temperature : Above ground 65 oC s) Buried 60 oC t) Pipeline laying : Buried u) Sectionalizing valves : Sectionalizing valves are provided as per ASME B 31.4 v) Power supply : Power supply to SVs, CPs and repeater stations and

Intermediate Pigging stations is drawn from the grid power. Battery back up is provided at all stations. For back-up, DG power is provided for full capacity.

w) Pipeline corrosion protection system : For external corrosion protection, Coal Tar Enamel coating is provided. Impressed current cathodic protection system is provided for the entire pipeline. Internal corrosion protection is provided through injection of automated corrosion inhibitor dosage linked to online monitoring system at Numaligarh Despatch Terminal and IP2 Noonmati.

x) Corrosion Monitoring System : Corrosion monitoring system is provided

A.3.4 PUMPING FACILITIES The pumping station at Numaligarh Despatch Terminal has Booster and Mainline Pumps.Both Mainline as well as Booster pumping system is having 1 working + 1 standby configuration. All the pumps are electric motor driven. A.3.5 BATTERY LIMITS Upstream -- From Product Inlet manifold at Numaligarh Downstream--To product distribution manifold(including the MOV), downstream of metering at Rangapani Receipt Terminal A.3.6 NUMALIGARH DESPATCH TERMINAL PARAMETERS Upstream Pressure: From Atmospheric Storage Tank Temperature: 45°C (Max) Downstream Pressure: 76-92.3 kg/cm2 Temperature: subsoil A.3.7 INSTRUMENTATION General PLC based instruments are provided at Numaligarh Despatch Terminal and Rangapani Receipt Terminal. Instrumentation at IP stations is panel based. Supervisory Control and Data Acquisition(SCADA) system is designed for Remote monitoring and control of the pipeline. Type of control: Electronic Final control element: Electro-Hydraulic at all locations. A.3.8 METERING SYSTEM Flow meters Ultrasonic flow meters with one redundant metering run as stand by (1+1) are providedat Numaligarh Despatch Terminal and Rangapani Receipt Terminal. Ultrasonic flow meters without redundant metering run (1+0) are provided at the four IP Stations. Basket filters are provided upstream of flow meters only at Numaligarh Despatch Terminal and Rangapani Receipt Terminal. Custody transfer Custody transfer with NRL is done as per ‘Custody Transfer Agreement’ between OIL and NRL.

A.3.9 SCADA SYSTEM The SCADA system is provided to ensure effective and reliable control, management & supervision of the pipeline from centralized location using Remote Telemetry Units (RTUs). The SMCS(Scada Monitoring and Control Station) for this pipeline is located at Numaligarh. A suitable real time leak detection software, batch tracking and batch scheduling software are provided for this pipeline. The system is integrated with SCADA network. A.3.10 FIRE PROTECTION SYSTEM As per the requirement of OISD-117 & OIL requirements fire protection facilities are provided at Numaligarh Despatch Terminal, Rangapani Receipt Terminal and at all intermediate pigging stations. Details are given in Section B.6 A.3.11 EQUIPMENT NUMBER AND DRAWING Numbering system followed Unit numbers : As per EIL Equipment : As per EIL Instruments : As per EIL Drawings/Documents : As per EIL Drawings/Documents All drawings and other documents are prepared as per EIL standard. Units of Measurement Metric, unless otherwise specified. A.3.12 PIPELINE ROUTE FEATURES

The entire Pipeline is buried except for Installations & Brahmaputra bridge. All suspension & bridge crossing in existing 259 km. section have been converted to submerged crossing by HDD.

The Pipeline is laid in OIL’s existing ROW parallel to the existing crude oil & IOC’s GSPL pipeline. New ROU of 52 km. used mainly to avoid railway bridge crossing and NRL to existing ROW (entry point).

ASSAM : ROU : 34.208 Km Districts : Golaghat, Nagaon, Morigaon, Kamrup (Metro), Kamrup (Rural),Barpeta, Nalbari, Bongaigaon, Chirang and Kokrajhar

West Bengal ROU : 17.620 Km Districts : Cooch Behar, Jalpaiguri and Darjeeling.

SECTION-B

OPERATIONS

SECTION B.1

DESCRIPTION OF FACILITIES B.1.1 INTRODUCTION The 406 mm (16”) cross country multi-product pipeline from Numaligarh refinery, Assam to Rangapani(Siliguri),West Bengal transports different products namely Motor Spirit (MS), High Speed Diesel (HSD) and Superior Kerosene Oil(SKO). This pipeline has only one pumping station at Numaligarh and total product is withdrawn only at Rangapani(Siliguri). At intermediate locations,pigging and corrosion inhibitor dosing facilities are provided. Pipeline Facilities: Following main facilities are provided under this project: a) Despatch Terminal at Numaligarh(excluding storage tanks) b) Receipt Terminal at Rangapani(excluding storage tanks) c) Four intermediate pigging stations at Sekoni, Noonmati, Bongaigaon and Madarihat d) Corrosion Inhibitor dosing facilities at Numaligarh and Noonmati e) Also enroute there will be sectionalizing valve stations in order to facilitate isolation of pipeline sections. There is no intermediate pumping station or intermediate withdrawal of products along theroute. B.1.2 Description of Facilities: Numaligarh Despatch Terminal: At Numaligarh Despatch Terminal petroleum products viz. MS, HSD and SKO is pumped into the pipeline from storage tanks. To ensure adequate NPSH to the Mainline Pumps(10-PA-CF-102 A/B), booster pumps(10-PA-CF-101 A/B) is provided. Basket Filter(10-GN-BK-101 A/B) is provided to remove the solid particles. Volumetric flow is measured using ultrasonic flow meter (10-FE-1101). Flow computer (10-FQY-1101) is provided to measure corrected flow rate. Density meter (10-DT-1101) is provided close to the flow meters to measure the density of petroleum product and to indicate product changeover. A Pressure Control Valve (PV-1201) downstream of mainline pumps ensures maximumoperating pressure in the pipeline within the design limits. A Pig launcher (10-MR-00-101) is provided for pigging operation. A Sump Tank (10-TT-00-101) is envisaged for collection of hydrocarbon drains. The hold up of the sump tank can either be transferred back into the piping to mainline pump or be loaded in road tankers with the help of sump pump (10-PA-SM-101). Corrosion Inhibitor is injected in the pipeline to prevent internal corrosion of the Pipeline. Corrosion Inhibitor dosing tank(10-TT-00-102) and Corrosion Inhibitor dosing pumps (10-PA-

RP-104 A/B) is provided for the same. One RO(RO-1201) is provided downstream of mainline pump which is utilized only during minimum flow condition of pipeline operation. Provision for meter prover is kept at Rangapani Receipt Terminal for proving the flowmeters. Electrical Facilities at Numaligarh Despatch Terminal: In the Pump Station electrical power is taken at 11KV voltage from Sub-Station no-4 of Numaligarh Refinery. There are 2 nos of 11KV incoming feeders from Sub-Station no-4 of Numaligarh Refinery. Power at 11KV voltage is then stepped down to 6.6KV voltage through 2 nos of 2500KVA, 11/6.9 KV transformer having On Load Tap Changer (OLTC). Power at 6.6 KV voltage is used to run the 2 nos of Main Line Pump Motors of capacity 1130 KW for pumping operation .One Motor is run at a time & other remains stand by. The power is again stepped down to 433V from 6.6KV through 2 nos of 500KVA, 6.6KV/433V Transformers (with OFF Load Tap Changer) for LT load distribution. The HT Switchgear used in the NSPL-NDT are indoor type Vacuum Circuit Breakers .There are 2nos of indoor 11KV Line Potential Transformers (LPT) for two incoming 11KV feeders and 2 nos of indoor 11KV Vacuum Circuit Breakers in the Primary Side (11KV) of 2500KVA Transformers. Similarly 2 nos of indoor 6.6 KV Line Potential Transformers (LPT) & Vacuum Circuit Breakers are used in the Secondary Side (6.6KV) of 2500KVA Transformers. One 6.6KV BUS COUPLER Breaker (VCB) is used between secondary sides (6.6KV) of two 2500KVA Transformers. Two nos of indoor Bus PTs are also used in 6.6 KV sides. One 1130KW Motor is fed from 6.6 KV Bus-1 and other motor fed from 6.6KV Bus-2.The two 2500KVA. The LT switchgears are Air-Circuit Breakers (ACB). There are 4 nos of indoor type Air-Circuit Breakers in the LT panel. Two ACBs are used as 433V incomer (secondary side of two 500KVA Transformers). Third ACB is used as Bus-Coupler between two 433V incomer powers from transformers and fourth one is used as Bus Couple between Normal Supply and Emergency Supply from 65KVA DG set. One 75KW Booster Pump Motor is fed from 433V Bus-1 and other 75KW Booster Pump Motor is fed from 433V Bus-2. In the Protection Scheme of the Transformers, Differential, REF, Over Current, Earth Fault, Under Voltage, Bucholtz, PRV, WTI and OTI relays are used. Motor Protection consists of Thermal Over Load, Negative Sequence, Stalling, Short Circuit, and Winding Temperature & Bearing Temperature Protection. The control circuit of the Protective Relays is of 110V D.C Voltage.110V D.C supply is fed from Dual Charger Panel having auto BOOST/FLOAT mode ,which is also charging a 110V back-up battery bank (55 no of Lead Acid Battery Cells)

Electrical Equipment List and Single Line Diagram is given below

Feeder-1 Feeder-2

______________________________________________________________________________

OIL INDIA Sub Station

Vacuum Ckt Breaker 11 KV Vacuum Ckt breaker 11 KV

2500KVA 11/6.9KV 2500KVA 11/6.9KV

Transformer No 1(Dyn1) Transformer No 2(Dyn11)

Vacuum Ckt Breaker 6.6 KV

6.6 KV BUS NO-1 6.6 KV BUS NO-2

BUS COUPLER

VCB VCB VCB VCB

500KVA 6.6/0.433 KV 500KVA 6.6/0.433KV

Trans No 1(Dyn11) Trans No 2(Dyn11)

Air Ckt Breaker 433V Air Ckt Breaker 433V

433V BUS NO-1 433V BUS

NO-2

Bus Coupler no-1 Bus Coupler no-2

Emergency Load AOP-1 AOP-2

Y

Motor 1 1130KW

NRL SUBSTATION NO-4

Y

Y

Motor 1130KW Y

Motor 2 1130KW Y

Booster Motor 1 75KW

Booster Motor 2 75KW

65 KVA Gen

Fire Protection System at Numaligarh Despatch Terminal: Fire Indication System The fire alarm system (Make-Safeway Security System) is used in the NSPL Pump Station to detect fire in various locations. Different locations of the Pump Station are divided into different fire zones in the Fire Detection Panel.. Smoke and Heat actuating devices are used in these locations. In case of a fire in a location, smoke and heat detectors installed in that particular location will send a signal to the Fire Control Panel, placed in the NSPL Control Room. The Fire Control Panel will indicate the zone at which the fire occurs. On receipt of fire signal, Control Panel will also generate an audible and visual alarm and operate the Siren placed above the electrical sub-station. From the indicating zone Duty Officer will know the fire location. However NSPL Control Room and UPS Room are not covered under this Fire Alarm System as another Fire Suppression System is installed in these two rooms. The manual break glass call points, installed in different locations are also connected to this Fire Indication System. The different locations are divided into following zones.

ZONE CHART OF NDT

SL. NO. ZONE NO. LOCATION

1. ZONE-1 1. BREAK GLASS (WALL MOUNTING IN FRONT OF CONTROL ROOM)

2. ZONE-2

1. BATTERY ROOM 2. PACKAGE A/C ROOM 3. OFFICE ROOM (ABOVE AND BELOW FALSE CEILLING ) 4. CABIN (BELOW FALSE CEILLING)

3. ZONE-3

1. BELOW FALSE CEILLING -CORRIDOR 2. REST ROOM. 3. IN FRONT OF TOILET. 4. PANTRY 5. CLEAN AGENT ROOM 6. E&C ENGG ROOM 7. CONFERENCE ROOM

4. ZONE-5 ABOVE FALSE CEILLING (EXCEPT OFFICE ROOM)

5. ZONE-8 1. MCP-02, 2. MCP-04, (MCP : MANUAL CALL POINT)

3. MCP-05.

6. ZONE-9

1. TR-1, TR-2 (500 KVA) 2. DG ROOM 3. BATTERY ROOM (SUB-STATION) 4. CABLE TRENCH (SWITCH GEAR ROOM, SUB- STATION) 5. BREAK GLASS (WALL MOUNTING NORTH SIDE OF SUB- STATION)

7. ZONE-10 1. SWITCH GEAR ROOM

8. ZONE-12 1. MCP-01 2. MCP-03 (MCP : MANUAL CALL POINT)

Fire Suppression System Fire Suppression and Alarm System, NN 100 (Make-Clean Agent) in the NSPL Control Room and UPS Room uses pure compressed Nitrogen gas as extinguishing agent. Nitrogen is used as total flooding agent for dilution of Oxygen concentration below the level that does not support combustion .If Oxygen concentration is reduced below 15 %, most ordinary combustible material will cease to burn. Nitrogen concentration will reduce the oxygen content to approx 13.2% with a design concentration of 37.5%. This system is interfaced with conventional fire detection and alarm system .Smoke and heat detectors are placed in the NSPL Control Room (above and below the false ceiling and floor) and UPS Room (above false ceiling).When fire is detected , a detector sends a signal to the control panel, which resisters fire. An audible alarm sounds in the control panel. When second verified signal is received from another detector in the same area, extinguishing sequence begins. An alarm will be initiated to evacuate the rooms; an output signal will be initiated to shut down the air-conditioning system of the rooms. Simultaneously Fire Dampers will also be shut down to prevent any air ingress/avoid any gas leakage from the protected areas. A time delay 23 seconds is provided in the control logic of the panel on receipt of two verified signal and before initiating a signal to open corresponding cylinder valve solenoid. Time delay is adjustable and it is provided allowing personnel to evacuate the area or to prepare the hazard area for discharge. Abort switch is also provided to abort the gas release function. Abort function must be performed, if required, before the lapse of time delay i.e. before the signal is initiated from the control panel to actuate solenoid valve. At the end of time delay, first the cylinder valve solenoid on the actuating cylinder is actuated. Second, actuating cylinder gas opens corresponding selector valve and N2 pilot cylinder valve traveling through line control valve.

N2 pilot gas flows into the control pipe and opens the N2 storage cylinder valve. Then the nitrogen in the storage cylinder flows into the manifold pipe through the loop pipe. Lastly, the nitrogen flows into the protected area via the selector valve and discharge nozzles. Furthermore, when nitrogen gas passes through the selector valve, the pressure of nitrogen operates the pressure switch through which the discharge indicator located at exit point of respective protected area will operate giving “agent discharge” indication. Sekoni Intermediate Pigging Station Sekoni Intermediate Pigging Station is located at 84.7 km chainage from Numaligarh. Although this is a pigging station, but a flow meter is also installed here for flowmeasurement which facilitate leak detection as well. Volumetric flow is measured using an ultrasonic flow meter (20-FE-1301). A Flow computer (20-FQY-1301) is provided to measure corrected flow rate. A Pig receiver (20-MR-00-101) and a Pig launcher (20-ML-00-101) are provided for pigging operation. Sump Tank (20-TT-00-101) is provided for collection of hydrocarbon drains. The hold up of the sump tank can either be transferred back into the pipeline or be loaded in road tankers with the help of sump pump(20-PA-SM-101) and two Slop transfer Pumps (20-PA-RP-102 A and B). Noonmati Intermediate Pigging Station Noonmati Intermediate Pigging Station is located at 225.7 km chainage from Numaligarh. Although this is a pigging station, but a flow meter is also installed here for flowmeasurement which facilitate leak detection as well. Volumetric flow is measured using an ultrasonic flow meter (30-FE-1401). A Flow computer (30-FQY-1401) is provided to measure corrected flow rate. A Pig receiver (30-MR-00-101) and a Pig launcher (30-ML-00-101) is provided for pigging operation. Sump Tank (30-TT-00-101) are provided for collection of hydrocarbon drains. The hold up of the sump tank can either be transferred back into the piping to mainline pump or be loaded in road tankers with the help of sump pump(30-PA-SM-101) and two Slop transfer Pumps (30-PA-RP-102 A and B). Corrosion Inhibitor is injected in the pipeline to prevent internal corrosion of the Pipeline. A Corrosion Inhibitor dosing tank (30-TT-00-102) and two Corrosion Inhibitor dosing pumps (30-PA-RP-103 A and B) are provided for the same. Bongaigaon Intermediate Pigging Station Bongaigaon Intermediate Pigging Station is located at 381.7 km chainage from Numaligarh. Although this is a pigging station, but a flow meter is also installed here for flowmeasurement which facilitate leak detection as well. Volumetric flow is measured using an ultrasonic flow meter (40-FE-1501). A Flow computer (40-FQY-1501) is provided to measure corrected flow rate. A Pig receiver (40-MR-00-101) and a Pig launcher (40-ML-00-101) are provided for pigging operation. A Sump Tank (40-TT-00-101) is provided for collection of hydrocarbon drains. The hold up of the sump tank can either be transferred back into the piping to mainline pump or be loaded in road tankers with the help of sump pump(40-PA-SM-101) and two Slop transfer Pump (40-PA-RP-102 A and B).

Madarihat Intermediate Pigging Station Madarihat Intermediate Pigging Station is located at 528.7 km chainage from Numaligarh. Although this is a pigging station, but a flow meter is also installed here for flowmeasurement which facilitate leak detection as well. Volumetric flow is measured using an ultrasonic flow meter (50-FE-1601). A Flow computer (50-FQY-1601) is provided to measure corrected flow rate. A Pig receiver (50-MR-00-101) and a Pig launcher (50-ML-00-101) are provided for pigging operation. A Sump Tank (50-TT-00-101) is provided for collection of hydrocarbon drains. The hold up of the sump tank can either be transferred back into the piping to mainline pump or be loaded in road tankers with the help of sump pump(50-PA-SM-101) and two Slop transfer Pump (50-PA-RP-102 A and B). Rangapani Receipt Terminal The petroleum product (MS, HSD and SKO) is filtered using basket filters (60-GNBK-101 A/B). The Volumetric flow is measured using an ultrasonic flow meter (60-FE-1701/ 1702). Flow computers (60-FQY-1701/ 1702) are provided to measure mass flow rate and corrected flow rate. One Density Meter (60-DT-1702) is provided close to the flow meters to measure the density of petroleum product and to indicate product changeover. Another Density Meter (60-DT-1701) is provided upstream of mainline block valve (in the mainline) to alert the operator about arrival of new products in the terminal. However MS, HSD and SKO interphase detection shall also be carried out based on total product flow from Numaligarh and Batch Tracking method. A Pressure Control Valve (60-PV-1701) downstream of filters ensures minimum operating pressure in the pipeline and maximum operating pressure downstream of PV-1701. A Pig receiver (60-MR-00-101) is provided for receiving the pig. A Sump Tank (60-TT-00-101) is provided for collection of hydrocarbon drains. The hold up of the sump tank can either be transferred back into the piping to storage tanks or be loaded in road tankers with the help of sump pump (60-PA-SM-101). Provision for meter prover is kept at Siliguri Receipt terminal for proving the flow meters. Sectionalizing Valve Stations There are 9 remotely operated Sectionalizing Valve (SV) stations and 30 Hand Operated Sectionalizing valve (HOV) stations along the route. Whenever required, the sectionalizing valves can be closed from SMCS or locally after ensuring the shutdown of entire pipeline operation. But these valves shall be opened locally by the operating personnel only. Electrical Facilities at Rangapani Receipt Terminal At Rangapani Terminal, Electrical power is taken at 440 voltage from NRL sub-station. There are two 440V incoming feeders from substation of Numaligarh Marketing Terminal. Power at 440v is then stepped down to 415v voltage through 2 nos of 80 KVA transformers having on load top changer. For changing over to emergency power, one Bus Coupler breaker is used and operated manually. One 65 KVA Diesel generator set is used for supply of emergency power in case of failure of normal power supply. The diesel generator is kept in auto condition. In the protection scheme of the transformers differential, REF, Over Current, Earth Fault, Under Voltage, WTI and OTI relays are used.

Electrical Equipment List and single line diagram is given below:

Equipment Number

Make Power Rated Voltage

Full load current/ Rated current

Speed Insulation Class

Type of Protection

Type of Breaker

WDG connection

80 KVA dry type transformer with off load tap

2 VOLTAMP

80 KVA

0.415/ 0.415KV

111.30/ 111.30A

F O/E/F WIRE OTI

DYN11

Sump Pump Motor

1 Crompton Greaves

11KW 415V 20A 2920 F O/L, ELCB, HRC FUSE

Contact DELTA

Emgn DG Set

1 ELMACH

65KVA 415V 104A 1500 H U/V,O/V,E/F

Contact Y

MAIN PANEL (AMF)

1 ASSAM ELECTRICALS

415V 150A AC SUPPLY CONTROL SELECTOR SWITCH

EMGN LT Panel

1 ASSAM ELECTRICALS

415V 60A

Normal LT Panel

1 ASSAM ELECTRICALS

415V 50A

AC Machine

2 EMERSON

415V CCB, HCB Contact

Fire Indication System of Rangapani Receipt Terminal The fire alarm system (Make-Safeway Security System) is used in the NSPL Receipt Terminal to detect fire in various locations. Different locations of the Receipt Terminal are divided into different fire zones in the Fire Detection Panel. Smoke and Heat actuating devices are used in these locations. In case of the fire in a location, smoke and heat detectors installed in that particular location will send a signal to the Fire Control Panel, placed in the NSPL Control Room. The Fire Control Panel will indicate the zone at which the fire occurs. On receipt of fire signal, Control Panel will also generate an audible and visual alarm and operate the Siren placed above the electrical sub-station. From the indicating zone duty officer will know the fire location. However NSPL Control Room, UPS Room and Telecom Room are not covered under this Fire Alarm System as another Fire Suppression System is installed in these three rooms. The manual break glass call points, installed in different locations are also connected to this Fire Indication System. The different locations are divided into following zones.

ZONE CHART OF RT

SL. NO. ZONE NO. LOCATION

1. ZONE-1

1. BREAK GLASS (WALL MOUNTING IN FRONT OF CONTROL

ROOM) 2. BREAK GLASS (WALL MOUNTING IN FRONT OF MAIN

GATE) 3. BREAK GLASS (WALL MOUNTING IN INDUSTRIAL AREA

04 NOS)

2. ZONE-2

5. BATTERY ROOM 6. PACKAGE A/C ROOM 7. OFFICE ROOM (ABOVE AND BELOW FALSE CEILLING ) 8. CABIN (BELOW FALSE CEILLING)

3. ZONE-3

1. BELOW FALSE CEILLING -CORRIDOR 2. REST ROOM. 3. IN FRONT OF TOILET. 4. PANTRY 5. CLEAN AGENT ROOM 6. TELECOM ROOM 7. CONFERENCE ROOM

4. ZONE-5 ABOVE FALSE CEILLING (EXCEPT OFFICE ROOM)

5. ZONE-8

1. MCP-01, 2. MCP-02, (MCP : MANUAL CALL POINT)

3. MCP-03.

6. ZONE-9

1. TR-1, TR-2 (500 KVA) 2. DG ROOM 3. BATTERY ROOM (SUB-STATION) 4. CABLE TRENCH (SWITCH GEAR ROOM, SUB- STATION)

7. ZONE-10 1. SWITCH GEAR ROOM

Fire Suppression System of Rangapani Receipt Terminal Fire Suppression and Alarm System, NN 100 (Make-Clean Agent) in the NSPL Control Room, Telecom Room and UPS Room uses pure compressed Nitrogen gas as extinguishing agent. Nitrogen is used as total flooding agent for dilution of Oxygen concentration below the level that does not support combustion .If Oxygen concentration is reduced below 15 %, most ordinary combustible material will cease to burn. Nitrogen concentration will reduce the oxygen content to approx 13.2% with a design concentration of 37.5%. This system is interfaced with conventional fire detection and alarm system .Smoke and heat detectors are placed in the NSPL Control Room (above and below the false ceiling and floor), Telecom Room (above false ceiling) and UPS Room (above false ceiling). When fire is detected , a detector sends a signal to the control panel, which resisters fire. An audible alarm sounds in the control panel. When second verified signal is received from another detector in the same area, extinguishing sequence begins. An alarm will be initiated to evacuate the rooms; an output signal will be initiated to shut down the air-conditioning system of the rooms. Simultaneously Fire Dampers will also be shut down to prevent any air ingress/avoid any gas leakage from the protected areas. B.1.3 INSTRUMENTATION, SCADA and LEAK DETECTION Instrumentation and control system is provided for safe and efficient operation of pipeline at Numaligarh Despatch Terminal, Intermediate pigging stations and Rangapani Receipt Terminal. PLC based control system is provided at Numaligarh Despatch Terminal and Rangapani Receipt Terminal for the process interlocks/ shutdown logic/MOVs operation and station monitoring. Control panel is provided for mounting the flow computers, density converter etc. At Intermediate Pigging Stations instrumentation is control room based panel mounted. SCADA (Supervisory Control and Data Acquisition) system is provided to ensure effective and reliable control, management and supervision of the pipeline from centralized location using Remote Telemetry Units (RTUs). SCADA Monitoring and Control Station (SMCS) for this purpose is located at Numaligarh Dispatch Station. A suitable real leak detection software, batch tracking and batch scheduling software for this pipeline are provided. The system is integrated with SCADA network.

SECTION B.2

CONTROL PHILOSOPHY B.2.1 NUMALIGARH-SILIGURI PIPELINE Numaligarh-Siliguri pipeline consists of one pumping station located at Numaligarh.The Receipt Terminal is located at Rangapani (Siliguri). SCADA system is installed to ensure effective and reliable control, management and supervision of the pipeline from Centralized location using Remote Telemetry Units (RTU). SMCS for this purpose is located at Numaligarh Dispatch Station. A suitable real time leak detection system, batch tracking and scheduling software is integrated with SCADA network. The control centre at Numaligarh Despatch Terminal has operational control on product despatch. All supply operations for the pipeline system is under the control of this Despatch Terminal and supply of the products at normal operating conditions is ensured from there. Product dispatch is done as per Custody Transfer Agreement with Numaligarh Refinery Limited. Despatch is done in liaison with NRL Marketing Division. The Despatch Terminal shall make all necessary arrangements for product dispatch and ensure proper lining up of the system in conjunction with the Receipt Terminal. The dispatch of product shall start only after receiving the ready-to-receive communication from Receipt Terminal. Numaligarh Despatch Terminal and Rangapani Receipt Terminal are manned stations and shall be operated locally. Important parameters shall be monitored at SMCS as indicated in the respective P&IDs. Pipeline operations can also be controlled from SMCS if required. There are four IP stations namely, IP-I (Sekoni), IP-II (Noonmati), IP-III (Bongaigaon) and IP-IV(Madarihat) along the route with Pigging facilities. Additionally flow measurement provision is also provided for leak detection purpose. Eventually these stations are intermediate pumping station for OIL’s existing Crude Oil pipeline. The Control Rooms are manned by OIL personnel. The following sections elaborate the Operation and Control Philosophy for Numaligarh-Siliguri Pipeline. B.2.2 NUMALIGARH DESPATCH TERMINAL Reference P&ID no. 6487-02-41-10-1211, 6487-02-41-10-1212 Three types of petroleum products namely MS, HSD and SKO are routed from tankage area of Numaligarh Refinery Limited to the Numaligarh Despatch Terminal using three individual headers. These headers are connected to the booster pump suction header. The individual headers of MS, HSD and SKO are provided with motor operated block valves close to the common header. Block valves are interlocked in such a way that when the pump station is operating, only one product valve is on-line (open). While switching over from one product to another product, the open switch of the desired product valve is actuated. Station start up

logic executes the opening command of the desired product valve and closing command of the product valve which ever is in open position. Opening and closing command is executed simultaneously. Closing command of the product header valve shall be executed only after desired product header valve is 25% open. This interlock prevents opening of two product valves at the same time. These valves are MOV’s, which are quick opening and quick closing type. The interlock no. is designated as 10-I-1 (Refer P&ID No.6487-02-41-10-1211). This logic checks the closure of product header valve (MOV-1101) after 45 seconds. If the valve is not closed, the logic generates an alarm “Manifold valve Malfunction” and trip all booster and mainline pumps at Numaligarh Despatch Terminal.

INTERLOCK ACTUATED BY ACTION

10-I-1 Opening command for MOV-1101/1102/1103 Opening command for 10-MOV-1014/ 1015/ 1016/ 1017/ 1018/ 1019 (any one of above).

Open desired product valve and close other opened product valve.

Start-up of Numaligarh Despatch Terminal Pumps The Numaligarh Dispatch Terminal is controlled by station and unit control sequence as explained below. Every pump unit is controlled by a unit control sequence/ logic. The individual pump control sequence in turn is linked to the station control sequence, which also monitors and controls all the critical parameters of the pump station. To start the Numaligarh Dispatch Terminal, it is required to confirm the following: a. Numaligarh Dispatch Terminal is ready to despatch the product. b. All station battery limit valves and sectionalizing valves are in open position. c. Receipt Terminal is ready to receive products. The above mentioned verifications are performed by Shift Engineers at MCS using information from SCADA as well as from the respective locations over voice communication channel. After verification of the above , Numaligarh Despatch Terminal is started by start-up push button 10-PB-1102. With the actuation of Station start-up push button the station control logic ensures the following and sends signal for the Booster pump start-up. a. ESD condition is absent b. Only one product header valve is in open position. c. At least one filter is in-line d. At least one metering skid is in-line e. 10-MOV-1207 is in open position f. To start the Booster Pump in AUTO MODE from Control Room MOV 1209 must be open.

Booster Pumps At Numaligarh there are two (1 working + 1 standby) booster pumps 10-PA-CF-101 A/B. During normal operation one pump will be operating and one pump will be standby. To start the booster pumps, booster pump start-up push button is actuated. Start-up push button actuates interlock 10-I-2 as explained below:


10-I-2A Pump unit start-up push button 10-PB-101A1

Bring 10-MOV-1105 to open and 10-MOV-1107 to close position

10-I-2B Pump unit start-up push button 10-PB-101B1


After ensuring the above mentioned conditions, the selected booster pump is started and after a time delay (adjustable) the discharge valve of the selected pump is opened. Once, one booster pump starts, one mainline pump is started. Each booster pump is also controlled by the following interlocks:


10-I-3A Tripping of pump 10-PA-CF-101A

For ESD: Close 10-MOV-1105 & close 1107 For other trips: Close 10-MOV-1107 with a time delay sufficient for pump coast down


10-I-3B Tripping of pump 10-PA-

CF-101B

For ESD: Close 10-MOV-1106 & close 10-MOV-1108 For other trips: Close 10-MOV-1108 with a time delay sufficient for pump coast down

10-I-4A 10-PSL-1101 Trip 10-PA-CF-101A

10-I-4B 10-PSL-1102 Trip 10-PA-CF-101B 10-I-4C 10-PSH-1101 Trip 10-PA-CF-101A 10-I-4D 10-PSH-1102 Trip 10-PA-CF-101B

Logic is such that during start up operation interlock bypass for 10-I-4C and 10-I-4D can be achieved with indication for the same. Once the booster pump is started, booster pump control sequence sends signal to station control sequence for the mainline pumps start up. There are two mainline pumps, 10-PA-CF-102 A/B. During normal operation one pump will be operating and one pump will be standby. To start mainline pumps, the mainline pump unit start-up push button is actuated. Start-up switch actuates interlock 10-I-5 as explained below:


10-I-5A Pump unit start-up push button 10-PB-102A1


10-I-5B Pump unit start-up switch 10-PB-102B1


After ensuring the above mentioned conditions, the selected mainline pump unit is started and after a time delay (adjustable) the discharge valve of the selected pump is opened. Each mainline pump is also controlled by the following interlocks:


10-I-6A Tripping of pump 10-PA-CF- 102A

For ESD: Close 10-MOV- 1201,1202 For other trips: Close 10- MOV-1202 with a time delay sufficient for pump coast down

10-I-6B Tripping of pump 10-PA-CF- 102B

For ESD : Close 10-MOV- 1203 & close 10-MOV-1204 For other trips: Close 10- MOV-1204 with a time delay sufficient for pump coast down

10-I-7A 10-PSL-1201 Trip 10-PA-CF-102A

10-I-7B 10-PSL-1202 Trip 10-PA-CF-102B

10-I-7C 10-PSH-1201 Trip 10-PA-CF-102A

10-I-7D 10-PSH-1202 Trip 10-PA-CF-102B

At the mainline pump discharge, a pressure control valve 10-PV-1201 is provided to control the pipeline inlet pressure as well as mainline pump suction pressure. The discharge pressure controller overrides the suction pressure controller when the discharge pressure increases above the set value and pipeline inlet pressure is maintained at the desired value. At the discharge of the Mainline pump, another pressure control valve 10-PV-1202 is provided to control pipeline inlet pressure during turndown(50% flow case). The discharge pressure controller overrides the suction pressure controller when the discharge pressure increases above the set value and pipeline inlet pressure is maintained at the desired value. Apart from the interlocks described above, for the whole Dispatch Terminal 10-I-8, 10-I-8A,10-I-10(ESD) is also provided. Description of the above mentioned Interlocks are as follows:

INTERLOCK ACTUATED BY INTERLOCK ACTION

10-I-8 • Tripping of Booster Pump Unit whichever is in operation • Tripping of Mainline Pump Units whichever is in operation • 10-PSLL-1201 • Voting System of PSHH- 1201/1202/120 3(2 o/o 3 logic) • Closure of MOV-1209 • 10-FAL-1101 or 10-FAL-1102

Trip all Mainline pumps and Booster Pumps at Numaligarh Despatch Terminal.

10-I-8A Closure of MOV-1207

Trip all booster and Mainline pumps, all other Pumps.

10-I-10 ESD implemented in PLC software

Trip all Mainline pumps and Booster Pumps Trip Sump Pump(10-PA-SM- 103), C.I. Dosing pump(10-PARP- 104 A/B) Close MOV-1207 at Numaligarh Terminal

Logic is such that during start up operation interlock bypass for 10-I-7D, 7E, 10-I-8(FAL-1101/1102) and 10-I-8A can be achieved with indication for the same. At Numaligarh Despatch Terminal, densitometer (DT-1101) is provided close to the flow meters to measure the density of petroleum products. Signal from densitometer is fed to the flow computer. Flow computer indicates the corrected volumetric flow rate as well as mass flow rate of the petroleum products to be transported. Numaligarh Despatch Terminal is a manned station and is to be operated locally. However important parameters are monitored and can be controlled from Numaligarh MCS. The critical MOV status, corrected and uncorrected flow, totalized flow, all trip alarms, pressure controller settings and monitoring, density, batch change over, pump operation status are monitored at MCS. These data are telemetered to MCS through RTU. Sump Tank and Pump Sump tank 10-TT-00-101 has been provided at Numaligarh despatch station for the collection of slops from various points such as header drain, scraper drain, line flushing, TSV relief etc. The collected slop is pumped into HSD product passing through mainline. Provision is also kept to load the slops into road tanker, if the situation demands. The sump pump 10-PA-SM-103 is interlocked to trip in case of low liquid level in the respective sump tank.


