Session 5 U K Dhoot

Pipeline Design and Construction Issues

U.K. DHOOT General manager (Projects-monitoring) IOCL (Pipelines Division) 18.2.2014

2

Vision Visionary Progress Strategic Vision & Long term Planning behind sound base and strong growth

1999

2009

Vision Formulated

New Shared Vision Formulated

A major, diversified, transnational, integrated energy company, with national leadership and a strong environment conscience, playing a national role in oil security & public distribution

Navratna Co. in 1997 Reconstituted Board started functioning in 1999

Maharatna Co. In May 2010 st st 1 Maharatna Board Meeting held in March, 2012

Objectives

4

Profile of Business

Turn over 2012-13 --- Rs. 414909 cr. (USD 76.2 billion)

As on 01.12.2013

Productivity - IndianOil Sales Th’put in (MT)

Th’put in (MT)

IBP

(2009)

(2008)

BRPL

AOD (1981)

Total Manpower

Th’put in (MT)

As on 31st March 13 6

Typical Mode-wise Transportation of Petroleum Products INDIA* Rail 30%

Road/ Coastal 31%

Pipelines 39%

* Source : PPAC

USA** Coastal 25%

Rail 3%

Road 4%

68%

Pipelines

** Source : Association of Oil Pipelines, 2006 http://www.aopl.org/posted/888/Shift_Report_1984_2004.126714.pdf

Modes for Transportation of Petroleum – A Comparison Head

Road

Rail

Pipeline

Energy cost

Very High

High

Low

Operating cost

Very High

High

Low

Pollution

High

Low

Nil

Movement congestion

High

Low

Nil

Handling loss

High

Low

Negligible

Safety Hazards

High

Low

Negligible

Reliability

Low

Low

100%

CONCEPT AND NEED FOR PIPELINES Identification

of Pipeline Crude/ Natural Gas/ LPG

Projects-Product,

Need and Justification Selection

of an available options.

alternative

from

different

FR/DFR preparation with cost Estimation and

Financial analysis Basic Design Detailed Design and Engineering 9

The Pipeline Design Philosophy

10

Hydraulic Design The hydraulic design is the process of Evaluating the physical characteristics of the product to be transported Quantities to be transported (MMTPA) The pipeline route and topography and the range of pressure (Head) Temperature and environmental conditions along the route.

Inputs Appropriate codes and standards. Projected Requirements.

Output Identify the number and location of pump stations with respect to the hydraulic design. Selection of the pipe type, material, diameter and thickness. .

11

Mechanical Design Governed by the codes and standards, experience in operating different pipeline system. Focus is on the selection of the pipe material and the specification of physical pipeline properties such as pipe diameter and wall thickness as required by the stress imposed on the system by the hydraulic and thermal conditions as well as structural loading. Other aspects of the mechanical design involves The type, size and power requirement of the pumps Other equipments or ancillary facilities required to meet the hydraulic – thermal design such as the support or burial requirement of the pipeline Development of piping and instrument diagram, layout, flexibility and surge analysis & related specification. 12

Operational Design This aspect of design takes in to consideration the day to day tasks of operating and maintaining the functional integrity of the system. These include: The necessary control system to operate the system within its design parameters and to promote safe and continuous operation. Methods to test the pipeline integrity. The preferred pipeline system for a given set of conditions is selected through an economic comparison of several systems, seeking to identify the system that yields the best economic return on the investment, depending on the initial and subsequent capital costs and the operating & maintenance costs for the economic life of the investment. 13

PIPELINE DESIGN PARAMETER REQUIRED Capacity of P/L (volume of flow/flow rate) For crude P/L system capacity is based on crude oil requirement of grassroots refinery/refinery augmentation For product P/L system capacity is based on DEMAND/SUPPLY analysis. Location of Pumping stations: Hydraulic considerations Location of Delivery/Terminal station crude oil pipeline system-Refinery location product pipeline system-As per demand projection (Generally for 10- 15 years) Pipeline Length Based on reconnaissance /detailed survey Elevation / Profile / Terrain Based on maps, reconnaissance/detailed route survey (preliminary analysis of alternative route is carried out, if required, and techno economically superior alternate is selected for detailed examination.) 14

PIPELINE DESIGN Residual Head Based on branch off /requirement at delivery station Fluid parameters specific gravity viscosity Friction loss To be calculated based on hydraulics/ type of fluid/profile Flow through Pipeline depends on fluid characteristics Viscosity specific gravity/density pour point vapor pressure Temperature compressibility Flow pattern Laminar Turbulent Transient 15

PIPELINE DESIGN No. of Pump Stations If SDH required > MAOP, more than one stations necessary. Depending on value of SDH / MAOP, determine number of stations. Minor variations could be taken care of by providing higher wall thickness and/or higher grade pipe. Adjustment may be required depending on location.

