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JLPL INTEGRITY MANAGEMENT SYSTEM AND MAINTENANCE MANUAL DOCUMENT No. : JLPL/IMS/JMM

Section-01 TABLE OF CONTENT

SL. NO. CONTENTS PAGE NO.

1.0 Integrity management system for JLPL 3

1.1 Introduction & definitions as referred in this document 31.2 Scope 41.3 Integrity management system of JLPL 41.4 Requirement under other statutes 41.5 Integrity management system for LPG pipelines 42.0 Introduction to the integrity management system (IMS) 53.0 Description of JLPL system 63.1 Physical description of JLPL 6

3.1.1 Steel pipeline networks 63.1.2 Control room/MCR 83.1.3 Instrumentation & electrical systems 93.1.4 System monitoring: SCADA & telecom system 103.1.5 Safety 123.2 Other description 214.0 Selection of appropriate integrity management system 225.0 Methods for integrity assessment and tools 225.1 In-line inspection(ILI) 225.2 CP monitoring 245.3 Surveillance 255.4 Pigging 265.6 SCADA 285.7 Pressure testing 295.8 Direct assessment and evaluation 295.9 Thickness assessment and periodic review against baseline values 306.0 Designing applicable integrity management system for LPG pipelines 316.1 Pipeline integrity management plan 31

6.1.1 Initial data gathering, review and integration 326.1.2 Threats identification 326.1.3 Consequence and impact analysis 336.1.4 Risk assessment specific to pipeline system 336.1.5 Integrity assessment 346.1.6 Mitigation & responses (repair and prevention) 346.1.7 Update, integrate and review data 366.2 Performance plan 36

6.2.1 Performance measures 376.2.2 Continuous improvement 376.3 Communication plan 386.4 Management of change plan 396.5 Quality control plan 397.0 Controls over integrity 407.1 Design 407.2 Procurement & supply chain 407.3 Fabrication, construction, installation & testing stage 40

Issue No. : 08 Dtd: November 1, 2012Revision No.:00 Dtd: November 1, 2012

Section-01: Pipeline Integrity Management System for JLPL of 73


7.4 System handover / takeover 407.5 Commissioning 407.6 Operations 407.7 In-service inspection, testing, maintenance, repairs & replacement 417.8 Instrumentation & electrical 417.9 De-commissioning, dismantling, demolition & disposal 428.0 Approval of integrity management system (IMS) 429.0 Review of the integrity management system 429.1 Periodicity 429.2 Review of IMS by PNGRB 4310.0 Adequacy of manpower positioned at JLPL station 43

Table-01 Details of main pipeline 44Table-02 Details of spur lines 44Table-03 Details of Pumping station Jamnagar & Kandla 45Table-04 Details of Pumping station Samakhiali, Aburoad, Nasirabad &

Mansarampura 46

Table-05 Details of SV/TOT/IP Stations, 47Table-06 Details of RT stations 52Table-07 List of electrical equipments at RT 66Table-08 Legal and statutory requirements 22Table-09 Details of ILI of JLPL main line section 23Table-10 Details of ILI of JLPL spur line 23Table-11 Cathodic Protection monitoring schedule 24Table-12 Details of CPL & DCVG of Mainline section 24Table-13 Details of CPL & DCVG of Spur line 25Table-14 Details of Cleaning Pigging of Mainline sections 27Table-15 Details of Cleaning Pigging of Spur line 27Table-16 Liquids-High Consequential Area Repair conditions 36

APPENDIX-I Physical description of JLPL 44APPENDIX-II Instrumentation and electrical system 53APPENDIX-III Reference standards, code of practice & guidelines 67APPENDIX-IV List of critical activities implementation schedule 68

APPENDIX-V Suggestive chart for selection of integrity assessment method with respect to specific threat 69

APPENDIX-VI Minimum qualification & experience for field personnel in project phase as well as O&M stage 70

APPENDIX-VII Records shall be maintained by the pipeline operators 71APPENDIX-VIII Annual health check-up report 72




1.0 INTEGRITY MANAGEMENT SYSTEM OF JLPL :

Jamnagar-Loni LPG Pipeline has developed and modified its Pipeline maintenance document and

Pipeline Integrity Management System in response to Risk analysis report & Mitigation measure,

HAZOP Report, OISD-214, PNGRB, Various Safety & Technical Audit report & its compliance. All

effort has been put to ensure quality of maintenance with safe practices.

1.1 INTRODUCTION & DEFINITIONS AS REFERRED IN THIS DOCUMENT :

a) “Authorized person” means a competent person who is assigned by GAIL to carry out a

specific job based on his competency level as laid down under regulations;

b) “Petroleum and petroleum products pipeline” means any pipeline including a branch or spur

lines for transport of petroleum and petroleum products and includes all connected

infrastructure such as pumps, metering units, storage facilities at originating, delivery, tap off

points or terminal stations and the line connected to the common carriers or contract carriers

including line balancing tanks and tankage required for unabsorbed interface, essential for

operating a pipeline system but excluding pipelines, which are dedicated for supply of

petroleum products to a specific consumer for their requirement and which are not for resale.

c) “Originating pump station” means facilities installed at the start of the pipeline system for

developing required fluid pressure so as to achieve desired flow rates in the pipeline system;

d) “Integrated electronic surveillance system” (“IESS”) means the pipeline surveillance for third

party encroachment activities along ROU. IESS may be operated on optical fiber cable,

microwave, and satellite communication system as per the system configuration and integrates

with SCADA system by the entity.

e) “Intermediate pump station” means the installation located at any place between starting point and

the terminal point having pumps to enhance the pressure of the fluid to achieve desired flow rate;

f) “Terminal station” means a facility to receive products at the end of the pipeline and this may

include the tankage for storage of petroleum and petroleum products;

g) “Operator” means an entity that operates Petroleum and Petroleum products Pipelines with the

authorization of the Board;

h) “Risk” means the risk as defined under the Petroleum and Natural Gas Regulatory Board (Codes of

Practices for Emergency Response and Disaster Management Plan (ERDMP) Regulations, 2010).

i) “Risk analysis” means the risk analysis as defined under the Petroleum and Natural Gas Regulatory

Board (Codes of Practices for Emergency Response and Disaster Management Plan (ERDMP)

Regulations, 2010).

j) “Risk assessment” means the risk assessment analysis as defined under the Petroleum and Natural

Gas Regulatory Board (Codes of Practices for Emergency Response and Disaster Management Plan

(ERDMP) Regulations, 2010).




k) “Risk management” means the risk management as defined under the Petroleum and Natural Gas

Regulatory Board (Codes of Practices for Emergency Response and Disaster Management Plan

(ERDMP) Regulations, 2010).

l) “Right of use (ROU) or right of way (ROW)” means the area or portion ( 5 meter in left and 15

meter in right from pipe center line towards flow direction) of land within which the pipeline

operator or owner has acquired the right through the relevant Statutory Acts or in accordance with

the agreement with the land owner or agency having jurisdiction over the land to lay and operate the

LPG pipelines;

m) “Subject Matter Expert (SME)” means an individual who possess knowledge and experience in the

process or discipline they represent as per ASME B 31Q.

1.2 SCOPE: The scope of this Pipeline Maintenance Manual is development and implementation of

an effective pipeline integrity management system based on available industry best practices and

processes for JLPL including all connected infrastructure such as pumps, metering units, storage

facilities at originating enroute and delivery points, Intermediate pumping station (IPS), tap off points

(TOT), Sectionalizing Valve (SV), Despatch terminals DT), Receipt terminals (RT), Intermediate

Pigging Station (IP), essential for operating a pipeline system.

Integrity Management System outlined in this document covers the entire ‘life cycle’ of the system

integrity inter-alia design, construction, commissioning, operation, and maintenance, including

modification, repair, decommissioning and dismantling.

1.3 INTEGRITY MANAGEMENT SYSTEM OF JLPL: The materials and processes followed in

JLPL are in accordance with Technical Standards and Specifications including Safety Standards for

Petroleum and Petroleum products Pipelines as issued by national and international agency. Further,

GAIL the owner of the JAMNAGAR LONI LPG Pipeline as a principal employer has been ensuring

the implementation of the Integrity Management System.

1.4 REQUIREMENT UNDER OTHER STATUTES: JLPL comply with all statutory rules,

regulations and Acts in force as applicable and requisite approvals has been obtained from the relevant

competent authorities for the LPG Pipelines.

1.5 INTEGRITY MANAGEMENT SYSTEM FOR LPG PIPELINES:

OBJECTIVE OF IMS:

i) The objective of Integrity Management System (IMS) is to maintain & improve the integrity of

pipeline systems and reduce risks at all the times to ensure public safety, protection of

environment, ensure maximum availability of LPG for its transportation without interruptions

and also minimizing business risks associated with accidents and loss of products.

ii) Since the LPG Pipelines represent a considerable financial investment and are critical business

assets, safety and reliability are critical to ensure financial success for a pipeline. The




availability of the Integrity Management Program will allow professionals and technicians

engaged in integrity tasks to have clearly established work aims and targets in the short,

medium and long term, which undoubtedly will better their efficiency and satisfaction to attain

them.

An effective JLPL-IMS has the following features:

Ensuring the quality of pipeline integrity in all areas which have the highest potential for

adverse consequences.

Promoting a more rigorous and systematic management of pipeline integrity and mitigation of

risk by pipeline operators;

Through OISD and other Statutory body maintaining the government’s prominent role in the

oversight of JLPL integrity plans and programs; and

Increasing the publics & stakeholders general confidence in the safe operation of the JLPL’s

network.

Optimizing the life of the pipeline with the inbuilt incident investigation and data collection

including review by the entity.

2.0 INTRODUCTION TO THE INTEGRITY MANAGEMENT SYSTEM (IMS) :

Pipeline integrity management is a process for assessing and mitigating pipeline risks in order to reduce

both the likelihood and consequences of incidents. It is an important aspect of the planning, design and

operation of new pipelines. These are important assets transporting hazardous products under pressure

across the country. As such, they expose people, communities and the environment to risks in case of

failure and loss of containment.

On the other hand, pipelines are themselves exposed to external damages caused by third parties and in

many cases such external damages are the main cause for pipeline failure. The proper management of

LPG pipeline system has developed an integrated and efficient integrity management system. The basic

JLPL-IMS has considered the following:

i) Important definitions

ii) Administrative components of IMP

iii) The processes used to assess and make decisions about risks in the operation of the LPG pipeline

system so as to minimize incidents.

iv) Threat identifications process.

v) Monitoring system. Ongoing process that monitors the condition of the pipeline system assesses

threats to their integrity and recommends actions to mitigate the risks.

vi) Mitigation program. Outlines the requirements for the mitigation activities recommended by the

monitoring activities.

vii) Implementation schedule




viii) Records management system. A system that allows timely access to records regarding the

pipeline system. It includes comprehensive pipeline details including material, workmanship,

inspection and testing and repairs.

ix) Organization & Control. Structure, Accountabilities and Responsibilities, Organization,

Relationships with Other Groups/Bodies, Communication Systems.

x) Integrity Management Plan (IMP): This encompasses collection and validation of data,

assessment of spectrum of risks, risk ranking, assessment of integrity w.r.t. risks, risks mitigation,

updation of data and reassessment of risk.

xi) Performance evaluation of IMP: This is a mechanism to monitor the effectiveness of integrity

management plan adopted and for further improvement.

xii) Communication Plan: This covers a structured plan to regulate information and data exchange

within and amongst the internal and external environment.

xiii) Management of Change: This is the process to incorporate the system changes (technical

physical, procedural and organization changes) in to integrity management plan to update the

integrity management plan.

xiv) Quality Control: This is the process to establish the requirements of quality in execution of the

processes defined in the integrity management plan.

3.0 DESCRIPTION OF JLPL SYSTEM :

HISTORICAL BACKGROUND: GAIL presented the case of laying LPG pipeline from Jamnagar to

Loni on 26th August 1997 to Public Investment Board (PIB). The cabinet committee on Economic

Affairs (CCEA) approved GAIL’s LPG pipeline project at a total cost of RS 1229.45 Crores in Sept

1997. Jamnagar – Loni LPG pipeline, the world’s longest exclusive LPG pipeline (1256 km) has been

commissioned on 15/01/2001 up to Loni (1177 Km) & inaugurated for the commencement of LPG

supply to OIL companies on 24/12/2000. The Jamnagar Loni P/L costing Rs 1230 Crores was funded by

ADB has got a designed capacity of 2.5 MMTPA.

3.1 PHYSICAL DESCRIPTION OF JLPL: Detail given in Appendix-I

Descriptions of Jamnagar-Loni LPG Pipeline Systems include specific description of the pipeline

with respect to design, specifications details, length, and major installations details has been given

in the Appendix-I:

3.1.1 STEEL PIPELINE NETWORKS: TOTAL Length: 1414 KMS Detail given in Appendix-I

Commissioning of JLPL-Phase-II (DT-Kandla, IPS- Mansarampura): Aug-2003

Commissioning of EOL-RIL Pipeline: August-2008

Commissioning of EOL-DT: 15th Jan, 2009

Commissioning of RT ICOL-Gurgaon: 13 Jan, 2010

Commissioning of KSPL 10” Pipeline: 17TH May, 2011




a) 16/14/12/10 INCH dia JLPL LPG main pipelines and 8/6/4 spur pipelines have been laid

underground to supply LPG to various customers (OMC) such as IOCL, BPCL and HPCL in

the states of Gujarat and Rajasthan, Haryana, Delhi & UP through a network of approximately

1414 km of pipeline.

b) The 16/14/12/10 INCH dia JLPL LPG main pipelines and 8/6/4 spur pipelines have been

provided with 3-layer poly-ethylene coating and impressed current cathodic protection (ICCP)

system. These pipelines are connected in a common ICCP system from CP station.




3.1.2 CONTROL ROOM/MCR:

Control room at IPS/DT and MCR at Jamnagar, Ajmer and Loni are the center for activities of

operation department and two technical persons are manning it on round the clock basis at MCR

Jamnagar. To achieve the company’s goal for providing the services of safe and economical handling of

LPG in the country, the list of responsibilities being undertaken is given below:

I. RESPONSIBILITIES OF MCR:

To ensure the boosting of pipeline product at desired parameters so as to maintain the supply as

per the contractual conditions and monthly ILP signed with OMC.

To ensure the supply of pipeline product as per the monthly agreed requirement to the local

customers.

To coordinate with different stations & departments for the optimum operation and

maintenance planning of major equipment and system.

To handle the Emergencies as per the laid down emergency action plans [ refer approved

document JLPL/PNGRB/ERDMP ISSUE-01, 16TH August,2012]

To coordinate with SV stations of respective P/L jurisdiction.

To ensure the safety and security compliance of the pipeline under the jurisdiction.

To ensure the availability of equipments as per the laid down procedure of the company.

To generate the DPR & MIS reports

II. RESPONSIBILITIES OF CONTROL ROOM:

Operation of the Control Room

Proper operation guidance to all operation engineers.

To review the log book & other formats & take corrective actions for any abnormality

Liaison with local OMC, RPL/RIL, EOL, IOCL and other JLPL installations for smooth

transfer of product.

Co-ordination for safety Aspects.

To issue Notification & Safety Work Permit for the maintenance job.

To ensure the safety and security compliance of the operating area.

Co-ordination with statutory authorities.

Shift duty management.

Coordination with maintenance department.

To coordinate & associate with safety department for conducting Mock Drills.

Booster pumps at RPL/RIL – DT: Booster pumps are provided in 2 running and 1 standby

configuration because of high flows.

Booster pumps at EOL – DT: Booster pumps are provided in 1 running and 1 standby configuration

because of low flows.




Booster pumps at KANDLA – DT: Booster pumps are provided in 1 running and 1 standby in

KSPL-1 & KSPL-2, configuration.

Mainline pumps at RIL/RPL – DT & IPS: Mainline pumps have been provided in two working and

one standby configuration because of high flows. These pumps are variable speed pumps with electric

motor drives. This is because variable flow pump can give flow rates in the range of 42% to 110%.