10-I-9 10-LSL-1101 Trip Sump Pump 10-PA-SM-103

Corrosion Inhibitor Tank and Pumps Corrosion Inhibitor is required to be dosed in the pipeline to reduce the pipeline corrosion rate. For this purpose a corrosion inhibitor tank (10-TT-00-102) and Corrosion Inhibitor Dosing Pumps (10-PA-RP-104 A/B) have been provided. The corrosion inhibitor is injected upstream of mainline pumps. Corrosion Inhibitor system has been provided with manual system for dosing rate adjustment based on product flow rate and corrosion rate. Based on corrosion rate ppm level of CI is to be set. Based on product flow rate corrosion inhibitor dosing rate is adjusted to maintain set ppm. After a certain time gap (adjustable) the ratio of cumulative quantity of product pumped and cumulative quantity of corrosion inhibitor dosed is to be compared with set ppm to have close loop control.

B.2.3 SEKONI INTERMEDIATE PIIGGING STATION Reference PandID no. 6487-02-41-20-1213 Products travel from Numaligarh to Sekoni intermediate pigging station. The distance between Numaligarh to Sekoni is 84.7 km (approx.). One number of sectionalizing valve is provided enroute the pipeline. The prerequisite for starting Sekoni pigging station is that the Numaligarh Despatch Terminal is operating. Sekoni intermediate pigging station is started by actuating the Station start up switch. With the actuation of Station start up switch, station inlet MOV i.e. MOV-1301 is brought to open condition. Sekoni intermediate pigging station is a manned station and is operated locally. However important parameters are monitored and can be controlled from Numaligarh MCS. The critical MOV status, corrected and uncorrected flow, totalized flow, all trip alarms, pressure controller settings and monitoring, density, batch change over are mentioned at MCS. Sump Tank and Pump Sump tank 20-TT-00-101 is provided at Sekoni Intermediate Pigging station for the collection of slops from various points such as header drain, scraper drain, line flushing, TSV relief etc. The collected slop is pumped into HSD product passing through mainline with the help of Sump Pump (20-PA-SM-101) and slop transfer pumps (20-PA-RP-102 A, B). Provision is also kept to load the slops into road tanker, if the situation demands using only Sump Pump. The following Interlocks are there at IP-I for Sump Pump and Slop transfer pumps:


20-I-1 20-LSL-1301 Trip sump pump 20-PA-SM-101 and Slop Transfer Pumps(20-PA-RP-102 A,B)

20-I-2 20-PSH-1301 Trip sump pump 20-PA-SM-101 and Slop Transfer Pumps(20- PA-RP-102 A,B)

20-I-3 Tripping of Sump Pump 20-PA-SM-101

Trip Slop Transfer Pumps(20- PA-RP-102 A,B)

B.2.4 NOONMATI INTERMEDIATE PIIGGING STATION Reference P&ID no. 6487-02-41-30-1214 Products will travel from Sekoni to Noonmati intermediate pigging station. The distance between Sekoni to Noonmati is 141 km (approx.). Two sectionalizing valves are provided enroute the pipeline. Operation of Noonmati intermediate pigging station is similar to Sekoni station. Noonmati intermediate pigging station is started by actuating the Station start up switch. With the actuation of Station start up switch, station inlet MOV i.e. MOV-1401 is brought to open condition. Noonmati intermediate pigging station is a manned station and is operated locally. Important parameters are monitored and can be controlled from Numaligarh MCS. The critical MOV status, corrected and uncorrected flow, totalized flow, all trip alarms, pressure controller settings and monitoring, density, batch change over are mentioned at MCS. Sump Tank and Pump Sump tank 30-TT-00-101has been provided at Noonmati Intermediate Pigging station for the collection of slops from various points such as header drain, scraper drain, line flushing, TSV relief etc. The collected slop is pumped into HSD product passing through mainline with the help of Sump Pump(30-PA-SM-101) and slop transfer pumps(30-PA-RP-102 A,B). Provision is also kept to load the slops into road tanker, if the situation demands using only Sump Pump. The following Interlocks are there at IP-II for Sump Pump and slop transfer pumps:


30-I-1 30-LSL-1401 Trip sump pump 30-PA-SM-101 and Slop Transfer Pumps 30-PA-RP-102 A,B

30-I-2 30-PSH-1401 Trip sump pump 30-PA-SM-101 and Slop Transfer Pumps 30-PA-RP-102 A,B


Trip Slop Transfer Pumps 30-PA-RP-102 A,B

Corrosion Inhibitor Tank and Pumps Corrosion Inhibitor is required to be dosed in the pipeline to reduce corrosion in the pipeline. For this purpose a C.I. Tank 30-TT-00-102 and a Corrosion Inhibitor dosing pump (30-PA-RP-103 A/B) has been provided. The Corrosion inhibitor is injected in the 14” pipe. The dosing capacity can be adjusted by stroke adjustment of pumps. B.2.5 BONGAIGAON INTERMEDIATE PIGGING STATION Reference P&ID no. 6487-02-41-40-1215 Products will travel from Noonmati to Bongaigaon intermediate pigging station. The distance between Noonmati to Bongaigaon is 145 km (approx.). Two sectionalizing valves are provided enroute the pipeline. Operation of Bongaigaon intermediate pigging station is similar to Sekoni station. Bongaigaon intermediate pigging station is started by actuating the Station start up switch. With the actuation of Station start up switch, station inlet MOV i.e. MOV-1501 is brought to open condition. Bongaigaon intermediate pigging station is a manned station and is operated locally. However important parameters are monitored and can be controlled from Numaligarh MCS. The critical MOV status, corrected and uncorrected flow, totalized flow, all trip alarms, pressure controller settings and monitoring, density, batch change over are mentioned at MCS. Sump Tank and Pump Sump tank 40-TT-00-101has been provided at Bongaigaon Intermediate Pigging station for the collection of slops from various points such as header drain, scraper drain, line flushing, TSV relief etc. The collected slop is pumped into HSD product passing through mainline with the help of Sump Pump(40-PA-SM-101) and slop transfer pumps(40-PA-RP-102 A,B). Provision is also kept to load the slops into road tanker, if the situation demands with the help of only Sump Pump (40-PA-SM-101). The following Interlocks are there at IP-III for Sump Pump and slop transfer pumps:


40-I-1 40-LSL-1501 Trip sump pump 40-PA-SM-101 and slop transfer pumps 40-PA-RP-102 A,B

40-I-2 40-PSH-1501 Trip sump pump 40-PA-SM-101 and slop transfer pumps 40-PA-RP-102 A,B


Trip slop transfer pumps 40-PA-RP-102 A,B

B.2.6 MADARIHAT INTERMEDIATE PIGGING STATION Reference P&ID no. 6487-02-41-50-1216 Products will travel from Bongaigaon to Madarihat intermediate pigging station. The distance between Bongaigaon to Madarihat is 147 km (approx.). Two sectionalizing valves are provided enroute the pipeline.Operation of Madarihat intermediate pigging station is similar to Sekoni station. Madarihat intermediate pigging station is started by actuating the Station start up switch. With the actuation of Station start up switch, station inlet MOV i.e. MOV-1601 is brought to open condition. Madarihat intermediate pigging station is a manned station and is operated locally. However important parameters are monitored and can be controlled from Numaligarh MCS. The critical MOV status, corrected and uncorrected flow, totalized flow, all trip alarms, pressure controller settings and monitoring, density, batch change over are mentioned at MCS. Sump Tank and Pump Sump tank 50-TT-00-101has been provided at Madarihat Intermediate Pigging station for the collection of slops from various points such as header drain, scraper drain, line flushing, TSV relief etc. The collected slop is pumped into HSD product passing through mainline with the help of Sump Pump (50-PA-SM-101) and slop transfer pumps (50-PA-RP-102 A, B). Provision is also kept to load the slops into road tanker, if the situation demands with Sump Pump only. The following Interlocks are there at IP-IV for Sump Pump and slop transfer pumps:


50-I-1 50-LSL-1601 Trip sump pump 50-PA-SM-101 and Slop Transfer Pumps 50-PARP- 102 A,B

50-I-2 50-PSH-1601 Trip sump pump 50-PA-SM-101 and Slop Transfer Pumps 50-PARP- 102 A,B


Trip slop transfer pumps 50-PARP- 102 A,B

B.2.7 RANGAPANI RECEIPT TERMINAL Reference P&ID no. 6487-02-41-60-1217 Products will travel from Numaligarh to Rangapani Receipt Terminal through Sekoni, Noonmati,Bongaigaon and Madarihat stations. The distance between Numaligarh to Rangapani is 655.7km (approx.). Nine numbers of sectionalizing valves are provided enroute the pipeline. At Rangapani Receipt Terminal, one densitometer (60-DT-1701) is provided close to the mainline block valve 60-MOV-1701 to alert the terminal operator about batch/interface arrival in advance. Another densitometer (60-DT-1702) is provided at the metering skid for density measurement and further data transmission to flow computer for mass metering. At Rangapani Receipt Terminal pressure control valve, 60-PV-1701 is provided to control upstream as well as downstream pressure of the control valve. High pressure protection is provided at down stream of 60-PV-1701. For this a pressure switch and ‘PT’ is provided. Pressure switch and ‘PT’ is interlocked to close Rangapani Receipt Terminal inlet valve i.e. MOV-1701 in case of high pressure.


60-I-1 60-PSHH-1701 Close 60-MOV-1703

At Rangapani Receipt Terminal, all the products except slop is received in Siliguri Marketing Terminal storage tanks of NRL. The individual receipt headers are provided with block valves one each near the respective tanks and common manifold. Block valves near the common manifold are interlocked with Station receipt start up switch 60-I-2 in such a way that when the station is receiving products, only one product valve is on-line (open). While switching over from one product to another product, the open switch of the desired product valve is actuated. Station receipt start up logic executes the opening command of the desired product receipt valve and closing command of the product receipt valve which is in open position. The opening and closing command is executed simultaneously. This interlock prevents opening of two product valves at the same time.This logic checks the closure of product header valve after a time lag. If the valve is not closed , the logic generates an alarm “Manifold valve malfunction” and close the station inlet valve,MOV-1703 These valves are MOV’s, which are quick opening/ quick closing type.


60-I-4 Opening command for MOV- 1704, 1705,1706, 1707, 1708 (any of the above)

Open desired product valve and close other opened product valve.

The Rangapani Receipt Terminal is a manned station and is operated locally. However, important parameters are monitored from Numaligarh MCS. The critical MOV status, corrected and uncorrected flow, totalized flow, all trip alarms, pressures controller setting and monitoring, density, batch change over, etc are monitored at MCS. These data are telemetered to MCS through RTU. The following repeat signals from Siliguri Marketing terminal shall be repeated at Rangapani Receipt Terminal control room: 1. Level indication from tanks 2. MOV status indication for tank valves, open/close status, remote/local status. Interlock 60-I-2 as indicated below is provided for Station ESD.


60-I-2 Station ESD Close all MOV at Siliguri Receipt Terminal

Sump Tank and Pump Sump tank 60-TT-00-101 has been provided at Rangapani Receipt Terminal for the collection of slops from various points such as header drain, scraper drain, line flushing, TSV relief etc. The collected slop is pumped into HSD product passing through mainline with the help of Sump Pump (60-PA-SM-101). Provision is kept to route the slop into receipt manifold. Provision is also kept to load the slops into road tanker, if the situation demands. The sump pump 60-PA-SM-101is interlocked to trip the running pump in case of low liquid level in the respective sump tank.


60-I-3 60- LSL-1701 Trip sump pump 60-PA-SM-101 Provision for product sampling is provided at Numaligarh and Siliguri. Apart from Densitometer and sampling, interface arrival can also be done by volume balancing in the pipeline B.2.8 SECTIONALISING VALVES Reference P&ID no. 6487-02-41-00-1225 and Along the Numaligarh-Siliguri pipeline 9 remotely operated sectionalizing valves and 30 nos. of hand operated sectionalizing valves are provided as per ANSI/ ASME B31.4 and safety requirements. When required, the sectionalizing valves are closed from MCS after ensuring the shutdown of entire pipeline operation. On issuance of close command from MCS for any of the sectionalizing valves, a prompt is made available to operator for verification of shutdown of the pipeline operation prior to closing of valves. After close command of any sectionalizing valve, a prompt is made available to operator for verification of shutdown of the pipeline operation prior to closing of valves. Close command of any sectionalizing valve gives prompt for shutdown of entire pipeline operation. It is mandatory for the operator to honor the prompt in order to close any mainline valve.All hand operated sectionalizing valves shall be closed only after a proper communication with/permission from SMCS.

B.2.9 LEAK DETECTION

In order to achieve overall objective of performing leak detection and location

under various conditions of the pipeline, the methodology of leak detection criteria

for Numaligarh-Siliguri product pipeline is as indicated below:

a. Leak detection system performs leak detection and leak location for

both static and dynamic condition of the pipeline with alarm.

b. The system is based on dynamic, statistical model using pressure,

temperature, flow rates, of 6 metering stations and 9 SV stations for

each legs of the pipeline.

c. Leak detection facility includes data validation, filtering and

suppression of nuisance alarms for authentic detection of leak.

d. The desired accuracy of detecting leaks is 1% of nominal flowrate,

detectable in as early as 10 minutes without reference to any false

alarms for steady state operation of the pipeline.

e. The desired resolution of leak location does not exceed 10 % of the

section length between pressure meters for a leak size greater than 25

% of nominal flow for steady state operation.

f. Since the response of detection of change due to operational

characteristics or due to faults such as bursts is required to be fast,

the scan time of flowrates is below 5 seconds for each legs.

B.2.10 CORROSION MONITORING SYSTEM For monitoring of internal corrosion and control, Corrosion Monitoring System (CMS) has been provided. Based on feed back of CMS system, ppm level of corrosion inhibitor is adjusted and accordingly corrosion inhibitor is dosed.

B.2.11 EMERGENCY / NORMAL SHUTDOWN Numaligarh-Siliguri Pipeline Emergency shutdown of the individual station is done by individual station ESD and it is responsibility of the station taking an emergency shutdown that informs MCS for the shutdown of the station. Emergency shutdown of the entire pipeline is not provided. However normal shutdown of the pipeline can be done by the actuation of a single Shut down switch in MCS to take action for the shutting down of the entire pipeline operation. Sectionalizing valves will be closed by MCS operator individually. The corrosion inhibitor dosing pump will be stopped by IP Station Engineer.

SECTION B.3

NORMAL OPERATION B.3.1 GENERAL This section describes the procedure for normal operation of the facilities and handling of emergency situations at Numaligarh Despatch Station, the Intermediate station and the Rangapani Receipt Terminal. To enable the operation of the facilities to their optimum utilization and to reduce unplanned breakdowns, some routine checks to be performed by the operators are also mentioned. These routine checks along with other operations as advised by the supervisors should be carried out for long and efficient use of pipeline systems. B.3.2 NORMAL OPERATION OF NSPL: Numaligarh-Siliguri pipeline consists of one pumping station located at Numaligarh. The receipt terminal is located at Rangapani. SCADA system is there to ensure effective and reliable control, management and supervision of the pipeline from Centralized location using Remote Telemetry Units (RTU). MCS for this purpose is located at Numaligarh. A suitable real time leak detection system, batch tracking and scheduling software is integrated with SCADA network. The control centre at Numaligarh Despatch Terminal has operational control on product despatch. All supply operations for the pipeline system shall be under the control of this Despatch Terminal and supply of the products at normal operating conditions shall be ensured from there. The Rangapani Receipt Terminal located at Siliguri shall communicate its requirement to the despatch station. The dispatch terminal shall make all necessary arrangements for product despatch and ensure proper lining up of the system in conjunction with the Rangapani Receipt Terminal. The despatch of product shall start only afterreceiving the ready-to-receive communication from Rangapani Receipt Terminal. Numaligarh Despatch Terminal and Rangapani Receipt Terminal are manned stations and shall be operated locally. However important parameters will be monitored at MCS as indicated in the respective P&IDs. Pipeline operations can also be controlled from MCS if required. Four IP stations namely, IP-I (Sekoni), IP-II (Noonmati), IP-III (Bongaigaon) and IP-IV (Madarihat) are there along the route with Pigging facilities. Additionally flow metering provision is there for leak detection purpose. Eventually these stations are intermediate pumping station for OIL’s existing Crude Oil pipeline. The Control Rooms at NDT and RT are manned by Shift Engineers. The following sections elaborate the Operation and Control Philosophy for Numaligarh-Siliguri Pipeline. B.3.3 OPERATION OF NUMALIGARH DESPATCH STATION: Three types of petroleum products namely MS, HSD and SKO are routed from tankage area to the Numaligarh pumping station using three individual headers. These headers are connected to the booster pump suction header. The individual headers of MS, HSD and SKO are provided with motor operated blockvalves close to the common header. Block valves are interlocked in such a way that when the pump station is operating, only one product valve is on-line (open). While switching over from one product to another product, the open switch

of the desired product valve is actuated. Station start up logic executes the opening command of the desired product valve and closing command of the product valve which ever is in open position. Opening and closing command is executed simultaneously. Closing command of the product header valve shall be executed only after desired product header valve is 25% open. This interlock prevents opening of two product valves at the same time. These valves areMOV’s, which are quick opening and quick closing type. B.3.3.1 Start-up of Numaligarh Despatch Station Pumps: The Numaligarh despatch station is controlled by station and unit control sequence as explained below. Every pump unit is controlled by a unit control sequence/ logic. The individual pump control sequence in turn is linked to the station control sequence, which also monitors and controls all the critical parameters of the pump station. To start the Numaligarh despatch station, it is required to confirm the following:

a. Numaligarh despatch station is ready to dispatch the product. b. All station battery limit valves and sectionalizing valves are in open position. c. Receipt Terminal is ready to receive products.

Following sequence of operation is done to start the Pump:

Tank Taken Over (Custody Transfer) Tank QC Certificate. Assured all the drain valves and other valves of the tank are sealed and the

documents taken over. Open tank main valve. Open NSPL valve. Pressure will show at pressure gauge near battery limit. Bleed the pipeline from tank to battery limit if necessary. Bleeding of air (Station line and equipment) with tank gravity. Bleeding of air after running Booster Pump. (Warning: during MS Booster pump

should not run more than 10 min. without MLP running which will leads to sudden temperature rise of MS)

Check the entire drain valve. Check lube oil level, CI level, and PCV reservoir oil level. Start auxiliary lube oil pump at least 10 - 15 min. before MLP starting. Check Station Alignment Logic. MOV 1209 (station O/L valve) to be open only before pumping. Co-ordinate with all IP station i/c and RT. Inform all IP station about scheduled time of pumping. Operate Remotely from SCADA all SV station valves, before 4-5 hrs scheduled

pumping. If any valve not opened or in transit condition, informed concerned IP station i/c

and ask them to send team to open the valve LOCALLY or Manually. Get assured all HOV are in open condition. PCV stroke to be checked from PLC on manual mode. Flow computer set for zero reading. Mode and % opening per PCV no 2 is 15% -18%. But per PCV no 1 % opening

should be 31% - 34%. Take clearance from CPP control room of NRL. Inform NRMT (Numaligarh Refinery Marketing Terminal) about Scheduled time of

pumping. Co-ordination with IP station i/c assured that all the valves are now in open

position.

Inform RT about Scheduled time of pumping. Asked RT not to operate inlet valve until unless clearance is given from MCS. Acknowledge all the alarms in PLC, SCADA and UCP. Go through electrical system checklist available in control room. AOP lube oil flow is normal (2.4 kg/cm2). Reset electrical alarm button in UCP, Reset electrical and field alarm in Sub-station

only after reset MLP will start. Never let RT to operate inlet valve before starting MLP. Get final clearance from CPP control room. Be sure suction of MLP is open and discharge is closed. Start MLP (Press on Group Start in AUTO mode) Check flow, current, lube oil pressure, and pump discharge pressure and

accordingly control. If everything is OK, inform NRMT, CPP. Asked to operate valve only after pressure transmit unto IP4. Asked RT to maintain PCV in such a way that RT flow rate should be equal to DPS. Keep the RT inlet pressure above 10 kg /cm2 when flow stables. Start CI dosing pump keeping 2-4 PPM. (Vary according to corrosive meter metal

loss reading.) Asked IP2 to operate CI dosing pump. Check bearing temperature and vibration. Immediately OIP/NSPL10 parameters to be noted down by operator/supervisor and

to be checked by control room i/c. Any leakage of station valve/equipment found in the system shall be immediately

reported to maintenance / (station engineer) Density checks as per IQCM and agreement. Sump tank level of all IP, s to be monitored from SCADA, if the rate of increase of

level in the sump tank due to unknown reason is more then 2 % in a shift, the reason for such receipt shall be analyzed and corrective action taken.

Despatch terminal is to transfer the batches as per schedule and achieve the desired results. These are also responsible for the smooth and safe operation of the pumping and pigging station facilities. B.3.4 PUMPING OF A BATCH When a batch is being pumped into the pipeline, it is necessary to keep an accurate account of the product being pumped and received. The Shift Engineer on duty at NSPL-MCS (Numaligarh) shall keep record in the station log sheet regarding the product being pumped, rate of pumping, rate of receiving, the location of the interphase etc. The Shift Engineer on duty at NSPL-MCS (Numaligarh) gets all this information from the SCADA. He shall transmit over phone all the data of the interphase location and the expected time of its arrival at the Rangapani Receipt Terminal. The location of interphase at any time can be read out in the computer at Numaligarh, Sekoni, Noonmati,Bongaigaon, Madarihat and Rangapani. This can also be manually calculated using the line fill volume per unit length and the pumping rate. A close watch shall be kept on the hourly readings of the meters at Numaligarh Deapatch station, IP Stations and Rangapani Receiving Terminal. Any significant

difference between the two meters can be a possible indication of a line leak. The meters in such cases should be rechecked and calibrated. It the corrected meter readings also shows a difference more than 0.25%, the pipeline should be inspected for any leak. B.3.5 BATCH CHANGING The Shift Engineer on duty at NSPL-MCS (Numaligarh) shall change the product batch from one to the other in pumping cycle as per the schedule. He shall get the appropriate tank lined up after checking the tank level and temperature and taking the sample. The product header changeover shall be done remotely from the MCS room. A close watch shall be kept on the density meter after switching over the product. When it registers a change in the density reading, that time shall be noted as the time of interphase leaving the station. Shift Engineer on duty at NSPL-MCS (Numaligarh) shall inform that time to the Rangapani Receipt Terminal. The Shift Engineer on duty at NSPL-MCS (Numaligarh) shall always keep a close watch on the position of interphase at any time. He/she shall get the interphaseposition from the SCADA. At Rangapani Receipt Terminal as soon as the interphase reaches the receipt station as indicated by the density transmitter, the Shift Engineer on duty at Rangapani Receipt Terminal Control Room shall remain alert and the necessary preparations for the switch over of the receiving tank shall be done. When the density recorder records change in the density, the pipeline Shift Engineer on duty at Rangapani Receipt Terminal Control Room shall be ready for switch over. Depending upon how the interphase is to be cut (based on density meter input or physical sampling); the pipeline Shift Engineer on duty at Rangapani Receipt Terminal Control Room shall switch over the product receipt to the appropriate storage tank taking into consideration the acceptable permissible contamination as specified in section 1.1. In addition to density, manifold valve status (opening / closing) shall also be used for batch launching purpose. B.3.6 INTERFACE STORAGE AND HANDLING The permissible level of contamination of SKO in MS is 1% (vol.) and SKO in HSD is 2.0% (vol.). The signal from 30-FQY-1701/1702 (from flow computer,provided for pipeline receipt flow rate at Rangapani Receipt Terminal) shall be utilized to set the ratio controller FRC-1701 / 1702 through selector switch (SS). B.3.7 STATION PRESSURE CONTROL This is the main control to be effected at Numaligarh Despatch Terminal in order to protect the main pumps from operation below the minimum required NPSH. During normal operation, the Control is automatic. The station Pressure Control Valve 10-PV-1201 receives signals from the pump suction pressure indicator controllers 10-PIC-1201 and will maintain the desired mainline pump suction pressure at Numaligarh. When the pump suction pressure drops below the minimum set value, the low signal will operate the station pressure control valve to maintain the required pressure at the suction of Pumps.

B.3.8 DOWNSTREAM/BACK PRESSURE CONTROL Downstream / backpressure control is important at Rangapani Receipt Terminal in order to have a tight line operation. This helps to minimize inter – mixing of products and keeps inter-phase to minimum. The tight line operation also helps to prevent hydraulic surging by minimizing the vaporization of products in the line. Back pressure controller 10-PIC-1703 is provided which controls the line pressure at Rangapani Receipt Terminal B.3.9 SECTIONALIZING & MAINLINE STATION INLET/OULET VALVES OPERATION When required, the sectionalizing valves & mainline station valves are closed from the MCS after ensuring the shutdown of entire pipeline operation. On issuance of close command from MCS for all mainline valves including sectionalizing valves a prompt should be available to the Shift Engineer at MCS for verification of shutdown of the pipeline operation prior to the closing of valves. Closing command of any sectionalizing valve or any mainline station inlet/outlet valve will give prompt for shutdown of entire pipeline operation. It is mandatory that engineer/operator shall honor the prompt or else he shall not be able to close any mainline valve. As soon as valve is in close position it should be put in local mode. Local switches will open all these valves only manually in presence of authorized operating personnel. B.3.10 ROUTINE CHECKS For smooth operation, some routine checks are suggested as under:

Every shift, check the level in filter separator at Numaligarh and Siliguri and drain the water manually.

In each shift check the level in the corrosion inhibitor tank, and top up the tank

as and when necessary. Check periodically different alarm and shutdown switches. Alternate the standby pumps weekly. Carry out weekly inspection of all fire and safety equipment. Check the differential pressure across the cartridge filters in each of the

stations. Calibrate the instruments/safety devices periodically or as per vendor’s

recommendations. Monitor all the process parameters and take appropriate actions. Monitor the despatch and receipt quantity.

B.3.11 LIST OF ALARMS AND SET POINTS Keeping in view the safety of the system, important parameters in pipeline operation has been alarmed. A list of such alarms with their set points is given in the next page. In the table below, pressure are indicated in kg/cm2. flow in m3/hr and level in mm. TABLE-B.3.11.1 (Numaligarh Despatch Station)

Tag. No. Description Set Point Action 10-PAL-1101/1102 Booster pump

suction pressure low

0.1 kg/cm2 Trip booster pump

10-PAH-1101/1102

Booster pump discharge pressure high

7.5 kg/cm2 Trip booster pump

10-PAL-1201/1202 Individual Mainline pump suction pressure low

1.5 kg/cm2 Trip Respective Mainline pump

10-PAH-1201/1202

Individual Mainline pump discharge pressure high

105 kg/cm2 Trip Respective Mainline pump

10-LAL-1101 Sump tank level low

150 mm Trip sump pump

10-LAH-1101 Sump tank level high

1400 mm Alarm

10-PALL-1201 Mainline pump common suction pressure low low

1 kg/cm2 Trip all mainline pumps

10-PAL-1205 Mainline pumps common discharge pressure low

15 kg/cm2 Alarm

10-PAH-1205 Mainline pumps common discharge pressure high

80 kg/cm2 Alarm

10-PAH-1204 Mainline pumps common discharge pressure hig

78 kg/cm2 Trip all pumps

Tag. No. Description Set Point Action 10-PAHH-1201 10-PAHH-1202 10-PAHH-1203

Pipeline pressure high high (2 out of 3 logic)

80 kg/cm2 Trip all pumps

TABLE-B.3.11.2 (Sekoni Intermediate Station)

Tag. No. Description Set Point Action 20-LAL-1301 Sump tank level low 150 mm Trip sump pump

20-LAH-1301 Sump tank level

high 1400 mm Alarm

20-PSH-1301 Slop pump discharge

pressure high 77 kg/cm2 Trip sump pump 20-PA-

SM-101 and 20-PA-RP-102 A, B

TABLE-B.3.11.3 (Noonmati Intermediate Station)

Tag. No. Description Set Point Action 30-LAL-1401 Sump tank level low 150 mm Trip sump pump

30-LAH-1401 Sump tank level high 1400 mm Alarm

30-PSH1401 Slop pump discharge

pressure high 64.5 kg/cm2 Trip sump pump 30 -PA-

SM-101 and stop transfer pump 30-PA-RP-102 A, B

TABLE-B.3.11.4 (Bongaigaon Intermediate Station)

Tag. No. Description Set Point Action 40-LAL-1501 Sump tank level

low 150 mm Trip sump pump


high 1400 mm Alarm

40-PSH-1501 Slop pump

discharge pressure high

44kg/cm2 Trip sump pump 50-PA-SM-101 and stop transfer pump 40-PA-RP-102 A, B

TABLE-B.3.11.5 (Madarihat Intermediate Station)

Tag. No. Description Set Point Action 50-LAL-1601 Sump tank level

low 150 mm Trip sump pump


high 1400 mm Alarm

50-PSH-1601 Slop pump

discharge pressure high

23 kg/cm2 Trip sump pump 50-PA-SM-101 and stop transfer pump 50-PA-RP-102 A, B

TABLE-B.3.11.6 (Rangapani Receipt Terminal)

Tag. No. Description Set Point Action 60-PAH-1701 Receipt header

pressure high

7 Alarm

60-PAHH-1701 Receipt header pressure high high

10 Close MOV- 1703

60-LAL-1701 Sump tank level low

150 mm Trip sump pump

60-LAH-1701 Sump tank level high

1400 mm Alarm

B.3.12 SHUTDOWN Shutdown of any station along the pipeline necessitates shutting down of the entire pipeline operation. Emergency shutdown of the station is done by individual station & it is the responsibility of the station taking an emergency shutdown that it informs MCS(Numaligarh) for the shutdown of the pipeline. The shutdown of the pipeline is done by the actuation of a single SD push button in MCS to take action for the shutdown of the entire pipeline operation. Following sequence of action needs to the taken for the shutdown. 1. Stop pumps at Numaligarh Despatch Terminal: 10-PA-CF-101 A/B 10-PA-CF-102 A/B 2. Close inlet station valve 60-MOV-1701 at Rangapani Receipt Terminal 3. Close all other station inlet & outlet valves 4. The sectionalizing valves are closed by the Shift Engineer on duty at MCS(Numaligarh) individually. The corrosion inhibitor pumps will be stopped by local Station Engineer

B.3.12.1 SHUTDOWN OF NUMALIGARH PUMPING STATION B.3.12.1.1 Normal Shutdown:

1. Inform all IP stations and RT about tentative time of shut down and reason.

2. Also inform NRMT and CPP Control room of NRL.

3. Decide whether sector wise or in-between IP station or only DPS and RT valve will remain close during shutdown in consultation with station in-charge based on whether shutdown will continue short time or long time.

4. Ask RT to close the Inlet valve when inlet pressure in-between18-25 kq per sq cm.

5. When DPS outlet pressure raise around 55-65 kg per sq cm. stop mainline pump to

maintain line pressure around 45-50 kg per sq cm.

6. If before shut down DPS outlet pressure is below 55 kg/cm2, RT inlet pressure should be raised to 24-28 kg/cm2 before closing the inlet valve of RT.

7. Stop mainline pump by clicking on GROUP STOP button. As per LOGIC discharge valve will automatically close to prevent reverse rotation of impeller.

8. Stop Booster pump and CID pump.

9. Close DPS station outlet valve, booster pump outlet valve and other station valves if

necessary.

10. Documents the Cumulative flow readings.

11. Inform NRMT and CPP Control room of NRL.

12. After stabilizing the flow inside pipeline, i.e. when flow becomes zero at all IP stations, close inlet and outlet valves of IPs.

13. Close all SV stations MOV.

14. Inform respective IP station I/C if there is any malfunctioning of valves.

B.3.12.2 SHUTDOWN OF Rangapani Receipt Terminal For a planned shut down of the receipt station proceed as under: - Inform Numaligarh Despatch Terminal, Sekoni, Noonmati, Bongaigaon,Madarihat intermediate station. - Get the clearance from MCS (Numaligarh). - Close MOV-1701/1715/1716 - Close the station pressure control valve 60-PV-1701. - Close Marketing Terminal inlet valve.

B.3.12.3 SHUTDOWN OF PIPELINE Shutdown of any station along the pipeline may cause shutting down of the entire pipeline operation. Shutdown of the pipeline, if required, shall be done manually and through the MCS. Shut down shall be done manually only when the MCS is not working due to any reason. Any station willing to have shutdown shall request MCS for the shutdown of the pipeline. The actions required to be taken for the shutdown of pipeline need not be executed all at the same instant. SHUTDOWN OF PIPELINE THROUGH MCS: Shutdown of the pipeline, if required, shall be done manually and through the MCS. Through MCS shutdown can be done using prompts and without prompts. 1) SHUTDOWN OF PIPELINE THROUGH MCS WITHOUT PROMPTS: Pipeline can be taken into shutdown by actuation of a single command in the MCS. Here the Shift Engineer is not required to follow the shut down steps. SMCS will follow all the steps to take smooth shut down of the pipeline. 2) SHUTDOWN OF PIPELINE THROUGH MCS WITH PROMPTS: Pipeline can be taken into shutdown by actuation of sequence of prompts in the MCS. Here the Shift Engineer is required to follow the shut down steps to take smooth shut down of pipeline. 3) SHUTDOWN OF PIPELINE MANUALLY: Pipeline can be taken into shutdown manually only when MCS is not working due to any reason. Here the Shift Engineer is required to follow the shut down steps to take smooth shut down of pipeline. B.3.12.4 SHUTDOWN OF RANGAPANI RECEIPT TERMINAL In case of fire, a big leak or other such emergencies, it is important to shutdown the receipt terminal at Rangapani. The Pipeline can be isolated completely by closing the station isolation valves by pressing ESD push buttons, which can be closed from MCS provided at Numaligarh Despatch Station. For the shutdown of pipeline Shift Engineer at Rangapani Receipt Terminal shall inform the pipeline control room. The fire alarm should be raised and appropriate steps should be taken. B.3.13 OPERATION OF CENTRIFUGAL PUMPS All the centrifugal pumps are driven by electric motor. Failure of pumps will paralyse the normal activities of the pipeline. General procedures for startup/shutdown and trouble shooting of centrifugal pump are discussed below. Vendor’s operating manual should be referred for further details.

B.3.13.1 START-UP:

Inspect and see if all the mechanical jobs are completed. Check oil level in the bearing housing; flushing may be necessary if oil is dirty or contains some foreign material. It is extremely necessary that oil and grease of proper grade and viscosity be used. Refer manufacturer’s instructions and recommended lubricating schedule.

Rotate the shaft by hand to ensure that it is free and coupling is secured. Coupling guard should be in position and secured properly.

Open suction valve. Ensure that the casing is full of liquid. Bleed, if necessary, from the bleeder valve. Keep discharge valve closed.

Energize the motor and start the pump. The discharge valve starts opening automatically.

Keep watch on the current drawn by the motor and discharge pressure. Check temperature of the bearings. Check the gland/seal and if necessary adjust gland tightness/flow of the coolant for the seal.