PIPELINE DESIGN No. of Pump Stations Case I : SDH < or = MAOP Case II : SDH > MAOP & < 2 MAOP i.e. SDH/MAOP between 1 & 2 Case III: SDH > 2 MAOP & < 3 MAOP i.e. SDH/MAOP between 2 & 3 SDH

Q3 Case III

Q2 Case II

Q1 Case I

Q3>Q2>Q1

Sample Hydraulics Calculations MAOP • Pipeline diameter (D)

-

8.625”

Wall thickness(t)

-

0.219”

Grade of pipe

-

API 5L-X46

Yield strength(s)

-

Factor of safety

-

46,000 psi

65%

Maximum Allowable Operating Pressure (MAOP) in psi =

(2x46000x0.219x0.65) / 8.625

=

1518 psi

=

106.7 kg/cm2

MAOP in mtr column of liquid (mcl) Water HSD

=

106.7 x 10 / 1.0

=

1067 mtr

=

106.7 x 10 / 0.85

=

1255 mtr

Sample Hydraulics Calculations • • • • • • • • • •

Th’put Operating hours Flow rate Length of pipeline Friction loss per km Friction loss for total length Elevation at A Elevation at B Residual head Total head required

1.1 MMTPA 8000 170 kL/hr 116 kms 9.22 mtrs 1070 mtrs 35 mtrs 50 mtrs 50 mtrs

1070 + (50-35) + 50 = 1135 mtrs Note: Total head required is less than the MAOP (1255 mcl). Therefore, no intermediate station is required.

PIPELINE DESIGN Nos. of Pump Stations - Adjustment for Peaks

Ground profile never uniform : peaks in-between.

Selected hydraulic gradient between end points may not cross the in-between peaks.

Minor variations could be corrected by using higher SDH in the same system with higher wall thickness and/or higher grade pipes.

Major variations may require addition of pump station.

Major Codes & Standards Used for Pipeline Design Sl. No

Standard

Description

Usages

1

ASME B31.3

Process piping

To Establish requirement for safe Design for station piping

2

ASME B 31.4

Pipeline Transportation To Establish Requirement System for Liquid for safe Design for cross Hydrocarbons and other country oil pipelines liquids

3

ASME B 31.8

Pipeline Transportation To Establish Requirement System for Liquid for safe Design for cross Hydrocarbons and other country gas pipelines liquids/ Gas pipelines

4

ASME B 16.10

Face to face and End to Pipeline valves end dimensions of valves


Standard

Description

Usages

5

ASME Sec VIII

Boiler and pressure vessel To Establish Requirement code for safe Design for pressure vessels (Barrel, sump tank etc)

6

API 5L

Specification for Line Pipes Mainline Pipes

7

API 610

Centrifugal Pumps for MLPU, BPU Petroleum, Petrochemical and Natural Gas Industries

8

API 650

Welded Steel Tanks for Oil Tanks Storage

9

API 1104

Welding of pipelines and Mainline welding related facilities

10

API 6D

Pipeline Transportation Valves System-Pipeline Valves


Standard

Description

Usages

11

API 600

Bolted bonnet steel gate Gate Valves valves for petroleum and Natural gas industries

12

API 602

Globe Steel gate, Globe and check Gate, valves for size 100mm and check valves smaller petroleum and Natural gas industries

13

ASTM A106 Gr.B

Standard specification for Station Pipes Seamless carbon steel pipes for high temperature service

14

ASTM A53 Gr.B

Specification for pipes, Station Pipes welded and seamless

15

IS 3589

Specifications for pipes for Pipes for fire water water service application

and

23


Std.