This is considered essential because of the multiplicity of the ownership of the receipt terminals and

unexpected delay in their commissioning. The variable speed pumps are more energy efficient as

killing of pressure developed by pumps is avoided.

CONTROLS: The Booster pumps for all the Despatch terminals have suction and discharge MOV.

Two PSL have been provided on each of the booster pump suction which on actuation of one out of

two on voting logic will trip the booster pump and also closes the pump suction and discharge MOV.

One PSH has been provided on each of the pump discharge, which on actuation closes the suction and

discharge MOV and also trips the pump. Pump Unit start command opens the suction and starts the

pump.

LPG as received from RPL/RIL/IOCL & EOL becomes the suction for M/L pump by two no. PCV

installed in each stream. The mainline pumps have suction and discharge MOV. Two PSL have been

provided on each of the mainline pump suction, which on actuation of one out of two on voting logic

will trip the mainline pumps and also closes, the pump suction and discharge MOV. One PSH has

been provided on each of the pump discharge, which on actuation closes the suction and discharge

MOV and also trips the pump. Pump unit start up push button opens the suction MOV and starts the

selected pump.

There is a control valve provided on M/L pump discharge header for controlling the pipeline pressure.

Three pressure switches (PSHH) have been provided downstream of the metering arrangement and

upstream of the flow tee. Actuation of 2 of 3 PSHH shall trip all the pumps at the station ; will

close all suction and discharge MOV, will also close station outlet MOV. A pressure switch low

(PSLL) has been provided downstream of the flow tee which on actuation causes the same

consequences as that of PSHH actuation and in addition it will close station inlet MOV.




3.1.3 INSTRUMENTATION & ELECTRICAL SYSTEMS ( Detail given in Appendix-II )

I. Instrumentation System: Systems mainly supplied by Tata Honeywell & David Brown related to

pump operation integrated in Plant-Scape SCADA & repeated to MCR through SCADA (M/s

YOKOGAWA) controls utility system, and provide backbone to pipeline safety and monitoring. The

whole system is divided into two categories viz,

a) Field instrumentation.

b) Control room Instrumentation.

II. ELECTRICAL SYSTEM At present RPL – DT, EOL-DT and Kandla-DT along with four Intermediate Pumping Stations at Samakhiali, Abu-

Road, Nasirabad and Mansarampura are in operation all along the JLPL system for receiving LPG from RPL &

boosting up the pressure of LPG for efficient transmission and to meet the contractual obligation of different

customers. Vertical / Horizontal centrifugal pumps, driven by VSD control electric motor, are installed at all

Dispatch Terminal & Intermediate Pumping Stations for pumping of LPG to required pressure.

3.1.4 SYSTEM MONITORING: SCADA & TELECOM SYSTEM

Supervisory Control & Data Acquisition (SCADA) has been installed and upgraded in the May-2012

system for Monitoring & Control of all JLPL installations from RPL – DT to RT Loni. A dedicated

Telecom system links the station to rest of the GAIL installations through Optical Fiber Cable &

satellite links.

SCADA FUNCTIONS

MONITORING:

Pipeline parameters – CP, Valve Status, Line Pressure, Temperature etc.

Power Source –Voltage, Current, Bus Voltage

Pumps – Start / Stop status & operating parameters

LPG supply / receipt status

Building /Door status

CONTROLS:

Start / Stop / Speed of the pumps

Adjustment of LPG flow rate at all the pumping stations/TOPS

Close / Open of Sectionalizing Valves/HPU Operation

Start / Stop / Reset of TEG at SV/IP stations (Wherever these are still in operations)

TELECOM SYSTEM

Optical Fiber Cable based system

Satellite based communication for SCADA back up

Satellite based mobile communication for O&M people

Digital Microwave radio link for integration with GAILNETIssue No. : 08 Dtd: November 1, 2012Revision No.:00 Dtd: November 1, 2012



EPABX for all attended stations to provide voice & fax connection

Video conferencing system for six locations

To extend voice & data facility to all GAIL locations.

PIPELINE OPERATION WITH SCADA: A Module based control system is envisaged for the

pipeline. The receipt terminals receive LPG under flow control. The operator at the MCS gives the set

point for the flow controllers. The total flow at the receipt terminals get summed up automatically in a

flow summation module.

Station bypass line is also provided for startup. All pump related signals are routed to the pump station

control room on a separate panel and the important signals will be tele-metered to the SMCS. In

addition, the control panels in the pump rooms are provided with pushbuttons. Detail P/L operation

from M.C.R. Jamnagar is covered separately in the SCADA manual.

LEAK DETECTION IN PIPELINE: Leak detection is accomplished by using validated relevant

dynamic point data base values in conjunction with pipeline transient model real time state for

detection, sizing and location of pipeline leaks.

The techniques implemented use the methodology of transient modeling enveloping mass balance and

in conjunction with shut in leak detection. These techniques are utilized to perform leak detection and

location simultaneously utilizing the voting algorithm to maximize operational safety & reliability, and

prevent incidence of false alarm.




3.1.5 SAFETY:

INBUILT SAFETY FEATURES AT DTs & IPS

1. All control signals are routed through intrinsically safe system by use of zener barriers, which

limits the transfer of amount of energy in the hazardous area to safe limits from Control Room.

2. Use of Flame Proof & Explosion proof junction boxes, isolators, field lighting systems.

3. Provision of Thermal Safety Valves

4. Safety Interlocks incorporated in the operation logic

5. LEL detectors are installed in the process area to detect LPG leak if any.

6. Fire water network along with fire hydrants & monitors

7. Deluge valve with water spray system in association with the LEL system.

8. Smoke detection system

9. Argonite flooding system

FIRE PROTECTION SYSTEM

GAIL LPG Despatch Terminals & Intermediate Pumping stations are provided with the following fire

protection system.

1. Fire water network with hydrant & monitor.

2. Automatic water spray system for the terminal

3. Smoke Detector & Heat Detector system.

4. Automatic detection cum Argonite fire-extinguishing system.

5. Manual call points break glass units for C/R, &Process area.

FIRE WATER NETWORK: Fire water line with minimum water pressure of 8.50 kg/cm2 is always

maintained by keeping the jockey pumps in auto mode. Along with the pipeline network Hydrants &

Water Monitors with Hose boxes form the part of the firewater network. Each Hose Box is provided

with 2 Nos. of Hoses and 2 Nos. of Branches. Hose Box Keys are provided outside the Box.

DELUGE VALVE (DV) SYSTEM: Automatic water spray by means of Deluge Valve is provided

for all the Pumps, Basket Filters, and Pig launcher/receiver. Automatic detection system is linked with

LEL detection. In case of any LPG leakage in this area & LEL level reaches to 60% it will actuate

deluge valve of water spray & automatic water spray starts. Water spray system can also be started

remotely from control room by pressing button provided on control panel. Similarly it can be started

manually from field by pulling down the lever provided on deluge valve from manual release.

LEL GAS DETECTION SYSTEM: All Mainline, Booster Pumps, Basket Filters and Valves area

are provided with Gas concentration detection system. This system monitors real time gas

concentration system in terms of percentage of lower explosive limit of LPG. In case the gas

concentration reaches 20% of LEL, an alarm is relayed and in case the gas concentration goes beyond

60 % of LEL, a trip signal is generated and activating the Deluge Valve through solenoid valve will




start water spray system. Apart from these on line LEL monitors, 03 Nos. of Portable LEL gas

concentration detectors are also available to monitor gas concentration at other areas.

SMOKE & HEAT DETECTION SYSTEM: All Rooms of Control Room are protected with smoke

detectors of photo-electric and Ionization type and heat detectors. Battery rooms are provided with

heat detectors. In case of any of the detector activates, hooter will be sounded, indication will come at

panel & also fire exit sign will glow.

Smoke Detectors of Control room building are also clubbed with automatic Argonite/FM-200

Flooding fire extinguishing system.

ARGONITE FLOODING SYSTEM: Control Room, UPS Room, VSD Room, & Telecom Room are

protected with smoke detection cum automatic fire extinguishing system.

The system consists of two parts viz.

A. Detection system by means of smoke detector.

B. Extinguishing by means of total flooding Argonite/FM-200 System.

AUTOMATIC SMOKE DETECTION:

Smoke detectors of Ionization & Optical type are provided in false Ceiling/flooring of Control

Room & cable trench. Detectors are installed zone wise. In one zone there will be both

ionization & photo-electric type detectors.

The system has been designed to activate automatically in case of emergency through Smoke

Detection system.

In case of fire at any of the location, indication comes at control panel & corrective action can

be taken.

In case of any of detector activates, hooters sounds, indication comes at panel and fire exist

sign glows.

In case of cross zoning, signal goes to FA Panel as well as Argonite Flooding system and

clean agent aragonite system gets released within a time lapse of few seconds.

Argonite system can also be released manually from cylinder room by removing safety pin &

pulling manual / pneumatic actuator provided on pilot cylinder valve and operating the

manual over ride on the solenoid controlling the relevant distribution valve.

EMERGENCY ACTION PLANS: The Emergencies may be broadly categorized into two levels. On Site

Emergency and Off Site Emergency depending upon the severity and intensity of an accident.

On Site Emergency: The emergency occurring within the plant including the pipeline, which may cause

injuries or loss of life or damage to property, the situation thus created is called on site emergency. This type

of emergency is contained to a particular place and doesn’t affect the neighborhood & surrounding places.

Off Site Emergency: If the emergency becomes uncontrollable and leads to damage to life and property in

the Installation and its neighborhood and requires the assistance of outside agencies to handle the situation,




that is called Off Site Emergency. Handling of Off-Site Emergency is within the purview of the District

Authorities.

ACTION PLANS: As stated above, depending the intensity & severity of the incident following emergency

action plans are ready & kept in the control room.

On Site Emergency Action Plan

Off Site Emergency Action Plan

An Offsite Emergency Action Plan prepared for IPS/DT/RT by the JLPL’s respective station with

information to District Crisis Group under the chairmanship of Collector, to meet any offsite

emergency occurring due to uncontrolled incidents by a particular industrial unit.

M/s Tata AIG Risk Management Services, New Delhi has prepared Disaster Management Plan (DMP)

and M/s Paladin, Canada prepared Emergency Response Plan (ERP) for JLPL project.

COMMON FEATURES OF EMERGENCY ACTION PLAN:

Over View of Emergency Plan: In such gas pipeline transportation system comprising of a network of

underground pipeline, Despatch Terminal, IPS, IP and RT the following emergencies may arise:

1. LPG Leakage 2. Fire 3. Explosion

The said emergencies may occur due to the following:

1. Natural Causes:

a. Earthquake

b. Lightning

c. Storm / Wind

d. Floods

2. Deliberate Causes

a. Sabotage / Espionage

b. Air Raids

c. Terrorist Activities / War

3. Unsafe Acts & Conditions:

a. Mechanical / Equipment failure

b. Electrical & Instrumentation failures

c. Corrosion / Rupture of Pipeline

d. Operation & Maintenance failures

e. Utility failure-Power, air, fuel gas.

Objectives of the Emergency Action Plan:

a) Controlling & localizing the emergency and eliminating the hazards.

b) Welfare of personnel managing the emergency.

c) Head counts and rescue operations.




d) Treatment of injured.

e) Safeguarding the other by timely evacuation.

f) Minimizing damage to property and environment.

g) Informing and collaborating with statutory authorities

h) Restoring normalcy.

The key components of Emergency Plan are

1) Technical Functions:

a) On Site Emergency Plan for industry.

b) Hazard analysis for industry.

c) Scenario development

d) Consequence analysis

e) Risk assessment

2) Management Functions:

a) Basic assumption of the incident

b) Plant Operation

c) Control Room

d) Access Control

e) Identification of key personnel

f) Head Count

3) Response Function:

a) Police

b) Fire Fighting

c) Medical

d) Transport

4) General Response Functions

a) Notification

b) Direction and Control

c) Public information

d) Resource Management

e) Communication

f) Personnel Safety

5) Other Elements of the Plan:

a) Containment

b) Clean up and disposal

c) Documentation and investigation




d) Plant testing and updating

e) Community awareness

f) Preparedness and training

The contents of the Emergency Action Plan

A) TECHNICAL

1. Hazard Analysis

2. Measures and procedures for accident prevention.

B) MANAGEMENT PLANS

1. Basic information about nature of emergencies

2. Identification of key personnel

3. Sequence of events

4. Mutual aid with District and Neighborhood Industries

5. Declaration of the On Site Emergency

6. Recovery

7. Clean up.

Hazard & Risk Analysis: Area details & the possible hazard causes are covered in details in the

document JLPL/PNGRB/EDMP ISSUE-01 Dtd 16TH August, 2012.

Protection/Preventive Measures: Keeping in view of the all-possible hazards, all national and

International Standards are incorporated in the design and construction stage itself, to prevent any miss-

happenings. In addition, the following systems are also available to tackle any untoward incident.

Management Control Centre (MCC): The pipeline system is designed to be operated from 3 Master

Stations (MS) located at Jamnagar, Ajmer and Loni. One of the MS i.e. Jamnagar is designated as MCC

and the other two is stand by. MCC will monitor entire pipeline with the help of SCADA system.

Emergency Shutdown (ESD): All Despatch Terminal and IPS ESD are provided in PLC and Push

Button at RTs to shut down the units/station in case of any emergency to protect the plant from damage.

Inbuilt Safety Features at Stations: All control signals are routed through intrinsically safe system by

use of zener barriers, which limits the transfer of amount of energy in the hazardous area to safe limits

from Control Room.

Use of flame proof & Explosion proof junction boxes, isolators, field lighting systems.

Provision of Thermal Safety Valves.

Safety Features of Pipeline:

1. Sizing of pipeline wall thickness according to the population density.

2. Corrosion allowance of 2mm to wall thickness.

3. Providing minimum ground cover of 1 meter for the buried pipeline.

4. Line pipes are having 3-layer polyethylene external coating.




5. 100% radiography of the welds

6. Pipeline Hydro tested at a pressure of 1.4 times of design pressure.

7. During the construction phase, the buried pipeline was immediately protected from corrosion by

providing Temporary Cathodic Protection (TCP – life of 2 years) and now is being protected with

the help of permanent CP consisting of TR/CPPSM units & Anode Ground Beds having the life of

35 years.

8. All along the pipeline OFC had laid for better and independent communication system at all

stations.

9. Intensive foot patrolling and aerial surveillance by helicopter patrolling on regular basis.

First Aid Training: First Aid Training to all the concerned persons

Safety Audits: To check the healthiness of the systems, periodical internal audits by multi-disciplinary

teams and conduct external safety audits and the observations noticed by the Audit Team Experts are

implemented.

Organization Structure during Emergency: To meet emergency situations effectively, organization

structures have been prepared and these will be applicable round the clock. The details of the

responsibilities of various coordination departments have been out lined as mentioned below.

The chief coordinator will be assisted by incident controllers and thereby the incident controllers by a

number of functional coordinators, depending upon situation and location. In case of designated

functional coordinators are not available due to any reason the successors down the line will perform

his duties and when the functional coordinator or one of the successors is performing the coordination

duties, the successor down the line will be assisting him (Unless the changes are specifically allocated

to the person by functional/chief coordinator.)

Communicating or Declaring Emergency: For declaring emergency the siren has been provided in

the Operation Control Room and the same will be operated as per laid down procedures. All Technical

Coordinators on hearing the siren will report to the Emergency Control Room and after obtaining the

requisite information they will rush to the site. All technical coordinators away from work place will

rush to the Emergency Control Room (ECR)/Site emergency control Room (SECR) on getting the

message on telephone before reaching to the site.

Authority to Declare Emergency: Shift in-charge is the prime authority to declare emergency. Shift

In-Charge has to get confirmation from Chief Coordinator or his functional coordinator for declaration

of major emergency.