SHUTDOWN

Stop the pump. The discharge valve starts closing automatically. If pump is to be prepared for maintenance, proceed as follows:

a) Close suction and ensure closure of discharge valves. b) Slowly open pump bleeder and drain liquid from pump. Ensure that there is no pressure in the pump. Also drain pump casing. c) Cut off electrical supply to pump motor prior to handing over for

maintenance. B.3.13.2 TROUBLE SHOOTING PUMP NOT DEVELOPING PRESSURE

Bleed/vent pump casing. Check the lining up in the suction side. Check the suction strainer. Check the liquid level from where the pump is taking suction (physical

verification) Check pump coupling and rotation. Check the temperature of liquid. If it is higher than for what the pump has

been designed, NPSH will come down. Check for any air leakage in the pump suction line or pump casing.This may

occur at various joints and packing boxes, as the packing gets old.

UNUSUAL NOISE:

Check if coupling guard is touching coupling. Check for proper fixing of fan and fan cover of the motor. Check for pump cavitation. Get the pump checked by a technician.

RISE IN BEARING TEMPERATURE

Check the foundation bolts. Check the fan cover for looseness. Check alignment Stop the pump and hand over to maintenance

LEAKY GLAND

Check the pump discharge pressure. Tighten the gland nut slowly, if possible. Prepare the pump for gland packing adjustment/replacement for mechanical

seal as the case may be. MECHANCIAL SEAL LEAK

Stop and isolate the pump and hand over to maintenance. Refer to vendor’s instruction for more details on Trouble shooting of pumps.

SECTION B.4

OIL MOVEMENT

B.4.1 Function and scope :- To direct the flow of High speed diesel(HSD), Motor Spirit(MS) and Kerosene through the product pipeline from its entry into the pipeline from product storage tanks at Numaligarh Refinery Marketing Terminal(NRMT) to its destination into the product tanks at Siliguri Marketing Terminal(SMT) of NRL. This includes custody transfer of tanks, joint gauging at both the ends, sampling and testing of product parameters, operation and security of the pipeline and the accounting for and reconciliation of products despatched from NDT and received at RT. B.4.2. Responsibility :- It is the direct responsibility of the Head(Ppipeline Operations) to coordinate these functions. Station incharge/ Station engineers, who will normally receive direct instructions from Head (Pipeline Operations), will ensure that instructions are faithfully carried out at all times and shall also, ensure that the despatch and receipt terminals are in operational readiness for the current pumping programme. The Duty Shift Engineer at NSPL-MCS (Numaligarh) shall be responsible for operations of Numaligarh Despatch Terminal(NDT) Iincluding custody transfer of tanks, batch changing and sample collection and monitoring of the entire pipeline in a safe and efficient way. It is the responsibility of the Duty Shift Engineer at Rangapani Receipt Terminal to cut the product interface accurately so that the quality of the mother tank of any product is not hampered as well as custody transfer and sampling. B.4.3 CUSTODY TRANSFER:- The custody transfer agreement signed jointly between NRL and OIL on 8th of November 2007 shall be followed for custody transfer at both ends. This agreement may be revised from time to time. The agreement is attached in annexure for reference. Formats given below shall be used for documentation for custody transfer and related details. B.4.4 DOCUMENTATION:- Documentation of custody transfer as provided in the joint Custody Transfer Agreement shall be done in the following formats.

OIL INDIA LIMITED

SAMPLE TAG NUMALIGARH / SILIGURI PIPELINE

BATCH NO.

PROCESS TANK NO.

PRODUCT

DATE OF SAMPLING

TIME OF SAMPLING

TYPE OF SAMPLE TANK SAMPLE / LINE SAMPLE

DENSITY OF SAMPLE

TEMPERATURE 0C(Nat)

REMARKS : SAMPLE DRAWN BY : SIGNATURE :

OIL INDIA LIMITED

QUALITY CONTROL MANUAL

RETENTION OF SAMPLE (BULK PRODUCT TRANSFER)

SL. NO EVENT/ ACTIVITIE

S

SOURCE OF

SAMPLE

QUANTIY OF SAMPL

E

TYPE OF

SAMPLE

SAMPLE TO BE

DRAWN BY

IQCM REFERE

CE CLUSE

NUMBER

REF. CLAUSE NO. OF PROD

ACCEPTANCE

MANUAL

RETENTION PERIOD

1 Before transfer

from Refinery through MPPL

Individual Nominate

d tank

2×2 litres

UML compos

ite

NRL Marketing & Oil India

Limited

Till batch Established

2 Transfer through MPPL

Manifold at

dispatching end

1×1 litre 1×1 litre 1×1 litre

Initial Middle End of Product pumpin

g

Oil India Limited


3 Transfer through MPPL

Manifold at

receiving end

1×1 litre 1×1 litre 1×1 litre

Initial Middle End of Product pumpin

g

Oil India Limited


4 After despatch through MPPL

Despatch Tank

2×2 litres

UML compos

ite

NRL Marketing & Oil India

Limited


for SKO, 3momths

after batch estd.

Certificate of Quality for Superior Kerosene Oil IS: 1459-1974

Sample ref : Request reference : Sample received on : Certificate issued on : Sample tested on : Certificate issued to : Batch No. : Certificate No : Address of the Client : Sampling Plan : Sl.No. METHOD

[P: ] Of IS 1448 CHARACTERISTICS UNIT REQUIREMENTS RESULT

1 P:2 Acidity, Inorganic Mg of KOH/g

2 P:5 Burning quality a) Char value mg/kg of oil consumed Max b) Bloom on glass chimney

Mg/kg

3 P:14 * Colour (Saybolt), Min 4 P:15 *Cu-strip corrosion for 3

hrs at 50°C

5 P:16 * Density at 15 °C Kg/m³ 6 P:18 Distillation

A) Percent recovered below 200°C, Min b) Final Boiling point, Max

% °C

7 P:20 *Flash point, min °C 8 P:31 *Smoke Point, min mm 9 P:34 *Total Sulfur % by mass

Representative of Numaligarh Refinery Limited

Certificate of Quality for EURO-III High Speed Diesel

Sample ref : Request reference : Sample received on : Certificate issued on : Sample tested on : Certificate issued to : Batch No. : Certificate No : Address of the Client : Sampling Plan : Sl.No. METHOD

[P: ] of IS 1448 CHARACTERISTICS REQUIREMENTS RESULTS

1 2 P:2 Inorganic Acidity, mg of KOH/g

* Acidity, Total, mg of KOH/g

3 P:4 Ash, % mass 4 P:8 Carbon Residuc (Ramsbottom), on 10% residue,

% mass

5 P:9 Cetane Number 6 ASTM D 4737 *Cetane Index 7 P:10 *Pour Point, °C 8 P:15 *Copper strip corrosion for 3 hrs at 100°C 9 P:18 *Distillation % volume recovery at 360°C 10 P:20 *Flash point, °C 11 P:25 *Kinematic Viscosity at

40°C, eSt

12 P:16 *Density at 15°C/Observed density at °C/ Kg/m³ 13 ASTM D 4294 *Total Sulfur, %mass 14 ISO: 12937 Water content, mg/kg 15 P:110 Cold Filter Plugging Point, °C 16 EN 12662 Total contaminations (Particulate matter), mg/kg 17 ISO 12205 Oxidation stability, g/m³ 18 EN 12916 Polycyclic Aromatic Hydrocarbon (PAH), %mass 19 ISO 12156-1 Lubricity corrected wear scar diameter 1.4 at

60°C, microns


SL NO.

METHOD [P:] Of IS 1448

CHARACTERISTICS REQUIREMENTS

1 Colour, Visual 2 P:16 * Density at 15 °C/Observed Density at

°C, Kg/m3

3 P:18 *Distillation Recovery upto 70 °C (E 70),% by vol. Recovery upto 100 °C (E 70),% by vol. Recovery upto 180 °C (E 70),% by vol. FBP, max, °C Residue, max, % by vol 4 P:27 *Research Octane Number (RON), Min 5 P:26 & P:27 *Anti-Knock Index(AKI), Min 6 P:29 *Existent Gum, max,g/cu.m 7 P:147 *Potential Gum, max,g/cu.m 8 P:34 *Total Sulfur, Max, %, mass 9 IP 252 Lead content(Pb), Max, g/l 10 P:39 * Reid Vapour Pressure, kpa 11 *Vapour Lock Index (VLI), max,

summer

(VLI=10RVP + 7E &)) 12 ASTM-D-

3606 Benzene content, % by vol, max For Metros % vol, max

13 Water tolerance of gasoline-alcohol Blends, tempreture for phase separation, °C Summer Winter

14 P:15 *Copper Strip Corrosion for 3hr. @ 50 °C

15 Engine intake system cleanliness


NUMALIGARH REFINERY LIMITED NSPL TRANSFER OUTTURN Marketing Terminal PLT No : Tank Batch No : Out –Turn Dip Memo Ref. : Date : Tank No : Product :

080810HSD03027 OIL BATCH NO 14 465 & 466 10.08.2010 005A HSD03

Before Transfer After Transfer

Date & Time Dip of Water & Oil in MM Dip of Water in MM Qty of Water in L Net Qty of Oil at Natural Temp. (L) Temperature Deg.C Density at Natural Temp. (Kg/m3) Density at 15 C (Kg/m3) Net Qty at 15 C (L15) Net Qty at 29 C (L29) Net Qty in Kg

08.08.2010 at 16:40:00 5,293.000 114.000 682,716.000 11,166,558.000 37.00 825.000 840.200 10,958,190.000 11,094,317.000 9,195,017.000

09.08.2010 at 15:00:00 3,518.000 130.000 717,913.000 7,217,232.000 37.00 825.000 840.200 7,082,559.000 7,082,559.000 5,942,975.000

Qty Transferred at Nat. Temp. (L) Qty Transferred at 15 C (L15) Qty Transferred at 29 C (L29) Qty Transferred in Kg

3,949,326.000 3,875,631.000 4,011,758.000 3,252,042.000

For Oil India Limited

For Numaligarh Refinery Limited

NSPL/ Form No. OIL INDIA LIMITED

NUMALIGARH-SILIGURI PRODUCT PIPELINE TANK OPERATION MEMO TANK TAKING OVER/HANDING OVER MEMO Location : ____________________ DATE :____________________ TIME :________________ SL. NO :_____________ TANK NO : ____________________ MS/SKO/HSD BEFORE RECEIPT / AFTER RECEIPT : _______ Cm REF. HT : ____________Cm PHYSICAL DIP : (a) OIL DIP : cm (b) WATER DIP : cm (c) TANK TEMPERATURE : 0C (d) SAMPLE DENSITY : gm/cc (e) SAMPLE TEMPERATURE : 0C SERVO GAUGE : DIP CR : Cm TEMP. : 0C

VALVE STATUS INLET VALVE GATE : OPEN / CLOSE LOCKED/UNLOCKED SEAL NO. : _________ MOV : OPEN / CLOSE LOCKED/UNLOCKED SEAL NO. : _________ OUTLET VALVE GATE : OPEN / CLOSE LOCKED/UNLOCKED SEAL NO. : _________ MOV : OPEN / CLOSE LOCKED/UNLOCKE SEAL NO. : _________ ITT VALVE 00 A : OPEN / CLOSE LOCKED/UNLOCKED SEAL NO. : _________ 00 B : OPEN / CLOSE LOCKED/UNLOCKED SEAL NO. : _________ 00 C : OPEN / CLOSE LOCKED/UNLOCKE SEAL NO. : _________ TANK DRAIN VALVE OPEN / CLOSE LOCKED/UNLOCKED SEAL NO. : _________ OPEN / CLOSE LOCKED/UNLOCKED SEAL NO. : _________ ROOF DRAIN VALVE OPEN / CLOSE LOCKED/UNLOCKED SEAL NO. : _________ OPEN / CLOSE LOCKED/UNLOCKED SEAL NO. : _________ SAMPLE : ______ SET OF _____ LITRES EACH SIGNED BY OIL AND SMT RETAINED. TANK TAKEN OVER BY TANK HANDED OVER BY NRL / OIL NRL / OIL

OIL INDIA LIMITED NUMALIGARH-SILIGURI PRODUCT PIPELINE

INLAND PIPELINE TRANSFER LOG BOOK (NUMALIGARH)

DATE

TIME

PRODUCT

BATCH NO.

PIPELINE KANIFOLD REMARKS DESPATCH/RECEIVING STATION

APPEARENCE TEMP. DENSITY

NAT. 150C

SIGNATURE

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B.4.5 TANKAGE B.4.5.2 Tankages at Numaligarh Refinery Marketing Terminal (NRMT):

Product Tank No Capacity of each tank in KL

MS

004A, 004B, 004C 29000

SKO

005A, 005B, 005C 3730

HSD

008A, 008B, 008C 27000

B.4.5.1 Tankages at NRL- Siliguri Marketing Terminal (SMT):

Product Tank No Capacity of each tank in KL

MS

001A, 001B, 001C 13000

SKO

002A, 002B 5000

HSD

003A, 003B, 003C,003D 15000

SLOP

004A, 004B 500

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SECTION B.5

EMERGENCY CONDITIONS AND EMERGENCY PROCEDURE B.5.1 EMERGENCY CONDITIONS: Several emergency conditions may arise during pipeline operations at any time. The following action lists are a general guide only and may be changed as a result of local conditions or circumstances. B.5.1.1 FEED FAILURE AT NUMALIGARH DESPATCH STATION: Feed supply may get cutoff from Numaligarh Despatch Station due to number of reasons e.g. Power failure, emergency conditions etc.

Inform the Sekoni, Noonmati, Bongaigaon, Madarihat & Siliguri Receiving Station immediately about the feed failure and for necessary action at their end (i.e closing of stations inlet valves at Sekoni, Noonmati, Bongaigaon, Madarihat & Rangapani Receipt Terminal)

Close the outlet valve of feed tank. Close the station isolation valve from pipeline. Stop the booster pumps and mainline pumps. Again when the terminal is ready for pumping, inform the receiving station

to line up the system. Start pumping after ensuring proper line-up of the system as per normal

operating procedure. AT RANGAPANI RECEIPT TERMINAL When the feed for Rangapani Receipt Terminal gets cut off

Rangapani receipt crew should immediately inform Numaligarh Despatch Station, Sekoni, Noonmati, Bongaigaon & Madarihat station.

Close the station & storage inlet valves Keep watch on process parameters. When, system is ready reline-up the system & start receiving product

again. B.5.1.2 SYSTEM PRESSURE HIGH/LOW System high pressure at any of the stations can occur due to blocked discharge condition, which will be indicated by high-pressure alarm and highhigh pressure alarms in the Despatch & Receiving Terminals (refer tables in section 6.9). The high-high pressure switches will trip the station pumps as per the interlock logic. In case of low pressure, due to any leak in the pipeline is indicated by lowpressure

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alarm (refer tables in section 6.9) and pressure alarm low low (which will trip all station pumps). The discharge line pressure needs to be monitored during normal operation. B.5.1.3 POWER FAILURE In the event of power failure at any of the stations the following shall happen.

Pumps will trip. All the MOVs will remain in their last positions. Emergency lighting in the control room is ‘ON’. Inform other pipeline stations about the emergency and ask them to take

necessary action. When power is restored, inform the other stations and after concurrence

from there, reline up the system and start pumping. Before pumping is started, ensure that all the controls/stature indications are available on the local station and on SCADA in Numaligarh Despatch Station.

B.5.1.4 PIPELINE FAILURE Any leakage in the pipeline can be detected by comparison of mass flow rate Of despatch and the receipt at Numaligarh, Sekoni, Noonmati, Bongaigaon, Madarihat & Rangapani Receipt Terminal.

In the event of any leakage, isolate the sections by closing respective sectionalizing valves between the leak points through SCADA/Leak Detection System

Monitor the pressure and temperature for each section of the pipeline. Send immediately patrol party for physical survey of the section isolated

to identify the leaking point. Once the leaky point is located, the particular section has to be emptied

out. This may be done by launching a Pig. Cordon off the spillage area. Clear the Spillage. Prepare the line for repair job after taking necessary safety precautions and

clearances. Restart the pipeline operation, once the repair job is over, after lining up

the system. B.5.1.5 MAJOR SPILLAGE IN STATIONS. In the events of major spillage in any of the stations at Numaligarh, Sekoni, Noonmati, Bongaigaon, Madarihat & Siliguri Receiving Stations due to joint failure/gasket failure or due to any other reason the following actions can be initiated.

Take shutdown of the system. Immediately inform the other stations. Isolate and depressurise/empty out or operate through alternative line if

available.

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The product is recovered using vacuum pump system and the area is cleaned using water Jets.

B.5.2 EMERGENCY PROCEDURE B.5.2.1 Definition and Objective: When a situation develops such that the efficient

movement of oil is prejudiced, a pipeline emergency occurs. The objective of the emergency procedure is to lay down action required to ensure that a co-ordinated plan to deal effectively with the emergency is effective from the start.

B.5.2.2 Scope: Movement of oil is effected by three board functions, namely NDT/the IP stations/RT, the Pipeline and the Communication system. Any unscheduled happening to these functions, which directly affects operation, must be considered in degree as a pipeline emergency. Emergency conditions of NSPL are defined in clause B.5.1 above alongwith sequence of actions to be taken.

B.5.2.3 Emergency Procedure: An emergency procedure usually takes six definite stages in following order:

B.5.2.3.1 Awareness: Awareness of an emergency may emanate simultaneously at several points or locally at one point either through the agency of an automated alarm or by visual observation of an employee, or by a report from an outside agency. All concerned should also be aware that when running plant /equipment has failed, and standby emergency plant/equipment has been brought into service, an emergency situation in degree has arisen and restoration to normal working must be undertaken urgently. B.5.2.3.2 Immediate Action: All employees should be fully trained in emergency action affecting their department such that on detection of an emergency they understand the immediate action required of them to locally minimize or control the emergency. B.5.2.3.3 Reporting: Concurrent with the immediate action taken at the locality the situation must be reported to the Duty Shift Engineer at NSPL-MCS (Numaligarh) and RT control room. Such reports should be immediately reported over the Company’s communication system or if this has co-incidentally failed by the Public telephone. B.5.2.3.4 Co-Ordination: The Duty Shift Engineer at NSPL-MCS (Numaligarh) on receipt of an emergency report, whatever its nature,is in the position to determine the degree of emergency involved and to take action accordingly .If the emergency is such that it necessitates a temporary reduction of pumping ratye he/she will immediately inform In-Charge Engineer(NT). If the emergency necessitates shutting down of pumping, he will immediately initiate the Emergency Call out.

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B.5.2.3.5 Emergency Call Out:

A. Pump Station Emergency: Duty Shift Engineer at NSPL-MCS (Numaligarh) shall immediately inform: General Manager (Pipeline Services) Head (Pipeline-Operations) Head(Pipeline-M&S) Head(TTI&FC) In-Charge Engineer(NT) In-Charge Engineer(RT)

B. Pipeline Emergency: Duty Shift Engineer at NSPL-MCS (Numaligarh) shall immediately inform General Manager (Pipeline Services) Head (Pipeline-Operations) Head (Pipeline-M&S) Head (TTI&FC) In-Charge Engineer (NT) In-Charge Engineer (RT)

Chief Engineer (Pipeline Maintenance) Chief Engineer Pipeline (Electrical & Cathodic)

If the emergency is a pipeline leak detected either by the Engineer on Duty NSPL MCS or by a report emanating from a IP station, the Engineer on Duty NDT MCS shall immediately take steps to shut down NDT pending the arrival of the personnel on the Emergency Call out list. Thereafter the Engineer on Duty NSPL MCS shall instruct the In-Charge Engineers of IP Stations concerned to proceed and close the appropriate valves on the RoW/RoU to minimize the spillage. The In-Charge Engineers of IP Stations should then proceed as follows: a) Leaving Station Engineer, Pump Station/IP Station to stand by and to be in

contact with PHQ, proceed and close line block valves(HOV) as instructed by Duty Shift Engineer at NSPL-MCS (Numaligarh), maintaining mobile radio contact with pump station.

b) After closing the valves in question he/she should then organize patrols in the section concerned to locate the leak.

c) On detection of the leak he/she should initiate the following action: Ensure Safety of the area by posting guards to keep villagers away from crude spillage, inform local police station immediately.

Report by radio the quickest approach for pipeline maintenance crews and if necessary obtain permission from local landowners.

Organise local labour to stand by for excavation, and if the spillage is severe, do everything possible to contain the spillage with earthen bunds.

Stand by at leak site pending arrival of maintenance crews keeping in radio contact with PHQ /NDT/IP stations/RT at all time.

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C. Communication Emergency: Duty Shift Engineer at NSPL-MCS (Numaligarh) shall immediately inform Head (Pipeline-Operations) Head (TTI&FC) In-Charge Engineer (NT) In-Charge Engineer (RT)

B.5.2.3.6 Repair Work: Once emergency action has been cooadinated and the operation moves to the field, a senior executive will be deputed in complete operation. During this final stage of the emergency, adequate communication between PHQ and the field is vital to ensure that repair work gets the umost logistic support.

B.5.2.3.7 Emergency Call Roster: In-Charge Engineers of NDT and RT will every

week draw up a roster to ensure that sufficient personnel are always available on call at the station to initiate emergency action. At IP Stations the roster shall be as maintained for the crude oil pipeline.At maintenance bases this roster shall include all categories of maintenance personnel. The In-Charge Engineer and the 2nd most senior engineer of a Station must never be out of station simultaneously. At Pipeline Head Quarter General Manager, Head and Chief Engineers will not simultaneously be out of station. Other Sectional Heads must obtain prior permission from the General Manager / Heads/Chief Engineers before leaving station.

B.5.2.3.8 General: During an emergency it is essential that communication facilities between PHQ, NDT/IP Station/Rangapani Terminal Station and field be

continuously manned. If the In-Charge Engineer of a station has to leave his station during this period, the 2nd most senior station Engineer shall stand by in Control Room. Mobile radio equipped vehicles shall always be kept as stand in every Station, or in regular radio contact when making routine ROW/ROU patrols or visiting SV Stations. As a routine, the mobile radio should be tested daily. It is essential in emergency that communication channels are not flooded with irrelevant matters. PHQ will ensure that all stations are kept fully in the picture, and intra-station /inter station communication, unless of significance to the emergency or operations, should be minimized. Whenever there is an emergency in the field, Deputy Chief Engineer / Superintending Engineers at Maintenance bases will ensure that the following personnel accompany pipeline maintenance crews.

One Telecom Engineer. One Maintenance Engineer. One Electrical Engineer.

B.5.2.3.9 Responsibility: Chief Engineers/Deputy Chief Engineers of different sections are responsible for coordinating all aspects of departmental training concerning action to be taken in an emergency. During an emergency, departmental personnel are liable to be subordinated to the direct instruction of

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an executive of another department, who by the nature of the emergency must necessarily issue the orders and be responsible for the work in hand.

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SECTION B.6

FIRE FIGHTING INSTALLATION

B.6.1 FIRE WATER RING MAIN AT NUMALIGARH DISPATCH TERMINAL / RANGAPANI RECEIVING TERMINAL AND INTERMEDIATE PIGGING STATIONS

1. Fire water Ring main has been laid all around the perimeter of the installation with hydrants/monitors spaced at intervals not exceeding 30 m when measured aerially as per OISD STD 117(Amended on Nov,2007). All the Hydrant points are located at a min. distance of 15 m from the periphery of the equipment under protection. At Numaligarh Dispatch Terminal, size of the Ring main is 250mm with proper hooking up with the existing Fire water Ring main of the Numaligarh Refinery. At IP stations, size of the Ring main is 150mm with proper hooking up with the Fire water Ring main of the respective Pump Stations. At Rangapani Receiving Terminal, size of the Ring main is 200mm with proper hooking up with the existing Fire water Ring main of the Rangapani Terminal of NRL.

2. As per clause 4.3.6(ii) of OISD STD117, the fire water piping is laid above ground at a height of 30 cm above finished ground level. Wherever the ringmain is laid underground for eg. at Road crossings, it is provided with proper protection as mentioned in clause 4.3.6(iii). The mains are supported at regular intervals not exceeding 6 m as per clause 4.3.6(iv).

3. Connections for fixed water monitors on the network have been provided with independent isolation valves.

B.6.2 FIRE WATER CALCULATION FOR NDT & RT As per OISD-117 Clause No.4.3 Fire water System, Sub. Clause 4.3.2.1(iv) Design Flow rate: Fire water flow rate for supplementary streams is based on using 4 single hydrants outlets and one monitor simultaneously. Capacity of each hydrant outlet as 36m3/hr and of each monitor as 144m3/hr min is considered at a pressure of 7 Kg/cm2. The Calculation for Supplementary Hose Stream is as under: Water for single hydrant streams = 4×36 = 144 m3/hr Water for 1 Monitor stream = 144 m3/hr Total Water requirement for each Terminal (i.e. NDT/RT) = 288 m3/hr The Fire ring main for both NDT and RT are hooked up with the NRL’s fire fighting system. Moreover, the existing fire fighting infrastructure of Numaligarh Refinery limited in both the NSPL Terminals (DT/RT) are additional back up to the fire fighting facility. B.6.3 FIRE WATER RING DIAGRAMS Refer annexure

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SECTION – C

INSPECTION, MAINTENANCE AND

DOCUMENTATION

SECTION C.1 Pipeline

C.1.1 GROUND PATROL AND LEAK SURVEY INSPECTION A. FUNCTION AND OBJECTIVES: To observe surface condition on and adjacent to the

right-of-way/right-of-use, indications of leak, construction activity other than performed by the company, encroachments, and any other factor affecting the safety and operations of pipeline. The patrolman is to pay attention to all cased railway and road crossings, rail bridge crossings. All rail bridge crossings are listed in attached Schedule/NSPL C.1.1-1 and cased crossings in Schedule/NSPL C.1.1-2. Any discoloration of vegetation on the right-of-way is to be thoroughly investigated for the possibility of leak.

B. REPORTING: A detailed report of conditions observed is to be prepared by petrolman

on OIP/NSPL-1 and distributed to the base and H.Q. offices. This report shall also include a complete description of any leaks found. Additionally, in accordance with the attached Schedule/NSPL C.1.1-3, specific reports of the installations listed are required on the dates mentioned.

C. SCOPE AND FREQUENCY OF PATROL: This ground patrol (Physically motoring/

walking down the pipeline) is to be regularly scheduled from each Pump Station at monthly intervals, to the extent possible, and at 6 monthly intervals within each Pipeline Base to include 100% of all main line right-of-way/right-of-use within the area of each Base.

D. RESPONSIBILITY: The selection of qualified personal to perform this function and over all administration of the patrol schedule and follow-up is the responsibility of the Head of the Pipeline Maintenance Section at Headquarter. The sectional limits for physically carrying out the patrol and the inspections are as per attached Schedule/NSPL C.1.1-4.

E. SPECIALISED LAND PATROL OF CONGESTED AREAS: In certain congested areas

of abnormal construction activity, it may be necessary to establish a frequent patrol schedule for protection of company’s facilities. Due to the many variable conditions, the need for these specialized patrols become a matter of judgment, which is to be evaluated by all field supervisory personnel and recommendations in this regard should be forwarded to Head of Pipeline Maintenance Section at Pipeline Headquarter.

SCHEDULE/NSPL C.1.1-1

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RAIL BRIDGE CROSSING AND JURISDICTION

KM River Bridge Bridge Authority

Jurisdiction

NSPL 244.80

Curde Oil Trunk Line 424.8

Brahmaputra Brahmaputra (Rail cum Roag Bridge)

C.E.N.F.Rly Maligaon

Pipeline Maintenance Base PS-5

SCHEDULE/NSPL C.1.1-2 LIST OF CASED CROSSINGS

LIST OF NATIONAL HIGHWAY CROSSINGS

Sl. NO.

DETAILS OF CROSSING PROGRESSIVE

NSPL CHAINAGE (m)

PROGRESSIVE CHAINGE

(Crude Oil P/L) (m)

Jurisdiction – Pipeline

Maintenance Base

1 2 3 4 5 1 NH – 39 (Dimapur –

Numaligarh) 5705.89 5705.89 PS-3

2 NH-37 (Kaziranga – Sapjuri) 30141.83 30141.83 PS-3 3 NH 37 (Numaligarh-Nagaon) 227.7 PS-3 4 NH 37 (Numaligarh-Nagaon) 228.6 PS-3 5 NH 37 (Numaligarh-Nagaon) 235.3 PS-3 6 NH 37 (Numaligarh-Nagaon) 235.7 PS-3 7 NH 37 (Numaligarh-Nagaon) 237.3 PS-3 8 NH 37 (Numaligarh-Nagaon) 244.3 PS-3 9 NH 37 (Numaligarh-Nagaon) 250.8 PS-3

10 NH 37 (Numaligarh-Nagaon) 255.2 PS-3 11 NH 37 (Numaligarh-Nagaon) 260.4 PS-3 12 NH 37 (Numaligarh-Nagaon) 227.7 PS-3 13 NH 37 (Numaligarh-Nagaon) 228.6 PS-3 14 NH 37 (Numaligarh-Nagaon) 272.5 PS-3 15 NH 37 (Numaligarh-Nagaon) 278.5 PS-3 16 NH 40 Nagaon-Hojai 304.7 PS-3 17 East-West Corridor Nagaon

bypass

18 East-West Corridor Nagaon bypass

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19 NH-37 (Raha – Nowgaon) 141975.18 321777.87 PS-3 20 NH-37 (Raha – Jagi Road) 153355.32 333158.01 PS-3 21 NH-37 (Jagi Road - Raha) 160943.64 340746.33 PS-3 22 NH 37/ East-West Corridor 416 PS-5 23 NH 37/ East-West Corridor 421.8 PS-5 24 NH 37 in University

Area/GHY-Goalpara RD. 422.9 PS-5

25 NH 37/ East-West Corridor (approach to Brahmaputra Bridge)

424.1 PS-5

26 NH 37/ East-West Corridor (near Pathsala)

496 PS-5

LIST OF NATIONAL HIGHWAY CROSSINGS

CR. NO.

DETAILS OF CROSSING PROGRESSIVE CHAINAGE IN

(m)

PROGRESSIVE CHAINGE (OIL) IN (m)


Maintenance Base

1 2 3 4 5

SV5 Barpeta Road – Rangapani Receipt Terminal

27 NH – 31 C (Chaprakata – Barabisa) 372632.10 552434.79 PS-5 28 NH – 31 C (Alipur – Barabisa) 471514.19 651316.88 PS-5 29 NH – 31 C (Madarihat – Birpara) 537342.12 717144.81 PS-8 30 NH – 31 C (Dalgaon – Birpara) 538801.91 718604.60 PS-8 31 NH – 31 C (Gayerkata – Birpara) 540501.29 720303.98 PS-8 32 NH – 31 C (Charon – Nagarkata) 572907.80 752710.49 PS-8 33 NH – 31 C (Sukhani – Nagrakata RS) 573502.97 753305.66 PS-8 34 NH – 31 C (Nagrakata – Chalsa) 586152.26 765954.95 PS-8 35 NH – 31 C (Mal Bazaar – Chalsa) 588630.50 768433.19 PS-8 36 NH – 31 C (Mal – Damdim) 595132.06 774934.75 PS-8 37 NH – 31 C (Odlabari – Mal Bazar) 597226.03 777028.72 PS-8 38 NH – 31 C (Mal Bazar – Odlabari) 602569.18 782371.87 PS-8 39 NH – 31 C (Sivok – Mal) 612282.17 792084.86 PS-8 40 NH – 31 C (Odlabari – Mangpong) 617099.44 796902.13 PS-8 41 NH – 31 (Siliguri – Odlabari) 623064.70 802867.39 PS-8 42 NH – 31 (Sivok – Sliguri) 626755.63 806558.32 PS-8 43 NH – 31 (NJP – Medical More) 648586.45 828389.14 PS-8

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LIST OF STATE HIGHWAY CROSSINGS

CR NO.

DETAILS OF CROSSING PROGRESSIVE

NSPL CHAINAGE (m)

PROGRESSIVE CHAINGE

(Crude Oil P/L) (m)


Maintenance Base

1 2 3 4 5

1 SH (Jagi Road) (NH-37 – Chenmari)

181100.32 360903.01 PS-5

2 Guwahati-Amingaon Road 426.4 PS-5

3 Guwahati-Hajo-Nalbari Road

426.7

PS-5

4 Guwahati-Hajo-Nalbari Road – Ganesh Mandir

429.6

PS-5

5 Guwahati-Hajo-Nalbari Road - Dolibari

431.2

PS-5

6 Guwahati-Hajo-Nalbari Road – Near BSNL Tower

432.4

PS-5

7 Guwahati-Hajo-Nalbari Road – Before Sessa river

437.5

PS-5

8 Guwahati-Hajo-Nalbari Road – After Sessa

438.8

PS-5


447.2

PS-5


451.4

PS-5


457.5

PS-5

LIST OF STATE HIGHWAY CROSSINGS

CR. NO.


(m)



Maintenance Base

1 2 3 4 5

SV5 Barpeta Road – Rangapani Receipt Terminal

12 SH – 31C (Dakshinparakata – Kamakhyaguri)

466602.33 646405.02 PS-8

13 SH (NH-31C – Satali Tea Garden) 515555.63 695358.32 PS-8

14 State Highway (NH-31C-Ranichera Tea Estate)

601196.64 780999.33 PS-8

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LIST OF RAILWAY CROSSINGS

CR NO. DETAILS OF CROSSING PROGRESSIVE

NSPL CHAINAGE (m)

PROGRESSIVE CHAINGE

(Crude Oil P/L) (m)


Maintenance Base

1 2 3 4 5

1

B.G. Non Electrified North East Frontier Railway Line Nagaon-Silghat Line near Jakhalabandha

265.1 PS-3

2

B.G. Non Electrified North East Frontier Railway Line Nagaon-Silghat Line near Puranigudam

296.9 PS-3

3

B.G. Non Electrified North East Frontier Railway Line (Chapramukh Silghat – Nagaon)

141925.71 321728.40 PS-3

4

B.G. Non Electrified North East Frontier Railway Line (Chapramukh Silghat – Jagi Road)

155113.67 334916.36 PS-3

5 B.G. Non Electrified North East Frontier Railway Line (Guwahati – Dharamtul R.S.))

171126.01 350928.70 PS-3

6 B.G. Non Electrified North East Frontier Railway Line (Guwahati – Dharamtul R.S.)

171133.21 350935.90 PS-3

7 B.G. Non Electrified North East Frontier Railway Line (Jagi Road R.S – Digaru R.S.)

204618.31 384421.00 PS-5

8 B.G. Non Electrified North East Frontier Railway Line (Airforce Area – Digaru R.S.)

204625.70 384428.39 PS-5

9

B.G. Non Electrified North East Frontier Railway Line (Air Force Campus – Digaru R.S.)

204644.02 384446.71 PS-5

10 B.G. Non Electrified North East Frontier Railway Line (Narangi station—Army

401.6 PS-5

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LIST OF RAILWAY CROSSINGS

CR. NO.