Description

Usages

16

OISD 118

Layouts for Oil & Gas Installation

F/F Facility

17

OISD 117

Fire Protection Facilities for Petroleum F/F Facility Depots, Terminals, Pipeline Installations and Lube Oil Installations

18

Material- ASTM A 234 WPB, MSS SP 75 Fittings WPHY 52,65 Dimension- ANSI 16.25, MSS SP75 Inspection – ANSI B16.9, MSS SP 75

19

Material- ASTM A 105, Flanges Mfg/Dimension- ANSI B16. 5, MSS SP 44, API 605

20

API 1589, API 1581

Separator Filter Elements

21

Material- ASTM A 216 WCB, Design- ANSI B16 104, ANSI B 16.5,

Valves 24


Standard

Description

Usages

22

IS 5120

Pump Design

Fire Fighting Pumping Units

23

API Standard 601

Metallic Gasket for Raised-Face Gaskets Pipe Flanges and Flanged Connections (Double-Jacketed Corrugated and spiral-wound)

24

API Standard 526

Flanged valves

25

API Standard 2510

Design and Construction of LPG installations

30

API 520/527/ ASME Section VIII

API standard 520, 526, 527 ASME section VIII

Steel

Pressure

Relief Relief Valves

TRVs

25

KEY ELEMENTS OF A GOOD SPECIFICATION • WORKABILITY • STRUCTURED & STANDRASIZED • WELL FORMATTED • SCOPE IS CLEARLY DEFINED & UNDERSTOOD BY SUPPLIER • REFERENCE TO APPLICABLE STANDARD • EASY TO PRICING • AVOID REPETITION

26

New Practices Adopted in IOCL Pipelines Use of Copper based IS 2062 Gr.C for Tank Roof in coastal region Use of Stringer ladder in tank with about 1’ gap between shell and

stringer plate to avoid corrosion between shell & stair Increased use of Ball valves instead of gate valves considering better

operation and maintenance flexibility Use of High pressure Reciprocating pumps for evacuating sump pump

product in intermediate pump station where residual inlet pressure is high Adopting Transmix tank(250 KL/500 KL) at all Terminal locations for

Interface splitting/accommodating excess Interface/Surge Use of Plug valves in Manifolds to ensure positive isolation and to

minimize interface during product changeover

New Practices adopted in IOCL Pipelines High

Integrity

Pressure

Protection

System(HIPPS)

for

surge

protection Mass flow meters in all stations. Dual Leak Detection System in Pipelines with independent server at

two locations- One acting as primary and other as secondary. Dual Master station for better monitoring and operation. OptoLink System for ensuring 100% Data/voice communication in

Pipeline system. Use of liquid mounted primary seal in tanks along with secondary

seal. Use of aluminum internal floating roof with

Typical Pump Station Equipments BOOSTER SECTION

STRAINER SECTION

FLOW METER

MASTER METER

TANKS

DENSITY METER

MAINLINE PUMPING SECTION

SUMP PUMP & TANK

MOV

PRESSURE/TEMPERATURE INSTRUMENTS

NRV HOV PIPELINE OPERATIONS THROUGH SCADA

SCRAPPER LAUNCHING BARRELTION

Mainline Pumping Units

30

Typical Delivery Station Equipments FCV

METERING

DENSITY MEAS.

S R VALVE

SRB

FROM PREV. STN

SUMP TANK & PUMP

MANIFOLD

FILTERATION

TANK FARM

Typical – Terminal Station

Madurai Terminal

Asanur TPoint

Trichy Terminal Chennai Pump station

Sankari Terminal

Pipeline System

Pipeline systems are the safest and the most environment friendly mode of transportation of crude petroleum, refined products and natural gas

Being a closed system, minimal handling and transit losses as compared to other means of transportation, hence most efficient

Safety & Reliability –minimum disruptions

Pipeline System

High Grade Steel Pipes (conforming to International Code API 5L) are used for constructing cross country Pipelines

The typical sizes of the Pipes are as under: Diameter : 4 inch – 56 inch Pipe thickness: 0.219 inch – 1 inch

Pipes are welded and inspected as per the most stringent international standards

Pipeline System The

flow in the pipeline is achieved using high capacity pumps (liquid lines) & compressors (gas lines).

The

normal flow in product pipeline is around 300-1000 KL/hr & for Crude Pipeline is around 1500-3400 KL/hr

The cross country pipelines are

designed to operate at very high pressures (upto 120 kg/cm2) to achieve throughput.

Pipeline System

To safeguard the Pipeline from external corrosion, the pipes are coated from the following type of materials

3LPE Three Layer Polyethylene 3LPP Three Layer Polypropylene DFBE - Dual Layer Fusion Bonded Epoxy Coal Tar Enamel

In addition to the anti-corrosion coating, the pipelines are also provided with custom designed Cathodic Protection systems

Challenges in Pipeline Projects Hostile Working Conditions

PIPELINES NO PICNIC An advertisement for Pipelines job, on 15th June 1942 Working and living conditions on this job are as different as those encountered on any construction job ever done in the united states or in foreign territory. Men hired for this job will be required to work and live under most extreme conditions imaginable. Temperature will range from 90 deg above zero to 70 deg below zero. Men will have to fight swamps, rivers, ice and cold. Mosquitoes, flies and gnats will not only be annoying but will cause bodily harm. If you are not prepared to work under these and similar conditions, do not apply.