Emergency Control Room: For On Site Emergency, Operation Control Room will be used as

Emergency Control Room (ECR). In case of any emergency in the pipeline segment, a Site Emergency

Control Center (SECC) may also be formed near the emergency site area in addition to the ECR

depending upon the situation.




Assembly Point: On hearing/getting the emergency message/siren, all employees (except the

emergency controller & coordinators) working in Adm. Building, Contractor workers working in the

area and visitors will assemble in the place at predefined assembly point and shall not leave the

premises until and unless they are directed to do so.

Evacuation: In case of major emergency it may be necessary to evacuate affected area and personnel

have to be shifted from the affected area to the safe location. Incident Controllers will arrange the

transportation to shift the personnel from assembly points through Welfare and Media Coordinator.

Head Count: Security In charge will carry out Head count of the following personnel

1. Technical Employees

2. Non-Technical Employees & Others

Functions of Coordinators: Functions of the Coordinators are, in brief, as listed below for major

emergency:

1. Chief Incident Coordinator (CIC): On receipt of the emergency message, Chief Incident Co-

ordinator will rush to the incident site and after brief discussion with Incident Controller, will direct

for the action to be taken. Take overall responsibility and pass necessary instructions and maintain

liaison with concern person to close/isolate the suction lines and take help from

RPL/EOL/IOCL/Local Authorities/Mutual Aid Member Units (as the case) to control the

emergency. Give clearances to inform Corporate Office & Statutory Bodies and approve statements

to be released to the news media and press. Control rehabilitation of affected areas on cessation of

the emergency.

2. Incident Controllers (IC): Rush to the site after obtaining the requisite information from

Emergency Control Room and take charge of the situation. Directly Support Co-ordinators for

necessary help and services. Ensure proper isolation/shutdown of the

machine/equipment/pipelines as per the instructions of CC. Establish Site Emergency Control

Centre and direct all operations within the affected area with the following priorities-

a) Secure the safety of personnel

b) Minimise damage to plant property & environment

c) Minimise loss of material.

3. Incident Coordinator: Shift In-Charge of Operation Control Room will act as Incident Co-

ordinator in all types of emergencies till the arrival and take charge by Incident controller on receipt

of emergency call, immediately he will assess the situation and if the situation is minor emergency

he will inform to Chief Coordinator & Incident Controllers. If the situation is beyond control that is

major emergency immediately he will blow the siren as per the situation and inform to Fire Station,

Security/Ambulance and also inform to the all concerned as per the Emergency Action Plan and

detail operator to rush to the site for necessary isolation or shut down of the system.




4. Fire & Safety Coordinator: Reach the site and coordinate with Fire Services in fire fighting or

rescue operations as per the situation. Maintain close liaison with MARG Officials/Local Fire

Services to monitor the situation and assess the damages.

5. Welfare & Media Coordinator: Rush to his office and take charge of welfare and media co-

ordinator. Arrange transportation as required by various co-ordinators. Maintain close liaison with

State Officials for the safe evacuation of public residing along the pipeline area. Issue press

statement with the approval of Chief Co-ordinator. Arrange basic needs i.e. catering services for

personnel at site. Take care of press/media and render necessary help to them.

6. Finance Coordinator: Rush to his/her Office to provide financial assistance as and when required.

7. Communication Coordinator: Rush to his/her office/Telecom Room to provide communication

facilities and give telephone connection to emergency control room if it is set outside the Control

Room. In case of any emergency in the Pipeline segment, necessary arrangements will be made

for establishing proper communication from the field to ECR (Emergency control Room).

8. Material Coordinator: Rush to his/her office and provide material required for emergency and

also arrange from outside if not available in our store on emergency basis.

9. Electrical Coordinator: Rush to the site after obtaining requisite information from Emergency

Control Room and take necessary action for electrical isolation of the effected equipment. Also

ensure power availability to fire fighting equipment.

10. Instrumentation Coordinator: Rush to the site after obtaining requisite information from

Emergency Control Room and assist to the Incident Controllers in isolating/closing of valves or

unit emergency shut down as per the requirement of the situation.

11. Security Coordinator: Rush to the site after obtaining requisite information from Emergency

Control Room and Maintain close liaison with Security for regulating traffic within the premises.

If the emergency is on Pipeline, take necessary help from local police to regulate traffic or to

evacuate nearby public to safer areas.

12. Role of O&M Personnel: Plant and facilities immediately affected or likely to be affected should

be isolated and efforts will be made to take safe shut down. O&M personnel those are trained for

such nature of work do this type of work. They should report to respective sections or work area

on declaration of emergency. Nevertheless it is imperative that the required actions are initiated

and directed by Incident Controllers.

13. Non-Technical Employees & Contract Workers: On declaration of On Site Major Emergency

in DT/IPS/RT non-technical personnel, contract workers and visitors should assemble at

Assembly Point near to them. But Security Personnel posted at different security posts in the plant

will not leave their duty posts unless they were directed to do so.




14. Siren Codes During Emergency: The actuation of the siren varies with regard to the incident nature

like major & minor emergency.

15. MARG Members: List of the MARG members with their contact numbers & to keep in the C/R.




3.2 OTHER DESCRIPTION:

3.2.1 Interfaces with Other Operators Facilities or Pipelines: Every All O&M Base of JLPL has

MARG document. Through this, they will interfaces with other operator’s facilities in their

jurisdiction. This document is available with each station.

3.2.2 Life cycle of the components installed in the pipeline system, with commissioning date:

GAIL Maintenance & Guidelines Sep-2010 has defined guideline on Life cycle of the

components. This document is available with each O&M Base. Every station has been

maintaining the commission date of pipeline and equipment.

3.2.3 Modification carried out in the system: Approval of GM (O&M) JLPL, HQ and details is

being maintained by respective O&M Base.

3.2.4. Inspection update: As per Maintenance format inspection record has been maintained by each

O&M Base and its respective department.

3.2.5 Incident, including product leak or pilferage details etc.: As per Document

JLPL/PNGRB/ERDMP ISSUE-01 Dtd 16TH August,2012 each O&M base has been

maintaining record pertaining with Incident, including LPG leak or pilferage.

3.2.6 Information on Documentation Relating to design, construction, operations, maintenance,

etc.: The equipment and pipeline related information has been uploaded in ERP-SAP PM

Module. The hard copies of document relating to design, construction, operation &

maintenance are being maintained at respective O&M Base. As per Corporate policies the

critical and important documents are being loaded in Document control Management System

(DCMS) Server in soft copies; it is being coordinated by its site coordinator. For JLPL IPS-

Mansarampura has been declared coordinator for DCMS of JLPL.

3.2.7 Pipeline Geometry, Ground Movement - Control, Mitigation and Monitoring: Pipeline

geometry and ground movement is to be practiced to monitor by respective O&M Base through

line walk patrolling, satellite picture (Using longitude and latitude coordinator of intelligent

pigging). Any abnormality observed will be mitigated through proper measure. Record is to be

maintained by respective O&M Base.

3.2.8 Statement of compliance with Technical Standards and Specifications including Safety

Standards for such Pipelines and Associated Laws, as applicable: It is stated that JLPL has

been following all international, national and local standard for designing, construction,

operating and maintaining the JLPL.

3.2.9 Legal and Statutory requirements: It is stated that JLPL has been complying all legal and

statutory requirements for designing, construction, operating and maintaining the JLPL. List of

legal and statutory requirement and its compliance by JLPL is given in Table-08, details is

available at each O&M base.




Table-08: Legal and Statutory requirements:

O&M BASE: Year : 20**-20**

Sl. No. Legal and Statutory requirements Valid uptoNext due and date of

apply.

1 Factory License

Record is being maintained by

respective O&M Base

2 Consent Order Under Air Act

3 Consent Order Under Water Act

4 Water Cess Report

5 Environmental Audit Report

6 Environmental Statement (Form No. V)

7 Diesel storage tank

8 PSV calibration

9 Certificate of Structural Stability

10 CEA Compliance

11 Weights & Measures

12 Any other as required by State / Central Government body

The details like date of inspection, next renewal date, capacity, license etc. shall be displayed nearby

respective equipment in the field, wherever applicable.

4.0 SELECTION OF APPROPRIATE INTEGRITY MANAGEMENT SYSTEM:

a) The failure of defects in pipelines has been defined in document JLPL/PNGRB/ERDMP ISSUE

No.-01 DTD 16TH AUGUST, 2012.

b) Just like any pressure equipment and facility containing and transporting hazardous products, LPG

pipelines are subject to regular statutory inspections, verifications and re-certifications.

c) LPG pipeline demonstrates and have documents, that the integrity of its pipeline facilities is being

maintained at all times. It is also specified that JLPL have assessed the risks associated with the

operation of their facilities and have taken all the measures and fully prepared to mitigate the

consequences of any failures.

5.0 METHODS FOR INTEGRITY ASSESSMENT AND TOOLS: The JLPL has been using

the following tools to achieve the IMS for JLPL pipeline. It is stated that the baseline data for specific

measurement has been available with the JLPL as a ready-reckoner:

5.1 IN-LINE INSPECTION(ILI): In-line inspection (ILI) is an integrity assessment method used

to locate and preliminarily characterize indications, such as metal loss or deformation, as well as

external and internal corrosion in a pipeline. Internal inspection tool or tools capable of detecting

corrosion and deformation anomalies including dents, gouges, grooves etc. Instrumented / Intelligent




Pigging / Any Other technologies that can provide a level of integrity assessment equivalent to Inline

Inspection / direct assessment in accordance with provisions of relevant standards or regulations issued

for managing System Integrity for Hazardous Liquid Pipelines, provides additional guidance on

pipeline in-line inspection.

In-line inspection tools are used for the purpose of locating and monitoring corrosion on both internal

and external surfaces of the pipeline. The survey tool is a self-contained system that performs a full

circumferential corrosion inspection from the pig launcher to the pig receiver.

The advantage of these inline tools is that they offer us “direct integrity information” previously only

available through hydrostatic proof testing or digs. Typical ILI output data includes: anomaly location –

both linearly along the pipe axis, as a function of internal or external position, and percentage wall loss.

Table-09: Details of ILI of JLPL Mainline SectionSr.No.

P/L Section DiaInch

LengthKm Grade/Thk ILI inspection

month/year Next due

01 EOL –RIL DT 6 23.7 API 5 LX 60 7.1/ 6.4 mm Aug-2008 2017

02 RIL DT –Samakhiali 14 166.7 API 5 LX 60 7.1/ 6.4 mm Jan-2007 2017

03 IOC Kandla- DT Kandla 12 8.3 API 5 LX 60 7.1/ 6.4 mm Dec-2007 2017

04Hook up point to GAIL’s scraper area inside IOCL

Kandla8 0.411 API 5 L Gr. X 60 7.1/ 6.4 mm N/A N/A


Kandla10 0.367 API 5 L Gr. X 52 7.8/ 6.4 mm N/A N/A

06 DT Kandla – Samakhiali 08 58.5 API 5 LX 60 7.1/ 6.4 mm Jan-2007 2017

07 DT Kandla – Samakhiali 10 58.5 API 5 LX 52 7.1/ 6.4 mm March-2011 2022

08 Samakhiali – Abu Road 16 272.0 API 5 LX 65 8.7/ 7.1 mm Jan-2007 2017

09 Abu Road - IP2 (Khinwada) 16 142.40 API 5 LX 65 8.7/ 7.1 mm May-2012 2022

10 IP2 (Khinwada) – Nasirabad

16 163.70 API 5 LX 65 8.7/ 7.1 mm May,2012 2022

11 Nasirabad- Mansarampura 12 121.4 API 5 LX 60 7.1/ 6.4 mm Sep-2011 2022

12 Mansarampura IP – Loni 12 309.3 API 5 LX 60 7.1/ 6.4 mm Jan-2012 2022

Total 1325.40Table-10: Details of ILI of JLPL of Spur lines

Sr.No.

P/L Section DiaInch

LengthKm Grade/Thk ILI inspection

month/year Next due

01 TOT- 1 To RT IOCL -Ajmer 8 N.B. 11.0 API 5 LX 42 7.1/ 6.4 mm Dec-2011 2021

02 IPS – Nasirabad To HPCL 8 N.B. 1.0 API 5 LX 42 7.1/ 6.4 mm N/A03 IPS – Nasirabad To BPCL 8 N.B. 2.2 API 5 LX 42 7.1/ 6.4 mm N/A04 TOT – 2 To RT Sanganer 8 N.B. 36.7 API 5 LX 42 7.1/ 6.4 mm Sep-2011 202105 Loni – HPCL 8 N.B. 2.5 API 5 LX 42 7.1/ 6.4 mm N/A

06 Loni – BPCL 8 N.B. 2.5 API 5 LX 42 7.1/ 6.4 mm N/A

07 Mansarampura-BPCL-RT 4 N.B. 13.6 API 5 LX 42 6.4 mm N/A08 SV 63 to RT, Gurgaon 6 N.B. 19.6 API 5 L X 42 6.4 mm March-2009 2021

Total length 89.1In addition the following shall be carried out:




a. Observing dampness of the area and smell of petroleum product during daily line walking.

b. Pressure loss in the segment during pipeline operation through SCADA monitoring system.

c. Feasibility of placing sensors for detecting LPG leaks in a confined area such as IPS/RT

wherever possible particularly for old pipelines which have a proven track record measured

through online corrosion monitoring system for > 10 mil loss).

5.2 CP MONITORING:

Table-11 Cathodic Protection Monitoring Schedule

Sr. No.

Cathodic protection monitoringmethods

Time period/Frequency

1 PSP Survey Once in three months2 Direct Bonding Station (Test station for

bonding both pipeline)Once in three months

3 TR / CPPSM- CP stations Once in a month in the field, if not online4 Coating Health Surveys (CPL & DCVG) Immediate after commissioning and once in a five

years.5 Foreign Pipeline interference Survey Immediate after commissioning. Based on the CP data

of such interference survey minimum once in 5 years.6 Anode Bed resistance Once in a year7 Anode Bed current dissipation Once in a three months8 Resistance of each Galvanic Anodes installed

for earthing at HT line crossingsOnce in a year.

Table-12: Details of CPL & DCVG of JLPL Mainline section

Sr.No.

P/L Section DiaInch

LengthKm Grade/Thk

CPL/DCVG inspection

month/yearNext due

01 EOL –RIL DT 6 23.7 API 5 LX 60 7.1/ 6.4

mm

Jan-2009 201302 RIL DT –Samakhiali 14 166.7 API 5 LX 60 7.1/ 6.4

mm

Aug-2007 201303 IOC Kandla- DT Kandla 12 8.3 API 5 LX 60 7.1/ 6.4

mm

Dec-2007 2013


Kandla8 0.411 API 5 L Gr. X 60 7.1/

6.4 mmDec-2007

2013


Kandla10 0.367 API 5 L Gr. X 52 7.8/

6.4 mmMarch-2011

2013

06 DT Kandla –Samakhiali 08 58.5 API 5 LX 60 7.1/ 6.4

mm

Dec-2007 2013

07 DT Kandla –Samakhiali 10 58.5 API 5 LX 52 7.1/ 6.4

mm

March-2011 2013

08 Samakhiali – Abu Road 16 272.0 API 5 LX 65 8.7/ 7.1

mm

Aug-2007 2013

09 Abu Road - IP2

(Khinwada) 16 142.40 API 5 LX 65 8.7/ 7.1

mmJun-2008 2013

10 IP2 (Khinwada) –

Nasirabad16 163.70 API 5 LX 65 8.7/ 7.1

mmJun-2008 2013

11 Nasirabad-

Mansarampura

12 121.4 API 5 LX 60 7.1/ 6.4

mm

March-2008 2013

12 Mansarampura IP –Loni 12 309.3 API 5 LX 60 7.1/ 6.4

mm

May-2008 2013Total 1325.4

0




Table-13: Details of CPL & DCVG of JLPL of spur line sectionSr. No.