(m)



Maintenance Base

1 2 3 4 5

SV5 Barpeta Road– Rangapani Receipt Terminal

12 B.G.Non Electrified North East Frontier Railway Line (Sorbhong R.S. – Barpeta)

338885.90 518688.59 PS-5

13 M.G.Non Electrified North East Frontier Railway Line (Sorbhong R.S. – Barpeta)

338921.64 518724.33 PS-5

14 M.G.Non Electrified North East Frontier Railway Line (Sorbhong R.S. – Bijni R.S.)

346267.17 526069.86 PS-5

15 B.G.Non Electrified North East Frontier Railway Line (Sorbhong R.S. – BBijni R.S.)

346283.54 526086.23 PS-5

16 B.G.Non Electrified North East Frontier Railway Line (Bobgaigaon – Chaprakata R.S.)

371240.14 551042.83 PS-5

17 M.G.Non Electrified North East Frontier Railway Line (Bobgaigaon – Chaprakata R.S.)

371252.01 551054.70 PS-5

18 M.G.Non Electrified North East Frontier Railway Line (Dabgtal – BRPL Plant)

381375.13 561177.82 PS-5

19 B.G.Non Electrified North East Frontier Railway Line (Dabgtal – BRPL Plant)

381380.17 561182.86 PS-5

20 B.G.Non Electrified North East Frontier Railway Line (Bongaogaon - Basugaon)

385556.28 565358.97 PS-5

21 B.G.Non Electrified North East Frontier Railway Line (Bongaigaon - Basugaon)

385623.12 565425.81 PS-5

Cantonment, Satgaon)

11

B.G. Non Electrified North East Frontier Railway Line (Guwahati—NJP mainline near Pathsala)

498.4 PS-5

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22 B.G.Non Electrified North East Frontier Railway Line (BTPS – BTPS R.S.)

398258.46 578061.15 PS-5

CR. NO.


(m)



Maintenance Base

1 2 3 4 5

23 B.G. Non Electrified North East Frontier Railway Line (Fakiragram – Basugaon)

410791.80 590594.49 PS-5

24 B.G. Non Electrified North East Frontier Railway Line (Fakiragram – Basugaon)

410814.99 590617.68 PS-5

25 B.G. Non Electrified North East Frontier Railway Line (Fakiragram – Chautara R.S.)

424742.31 604545.00 PS-5

26 B.G. Non Electrified North East Frontier Railway Line (Fakiragram – Chautara R.S.)

424827.70 604630.39 PS-5

27 B.G. Non Electrified North East Frontier Railway Line (Alipur - Fakiragram)

470683.20 650485.89 PS-5

28 B.G. Non Electrified North East Frontier Railway Line (Alipur - Fakiragram)

470760.49 650563.18 PS-5

29 B.G. Non Electrified North East Frontier Railway Line (Alipur Duar – Rajabhat Khawa)

492351.39 672154.08 PS-5

30 B.G. Non Electrified North East Frontier Railway Line (Madarihat – Kalchini R.S.)

521990.12 701792.81 PS-5

31 B.G. Non Electrified North East Frontier Railway Line (Madarihat R.S. - Birpara)

534990.13 714792.82 PS-8

32 B.G. Non Electrified North East Frontier Railway Line (Binnaguri R.S. - Siliguri)

549893.14 729695.83 PS-8

33 B.G. Non Electrified North East Frontier Railway Line (Banarhat R.S. – Chengmari R.S.)

564054.47 743857.16 PS-8

34

B.G. Non Electrified North East Frontier Railway Line (Cemetery Nagrakata – Charan Railway Station)

569053.27 748855.96 PS-8

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CR. NO.


(m)



Maintenance Base

1 2 3 4 5

35


569057.27 748859.96 PS-8

36


569062.35 748865.04 PS-8

37

B.G. Non Electrified Bengal Daurs Railway Line Eastern Extension (Chara R.S. – Cemetery Nagrakata R.S.)

571616.69 751419.38 PS-8

38 B.G. Non Electrified North East Frontier Railway Line (Punba Hal Hal Pathar – Mal Bazar)

596213.63 776016.32 PS-8

39 B.G. Non Electrified North East Frontier Railway Line (Damdim R.S. – New Mal)

597097.82 776900.51 PS-8

40 B.G. Non Electrified North East Frontier Railway Line (Mal Bazar – Odlabari R.S.)

604403.36 784206.05 PS-8

41 B.G. Non Electrified North East Frontier Railway Line (Piltons hat R.S. – Bagrakot R.S.)

614244.19 794046.88 PS-8

42 B.G. Non Electrified North East Frontier Railway Line (Piltons hat R.S. – Sivok)

622038.89 801841.58 PS-8

43 B.G. Railway Line (Siliguri R.S. – New Jalpaiguri R.S.)

644740.16 824542.85 PS-8

44 B.G. Non Electrified North East Frontier Railway Line (Siliguri R.S. – New Jalpaiguri R.S.)

644744.40 824547.09 PS-8

45

B.G. Non Electrified North East Frontier Railway Line (New Jalpaiguri R.S. – Rangapani R.S.)

649584.67 829487.36 PS-8

46

B.G. Non Electrified North East Frontier Railway Line (New Jalpaiguri R.S. – Rangapani R.S.)

649692.12 829494.81 PS-8

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LIST OF ASPHALTED / OTHER ROAD CROSSINGS

CR NO.


(m)

PROGRESSIVE CHAINGE

(OIL) IN (m)


Maintenance Base

1 2 3 4 5

1 Asphalted Road (NH-39 – Ponkagaon)

2717.81 - PS-3

2 Asphalted Road (NH-39 – NRL Township)

4298.99 - PS-3

3 Asphalted Road (NH-39 – NRL Township)

4740.50 - PS-3

4 Metalled Road (Ranga Saligaon – NH-39)

7635.62 - PS-3

5 Metalled Road (Ghagara – Lakhaujan)

15723.33 195526.02 PS-3

6 Asphalted Road (Naharjan – NH-37)

19761.07 199563.76 PS-3

7 Asphalted Road (Diphlugaon – NH-37)

22237.94 202040.63 PS-3

8 Asphalted Road (Diphlugaon – NH-37)

25111.25 204913.94 PS-3

9 Metalled Road (Dalamara – Tin Sukiabasti)

26703.41 206506.10 PS-3

10 Asphalted Road (Dalamara – NH-37)

26807.62 206610.31 PS-3

11 Mud Road (NH-37 – Bebjiya Jan)

33206.67 213009.36 PS-3

12 Road From NH 37 to Nonoi 284.8 PS-3

13 Road From NH 37 to Samaguri

286.3

PS-3

14 Village Road to NH 37 Near Puranigudam St

294.2

PS-3

15 Road From NH 37 to Nonoi 300.7 PS-3

16 Metalled Road (Jagialgon – NH-37)

136703.56 316506.25 PS-3

17 Metalled Road (Sugar Factory – NH-37)

138588.21 318390.90 PS-3

18 Asphalted Road (Mohgar – NH-37)

139096.63 318899.32 PS-3

19 Mud Road (NH-37 – Katahguri)

142675.42 322478.11 PS-3

20 Asphalted Road 146416.58 326219.27 PS-3

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NH-37 – Baropujla)

21 Metalled Road (Kamgaon – NH-37)

153703.63 333506.32 PS-3

22 Metalled Road (Chaubarigaon – NH-37)

155985.66 335788.35 PS-3

23 Asphalted Road (Pachutiagaon – NH-37)

158953.48 338756.17 PS-3

24 Metalled Road (NH-37 – Field)

161143.26 340945.95 PS-3

25 Asphlted Road (Bangaldhara –SholMarigaon)

162001.13 341803.82 PS-3

26 Metalled Road (NH-37 – Dharamtul R.S.)

162858.98 342661.67 PS-3

27 Mud Road (Kotagaon – Barbarigaon)

166278.79 346081.48 PS-3

28 Metalled Road (Montabari – Chunwabari)

168635.42 348438.11 PS-3

29 Metalled Road (NH-37 – Bangphar)

177745.27 357547.96 PS-5

CR NO.


(m)

PROGRESSIVE CHAINGE

(OIL) IN (m)


Maintenance Base

1 2 3 4 5

30 Metalled Road (NH-37 – Bangphar)

177785.16 357587.85 PS-5

31 Metalled Road (NH-37 – Paliguri)

179700.94 359503.63 PS-5

32 Mud Road (Ingpur/Bistinupur – Kalkari)

187426.79 367229.48 PS-5

33 Mud Road (Koraiguri – Kalkari)

188010.68 367813.37 PS-5

34 Mud Road (NH-37 Molaibari) 192299.87 372102.56 PS-5

35 Asphalted Road (Khetri – Golap)

193759.57 373562.26 PS-5

36 Asphalted Road (Ratabari – Gandhi Ashram)

197658.99 377461.68 PS-5

37 Asphalted Road (Sometapathar – Sonapur Tea Garden)

201067.38 380870.07 PS-5

38 Asphalted Road (Dharbami – Bajrang Basti)

204057.38 383860.07 PS-5

39 Asphalted Road (Sonapur – Digaru R.S.)

204782.45 384585.14 PS-5

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40 Metalled Road (Digaru – Belguri)

205653.19 385455.88 PS-5

41 Metalled Road (Bamankhat – Jubai)

206999.01 386801.70 PS-5

42 Asphalted Road (Ghugua - Jubai)

207316.65 387119.34 PS-5

43 Asphalted Road (Digaru - Narangi)

210026.63 389829.32 PS-5

44 Asphalted Road (Narangi - Digaru)

210168.05 389970.74 PS-5

45 Asphalted Road (Batakuchi - Narangi)

213277.87 393080.56 PS-5

46 Metalled Road (Marcutchi – Sonapur)

215477.22 395279.91 PS-5

47 Asphalted Road (Jorabat - Sonapur)

215653.69 395456.38 PS-5

48 Asphalted Road (Sonapur – Army Staff Quarters)

215840.96 395643.65 PS-5

49 Matalled Road (Sonapur Main Road – Army Staff Quarters)

216093.68 395896.37 PS-5

50 Asphalted Road (Sonapur Main Road – Singh Jadumath Enclave)

216138.83 395941.52 PS-5

51 Asphalted Road (Sonapur Main Road – Karam Singh Enclave)

216422.18 396224.87 PS-5

52 Asphalted Road (Sonapur Main Road – Abdul Kalam Enclave)

216756.54 396559.23 PS-5

53 Asphalted Road (Sonapur Main Road – Bana Singh Enclave)

216915.06 396717.75 PS-5

54 Asphalted Road (Sonapur Main Road – Hoshiar Singh Enclave)

217340.13 397142.82 PS-5

55 Asphalted Road (Sonapur Main Road – Staff Quarters)

217399.02 397201.71 PS-5

56 Concrete Road (Sonapur Main Road – MES Service Center)

217488.84 397291.53 PS-5

57 Asphalted Road (Sonapur Main Road – Barrack Store Office & FurnitureYard)

217519.43 397322.12 PS-5

58 Asphalted Road (Sonapur Main Road – AGE B/R No.2 Service Station)

217544.00 397346.69 PS-5

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59 Asphalted Road (Sonapur Main Road – Army Staff Quarters)

217710.41 397513.10 PS-5

60 Asphalted Road (Central MI Center – Garrison Engineers Office)

217761.26 397563.95 PS-5

61 Asphalted Road (Sonapur Main Road – MES Club)

217829.78 397632.47 PS-5

62 Asphalted Road (Sonapur Main Road – Army Staff Quarters)

217936.47 397739.16 PS-5

63 Asphalted Road (Sonapur Main Road – Army Quarters)

218234.99 398037.68 PS-5

64 Asphalted Road (Elephant House – Ration Payment Office)

218273.50 398076.19 PS-5

65 Asphalted Road (Sonapur Main Road – Guard Quarters)

218341.56 398144.25 PS-5

66 Asphalted Road (Sonapur Main Road – Officers Mess)

218451.61 398254.30 PS-5

67 Asphalted Road (Ordinace Depot – Ex Military Quarters)

218554.75 398357.44 PS-5

68 Asphalted Road (Sonapur Main Road – School Staff Quarters)

218721.39 398524.08 PS-5

69 Asphalted Road (Sonapur Main Road – Kendriya Vidyalaya School)

218799.33 398602.02 PS-5

70 Asphalted Road (Asphalted Road Office)

218871.36 398674.05 PS-5

71 Asphalted Road (Sonapur Main Road – Local Area Office)

219028.89 398831.58 PS-5

72 Asphalted Road (Sonapur Main Road – Signal Office)

219081.29 398883.98 PS-5


219110.81 398913.50 PS-5


219258.35 399061.04 PS-5

75 Asphalted Road (Staff Quarters – Staff Quarters)

219593.98 399396.67 PS-5

76 Asphalted Road (New Guwahati – Controller of Defence Accounts Office)

220276.10 400078.79 PS-5

77 Asphalted Road (Guwahati 221305.99 401108.68 PS-5

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Pumping Station No.5/IP2 – Oil India Office)

78 Asphalted Road (Kahelipeta – Oil India Office)

221497.35 401300.04 PS-5

79 Asphalted Road (Kahelipeta – Guwahati Pumping Station No.5/IP2)

221526.30 401328.99 PS-5

80 Road to Satgaon 401.9 PS-5

81 Express Highway to be Constructed

403.8

PS-5

82 Guwahati-Siliguri Road 406.5 PS-5 83 Basistha Road 407.2 PS-5

84 Kalapahar-Guwahati Road/NH 37

411.8

PS-5

85 Road From Maligaon to NH 37/Gravelled Road

415.8

PS-5

86 NH 37 – Engineering College Road

420.2 PS-5

87 Guwahati-Hajo-Nalbari Road-Brick Field

428.2 PS-5

88 Nalbari-Barpeta Road in Front of RS.8

468.4

PS-5

89 Chamata-Kaithalkuchi Road 473.8 PS-5 90 Sarupeta-Rupahi Road 501.2 PS-5 91

LIST OF ASPHALTED / OTHER ROAD CROSSINGS

CR. NO.


(m)



Maintenance Base

1 2 3 4 5

SV5 Barpeta Road– Rangapani Receipt Terminal

92 Asphalted Road (NH-31C/(Simalaguri) – Barpeta Road)

332971.88 512774.57 PS-5

93 Metalled Road(NH-31C/(Simalaguri) – Barpeta Road)

333610.64 513413.33 PS-5

94 Metalled Road (NH-31 – Kolahbhanga)

333863.53 513666.22 PS-5

95 Metalled Road(NH-31C/(Chandidad) - Satbeinirtub)

334922.03 514724.72 PS-5

96 Metalled Road(NH-31 - CBarpeta) 336183.00 515985.69 PS-5

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97 Metalled Road(Sorbhong - Sahapur) 340598.94 520401.63 PS-5

98 Asphalted Road (Sorbhong – Sukharnjani)

341109.11 520911.80 PS-5

99 Asphalted Road (Sorbhong – Puttimari)

341787.12 521589.81 PS-5

100 Asphalted Road (NH-31 - Balukadoba)

345877.48 525680.17 PS-5

101 Asphalted Road (NH-31/(Lumgjhar – Patiladaha)

350562.07 530364.76 PS-5

102 Asphalted Road (NH-31 – Bijni R.S.)

360538.76 540341.45 PS-5

103 Asphalted Road (NH-31 – Bijni Bazar)

361176.87 540979.56 PS-5

104 Asphalted Road (NH-31 – Bijni Bazar)

361256.05 541058.74 PS-5

105 Metalled Road (NH-31 – Bijni Bazar)

361454.52 541257.21 PS-5

106 Metalled Road (Majhrabari – Bijni Bazar)

362064.63 541867.32 PS-5

107 Metalled Road (Kauwatika – Railway Track)

362598.57 542401.26 PS-5

108 Metalled Road (NH-31C – Chaprakata)

370508.14 550310.83 PS-5

109 Metalled Road (Bongaigaon NH31C/(Dologaon))

375104.29 554906.98 PS-5

CR. NO.


(m)



Maintenance Base

1 2 3 4 5 110 Mud Road (Salbari – NH-31C) 376412.94 556215.63 PS-5

111 Asphalted Road (Bongaigaon Town – NH31C)

377070.76 556873.45 PS-5

112 Asphalted Road (Bongaigaon – CISF Office)

377352.69 557155.38 PS-5

113 Asphalted Road (Bongaigaon – As[halted Road)

377674.32 557477.01 PS-5

114 Asphalted Road (Bongaigaon – NH-31C)

377949.42 557752.11 PS-5

115 Asphalted Road (Bongaigaon – Dolaigaon)

379383.32 559186.01 PS-5

116 Metalled Road (Changapota – Dolaigaon)

380347.67 560150.36 PS-5

117 Metalled Road (Dangtal – Manglagaon)

382412.49 562215.18 PS-5

OIL INDIA LIMITED


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118 Metalled Road (Dangtal – Tilapath)

385525.86 565328.55 PS-5

119 Unmetalled Road (Kalkragaon – Bangaldobe)

386875.01 566677.70 PS-5

120 Metalled Road (Kakragaon - Bangaldobe)

387312.61 567115.30 PS-5

121 Metalled Road (Kakragaon - Basugaon)

389142.20 568944.89 PS-5

122 Asphalted Road (Goglapur – Basugaon)

391264.03 571066.72 PS-5

123 Metalled Road (Bhadeyaguri - Basugaon)

391520.42 571323.11 PS-5

124 Asphalted Road (Bandarchara– Basugaon)

393018.62 572821.31 PS-5

125 Asphalted Road (Basugaon – Bandarchara)

393477.80 573280.49 PS-5

126 Asphalted Road (Bandarchara– Basugaon)

393857.92 573660.61 PS-5

127 Asphalted Road (Chhota Kurshakati – Bara Kurshakati)

396187.04 575989.73 PS-5

CR. NO.


(m)



Maintenance Base

1 2 3 4 5

128 Asphalted Road (Phukagaon – BTPS Colony)

396428.44 576231.13 PS-5

129 Asphalted Road (Phukagaon – Benibari)

396704.90 576507.59 PS-5

130 Asphalted Road (Phukagaon – Benibari)

396871.83 576674.52 PS-5

131 Asphalted Road (BTPS Gate – BTPS Coal Handling Area) 397770.80 577573.49 PS-5

132 Asphalted Road (BTPS Gate - Chhalakatti)

398465.39 578268.08 PS-5

133 Asphalted Road (Basugaon – BTPS Guest House)

398592.43 578395.12 PS-5

134 Asphalted Road (Kokrajhar – BTPS Hospital)

399872.11 579674.80 PS-5

135 Asphalted Road (BTPS Quarters – BTPS Quarters)

399908.22 579710.91 PS-5

136 Asphalted Road (BTPS Colony – BTPS Colony)

400005.97 579808.66 PS-5


OIL INDIA LIMITED


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(BTPS Staff Quarters – BTPS Staf14f Quarters)

138 Asphalted Road (Chhota Adabari - Kokrajhar)

407241.58 587044.27 PS-5

139 Metalled Road (Chota Gendra Bil - Kokrajhar)

407613.00 587415.69 PS-5

140 Asphalted Road (Narobari - Kokrajhar)

409124.24 588926.93 PS-5

141 Metalled Road (Chamaguri - Magurmari)

414030.20 593832.89 PS-5

142 Metalled Road (Chamaguri – Fakiragram Shakti Ashram Main Road)

415300.62 595103.31 PS-5

143 Metalled Road (Chamaguri – Fakiragram Shakti Ashram Main Road)

415568.88 595371.57 PS-5

144 Metalled Road (Morendubi – Fakiragram Shakti Ashram Main Road)

415793.27 595595.96 PS-5

145 Metalled Road (Magurmari – Shakti Ashram

418741.43 598544.12 PS-5

CR. NO.


(m)



Maintenance Base

1 2 3 4 5

146 Asphalted Road (Fakiragram Shakti Ashram)

418769.31 598572.00 PS-5

147 Mud Road (Bhubannagar – Shalbari)

423365.08 603167.77 PS-5

148 Asphalted Road (Tulsibil - Mahendrapur)

428891.34 608694.03 PS-5

149 Mud Road (Ahmadpur – Patialpara) 432137.50 611940.19 PS-5

150 Metalled Road (Barkhambilgaon – Rajapara)

438656.71 618459.40 PS-5

151 Metalled Road (Padmapukhuri – Gossaigaon)

439304.46 619107.15 PS-5

152 Asphalted Road (Satyapur – Gossaigaon)

440589.31 620392.00 PS-5

153 Metalled Road (Damriguri - Srirapur)

446985.21 626787.90 PS-5

154 Asphalted Road (Jacobpur - Srirampur)

447787.39 627590.08 PS-5

155 Metalled Road (Majer Dabri – NH31C )

453081.86 632884.55 PS-5

OIL INDIA LIMITED


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156 Mud Road (Chhat Bhalka – Barabisa) 456473.61 636276.30 PS-5

157 Asphalted Road (Dakshin Rampura – Jorai)

457482.68 637285.37 PS-5

158 Asphalted Road (Rampura - Barabisa)

457823.62 637626.31 PS-5

159 Mud Road (Dakshin Rampura – Barabisa)

458158.79 637961.48 PS-5

160 Metalled Road (Nauthua – Jorai) 460207.71 640010.40 PS-5 161 Mud Road (Khagribari – NH31C) 463803.61 643606.30 PS-5

162 Metalled Road (Dakshin Narathali – Kamakhyaguri)

464986.15 644788.84 PS-5

163 Asphalted Road (Dakshin Narathali – Kamahkyaguri)

465315.64 645118.33 PS-5

164 Asphalted Road (Dakshin Kamakhyaguri – Kamakhyaguri)

466954.81 646757.50 PS-5

165 Asphalted Road (Uttar Parakata – Kamakhyaguri)

468068.13 647870.82 PS-5

166 Metalled Road (Purba Chikliguri – NH31C)

471146.88 650949.57 PS-5

CR. NO.


(m)



Maintenance Base

1 2 3 4 5 167 Metalled Road (NH31C – Chepani) 472715.66 652518.35 PS-5

168 Asphalted Road (Koyakhata – Mahakalguri)

476244.61 656047.30 PS-5

169 Metalled Road (NH-31C – Sibkata) 480953.17 660755.86 PS-5

170 Metalled Road (Dhalkor – Forest Office)

482538.43 662341.12 PS-5

171 Asphalted Road (NH-31C – Forest Office)

484553.10 664355.79 PS-5

172 Asphalted Road (NH-31C – Rajabhat Khawa)

492059.51 671862.20 PS-5

173 Mud Road (Dima Nadi – Rajabhat Khawa)

494581.52 674384.21 PS-5

174 Metalled Road (Nimati – Atiabari) 502112.84 681915.53 PS-5

175 Asohalted Road (Damohani – Hamiltonganj)

504467.80 684270.49 PS-5

176 Asphalted Road (Nimati - Gurdwara) 505906.04 685708.73 PS-5 177 Asphalted Road (Nimati - Gurdwara)

178 Asphalted Road (Mandalpara - Patabari)

511746.88 691549.57 PS-5

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179 Asphalted Road (Airforce Quarters – Madhu Tea Garden)

512877.70 692680.39 PS-5

180 Asphalted Road (NH-31C – Hasimara Railway Station)

516025.39 695828.08 PS-5

181 Asphalted Road (Madharihat - Mujnal)

523568.12 703370.81 PS-5

182 Asphalted Road (IOCL Plant – Mujnal Asphalted Road)

524307.89 704110.58 PS-5

183 Metalled Road (Madhya Chhekamari – Mujnal)

527311.01 707113.70 PS-5

184 Asphalted Road (NH-31C - Mujnal) 530337.99 710140.68 PS-5

185 Asphalted Road (Shishubari Hat – Dumchi Chhapauri)

533492.52 713295.21 PS-5

186 Asphalted Road (Shishubari Hat - Gopalpur)

534216.93 714019.62 PS-5

187 Mud Road (NH-31C – Hampur) 536337.83 716140.52 PS-5

188 Asphalted Road (Birpara Tea Garden – NH-31C)

537882.72 717685.41 PS-5

189 Asphalted Road (Dalgaon - SH) 539456.07 719258.76 PS-5 190 Asphalted Road (Dim Dima - SH) 540084.49 719887.18 PS-5

CR. NO.


(m)



Maintenance Base

1 2 3 4 5

191 Asphalted Road (Tea Garden – Mud Road)

542204.23 722006.92 PS-8

192 Mud Road (NH-31C – Nangdala Tea Garden)

542965.55 722768.24 PS-8

193 Asphalted Road (NH-31C - Binnaguri)

547756.86 727559.55 PS-8

194 Asphalted Road (Binnaguri R.S. - Binnaguri)

548510.56 728313.25 PS-8

195 Asphalted Road (Binnaguri R.S. – Asphalted Road)

548733.92 728536.61 PS-8


548908.32 728711.01 PS-8


548984.72 728787.41 PS-8

198 Asphalted Road (Binnaguri R.S. – Binnaguri Tea Garden)

550869.41 730672.10 PS-8

199 Asphalted Road (NH-31C - Banarhat) 553877.18 733679.87 PS-8 200 Asphalted Road (NH-31C - Banarhat) 556772.96 736575.65 PS-8 201 Metalled Road (Banarhat Asphalted 557606.70 737409.39 PS-8

OIL INDIA LIMITED


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Road – Lakhipara Garder)

202 Asphalted Road (Gendrapara Tea Garden – Lakhipara Tea Garden)

559158.03 738960.72 PS-8

203 Asphalted Road (NH-31C – Debpara Tea Garden)

561334.73 741137.42 PS-8

204 Asphalted Road (NH-31C – Diana Tea Factory)

563511.47 743314.16 PS-8

205 Asphalted Road (NH-31C – Chengmari R.S.)

565979.83 745782.52 PS-8

206 Asphalted Road (NH-31C – Lakshan Hat)

568122.88 747925.57 PS-8

207 Asphalted Road (NH-31C – Lakshan Hat)

568428.18 748230.87 PS-8

208 Asphalted Road (NH-31C – Ghatia Tea Factory)

571563.60 751366.29 PS-8

209 Asphalted Road (NH-31C – Cemetary Nagrakata R.S.)

572235.26 752037.95 PS-8

210 Asphalted Road (Asphalted Road Sukhani)

574839.18 754641.87 PS-8

CR. NO.


(m)



Maintenance Base

1 2 3 4 5

211 Asphalted Road (Sukhani - NH-31C)

574878.49 754681.18 PS-8

212 Asphalted Road (Sukhani – Nagrakata R.S.)

575030.61 754833.30 PS-8

213 Asphalted Road (Sukhani - Nagrakata)

575083.73 754886.42 PS-8

214 Asphalted Road (Sukhani - Nagrakata)

575364.87 755167.56 PS-8

215 Asphalted Road (NH-31C - Chapramari)

580398.36 760201.05 PS-8

216 Asphalted Road (Mangalbari Hat - NH-31C)

586719.47 766522.16 PS-8

217 Asphalted Road (Satkaya Tea Garden - NH-31C)

587384.22 767186.91 PS-8

218 Asphalted Road (Satkaya - NH-31C)

588229.34 768032.03 PS-8

219 Asphalted Road (NH-31C – Nakhati Tea Garden)

591242.62 771045.89 PS-8

220 Asphalted Road (NH-31C – Soongachi Tea Garden)

591713.20 771516.01 PS-8

221 Metalled Road (NH-31C – Tunbari) 592952.20 772754.89 PS-8

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222 Asphalted Road (NH-31C – Gurjang Jhora Tea Estate)

593159.57 772962.26 PS-8

223 Metalled Road (New glenco Tea Factory – NH-31C)

596903.76 776706.45 PS-8

224 Asphalted Road Disused (NH-31C – Mal Bazaar)

597209.21 777011.90 PS-8

225 Asphalted Road (NH-31C – Army camp)

599422.25 779224.94 PS-8

226 Asphalted Road (NH-31C – Rangamati)

599623.96 779426.65 PS-8

227 Asphalted Road (NH-31C – Army Campus)

600501.81 780304.50 PS-8

228 Asphalted Road (NH-31C – Army Campus)

600606.45 780409.14 PS-8

229 Asphalted Road (Stone Crusher - NH-31C)

605205.42 785008.11 PS-8

230 Asphalted Road (Karadhura -NH-31C)

606406.08 786208.77 PS-8

231 Asphalted Road (Chel Khali - NH-31C)

606920.02 786722.71 PS-8

CR. NO.


(m)



Maintenance Base

1 2 3 4 5 232 Asphalted Road (Bansbari - NH-31C) 610149.66 789952.35 PS-8 233 Asphalted Road (Bansbari - NH-31C) 610378.22 790180.91 PS-8 234 Asphalted Road (Phulbari - Bagrakot) 611352.23 791154.92 PS-8

235 Asphalted Road (Kalagati Tea Garden - Washabari)

614452.72 794255.41 PS-8

236 Asphalted Road (NH-31C – Washabari Tea Garden)

615652.32 795455.01 PS-8

237 Asphalted Road (Army Area - NH-31C)

619925.44 799728.13 PS-8

238 Asphalted Road (NH-31 – Suknatista Forest)

626381.44 806184.13 PS-8

239 Asphalted Road (Military Quarters - NH-31)

633302.22 813104.91 PS-8


633475.03 813277.72 PS-8


633707.67 813510.36 PS-8

242 Asphalted Road (Asphaltd - NH-31) 634613.21 814415.90 PS-8

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243 Asphalted Road (Asphaltd - NH-31) 634932.62 814735.31 PS-8 244 Asphalted Road (Asphaltd - NH-31) 635116.21 814918.90 PS-8 245 Asphalted Road (Salugara - NH-31) 636327.24 816129.93 PS-8

246 Asphalted Road (Siliguri Town - Chayanpur)

637923.43 817726.12 PS-8

247 Asphalted Road (Jalpaiguri Bypass Road NH-31)

638799.38 818602.07 PS-8

248 Mud Road (Ektiasal – Siliguri) 640102.38 819905.07 PS-8

249 Asphalted Road (Army Area – Siliguri)

640588.36 820391.05 PS-8

250 Asphalted Road (Eastern Bypass Road – Siliguri)

642290.21 822092.90 PS-8

251 Asphalted Road (Jalpaiguri – Siliguri) 642382.43 822185.12 PS-8


642719.67 822522.36 PS-8


642842.81 822645.50 PS-8


643106.70 822909.39 PS-8

255 Asphalted Road Eastern Bypass Road – Siliguri)

643467.44 823270.13 PS-8

CR. NO.


(m)



Maintenance Base

1 2 3 4 5

256 Asphalted Road (Shanthi Nagar - Eastern Bypass)

644473.40 824276.09 PS-8

257 Asphalted Road (South Shanthi Nagar - Siliguri)

644752.53 824555.22 PS-8

258 Asphalted Road (Bhakti Nagar - Siliguri)

645313.63 825116.32 PS-8

259 Asphalted Road (Bhakti Nagar - Siliguri)

645579.95 825382.64 PS-8

260 Asphalted Road (New Jalpaiguri R.S. - Siliguri)

645957.63 825760.32 PS-8


646164.06 825966.75 PS-8


646256.30 826058.99 PS-8


646423.81 826226.50 PS-8


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(Gate Bazaar – Siliguri Town)

265 Asphalted Road (Gate Bazaar – Teenbathi More)

647091.83 826894.52 PS-8

266 Asphalted Road (Gate Bazaar – Medical More)

647539.35 827342.04 PS-8

267 Asphalted Road (NJP – Medical More)

648607.87 828410.56 PS-8

268 Asphalted Road (New Jalpaiguri – Medical More)

648644.13 828446.82 PS-8

269 Asphalted Road (New Jalpaiguri – Gautham Colony)

648842.02 828644.71 PS-8

270 Asphalted Road (NH-31C – Gautham Colony)

648925.60 828728.29 PS-8

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SCHEDULE/NSPL C.1.1-3 OIL INDIA LIMITED

GROUND PATROL INSPECTIONS AND REPORTS:

SL. No.

Description Frequency Inspection & reporting month

Section responsibility

1 100% GROUND PATROL, MOTORING/ WALKING THE ENTIRE RIGHT OF WAY /RIGHT OF USE FOR ALL ASPECTS OF INSPECTION INCLUDING ALL CASED RAIL & ROAD CROSSINGS, ENCROACHMENTS, WAS HOUTS ETC.

HALF– YEARLY

MAY NOVEMBER

BASE PIPELINE IN-CHARGE

2 AS ABOVE BUT TO THE EXTENT MOTORABLE

MONTHLY EACH MONTH PUMP STATION IN-CHARGE

3 RAILWAY BRIDGES

QUARTERLY FEBRUARY MAY AUGUST NOVEMBER

BASE PIPELINE IN-CHARGE

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SCHEDULE/NSPL C.1.1-4 OIL INDIA LIMITED

PUMP STATION/BASE PATROL LIMITS:

From Km. To Km. Responsibility

0.0

34.5

171.0

317.0

452.0

603.0

0

170.74

524.80

34.5

171.0

317.0

452.0

603.0

654.3

170.74

524.80

660.325

Station In Charge NT

Station In Charge P.S. – 4




Station In Charge RT

Engineer In Charge P.S.-3 Base

(Pipeline Maintenance)


(PipelineMaintenance)


(Pipeline Maintenance)

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OIP /NSPL– 1

OIL INDIA LIMITED PIPELINE PATROL REPORT

Base______________________Subject___________________Date_________________ From Km. P.

To Km. P.

Observations Remarks

Signed ______________________________ Designation__________________________ Distribution (Check original and each copy):

o Original - Base o Duplicate - Head Quarter o Triplicate - Administration

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C.1.2 INSPECTION OF SUBMERGED RIVER CROSSINGS: A. FUNCTION AND OBJECTIVE: To detect any condition such as scouring, erosion, and

river bank protection damage, which exists, or would possibly develop into conditions which would impair the operation of the pipeline crossing. The appropriate preventive or corrective maintenance work will be based on these inspection reports.

B. REPORTING: A detailed report of conditions observed is to be prepared by the Base

Pipeline Engineers on Form OIP/NSPL -1 and distributed to Base and H.Q. offices.

C. SCOPE AND FREQUENCY OF INSPECTION: All submerged river crossings are to be inspected at six monthly intervals, i.e. during high flood and low water conditions. Such inspection reports are to be submitted in July and January of each year.

D. RESPONSIBILITY: The administration and follow up of the inspection schedule is the

responsibility of Head of the Pipeline Engineers in accordance with Schedule/NSPL A2-1 attached.

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SCHEDULE/NSPL C.1.2-1

LIST OF SUBMERGED RIVER, RIVULET,NULLAH AND EMBANKMENT CROSSINGS

A. LIST OF RIVERS

SL. NO.

NAME OF RIVERS

DETAILS OF CROSSING

WIDTH (m)

PROGRESSIVE CHAINAGE IN

(m)

PROGRESSIVE CHAINGE

(OIL) IN (m

JURISDICTION PIPELIME

MAINTENANCE BASE

1 KALIYANI OPEN CUT 3708.84 - PS-3 2 DIPHALU OPEN CUT 24307.58 204110.27 PS-3 3 KALANG OPEN CUT 150394.09 330196.78 PS-3 4 KOPILI HDD 171624.61 351427.30 PS-5 5 DIGARU HDD 231 203339.25 383141.94 PS-5

6 PUTHIMARI

HDD 332.55 266.3 PS-5

7 CHAULKHOWA

HDD PS-5

8 DUMARKIJAN

HDD 328.21 317.6 PS-5

9 PALLAH HDD 295.91 326.1 PS-5

10 BEKI MICRO

TUNNEL 401.0

338.3 517.70 PS-5

11 BHULKADOBA

HDD 294.7 346.8 526.10 PS-5

12 DULANI HDD 184.66 362.4 12 MANAS HDD 239.0 353.6 533.00 PS-5

13 AIE MICRO

TUNNEL 335.0

366.5 545.90 PS-5

14 CHAMPAMATI

573.30 PS-5

15 GAURANG HDD 335.0 410.5 _ _ _ _ _ PS-5 16 GANGIYA HDD 210.0 425.3 604.00 PS-5

17 GARUFELLA

MICRO TUNNEL

164 433.1

612.00 PS-5

18 HARUAPUTA

MICRO TUNNEL

173 448.2

627.80 PS-5

19 SANKOSH MICRO

TUNNEL 412

452.4 631.30 PS-5

20 RAIDAK-II OPENCUT 383.10 PS-5

21 RAIDAK-I MICRO

TUNNEL 129

470.6 PS-5

22 TORSA OPENCUT PS-5 23 DIANA OPENCUT PS-8

24 JALDHAKA

OPENCUT PS-8

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25 MURTI OPENCUT PS-8 26 NEORA OPENCUT PS-8 27 MAL OPENCUT PS-8 28 CHEL OPENCUT PS-8 29 LISH OPENCUT PS-8 30 GISH OPENCUT PS-8

31 TEESTA MICRO

TUNNEL 501

623.6 PS-8

B. LIST OF CANALS / RIVULETS / NULLAHS

SL. NO.