Pipeline Route

Pipeline route is carefully selected to stay clear of inhabited areas

Pipeline route is selected to avoid reserved & protected forest area, wild life sanctuaries, water logged and marshy areas etc. to the maximum extent possible

Global Positioning System (GPS) based Geographical Information Systems (GIS) are also used for route selection and finalization

RIGHT OF WAY (ROW) 18 M strip of land (ROW –

Right of Way) acquired through 3(1) & 6(1) Gazette Notification of PMP Act for ROW

Notices served to individual

landowners for start construction activities

of

Land is restored and handed

over to owner. Owner continues to use the land for agriculture and other activities.

PIPELINE CONSTRUCTION

ROW Grading/Leveling

Trenching

Pipeline Construction

Pipelines are generally laid at a depth of 1- 2 M.

At locations where the pipelines cross Roads, Railway Lines and Rivers or water bodies the following special arrangements are made:

Pipeline is laid at greater depth Use of Heavy Pipes (Higher wall thickness) Casing Pipe for Road & Rail Xing Horizontal Directional Drilling for River Xing Concrete weight coating for crossing water bodies for anti-buoyancy


Transportation of Pre-coated Pipes to Site

String of Pipes in ROW


Welding of Pipes in Progress

Joint after Welding


Coating of the Welded Joint


Lowering of the Pipeline

ISSUES & CHALLENGES

ISSUES & CHALLENGES 1. ROW acquisition 2. Land Acquisition for Stations 3. Statutory clearances 4. Laying of Pipeline in Common RoW 5. Resource Mobilization by Contractors 6. Line Pipe Quality & Supply 7. Offshore Installations 8. Implementation of MB Lal Committee Recommendations 9. Socio-Political Scenario

LAYING OF PIPELINES : SUGGESTIONS o Pipeline industry to be declared as “Infrastructure Industry” o Single window clearance for various types of crossings by respective State Govt. o Speedy deputation of Competent Authorities (CA) by State Govt. o Appropriate amendment in P&MP Act 1962 for land compensation for obtaining RoU in land for laying of pipeline o Review of MB implementation

Lal

Committee

Recommendations

and

its

o Approach Govt. of India for developing ENERGY SUPER HIGH WAYS or UTILITY SUPER HIGH WAYS for laying the petroleum/gas pipelines o May form JVs with state governments for laying of pipelines

Oil Pipelines Network in India Jalandhar Ambala Roorkee Sangrur Najibabad Panipat Meerut Nahorkatiya Tinsukia Delhi Rewari Loni Sanganer MathuraShahjahanpurSiliguri Bongaigaon Digboi Ajmer Jodhpur Numaligarh Chaksu Tundla Lucknow Kanpur Guwahati Jagdishpur Kot Chittaurgarh Barauni Sidhpur Ahmedabad Rajbandh Kandla Ratlam Navagam Budge Mundra Jamnagar Maurigram Koyali Budge Indore Vadinar Dahej Ankleshwar Haldia Bhatinda

Hazira Mumbai High

Manmad

Mumbai Pune Secunderabad Uran Hazarwadi Pakni Mangalore

49

Vijayawada

Bangalore

Sankari Karur Coimbatore Kochi

Paradip Vizag

Chennai

Asanur Trichy Madurai

IOC’s Pipelines (Existing) Product Crude Oil IOC’s Pipelines (On-going) Product Crude Oil Other Companies’ Pipelines(Existing) Product Crude Oil LPG

Network of Gas Pipelines in India Tu rk-

Iran

Af g-P a

k-I

nd ia

NANGAL

Pip eli ne

BHATINDA

-Pa k-In dia Pip elin e

DELHI

BAREILLY

GURGAUN MATHANIA AGRA

AURAIYA LUCKNOW

DISPUR

JAGDISHPUR

DAHEJ 10 mmtpa*

BARMER

KANPUR

GWALIOR

KOTA MUNDRA 6.5 mmtpa

PATNA

PHOOLPUR

JHANSI

VARANASI

UJJAIN VIJAYPUR

RAJKOT

GAYA

AGARTALA

LNG

BOKARO

BHOPAL

Existing

AHMEDABAD

KOLKATA

HAZIRA 2.5 mmtpa

BARODA

DAMRA

SURAT

MUMBAI

DABHOL 5 mmtpa

Upcoming

CUTTACK

BHARUCH

BHUBANESHWAR

PUNE

Transmission Pipelines Existing

KRISHNAPATNAM

RAJAMUNDRY

SOLAPUR

GAIL’s Planned Pipeline RIL’s East West Pipeline RIL’s Planned Pipeline GSPC’s Planned Pipeline