P/L Section DiaInch

LengthKm Grade/Thk

CPL/DCVG inspection

month/yearNext due

01 TOT- 1 To RT IOCL -Ajmer 8 N.B. 11.0 API 5 LX 42 7.1/ 6.4 mm May-2008 2013

02 IPS – Nasirabad To HPCL 8 N.B. 1.0 API 5 LX 60 7.1/ 6.4 mm March-2008 201303 IPS – Nasirabad To BPCL 8 N.B. 2.2 API 5 LX 60 7.1/ 6.4 mm March-2008 201304 TOT – 2 To RT Sanganer 8 N.B. 36.7 API 5 LX 60 7.1/ 6.4 mm Jan-2008 201305 Loni – HPCL 8 N.B. 2.5 API 5 LX 60 7.1/ 6.4 mm Apr-2008 201306 Loni – BPCL 8 N.B. 2.5 API 5 LX 60 7.1/ 6.4 mm Apr-2008 201307 Mansarampura-BPCL-RT 4 N.B. 13.6 API 5 LX 42 6.4 mm Aug-2008 201308 SV 63 to RT, Gurgaon 6 N.B. 19.6 API 5 L X 42 6.4 mm 2009 2013

Total length 89.1CORROSION:

a) Areas of external or internal metal loss with a maximum depth greater than 80% pipe thickness

shall be removed or repaired.

b) Externally corroded areas exposed for examination shall be cleaned to bare metal. In general, areas

of corrosion with a maximum depth of 20% or less of the thickness required for design need not be

repaired. However, measures should be taken to prevent further corrosion. An area of corrosion

with maximum depth greater than 20% but less than or equal to 80% of the wall thickness can be

permitted to remain in the pipeline unrepaired provided that the pressure at such an area does not

exceed a safe level. Calculations for safe operating pressure shall be done as per the regulations

issued by the Petroleum & Natural Gas Regulatory Board for such pipelines.

c) If the safe operating pressure is less than the intended operating pressure, the affected area shall be

removed or repaired.

5.3 SURVEILLANCE :

Various effective surveillance methods are being used as direct integrity assessment tools. Based upon

the experience and resource management, one or multiple tools are being followed by JLPL; some of

them are detailed as under:

I. Patrolling / Ground Survey:

JLPL maintain a periodic pipelines patrol programme. The Patrolling is carried out as per the

following minimum intervals. And the IMS document includes the following:

(a) The right of way is inspected and maintained once in a year to ensure clear visibility of

ROW/ROU, access to maintenance crew along the ROW/ROU, valve locations and other

pipeline facilities. All pipeline markers/kilometer posts and other signs/specific indication

marks shall be maintained once in a year.

(b) Patrolling to observe surface conditions, leakage, construction activity other than performed by




the pipeline owning entity, encroachments, washouts and any other factors affecting the safety

and operation of the pipeline, in any of the following methods.

i) ROU tracking through satellite imagining method by satellite for critical stretches in

JLPL may be carried out as per available facilities. This may be done as and when

required, to track for any ground profile disturbance.

ii) Aerial survey of ROU in JLPL is being done monthly by GAIL personnel.

iii) Line Walk by the officials of the JLPL is being carried out at least once in a year for

entire length of pipeline; it is carried out after the monsoon.

II. Requirement of Night Patrolling by Line walkers or alternative security surveillance system

has been reviewed by Pipeline core Group, Security and Safety and it concluded that it is not

required, as such there is no pipeline location is vulnerable from pilferage point of view. But

time to time its requirement will be reviewed by pipeline core group members.

III. Integrated Electronic surveillance system: The necessity of following Detection System for

JLPL will be reviewed by pipeline core group members for implementation on the system

requirements basis:-

1. Fiber Optics System: This detection system works on seismic vibration principle which may be

employed for any kind of terrain and soil and is useful for pipelines crossings. This system is

primarily used for buried pipelines.

2. Ground Censor System: This detection system also works on seismic vibration principle and

may also be used for any kind of terrain and soil. Ground censor system may be used for

buried pipelines as well as above ground pipelines.

3. Fence secure data access system: This system works on the principle of violation of boundary

and useful in installation along the pipeline system. The other use of this system could be for

pipeline corridor securing pipeline in very sensitive area where there is attacks by terrorists or

otherwise

IV. Awareness Programs: Villagers and general public along the right of way are being made

aware of the possible consequence of hydrocarbon leaks with providing a list of Do’s and

Don’ts. This is included as a part of regular audit. Awareness with the administration and local

public is also obtained by conducting Offsite Disaster Management Plan on the country side

pipeline in line with the PNGRB (Codes of Practices for Emergency Response and Disaster

Management Plan), Regulations, 2010 which highlight the Safety awareness among the Local

Public and District Administration.

5.4 PIGGING:

The frequency of de-scaling/cleaning of pipelines transporting LPG products shall be once in a year and

intelligent pigging shall be carried out once in ten years. Record of quantity and quality of deposits (pig




residue) collected after de-scaling shall be examined to monitor condition of the Pipeline. Depending

upon the outcome of the chemical analysis and review, pigging frequency may be increased.

Table-14: Details of Cleaning Pigging of JLPL Mainline Section

Sr.No.

P/L Section DiaInch

LengthKm Grade/Thk

Cleaning Pigging

month/year

Next due

01 EOL –RIL DT 6 23.7 API 5 LX 60 7.1/ 6.4 mm 2008 2013

02 RIL DT –Samakhiali 14 166.7 API 5 LX 60 7.1/ 6.4 mm 2007 2013

03 IOC Kandla- DT Kandla 12 8.3 API 5 LX 60 7.1/ 6.4 mm 2007 2013


Kandla8 0.411 API 5 L Gr. X 60 7.1/ 6.4 mm N/A

2013


Kandla10 0.367 API 5 L Gr. X 52 7.8/ 6.4 mm N/A

2013

06 DT Kandla – Samakhiali 08 58.5 API 5 LX 60 7.1/ 6.4 mm 2007 2013

07 DT Kandla – Samakhiali 10 58.5 API 5 LX 52 7.1/ 6.4 mm 20112013

08 Samakhiali – Abu Road 16 272.0 API 5 LX 65 8.7/ 7.1 mm 2007 2013

09 Abu Road - IP2 (Khinwada) 16 142.40 API 5 LX 65 8.7/ 7.1 mm 2012 2013

10 IP2 (Khinwada) – Nasirabad 16 163.70 API 5 LX 65 8.7/ 7.1 mm 2012

2013

11 Nasirabad- Mansarampura 12 121.4 API 5 LX 60 7.1/ 6.4 mm 2011 2013

12 Mansarampura IP – Loni 12 309.3 API 5 LX 60 7.1/ 6.4 mm 20122013

Total 1325.40 2013

Table-15: Details of Cleaning Pigging of JLPL Spur line

Sr. No.

P/L Section DiaInch

Length

KmGrade/Thk

Cleaning Pigging

month/year

Next due

01 TOT- 1 To RT IOCL -Ajmer 8 N.B. 11.0 API 5 LX 42 7.1/ 6.4 mm 2011 2013

02 IPS – Nasirabad To HPCL 8 N.B. 1.0 API 5 LX 42 7.1/ 6.4 mm N/A 201303 IPS – Nasirabad To BPCL 8 N.B. 2.2 API 5 LX 42 7.1/ 6.4 mm N/A 201304 TOT – 2 To RT Sanganer 8 N.B. 36.7 API 5 LX 42 7.1/ 6.4 mm 2011 201305 Loni – HPCL 8 N.B. 2.5 API 5 LX 42 7.1/ 6.4 mm N/A 201306 Loni – BPCL 8 N.B. 2.5 API 5 LX 42 7.1/ 6.4 mm N/A 201307 Mansarampura-BPCL-RT 4 N.B. 13.6 API 5 LX 42 6.4 mm N/A 201308 SV 63 to RT, Gurgaon 6 N.B. 19.6 API 5 L X 42 6.4 mm 2009 2013

Total length 89.1




5.6 SCADA:

The monitoring and control of JLPL pipeline network is done through Centralized SCADA system

which has been commissioned in May 2012. It provides real time data on 24X7 basis to the operator for

the effective and efficient running of the pipeline. M/s Yokogawa Bangalore is the SCADA software

vendor of Centralized SCADA system.

The Centralized SCADA system is based on dual Master Station concept with Main Master Station

(MMS) at Noida and Backup Master Station (BMS) at Jaipur. It has modular and distributed

architecture for polling of the RTUs through FEP (Front End Processor) servers. For JLPL pipeline,

FEP servers have been installed in hot standby redundant configuration at three key locations namely

Jamnagar, Ajmer and Loni. These FEP servers poll the RTUs of their region and communicate with

MMS/BMS for data transfer through high speed links.

The RTUs of Jamnagar to IPS-Ajmer section are polled by Jamnagar FEP whereas Loni FEP polls the

RTUs of IPS-Ajmer to Loni section. The FEP at IPS-Ajmer carries out the polling of all the RTUs of

JLPL pipeline.

To provide data to the operators in Control rooms, Remote Workstations have been provided at

Jamnagar, EOL DT, Kandla, Samakhiali, Abu Road, Nasirabad, Mansarampura and Loni. These RWS

are connected to MMS/BMS for presenting the data to the operator. The RWSs can also be connected

to any of the three FEPs of JLPL in the unlikely event of non-availability of SCADA servers at MMS

and BMS.

Apart from the real time monitoring of the pipeline, various types of controls can be done by the

operator based on this authorizations. Some of the controls which are available in SCADA system are,

valve operation, pump speed control, start/stop of the TEGs etc.

RTUs are installed in the field and act as an interface between the field facilities and the SCADA FEP

servers. The data of the field parameters comes to the RTU in the form of analog (4-20mA) signals and

digital (NO/NC) signals. This data is passed on to the FEP server by the RTU on receipt of valid

request from the FEP server. Total 84 nos. of GE Harris D-20 and D-20+ RTUs supporting IEC-101

communication protocol are installed in JLPL.

Multiple low speed telecom channels have been extended from one FEP to another FEP for polling the

RTU. On each channel, 6-10 RTUs are polled for data and health. Also each RTU is dropped on two

telecom channels. On one channel, the RTU is polled for data from one side FEP. The other side FEP

polls this RTU on the second channel for health. The polled data and RTU health status is passed on by




the FEP servers to the active SCADA server at MMS/BMS for further processing. In case of OFC cut

between two FEP locations, each FEP server polls the RTUs available to it for data and passes the

polled data to MMS/BMS servers.

Multiple types of RTU protocols like, IEC-101, IEC-104, DNP3.0 over serial and TCP/IP, Modbus etc

are supported by the JLPL SCADA system. Any RTU supporting these protocols can be integrated in

the SCADA system for future pipeline expansion.

The SCADA system is also Web enabled so as to allow wider accessibility of data. The web facility is

used by the pipeline engineers where dedicated RWSs have not been provided. Multiple concurrent

users can log on to the SCADA web-server to monitor the data. Through this, data pertaining to OMCs

can also be presented to them after suitable authorizations.

E-mail and SMS facility has also been implemented in the new SCADA system. SMS can be auto-

generated and sent to concerned pipeline engineers on occurrence of critical alarms. Multiple types of

reports can be generated related to pipeline operations, gas receipt and dispatch, PSP, Fire water

pressure, TEG, etc. and sent to configured e-mail recipients.

Various types of pipeline parameters like flow, pressure, temperature, valve status etc are logged in

history servers to make them available to operator in future. The types of parameters and the frequency

of data logging is system configurable.

For interfacing with the third party systems like APPS system, SAP etc, the SCADA system is object

linking and embedding for process control (OPC) compliant. It can exchange the real time data along

with quality and time-stamp with 3rd party systems.

5.7 PRESSURE TESTING:

Pressure testing is appropriate for integrity assessment when addressing certain threats, at the pre-

commissioning stage itself. Pressure testing for operating pipelines or pipeline section has been done

during commissioning of JLPL as specified in the relevant standards ASME B31.4, OISD-214 or

regulations issued by the Petroleum & Natural Gas Regulatory Board.

5.8 DIRECT ASSESSMENT AND EVALUATION

This includes visual NDT examination to reinforce and validate findings from Inline-inspection (ILI)

and other incidental findings, like during incidental pipeline exposure, pipeline damages and other

maintenance activities.

External Corrosion Direct Assessment (ECDA) can be used for determining integrity for the external

corrosion threat on pipeline segments. The ECDA process has the following four components:

a) Pre-assessment- incorporating various data gathering, database integration, and analysis

b) Identification - using either tools or calculations to flag possible corrosion sites, or calls, based

on the evaluation or extrapolation of the database




c) Examinations and evaluations - excavation and direct assessment to confirm corrosion at the

identified sites, and remediation as defined in regulation,

d) Post-assessment - to determine if dig call decision are taken on a pipeline segment. However,

Call decisions are driven by various tools, technologies, or engineering evaluations, but are

highly dependent on the level of experience and expertise utilized.

While implementing ECDA and when the pipe is exposed, the company is advised to conduct

examinations for threats other than that for external corrosion also (like mechanical and coating

damages).

Internal Corrosion Direct Assessment (ICDA) can be used for determining integrity for the internal

corrosion threat on pipeline segments. The ICDA process has the following four components.

(a) Pre-assessment

(b) Identifications

(c) Examinations and evaluations

(d) Post-assessment

5.9 Thickness assessment and periodic review against baseline values

Periodic thickness assessment for all the pipeline above ground, skids and pressure vessels and

comparison to baseline values shall be done once every two years.

Such other methods for integrity assessment may be also adopted by the pipeline company as it thinks

fit, apart from the above mentioned ones.




6.0 DESIGNING APPLICABLE INTEGRITY MANAGEMENT SYSTEM FOR LPG PIPELINES

JLPL has developed an integrity management Program comprising the necessary plans, implementation schedule and assessment of its effectiveness in order to ensure safe and reliable operation of the LPG pipelines. It is recognized that the comprehensive pipeline integrity management program is based on continuous exercise of extensive data collection, assimilation and analysis. Further, an integrity management Program has been devised on specified methods, procedures and time intervals for assessments and analyses or on the basis of performance of the programme with regard to efficacy of integrity assessment plan, its results and mitigation efforts.

6.1 PIPELINE INTEGRITY MANAGEMENT PLANLPG pipelines and associated facilities installed as a part of pipeline has been covered in pipeline Integrity Management Plan. The cycle of basic processes of integrity management Plan is illustrated (Fig -1): Figure-1: Pipeline Integrity Management Plan - Flow Diagram

No

Yes



Initial data gathering and review

Threat Identification

Whether all threats evaluated

Consequences & Impact Analysis

Review of IMS as per ERDMP

Risk Assessment / Evaluation

Integrity Assessment

Mitigation and Responses

Data updation & integration


6.1.1 INITIAL DATA GATHERING, REVIEW AND INTEGRATION:

One of the most critical parts of the pipeline integrity program or risk management is the collection of

accurate information on the present condition of the pipeline collected by excavations or various survey

techniques. A method used by JLPL for collecting accurate data is to inspect the pipeline via a “smart

pig” or In-Line Inspection Tool (ILI). The data so collected are being analyzed for corrective actions.