NAME OF RIVERS PROGRESSIVE CHAINAGE IN

(m)

PROGRESSIVE CHAINGE (OIL) IN (m

JURISDICTION

PIPELIME MAINTENANCE BASE

1 DULANI 541.9 PS-5 2 KUJIA RIVER 553.4 PS-5 3 KUJIA NULLAH 563.9 PS-5 4 KHANI BHAR 569.5 PS-5 5 DURAMARI NULLAH 570 PS-5 6 TARANG NEW 582.1 PS-5 7 TARANG OLD 582.5 PS-5 8 HEL 597.4 PS-5 9 LOSKA 600.7 PS-5

10 MAINAJAN DRY IRRIGATION CANAL 361 PS-5

11 40 Mtrs. WIDE NULLAH 383 PS-5

ADDITIONAL LIST OF SMALLER NULLAHS

SL. NO.

NAME OF NULLAH PROGRESSIVE CHAINAGE IN

(m)


JURISDICTION PIPELIME MAINTENANCE BASE

1 PICHHIAJAN NULLAH 2536.32 - PS-3

2 RANGSALI NULLAH 6288.76 - PS-3

3 RANGSALI NULLAH 6330.24 - PS-3

4 Nala 6663.19 - PS-3

3 NULLAH 14904.44 194707.13 PS-3

4 NULLAH 16302.62 196105.31 PS-3

5 DIMOUBIL NULLAH 136248.75 316051.44 PS-3

6 SINGIMARIBIL NULLAH 140719.21 320521.90 PS-3

7 UDMARIBIL NULLAH 175954.29 355756.98 PS-5

8 TARANGBIL NULLAH 177674.90 357477.59 PS-5

9 NULLAH 201470.11 381272.80 PS-5

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10 NULLAH 213358.50 393161.19 PS-5

11 NULLAH 214123.78 393926.47 PS-5

12 NULLAH 214364.03 394166.72 PS-5

13 NULLAH 216602.69 396405.38 PS-5

14 NULLAH 536.600 PS-5 15 NULLAH 555.800 PS-5 16 NULLAH 556.000 PS-5 17 NULLAH 562.700 PS-5 18 NULLAH 563.900 PS-5 19 NULLAH 564.200 PS-5 20 NULLAH 575.000 PS-5 21 NULLAH 580.200 PS-5 22 NULLAH 581.400 PS-5 23 NULLAH 582.000 PS-5 24 NULLAH 582.100 PS-5 25 NULLAH 583.000 PS-5 26 NULLAH 584.200 PS-5 27 NULLAH 584.800 PS-5 28 NULLAH 585.100 PS-5 29 NULLAH 585.300 PS-5 30 NULLAH 586.000 PS-5 31 NULLAH 586.800 PS-5 32 NULLAH 588.200 PS-5 33 NULLAH 589.300 PS-5 34 NULLAH 594.200 PS-5 35 NULLAH 594.300 PS-5 36 NULLAH 594.400 PS-5 37 NULLAH 594.900 PS-5 38 NULLAH 595.600 PS-5 39 NULLAH 601.100 PS-5 40 NULLAH 608.900 PS-5 41 SAGTAL NULLAH 614.000 PS-5 42 NULLAH 614.800 PS-5 43 MARIJOIMA NULLAH 615.200 PS-5 44 NULLAH 617.400 PS-5 45 NULLAH 624.300 PS-5 46 NULLAH 625.500 PS-5 47 NULLAH 626.400 PS-5 48 NULLAH 635.300 PS-5 49 NULLAH 636.400 PS-5 50 NULLAH 636.500 PS-5

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C. LIST OF EMBANKMENTS

SL. NO.

NAME OF RIVERS PROGRESSIVE CHAINAGE IN

(m)

PROGRESSIVE

CHAINGE (OIL) IN (m

JURISDICTION PIPELIME MAINTENANCE BASE

1 FLOOD EMBANKMENT 326 PS-5 2 FLOOD EMBANKMENT 517.3 PS-5

Annexure “G” LIST OF CANAL CROSSINGS

CR NO.


(m)


JURISDICTION PIPELIME

MAINTENANCE BASE

1 2 3 4 5

Section – II: Ghani Repeater Station – Guwahati Pumping Station

1 Unlined Canal 181373.87 361176.56

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C.1.3 AERIAL PATROL INSPECTION

A. FUNCTION AND OBJECTIVE – A helicopter patrol programme is

maintained to observe surface conditions on and adjacent to the pipeline right-of-way, indications of leaks, construction activity, other than that performed by the Company, encroachment, and any other factors affecting the safety and operation of the pipeline.

B. REPORTING – Any of the above conditions are to be reported on Form OIP/NSPL-1 and promptly distributed in accordance with the prescribed distribution on the bottom of this form.

C. RESPONSIBILITY – The administration and follow up of this inspection, and the effective use of helicopters is the responsibility of the Head of the Pipeline Maintenance Section at Pipeline Headquarter, Who will ensure that adequate flying time is allocated to bases to carry out aerial patrols.

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OIP /NSPL– 1

OIL INDIA LIMITED PIPELINE PATROL REPORT

Base______________________Subject___________________Date_________________ From Km. P.

To Km. P.

Observations Remarks

Signed ______________________________ Designation__________________________ Distribution (Check original and each copy):

o Original - Base o Duplicate - Head Quarter o Triplicate - Administration

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C.1.4 INSPECTION OF IDENTIFICATION FACILITES:

A. OBJECTIVE AND RESPONSIBILITY: The objective of installing, inspecting and maintaining the various identification signs, etc., is to make the general public aware of the existence and ownership of the Company’s facilities in order that these facilities may be respected and protected. The responsibility for the upkeep of these on the right-of-way/right-of use is that of the Base Pipeline in-Charges.

B. REPORTING: During the semi-annual Ground Patrol, these signs and markers will be

inspected and any needed repairs will be reported on the Pipeline Patrol Report (OIP/NSPL -1).

C. IDENTIFICATION OF RIGHT-OF-WAY/RIGHT-OF-USE: Kilometer Post Markers: These are installed every kilometer adjacent to the

pipeline and are permanently numbered. The sign is to be painted annually bright yellow for ready identification and to be maintained free of growth or any obstruction to normal view.

Special Marker: These are installed at special places where there are unusual constructional activities or high population density necessitating a more precise definition of pipeline route. Spacing, downwards to 100 ft (30 meters) will depend on circumstances. These signs are to be painted bright yellow and inspected during monthly motor patrols by Station in-charges.

Right-of-Way/Right-of-Use boundary marker: The NSPL pipeline is generally laid in the Naharkatia-Barauni crude oil trunk pipeline RoW and hence is bound by the same boundary markers. From Numaligarh Despatch Terminal where NSPL is laid in an independent RoU and wherever NSPL has deviated from the crude oi trunkline RoW and is laid in RoU, the pipeline route is demarketed by OIL boundary markers coloured in golden yellow paint. These concrete markers are installed on either side of the RoU at I.P.s and approximately 150m interval berween I.P.s. These markers shall be cleared of growth and cultivation semi-annually, askewed markers shall be straightened and missing markers replaced and local police informrd. Annually the markers shall be white washed OIL letters shall be painted black. The markers shall be maintained so that they are identifiable at all times.

D. IDENTIFICATION OF BLOCK VALVES: All block valve covers on the right-of-way/right-of-use shall be painted with aluminium paint and the valve number shall be painted in large black letters on the top cover so as to be identifiable at all time from air. On the doors of all block valve covers the following sign shall be embossed “OIL INDIA PIPELINE. IN EMERGENCY PHONE - XXXXXXX “The telephone number will be that of the pump station in whose Jurisdiction (right-of-way/right-of-use) the block valve is located. Station In-Charge shall be responsible for keeping the valve area clear of wild growth and accessibility in their respective jurisdiction. The list of block valves is given in

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Schedule/NSPL C.1.4-1.

E. IDENTIFICATION OF SUBMERGED CROSSINGS: Identification sign shall be erected, inspected, and maintained at all scheduled submerged crossings and canals. These signs shall be placed 100 ft (30 meter) from the river bank on either side and planed adjacent to the pipeline at that spot.

E. IDENTIFICATION OF IP STATIONS AND SV STATIONS: The IP and SV stations

are located inside the fenced premises of the Naharkatia-Barauni the crude oil trunk pipeline as given below Schedule/NSPL C.1.4-2.

The “OIL INDIA” sign shall be separately maintained for NSPL installations within the crude oil pipeline installations to give a smart appearance at all times. Standard pattern “NO UNAUTHORISED ENTRY” and “NO SMOKING” sign shall be placed and maintained at all entry gates in use. All inventory number signboards to be inspected and maintained as necessary semi-annually. F. INSULATING FLANGE MARKERS: These are to be inspected and maintained half yearly. G. SPEACIAL NOTE: During any National Emargency declared by the Government of India, No sign be exhibited identifying the name of the town, village or place.

Schedule/NSPL C.1.4-1. POSITION OF LINE VALVES & INSULATION JOINTS

POSITION OF LINE VALVES & INSULATION JOINTS

INSTALLATION CHAINAGE LOCATION INSULATION JOINT

POSITION OF IJ

NDT 0 Numaligarh Refinery 1 Pig Launcher HOV1 Ball 15.6 Rajabari SV1 34.5 Kaziranga 1 MOV HOV2 Gate 52 Bagori HOV3 Gate 66.6 Kanchanguri IP1 80 Sekoni 2 Pig Launcher &

Pig Receiver HOV4 Gate 95.5 Misa HOV5 Gate 114.3 Puranigudam HOV6 Gate 130 Krishna Ghat SV2 133.3 Ghani 1 MOV HOV7 Ball 153.5 Mahadev khola

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HOV8 Ball 170.74 Kopili U/S SV3 181.5 Jagiroad 1 MOV HOV9 Ball 197.8 Digaru IP2 221.6 Noonmati 2 Pig Launcher &

Pig Receiver HOV10 Gate 226.5 Down Town Hospital HOV11 Gate 236 Gorchuk/Lokhora HOV12 Gate 244 Brahmaputra U/S HOV13 Gate 246 Brahmaputra D/S HOV14 Gate 263.2 Puthimari U/S HOV15 Gate 266.6 Puthimari D/S HOV16 Gate 273.2 Chowlkhowa U/S HOV17 Gate 274.2 Chowlkhowa D/S SV4 299.3 Dharampur 1 MOV HOV18 Gate 303.5 Konimara‐Patacharkuch HOV19 gate 310 Tikka‐pathsala HOV20 Gate 317.1 dumarkijan U/S HOV21 Gate 318.1 dumarkijan D/S HOV22 Gate 325.8 palla U/S HOV23 Gate 326.3 palla D/S SV5 333 Barpeta Road 1 MOV HOV24 Ball 360.65 Bijni IP3 377.5 Bongaigaon 2 Pig Launcher &

Pig Receiver HOV25 Ball 397 BTPS (kokrajar) SV6 423.4 Pratapkhata 1 MOV HOV26 Ball 448 Srirampur

POSITION OF LINE VALVES & INSULATION JOINTS

INSTALLATION CHAINAGE LOCATION INSULATION JOINT

POSITION OF IJ

SV7 476.4 Chapani 1 MOV HOV27 Ball 502.5 Buxa RF HOV28 Ball 515.9 Hasimara IP4 524.8 Madarihat 2 Pig Launcher & Pig SV8 551.2 Binaguri 1 MOV HOV29 Ball 581.15 Upper Tunda SV9 607.1 Odlabari 1 MOV HOV30 Ball 615.25 Washabari HOV31 Ball 627.3 Mahananda Wildlife RF RANGAPANI,R 653.325 Rangapani 1 Pig Receiver

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Schedule/NSPL C.1.4-2

NSPL SV & IP STATION VIS-À-VIS CRUDE OIL TRUNK PIPELINE INSTALLATION Sl No STATION NAHARKATIA-BARAUNI THE CRUDE OIL TRUNK PIPELINE

INSTALLATION

1 SV-1 REPEATER STATION-3

2 IP-1 PUMP STATION-4












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C.1.5 OPERATING PIPE DEFECTS AND LEAKS A. FUNCTION AND SCOPE: The function of this report is to record all known facts and condition related to an operating pipeline defect or leak and its temporary or permanent repair. These records are to be retained as long as the section of line involved remained in service. This report is not intended for use on stock pipe or pipe under construction. B. REPORT: The pipe defect and leak report, Form OIP/NSPL-2, is designed to easily record essential information pertaining to a leak or defect such as location, type, description and cause of defect, physical properties of the pipe, type and condition of coating and type of repair. In the event permanent repairs cannot be made immediately, a space is provided for recommendation on the method of permanent repair. In the upper left hand corner of this form a space is provided for classifying the repair as permanent or temporary. The record of each defect will remain under review until a report is received on the permanent repair. The section on coating is an essential part of the report in that the coating is often a factor in the defect and leak development, and in any case an opportunity is given to check the condition thereof. The Cathodic Engineer should be given an opportunity to examine the condition of the coating and leak prior to cleaning or otherwise disturbing the natural condition. C. RESPONSIBILITY: The responsibility of preparing and submitting this report is that of the Head of Pipeline Maintenance Section at Pipeline Headquarter. E. REPAIR OF PIPE DEFECTS AND LEAKS: Each pipe defect or leak discovered in an operating pipeline requires individual consideration and judgment as to the potential danger of the leak or defect which therefore dictates the method of repair. Basically, defects or leaks fall in one of two general categories -- those requiring immediate cut-out or weld repairs and those which may be temporarily rectified by emergency repair pending a permanent repair at a later stage. For maintenance procedure relating to such repairs Refers Sub-Section 6

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OIP/NSPL-2 OIL INDIA PIPELINE OPERATING PIPE DEFECT AND LEAK RECORD

Report of Initial Discovery Temporary Permanent Repair

1. LOCATION BASE__________________________Km. P____________________Meters East/West_________________________ SPECIAL FEATURES_____________________________________________________________________________

2. OCCURRENCE: DATE____________________TIME_________________DISCOVERED BY WHOM_________________________ DATE____________________TIME_________________ DISCOVERED BY WHOM_________________________

3. CLASSIFICATION: OIL LEAK MAJOR / MINOR PIPE DEFECT MAJOR / MINOR

4. TYPE OF DEFECT:

SEAM LENGTH______________” WIDTH______________” DEPTH________________” DENT LENGTH______________” WIDTH______________” DEPTH________________” CORROSION LENGTH______________” WIDTH______________” DEPTH________________” CRACK LENGTH______________” WIDTH______________” DEPTH________________” POROSITY NUMBER OF HOLES_______________________

DIAMETER____________________” OTHER INFORMATION

__________________________________________________________________________ ________________________________________________________________________________________________ ________________________________________________________________________________________________

DEFECT IS LOCATED AT ___________________________O’CLOCK ON PIPE LOOKING DOWNSTREAM

ON PIPEWALL* / LONGITUDINAL WELD*. IF DEFECTNOT ON GIRTH WELD, LOCATING DISTANCE TO GIRTH WELD UPSTREAM___________________’ ________________”

DOWNSTREAM_______________’________________” DIAMETER OF PIPE________________________________” WALL

THICKNESS__________________________” PIPEMANUFACTURER FROM STRINGING

CHART__________________________________________________

5. TYPE OF TEMPORARY REPAIR: BOLTED LEAK CLAMP* LEAK COUPLING* OIL LEAK SEALED OFF YES / NO * OTHER INFORMATION__________________________________________________________________________

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________________________________________________________________________________________________

6. TYPE OF PERMANENET REPAIR:

CUT OUT AND REPLACE SECTION * ___________________LENGTH __________’ ______________________” WELDED TYPE CLAMP* WELDED TYPE COUPLING* OTHER* DESCRIBE______________________________________________________________________________ METHOD APPROVED BY CHIEF ENGINEER________________________________________________________

7. COAT AND WRAP CONDITION:

TYPE __________________________________________________________________________________________ ACTUAL THICKNESS_______________________ BOND TO METAL GOOD / FAIR / BAD* EVIDENCE OF SOIL STRESS YES / NO* REMARKS_____________________________________________________________________________________

8. OPERATION: LINE CLEARED FOR OIL MOVEMENT AT ________________________KG / CM² PRESSURE

Delete which is not applicable ___________________________________

Sectional Head / Base in charge (Pipeline Maintenance) Date_______________________________________

Distribution

Chief Engineer Pipeline (Operation) Addl. / Deputy Chief Engineer (Pipeline Maintenance) / (Oil Movement) / (Electrical &

Cathodic) BASE PIPELINE INCHARGE.

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C.1.6 PIPELINE MAINTENANCE PROCEDURE: A. FUNCTION AND SCOPE: The function of this section is to lay down acceptable maintenance procedure for temporary and permanent repairs to the pipeline, and to ensure that adequate safety measures are adopted. B. RESPONSIBILITY: The responsibility for ensuring that such practices are adhered to in the field is that of the Base Pipeline Maintenance Engineers in charge of the work in progress. C. TEMPORARY LEAK REPAIRS: A complete range of approved leak repair materials is stocked at each maintenance base as listed in the Schedule of Pipeline Maintenance Equipment. For the majority of defects likely to be encountered, this range of equipment will provide for a safe and temporarily cold repair. If, as a result of a major leak, a pipe joint/pup is to be replaced/inserted , a cold repair using `weld+ end` couplings is acceptable as a temporary repair bearing in mind the need to get the line operational soonest, and that crude spillage may prevent welding for the time. A temporary repair in these categories should be made permanent at the first opportunity, and here, each case must be judged in its merits. Generally speaking, subsequent welding of approved leak couplings, `weld+end` couplings, and leak patches will constitute a permanent repair, however, approval of the Head of the Pipeline Department is required before so doing. Subsequent welding should only be carried out when the area is gas free and with oil moving in the line at reduced pressure. All repairs in the category of temporary must be regularly inspected, and any temporary-leak-clamps having neoprene inserts checked for tightness fortnightly. D. SCHEDULED PERMANENT REPAIRS: When any permanent repair is scheduled necessitating cutting the line, a water plug should whenever possible, be inserted to minimize crude spillage and for safer working. If the faulty section is to be adjacently stoppled, such welding as required for tapping should be carried out with moving at reduced pressure, before insertion of water plug. If the distance between stoppled is not excessive, a water plug need not be [placed provided adequate and prior arrangement are made for disposing crude spillage. Immediately after the line is cut, arrangement must be made for blinding the upstream and downstream ends of the line. If the line is shut down. Maloney Templugs may be used to contain any static head developing/ resulting from nearest block valves.

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If the faulty section is by-passed with a temporary line such that pressure other than static head exists at valves/stopple valves immediately upstream and downstream, the line when cut, must be immediately blinded by either adequately rated cone-lock-stoppers or capped - ‘weld + end’ – couplings. Maloney Templugs must never be used for blinding when pumping is in progress under these conditions. The Base Pipeline Maintenance Engineer In-charge of the work is solely responsible for and solely authorized for valve operation and safely connected therewith when field repairs are in progress. This responsibility can in no circumstances be delegated.

Cold Closing Tie In: This is permissible under certain circumstances to be decided by the Chief Engineer, and would consist of using ‘weld + end’ coupling to be welded later on when oil is again moving in the line at reduced pressure.

Hot closing Tie In: This is the preferable method of tying in, but may only be carried out by trained crews. In each case the trained welder must be authorized on Form OIP-3 in writing by the Base Pipeline Maintenance Engineer In-charge before carrying out this work, and authorization must be cleared by Head of the Pipeline Department before commencement of hot tie in.

E. OIL SPILLAGE: E.1. Adequate arrangements must always be made to safely contain spillage, if the line has to be cut for any reason or if major leak occurs. If a line cut is scheduled, usually a water plug will be inserted into the section in question. However, the resultant emulsion should be treated as oil spillage insofar as safety and crop damage is concerned. Safety points to be observed era as follows:

Spillage storage, if not mobile, is to be sited at not less than 60 meters distance from bell hole if welding is to be carried out later on.

Posting of guards to keep villagers away from spillage and forbidding the use of smoking and naked lights.

E.2. If serious leak occurs, e.g., a split seam, it is possible that a large area will be affected by spillage, particularly, if the pipe section is under a static head. The following precautions must be immediately taken.

Enclosing the area with an earthen bund to contain the spillage. Posting of guards to keep villagers away from bunds and forbidding of use of

smoking and naked lights. If welding is to be carried out in the vicinity of a spillage/pit, the following

precautions must be adopted.

Since petroleum oils are volatile with low flash point, due attention must be paid to dangers of “flashback”. Welding should not be carried out within at least 60 meters of a oil spillage pit, and windward side. This distance is to be increased to atleast 150 metre in case the spilled oil is Motor Spirit.

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- Irrespective of this distance, however, continuous explosimeter-readings must be taken during welding. If, for any reasons, concentration of inflammable gases causes the instrument to register danger signal, welding must be immediately discontinued, until the atmosphere again registers safe. - Welding sets should be located at least 60 meters away from the spillage. Plant attendants should have strict instruction to shut down the set if the explosimeter indicates a hazardous atmosphere emerging.

F. WELDING: Welding shall be done as per API 1104. G.TESTING: When the line has been cut, or a new section introduced, the line section shall, whenever possible, be brought up maximum working pressure for a period of at least four hours. Any section so introduced shall, however, be tested in accordance with ANSI B 31.4 (latest edition) before tieing in. H. OIL RECOVERY: H.1. Petroleum oil temporarily stored in spillage pits must be recovered as soon as possible, both from a safety and an economical aspect. If quantities involved are small and the area accessible, mobile tanks should be employed, and recovery effected at NDT, RT or the nearest IP Station. If the amount involved is large, line tapping may be used and the oil pumped into the line by means of a high-pressure recovery pump. The same precautions outlined under Oil Spillage should be adopted as applicable. H.2. Clean up of the area is an important and necessary conclusion after all oil has been disposed of. This is achieved by spreading a layer of dirt over the area, sufficient to soak up all patches. I. SAFETY: The following safety points must at all times be strictly observed. GENERAL: a) The Pipeline In-charge or his authorized representative in charge of the job shall brief

the welder on the possible hazards of specific job.

b) The Pipeline In-charge or his authorized representative in charge shall obtain the necessary approvals and notify those concerned before the welding operations begins.

c) Welders are responsible to the Pipeline Maintenance Engineer In-charge for the proper maintenance and safe operation of welding equipment.

d) The welder should always thoroughly instruct his helpers concerning the work procedures and safety procedures in the specific job before it is begun.

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e) The Pipeline Maintenance Engineer In-charge and the welder should see that the welder and helpers wear adequate eye protection and follow safety precautions while the welding job being performed.

f) Each welding unit should have available at least two 10 kg DCP Type fire extinguishers and a first aid kit including a special eye burn kit. The welder is responsible to the Pipeline Maintenance Engineer In-charge for the condition of the safety equipment carried with the welding unit.

g) Flames, sparks, molten slag, and hot metal should be prevented from coming in contact with combustible materials.

h) Whenever practicable, the object to be welded upon should be moved to a location designated as safe for welding, or movable fire hazards should be removed.

i) Before welding in any bell hole or building at any location where there has been a petroleum oil spillage, the area is to be tested with an explosimeter and must be gas-free. This testing should be continued at short intervals during the repairs to insure against the encroachment of explosive mixtures. Before the welder begins his actual welding operation, he should test the pipe or bell hole by lowering a lighted welding torch into it.

j) Welding must be stopped if vapours become noticeable in the area in which the work is being performed and should not be resumed until the area is tested with an explosimeter and found to be gas-free.

k) Screens or other suitable means should be used to protect nearby employees from the rays of the welding arc.

l) When a weld is to be made on a partition or on the side of a building or structure, all combustible material should be removed from the opposite side of the partition or wall.

SAFETY PRACTICES IN PIPE LINE WELDING: a) Only experienced Pipeline Maintenance Engineer and trained welder/workman should

work on a loaded pipeline.

b) In welding on a loaded pipeline, only electric arc welding shall be used, and only when enough fluid is flowing through the pipeline to carry away the heat of the arc. (Welding limitation on specific types of pipe should be closely followed).

c) Bell holes for repairs to pipelines should provide sufficient room for the welder to work freely and to make a quick exit in an emergency. The Pipeline Maintenance Engineer In-charge should determine if shoring is needed to prevent a cave-in.

d) A safety belt with lifeline attached should be worn by the welders who work in deep bell holes.

e) An experienced employee should hold the lifeline during the welding operation.

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f) Only the welder should be permitted in the bell hole during welding operations.

g) Fire extinguishers shall be manned and be ready for instant action should a fire occur when welding on a loaded pipeline.

h) A first-aid burn-kit should be placed in readiness and be available for instant use before starting a welding operation.

i) When welding on a loaded pipeline, mobile radios must be used for communication, and should be kept “on” at all times for ready communication with NSPL Master Control Station and Oil Movement Engineer on Duty (Despatcher) in the Crude oil trunkline Master Control Station. Before welding on a trunk or main line, in addition to the precautions as listed in this section , the following specific procedures must be followed:

The Pipeline Maintenance Engineer in charge of the welding must notify the Head of Oil Movement and Pipeline Maintenance Sections at Pipeline Headquarters before commencing work. If the welding is to be done on a loaded line, the Head of the Oil Movement Section / In-Charge NT/Duty Engineer at NSPL Master Control Station and the Pipeline Maintenance Engineer In-charge will discuss repairs to be made to the end that a safe working pressure may be determined and maintained and other safety precautions may be taken.

The Head of Oil Movement Section / In-Charge NT /Duty Engineer at NSPL Master Control Station/Duty Oil Movement Engineer will be responsible to see that the pressure agreed upon is not exceeded until the welding operations are completed.

If welding is to be done on an open line, the Head of Oil Movement Section / In-Charge NT/ Duty Engineer at NSPL Master Control Station will ensure that all pumping units have shut down and give clearance to the Pipeline Maintenance Engineer In-Charge to enable him to close the immediate block valves pertinent to the job in hand. The Pipeline Maintenance Engineer In-Charge of the work alone is responsible in ensuring that these block valves are closed and locked out to prevent operation by unauthorized persons. All block valves so locked out are to be tagged with a red danger bond “Danger Do Not Operate- work in Progress”.

On the completion of the welding operation the Pipeline maintenance Engineer In-Charge of the job will notify the Head of Oil Movement / In-Charge NT/ Duty Engineer at NSPL Master Control Station /Duty Oil Movement Engineer that the welding is completed and that line is ready for normal operations.

All automotive equipment, welding machines, tractors, portable pumping equipment, and other sources of ignition are to be kept at a safe distance (60 metres minimum) and on the windward side, if possible, from Pertoleum oil to be gas-free after testing with an explosimeter.

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xii) When working near petroleum oil spillage all employees are to leave matches, lighters and smoking material in a location designated by the Pipeline Maintenance Engineer In-charge and at least 60 metres away from the operations.

xiii) On pipeline which carries induced cathodic protection currents, the current must be turned off or disconnected.

xiv) When pipelines which have been in petroleum oil service are to be parted, or, when sections of lines are to be joined, a bonding cable must be installed between the two sections to reduce the possibility of spark ignition of combustible vapours. This bond must be made before the line is cut, or before the last connection is made in joining two sections. (Further, on well-coated lines, in order to effectively eliminate possible straying earth current hazards, the bonding cable should be grounded. this may be accomplished by connecting the cable to a grounded. This may be accomplished by connecting the cable to a ground rod driven approximately two metres into the bottom of the bell hole. The rod should be a pipe of a minimum diameter 19mm or 16mm diameter iron rod). The purpose of these electrical bonds is to minimize the possibility of electric sparks from induced currents, stray current or static electricity by providing safe metallic circuits for anticipated electrical flow paths.

xv) Following the attachment of the bonding of cable and the cutting of the line, vent holes should be cut. Vent holes must not be drilled by electrically powered drill. Holes should be located at least 60 meters (if possible) both ahead of and behind where the line is cut. When it is necessary to the vent the line closer than 60 meters, a line or hose should be connected to the vent carry unexpected gas vapours or oil to a safe distance from the job.

xvi) When the “cut-out” section of the line has been removed and drainage cleaned up, each of the line should be plugged with an expandable mechanical plugging device or a clay or drilling mud plug. The mud plugs should be located from 0.6 meter to 1 meter back from the proposed welds. It must be packed solid with a skid or tamp so that it is of sufficient strength to trap drainage or any surge within the line.

xvii) All oil and oil-soaked earth must be removed from the bell hole and the immediate vicinity. The removed oil-soaked dirt should be replaced with dry dirt to prevent flashing from welding. After the area is freed of gas and oil, tests with an explosimeter should be made.

xviii) Even though the gas tests are negative, it is considered a safe practice to drop a lighted welding torch into the ditch near the open lines as an additional safeguard before entering the immediate area.

xix) An employee should be stationed at each vent or vent line and be stationed there to remain during the entire welding procedure. They should be alert at all times to observe any undue quality of air, gas or oil escaping from the vent or vent lines, so that welding may be stopped immediately pending further investigation.

xx) After welding has been completed, the vent holes in the line must be plugged, or closed with a patch and leak clamp. The patch should be welded after the line has been filled.

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WELDING AT IP/SV STATION:

i) Prior authorization must be obtained from the Heads of the Pipeline Maintenance/Operations sections before beginning welding operations within a IP Station area which falls within Pump Station area of crude oil pipeline.

ii) The engineer in-charge of the welding job shall discuss the proposed work with the Station Engineer In-charge responsible for the station to ensure compliance with all safety practices.

iii) Generally, the station should be shut down and by-passed. All power circuits should be isolated at the distribution panel. All of the switches, gate valves and control points instrumental in the shut down should be locked out and tagged with the red danger board “Danger Do Not Operate- Work in Progress”.

a) All gate valves and other connections involved must be blank flanged. All gate valves and controls must be tagged with the danger board “Danger Do Not Operate- Work in Progress”.

b) During the welding operation all nearby pump pits likely to cause danger should be covered with water soaked tarpaulins.

c) Just prior to welding on or cutting on a line that has contained oil or gas, the line must be thoroughly washed out with water and purged with air until such time as tests indicate it is gas-free.

iv) Prior to welding, explosimeter tests must indicate the area is free of gas. These tests must be repeated frequently to insure that the atmosphere continues to be gas-free until welding is finished.

v) Before the welder begins his actual welding operation, he should test the pipe or bell hole by lowering a lighted welding torch into it.

vi) While welding, fire extinguishers must be manned and ready for instant action.

vii) While welding in vicinity of the station, no employee should be in a confined space such as a pump pit or sump, etc.

vii) When the welding is completed and the Station Engineer notified, the station operation should be brought back to normal.

ix) When welding is to be done on a line in a station for installation of instruments, tapping connections, thermowells, etc. in addition to the precautions already listed in this section, the following procedure must be observed:

a) In order to keep oil circulating in the line to be welded on, a portable pumping unit should be used. The lines from this unit should be hooked up so that oil can be circulated and the line to be welded on will be kept packed with fluid.

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ELECTRIC WELDING EQUIPMENT:

I) Portable electric welding equipment:

Protection of equipment: When used outdoors, welding machines should be protected against the weather.

Service cable and connectors: When it becomes necessary to connect or splice lengths of cable one to another, substantial insulated connectors, of a capacity at least equivalent to that of the cable, should be used. If connections are effected by means of cable lugs. Then these should be securely fastened together by more than one bolt to give good electrical contact. The exposed metal parts of the lugs should be completely insulated.

GAS WELDING AND CUTTING:

I) The following precautions should be observed in the storage, handling, and use of oxygen and acetylene cylinders, fitting, and hose:

Cylinders should be stored in a definitely assigned place away from sources of heat such as a radiator, stove, etc. Cylinders which are stored outdoors should be protected against extremes of weather. Oxygen cylinders should not be stored near reserve stocks of acetylene or other fuel gas cylinders, or near any other substance likely to cause or accelerate fire. Pure oxygen will not burn, but it supports and accelerates combustion, and this will cause oil and similar materials to burn with great intensity.

Cylinders of oxygen and acetylene should be used in rotation as they are received from the supplier.

Always describe oxygen by its proper name “oxygen”, and never “air”. Never use oxygen for compressed air. A serious accident may result if oxygen is used as a substitute for compressed air. Oxygen must never be used in pneumatic tools, on oil preheating burners, to start internal combustion engines, to blow out pipelines, to “dust” clothing or work, to dry hands, for pressure tests of any kind or for ventilation.

Oil or grease must not be used on or around an oxygen cylinder, cylinder valve, regulator, fitting or hose.

Oxygen and acetylene cylinders should be placed with the valve end up whenever they are in use.

When cylinders are moved by hand, they may be tilted and rolled at their bottom edge. Dragging and sliding of cylinders should be avoided. Cylinders should not be dropped nor should they be permitted to strike anything violently.

Valve protection caps should not be used for lifting cylinders from one vertical position to another.

Cylinders whether in use or in storage must be secured to prevent them from being knocked over.

Cylinder in use should be kept far enough away from the welding or cutting operation to prevent their coming in contact with sparks, hot slag or flame.

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Cylinder should not be placed where they might become part of an electric circuit such as a ground return circuit for an arc-welding machine. Never strike an arc against a cylinder.

Cylinder should not be used for any purpose except those specified by the supplier. Do not exeperiment, in any way,with an unknown gas in an unknown cylinder.

If a valve leak develops, the cylinder should not be used. It should be tagged for the advice of the supplier and placed outdoors away from all sources of ignition, where the contents may be expelled harmlessly.

Before a cylinder is placed in use, the valve should be opened slightly and closed immediately to clear the valve of dirt which might enter the regulator. This must not be done near other welding work, sparks, flames, or other sources of ignition.

To determine if tight connections have been obtained in the installation of the pressure regulator and other connections, soapy water may be used.

The oxygen cylinder valve should be opened slightly, after the installation of the regulator, so that the high pressure gauge hand will move slowly. The valve should never be opened suddenly, and the operator should not stand directly in front of the gauge faces.

Welding hose is manufactured in distinctive colours for ready identification. Red is the recognized colour for acetylene and black for oxygen. Hose connections on the regulator should similarly be marked for identification.

If parallel lengths of oxygen and acetylene hose are taped together to prevent their becoming tangled, not more than 100 mm (4”) out of each 200 mm (8” ) should be covered with tape.

The hose should be inspected frequently for leaks, worn places, and loose connections. Leaks may be detected by immersion of the hose in water under normal working pressure. A defective hose must not be used.