KAKINADA HYDERABAD

KOLHAPUR

VIJAYAWADA

GOA NELLORE HASAN

BANGLORE

CHENNAI

TIRUCHCHIRAPALLI

KANJIKKOD

ENNORE 2.5 mmtpa

City Gas/ CNG Existing Planned LNG Terminal

COIMBTORE

50

KOCHI 5 mmtpa

TUTICORIN

Total Length = 11360 (Approx.)

Thank you

ISSUES & CHALLENGES

ISSUES & CHALLENGES Dadri Panipat Gas Pipeline

ISSUES & CHALLENGES Dadri Panipat Gas Pipeline

ISSUES & CHALLENGES Paradip-Raipur-Ranchi Pipeline

ISSUES & CHALLENGES 2. Land Acquisition for Stations a.

Acquired as per provisions of L&LA Act-1894 or through Direct Purchase

b.

Land is acquired for Pump stations, Booster Stations, Repeatercum-Cathodic Protection Station, Block valve locations

c.

Increasing awareness in land owners

d.

Phenomenal increase in land cost and usage

e.

Big

difference

in

cost

of

land

acquired

through

State

Government and prevailing market cost. f.

Agitation by land losers, demand for employment, demand for higher compensation over and above already paid through state administration and subsequent court cases

ISSUES & CHALLENGES 3. Statutory Clearances for linear projects a.

Various statutory clearances are required for setting up a cross country pipeline viz State Pollution Control Board, Environment & Forest clearance

b.

Amongst all statutory clearances, obtaining Forest clearance is very cumbersome process which may take about 18 to 24 months and in some cases over 30-36 months

c.

MoE&F, Delhi has recently eased some processes for obtaining forest clearance for linear projects. However, abnormal delay is still observed in completing the process and obtaining forest clearance due to linear nature of the project

d.

For obtaining Consent to Establish (CTE), different requirements are there for different states. No uniform process is followed

ISSUES & CHALLENGES 4. Laying of Pipeline in Common RoW a.

Normally, pipeline route selection is as “crow flies”.

b.

Competition amongst oil industries in picking lions share in this growing industry.

c.

RoW not shared by one company with other on the pretext of future pipelines of their own in the same RoW.

d.

Considering increasing difficulties in acquisition of RoW and anticipated growth of pipeline industry, Government of India to create

a

mechanism

through

MoP&NG

or

through

an

autonomous body of Oil Industry itself for sharing of RoW by different pipeline industries on agreed terms and conditions including technical and commercial conditions. This would help reduced maintenance cost of RoW, encroachment removal etc.

ISSUES & CHALLENGES 5. Resource Mobilization by Contractors a.

With growing pipeline industry, development of contractors and vendors is very important

b.

Specialized works like laying of pipeline across major water body through Horizontal Directional Drilling (HDD), Rim Seal Fire Protection System etc. - availability of less number of contractors

c.

New contractors take up jobs by quoting very competitively and agreeing to all terms and conditions, however, needs lot of hand holding during execution for ensuring cash flow, quality and timeliness of the project

d.

Resource deployment and finance management normally an issue with the contractors jeopardizing the targeted schedule of the project which may be due to their financial vulnerability or lack of understanding by their project manager

e.

Extensive care to be taken for choosing the right contractor for offshore jobs.

ISSUES & CHALLENGES 6. Line Pipe Supply & Quality a.

Line pipe cost forms major component of pipeline project cost

b.

Quality of line pipes is a must for ensuring safe and sustained operation

c.

Globally, line pipe specifications are developed on the basis of API 5L Standard

d.

Individual operator add specific requirement over and above API 5L

e.

IndianOil has customized specifications of various types of pipes e.g. High Frequency Electric Resistance Welded (HFERW), Submerged Arc Welded (SAW) and Seamless Pipes. (Continued)

ISSUES & CHALLENGES 6. Line Pipe Quality & Supply (Continued) f.

IOCL has elaborate scheme for qualifying pipe mill for sourcing of line pipes by undertaking visit of pipe mills by multi-disciplinary team of experts to observe performance of facilities installed in the pipe mill.

g.

For upgradation of such qualified pipe mills, re-qualification is done as per requirement

h.