6.1.2 Threats Identification: Pipeline incident data analyzed and classified by Pipeline research

Committee International (PRCI) represents 22 root causes for threat to pipeline integrity. One of the

causes reported by the operator is “unknown”. The remaining 21 threats have been grouped into three

groups based on time dependency and further in to nine categories of related failure types according to

their nature and growth characteristic as below:

(I) Time Dependent Threats:

1) External Corrosion

2) Internal Corrosion

3) Stress Corrosion Cracking

(II) Stable Threats:

4) Manufacturing related defects

i. Defective pipe seam

ii. Defective pipe

5) Welding /fabrication related

i. Defective pipe girth weld

ii. Defective fabrication weld

iii. Wrinkle bend or buckle

iv. Stripped threads /broken pipe /coupling failure

6) Equipment

i. Gasket O-ring failure

ii. Control/relief equipment malfunction

iii. Seal pump packing failure

iv. Miscellaneous

(III) Time independent Threats:

7) Third party /mechanical damage:

i. Damage inflicted by first, second or third party (instantaneous /immediate failure)

ii. Previously damaged pipe (delayed failure mode)

iii. Vandalism




8) Incorrect operational procedure

9) Weather related and outside force:

i. Weather related

ii. Lightening

iii. Heavy Rains or Floods

iv. Earth Movements

Besides the above, certain other threats may be applicable based upon the land pattern:

i. Creek Area effects

ii. Muddy Land effects

iii. River bed movements

6.1.3 Consequence and Impact Analysis

Once the hazardous events are identified, the next step in the risk analysis is to analyse their

consequences, i.e., estimate the magnitude of damage to the public, property and environment of all the

identified threats. These consequence may include:

(i) Leak

(ii) Mass release/Continuous release

(iii) Flash fire/Jet fire

(iv) Explosion

(v) UVCE (unconfined vapour cloud explosion)

(vi) CVCE (confined vapour cloud explosion)

(vii) Gas cloud

(viii) Fireball

(ix) Pool fire

(x) Tank fire

Consequence estimation can be accomplished by using mathematical models (e.g. consequence

modeling), which can be at various levels of detail and sophistication.

Identification of High-consequence area (HCA) – Locations along the pipeline system meeting the

criteria for High-Consequence Areas are identified. Generally, these are high-population-density areas,

difficult-to-evacuate facilities (such as hospitals or schools), and locations where people congregate

(such as places of worships, office buildings, or fields).

6.1.4 RISK ASSESSMENT SPECIFIC TO PIPELINE SYSTEM:

6.1.4.1 Risk Management and Risk Assessment

Risk management is the overall process by which management decides what actions to take, if any, to

control or reduce existing or anticipated risks. Risk management involves the systematic application of




management policies, procedures, resources, and practices to the tasks of assessing, analyzing, and

controlling risk.

The goal of a good risk management system is to protect employees from safety and health point of

view, the general public, the environment, and company assets. Risk assessment is only one component

within the overall process of risk management. Traditional pipeline risk management has been based on

regulatory code compliance issues as it relates to renewing or replacing corrosion damaged areas,

maintaining corrosion prevention potentials, third party protective measures (i.e., ground cover depth,

signage), or population encroachment issues.

6.1.4.2 Developing a Risk Assessment Model: It has been carried out by third party expert consultant.

List of HAZOP and Risk analysis of JLPL is being given below.

1) ENVIRONMENT IMPACT ASSESSMENT OF LPG PIPELINE –BY EIL-NOV1996

2) RAPID RISK ANALYSIS OF LPG PIPELINE-BY EIL-1996

3) RISK ASSESSMENT OF JLPL-LPG PIPELINE -BYTATA AIG-2001

4) DMP OF JLPL,LPG PIPELINE—BY TATA AIG-2001

5) HAZOP STUDY FOR STAGE II&III OF JLPL, LPG PIPELINE-BY ENTEC UK LTD.-2001

6) HAZOP STUDY OF JLPL , LPG PIPELINE-BY EIL.-2005

7) HAZOP STUDY OF JLPL PIPELINE-BY TRIUNE -2012

8) RISK ASSESSMENT OF JLPL PIPELINE-BY TRIUNE -2012

6.1.5 INTEGRITY ASSESMENT: A plan for Integrity assessment has been developed to address

the most significant threats/risks as per previous section and has determined appropriate

integrity assessment methods to assess the integrity of the pipeline segment. The following

methods are being used for Integrity Assessment:

a) Hydro testing before commissioning, at test pressure as per ASME B31.4, OISD-214

PNGRB (Technical Standards and Specifications including Safety Standards).

b) Inline inspection (ILI) as per OISD-214, PNGRB and GAIL Maintenance Policy &

Guidelines-2010.

c) External & Internal Corrosion Direct Assessment(ECDA/ICDA): CPL/DCVG survey

d) Various forms of pipeline surveillance and monitoring e.g. patrolling, Integrated

Electronic Surveillance System (IESS) etc.

JLPL has developed a chart of most suited integrity assessment method and assessment interval for

each threat and risk. A suggestive chart is placed at Appendix –III.

6.1.6 MITIGATION & RESPONSES (Repair and Prevention): After the completion of integrity

assessment the results are being evaluated, and the necessary repairs and preventive actions are

undertaken to eliminate the threat to pipeline integrity. Immediately upon completion of

integrity assessment a comprehensive schedule of repair is prepared. All anomalous conditions




discovered through the integrity assessment is evaluated and classified under the following

three categories based on severity of defect. Mitigation action (repair and prevention) is

undertaken to eliminate an unsafe condition to the integrity of a pipeline or ensured that the

condition is unlikely to pose a threat to the integrity of the pipeline until the next reassessment.

(A) Mitigation through Repair Actions: At the time of establishing schedules, responses is divided

in to three groups and repair actions are as follows:

(a) Immediate repair conditions: Such indication shows that defect is at failure point, this include

but not limited to any corroded area having

i) Metal loss equal to or more than 80% of wall thickness

ii) Predicted failure pressure less than equal to 1.1 times the maximum allowable operating

pressure (MAOP) as determined by ASME B31G or equivalent.

iii) Metal loss indication affecting a detected longitudinal seam, if that seam was form by

direct current or low frequency electric resistance weld or by electric flash welding.

iv) Any indication of adverse impact on the pipeline expected to cause immediate or near

term leaks or ruptures based on their known or perceived effects on the strength of

pipeline which include dents with gouges.

v) Any near term failure indication

(b) Scheduled conditions: – Such indication shows that defect is significant

but not at failure point. Following indications is examined within one year of discovery:

i) A plain dent that exceeds 6% of nominal pipeline diameter for pipeline operating at or

above 30% of SMYS

ii) Mechanical damage with or without concurrent visible indentation of the pipe

iii) Dent with cracks

iv) Dent that affect ductile girth or seam wells if the depth is in excess of 2% of the nominal

pipe diameter

v) Dents of any depth that affect non ductile welds

* For more information on scheduled conditions,” Repair Procedures for Steel Pipelines” Para A51.60

of ASME 31.4 may be referred.

(c) Monitored conditions: Monitored indications shows that defect will not fail before next

inspection. Such indications are the least severe and will not require examination and evaluation

until next scheduled integrity assessment interval provided that they are not expected to grow to

critical level prior to the next scheduled assessment.

(B) Mitigation through Preventive Actions: Some of the mitigation actions are listed below:

a) Actions for increasing the adequacy levels of CP protection, like increasing CP current

levels, installation of additional capacity etc.




b) Replacement / repair of pipe sections based on analysis outcomes. This has to be based on

the applicable PNGRB standards

c) Consultation with equipment suppliers for deciding course of actions

Table-16: Liquids – High Consequential Areas Repair Conditions

Immediate

Metal Loss > 80%Metal Loss predicted burst pressure < MOPDent top of pipe with metal loss, crack stress riserDent top of pipe > 6% Anomaly that analyst believes to warrant immediate repair

60 Days Dent top of pipe > 3% (or > 0.25” if pipe diameter < 12”)Dent bottom of pipe with metal loss, crack, stress riser

180 Days

Dent > 2% that affects pipe curvature at girth or seam weld Dent top of pipe > 2% (or > 0.25” if pipe diameter < 12”)Dent bottom of pipe > 6%Metal loss calculated MAOP < MOPMetal loss area of general corrosion > 50%Metal loss > 50% affecting girth weld or at pipeline crossing CrackCorrosion along seam weld Gouge > 12.5%

In short, the below approach may be followed for mitigation actions:

The plans for critical activities are reviewed periodically by GM (O&M) JLPL HQ address the resources

(means) requirement and necessary changes in organizational and external factors affecting integrity

management.



Integrity assessment results

Mitigation actions

evaluated?

Incorporate additional frequencies or include actions in subsequent Annual Maintenance Plans

Develop plans for all such critical or special activities and include in subsequent business and yearly plans, including allocation of resources

Normally undertaken

Activities

Critical activities or activities

Requiring special focus


6.1.7 Update, integrate and review data: After the initial integrity assessments are completed, the

results has been maintained in soft and/or hard versions which are used for future risk and

integrity assessments in addition to operational information that is recorded on continuous basis

for assessments and implementing risk mitigation plan.

6.2 PERFORMANCE PLAN: JLPL has defined suitable performance indicators which are

monitored to give a picture of the integrity levels of various aspects of the GAIL’s pipeline

assets. Performance indicator measure either or all of the below as applicable:

1) Process measures e.g. Number of damages per excavation notification received

2) Operational measures e.g. No. of significant ILI anomalies

3) Direct integrity measures e.g. No. of damages per km. of pipeline length

JLPL conduct periodic audits to validate the effectiveness of its integrity management programs and

ensure that they have been conducted in accordance with the plan. A list of essential items as provided

below has been considered in developing JLPL integrity management and performance evaluation

program:

1) An integrity management ISO policy and program for all applicable elements is in place.

2) Written integrity management plan procedures and task descriptions are upto date and readily

available.

3) Activities are performed in accordance with the plan.

4) Individuals have received proper qualification and training for activities which they are to

undertake.

5) The integrity management program meets the requirements of this document

6) All required activities are documented.

7) All action items or non-conformances are closed in a timely manner.

8) The risk criteria used have been reviewed and documented.

9) Prevention, mitigation, and repair criteria have been established, met, and documented.

10) Data developed from program-specific performance indicator measures, results of internal

benchmarking, and audits are used to provide an effective basis for evaluation of the integrity

management program




6.2.1 PERFORMANCE MEASURES: Performance measures are a tool for evaluating the success

of the Pipeline Integrity Management System. The performance measures have been developed as a

method to gauge the extent to which the Pipeline IMS goals have been met. Performance results

demonstrate whether integrity management activities are appropriate or require improvements. The

results are evaluated annually by the GM (O&M) JLPL HQ, at which time the appropriateness of each

performance measure is assessed. Some of the goals as part of performance measures are illustrated

below for reference. In GAIL Maintenance Policy & Guideline-2010 goals on priorities & specific

problems has been defined in its Annexure-1 and same has been reproduced here as Appendix-VI.

For performance measures relating to damage events, the following points have been documented in the

JLPL’s Damage Prevention Report in maintenance manual:

The number of third party damage events and near misses.

The number of pipeline hits by third parties due to lack of notification as locate request.

Aerial surveillance and patrolling reports.

6.2.2 Continuous Improvement: The Integrity Management System will be continuously evaluated

and modified to accommodate changes in pipeline design and operation, changes in both the

physical and regulatory environment in which the system operates and new operating data or

other integrity related information. Continuous evaluation is considered to make sure that the

program takes appropriate advantage of improved technology and that the program remains

integrated with the GAIL’s business practices and effectively supports the JLPL’s integrity

goals.

Integrity Management System shall be evaluated and reviewed as per the frequency described

in PNGRB-Schedule-9. Issues that would typically be reviewed are given below:

a) Performance measures,

b) Testing and inspection successes and failures,

c) New threat identification ,

d) Root causes analysis of pipeline breakdowns & accidents

e) Process enhancement / changes(MOC),

f) Recommended changes for the IMS,

g) Additional training requirements necessary to support IMS,

h) Public awareness program

i) Inspection tool performance(Whenever applicable)

j) Inspection tool vendor performance

k) Alternative repair methods,

l) Staffing for inspections, testing and repairs

m) Past and present assessment results,




n) Data integration and risk assessment information,

o) Additional preventive and mitigating actions,

p) Training needs of O&M personnel

q) Additional items as necessary to aid in the success of the IMP program.

Based on results of the internal reviews, integrity assessment & mitigation program will be

improved & documented.

6.3 COMMUNICATION PLAN : JLPL has communications plan to keep appropriate GAIL

personnel, jurisdictional authorities, and the public informed about their integrity management

efforts and the results of their integrity management activities. The information is

communicated as part of other required communications.

6.4 MANAGEMENT OF CHANGE PLAN: Formal management of change procedures is in

placed in ISO standard procedure and OISD guidelines is being followed to identify and

consider the impact of changes to pipeline systems and their integrity.

6.5 QUALITY CONTROL PLAN: JLPL has integrated ISO system of ISO 9001:2008 QMS,

ISO 14001: 2004 EMS, and OHSAS 18001: 2007 and maintain documented procedure and

records as per the requirement of this standard. The following activities have been made part of

quality control program:

(i) Identify and maintain the document required for Integrity management plan procedures

and records. This includes both controlled and uncontrolled documents.

(ii) Defining Roles & responsibilities for implementation of programme, documentation

etc.

(iii) Review of Integrity management plan and implementation of recommendation at

predefined interval

(iv) Training and awareness of persons implementing the Integrity management plan

(v) Periodic internal Audit of integrity management plan and quality plan

(vi) Documentation of corrective actions taken /required to improve the integrity

management plan or quality plan

Internal Audits of the Pipeline Integrity Management System is performed on a regular basis. The

purpose of the audits is to ensure compliance with the policies and procedures. Recommendations and

corrective actions taken is documented and incorporated into the Pipeline IMS.

Internal audits are conducted by the audit group nominated by GM (O&M)/OIC JLPL HQ at least once

in a year. Internal audits aim to ensure that the Integrity Management System’s framework is being

followed. The following essential items are focused on for any internal audit and external audit of the

entire IMS:




a) Ensure that the Baseline Plan is being updated and followed and that the baseline inspections

are carried out.

b) Verify qualifications of O&M personnel and contractors based on education qualification

(Appendix-IV), formal training received through in-house or external program, demonstrated

practical skills, and experience records in the relevant areas. Refer ASME B31Q for Guidance.

c) Ensure adequate documentation is available to support decisions made.d) Determine if annual performance measures have been achieved.

e) A written integrity management policy and program for all elements

f) Written IMS procedures and task descriptions are up to date and readily available.

g) Activities are performed in accordance with the IMS.

h) A responsible individual has been assigned for each task.

i) Individuals have proper qualification-Same to be documented.

j) All required activities are documented.

k) All action items or non-conformances are closed in a timely manner.

l) The risk criteria used have been reviewed and documented.

m) Prevention, mitigation and repair criteria have been established, met and documented.

7.0 CONTROLS OVER INTEGRITY: JLPL have in place various controls which put over at

various stages, to achieve sound integrity management. The various stages are described below:

7.1 DESIGN: Integrity management of a pipeline starts with a sound design and construction of

the pipeline. JLPL has ensured that relevant standards (including PNGRB standards and those

referenced in it) are applied to the design and designer considers the area the pipeline traverses

and the possible impacts that the pipeline may have on that area and the people that reside in

the vicinity. JLPL maintain a document for Basis of Design, and all the pipelines laid by it and

all other facilities.

7.2 PROCUREMENT & SUPPLY CHAIN: JLPL ensure that purchased products confirm to

specified purchase requirements. The purchase specifications are reviewed on a regular basis.

The C&P Dept. evaluates and selects suppliers based on their ability to supply to its

specifications. The critical items are inspected by a Quality Control / Assurance team and / or

by certified third party agencies.

7.3 FABRICATION, CONSTRUCTION, INSTALLATION & TESTING STAGE: JLPL

ensure that pipework and other components are fabricated, constructed, inspected and tested in

compliance with the specifications developed for different purposes. Quality of fabrication,

construction, installation is being assured by conducting quality audits, by appointing TPIs,

etc. The means of ensuring compliance with specifications is addressed and deviations to

planned arrangements are recorded. For critical items, JLPL maintenance department invokes

independent inspection, even if only on a sampling basis.




The key integrity measures for Fabrication, Construction, Installation and Testing are:

o Compliance with design & construction specifications

o Appropriate fabricators

o Quality control / assurance

o Construction documentation

o Deviations / concessions recorded

o Confirmation of integrity as appropriate (pressure testing / NDT etc.)

o Commissioning plans and procedure

7.4 SYSTEM HANDOVER / TAKEOVER: At corporate level policy and procedure has been

circulated.

7.5 COMMISSIONING: Plans and procedures are in place for safe commissioning. Pre

commissioning checks, tool box talk and safe control operations; these are the tools to assure

mechanical integrity of system under commissioning.