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OIP/NSPL – 3 OIL INDIA LIMITED HOT TAPPING / HOT TIE IN AUTHORISATION Location____________________________________________ Date______________ Description of work

Authorised Welder Name ______________________ Date of Hot Welding Training ______________________ Pipeline Engineer in Charge ______________________ Date to be carried out ______________________ Authorised by Chief Engineer __________________ Date________________ Special Precaution to be adopted

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C.1.7 CORRORION CONTROL INSPECTIONS:

A. Objective and Responsibility: To maintain a positive control programme against

corrosion attack, so as to ensure the continuous and uninterrupted operation of the pipeline facilities. The administration of this programme is the overall responsibility of Chief Engineer Pipeline ( Electrical & Cathodic )

B. Minimum and maximum Pipe To Soil Potential:

Minimum Pipe To Soil Potential: A minimum cathodic polarization potential of negative 100 mV between the pipe surface and a stable reference electrode in contact with the electrolyte as per OISD/STD-188 & NACE-RP 0169-96.

Maximum Pipe To Soil Potential: A maximum polarization potential of negative 1200 mV (instant ‘OF’ potential). This polarization potential is measured with respect to copper /coper sulphate reference electrode as per OISD/STD-188

C. Inspection and reports:

Rectifiers: Once in every 10 days inspection of all rectifier installations and record of instrument readings are to be made by responsible Superintending/Senior Station Engineers and reported on OIP/NSPL-4 for NDT, IP Stations, RT and SV Stations station rectifier units. In the

Drains point PSP: Monthly Readings of pipe to soil potentials at drainage points for Pump and Repeater Stations are to be checked by Engineer / Junior Engineer (Electrical & Cathodic) and reported on OIP/NSPL-5.

Pipe-to-soil Potential: Monthly Readings of pip- to-soil potentials at the specified test points are to be taken and checked by Engineer / Junior Engineer (Electrical & Cathodic) and reported on OIP/NSPL-5.

F. Semi-annual inspections and reports:

Pipe-to-soil Potential: Semi-annual reading are to be taken with corrosion voltmeters on both sectors at test points (Every fifth kilometer post) . This information to be plotted on a strip chart by the superintending Electrical and Cathodic Engineer to graphically indicate the degree of pipeline protection on each sector.

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G. Annual inspection and reports: For cased crossing , block valves, suspension river crossings, annual readings are to be taken with cathodic voltmeter by the Superintending Electrical & cathodic Engineer once in a year during the period from November to February and any defect observed will be reported to superintending/ Senior Engineer ( Pipe line Maintenance ) for necessary repair.

F. Specialised inspections and reports:

Exposing the pipeline: Whenever is to be exposed, the Deputy Chief engineer (Pipeline Maintenance) will notify the Deputy Chief Engineer (Electrical and Cathodic). If the area in which the exposure will be made is one requiring additional corrosion study, the Superintending Electrical and Cathodic Engineer shall be present. Normal conditions of coating and pipe need not be reported , however , conditions of por coating , corrosion evidence etc. will be submitted on OIP/NSPL-2 to the Chief Engineer Pipeline (Operations)

Holiday surveys: Electronic holiday survey to determine coating condition will be made in area where protection is difficult to maintain and severe corrosion conditions are known to exist or develop with time. Any coating defect observed will be reported to Deputy Chief Engineer (Pipeline Maintenance) for necessary repair.

Operating facilities taken out of service: When a facility (pipe, meter, station etc.) is taken out of service, the Superintending /Senior Engineer (Pump Station) will notify the Senior Engineer / Engineer (Electrical & Cathodic) in order that he may inspect the condition of the internal surfaces and ensure the continuance of cathodic protection to the remaining and adjoining facilities.

1. PSP reading of Insulating Joint: PSP reading of Insulating flanges of Station Inlet and Outlet valves should be taken monthly to check the integrity of insulating joints (IJ) and will be reported on the cathodic Engineer’s monthly report (OIP/NSPL-5)

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OIP/NSPL-4

OIL INDIA LIMITED TRANFORMER RECTIFIER DATA:

Period ending _ Station

Date Serial Number Voltage Current Remarks

RS-

PS- U/S-

PS- NSPL ( NDT ) D/S-

101426 - 07G55

PS- Station

RS-

PPL

Station PS-U/ S Station PS- D/ S

Station RS- Station RS- Station Station Station

Signature of JE (E&C)/ENGG (E&C)______________

Date_____________________

Original-Installation Manager Operation(NT-NSPL) Duplicate- Installation Manager (E&C)[PS3/PS5/PS8] Triplicate-H.O.D(E&C),PHQ

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PREVENTION OF INTERNAL CORROSSION

G. CORROSION MONITORING SYSTEM:

For corrosion monitoring and control, CMS system has been provided. Based on feed back of CMS system, ppm level of corrosion inhibitor is adjusted and accordingly corrosion inhibitor is dosed. INTERNAL CORROSION MONITORING SYSTEM AND CONTROL To mitigate internal corrosion in product pipeline due to sulphur, water and impurities corrosion inhibitor is used. The corrosion coupon made of same material as pipeline, disc type is inserted into pipeline matching internal surface of line. Coupon is installed in NDT, RT and in all IP’s. The corrosion rate can be found out from coupon loss after withdrawn it for a specified time interval which shall be half-yearly. The findings shall be recorded in OIP/NSPL 7 Also online corrosion monitoring is available at NDT, IP Stations and RT by means of ER probe. Metal loss (in Micro mills) and instantaneous corrosion rate (in micro mills per year) are monitored in Corrosion Monitoring Syatem(CMS). The data shall be recorded daily in OIP/NSPL 8 Corrosion rate value of coupon shall be compared with the corrosion rate value of CMS for a particular period. After a series of coupon test CI dosing ppm at NDT and IP2 may be varied as per requirement to mitigate internal corrosion. NACE TM 0172-2001(LATEST EDITION) and manuals of the system manufacturer shall be refered to for interpretation of data obtained from CMS and corrosion coupon weight test and adjusting CI dosing Record of monthly CI dosing shall be maintained in OIP/NSPL-17

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OIP:/NSPL-7

OIL INDIA LIMITED

MONITORING AND CONTROL OF INTERNAL CORROSION STATION:- DATE:- Corrosion coupon CMS(Corrosion

Monitoring System) Corrosion inhibitor Dosing

Remarks

Initial weight Monthly corrosion rate From metal loss

Monthly ppm

Serial no Yearly ppm Date of installation

Yearly corrosion rate From metal loss

Make Alloy Monthly average

corrosion rate

density Coupon area Yearly average

corrosion rate

Date of withdrawn

Final weight Corrosion rate Weight measurement And test done by

Maintenance if any

CIDP1 CIDP2

CMS

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OIP:/NSPL-8

OIL INDIA LIMITED Corrosion Rate Calculation(in CMS) The Model 4021L receiver unit operates on a simplified algorithm that calculates corrosion rate every 6 hours. The rate is computed from the metal loss change over the previous 48 hours.

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OIP/NSPL-17

OIL INDIA PIPELINE NUMALIGARH-SILIGURI PRODUCT LINE

CORROSION INHIBITOR DOSING RECORDS Pump Station No. NSPL/NDT &IP2 Month Ending 2011

DATE CI INJECTION(Ltrs)

PRODUCT PUMPED(KL)

CI INJECTION RATE(PPM)

CI TOP UP

TOTAL Cumulative

(From 1.4.11)

__________________________ Station Engineer In Charge

Date ______________________

o Original ‐ Pump Station

o Duplicate ‐ Maintenance Base

o Triplicate ‐ Head Quarter

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C.1.8 VALVE INSPECTION:

A. FUNCTION AND OBJECTIVE: The objective of this inspection programme is to

provide safe and proper operating valves for use during an emergency and during the course of normal operations. Reference shall be drawn to Schedule NSPL C.1.4-1

B. CLEARANCE FROM NSPL DESPATCH CONTROL STATION: Prior clearance is to be obtained from NSPL Despatch Control Station in the event a valve is operated from ‘OPEN TO CLOSE’ or ‘CLOSE TO OPEN to check the operation of the valve. After inspection, NSPL Despatch Control Station and Head(PL-Operations) and Head of Pipeline Maintenance section shall be notified of any abnormal operating conditions.

C. SEMI-ANNUAL INSPECTION: Prior to pigging operation and during the month of April and November of each year, all main line valves are to have the bevel gears inspected and then operated a few turn and returned to their original position. During the operation of each valve, its operating condition is to be checked and corrections made where necessary. Such items as the condition of the gears, gear lubrication, ease of operation condition and position of indicator, water tightness of bevel casing gasket and seals around indicator, etc. Should be checked.

D. REPORTING: From OIP/NSPL-6 shall be used to report the result of the valve inspections outlined above.

E. RESPONSIBILITY: The administration of the above tests and inspections is the responsibility of the Head of Pipeline Maintenance section and will be carried out by the Pipeline /Station Engineer in-charge of NDT, IP Stations and RT.

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OIP/NSPL-06

OIL INDIA PIPELINE

VALVE INSPECTION REPORT NSPL_____________ SL.No

Valve No.

Date this Inspection

Date last inspection

Operating Condition of Valve

Leakage: Test time (Block Valve)

Remarks

Good: Valve can be closed with minimum effort. Fair: Some friction present. Poor: Excessive effort need to close valve. Inspected by ________________ Signed by_______________ Base P/L Engineer Chief Engineer Pipeline (P/L Maint.) Distribution (Check original and each copy): Original: Pipeline HQ. Duplicate: Chief Engineer Pipeline (Operations). Triplicate: Pipeline Base Office.

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SUB-SECTION A-8

C.1.9 PIGGING AND LINE SCRAPING: A. Function and objective: To clean deposits from the inside of the pipe in order to

restore the original condition of the inner surface of the pipeline and to retard corrosion by reducing the amount of corrosive material inside the pipe.

B. Responsibility: The overall responsibility of coordinating all pig runs is that of Chief Engineer(Oil Movement) and Engineer In-Charge NT. Engineer (NSPL/NDT MCS) is responsible for the security of the pig when in the line and will issue instructions to Engineer In-Charge (Pump Stations/IP Stations) concerning launching and receiving schedules, and intermediate security checks.

C. Frequency: Chief Engineer (Oil Movement) and Engineer In-Charge NT will be responsible for ordering scraper pig runs. Generally cup type pig shall be run bi-annually in the pipeline.

D. Security: The progress of the pig in any sector will be tracked by the Engineer (NSPL/NDT MCS) and shall be intimated to the respective Engineer-In-charge of the sections. In case of loss of any pig in the line, the course of action shall be decided by Chief Engineer (Oil Movement) and Engineer In-Charge NT

E. Inspection: All pigs will be inspected by the respective Engineer-in-charge of the stations and the condition of the same shall be reported to Head(PL-Operations), Chief Engineer(Oil Movement), Engineer In-Charge NT and HEAD Pipeline Maintenance Section. Detailed report of the Pigging operation shall be sent to Chief Engineer (Oil Movement)/Engineer In-Charge NDT. Chief Engineer PL(E&C) will arrange to inspect all pig run residues for assessing internal corrosion implications.

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SECTION C.2 Plant

C.2.1 Pumping Equipment

PUMPING EQUIPMENT AT NUMALIGARH DESPATCH TERMINAL A. Function and Scope: To ensure by regular condition monitoring and maintenance the

operating efficiency to give uninterrupted service of all the pumping equipment at Numaligarh Despatch Terminal, IP stations and Rangapani terminal. Refer to Schedule/NSPL C.2.1-1

B. Responsibility: The Engineer In-Charge NT is locally responsible for the operation

and maintenance of Pumps under his control. This include routine servicing and ensuring through Base Maintenance Engineers that major maintenance is timely performed, in accordance with plant running hours and condition monitoring. The overall professional responsibility for the maintenance of the Pumps on the entire pipeline is that of the HEAD(PL-M&S) /Chief Engineer Pipeline (Maintenance) based at the Pipeline Headquarter. He is responsible for coordinating the Maintenance by Engineer In-Charge NT/ In-Charge Engineer(Mechanical Maintenance) based at the Maintenance base at PS3.

C. Operating Record Sheet:

The daily Record Sheet (OIP/NSPL–10): The Daily Record Sheet is to be completed by the Station Technician on at two hourly intervals during the working shift on so that a record of Pump performance exists, and trends can be noted.

The Monthly Record sheet (OIP/NSPL-11): These provide a summary of the Pump performance and maintenance recorded during the month.

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OIP/NSPL 11 Page 1 OIL INDIA PIPELINE KIRLOSKAR EBARA MAINLINE PUMP NSPL /NDT MONTHLY RECORD SHEET 20 Pump Engine No.

Availability Power Consumption Lub.Oil Consumption

Running Hrs. to date

Running Standby U/S product pumped(KL)

KW Hrs…. kwh/kL Lub.Consd.

LTRS/Eng.Hr.

1 2

Running Hours Since Lat Maintenenance Diesel Engine MECHANICAL SEAL

COUPLING SHAFT IMPELLER Lub.-Oil Change

Major Overhaul

AOP MOP SEAL LEAKAGE MONITORING

1 2 3 4 5

Spare Parts Used During Month Excluding Major Overhauls Part No. Description No. Part No. Description No. Part No. Descripti

on No.

1

2

Remarks and Summary of all Maintenance / Breakdown during the month: ______________________________________________________________________________________________________________________________________________________________________________________________________________

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OIP/NSPL 11 Page 2 OIL INDIA PIPELINE FLOWAY BOOSTER PUMP NSPL /NDT MONTHLY RECORD SHEET 20 BOOSTER PUMP NO.

Availability Power Consumption Lub.Oil Consumption Running Hrs. to date

Running Standby U/S product pumped(KL)

KW Hrs….

kwh/kL Lub.Consd. LTRS/Eng.Hr.

1 2 Running Hours Since Lat Maintenenance

Diesel Engine MECHANICAL SEAL

COUPLING SHAFT IMPELLER SEAL LEAKAGE MONITORING

Lub.-Oil Change

Major Overhaul

AOP MOP

1 2 3 4 5 Spare Parts Used During Month Excluding Major Overhauls

Part No. Description No. Part No. Description

No. Part No. Description

No.

1

2

Remarks and Summary of all Maintenance / Breakdown during the month

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_______________________________________________________________________________________________________Signed Station Engineer Date: Seen by Chief Engineer Date: Distribution Original:-Station Engineer

Duplicate: - Head Quarter

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OIP/NSPL-10

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OIP/NSPL-12 EMERGENCY GENERATOR MONTHLY RECORD SET STATION :- NDT/RT (Emergency Set) Month…

DATE Av. Load Amps

Exh. Temp in °C

C.W Temp in °C

C.W Temp out °C

L.Oil Temp

°C

L.Oil Press

Kg/cm²

R.P.M SET ON DUTY

From …Hrs To…Hrs

Monthly Running

Hours

Cuml. Running

Hours

Running Hours since

L.Oil Consumed Ltrs.

Avg. Fuel

Cons. Ltrs/ Hrs

KWH Reading

EMERGENCY SET Eng.No. Alt.No

Major Ovhl.

Top Ovhl.

L.Oil Change

Closing

Opening

Total

Average KWH

DISTRIBUTION-STATION/CEPL (M)/CEPL (E&C)/ Dy.C.E (Maint.) Maintenance Report Overleaf Dy.C.E (NT)/ S.E (NT) NDT/RT Page 1

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MAINTENANCE CARRIED OUT ENGINE FAILURE:CAUSE & ACTION TAKEN

EMERGENCY GENERATOR

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Schedule/NSPL C.2.1-1

Plant Equipment Data NSPL

Name of The Plant and Location :NDT EQUIPMENT EQUIPMENT NO SPECIFICATION

Mainline pump A 10-PA-CF 102A PUMPING HEAD 1050 METER

DRIVER 1130 KW RATE OF FLOW 291.5 M3/HR

MAX OPERATING

SPEED 2969 RPM

CASING HYDRO

TEST PRESSURE 210 KG/CM2

WEIGHT 4600 KG

MAWP 140 KG/CM2 NPSH REQUIRED 9.3 M EFFICIENCY 73 %

SUCTION

PRESSURE (MAX./RATED)

9.53/3.0 KG/CM2

LUBE OIL

VISCOSITY VG46

Mainline pump B 10-PA-CF 102B PUMPING HEAD 1050 METER DRIVER 1130 KW

RATE OF FLOW 291.5 M3/HR

MAX OPERATING

SPEED 2969 RPM

CASING HYDRO

TEST PRESSURE 210 KG/CM2

WEIGHT 4600 KG MAWP 140 KG/CM2


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NPSH REQUIRED 9.3 M EFFICIENCY 73 %

SUCTION

PRESSURE (MAX./RATED)

9.53/3.0 KG/CM2

LUBE OIL

VISCOSITY VG46

Booster Pump A 10-PA-CF 101A FLOW RATE 291.5 M3/HR

POWER 75 KW RPM 1488 RPM HEAD 65 M

IMPELLER SETTING FROM THE BOTTOM

3.14 MM

MAWP 50(711) KG/CM2(PSI)

HYDRO TEST PRESSURE

75(1050) KG/CM2(PSI)

STAGES 3 NO.

Booster Pump B 10-PA-CF 101B FLOW RATE 291.5 M3/HR

POWER 75 KW RPM 1488 RPM HEAD 65 M

IMPELLER SETTING FROM THE BOTTOM

3.14 MM

MAWP 50(711) KG/CM2(PSI)

HYDRO TEST PRESSURE

75(1050) KG/CM2(PSI)

STAGES 3 NO.

C.I. Dosing Pump A 10-PA-RP-104A

MAX. CAPACITY 5.5 LTR/HR

PRESSURE 8 KG/CM2

RATIO 30-1 -

C.I. Dosing Pump 10-PA-RP-104A MAX. CAPACITY 5.5 LTR/HR


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B

PRESSURE 8 KG/CM2 RATIO 30-1 -

SUMP PUMP COLUMN LENGTH 2900 MM DEL. PIPE SIZE 40 MM TOTAL HEAD 61.8 M SPEED 2920 RPM

DISCHARGE 5 M3/HR PUMP INPUT 7.64 KW IMPELLER DIA. 228 MM

D.G.SET 10-DG 001 RATING 77.3/105 KW/HP RPM 1500 RPM DISPLACEMENT 4160 CC

COMPRESSON

RATIO 17:01

WEIGHT 870 KG MAXIMUM TORQUE 50 KG-M BORE X STROKE 105X120 MM X MM

Basket Filter A 10-GN-BK-101A Hyd. Test Pressure 25 KG/CM2

Mesh 40

Max. Presure 3 to 4 KG/CM2

Basket Filter B 10-GN-BK-101B Hyd. Test Pressure 25 KG/CM2 Mesh 40

Max. Presure 3 to 4 KG/CM2

HOT Crane main Hoist Capacity 10 MT

Span 15 Mtrs

Highest position of

main Hook from Ground

7 Mtrs


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Type of Crane Double girder Class of Duty M5

Maximum lifting Pull at

Full Load 65 kg

Bay Length 35 Mtrs Gantry Rail Size 50 mm Weight Of The Crane 8000 kg


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EQUIPMENT AT IP STATIONS AND RT

Name of The Plant and Location : IP‐1,SEKONI IP‐2, NOONMATI IP‐3, BONGAIGAON IP‐4, MADARIHAT RT

EQUIPMENT SPECIFICATION

SLOP TRANSFER PUMP

Identification no

20‐PA‐RP‐102A 30‐PA‐RP‐102A 40‐PA‐RP‐102A 50‐PA‐RP‐102A

Model no WDD2000/52‐T WDD2000/52‐T WDD2000/52‐T WDD2000/52‐T

Manu Sl no 20365/07 20367/07 20369/07 20842/07

CAPACITY L/H 2500 2500 2500 2500

DISCHARGE PRESSURE

KG/CM2 64.3 54 37 19

Lubricant required

Servo System 320 Servo System 320 Servo System 320 Servo System 320

RPM RPM 1460 1460 1460 1460

Driver kw/hp 22 /30 22 /30 22 /30 22 /30

Stroke Stroke/min 100 100 100 100

SLOP TRANSFER PUMP

Identification no

20‐PA‐RP‐102B 30‐PA‐RP‐102B 40‐PA‐RP‐102B 50‐PA‐RP‐102B

Model no WDD2000/52‐T WDD2000/52‐T WDD2000/52‐T WDD2000/52‐T

Manu Sl no 20366/07 20368/07 20370/07 20843/07

CAPACITY L/H 2500 2500 2500 2500

DISCHARGE PRESSURE

KG/CM2 64.3 54 37 19

Lubricant Servo System 320 Servo System 320 Servo System 320 Servo System 320


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required

RPM RPM 1460 1460 1460 1460

Driver kw/hp 22 /30 22 /30 22 /30 22 /30

Stroke Stroke/min 100 100 100 100

SUMP PUMP

Identification no

20‐PA‐SM‐101 30‐PA‐SM‐101 40‐PA‐SM‐101 50‐PA‐SM‐101 60‐PA‐SM‐101

Model no CVE 32.250 CVE 32.250 CVE 32.250 CVE 32.250 KPDS 32/26

Manu Sl no 29170 29171 29172 29453 1670407009

FLOW RATE M3/HR 5 5 5 5 5

RPM RPM 2900 2900 2900 2900 2920

EFFICIENCY % 85 71 70 71 85

HEAD M 70 70 75 70 68.1

SLOP TRANSFER PUMP 40-PA-RP-102A MOTOR

Identification no

20‐PA‐SM‐101/M 30‐PA‐RP‐102A/M 40‐PA‐RP‐102A/M

50‐PA‐RP‐102A/M

Model no MD18L473 MD18L433 MD16L4/3 MD13M473

Manu Sl no M0704374 M0704377 M0702672 M0805332

KW KW 22 18.5 15 15

HP HP 30 25 20 20

RPM RPM 1460 1460 1450 1450

VOLTAGE V 415 415 415 415

CURRENT A 39.5 33.2 27.6 27.6

SLOP TRANSFER PUMP 40-PA-RP-

Identification no

20‐PA‐RP‐102B/M 30‐PA‐RP‐102B/M 40‐PA‐RP‐102B/M

50‐PA‐RP‐102B/M

Model no MD18L473 MD18L433 MD16L473 MD13M473

Manu Sl no M0704375 M0703736 M0702668 M0807351


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102B MOTOR KW KW 22 18.5 15 15

HP HP 30 25 20 20

RPM RPM 1460 1460 1450 1450

VOLTAGE V 415 415 415 415

CURRENT A 39.5 33.2 27.6 7.5‐10.0

SUMP PUMP MOTOR

Identification no

20‐PA‐SM‐101/M 30‐PA‐SM‐101/M 40‐PA‐SM‐101/M 50‐PA‐SM‐101/M 60‐PA‐SM‐101/M

Model no E132M E132M E132M1 E135M E160L

Manu Sl no BEG10F2DJ BEG104F2DJ BEG10F2DJ BEG120JQ KEG14110

KW KW 7.5 7.5 7.5 7.5 11

HP HP 10 10 10 10 15

RPM RPM 2865 2865 2865 2865 2920 EFFICIENCY % 85 85 85 85 85 VOLTS V 400±10 400±10 400±10 400±10 415

CID PUMP

Identification no

30‐PA‐RP‐103A

Model no WDD‐1125/08

Manu Sl no 20371/07

Stroke Stroke/min 100

CAPACITY L/H 5

DIFF HEAD MLc 65

DISC PRESSURE KG/CM2 65

CID PUMP Identification no

30‐PA‐RP‐103B


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Model no WDD‐1125/08

Manu Sl no 20372/07

Stroke Stroke/min 100

CAPACITY L/H 5

DIFF HEAD MLc 65

DISC PRESSURE KG/CM2 65

CID PUMP MOTOR

Identification no

30‐PA‐RP‐103B/M

Model no MD804A3

Manu Sl no M0702904

KW KW 0.37 HP HP 0.5

RPM RPM 1415 VOLTAGE V 415 CURRENT A 0.98

CID PUMP MOTOR

Identification no

30‐PA‐RP‐103A/M

Model no MD804A3

Manu Sl no M0702980

KW KW 0.37 HP HP 0.5

RPM RPM 1415 VOLTAGE V 415 CURRENT A 0.98


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OIP/NSPL-13

(OIL INDIA PIPELINE) NUMALIGARH-SILIGURI PRODUCT LINE

ROUTINE AND BREAKDOWN MAINTENANCE OF MAINLINE PUMPS

Pump Station No. NSPL_NDT Date : Running Hrs:--

Unit : Sr. No.__________ U/S Hrs :

Work Started on ............... at ......... Hrs Completed on ............. at ....... Hrs Work Done :

TEAM : 1. 2.

3. 4. Parts Replaced SL NO PART NO DESCRIPTION QUANTITY REMARKS

Distribution : 1. Maint. Base (PS3) 2. CEPL(M) 3. NSPL_NDT Maintenance In-charge (PS3)


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OIP/NSPL-14 OIL INDIA PIPELINE

NUMALIGARH-SILIGURI PRODUCT LINE

MONTHLY SUCTION STRAINER CLEANING &SHUT DOWN REPORT Pump Station No. NSPL/NDT &NT Month Ending JULY 2011 EQUIPMENT

DATE DPI TRH INBETWEEN LAST CLEANING

DAY IN BETWEEN LAST CLEANING

MLP-A NIL MLP-B

29.07.2011 0.39 KG/CM2 67 DAYS

BP-1 06.07.2011

0.06 KG/CM2 44 DAYS

BP-2 15.07.2011

0.07 KG/CM2 53 DAYS

BF-1

BF-2


Date ______________________





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NUMALIGARH-SILIGURI PRODUCT LINE

MONTHLY SHUT DOWN REPORT Pump Station No. NSPL/NDT &NT Month Ending 2011

MONTH START STOP

REASON Date Time Date Time

JUNE 13.06.2011 07:57 hrs 29.07.2011

11:50 hrs

Maintanance Work By OIL upto 29.07.2011 at 1300 hrs. Then due to shortage of products

at NRMT


Date ______________________





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OIP/NSPL – 16 OIL INDIA PIPELINE

NUMALIGARH-SILIGURI PRODUCT LINE MONTHLY PLANT RUNNING HOURS REPORT

Pump Station No. NSPL/NDT Month Ending 15th 201

Unit Serial No.

Maker’s No Monthly Running

Hours

Cumulative Running Hours

PUMP / ENGINE HOUSE MAIN LINE PUMP A 1 50279 MAIN LINE PUMP B 2 50280 BOOSTER PUMP HOUSE BOOSTER PUMP A 1 59674-1-1 BOOSTER PUMP B 2 59674-1-2 SUMP PUMP 1670407008 EMERGENCY GENERATOR NSPL/NDT

1 EOGC-65-344

EMERGENCY GENERATOR NT

2 03.1151/9800009

C I DOSING PUMP A 1 07017426 C I DOSING PUMP B 2 07017427


Date ______________________





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OIP 18

OIL INDIA LIMITED AUXILARY PLANT RECORD SHEET

Pump Station: NSPL- Dated : Unit : Serial No. Maker’s No: Running Hours : Work Done: (Report Replacement Parts used overleaf) Distribution : Original : Pump Station Duplicate : Base Triplicate : H.Q ________________________ Station Engineer In Charge

Page 1


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2.Replacement Parts Used :

__________________ ______

Page 2


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C.2.2 VALVE LUBRICATION INSPECTION: A. Scope and Objective: To outline safe and lubricating method for Ball valves and Plug

Valves throughout the stations, to ensure their being operative when required and to provide safe and properly operating valves for use during an emergency and during the course of normal operations

B. Lubrication of Ball valves and Plug Valve: All Ball valves and Plug valves shall be

lubricated every three months in conjunction with the three monthly valve inspection schedules. Valves of 200MM NB (8’’) and above, which are operated frequently, shall be lubricated as and when necessary but should not exceed one month between such lubrication.

C. Clearance from Master Control Station: Clearance is to be obtained from NSPL/MCS

before operation of valves at NDT,IP Stations,RT and SV Stations affecting mainline flow. After inspection, NSPL-MCS and HEAD(Pipeline -Operations) shall be notified of any abnormal operating condition.

D. Querterly Inspection: During the months of January,Apri, July and October of each

year all valves at NDT,IP Stations,RT and SV Stations shall be inspected and completely operated and returned to their original positions. During the operation of each valve, its operating condition is to be checked and corrections made where necessary. Such items, where applicable, as the condition of gears, gear lubrication, ease of operation, condition and position of indicator, water tightness of bevel casing gasket and seals around indicator etc. should be cheched.

E. Motorised Valves: Including the foregoing, all motorized valves at NDT,IP Stations,RT and SV Stations shall be electrically operated every month both locally and remotely and returned to their original position. During this check, the control board valve state indication lights should be watched to ensure correct indication is given. At six monthly intervals the insulation resistance of the actuator motors shall be measured.

F. Reporting: Form OIP/NSPL-19 shall be used to report the result of each of the valve

inspections outlined above.

G. Responsibility: The administration of the above tests and inspections is the responsibility of the Head Pipeline (Operation) and shall be coordinated by In-charges of NDT,IP Stations and RT.


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VALVE INSPECTION REPORT

NSPL--NDT,IP,RT and SV STATION _____________________ Valve No.

Type Size

Date this Inspection

Date last inspection

Operating Condition of Valve

I.R. if Motorised

Remarks

Good: Valve can be closed with minimum effort. Fair: Some friction present. Poor: Excessive effort need to close valve. Inspected by ___________________ Signedby____________________________ Station Engineer in Charge Chief Engineer Pipeline (Operations) Distribution (Check original and each copy): Original - Station Engineer in Charge Duplicate - Chief Engineer Pipeline (Operations)


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C.2.3 ELECTRICAL PLANT AND EQUIPMENT

A. Function and Scope – To ensure by regular preventive maintenance the operating efficiency to give uninterrupted service of all electrical plant and equipment and to ensure the safety against electrical shocks of operational and maintenance personnel.

B. Responsibility – In-Charge of NDT and Engineer(E&C)NT shall be responsible for

the operation and maintenance of electrical plant and equipment at NDT in co-ordination with In-Charge E&C Maintenance Base PS-3,while In-Charges of IPs and RT Stations shall be responsible for the operation and maintenance of electrical plant and equipment at IPs and RT in co-ordination with respective In-Charge E&C Maintenance Base. The officers responsible operation and maintenance of electrical plant and equipment shall also be responsible for strict observance of the Indian Electricity Rules. Chief Engineer Pipeline (Electrical and Cathodic) is professionally responsible for the installation and maintenance of electrical equipment on the entire pipeline and the enforcement of the Indian Electricity Rules and where applicable to hazardous area.

C. Isolation of Electrical Equipment - Except electrical maintenance base, the In-

Charges of respective stations shall ensure the isolation of electrical feeder through electrical Engineer/Supervisor in co-ordination with base to permit safe working on equipment connected thereto. This includes isolation and in case of earthing of the conductors on which work has to be carried out and issuing the clearance permit. The sign ‘‘DANGER MEN WORKING’’ must always be exhibited on electrical equipment isolated for maintenance.

D. Maintenance Reports - Check list for pump station (OIP/NSPL-21) will be

submitted monthly by the Superintending/Senior Engineer/ Engineer (Pump Station) and frequency of check i.e. weekly, monthly will be carried out as stipulated. All additional electrical maintenance will also be reported on these forms.

E. Plant Record Sheets – All rotating electrical plant and associated control gear will

be annually inspected and overhauled as necessary and data reported on the record sheet (OIP/NSPL-23). The responsibility for coordinating this is that of base Superintending/Senior Engineer / Engineer (Electrical and Cathodic) and such overhauls will be carried out by Base Electrical Maintenance crews under super vision of Base Superintending/Senior Engineer / Engineer (Electrical and Cathodic)

F. Earth Electrode - The resistance of all earth electrodes used for earthing of

electrical equipment and storage tank shall be tested semi-annually during February and August, and reported on OIP/NSPL-24.

G. Insulation Resistance Test of Electrical Equipment- At six monthly intervals the

insulation resistance of the Transformers , Motor & Actuator motors shall be measured. and reported on ELEC/NSPL-2

H. Breakdown Voltage of the Transformer Oil- Breakdown Voltage of the Transformer Oil shall be measured quarterly and reported on ELEC/NSPL-8


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I. Battery Maintenance/Inspection Report-The 110V battery bank (55 no of lead

acid cells) ,shall be inspected EVERY MONTH & specific gravity & voltage of each cell shall be measured and repoted on ELEC/NSPL-1. Same shall be carried out for 12v emergency generator(65KVA) battery

J. Safety – All Superintending Stations Engineers/Senior Engineers will familiarize themselves with treatment of electric shock by artificial respiration and will carry out regular training of station personnel I this respect. Proper Shock Treatment Chart will be displayed prominently in various locations of electrical installations. Schedule B-4.1 attached gives some common sense precautions on safety against electrical accidents and should be read in conjunction with the Indian Electricity Rules, a copy of which will be kept at each pump station.

SCHEDULE B3-1


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OIL INDIA PIPELINE ELECTRCAL SAFETY PRECAUTIONS

THESE NOTES ARE SUPPLEMENTARY TO THE AUTHORITY REGUALTIONS GOVERNING WORK ON ELCTRICAAL INSTALLATIONS

AND MUST BE READ IN CONJUNCTION WITH THE STATUTORY REGULATIONS.

ATTENTION IS DRAWN TO THE NECESSITY FOR PRECAUTIONS AGAINST

ACCIDENTS FROM ELECTRICAL APPARATUS AT ALL TIMES

REMEMBER

ELCTRICITY CAN KILL The following instructions are for compliance by all concerned. They are for your safety. Read them carefully and apply them with common sense

1. GENERAL SAFETY RULES

i) Be careful at all times - Personal caution and commonsense must be Applied along with the rules and safeguards. Be alert at all times and keep your kind on the job.

LEAVE NOTHING TO CHANCE

ii) Treat all electrical lines and apparatus as potentially lethal. iii) Observe all warning signs and danger notices. Do not remove any

“DANGER” signs, unless you are the person who has placed them in position.

iv) The “NO SMOKING” regulations must be rightly observed. v) On no account will any work be commenced until the Junior Engineer

(Electrical)/Electrician is issued with the ELECTRICAL CLEARANCE PERMIT (OIP-20).

vi) When working at a height always wear a safety belt and have lifeline secured as short as practical.

vii) Use only ladders in a good and clean condition. The rungs should be kept clean and free from oil, grease, mud, etc. When using a ladder, make sure it is firmly held until the top is secured into position.

viii) Under NO CIRCUMSTANCES will the Electrician/Lineman go up a pole or work on a line without having first getting clearance permit and putting on rubber gloves.

ix) Before proceeding with work to be carried out on lines the Junior Engineer/Electrician will test the lines by a Discharge Stick connecting it across earth and each line of the pole. When the lines have been tested, these will then be effectively short circuited with a piece of bare aluminum/copper wire connected to earth.

x) On completion of the work to be carried out the Electrical Supervisor will satisfy himself that the lines are clear and that all short circuiting wiring has been removed. This will be communicated in writing through clearance permit.