Off late, pipe supply is getting affected due to deteriorating financial conditions of reputed suppliers thereby affecting project schedule adversely

ISSUES & CHALLENGES 7.

Offshore Installation - Problem Faced during SPM System Installation Work at Paradip - A CASE STUDY

• Heavy and complicated configuration of spools required not only air bag inflation but also main crane assist which has been greatly influenced by offshore weather condition. Further the complicated configuration also resulted in additional use of pulling wires and thus a lot of time was spent in preparation of rigging lines.

• The invisibility on the sea bed - Difficulties of diver operation, in addition to the inconvenience of monitoring diving works on the sea bed, making diving supervision in the diving control room ineffective.

• Rough weather accompanied by squalls, high sea swell, strong sea current made the process of installation all the more difficult coupled with the concern of safety in high seas of man, machine and material.

Integrated Offshore Crude Handling Facilities at Paradip Pipeline Laying and SPM Installation - Challenges

11


16


14

ISSUES & CHALLENGES 8.

M.B. Lal Committee Recommendations - Major Recommendations to be Complied during Project Implementation

Provision of Remote Operated Shut-off Valves (ROSOV) as tank body valve. Push buttons on the MOV should also be brought just outside the dyke Hydrocarbon (HC) detectors shall be installed near all potential leak sources of class ‘A’ and ‘B’ petroleum products e.g. tank dykes, tank manifolds, pump house manifolds, etc. Medium expansion foam generators shall be provided to arrest vapour cloud formation from spilled volatile hydrocarbons Remote operated long range foam monitors (1000 GPM and above) to fight tank fires shall be provided which should be of variable flow Buffer safety zone around the Petroleum Installations. A distance of 250 to 300 meters from the likely point of ignition is necessary to be kept clear.

ISSUES & CHALLENGES 8. M.B. Lal Committee Recommendations The fire water requirement for terminals shall be based on

two fire contingencies simultaneously as is the case in Refineries. The dyke volume has been revised to 110% of largest tank

in certain international standards. Incorporation of above broad recommendations along with other recommendations, shall affect project viability adversely. Presently IOCL (Pipelines Div) is spending about Rs. 900 Cr. on implementing new / upgraded provisions of revised OISD-117. Buffer zone of 250 – 300 meters around oil installation shall be the biggest hurdle.

ISSUES & CHALLENGES 9. Socio-Political Scenario a.

During opening of RoW for laying of pipeline, many interferences are faced in terms of demand for higher land compensation over and above provided as per P&MP Act-1962, issues not related to particular project, different local groups of muscle men operating en route pipeline demanding money.

b.

At times, land compensation do not go to correct land owners inspite of best possible mechanism for tracing the right owners.

c.

Increasing court cases on compensation issue

d.

Demanding higher compensations.

e.

Expectations of locals for permanent employment duly supported by conflicting active groups at local level

crop

compensation,

presumptive

crop

Kochi-Bangalore Gas Pipeline of GAIL

Kochi-Bangalore Gas Pipeline of GAIL

Clearances / Permissions during Construction Acquisition of ROU in land under P&MP Act ’1962 Private land CA and MoP&NG , GOI Permission to lay pipeline in From District Collector Govt. land Defense clearance for laying Ministry of Defence, GOI the pipeline in their land Clearance from authorities for Concerned authorities way leave charges (Port authorities, Railway, Development authority etc.) To lay pipeline in Air port area

National Airports Authority of India

Clearances / Permissions during Construction Allotment of land Allotment of land/ shed in Concerned Industrial industrial Areas Development Authority Allotment Land

of

Government District Collector office

Acquisition of land

District Collector/State Govt.

Conversion of Land use to District Collector office None Agriculture purposes Change in land use in urban Town Planning Department areas

Clearances / Permissions during Construction Approval of building plan Approval of building plans in Concerned Industrial areas Development Authority.

Industrial

Approval of building plans in Local Authorities other areas Others Water Cess

Power supply

Central Ground Water Authority / Concerned state Govt. authority State Electricity Board

NOC for VHF communication

Clearance from WPC

Clearances / Permissions during Construction Prior to Commissioning NOC from District Collector for District collector operation of installation. No Objection’ from district Fire Fire Services Department Department Registration as a Factory Consent

to

operate

Chief Inspector of Factories under State Pollution Control Board

Water and Air Approval for commissioning of CCE, new facilities (project). Clearance inspector

from

Petroleum

&

Explosive

safety Org.