7.6 OPERATIONS: In SOP and ISO document JLPL/OPN Issue-06 Dtd 1st July,2011 has

established its operations philosophy and implement it by operations management procedures

and controls developed by it. Through SOP JLPL has provided adequate operational controls

and procedures to avoid adverse incidents impacting the health, safety and security of the work

force, the environment.

Clear, up-to-date procedures and instructions are available to cover normal operating

conditions, emergencies and management of changes. Safe operating levels have been defined

to demarcate between normal operating deviations and operating outside the design envelope.

The key integrity controls for operations are:

Operating instructions /procedures which have clearly defined operating boundaries

including allowable start-up / shutdown excursions

Emergency procedures

System for operational alarms and their handling and management

Procedure for management of changes

Adequate management systems to ensure operational efficiency

Pipe work is operated within agreed boundaries

Reporting of abnormal operation, or excursions beyond operational boundaries including

notification for actions

7.7 IN-SERVICE INSPECTION, TESTING, MAINTENANCE, REPAIRS &

REPLACEMENT: GAIL CO has circulated its Maintenance Policy & Guidelines-2010 and

same is available in soft in GAIL-Intranet.




The approach for inspection and testing has been mentioned in the maintenance philosophy.

JLPL also have preventive maintenance initiatives in place. These processes have been

specifically targeted to minimize identified risks. Examples include

Initiatives to minimize third party damages

Pipeline patrolling - to monitor activity near pipelines

Leakage management process

Scheduled maintenance - to minimize equipment malfunction

Corrosion management process

Replacements - to replace unserviceable installations

The capability for effective response to leaks and equipment breakdown or malfunction should be

maintained on a 24 HR* 7 days a week basis.

7.8 INSTRUMENTATION & ELECTRICAL: Instrumentation and Electrical management

system is fully geared towards maintaining the Instrumentation & Electrical assets in good

working order to ensure an optimal operational management during the planned operational life

cycle while complying with the company policy. This is achieved by planning and

implementing a comprehensive maintenance plan for assets and ancillary equipment that

protects the health and safety of personnel, protects the environment, protects and preserves the

company’s capital investment, and enables targeted performance

1. Minimizing the number of equipment failures

2. Planning of repairs to ensure minimum disruption

3. Monitoring for wear and tear and random failures

7.9 DE-COMMISIONING, DISMANTLING, DEMOLITION & DISPOSAL: Plans and

procedures have been developed for safe decommissioning, dismantling, demolition and

disposal. These also address isolation, decontamination and environmental issues. Each

pipeline abandoned in place shall be disconnected from all sources and supplies of LPG;

purged of LPG and sealed at the ends (usually with the use of end caps). Whenever supply to a

delivery terminal is discontinued, one of the following is done.

a) The valve that is closed to prevent the flow of LPG to the terminal has been provided with

a locking device or other means designed to prevent the opening of the valve by persons

other than authorized persons;

b) A mechanical device or fitting that will prevent the flow of LPG is installed in the line or

somewhere along the assembly;

c) The terminal’s piping is physically disconnected from the LPG supply and the open pipe

ends sealed.




8.0 APPROVAL OF INTEGRITY MANAGEMENT SYSTEM (IMS): A JLPL Integrity

Management System is a management plan in the form of a document that explains to JLPL’s

employees, customers, regulatory authorities, etc., how the PIPELINE and its assets are

managed, by stating:

(i) Organogram and Role & Responsibility who is responsible for each aspect of the asset

and its management has been defined in this document;

(ii) Policies and processes are in place to achieve targets and goals, and the same has been

given in this document;

(iii) They are implemented through Respective O&M Base WIC/OIC;

(iv) Performance is measured through online data and frequency base MIS report;

(v) The whole system is regularly reviewed and audited through Half yearly Management

Review Meeting conducted.

9.0 REVIEW OF THE INTEGRITY MANGEMENT SYSTEM:

9.1 Periodicity: In line with PNGRB requirement JLPL shall review their existing IMS every 3

years based upon the:

(i) Revised Baseline data

(ii) Critical Inputs from various departments

9.2 Review of IMS by PNGRB: There shall be a system for ensuring compliance to the provision

of these regulations by conducting following audits during operation phase:

(a) Internal Audit as per the checklist for LPG pipelines provided by PNGRB is carried out by

the management of JLPL every year.

(b) External Audit (EA) by third party, approved by the Board, as per the methodology

specified by the PNGRB every 3 years.

10.0 Adequacy of Manpower positioned at JLPL STATION : GAIL Management and CO HR

DEPT takes care of the requirement of manpower for different stage of project, namely: Design,

construction, commissioning, operation and maintenance. In JLPL the GAIL management has deployed

manpower of the qualification in conform to Appendix-IV. The respective O&M Base is having the

detailed records of all manpower as posted to their station.




APPENDIX-I1.1 PHYSICAL DESCRIPTION OF JLPL:

DESIGN CAPACITY

The LPG pipeline system has been designed for the transportation 2.5 MMTPA. LPG will be received

from different sources as detailed hereunder,

RPL – Jamnagar : 1.5 MMTPA

EOL – Jamnagar : 0.5 MMTPA

Imported LPG – KANDLA : 0.5-1.5 MMTPA

DESIGN CODES

The LPG pipeline has been designed as per ASME B 31.4 & OISD 141 & 214

TABLE-01: DETAILS OF MAIN PIPELINESr.

No.P/L Section

Diameter

Inch

Length

KmGrade/Thk

Operating Press

Kg/cm2

01 EOL –RIL DT 6 23.7 API 5 L X 60 7.1/ 6.4 mm 20 – 5002 RIL DT –Samakhiali 14 166.7 API 5 L X 60 7.1/ 6.4 mm 40 - 8503 IOC Kandla- DT Kandla 12 8.3 API 5 L X 60 7.1/ 6.4 mm 14 - 25

04Hook up point to GAIL’s

scraper area inside IOCL

Kandla

8 0.411API 5 L Gr. X 60 7.1/ 6.4

mm

14 – 25

05Hook up point to GAIL’s

scraper area inside IOCL

Kandla

10 0.367API 5 L Gr. X 52 7.8/ 6.4

mm14 - 25

06 DT Kandla – Samakhiali 08 58.5 API 5 L X 60 7.1/ 6.4 mm 35 - 4507 DT Kandla – Samakhiali 10 58.5 API 5 L X 52 7.1/ 6.4 mm 35 - 45




08 Samakhiali – Abu Road 16 272.0 API 5 L X 65 8.7/ 7.1 mm 40 - 85

09 Abu Road - IP2 (Khinwada) 16 142.40 API 5 L X 65 8.7/ 7.1 mm 40 - 85

10 IP2 (Khinwada) – Nasirabad 16 163.70 API 5 L X 65 8.7/ 7.1 mm 40 - 8511 Nasirabad- Mansarampura 12 121.4 API 5 L X 60 7.1/ 6.4 mm 40 - 8512 Mansarampura IP – Loni 12 309.3 API 5 L X 60 7.1/ 6.4 mm 15 - 85

Total 1325.40

TABLE-02: DETAILS OF SPUR PIPELINE Sr. No. P/L Section Diameter

InchLength

Km Grade/Thk Operating Press Kg/cm2

01TOT- 1 To RT IOCL -

Ajmer8 N.B. 11.0 API 5 L X42 7.1/ 6.4 mm 15-40

02 IPS – Nasirabad To HPCL 8 N.B. 1.0 API 5 L X42 7.1/ 6.4 mm 15-25

03 IPS – Nasirabad To BPCL 8 N.B. 2.2 API 5 L X42 7.1/ 6.4 mm 15-25

04 TOT – 2 To RT Sanganer 8 N.B. 36.7 API 5 L X42 7.1/ 6.4 mm 40–65

05 Loni – HPCL 8 N.B. 2.5 API 5 L X42 7.1/ 6.4 mm 15 – 25

06 Loni – BPCL 8 N.B. 2.5 API 5 L X42 7.1/ 6.4 mm 15 - 25

07 Mansarampura-BPCL-RT 4 N.B. 13.6 API 5 L X42 6.4 mm 15 - 50

08 SV 63 to RT, Gurgaon 6 N.B. 19.6 API 5 L X42 6.4 mm 15 - 50

Total length 89.1

1.1.2 STORAGE FACILITIES: No LPG storage. In JLPL there is only Diesel Storage facility is

available that to run the back-up power Diesel Engine Generator for operating the LPG Pumps and to

maintain emergency power at station.

1.1.3 MAIN LINE AND BOOSTER PUMPS:

The pipeline has Six Pumping Station in JLPL and Three Despatch Terminals at Jamnagar and Kandla.

Detail as below shows pipeline network consisting of different Receipt and Despatch terminals and

pumping stations. Details of the pumps all along the Jamnagar – Loni LPG pipeline are as detailed

hereunder in Table-03 & 04.

DETAILS OF INTERMEDIATE PUMPING STATIONS ALONG THE P/L [TABLE-03]

SL. NO

.PARAMETERS

JAMNAGAR KANDLARIL-

BOOSTER M/L-PUMP EOL DT OLD PUMPS KSPL-II PUMPS

1 Pump No. 20-PA-CF-101 A/B/C

20-PA-CF-102 A/B/C

10-PA-CF-101 A/B

40-PA-CF-101 A/B

40-PA-CF-201 A/B

2 POWER RATING (KW) 194 478.5 231 630 320

3 Capacity(M3/HR) 258.5 258.5 129.8 130 260

4 Head(M) 347 891 787 550 574

5 Efficiency (%) 73.6 78.6 70.5 68 76

6(NPSHR) Net

Positive Suction Head Required(M)

2 10.2 4.5 NA 10.3

7 Speed(RPM) 2950 3420 2950 3420 3475




8 Stages 3 8 10 5 5

9Suction Pressure

3.5 - 10.5 19 - 26.5 3.5-10.5 12 13 - 18(KG/CM2 )

10Discharge Pressure

23.8 - 30.8 71.1 - 78.1 49.5 - 56.5 46 43 - 49(KG/CM2 )

11 Diff. Pressure (KG/CM2 ) 20.3 52.1 46 23 31

12 Pumping Temp. ( °C) 15 - 45 15 - 45 15 - 45 15 - 25 15 - 25

13 Motor Efficiency (%) 95.2 95.6 95.2 95.6 96.6

14 Motor Rating(KW) 230 530 280 630 375

15 Pumping Fluid LPG LPG LPG LPG LPG

16 Fluid Density 0.515 - 0.585 0.515 - 0.585 0.515 - 0.585 0.515 - 0.585 0.515 - 0.585

17 MAKE OF PUMPINGERSOLL -

DRESSER, AUSTRIA

M/s CLYDE UNION

(earlier DAVID BROWN), UK

INGERSOLL - DRESSER, AUSTRIA

M/s CLYDE UNION


M/s CLYDE UNION (earlier DAVID

BROWN), UK

18 MAKE OF MOTOR BHEL, INDIA ANSALDO,

ITALY BHEL, INDIA LOHER, GERMANY

WEG, GERMANY

19DATE OF

COMMISSIONING

Year-2000 Year-2000 Year-2008 13 AUG, 2003 20 MAY, 2011

20

RUNNING HOUR OF EACH PUMP TILL 25TH MAR,

2012

1. Booster pump-A: 45194 hrs2. Booster

pump-B: 39405 hrs

3. Booster pump-C: 41205

hrs

1. M/L pump-A: 49681 hrs

2.M/L pump-B: 53705 hrs

3. M/L pump-C: 65275 hrs

1. B/P-A: 9254 HRS

2.B/P-B: 8736 HRS

PUMP-101 A : 15258 Hrs.

PUMP 101-B : 9251 Hrs.

PUMP-201 A : 942 Hrs.

PUMP 201-B : 859 Hrs.

DETAILS OF INTERMEDIATE PUMPING STATIONS ALONG THE P/L [TABLE-04]

SL. NO. PARAMETERS

SAMAKHIALI ABU ROAD NASIRABAD MANSARAMPURA

1 Pump No. 50-PA-CF-101 A/B/C

60-PA-CF-101 A/B/C

70-PA-CF 101 A/B/C 80PA-CF-101 A/B/C

2 POWER RATING (KW) 758 836 556.4 580

3 Capacity(M3/HR) 323 323 270 195

4 Head(M) 1160 1282 1002 1180

5 Efficiency (%) 78.8 78.9 77.6 75.8

6(NPSHR) Net

Positive Suction Head Required(M)

9 9 6.3 7

7 Speed(RPM) 3420 3370 3125 3420

8 Stages 7 8 7 10

9Suction Pressure

19 19 21 21(KG/CM2 )

10 Discharge Pressure 86.9 94 79.7 90




(KG/CM2 )

11 Diff. Pressure (KG/CM2 ) 67.9 75 58.7 69

12 Pumping Temp. ( °C) 20 - 25 20 - 25 20 - 25 20 - 25

13 Motor Efficiency (%) 95.3 95.6 95.3 95.3

14 Motor Rating(KW) 898 984 690 690

15 Pumping Fluid LPG LPG LPG LPG

16 Fluid Density 0.515 - 0.585 0.515 - 0.585 0.54 - 0.585 0.515 - 0.585

17 MAKE OF PUMP

M/s CLYDE UNION


M/s CLYDE UNION


M/s CLYDE UNION


M/s CLYDE UNION


18 MAKE OF MOTOR ANSALDO, ITALY ANSALDO, ITALY ANSALDO,

ITALYLOHER,

GERMANY

19 DATE OF COMMISSIONING 10 NOV, 2000 7 FEB, 2001 10 DEC, 2000 25 AUG, 2003

20

RUNNING HOUR OF EACH PUMP TILL 25TH MAR,

2012

PUMP 101 A : 43995 Hrs.

PUMP 101-B : 43613 Hrs.

PUMP 101-C : 40735 Hrs.

PUMP 101 A : 43884 Hrs.

PUMP 101-B : 52306 Hrs.

PUMP 101-C : 47821 Hrs.

PUMP 101 A : 48179 Hrs.

PUMP 101-B : 42364 Hrs.

PUMP 101-C : 30989 Hrs.

PUMP 101 A : 29170 Hrs.

PUMP 101-B : 19614 Hrs.

PUMP 101-C : 23609 Hrs.

1.1.4 SECTIONALISING VALVE (SV) STATIONS:

To isolate the pipeline segment 74 Nos. Sectionalizing Valves are installed at an average distance of 20

km all along the pipeline including the spur line from TOT-2 to RT Sanganer. Mainline valves of full

bore gate type are installed for isolating different sections of pipeline in case of leak/burst etc. Out of 74

valves 62 Nos. can be remotely operated from MCR at Jamnagar/Loni and remaining 12 Nos. located

near to manned stations can be operated manually. However, in case of emergency remotely operated

valves can also be operated manually. At SV/IP/TOT stations PT, TT, Pressure gauge and temperature

gauges are installed to monitor the pressure and temperature at these locations locally as well as from

MCRs.

Details with respect to each SV are as mentioned hereunder in Table-05:

Sl. No.