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xi) Use only the explosion proof type of portable light in flameproof areas. Ensure that the glass and guard etc. are in a clean perfect condition. Any defective vapour-proof gloves, fittings or other electrical equipments must be reported immediately. Such fittings must not be used until replaced or repaired.

xii) If whilst working you observe any electrical equipment that is unsafe or faulty, report the matter to the Electrical Engineer who should immediately inform the Station Engineer.

2. PRECAUTIONS AGAINST ACCIDENT

i) No work, alterations or repairs shall be carried out to an electrical Installation by any person other than an authorized Competent Personnel. The Station Engineer should satisfy himself that the Electrical Junior Engineer /Electricians have been issued with a Company electrical Authorisation Certificate issued on behalf of the Company by the Superintending Electrical Engineer.

ii) NO LIVE PARTS SHALL BE EXPOSED that can be touched by Persons not intended to have access to them. iii) NO REPAIR ON ANY PART OF ANY APPARATUS SHALL BE

CARRIED OUT WHILST LIVE. The works DANGER in 11 KV,6.6KV ,400V both in English and in the vernacular shall be fixed permanently in a conspicuous position, wherever possible, on every generator,panel,transformer and motor and regulating or controlling apparatus at this voltage.

iv) The frames of all generators, stationary motors and regulating or controlling apparatus connected with the supply, shall be earthed by two separate and distinct connections with earth. vi) Earth connections must be connected to the metal sheating or conduit of wiring, and normally also to the metal casing of all apparatus, motors and generators against the possibility of an insulation failure. vii) The Station Engineer shall ensure that all authorized persons employed on electrical work are acquainted with an able to apply the instructions for artificial respiration on persons suffering from electrical shocks. viii) Instructions for the rescue and restoration of persons suffering from Electric shock, both in English and the vernacular, shall be placed in conspicuous places in the Power House and Workshop Buildings. ix) Portable or Transportable Electrical Equipments: Portable or transportable electrical machines using 400 volts supply are inherently dangerous and should not be used unless absolutely Unavoidable. When they have to be used particular care must be taken to ensure continuity of earthing at all times.

X) Use of Electrical Extension Cables


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Before using electric extension cables inspect them to ensure good condition. Never wrap them around your arms and legs whilst carrying or holding them nor stand in water or allow the cable to pass through or lie in water when using them.

3. PROCEDURE FOR WORKING ON LINES AND EQUIPMENT i) The line or apparatus on which work is to be done must be made dead by opening all switches and isolators and removing all fuses so that should a Switch be accidentally closed while work is proceeding the line or apparatus will not become live. Notices “DANGER MEN WORKING” will be prominently placed on all switches opened and on the equipment on which work is to be done. ii) The Station Engineer will be responsible for ensuring that the precaution is taken before allowing work to be done on any line or apparatus. When the Station Engineer has satisfied himself by inspection that the precautions taken he will issue an ELECTRICAL CLEARANCE PERMIT (OIP/NSPL-20) TO THE JUNIOR Electrical Engineer / Electrician who will be carrying out the work. Under NO CIRCUMSTANCES will work be done on line or equipment before the ELECTRICAL CLEARANCE PERMIT (OIP/NSPL-20) ISSUED BY THE Station Engineer? iii) On completion of the work the Junior Electrical Engineer / Electrician will remove temporary shorting/earthing of the equipment return the ELECTRICAL CLEARANCE PERMIT (OIP/NSPL-20) to the Station Engineer who will again inspect and if satisfied that the work is satisfactorily completed and that no danger exists in making the line and equipment live, authorize the Junior Electrical Engineer /Electrician to restore power and to remove the DANGER MEN WORKING signs. iv) When work is to be done in Repeater Stations the Electrical Supervisor / Electrician in charge of the work will be responsible for taking the above precautions.

4. WORK IN FLAMEPROOF AREAS i) No non-flameproof apparatus may be used within 50 ft. of a flameproof area. ii) No work shall be carried out upon any apparatus or wiring nor shall be flameproof or explosion proof enclosure of any part of it be opened, until the apparatus or wiring has been made “dead”. Completely replaced to ensure its flame or explosion proof qualities. iii) It is not permissible, for effecting repairs on explosion proof qualities. iv) It is not permissible, fro effecting repairs or alterations, to use soldering apparatus or other means involving flame, heat or fire in any normally “DANGEROUS AREA”, unless such area is maintained to be ‘safe’ whilst the work is in progress. v) No electrical instrument such as a “Megger” or “Avometer” may be used in a flameproof area until certified “GAS FREE” by the Station Engineer.


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5. TREATMENT FOR ELECTRIC SHOCK

i) Removal from contact If the person is still in contact with the apparatus that has given him the shock, The rescuer should, if possible, stand on a wooden chair while removing the victim. If not pull him free by using a dry coat, dry rope, coconut matting or stick, preferably standing on a rubber mat or any other dry mat handy.

ii) Preliminary steps: Extinguish any sparks if the casualty’s clothes are smouldering, ascertain if he is still breathing and send for a doctor. If apparently not breathing, proceed as follows:

To revive Casualty: If there are any burns, avoid touching or making any contact with them if possible, and place the casualty so as not to bring pressure on them. First Motion – Expiration Kneel over the patient, ret the hands flat on the small of his back, let your Thumbs nearly touch, spread your fingers on each side over his lower ribs. Now lean firmly but gently forward over the patient, exerting a steady pressure downward. Second Motion – Inspiration Rock yourself gently backwards but do not remove your hands. Merely keep Them in a position for the next expiration pressure. Continue these two movements. The double movement should be gone through about fifteen times per minute.

The object is to keep expanding and contracting the patient’s lungs so as to Initiate slow breathing. Do not cease operations will natural breathing is re- established or the victim is declared dead by a qualified doctor. General: Be careful to avoid violent movement of the patient as injury of the internal Organs may result from excessive and sudden pressures. Upon Recovery Burn s, if serious, should be treated with the proper oil dressing. Avoid exposing the patient to cold, and administer no restoratives until the doctor arrives.

6. REPORTING OF ELECTRICAL ACCIDENTS: The Senior Electrical Inspectors of all states required that immediate attention of all Owners and occupiers of electrical installations is drawn to the provisions of Rules 29,32,36 and 38 of the Indian Electricity Rules, 1956, and also to Rule 136 in which the obligation and responsibilities for providing suitable appliances and connecting cables in good order have been imposed on the Management’s to ensure safety of the operators or users of such appliances for avoidance of possible electric accidents. The Indian Electricity Act, 1910, also makes it obligatory on the part of the Management, In the case of an accident, to report its occurrence to the State Senior electrical Inspector within 24 hours. A copy of the prescribed pro-forma is attached herewith.They are also required in such cases to produce before the electrical Inspector, who may be deputed for


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enquiry, such appliances, accessories or cables in the same condition as at the time of the accident, for examination and investigation. According to Rules 45 (1) of the India Electricity Rules, 1956, the electrical installation work, including additions, alterations, repairs and adjustments to existing installations, except such replacement of lamps, fans, fuses, switches, low voltage domestic appliances and fittings as in no way alters its capacity or character, is to be carried out upon the premises of or on behalf of any consumer or owner, for the purpose of supply to such consumer or owner, any licensed electrical contractor. The supply of electricity to low and medium voltage installations should be given after necessary test carried out under Rule 47 of the Indian Electricity Rules, 1956. For high voltage installations it is always Obligatory to obtain prior approval for the Electrical Inspectors before the connection is given. In case of Electrical Shock or any accident prevailing rules of the Company are to be followed.

OIP/NSPL – 20 OIL INDIA PIPELINE


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ELECTRICAL CLEARANCE PERMIT PART “A” To Superintending/Senior Engineer (Pump Station), Please isolate feeder supplying to enable the following work to be carried out Signature -------------------- Designation ------------------ Date ------------------------- PART “B” To ------------------------------------------------------ Please note that above feeder is dead and isolated, the fuses have been removed and a “DANGER” board placed on the isolator / switch fuse. The line has been grounded at both ends and is in a safe condition for work to be carried out. Signature ------------------- Designation ------------------ Date ------------------------ PART “C” To Superintending/Senior Engineer (Pump Station), Please note that work on the above feeder is completed and men and equipment are clear and the feeder may be switched on. Signature ----------------- Designation ------------------ Date ------------------------ PART “D” The above feeder energized at ------------------ Hrs Signature ------------------- Designation ------------------ Date ------------------------- OIP/NSPL-21 OIL INDIA PIPELINE


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ELECTRICAL MAINTENANCE REPORT – NSPL-………..

Pump Station _________________________ Date __________________________

1. Weekly Checklist: (a) All Transformers cleaned including cathodic transformer (b) Emergency generator started in the local position and run for one hour without load. (c) Battery Electrolyte level checked. (e) Battery connections checked. (f) Oil level in Transformer Main conservator tank checked. (g) Oil level in Transformer OLTC conservator tank checked. (h) Oil leakage checked. 2. Monthly Checklist: (a) All Transformers cleaned (b) Battery electrolyte level /specific gravity checked. (c) Oil level of Transformer Main conservator tank checked. (d) Oil level in Transformer OLTC conservator tank checked.. (e) Emergency generator started under a fault condition. (f) All earth connections of motors, transformers, panels, distribution board checked for tightness. (g) All electric motors cleaned. (h) All air conditioners checked and cleaned. (i) Switch gear panels cleaned and blown out. (j) Insulators & bushings checked for any cracks. (k) Condition of Silica Gel in the transformers checked 3. Additional maintenance carried out (Continue on reverse side)

_____________________________________________________________ ________________________________________________________________ ________________________________________________________________ Distribution: Original - Pump Station Duplicate - Maintenance Base Signed ________________________ Triplicate - H.Q. Station Engineer in Charge


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OIP/NSPL-23

OIL INDIA PIPELINE

ELECTRICAL PLANT REPORT – NSPL-……….

Station ______________________Equipment __________________________________ Serial No _______________ H.P/KW/KVA ______________ Rated Volt ____________ Rated Current.____________ Insulation Class__________Main SFU/ Fuse Rating______ Control Fuse Rating ________Control Voltage_______Contactor Coil Voltage__________Type of Protection (Relay) __________________________________ Setting ______________________________

Date Details of Maintenance Insulation Resistance Remarks

________________________________ Senior Engineer (Electrical & Cathodic)

Distribution: Original _ Maintenance Base Duplicate - H.Q.


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OIP/NSPL-24 OIL INDIA LTD (PIPE LINE)

EARTH ELECTRODE TEST REPORT STATION: NSPL-…………….

SL NO. LOCATION ELECTRODE

NO. DATE E.R IN

OHMS REMARKS DATE

E.R IN

OHMS REMARKS

1 SUB.

STATION (NSPL)

LEP-1

LEP-2

NEP-1

NEP-2

NEP-3

NEP-4

NEP-5

NEP-6

NEP-7

NEP-8

NEP-9

NEP-10

NEP-11

NEP-12

DGNEP-1

DGNEP-2

LEP-3

LEP-4

2

MAIN LINE PUMP

HOUSE (NSPL)

EP-7

LEP-14

LEP-15

LEP-16

3 SCRAPER RECEIVER

EP-6

LEP-5

LEP-6

4 CONTROL BUILDING

NSPL

LEP-7

LEP-8

LEP-9

LEP-10

IEP-1

IEP-2


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IEP-3

5

BOOSTER PUMP

HOUSE NSPL

LEP-11

LEP-12

LEP-13

6 NSPL

DESPATCH TERMINAL

EP-1 O

EP-3

EP-4

EP-5

7 SUMP TANK

EP-6 EP-7

8 NEAR

LOADING POINT

EP-8 EP-9

Checked By………………………… Signature ______________________ Designation ____________________ Distribution Date__________________________ * Original : Station -In- Charge * Duplicate: Base (E&C) * Triplicate: Sectional Head (E&C)-PHQ


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OIL INDIA LIMITED (PIPELINE)

ELECT / NSPL-2

Insulation Resistance Test of Electrical Equipment

Half-Yearly Test Records : April / November, 2011

Pump Station No : NSPL (NDT)

SL. No.

PARTICULARS IR VALUES DATE OF TEST

TEMP. REMARKS

TRANSFORMERS :

1 2500KVA, TR NO. 1 (11 /6.9 KV) HV-LV

2 2500KVA, TR NO. 1 (11 /6.9 KV) HV-E

3 2500KVA, TR NO. 1 (11 /6.9 KV) LV-E

4 2500KVA, TR NO. 2 (11 /6.9 KV) HV-LV

5 2500KVA, TR NO. 2 (11 /6.9 KV) HV-E

6 2500KVA, TR NO. 2 (11 /6.9 KV) LV-E

7 500KVA, TR NO. 1 (6.6KV /433V) HV-LV

8 500KVA, TR NO. 1 (6.6KV /433V) HV-E

9 500KVA, TR NO. 1 (6.6KV /433V) LV-E

10 500KVA, TR NO. 2 (6.6KV /433V) HV-LV

11 500KVA, TR NO. 2 (6.6KV /433V) HV-E

12 500KVA, TR NO. 2 (6.6KV /433V) LV-E

MOTORS :

1 Main line pump Motor-1

2 Main line pump Motor-2

3 Booster Motor-1

4 Booster Motor-2


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5 Dosing Motor-1

6 Dosing Motor-2

SL. No.

PARTICULARS IR VALUES DATE OF TEST

TEMP. REMARKS

7 Auxilary Oil pump Motor-1

8 Lub oil cooler fan-A for mainline pump-A

9 Lub oil cooler fan-B for mainline pump-A

10 Auxilary Oil pump Motor-2

11 Lub oil cooler fan-A for mainline pump-B

12 Lub oil cooler fan-B for mainline pump-B

13 Sump Tank Motor

Valve Actuators :

1 MS from tank

2 HSD from tank

3 SKO from tank

4 Boosterpump-1(Suction)

5 Boosterpump-1(Dicharge)

6 Boosterpump-2(Suction)

7 Boosterpump-2(Dicharge)

8 Busket filter-1(Inlet)

9 Busket filter-1(Outlet)

10 Busket filter-2(Inlet)

11 Busket filter-2(Outlet)

12 Flow meter-1(Inlet)

13 Flow meter-1(Outlet)

14 Flow meter-2(Inlet)

15 Flow meter-2(Outlet)


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16 Main line pump-1( Inlet)

17 Main line pump-1(Outlet)

18 Main line pump-2 (Inlet)

19 Main line pump-2(Outlet)

20 MOV after PCV

21 Scraper Barrel (at)

22 Station Outlet

Distribution :

o Original- Installation Manager Operation (NT) Signature ______________________

o Duplicate- Installation Manager (E&C) PS3 Designation ____________________

o Triplicate-Sectional Head (E&C),PHQ

Date__________________________


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OIL INDIA LIMITED

ELEC/NSPL-8 PIPELINE DEPARTMENT

ELECTRICAL & CATHODIC SECTION TRANSFORMER OIL TEST REPORT FOR

NSPL PUMP STATION (Numaligarh)

DATE TR NO. CAPACITY LOCATION GAP

BETWEEN ELECTRODE

BDV VALUE REMARKS

01.11.2011 12452/1 2500 KVA,11/6.9 KV

NO-1 NSPL PUMP

STATION 2.5 MM 51.6 KV

The test kit was programmed as per IEC 156 standard .The BDV value shown is the average value of 06 nos. of test in a sample with continous magnetic streeing .The first test was done after 5 min. of magnetic streeing and remaining tests were done after 2 min of magnetic streeing. BDV Test Kit (Make- Megger) Sl no. 58990350444

Distribution :

1. Original - Installation Manager Operation (NT) Signature…………

2. Duplicate- Installation Manager (E&C) PS-3 Designation………

3. Triplicate- Sectional Head (E&C),PHQ Date……………………………..


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OIL INDIA LIMITED

ELEC/NSPL-1 PIPELINE DEPARTMENT

BATTERY BANK MONTHLY RETURN

DATE CELL NO.

CELL VOLT

SPECIFIC GRAVITY

CELL NO. CELL VOLT SPECIFIC GRAVITY REMARKS

15.1

2.20

11

1

29 2

30

3

31 4

32

5

33 6

34

7

35 8

36

9

37 10

38

11

39 12

40

13

41 14

42

15

43 16

44

17

45 18

46

19

47 20

48

21

49 22

50

23

51 24

52

25

53 26

54

27

55 28

CHARGING CURRENT : …5 A……………… CHARGING RATE : FLOAT/BOOST

25 KVA EMERGENCY DG SETS BATTERIES ( NT ) Date : DEC--2011

BA

TT

ER

Y N

O-1

(4

38)

CELL NO.

CELL VOLT

SPECIFIC GRAVITY

BA

TT

ER

Y N

O-2

(4

21)

CELL NO. CELL VOLT SPECIFIC GRAVITY

1 1 2 2 3 3


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4 4 5 5 6 6

CHARGING CURRENT: …2.4 A……………… CHARGING RATE: LOW / HIGH

65 KVA EMERGENCY DG SETS BATTERY ( NSPL PUMP STATION ) Date : DEC-2011

BA

TT

ER

Y N

O-

(418

) S

/F

CELL NO. CELL VOLT SPECIFIC GRAVITY CHARGING CURRENT : AUTO CHARGING RATE :AUTO MODE

1

2

3

4

5

6

Concluded

Distribution :

o Original- Installation Manager Operation(NT) Signature ________________________

o Duplicate- Installation Manager (E&C) PS-3/PS-5/PS-8 Designation ______________________

o Triplicate-Sectional Head (E&C), PHQ Date____________________________


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C.2.4 COMMUNICATION EQUIPMENT A. FUNCTION AND SCOPE: To ensure the availability of the telecommunication system installed at the Pump/ IP and Repeater/SV stations along the pipeline at all times for the operation, maintenance and safety of the pipeline. The facilities and services include the following:

Optical fiber communication system Multiplexer system Party line Signaling System VHF Mobile system Facsimile System Electronic Exchange Internet and LAN IP Phone

B. Responsibility:Senior Engineer (Telecommunication)/Telecommunication Engineer at NDT, IP stations and Rangapani Terminal Station is locally responsible for the maintenance of all the telecommunication equipment of their respective Pump stations,IP Stations and the adjacent SV stations. In-Charge Engineers of Telecommunication maintenance Bases(PS-3, PS-5 and PS-8) are responsible for maintenance of the Communication system of the stations under PS-3, 5 and 8 base sectors respectively. Chief Engineer,Pipeline (Telecommunication) is professionally responsible for the maintenance of the Communication system and Services of the Pipeline and will report to HEAD(TTI & FC) who heads the Telecommunication Section of the Pipeline Department. C. General: 1. All equipment must be maintained precisely in accordance with maintenance procedures contained in various manufacturers’ handbooks, except where maintenance procedures have been subsequently modified by Telecommunications Engineering Circulars, issued by Chief Engineer Pipeline (Telecommunications). 2. For each individual unit of OFC Node a separate record sheet must be maintained. 3. The original copy of the record sheets for OFC, and multiplexing equipment should always be maintained at the equipment site, so that it can always be referred to. D. Daily Functional Tests (OIP-27): A functional test of all communication facilities terminating at PHQ will be conducted from HQ at the beginning of each working day. Telecommunication engineers resident at Pump Stations should at the same time locally conduct a functional test of all channels terminating at their stations and verbally report any defects to HQ. The duty Telecommunications Engineer at HQ and at respective Pump Stations will daily log such defects in OIP-27.


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E. O F C System: 1. Monthly report of OFC and multiplex equipment (OIP-28): The cause of communication failure and action taken should be summarized in form OIP-28. The repair work carried out and spare part holding and requirement should be briefly indicated. The outage of telephone channels and an error report should be separately indicated. 2. Inspection Report (OIP-29 and OIP29 A): LASER Power transmitted and received, various DC voltages and presence of any alarm on the individual modules of OFC and multiplex equipment should be noted clearly as per form OIP-29.The status of the battery charger with individual current to equipment and battery banks should also be noted. Optical fiber details, availability of Mobile, Engineering order wire, facsimile and partyline signaling systems should be shown as per this form. Status of ancillary communication equipments and instruments are recorded in OIP -29 A. These equipment include: LAN switch, media converter, router, VSAT Receiver, OTDR, GPS , Splicing machine, Laser source, Optical Power meter, SDH Analyser,BSNL Land lines, etc. 3. Routine check record sheet (OIP-30): All the communication and ancillary equipment are required to be checked fortnightly as per check list mentioned in form OIP-30. This equipment include Battery terminals, Electrolyte levels, mast lamps, connectors of MUX/Impedance converter, 0 db Connectors in FTB, OFC earthing connections, 48 VDC Surge Protector etc. Status of the battery (specific gravity/cell voltage) should be logged and condition of air-conditioners and exhaust fans to be indicated along with the action taken.


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OIP-28

OIL INDIA LTD (PIPELINE DEPT) Monthly Report Optical Communication System Date:_ Station:_ Month:_

A. Details of Optical Equipment Failure: Date Cause of Failure Action taken

B. General Remarks/Work Done:

C. Modules/Sub unit and spare parts requirements:

D. Spare module/sub units and parts available: (Annexure may be enclosed) ** As per list enclosed. Signature of Telecom In Charge: Designation:


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OIP: 28

VOICE AND DATA CHANNELS (E&M / E1) Date: Station: Month:

Channels

E&M / E1 (StnA/StnB)

Down Time

% Availability

Fault Details


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OIP-29 Oil India Limited (Pipeline Department)

Optical Communication System : Monthly Inspection Report Date: Station : Month: Station IP Addr: 1. Aggregate Cards:

Slot No Card Details Destination Station

Transmitted Power(dB)

Received Power (dB)

Alarm Indication

5 10

2. Other TJ100MC16 Optical Equipment Modules :

3. Power Filter Units: Slot No PFU 48V 12V Ripple Alarm Indication 16 PFU A 17 PFU B 4. Optical Link Availability:

Services Downtime % Availability Fault Details Optical Link

Ethernet Engineering O/W Voice /Data Ch

Slot No Card Name Status

“Card present” status in Slot View

Alarm Indication

Remarks

1 Adapter Card (ADP1) 2 Ethernet Card (TP01) 7 Cross-Connect Card(XCC128L) 8 Cross Connect Card(XCC128L)

13 E1/DS1 Interface Card(LA84) 15 Multi Function Card(MFC) 18 Fan Tray Unit (FTU4) 19 Fan Tray Unit (FTU4) 20 Fan Tray Unit (FTU4)


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OIP-29 5. Optical Link Details: Working Fiber Nos Avg. Fiber

length Faulty/High loss Fiber No(if any) Remarks

E A S T W E S T 6. Float –cum-Battery Charger:

Charger Voltage

C U R R E N T I N A M P E R E S Alarms

Total Equipment Battery1 Battery2

7. Party Line Signalling(PLS) :-

Date Down Time % Availability Fault Description

8. VHF Mobile Radio system (RBC40,Base Set,Mobile Set,Walkie Talkies): Date of mobile test:

9 .Fax :


10. Digital Orderwire / DTMF (Tummala) Telephone :


Signature of Telecom Incharge:



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Designation:

OIP-29A

Auxiliary Communications Eqpt Station:

Month: 1. Local Area Network(LAN) Elements:

2.V-SAT:

3. BSNL Landlines :

4. DID (BSNL) (for PS5 and PS8) :

5. MPLS and Transvirtual Internet (for PS5):

6. AP Communication ( for PS1):

7. IOC-GSPL Channels: (for PS5,PS6,PS7,PS8):

Signature of Telecom Incharge: Designation:

S No Elements Qty in LAN Status Faults during the month

1 8 port LAN Switch

2 24 port LAN Switch

3 Media Converter( MM )

4 Media Converter (SM)

5 Router

Module IP Address Ping status Whether synchronized Remarks

Satellite Receiver --- ---


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OIP-29A

Monthly Check-list for OFC Communications Station : Month :

1. ROW Patrolling Report :

2. NMS HMI (for PS5):

a. All Nodes reflected in NMS Fiber view (Y/N): b. Nodes Accessible through NMS (Y/N): c. Status of Trunk Ckts in NMS: d. Remarks:

3. SYNCHRONISATION:

a. Oscilloquartz PRC (Cesium Clock at PHQ): b. Clock Lock status at PS5(Please Tick) : Locked on GPS:

Locked on Auxiliary I/P: c. GPS Clock( For PS1,PS5,BPS): OK ʺ Alarm ʺ d. Timing reference locked to (Please tick): BITS PORT INTERNAL

4. Status of Optical Measuring Instruments:

S No Item Status Fault (if any) 1 OTDR 2 Local Croft Terminal 3 GPS receiver 4 Splicing machine 5 Optical Power meter 6 Laser source 7 SDH Analyser (PS3/5/8)

Signature of Telecom Incharge: Designation:


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OIP-30 OFC COMMUNICATION SYSTEM

INSPECTION REPORT A. Routine Check Station: Month:

S No Description Checked on (Date) Remarks (Show spares consumed)

1.

Battery Terminals

2.

Electrolytic levels a. Exch. Batteries b. PS/RS batteries

3.

Mast lamps

4.

Connectors of MUX /

75Ω-120Ω Impedance converter

5 .

0dB Connectors in FTB

6.

OFC Earthing

connections a) Earth Pit Terminal strip

b) Telecom Room

7.

48V DC Surge Protector

8.

MC16 Eqpt MCB

9. Others


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OIP-30 Date: Station :

Month :

A. Communication Battery Status:

Date Bank 1/13 2/14 3/15 4/16 5/17 6/18 7/19 8/20 9/21 10/22 11/23 12/24 Specific Gravity

I

II

Cell Voltage

I

II

B. Air Conditioners:

A/C Off Fan Low Cool High Cool Not Cooling A/C -1

A/C -2

C. Exhaust fans :

D. Action Taken on the above: Distribution: 1) Sectional Head(Telecom),PHQ Signature of Telecom Incharge: 2)Base Incharge: Designation: 3) File:

Fans Off Working Faulty Battery Room Charger Room


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C.2.5 TELEMETRY & SCADA

B. FUNCTION AND SCOPE: To ensure the availability of the Telemetry/Supervisory

Control and Data Acquisition (SCADA) System installed at NDT, IP Stations, SV Stations and Rangapani Terminal station along the Pipeline at all times for the operation ( monitoring and control of flow of product, Leak detection, Batch tracking and Pig tracking), maintenance and safety of the pipeline.

C. RESPONSIBILITY: Senior Engineer(Telecommunication)/Telecommunication engineer at NDT, IP Stations and Rangapani Terminal station is locally responsible for the maintenance of all the Telemetry equipment of the respective Pump station, IP Stations, Terminal Station and adjacent Sectionalising Valve stations. Deputy Chief Engineer Telecommunication (Instrumentation) at PS-5 is responsible for the maintenance of telemetry system of the respective IP Stations and Sectionalising Valve stations under PS-5 Base sector. Deputy Chief Engineer (Telecommunication) (PS-3 and PS-8) is responsible for the maintenance of the Telemetry System of Pump Station, IP Stations and Sectionalising Valve stations under PS-3 and PS-8 base sectors respectively. Rangapani Terminal is also under PS8 Base Telecom Incharge.Superintending Engineer (Telemetry) / Deputy Chief Engineer Pipeline (Telecommunication-Telemetry) is responsible for the maintenance of the Master Telemetry equipment at Master Control Station. Chief Engineer Pipeline (Telecommunication- Instrumentation & Telemetry) is professionally responsible for the telemetry System of the Pipeline. The Head of Telecommunication Section of the Pipeline Department is responsible for all the three sections of Telecom including Telemetry.

D. GENERAL

1. All equipment must be maintained precisely in accordance with laid down

maintenance procedures spelt out in manufacturers hand books, except where maintenance procedures have been subsequently modified by the competent authority through intra departmental note / Engineering circulars, issued by Chief Engineer Pipeline (Instrumentation & Telemetry). Preventive maintenance of the telemetry equipment will be carried out on the basis of test measurements and performances.

2. Weekly record sheets-Master Control Station: A record of all maintenance carried out on the Master Telemetry Equipment including the uninterrupted Power Supply system at the Master Control station at Pipeline Headquarter shall be recorded on OIP-33.

3. Weekly record sheets-Pump stations: Weekly tests will be conducted on the telemetry equipment at the Pump station, Rangapani Terminal and IP Stations by maintenance personnel of the Telecommunication Section and reported on Form OIP/NSPL/34A and submitted monthly in accordance with required distribution.

4. Weekly Record sheets-Sectionalising Valve Station : Functional test will be made on every maintenance visit to the SV stations by maintenance personnel of


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the Telecommunication section from controlling IP stations recorded on Form OIP/NSPL/35A and submitted monthly in accordance with required distribution.

5. Performance records: Telemetry outages of Discharge pump station, Sectionalising Valve station, Intermediate Pigging stations and Rangapani Terminal station will be recorded every day. Telemetry availability data of all these stations will be recorded along with total outage due to Telemetry equipment faults and outage due to faults other than Telemetry equipment and a monthly report shall be generated and distributed within the department. The availability will be calculated in accordance with the following formulae:

Percentage availability of NSPL = 100 – Percentage of outage Total Downtime in minutes = 100 - --------------------------------- * 100 Days in month*24*60*15 Where 15 is the number of stations in NSPL Product line Fault recording – A record of all faults reported will be kept in a log book at H.Q. Showing:

Nature of fault reported with time and date Nature of defect Action taken and spares used Date and time completed Name and signature

Note: Maintenance staff must always inform the NSPL Despatch Engineer at NDT on duty before putting any equipment on test affecting normal services.


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OIP-33 OIL INDIA LIMITED Page 1 PIPELINE DEPARTMENT TELEMETRY – RECORD SHEET

STATION : MASTER STATION (MCS) MONTH:__________________

DATE

UPS INPUT VOLTAGE AND CURRENT

PHASE - 1

PHASE - 2

PHASE - 3

UPS OUTPUT VOLTAGE AND CURRENT

SCADA SERVERS STATUS REMARKS

MCSAS1

MCSAS2

UDW1

UDW2

LDS

IDES

CONTROL DESK CRUDE PIPELINE PRODUCT PIPELINE MCSWS3 MCSWS4 MCSWS1 MCSWS2

CPU

MONITOR

KEY BOARD

MOUSE

JSB DEVICE

STATUS REMARKS

MIMIC

TERMINAL SERVER

LAN SWITCH

PCU

RSX SWITCH


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General remarks: Total down time of 14” sector = Percentage availability of 14” sector = Total down time of 16” sector = Percentage availability of 16” sector = Total down time of NSPL Telemetry = Percentage availability of NSPL Telemetry = Telemetry Repairs / Modification Carried Out: Distribution: Original – Equipment Duplicate – H.Q. Sr. Engineer (Telemetry) / Supdtg. Engineer (Telemetry) Date: ______________


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Page 2 TELEMETRY FAULT RECORD

DATE AND TIME REPORTED

NATURE OF FAULT DEFECT FOUND ACTION TAKEN (SPARES USED)

DATE/TIME COMPLETED


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OIP/NSPL/34A Page 1

OIL INDIA LIMITED PIPELINE DEPARTMENT TELEMETRY – RECORD SHEET NSPL / IP STATION :___________ MONTH:_______ RTU560C DATE INPUT VOLTAGE

230 VAC 48 VDC

OUTPUT VOLTAGE

24 VDC 5 VDC

RIPPLE LED STATUS AND ALARMS RTU 560 CPU Module- I

A L Err Tx Rx CE

A B

1 2

A B

1 2

A B

1 2

RTU 560 CPU Module - II (only for NDT & RT)

A L Err Tx Rx CE

A B

1 2

A B

1 2

A B

1 2

Equipment Status Remarks Media Converter LAN Switch Router Workstation 1

CPU Monitor Keyboard Mouse JSB Device

Workstation 2

CPU Monitor Keyboard Mouse JSB Device


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HMI status: General Remarks : Distribution: Original – Equipment Duplicate – Base Triplicate – PHQ. Telecom Engineer/Sr. Engineer(T)/Supdtg. Engineer (T) Date:


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Page 2

TELEMETRY FAULT RECORD


NATURE OF FAULT DEFECT FOUND

ACTION TAKEN

(SPARES USED)

DATE/TIME COMPLETED


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OIP/ NSPL/35A Page 1

OIL INDIA LIMITED PIPELINE DEPARTMENT TELEMETRY – RECORD SHEET SV STATION:___________ MONTH:_______

16 “ SECTOR 14 “ SECTOR

VISIT 1 2 3 DATE INPUT VOLTAGE

230 VAC 48 VDC

OUTPUT VOLTAGE

24 VDC 5 VDC

RIPPLE LED STATUS AND ALARMS CPU Module

A L Err Tx Rx CE

A B

1 2

A B

1 2

A B

1 2

LAN SWITCH

1 2 3 4 5 6 7 8

MODULE SLOT NO. LED STATUS 23 BE 23

23 BA 23

23 AE 21

General remarks : Telemetry repairs / modifications carried out : Distribution: Original – Equipment Duplicate – Base Triplicate – PHQ. Telecom Engineer/Sr. Engineer(T)/Supdtg. Engineer (T)


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Page 2

TELEMETRY FAULT RECORD


NATURE OF FAULT DEFECT FOUND ACTION TAKEN (SPARES USED)

DATE/TIME COMPLETED


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C.2.6 INSTRUMENTATION

A. FUNCTION AND SCOPE: To ensure the availability of the instrumentation system installed at Numaligarh Despatch Terminal (NDT), Intermediate Pigging (IP) stations and Sectionalising Valve (SV) Stations and Rangapni Terminal Station (RTS) along the pipeline at all times for the operation, maintenance and safety of the pipeline.

B. RESPONSIBILIY: Telecommunication Incharge at each station at Numaligarh Despatch Terminal and Intermediate Pigging stations is locally responsible for the maintenance of all the instrumentation equipment of the respective station and the adjacent SV stations. Telecommunication Incharge, PS-8 is responsible for the maintenance of all the instrumentation equipment of the RTS and SV 9. Deputy Chief Engineer, Telecommunication (Instrumentation) at PHQ is responsible for the maintenance of the instrumentation system of the Intermediate Pigging station and Sectionalising Valve Stations under PS-5 Base sector. Telecommunication Incharge (PS-3 and PS-8) are responsible for the maintenance of the instrumentation system of the Intermediate Pigging stations and Sectionalising Valve Stations under PS-3 and PS-8 base sectors respectively. Chief Engineer Pipeline (Instrumentation &Telemetry) is professionally responsible for the Instrumentation System of the pipeline and reports to the Head (TTI&FC) who heads the Telecommunication Section of the Pipeline Department.

C. GENERAL 1. All equipment must be maintained precisely in accordance with maintenance

procedures, contained in various manufacturers’ handbooks, except where maintenance procedures have been subsequently modified by Telecommunications Engineering Circulars, issued by Chief Engineer Pipeline (Instrumentation & Telemetry).All instruments, transducers, alarm devices etc. as appropriate should be cleaned, connections and fixings tightened moving parts lubricated and adjusted, oil level of immersed components checked and the equipment re- calibrated every four months.

2. Permission from oil movement-Maintenance staff must always inform the oil movement engineer on Duty (Duty Despatcher) before removing and instrument from service or calibration inputs. Controls will be tested when pumping conditions allow and only after permission has been obtained from the oil movement engineer on duty(duty despathcer)

3. Work Permit-“Cold Work Permit” shall be obtained from competent person/installation manager before commencement of removal, replacement and calibration of instruments at NDT,IP stations SV stations and RTS.