electrical HT – CEA ; LT – Elect Inspector

MAINLINE PUMPING UNIT

MAIN LINE PUMP WITH SUCTION / DISCHARGE ARMS

FIRE WALL

GEAR BOX

M/L ENGINE

MAINLINE ENGINE AUXILIARIES

FUEL OIL DAILY SERVICE TANK

EXHAUST SILENCER

RADIATOR ASSEMBLY

SCRAPPER LAUNCHING BARREL

SCRAPPER RECEIVING BARREL

SCRAPPER BARRELS

TYPICAL PIPE CONNECTIONS

TRV PI PS/P T

BASKET STRAINER WITH ISOLATING MOV’S

‘Y’ TYPE STRAINER

U/S FLOW STRAIGHTENER

INSTALLATION OF TURBINE METER

D/S FLOW STRAIGHTENER

Supply Chain

Crude evaluation & Procurement ?

Demand Forecast ?

What and How to Feed ?

Distribution Planning ?

What & Where To Make ?

What & where to Store and from where ?

Introduction of Pipelines in Oil Transportation The

first cross country oil pipeline was laid in Pennsylvania (USA) in 1879 from Bradford to Allen town, about 109 miles long and 6” in diameter

In India after 1960, most of the refineries were installed in

land-locked locations and then crude / product pipelines were laid. During 1960-63, Oil India Limited laid the first trunk crude

oil pipeline, 1156 km long from Naharkatiya and Moran oil fields to the refineries at Guwahati and Barauni The first cross country product pipeline was laid by IOCL

during 1962-64 to transport products from Guwahati refinery to Siliguri Pipeline

industry has grown development of oil industry

in

parallel

with

the

Transportation ofPetroleum Petroleum Transportation of Products (Tentative Projections) Products (Tentative Projections) Present Transport Modal-Mix (2010-11)

Projected Transport Modal-Mix (2030-31)

PRODUCT PIPELINES- PRESENT SCENARIO

*Source : IPR 2010-11

IOCL leads the industry with 46% share in Pipeline capacity.

Advantages of Pipeline Transportation

Lower cost of transportation Lower transit losses Energy efficient Economies of scale Safety & Reliability- minimum disruptions Environment friendly

Multi-product handling

Stationary carrier

Augmentation at low cost

Minimal land costs

Decongestion of surface transport systems Pipelines are the best suited mode for transportation of large volumes of petroleum over long leads.

Pipeline Transportation of Liquid Petroleum Scenario in India

Indian

oil

industry

has

around

five

decades

of

experience in transportation of crude oil and finished petroleum products through pipelines

The crude oil pipelines transport waxy crude as well as low sulphur & high sulphur crude

Liquid Product Pipelines transport various products viz. MS, HSD, SKO & ATF in multi-product pipelines

LPG is also transported through dedicated pipelines

Pipeline Project Management –Key Issues A. Route Selection & ROW Acquisition a)

Route survey - Reki

b)

Detailed Route survey

c)

Cadastral survey

d)

3(1) schedule publication

e)

Hearing

f)

6(1) publication

g)

ROW acquisition

h)

Land compensation and Crop Compensation payments

Pipeline Project Management –Key Issues

B. Land acquisition- P/Station, RCP & Valve Location a)

Identification of land for Stations and RCPs

b)

Acquisition of land through Government

c)

Private land purchase through committee

Development of Pipelines in India The first cross country product pipeline was laid by IOCL during 1962-64 to transport products from Guwahati refinery to Siliguri. Subsequently, number of product and crude oil pipelines were laid in the 60’s, 70’s and 80’s, including sub-sea crude oil pipelines. The pipelines laid during the 60’s were designed, engineered and constructed by foreign companies. However, the exposure to this technology enabled Indian engineers to gain confidence, and the pipelines which came up later, were designed and constructed with indigenous expertise. IndianOil today has 10,909 km of crude oil and product & gas pipelines.


Pre-construction activities involve : Conducting

engineering & cadastral survey for route finalisation, alignment checking , collection of details in respect of various crossings and for collection of village maps .

Marking of P/L route and width of ROW on village maps Extraction of plot-wise area within ROW and Consolidation of list of plot nos. & respective area village-

wise in sequential manner. Segregation of private land from Govt. land and public

bodies


to list out names & addresses of all affected landowners as per state Revenue records/ maps

to assess amount of compensation towards ROW acquisition and

to assess amount of compensation towards standing crop, trees etc. required to be paid at the time of taking of ROW and of presumptive crops during PL laying .

Many of the times farmers show reluctance to surveyor’s entry to their farms to undertake engineering survey.