DT/SV/IP/TOT/IPS

Chainage (Km) Village / Tehsil / Distt. Manual /

RemoteBattery Bank

Mobile Flare line Remarks

0 RIL/RPL 0 Motikhavri/Jamnagar Yes CP Stn.

1 SV-1 7.125 Japar/JGA/JGA Manual - Yes

2 SV-2 17.290 Lakhabaval/JGA/JGA Remote 2 X 19,2390AH -

3 SV-3 28.128 Morkanda/JGA/JGA Remote 2 X 19,2390AH Yes CP Stn.

4 SV-4 41.721 Sekhpat/JGA/JGA Remote2 X

38,15508AH

-




5 SV-5 66.831 Bhadra/Jodia/JGA Remote 2 X 19,2390AH Yes CP Stn.

6 SV-6 77.215 Balambha Jodia/JGA Remote 2 X 19,2390AH -

7 SV-7 105.787 Kuntari/Jodia/Rajkot Remote 2 X 38,2000AH Yes CP Stn.

8 SV-8 136.793 Haripar/Malia/Rajkot Remote 2 X 19,2390AH - CP Stn.

9 SV-9 153.775 Sikarpur/Bhachau/Kutch Remote 2 X 19,2390AH Yes CP Stn.

10 SV-10 157.771 Naransari/Bhachau/Kutch Manual Manual -

11 IPS 166.7 Lakadia/Bhachau/Kutch Remote - CP Stn.

12 SV-11 179.268 Dedarwa/Rapar/Kutch Manual Manual -

13 SV-12 192.369 Kidiyanagar/Rapar/Kutch Remote 2 X 19,2390AH Yes

14 SV-13 206.378 Bhimasar/Rapar/Kutch Remote 2 X 19,2390AH - CP Stn.

15 SV-14 220.549 Lakhpat/Rapar/Kutch Remote 2 X 19,2390AH Yes CP Stn.

16 SV-15 239.026 Garamadi/Santalpur/Patan Remote2 X

38,15508AH

-

17 SV-16 250.011 Par/Santalpur/Patan Remote 2 X 19,2390AH Yes CP Stn.

18 SV-17 263.881 Vagphura/Santalpur/Patan Remote 2 X 19,2390AH -

19 SV-18 279.822 Nanipipli/Radhanpur/Patan Remote 2 X 19,2390AH Yes CP Stn.

20 IP - 1 309.281 Unn/Kankrej/Palanpur Remote 2 X 38,2000AH -

21 SV-19 322.357 Jampura/Kankrej/Palanpur Remote 2 X 19,2390AH Yes CP Stn.

22 SV-19A 342.385 Rakhav/Patan/Patan Remote 2 X 19,2390AH -




23 SV-20 352.394 Laxmipura/Patan/Patan Remote 2 X 19,2390AH Yes E/R

24 SV-21 363.705 Madangadh/Palanpur/ Remote 2 X 19,2390AH - CP Stn.

25 SV-22 378.143 Khodla/Palanpur/ Remote2 X

38,15508AH

Yes E/R

26 SV-23 386.261 Parpada/Palanpur/ Remote 2 X 19,2390AH -

27 SV-24 400.033 Rajpuria/Palanpur/ Remote 2 X 19,2390AH Yes CP Stn.

28 SV-25 411.126 KalimatiAmirgadh/ Palanpur Remote 2 X

19,2390AH - CTSU

29 SV-26 424.005 Awal/Amirgadh/ Palanpur Manual Manual Yes E/R

30 IPS - 2 438.678 Tartoli/Abu-Road/Sirohi Remote - CP Stn.

31 SV-27 452.902 Bhajwa/Pindwara/Sirohi Manual Manual -

32 SV-28 462.815 Bhawari/Pindwara/Sirohi Remote 2 X 19,2390AH Yes E/R

33 SV-29 472.849 Banas/Pindwara/Sirohi Remote 2 X 19,2390AH - CTSU

34 SV-30 486.45 Pindwara/Pindwara/Sirohi Remote 2 X 38,2000AH Yes CP Stn.

35 SV-31 519.641 Bhatund/Bali/Pali Remote 2 X 19,2390AH - E/R

36 SV-32 529.04 Borwa/Bali/Pali Remote 2 X 19,2390AH - CP Stn.

37 SV-33 557.262 Kotadi/Desuri/Pali Remote2 X

38,15508AH

YesE/R &

CTSU

38 SV-34 568.536 Bordi/Desuri/Pali Remote 2 X 19,2390AH - CP Stn.

39 IP-2 582.123 Bera/Desuri/Pali Remote2 X

38,15508AH

-

40 SV-35 593.789 Kadu/Marwar Jn./Pali Remote 2 X 19,2390AH -




41 SV-36 608.364 Bari/Marwar Jn./Pali Remote 2 X 19,2390AH Yes CP Stn.

42 SV-37 622.575 Kantaliya/Marwar Jn./ Pali Remote

2 X 38,15508A

H-

43 SV-38 634.696 Kelwad/Sojat/Pali Remote 2 X 19,2390AH Yes

44 SV-39 654.556 Kapurdi-dhani/Raipur/ Pali Remote 2 X

19,2390AH - CP Stn.

45 SV-40 680.742 Naharpura/Raipur/Pali Remote2 X

38,15508AH

YesE/R &

CTSU

46 SV-41 691.379 Kolpura/Raipur/Pali Remote 2 X 19,2390AH - CP Stn.

47 SV-42 715.68 Daulat Khera/Pisangan/Ajmer Remote 2 X

19,2390AH Yes E/R

48 TOT - 1 733.349 Nasirabad/Ajmer Remote 2 X 38,2000AH - CP Stn.

49 IPS-3 744.855 Nasirabad/Ajmer Remote - CP Stn. E/R

50 SV-43 762.704 Tikawada/Kishangarh/Ajmar Remote 2 X

19,2390AH -CP Stn

CTSU,E/R

51 SV-44 776.9 Kalanda/Kishangarh/Ajmer Remote 2 X 19,2390AH Yes E/R

52 SV-45 806.193 Dudu/Dudu/Jaipur Remote 2 X 38,2000AH - CP Stn.

53 SV-46 834.806 Nandlalpura/Phagi/Jaipur Remote 2 X 19,2390AH Yes

CTSU &

E/R

54 SV-47 843.934 Badi Ka Khera/Sanganer/Jaipur Remote 2 X

19,2390AH - CP Stn.

55 SV-48 + TOT-2 855.821 Sinwar/Jaipur/Jaipur Remote 2 X

38,2000AH Yes CP Stn.

56 IP - 3 866.279 Mansarampur/Jaipur/Jaipur Remote 2 X 38,2000AH - CP Stn.

57 SV-49 878.168 Nagala Purohit/Amer/Jaipur Manual Manual -




58 SV-50 891.901 Ishwar Ka Nangal/Amer/Jaipur Remote 2 X

19,2390AH -

59 SV-51 905.603 Sunder Ka Bas/Amer/ Jaipur Remote 2 X

19,2390AH Yes E/R

60 SV-52 915.859 Manoharpura / Shahpura / Jaipur Remote 2 X

19,2390AH - CP Stn.

61 SV-53 928.604 Dhani jogiyan / Viratnagar / Jaipur Remote 2 X

19,2390AH Yes CTSU

62 SV-54 941.324 Dhoolkot / Viratnagar / Jaipur Remote

2 X 38,15508A

H- E/R

63 SV-55 953.645 Panch Pahari / Kotputli / Jaipur Remote 2 X

19,2390AH Yes

64 SV-56 967.958 Milakpur / Bansur / Alwar Remote 2 X 19,2390AH - CP Stn.

65 SV-57 982.151 Mothuka / Bansur / Alwar Remote 2 X 19,2390AH Yes E/R

66 SV-58 995.176 Tatarpur / Mundawar / Alwar Remote

2 X 38,15508A

H-

67 SV-59 1009.610 Bhojpur / kotkasim / Alwar Remote 2 X 19,2390AH Yes CP Stn.

68 IP - 4 1023.289 Naya Gaun/Kishangarh/ Alwar Remote

2 X 38,15508A

H- E/R

69 SV-60 1037.611 Bichhala /Tijara/Alwar Remote 2 X 19,2390AH - CTSU

70 SV-61 1051.773 Guwalda /Tijara/Alwar Remote 2 X 38,2000AH Yes CP Stn.

71 SV-62 1065.715 Buya ka Taddu/Taavru/Gurgaon Remote 2 X

19,2390AH Yes

72 SV-63 1075.92 Sohna/Sohna/Gurgaon Remote 2 X 19,2390AH - E/R

73 SV-64 1088.954 Bihaka/Sohna/Gurgaon Manual Manual Yes

74 RT Piyala 1103.376 Piyala/B.Garh/Faridabad Remote - CP Stn.

75 SV-65 1116.753 Sithi/B.Garh/ Faridabad Manual Manual Yes E/R

76 SV-66 1128.493 Etmadpur/Faridabad/ Faridabad Manual Manual -

77 RT M'Khadar 1137.152 M'khadar/Delhi/Delhi Remote - CP Stn.

78 SV-67 Manual Manual

79 SV-68 1142.097 Kalindi kunj / Noida Remote 2 X 19,2390AH Yes CTSU

80 SV-69 1156.22 Indrapuri/Gaziabad/ Gaziabad Manual Manual - E/R

81 SV-70 1164.948 Karhera/ Gaziabad/ Gaziabad Remote 2 X

19,2390AH Yes




82 RT Loni 1175.544 Loni/Gaziabad/Gaziabad Remote - CP Stn.

83 SV-71 Does not exist

84 SV-72 12.342 Jaysingh pura/Sanganer/Jaipur Remote 2 X

19,2390AH Yes

85 SV-73 26.014 Shypura/Sanganer/Jaipur Manual Manual -

86 RT Sanganer 36.678 Sitapura/Sanganer/Jaipur Remote - CP Stn.

87 RT-Jaipur88 RT-Gurgaon89 IOCL-Kandla 1.079 Kharirahar/Kandla/Kutch90 DT-Kandla 7.19191 SV-01 39.8 Vondh/Bhachau/Kutch Remote

92 IPS-Samakhiali Lakadia/Bhachau/Kutch Remote

1.1.5 DELIVERY STATIONS/TERMINALS

RECEIPT TERMINALS (RT)

To deliver filtered & uninterrupted LPG at specified pressure & flow to OMCs total Eleven No. receipt terminals are installed along JLPL. Details has been given in Table-06

Sr. No. Receipt TerminalP/L distance from

JamnagarKm

Allocated Throughput as per TSAMMTPA

01 Ajmer (IOCL) 744.755 0.07002 Ajmer (HPCL) 747.141 0.07003 Ajmer (BPCL) 748.895 0.10004 Sanganer (IOCL) 894.551 0.16005 Jaipur (BPCL) 879.873 0.03806 Gurgaon (IOCL) 1095.52 0.15007 Piyala(BPCL) 1103.108 0.20008 Madanpur Khadar (IOCL) 1137.152 0.16009 Loni (IOCL) 1174.627 0.37010 Loni (BPCL) 1176.978 0.13011 Loni (HPCL) 1177.310 0.230

DESPATCH TERMINAL (DT)

Despatch Terminal is the terminal where LPG is received from the source & then pumped to required

pressure. The pipeline has two dispatch terminals at Jamnagar & one Despatch terminal at Kandla.

Two Despatch terminals at Jamnagar are,

ESSAR OIL LTD. (EOL)

Reliance Petroleum Limited (RPL/RIL).

At present RPL –DT Jamnagar is receiving 1.5 MMTPA of LPG from RPL. This DT receives LPG

from the RPL/RIL spheres at 4-6 Kg/cm2 and pump by booster Pumps up to 19 kg/Cm2 to Mainline

Pumps. Mainline Pump is pumping LPG at 60-85 Kg/Cm2 to IPS Samakhiali. Facilities like Pig

Launching/Receiving, Filtration, Metering Instrumentation, controls & Interlocks, Power, F&S, have

been provided for safe operation LPG Pumps. Considering the high flow rate, two running and one

stand by Pump sparing philosophy is adopted.




EOL – DT is upstream of the RPL – DT & presently in operation. Throughput of 0.5 MMTPA of

LPG is received from the EOL spheres at 4-6 Kg/cm2 and pump by booster Pumps 10-PA-CF-101

A/B to 40-50 Kg/cm2 to Mainline Pumps. At RPL Facilities like Pig Launching, Filtration, Metering

Instrumentation, controls & Interlocks, Power, F&S, have been provided for safe operation LPG

Pumps. Considering the low flow rate, one running and one stand by Pump sparing philosophy is

adopted.

Kandla DT has been to cater 1.5 MMTPA of LPG from IOCL terminal & to deliver at the suction of the IPS-Samakhiali pumps. Facilities similar to EOL-DT have been provided for safe operation LPG Pumps. Considering the low flow rate, one running and one stand by Pump sparing philosophy is adopted.

APPENDIX-II

2.1.7 INSTRUMENTATION & ELECTRICAL SYSTEMS:

GENERAL DESCRIPTION: Systems mainly supplied by Tata Honeywell, Chemtrols & David

Brown related to pump operation integrated in PLC-HMI & repeated to MCR through SCADA (M/s

YOKOGAWA) controls utility system, and provide backbone to pipeline safety and monitoring. The

whole system is divided into two categories viz,

c) Field instrumentation.

d) Control room Instrumentation.

a) FIELD INSTRUMENTATION: There are several field instruments use d for different purposes

such as pressure transmitter for sensing pressure and transmitting it to control room, Pressure switch

for alarms and initiation of interlock operation, LEL sensors for sensing explosive gas (LPG for our

case) sending signal to control room, 60% LEL sensing causes water sprinkler system actuation.

Besides this flow metering provided for safe operation of pump as well as leak detection. RTDs

provided for temperature sensing & signal to control room. Except these for local parameter monitoring

Temperature gauges and pressure gauges are provided.

Control valves provided for suction and discharge pressure control of Mainline Pump through LSS.

Motorized operated valves or MOVs are mounted in pipeline. In utility system Fire and Diesel

Generator system pressure switches, level transmitters are mounted.

b) CONTROL ROOM INSTRUMENTATION: Process signals from field are coming to the control

room where PLC (Programmable logic controller, having redundancy both in processor level as well as

I/O rack level) plays the vital role .It receives signal from field and execute logic for safe operation or

providing interlocks. Flow computer mounted in panel provide all data regarding flow. Controllers are

provided for suction and discharge pressure control whenever required, in RT’s these controllers

control LPG pressure and flow based on OMC demand. In Central control panel an Annunciator is

provided. In different panel barriers, Repeater, Relays is provided.




I. INSTRUMENTATION SYSTEM AND ITS COMPONENTS

The major components of the system are described in brief in this section.

1. Unit Control Panels (UCP)

2. Marshaling Rack (MR)

3. Interlock Relay Cabinet (ILRC)

4. Power Distribution Center (PDC)

Mostly all the system components are essentially incorporated in the above-mentioned panels, barring

those present in the Local Control Stations.

The Unit Control Panel (UCP): The unit control panel serves as an interface between the operator

and machines. It serves to provide all the necessary information needed for the operator to monitor the

running of the pumps whilst at the same time serving as a remote control panel from which the

operator can easily operate and control pumps. It contains the Start, Stop Push buttons of the mainline

pumps, the lube oil pumps for Phase-I pump, the cooler fans as well as their running and Stopped

indications and also an ammeter reading the motor current. However the other more important systems

present in this panel are as follows: -

1. The Annunciator module.

2. The vibration and temperature monitoring system.

3. Three Nos. of programmable process meters used to indicate remote speed set point, local set point

and running speed.

4. The Ramp generator unit.

The Marshaling Rack (MR): The marshaling rack in a way serves as the ear, eye and the mouth of

the system handling all the signals coming and going from the field. The MR is equipped to deal with

all the different kind of signals coming and going taking care all the time to maintain the line

separating hazardous and non-hazardous area limits. The MR houses the following devices that play a

crucial role in handling of the signals: -

1. IS Isolators (Resistance Isolating Barriers)

2. IS Isolators (Switching Repeaters)

3. Safety Barriers (Safety Barriers)

The Interlock Relay Panel (ILRC): The interlock relay panel houses the necessary elements to give

result to the complex logic designed to be executed in order to have a smooth operation of the pumps.

The safe operation of the pumps and the accessory units are as per the execution of a certain desired

sequence of actions and satisfaction of interlocks failure of which leads to the tripping of the pumps.

This logical sequence and the interlocks are achieved by a combined action of relays and timers and

are commonly termed as Relay Logic action. Thus it is clear that the ILRC contains the relays and the

timers required to achieve the above mentioned. The types of relays and timers present are: -




1. Multifunctional Timers.

2. 24VDC MY4H Relays.