4. Instrument out of service-If any instrument and cable is taken out of service or not in operational use then it should be indicated clearly using labels marked as” NOT IN USE”/ ” OUT OF SERVICE” as applicable.

5. Daily maintenance log- Form OIP/NSPL/ 36 schedules daily maintenance and functioning of all the instruments installed in all Stations. Any discrepancy found shall be attended to and reported to base Telecommunication Incharge.


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6. Monthly Maintenance Report-

a) Form OIP/NSPL/37 schedules monthly routine maintenance to be carried out at Numaligarh Despatch Terminal, Intermediate Pigging stations and Sectionalising Valve Stations) and Rangapni Terminal Station in the form of a check list. Additionally a fault record is provided on the reverse for detailing any other unscheduled maintenance carried out during the month. At the end of every month the status of the serviceability of these instruments shall be recorded in form OIP/NSPL/37 and copies to be dispatched to Telecommunication Incharge of base and PHQ Instrumentation Section for record.

b) Indicating Instruments- All indicating instruments of the Numaligarh Despatch Terminal, Intermediate Pigging stations, Sectionalising Valve Stations and Rangapni Terminal Station shall be regularly checked for serviceability. Faulty gauges shall be repaired/ replaced. At the end of every month the status of the serviceability of these instruments shall be recorded in for OIP/NSPL/ 37.

7. Four Monthly Calibration Report- At the beginning of each four monthly period i.e. January/ May/September, Telecommunication Incharge of base should submit on forms OIP/NSPL/ 38 A, B, C and OIP/NSPL/39 A, B, C a summary of all alarm instrument and transducers checked and calibrated during the preceding period. The instruments should be listed in accordance with the instrument schedule for the relevant station.

8. Automation System at NDT /RTS- Local control system at NDT/RTs is PLC

based with signal flowing parallel to the SCADA / Telemetry. Instrumentation section is centrally responsible for the logistics support of functioning of the control system at both the stations with local responsibility lying on Telecommunication Incharge.

Form OIP/NSPL/37 A to be maintained monthly for PLC status and copies to be

dispatched to Telecommunication Incharge of base and PHQ Instrumentation Section for record.


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OIP/NSPL/36

Time: (1) Pressure Gauge:

Sl. No. Tag No

RangeKg/Cm2

Field Reading Kg/Cm2

Status

1

2

3

4

5


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(2) Pressure Transmitter:

Sl. No. Tag No Range Kg/Cm2

Field Reading Kg/Cm2

Reading PLC HMI (Kg/Cm2)

Reading SCADA HMI (Kg/Cm2) Status

1

2

3

4

5

6

7

8

9

6

7

8

9

10

11

12

13


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OIP/NSPL/ 36 OIL INDIA PIPELINE (NSPL)

PIPELINE DEPARTMENT INSTRUMENTATION DAILY LOG SHEET

STATION: Date (3) Density Transmitter:

Sl. No. Tag No SOLARTRON

Reading Reading PLC HMI

Reading SCADA HMI Status

1

2 (4) Pressure Control Valve:

Sl. No. Tag No Field Opening % PLC Opening

% Field Status Auto/Local

PLC Control Status

Auto/Manual

1

2

(5) Differential Pressure Transmitter:

(6) Temperature Transmitter:

Sl. No. Tag No

Range Kg/Cm2

Field Reading

Kg/Cm2 Reading PLC HMI (Kg/Cm2)

Reading SCADA HMI Kg/Cm2 Status

1

2

3

3

4 5

Sl. No. Tag No

Range oC

Field Reading

oC Reading

PLC HMI oC Reading SCADA HMI

oC Status

1

2

3

4 5


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OIP/NSPL/ 36 OIL INDIA PIPELINE (NSPL)

PIPELINE DEPARTMENT INSTRUMENTATION DAILY LOG SHEET

STATION: Date

(9) PLC STATUS: (10) General remarks/observation :

Signature of Telecom Incharge: Designation: JE (T) Date :

(7) Level Transmitter:

Sl. No. Tag No Field Reading

mm Reading PLC HMI

% / mm Reading SCADA HMI

mm Status

1

2

(8) Flow Computer:

Sl. No. Tag No OMNI Reading

M3/Hr Reading

PLC HMI (M3/Hr) Reading SCADA HMI

M3/Hr Status

1

2


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OIP/NSPL/ 37

OIL INDIA PIPELINE (NSPL) INSTRUMENTATION MONTHLY MAINTENANCE REPORT

DESPATCH, RECEIVING AND IP STATIONS

STATION: MONTH:

MAINTENANCE CHECKS: a. Pump House/ Booster House and Field junction box cleaned, terminals tightened. b. HI‐REL UPS Input / Output checked. c. 180 No’s Kirloskar B150S Battery Electrolyte checked, Sulphation removed . d. Indicating Gauges at Mainline Pump, Booster pump and field checked and cleaned. e. Lube Oil Skid gauges checked and cleaned. f. RTD taping points at mainline pump checked for leaks and tightened. g. SS piping /Instrument taping points checked for any leak.

1. SERVICEABILITY OF INDICATING INSTRUMENTS: Certified that all indicating gauges/ instruments except those listed below are in good working condition. 2. GENERAL REMARKS: Signature of Telecom Incharge: Designation: Date:


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OIP/NSPL/ 37

OIL INDIA PIPELINE (NSPL) INSTRUMENTATION MONTHLY MAINTENANCE REPORT

STATION: MONTH:

3. Fault Record:

Fault Reported

Time and

Date

Defect found

Corrective

action

Taken

Completed on

Time and date Signature

Signature of Telecom Incharge: Designation: Date:


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OIP/NSPL/ 37 A OIL INDIA PIPELINE (NSPL)

MONTHLY PLC –RECORD SHEET STATION: MONTH:

1. MAINTENANCE CHECKS:

CHECKED ON DATE:


of 205

PLC SYSTEM COMPONENT STATUS/OBSERVATION

Engineering Console: RSLogix 5000, RSView 32 Work

Operator Console: RSView 32 Runtime

CNH-Controlnet HMI

CNM-Controlnet Main

CNR-Controlnet Redundant

System Configuration Node No.

Components

11/13/15 1756PA75R 1756PA75R 1756PSCA 1756L55M16 1757SRM 1756CNBR 1756CNBR 1756CNBR

Status

12/14/16 1756PA75R 1756PA75R 1756PSCA 1756L55M16 1757SRM 1756CNBR 1756CNBR 1756CNBR

Status

10 1794ACNR15 IB16D IB16D OB16D OB16D MVI94MCM MVI94MCM ----

Status

9 1794ACNR15 IB16D IB16D OB16D OB16D MVI94MCM MVI94MCM OE4

Status

8 1794ACNR15 IE8 IE8 IE8 IE8 IE8 IE8

Status

7 1794ACNR15 IE8 IE8 IE8 IE8 IE8 IE8

Status

6 1794ACNR15 IB16D IB16D IB16D IB16D IB16D IB16D OB16D

Status

5 1794ACNR15 IB16D IB16D IB16D IB16D IB16D IB16D OB16D

Status

4 1794ACNR15 IB16D IB16D IB16D IB16D OB16D OB16D

Status

3 1794ACNR15 IB16D IB16D IB16D IB16D OB16D OB16D

Status


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MONTHLY PLC –RECORD SHEET STATION: MONTH:

2. GENERAL REMARKS / OBSERVATIONS:

3 . FAULT RECORD :

Fault Reported

Time and Date

Defect found Corrective action

taken

Completed on

Time and date

Signature

Signature of Telecom Incharge: Designation : Date:

System Configuration Node No.

Components

2 1794ACNR IB16D IB16D IB16D IB16D IB16D IB16D

1 1794ACNR IB16D IB16D IB16D IB16D IB16D IB16D


of 205


PIPELINE DEPARTMENT STATION: Date:

CALIBRATION REPORT FOR PRESSURE SWITCHES

INSTRUMENT DETAILS: TAG NO : SERVICE : MAKE : MODEL NO : SERIAL NO : CALIBRATION RANGE : ELECTRICAL RATING : SWITCH TYPE : SWITCH ACTION : MAX WORK PRESSURE : SWITCH SET VALUE : Rising / Falling ELECTRTICAL AREA CLASSIFICATION :

TEST EQUIPMENT USED: NAME : MAKE : MODEL NO : SERIAL NO : RANGE : ACCURACY : TEST CERTIFICATE : NO. & VALIDITY : POWER SUPPLY :

CALIBRATION RECORD:

SET VALUE OBSERVED READING REPEATIBLITY

ACTUAL Units:

SET Units:

RESET Units:

* Whether the Switch is finally set at the process set value as YES NO NA Per date sheet & the contact action checked at set value.

* Whether the accuracy / result of calibration meet the requirement. YES NO NA

REMARKS :

Calibration done & Report prepared by

Calibration Witnessed by Witnessed / Report Verified by

NAME:

SIGN:

DATE:


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OIP/NSPL/ 38 B OIL INDIA PIPELINE (NSPL)


CALIBRATION REPORT FOR LEVEL SWITCHES

INSTRUMENT DETAILS: TAG NO : SERVICE : MAKE : MODEL NO : SERIAL NO : ELECTRICAL RATING : SWITCH TYPE : SWITCH ACTION : SWITCH SET VALUE : Rising / Falling ELECTRTICAL AREA CLASSIFICATION : DEAD BAND :

TEST EQUIPMENT USED: NAME : MAKE : MODEL NO : SERIAL NO : RANGE : ACCURACY : TEST CERTIFICATE : NO. & VALIDITY : POWER SUPPLY :

CALIBRATION RECORD: 1. Calibration at Room Temperature C – C

DISTANCE SET VALUE OBSERVED READING REPEATIBILITY

SET RESET

Units: Units: Before Adjustment After Adjustment * Whether the Switch is finally set at the process set value as YES NO NA Per date sheet & the contact action checked at set value.

* Whether the accuracy / result of calibration meet the requirement. YES NO NA REMARKS: Calibration done & Report prepared by Calibration Witnessed by

Witnessed / Report Verified by

NAME:

SIGN:

DATE:


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OIP/NSPL/ 38 C OIL INDIA PIPELINE (NSPL)


CALIBRATION REPORT FOR SAFTEY RELIEF VALVES INSTRUMENT DETAILS:

TAG NO : SERVICE : MAKE : MODEL NO : SERIAL NO : CALIBRATION RANGE : INLET CONN. SPEC. : OUTLET CONN. SPEC. : MAX. WORKING PRESS : ACTUAL SET PRESS :

TEST EQUIPMANT USED: NAME : MAKE : MODEL NO : SERIAL NO : RANGE : ACCURACY : TEST CERTIFICATE : NO. & VALIDITY : BACK PRESSURE : RELIEVING TEMP. :

CALIBRATION RECORD:

Specified Cold Set Pressure

Popping Pressure

Reset Pressure % Error

Before

Adjust

Before

Adjust

Tightnest Test (Leakage Check) Unit: Bubbles / min.

Below Leak Test Testing Pressure: Unit : No Leak : Leak : Pilot Valve Test

Required Set Pressure Actual Set Pressure Result Remarks

*Whether the Valve is finally set at the process set value as per data sheet & the POP action checked at set value. YES NO NA * Whether the accuracy / result of calibration meet the requirement. YES NO NA REMARKS: Sealed after Test : YES No

Calibration done & Report prepared by Calibration Witnessed by Witnessed / Report Verified by

NAME:

SIGN:

DATE:


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OIP/NSPL/ 39 A:

OIL INDIA PIPELINE (NSPL) PIPELINE DEPARTMENT

STATION Date: CALIBRATION REPORT FOR DISPLACER TYPE LEVEL TRANSMITTER

INSTRUMENT DETAILS:

TAG NO : SERVICE : MAKE : MODEL NO : SERIAL NO : SUPPLY VOLTAGE : OUTPUT : CALIBRATION RANGE : SPECIFIC GRAVITY OF PROCESS FLUID : VALIDITY : ELECTRTICAL AREA CLASSIFICATION :

TEST EQUIPMENT USED: NAME : MAKE : MODEL NO : SERIAL NO : RANGE : ACCURACY : TEST CERTIFICATE : NO. & VALIDITY : SP. Gr. OF LIQ. USED :

CALIBRATION RECORD:

SL. No.

APPLIED INPUT TRANSMITTER OUTPUT ERROR ± % of FSD

% ACTUAL READING Units:

DESIRED READING Units:

ACTUAL READING Units:

1

INCREASING

0

2 25

3 50

4 75

5 100

6 DECREASING

75

7 50

8 25

9 0

* Whether any zero or span or linearity error adjusted during calibration. YES NO NA * Whether the accuracy/result of calibration meet the requirement. YES NO NA

REMARKS: Calibration done & Report prepared by Calibration Witnessed by Witnessed / Report Verified by NAME SIGN.

DATE:


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OIP/NSPL/ 39 B OIL INDIA PIPELINE (NSPL)

PIPELINE DEPARTMENT STATION: Date: CALIBRATION REPORT FOR TRANSMITTER (PRESSURE / TEMPERATURE)

INSTRUMENT DETAILS: TAG NO : SERVICE : MAKE : MODEL NO : SERIAL NO : SUPPLY VOLTAGE : OUTPUT : CALIBRATION RANGE : ACCEPTABLE TOLERANGE : VALIDITY : AREA CLASSIFICATION :

TEST EQUIPMENT USED: NAME : MAKE : MODEL NO : SERIAL NO : RANGE : ACCURACY : TEST CERTIFICATE : NO. & VALIDITY :

CALIBRATION RECORD: SL. No. APPLIED INPUT TRANSMITTER OUTPUT

ERROR ± % of FSD

% ACTUAL READING Units:

DESIRED READING Units: mA

ACTUAL READING Units: mA

1

INCREASING

0

2 25

3 50

4 75

5 100

6 DECREASING

75

7 50

8 25

9 0 * Whether any zero or span or linearity error adjusted during calibration. YES NO NA * Whether any zero elevation/suppression done during calibration. YES NO NA * Whether the accuracy/result of calibration meet the requirement. YES NO NA REMARKS:

Calibration done & Report prepared by Calibration Witnessed by Witnessed / Report Verified by NAME

SIGN.

DATE:


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* Whether the accuracy/result of calibration meet the requirement. YES NO NA REMARKS:

OIP/NSPL/ 39 C OIL INDIA PIPELINE (NSPL)


CALIBRATION REPORT FOR PRESSURE GAUGE

INSTRUMENT DETAILS: TAG NO : SERVICE : MAKE : MODEL NO : SERIAL NO : CALIBRATION RANGE : ACCEPTABLE TOLERANGE : VALIDITY : AREA CLASSIFICATION :

TEST EQUIPMENT USED: NAME : MAKE : MODEL NO : SERIAL NO : RANGE : ACCURACY : TEST CERTIFICATE : NO. & VALIDITY :

CALIBRATION RECORD:

SL. No.

APPLIED INPUT %

ACTUAL READING Units:

ERROR ± % of FSD

1

INCREASING

0

2 25

3 50

4 75

5 100

6 DECREASING

75

7 50

8 25

9 0

Calibration done & Report prepared by Calibration Witnessed by

Witnessed / Report Verified by

NAME

SIGN.

DATE:


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C.2.7 FIRE FIGHTING EQUIPMENT: A. Function and Objective: To maintain in a state of emergency preparedness all fire fighting equipment. To aid in achieving this standard, the inspection procedures as detailed below have been established. B.Weeky Fire Drill: In-Charges of NDT, IPs and RT shall hold weekly fire drills to train station personnel in the use of equipment and their specific tasks in the event of a fire emergency. The drill at NDT and RT shall be carried out in co-ordination with NRL authorities and at IP station the drill shall be combined with the weekly fire drill of the respective crude oil pump stations.

C. Fire Emergency Rooster: This rooster shall be drawn up by the In-Charges of NDT, IPs and RT and shall ensure that sufficient personnel are present on the station at all times to cope with a fire emergency. D. Inspection and Reporting: Apart from the physical check during the weekly Fire drill, equipment will be inspected as detailed below and reported on the fire fighting equipment report (OIP/NSPL-26 ). 1. Fire Extinguishers:

CO2 Extinguishers: The extinguishers, hose reel units and operating valves are to be checked quarterly, and contents of CO2 bottle checked by weighing annually. When loss of contents exceeds 10%, the bottle should be discharged and returned to Stores for re-filling. (Such discharging should be carried out during a fire drill as a training function.) After contents of a CO2 bottle have been checked, the inspection date should be updated on the bottle.

Mechanical and Chemical Foam Extinguishers: The extinguishers and the components are to be checked by inspection at three monthly intervals and replenished as required. The date should be embossed on the container after each inspection.

Dry Chemical Powder (DCP) Extinguishers: The extinguishers and their components are also to be checked quarterly. Contents (Powder) shall be checked for signs of caking and the CO2 cartidge to be checked by at three monthly intervals. The date should be embossed on the container after each inspection.

2. Foam Equipment: All fixed foam fire fighting equipment is to be checked quarterly, and the foam chemical tank checked for contents monthly. 3. Loose Equipment: All loose fire fighting equipment, i.e. hoses, masks, axes, etc, are to be physically checked during the weekly Fire Drill.


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OIP/NSPL-26

OIL INDIA PIPELINE

FIRE FIGHTING EQUIPMENT REPORT: Installation _________________________Date __________ Extinguisher Cyl. /

Ext. serial No.

Cyl. / Cart. Gross Wt. (gm/Kg.)

Cyl. / Cart. Tare Wt. (gm/Kg.)

CO2 Net Wt. (gm/Kg)

Date of weighing Location Type Capa

city

Quantity of Foam at Installation (In Liters) *Report Defects overleaf Station Engineer in Charge Distribution:

o Original - Installation o Duplicate - Head ( Pipeline Operations) o Triplicate - Chief Engineer Pipeline (Safety & Environment)

AUTOMATIC FIRE DETECTION CUM SUPPRESSION SYSTEM-NN100 SYSTEM: The automatic fire detection and suppression system at NDT and RT shall be maintained in full operating condition at all times. For this purpose, trained competent personnel shall perform the following periodical inspections and tests thoroughly. The results shall be recorded.If there is any defect or inferior function, it shall be corrected quickly.If there is any change in the hazard space occurs, proper corrective measures shall be taken. Monthly Inspection: Visual inspection shall be performed on the storage cylinder unit, the selector valve, the actuating cylinder, the piping, the 4mm in dia. Control line and the discharge nozzle. If there is any damage of the suppression system, proper corrective measures shall be taken.


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Quarterly Inspection: The storage cylinder pressure and the pilot cylinder pressure shall be checked every 3 months.The pressure gauge assembly attached to each storage cylinder shall be used for measuring the pressure of storage cylinder and pilot cylinder. If the pressure loss is more than 10% of the charge pressure, adjusted for the temperature, the cylinder shall be refilled. Semiannual (every 6 month) Inspection: In addition to the routine inspection every 3 months, the following test shall be carried out every 6 months. The operating tests of the cylinder valve solenoid, the pressure switch and the selector valve shall be performed. System Reset: Upon completion of the inspections and tests, the storage cylinder, the pilot cylinder and the actuating cylinder shall be returned to their original positions, the loop pipe and the sontrol pipe shall be connected, and the cylinder valve solenoid shall be fitted. Fitting of the releaser and connection of the control pipe to the storage cylinder, the pilot cylinder and the actuating cylinder shall be carefully performed. OIP is to be designed for AUTOMATIC FIRE DETECTION CUM SUPPRESSION SYSTEM-NN100 SYSTEM and inserted here:

System, Do’s & Don’ts for the NN 100 Fire Suppression System

System

1. If fire (smoke or heat) is detected/ sensed by any Single detector installed in each of the 03 protected rooms/zones i.e Control room, Telecom room & UPS room then Speaker with Strobe of the particular zone / room will be actuated. Further the information will be displayed in the Fire Alarm Panel (FAP) installed in the Control Room.

2. If fire (smoke or heat) is detected/sensed by double or more detectors (which is called cross zone) then Pre-Discharge Sounder of the particular zone / room will be actuated.

3. Nitrogen gas will be released after 23 seconds of the pre discharge sounder (with intermittent light flash) actuation. Hence, occupants of that room will have to evacuate the particular room with in 23 seconds.

4. If it is ascertained that the actuation of Pre discharge sounder is due to false detection then Manual Abort Button installed at left side wall of the entrance door of each of the protected rooms; may be used to stop the release of the gas. The Manual Abort Button shall be pressed/hold till the pre discharge sounder stops.

5. Further, if it is ascertained that there is indeed a fire and use of Manual Abort Button was a mistake and has resulted in bringing silence to the pre discharge sounder and the system needs to be re-activated, immediately. Then firstly, the FAP has to Re-


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Set and then the Manual Release button installed at left side wall of the entrance door of each of the protected rooms; may be used to release the Nitrogen gas / re-activate the system.

6. In case of failure of Auto fire suppression system during fire in a particular room;

a) The Nitrogen gas can be released by operating the Manual Release button installed on left side of entrance door of the protected room.

b) If still Nitrogen gas is not released then the system can be activated by pulling upward the Knob (white ball) of the Solenoid Valve (SOV) mounted on the top of CO2 cylinder for the particular room.

c) If still Nitrogen gas is not released then the system can be activated by two (02) nos. related actions i.e First open the Selector valve (SV) of the particular room (where fire has happened) and then pull the chain on the pilot cylinder and press the Knob on it.

7. When fire is extinguished & Nitrogen gas is completely released then change the selector switch for cylinder bank from Main Bank to Spare Bank and re-set the FAP.

Do’s

1. Ensure that the selector switch for cylinder bank is always in Main bank (not in spare bank).

2. Nitrogen gas will be released after 30 seconds of the pre discharge sounder (with intermittent light flash) actuation. Hence, Occupants of that room will have to evacuate the particular room with in 30 seconds. Please ensure that there is no person left inside the room.

3. If it is ascertained that actuation of Pre discharge sounder is due to false detection then Manual Abort Button installed on left side of entrance door in each of the protected rooms may be used to stop the release of the gas. The Manual Abort Button shall be pressed/hold till the pre discharge sounder stops.

4. Further, if it is ascertained that there is indeed a fire and use of Manual Abort Button was a mistake and has resulted in bringing silence to the pre discharge sounder and the system needs to be re-activated, immediately; Then firstly, the FAP has to Re-Set and then the Gas Release button installed on left side of entrance door in each of the protected rooms may be pushed/used to release the Nitrogen gas / activate the system. This action will re-start the pre discharge sounder and gas will be released after 30 seconds.

5. In case of failure of Auto fire suppression system during fire in a particular room;

a) The Nitrogen gas can be released by operating the Manual Release button installed on left side of entrance door of the protected room.

b) If still Nitrogen gas is not released then the system can be activated by pulling upward the Knob (white ball) of the Solenoid Valve (SOV) mounted on the top of CO2 cylinder for the particular room.

c) If still Nitrogen gas is not released then the system can be activated by 02 related actions i.e First open the Selector valve of the particular room (where


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fire has happened) and then pull the chain on the pilot cylinder and press the Knob on it.

6. When fire is extinguished & Nitrogen gas is completely released then :-

(a) Change the cylinder bank switch from Main Bank to Spare Bank.

(b) Ensure that the FAP shall be in Auto Mode (Not in Manual mode).

(c) Re-set the FAP and the system becomes healthy.

7. Arrange for refill of the empty storage, Pilot & CO2 cylinders.

(a) Before replacement of the empty cylinders with the filled cylinder; Please re-set the SOV mounted on the empty CO2 cylinder by using Re-Setting tool.

(b) Change the selector switch from Spare bank to Main Bank & again Re-Set the FAP.

8. Please be informed that the NN 100 system has been designed for Closed area hence, Please ensure that all the windows shall normally remain closed and the doors/entrance shall not remain in open condition. Also please ensure that the Window closing knobs/hooks shall be properly tightened.

9. For additional support and help, Please call the Fire Brigade.

10. It is advised to periodically clean the detectors & all the equipments of the system by deploying skilled persons.

11. Check the pressure of the Storage, Pilot & CO2 cylinders, periodically.

12. Observe on daily basis, the various indications on the FAP; If any fault is indicated in the FAP or detected in the system then please inform CEPL(S&E)/ DySE(FS) PHQ.

13. The healthiness of the system can be checked by doing mock testing periodically by using the following procedure:-

(a) Remove the SOV from the CO2, of any particular room. This is done to prevent the release of Nitrogen gas.

(b) Create false fire and get the detectors sense the smoke; in sequence i.e first by one detector & then by second detector, to achieve cross-zone.

(c) Pre discharge sounder will start and finally it will activate the SOV. The bullet on the SOV will be fired.

(d) This will prove the system is healthy and good in Auto Mode.

(e) Now re-set the SOV, install the SOV on the CO2 cylinder and then re-set the FAP.

14. Please periodically check the battery backup for the FAP; if required please replace it. Must be replaced at the end of 02 years from the date of manufacturing.

Don’ts

1. Do not use / store inflammable articles, articles etc. within the Control room, Telecom room & UPS room.


of 215

2. Do not smoke Cigarettes etc. within the protected area. Smoke if any, will be detected by fire sensors and will automatically activate the NN 100 System.

3. Do not panic if a fire is detected / fire alarm sounds / evacuation alarm sounds.

4. Do not tamper any parts of the fire Suppression System neither in the FAP, Protected rooms & the Cylinder Room.


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OIP/ NSPL-26A

PIPELINE DEPARTMENT

Automatic Fire Detection, Alarm and Suppression System Testing Record (NN 100)

Pump Station/ Repeater Station: (Name of Installation with location like Engine Room, Pump Room, Generator Room, Battery Room, Charger Room, etc.)

Sl. No.

Date of Inspection

Action Taken* Remarks* Sign. of the

personnel

Sign. of Installation

Manager


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*Note: Action taken to be recorded as tested/ repaired/ replaced the detectors, Control Panel, battery, etc. And remark to be recorded as OK or action needs to be taken if found defects. C.2.8 STATION HOUSE KEEPING: A. Function and Objective: Good house keeping is an important function of NDT, IP

stations, RT and SV station daily operations. The importance of this cannot be over-emphasised, since the overall efficiency of operations is closely connected thereto. The primary objective is to ensure that the stations are always maintained at a high standard of neatness and efficiency. A secondary objective of good house keeping is to present to the public an image of organization and an efficient company.

B. Scope: Good house keeping extends to all aspects of station activities, including general

tidiness of station and domestic areas, upkeep of roads, drains and buildings, cleanliness of plant and a shipshape approach to all maintenance in hand.

C. Painting and Redecoration: All installations shall be repainted/ redecorated every four

years in accordance with standard colours and approved colour codes.

D. Grass cutting: All immediate pump and repeater station area should have grassed area maintained in a closely clipped state. In stations having large areas of unutilized land within the perimeter, grass should be maintained in this condition to a distance of 6 meters from the boundary roads.

E. Responsibility: It is the responsibility of the In-Charges of NDT,IP Stations and RT to

ensure this high standard of house keeping at the pump and repeater stations under his control.


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Annexure-

LEGISLATIONS APPLICABLE TO NSPL OPERATIONS & MAINTENANCE

The Factory Act, 1948.

a) The Assam Factories Rules, 1950.

b) The West Bengal,

The Petroleum Act, 1934.

The Mines Act, 1952.

The Water (Prevention and Control of Pollution) Act, 1974.

The Water (Prevention and Control of Pollution) Rules, 1975.

The Water (Prevention and Control of Pollution) Cess Act 1977.

The Water (Water Prevention and Control of Pollution) Cess Rules, 1978.

The Air (Prevention and Control of Pollution) Act, 1981.

The Air (Prevention and Control of Pollution) Rules 1982 and 1983.

The Environment (Protection) Rules, 1986.

The Environment (Protection) Rules, 1986.

The Hazardous Wastes (Management and Handling) Rules, 1989.

Manufacture, Storage and Import, of Hazardous Chemical Rules, 1989.

The Public Liability Insurance Act 1991.

The Public Liability Insurance Rules 1991.

Environmental (Protection) Rules, 1992 and 1993 – “Environmental Statement”.

Environmental (Protection) Rules 1993 – “Environmental Standards”.

Environmental (Protection) Rules, 1994 – “Environmental Clearance”.

Batteries (Management and Handling) Rules, 2001¹².

Ozone Depleting Substances (Regulation and Control) Rules, 2000.


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Annexure-

NSPL ELEVATION PROFILE


of 220

Annexure-

NSPL ELEVATION PROFILE--Sectorwise


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NSPL ELEVATION PROFILE--Sectorwise


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Annexure-

TYPICAL HYDRAULIC GRADIENT LINE OF NSPL

In NSPL pipeline system there are two peaks. During pumping The back pressure at RT should be maintain in this way so that the Hydraulic Gradient Line is always maintained at a minimum of 10-20 m above the peak.


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Annexure-

M A IN L IN E PU M P

D EN SIT O M ET ERB O O STE R PU M P

S IL IG U R I C H A IN A G E - 660 km

IP-4 (M A D A RIH A T ) C H A IN A G E - 528 km

IP -3 (B O N G A IG A O N ) C H A IN A G E - 381 .7 km

IP-2 (N O O N M A T I) CH A IN A G E - 225.7 km IP-1 (SE K O N I)

C H A IN A G E - 84 .7 km N U M A L IG A R H C H A IN A G E - 0 .0 km

PR

OD

UC

T F

RO

M T

AN

KA

GE

TO

ST

OR

AG

E T

AN

K

PR

OD

UC

T D

IST

RIB

UT

ION

H

EA

DE

R

SE

CT

ION

HE

AD

ER

PRE SSU RE CO N TR O L V A L V E

PT

C O RR O SIO N IN H IB IT O R

ST O RA G E T A N K

C O RR O SIO N IN H IBITO RD O SIN G PU M P

M S

SK O

H S DD T

8

PIG L A U N CH ER

T U RB IN E M E TE R

FR O M D R A IN S

SU M P TA N K

SU M P PU M PT O RO A D T A N K E R FILL IN G

8

SU M P PU M P

FRO M D RA IN S

SU M P TA N K

SL O P T R A N SFE R PU M P

T O RO A D T A N K E R FILL IN GSU M P PU M P

SU M P TA N K

FRO M D RA IN S

T U R B IN E M E TE R

P IG L A U N C H E RPIG R E C E IV E R

88

PIG R E C E IV ER P IG L A U N C H E R

T U R B IN E M E T ER

FR O M D R A IN S

SU M P TA N K

SU M P PU M PT O RO A D T A N K E R FILL IN G


D O SIN G PU M PCO R R O SIO N IN H IB ITO R

STO R A G E TA N KC O R R O SIO N IN H IB IT O R


T O RO A D T A N K E R FILL IN GSU M P PU M P

SU M P TA N K

FRO M D R A IN S

TU R B IN E M ET ER

PIG LA U N CH ERPIG R EC E IV ER

88

PIG R E CE IV ER PIG L A U N CH E R

TU R BIN E M ET ER

FR O M D R A IN S

SU M P TA N K

SU M P PU M P

T O RO A D T A N K E R FILL IN G


PTPT

D EN SIT O M E TER

D T

D T

PIG R EC EIV E R

T O RO A D T A N K E R FILL IN G

PR E SSU R E CO N TR O L V A L V E

TO SL O P TA N K

SR V

T U R BIN E M ET ER

M ET ER PR O V ERFIX ED TY PE

D E N SITO M ETE R

SLO P

H SD

SK O

M S

FIG. PROCESS FLOW DIAGRAM


of 224

PROCESS MIMIC:NUMALIGARH DESPATCH TERMINAL

T1

T2

T3

T4

T5

T6

T7

T8

T9

P1

P2

CIT-1

DP1

DT1 F1

F2

S1

S2

B1

B2

ST1

SP1DP2

V1105V1107V1109V1111V1113V1115

V1106V1108V1110V1112V1114V1116

V1207

V1208V1209

PV1201B

PV1201A

V1202 V1201

V1204 V1203

V1103

V1102

V1101

SUMP TANK & PUMP

PUMP STATION REFINERY TERMINAL

TO IP-1(SEKONI)


of 225

PROCESS MIMIC: INTERMEDIATE PIGGING STATION

ST1

V1X15 V1X14

V1X13

SLP2

SLP1

V1X01V1X02

V1X03

SP1

SP1

V1X03

V1X02 V1X01

SLP1

SLP2

V1415

V1414V1413ST1

CIT-1

DP1

DP2

F1

F1

(FOR IP-1, IP-3, AND IP-4)

(FOR IP-2 ONLY)NOONMATI

FROM IP-1, SEKONI

IP-4,MADARIHAT

FROMDPS, NUMALIGARHIP-2, NOONMATIIP-3, BONGAIGAON

TOIP-2, NOONMATIIP-4,MADARIHATRT, SILIGURI

TO IP-3, BONGAIGAON

X= 3 FOR IP-1X= 5 FOR IP-3X= 6 FOR IP-4

X= 6 FOR IP-4X= 5 FOR IP-3X= 3 FOR IP-1


of 226

PROCESS MIMIC:SILIGURI RECEIVING TERMINAL STATION

T1

T2

T4

T3

T7

T8

T6

T5

T13

T14

T16

T15

T11

T12

T10

T9

V1704

V1705

V1706

V1707

V1708

V1716 V1714

V1715 V1713

F2

F1

V1702 V1710

V1711 V1709

S2

S1

SP1

ST1

V1701V1702

V1703

MARKETING TERMINAL


of 227

PRESSURE CONTROL VALVE

SUMP TANK

MAIN LINE PUMP

DENSITOMETERBOOSTER PUMP

NUMALIGARH CHAINAGE - 0.0 km

PR

OD

UC

T F

RO

M T

AN

KA

GE

SE

CT

ION

HE

AD

ER

PT

CORROSION INHIBITOR

STORAGE TANK

CORROSION INHIBITORDOSING PUMP

MS

SKO

HSDDT

PIG LAUNCHER

FROM DRAINS

SUMP PUMPTO ROAD TANKER FILLING

FLOW METER

8

NUMALIGARH DISPATCH TERMINAL


of 228

INTERMEDIATE PIGGING STATIONS (IP-1,IP-2,IP-3 & IP-4)

8FLOW METER

SLOP TRANSFER PUMP

TO ROAD TANKER FILLING

SUMP PUMP

SUMP TANK

FROM DRAINS

PIG LAUNCHERPIG RECEIVER


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SILIGURI DESPATCH TERMINAL

SUMP TANK

FROM DRAINS

SUMP PUMP

HSD

SLOP

DENSITOMETER

TO ROAD TANKER FILLING

PR

OD

UC

T D

IST

RIB

UT

ION

H

EA

DE

R

TO

ST

OR

AG

E T

AN

K

8

MS

SKO

FIXED TYPEMETER PROVER

FLOW METER

SRVTO SLOP TANK

PRESSURE CONTROL VALVE

PIG RECEIVER

DT

DENSITOMETER

PT PT

DT


of 230

FIRE RING MAIN OF NUMALIGARH DESPATCH TERMINAL

HOOK UP WITH NRL

HOOK UP WITH NRL

10” dia


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FIRE RING MAIN OF RANGAPANI RECEIPT TERMINAL

8” dia


of 232

FIRE RING MAIN OF IP STATIONS

NSPL OPERATION MANUAL - · PDF file(MS), High Speed Diesel ... Hydrotesting pressure : ... At...

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Transcript of NSPL OPERATION MANUAL - · PDF file(MS), High Speed Diesel ... Hydrotesting pressure : ... At...