Retrieval of land records from government offices is time consuming and old government land records, prepared without advanced technological aids, have problems of updation.

required to be paid


Difficulty in establishing ownership due to inaccuracies in govt records

Inadequacy of land compensation payable as per P&MP Act, 1962.

Litigations

Volatile socio-political situation

Law & Order issues

Rapid urbanisation and growth of industry clusters around towns.


For ROW acquisition ( under P&MP ACT,1962)

Request required to be made for services of state govt. revenue personnel on deputation to serve as Competent Authority (C.A) and other sub-ordinate staff to assist him

To engage retired revenue officials if govt. officials are found not spareable on deputation.

Upon joining, to notify in central gazette regarding declaration of “ C.A” u/s 1 of P&MP ACT- for dealing with cases related to land and further notifications etc. Enough time elapses for positioning of C.A for the job.


Procurement of Land for Pumping/ Delivery stations : By Direct purchase from Private parties (Normally no such

big plot suitable for pumping/ delivery stations, owned by single person is available) By Transfer of Govt. land (Availability is less for such

suitable big plot) By Govt. acquisition as per Land Acquisition Act, 1894.


Application to concerned State Govt. along with land details

all the

Recommendation from the Collector

Notification under LA Act & Filing / Hearing of objections/inviting claims

Order for Acquisition , marking & measurement

Procurement of land through Govt, acquisition is very much time consuming.


Statutory Clearances

CCoE Clearance

Consent to Establish (CTE) from respective Pollution Control Boards

Environment & Forest Clearances from MoE&F

NOC from National Highway Authorities

Railway crossing Permissions

Clearances for Water Bodies

CRZ clearances (wherever required)

Piping Pressure Rating CLASS RATING

WORKING PRESSURE(PSI)

WORKING PRESSURE(KG/CM2)

150

275

19.34

300

720

50.63

400

960

67.51

600

1440

101.26

900

2160

151.89

1500

3600

253.16

SPM System – General Arrangement

25 February 2014 100

Commonly used ASME standards

ASME B3 1.3, Process Piping.

ASME B31.4, Liquid Transportation Systems for Hydrocarbons, Liquid Petroleum Gas, Anhydrous Ammonia, and Alcohol.

ASME B31.8, Gas Transmission and Distribution Piping Systems.

ASME Section VIII,Div-I & II

B16.5, Pipe Flanges and Flanged Fittings.

B 16.47, for Pipe flanges larger than 24”.

B16.9, Butt welded Fittings.

B16.11, Forged Steel Fittings, Socket-Welding and Threaded.

B16.20, Metallic Gaskets for Pipe Flanges-Ring Joint, Spiral-Wound, and Jacketed.

B16.25, Butt Welding Ends.

B16.28, Wrought Steel, Butt Welding, Short Radius Elbows and Returns.

B16.34, Valves-Flanged, Threaded, and Welding End.

B36.10M, Welded and Seamless Wrought Steel Pipe.

Commonly used API standards API 5L-Line pipe API 610 – Centrifugal pumps API 1104-Welding of Pipeline and related Facilities API 6D-Pipeline valves API 1581-ATF Seperator filters API 1590- Micron filters API 526-Flanged Steel Pressure Relief valves API 600-Steel Gate, Globe and check valves 4” & larger API 602- Steel Gate, Globe and Check Valves for sizes DN

100 and smaller API 2510-Design and Construction of LPG installations API 520-Sizing, selection & installation of TRVs

Commonly used other standards ASTM 53/106 – Carbon steel pipes BS 5352 – Ball valves BS 1868 – Swing check valves BS 1873 – Globe valve ASTM A537 – Carbon steel plates IS 2062 – Carbon Steel plates MSS-SP-97 – Weld-o-let NACE RP 394- For Fusion bonded epoxy

coating DIN 30670- For Polyethylene coating for pipe and fittings ASME SEC IX – for Welding Procedure Qualification & Welder Qualification

Commonly used OISD standards OISD 118-Layouts for Oil & Gas Installation OISD117-Fire Protection Facilities for Petroleum

Depots, Terminals, Pipeline Installations and Lube Oil Installations OISD 141-Design and construction requirements for cross country Hydrocarbon pipelines OISD 214-Cross Country LPG Pipelines OISD 226 – Natural gas Transmission pipelines OISD 138 – Inspection for cross country pipelines

Relevant codes and standards •ASME 31.4/31.8 •OISD 118 •OISD 117 •OISD 141 •Electrical Standards

Station Equipments – Mechanical, Electrical and T&I

105

Session 5 U K Dhoot

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