3. Makes 110VDC MY4 Relays.

The Power Distribution Center (PDC): The PDC distributes UPS single phase supply of 230 VAC

to instrument panel like MR, PLC, Process, I/O Pump-Panel, etc.,

The Local Control Stations (LCS): The local control stations or the LCS’s actually are control panels

located in the field wherefrom one can operate the mainline pump and the accessory units. It is

however to be noted that one cannot control the mainline pumps from the mainline pump LCS as it

consists of only start and stop push buttons.

Apart from the system components described above there is also a local indication panel in the field

(one with each pump) wherein one can access important parameters related to the operation of the

mainline pumps like Auxiliary lube oil pump discharge pressure (Phase-I pumps), Main lube oil pump

discharge pressure (Phase-I pumps), Suction strainer differential pressure etc. to name few. This panel

also has in it mounted the pressure/diff pressure and temperature switches related to the various

parameters of pump operation (the signals of which are linked with the safety interlocks).

Speed Variation : This operation can be performed from the PLC or the UCP. While the speed set

point setting from the PLC takes place through a 4-20mA scaled analog output (AO) signal, the setting

of the set point from the UCP involves a 4-20mA-ramp generator, which generates the required signal

corresponding to the set point. Manual speed control ‘is also possible from UCP.

The 4-20mA signal from the AO of the PLC or the ramp generator passes through a 4-20mA signal

isolator and goes to the VSD end as a reference .The VSD interprets the signal and changes the speed of

the motor thus changing the pump speed.

Interlocks: For the safe operation of the pumps various interlocks are provided in the PLC. On

actuation of these interlocks it trips the pumps or does not allow starting. List of the interlocks & action

on actuation is described in individual station operation.

The Annunciator Module: The Annunciators features mono alarm, bi-alarm and tri-alarm displays

within standard Ronan modules. Each module accepts a single plug-in alarm PCB containing single,

dual or triple channel logic circuitry of conventional CMOS design.

All of these sequences differ in the way the actuated alarm is treated and the classification and priority

assignment of different alarms occurring at different times/time intervals. For technical specifications

and details of the different alarm sequences kindly refer the Technical Manual.

Programmable Process Meters: The programmable process meters are installed in the UCP’s to

indicate the remote speed set point, local speed set point and the running speed. The process input

version can read both mA & mV inputs. The selection can be made by a link.




I.S Isolators & IS Safety Barriers: Normally used are RTD Temperature Barriers, Switching

Repeaters (Contact Isolators), Analog Isolators (4-20mA Signals). This provides intrinsic safety for

field interface & positive signal isolation.

Timers and Relays-24VDC OR 110VDC (Description for M/L Pump): Relays and timers of the Relay

logic are hard-wired and are housed in ILRC. The timers used in the mainline system are

multifunctional timers. The suffix ‘M2’ signifies multifunctional. DPDT type timers where ‘M’ stands

for multifunctional and ‘2’ for DPDT type of contacts. These timers can be programmed for different

kinds of operation as is indicated by the following (We use A, D & J)

A – On delay,

B – Flicker Off Start,

B2 – Flicker On Start,

C – Signal On/Off Delay,

D – Signal Off Delay,

E – Interval,

G – Signal On/Off Delay,

J – One Shot.

Ramp Generator Unit. (Mainline only): In manual speed various mode, it changes the output reference

to VSD in such a manner than it follows a constant rise / fall ramp, so that bumping in output and hence

speed of the motor (pump) is eliminated.

Vibration and Temperature Monitoring system: All the pumps/motors are provided with Bentley

Nevada vibration monitoring system for tripping in case of any abnormalities during operation.

The Bentley Nevada Vibration and Temperature monitoring system one each per pump, comprises of

varied combination of dual vibration monitors, six channel temperature monitors with provisions for

keyphasor signals and alarm relay outputs. Velometer probes sense the vibrations and the temperatures

by typical three wire RTD’s. Vibration probes are based on proximity / eddy current principle.

Especially at RPL-DT Booster pumps & mainline pumps are kept in series & hence speed

synchronization of both the pumps is very much essential. Giving utmost importance to safety &

optimum operation of the pumps logic has been incorporated in PLC.

RESPONSIBILITY AND AUTHORITY : The heads of Department, Instrumentation Maintenance at each

O&M Base shall maintain an Organogram of his department. Each employee of instrument maintenance

department is responsible that all the instrument systems are well maintained.

HOD (INST) is responsible to ensure that the procedures described in this manual are followed for all the

maintenance activities (preventive, predictive and break-down) and other related activities such as spares planning




and management & contract jobs. Core group as constituted by GM (O & M) JLPL shall be responsible for

carrying out Engineering changes, import spares and implementation of corrective and preventive action for all

stations along JLPL.

HISTORY SHEET: History sheet of the master and custody transfer instruments under the head “Calibration”

shall be maintained as per format “CALIBRATION HISTORY SHEET”.

LIST OF INSTRUMENTS: A consolidated list of instruments to be covered under the “CALIBRATION”

procedure shall be prepared as per format “LIST OF INSTRUMENTS” & “ LIST OF MASTERS” by the

HOD(INST) in consultation with other departments such as Electrical, Mechanical, Pipeline, Telecom, Telemetry,

Fire & Safety, C&P as applicable. The concerned Station In-charge shall approve the list.

The periodicity of calibration shall be based on OISD guidelines as well as on previous calibration results and be

indicated against each of the instrument identified under the head “Calibration”. A list of Instruments/test

equipments in the calibration Lab that is not covered under “calibration” shall be prepared by HOD(INST).

IDENTIFICATION: All field and master instruments as identified above will have a unique identification

number designated as “TAG NUMBER”. The identification and status of calibration of test equipments covered

under list of Master & Instruments shall be indicated on the body of the instrument in the form of stickers/tag

(Green color) indicating the following details:

Instrument Name :

Tag Number :

Calibrated on :

Next Due :

Identification tag shall be put on the test equipments by using sticker/Tag with above details (Yellow color).

NOT UNDER CALIBRATION: All the instruments in the field shall be identified as per the tags/name plate on

the instrument.

TOOLS & TACKLES: Instrument Engineer shall ensure availability of tools and tackles required for IMM.

SEALING FOR INTEGRITY: In order to prevent tampering of setting by unauthorized personnel all the

adjustment points affecting the performance of the instruments used in custody transfer measurement system,

shall be locked with suitable device & as per prevailing Transport service agreement.

TRACEABILITY: To verify the measurement uncertainty and to ensure the consistency of required capability of

measuring instruments & test equipments which are used to demonstrate the conformance of product/services

through traceability of measurements to National/International standards. Also ensure safe operation of Pipeline &

associated systems through effective & adequate control systems & mechanisms.

HOD (INST) shall ensure the upkeep of Master Instruments with regard to safety, accuracy & repeatability. As far

as possible the “Masters” shall be calibrated traceable to National/International standards through an unbroken

chain.

In some situations, where such facilities are not available or are far off, the calibration of Master Instruments will

also hold good if the same are calibrated using customer’s calibration facilities and certificate of conformance is

issued by the Calibration Lab. Such calibration will hold good for a period not exceeding six months from the date

of calibration. The record shall be maintained for calibration of Master Instruments.




II. ELECTRICAL SYSTEM AND ITS COMPONENTSAt present RPL – DT, EOL-DT and Kandla-DT along with four Intermediate Pumping Stations at Samakhiali, Abu-

Road, Nasirabad and Mansarampura are in operation all along the JLPL system for receiving LPG from RPL &

boosting up the pressure of LPG for efficient transmission and to meet the contractual obligation of different

customers. Vertical / Horizontal centrifugal pumps, driven by VSD control electric motor, are installed at all

Dispatch Terminal & Booster stations for pumping of LPG to required pressure.

EOL – DT JAMNAGAR: At EOL-DT LPG is received from EOL & pumped to required pressure through

pumps which are driven by VSD controlled motors. The EOL dispatch terminal receives power at 6.6KV

level from EOL through 2 nos. of independent feeders. The list of the main electrical equipment at EOL-DT

is given below.

BOOSTER PUMPS (10-PM-CF-101A, B)

10-PM-CF-101A/B Booster LT Motor (280 KW EACH)

GENERATORS

DG 125 KVA Diesel Generators

PANELS

VSD Controller–101A/B Variable Speed Drive Panel for Booster Pumps

PCC-301 415 V LT distribution Panel

MCC-302 415 V LT distribution Panel

AC PACKAGE

10-AC-PKG-UN-1/ 2/ 3 Compressor Motor (36 KW each) Blower motor (2.2 KW each)Condenser Fan Motor (0.375 KW each)

UPS

US- 702: 1-Phase, 230 VAC, 2X10 KVA (DR) with 48 VDC & 24 VDC supplies for Telecom & control

supply loads.

DC BATTERY CHARGERS

DC-701 110 VDC, 20A Float cum Boost Charger

BATTERY BANKS




BT-702 405V, 300 AH

BT-701 110V, 120 AH

RPL/RIL-DT JAMNAGAR: At Jamnagar Despatch Terminal LPG is received from RIL/RPL & pumped to

required pressure through pumps which are driven by VSD controlled motors . The Jamnagar dispatch terminal

receives power at 6.6KV level from RPL through 2 nos. of independent feeders. The list of the main electrical

equipment at Jamnagar is given below.

MAIN LINE PUMPS Motors, 3.3KV, 530 KW :20-PM-102-A, B & C

Booster Pump Motor 415 V, 230 KW :20-PM-101-A, B & C; 20-PM-101A, B & C

Variable Speed Drive Panel for Booster Pumps : Siemens VSD Panel–101-A, B & C

Variable Speed Drive Panel for ML Pumps Ansaldo : VSD Panel–102-A, B & C

HT-204 : 6.6 kV HT distribution Panel

PC-303 : 415 V LT distribution Panel

MC-304 : 415 V LT distribution Panel

MC-308 : 415 V LT distribution Panel

A/C panels (3 Nos.) : 415 V LT distribution Panel for Air-conditioning loads

TRANSFORMERS

TR-023 & TR-024 : Transformer 6.6/ 0.433 kV 1250kVA)

TR-IP-102A, B & C : Transformer 6.6/ 0.69 kV (697 kVA)

TR-OP-102A, B & C : Transformer 0.613/ 3.4 kV (666 kVA)

UPS

UPS- 704 : UPS 1-Ph, 230 Vac, (45 kVA) with 48 Vdc & 24 Vdc

DC BATTERY CHARGERS

SWGR Room DC-711 :110 V DC Battery Charger (60 A)

Sub-station DC-703 :110 V DC Battery Charger (60 A)

BATTERY BANKS

UPS-704 :250 AH

Sub-station DC-703 :350 AH

SWGR Room DC-711 :250 AH

DG SET DG-03 : 225KVA




KANDLA DESPATCH TERMINAL: At KANDLA Despatch Terminal LPG is received from

IOCL & pumped to require pressure through pumps which are driven by VSD controlled motors. The KANDLA

dispatch terminal receives power at 11 KV level from PGVCL through 1 No. of independent feeder. The list of the

main electrical equipment at Kandla is given below.

MAIN LINE PUMPS (40P-101A, B & P201A,B)

40P-CF-101A, B Main HT Motor (630 kW)

P-201A, B Main HT Motor (375 kW)

Seal Cool Fan P201A,B 0.25 KW

GENERATORS

DG–011 350 KVA Diesel Generators

SERVICE PUMPS

40-P-101 & 102 Jockey Pump (18.5 KW)40-PA-CF-111 Diesel Transfer Pump (2.35 KW)RAW Water Pump A & B Drinking Water Pump (3.7 KW)

PANELS

VSD Panel–101A/B & 201A/B Variable Speed Drive Panel for ML PumpsHT-221 & 222 11 KV HT I/C VCB PanelPCC-311 415 V LT distribution PanelPMCC-312 415 V LT distribution PanelMCC-HVAC 415 V LT distribution Panel – HVAC

HVAC

40- UT- A,B.C&D Compressor Motor (20 kW)40-UT- A,B,C&D Condenser Fan Motor (2.0 kW)40-UT-101 / 102 Air Handling Unit Motor (5.5 kW)

TRANSFORMERS

TR-041/TR-042 Transformer 11/ 0.433 kV (2000 KVA)TR-VSD101A /101B Transformer 0.433/ 0.635 kV (687 KVA)

UPS

UPS UPS- 1 Ph, 230 V AC, 20 KVA with 48 V DC & 24 V DC supplies for Telecom & INST. loads




DC BATTERY CHARGERS

DC 110 V DC Battery Charger (350 AH)DC-DG 24 V DC Battery Charger (650 AH)Fire Water Pump 103/ 104 24 V DC Battery Charger (650 AH)SV01 Battery Charger 48 V, 200A Float cum Boost Charger BATTERY BANKS

UPSY-LABB 120 AHDG-011 650 AH11 KV SWGR DC 350 AHFire water pump 103/104 650 AH

IPS SAMAKHIALI: This station receives power at 66kV level from GEB (GETCO Shivlakha) through

single feeder. It has one no. of 1475 KVA DG set as a backup of GEB (grid) supply to ensure continuation of

pumping in the event of failure of GEB (grid) power. The main electrical equipment of IPS Samakhiali is

given below:

66 KV SWITCHYARD

ISO-89-102, 301, 201, 302, 402 & 501 : Isolator without Earth Switch (630A)ISO-ES-89-101, 202, 401 & 502 : Isolator with Earth Switch (630A)CB-101, 201, 301, 401 & 501 : SF6 Circuit Breaker (600A)CT-L1, L2, GEB-L1, GEB-L2, B/C, TR-1 & TR-2 : C.T (30, 15/1 A)PT –L1 & L2 : P.T (66/ √3/ 110/√ 3)LA- L1, L2, TR-1 & TR-2 : Lightning Arrester

MAIN LINE PUMPS (50-CF-101A, B & C)

50-PM-101A, B & C : Main HT Motor (898 kW)50-LOPM-101A, B & C : Aux. Lube Oil Pump Motor (2.2 kW)50-LOFM-101A, B & C : Aux. Lube Oil Fan Motor (1.1 kW)50-LOP-101A, B & C : Lube Oil Heater (1.5 kW)

GENERATORS

DG–005 : 1475 kVA Diesel Generators

SERVICE PUMPS

50-P-101 & 102 : Jockey Pump (15 KW)

PANELS

VSD Panel–101A/B/C : Variable Speed Drive Panel for ML PumpsHT-204 : 6.6 kV HT distribution PanelPCC-305 : 415 V LT distributions PanelPCC-307 : 415 V LT distributions Panel – SwitchyardMCC-HVAC : 415 V LT distributions Panel – HVAC

HVAC

HVAC-2041 A & B : Compressor Motor (55 kW)50-HVAC-2042 A & B : Air Blower Motor (7.5 kW)50-HVAC-2044 : Air Handling Unit Motor (15 kW)

TRANSFORMERS

TR-001/TR-002 : Transformer 66/ 6.6 kV (3000 kVA)TR-027/ TR-028 : Transformer 6.6/ 0.433 kV (630 kVA)TR-IP-101A/ B/ C : Transformer 6.6/ 0.69 kV (1137 kVA)TR-OP-101A/ B/ C : Transformer 0.613/ 3.3 kV (1221 kVA)

UPS

UPS- 706UPS 1-Ph, 230 V AC, 25 kVA with 48 V DC & 24 V DC : Supplies for Telecom & Instrument loads




DC BATTERY CHARGERS

66kV Switchyard : 110 V DC Battery Charger (150 AH)DC-705 : 110 V DC Battery Charger (350 AH)DC-DG-005/ DC-DG-006 : 24 V DC Battery Charger (180 AH)Fire Water pump 103/ 104 : 24 V DC Battery Charger (180 AH)

BATTERY BANKS

UPS-706 : 120 AHDG-005/ DG-006 : 180 AH66 kV-Switch yard : 150 AH6.6 kV SWGR DC705 : 350 AHFire water pump 103/104 : 180 AH

IPS ABUROAD: This station is second booster station in JLPL It receives power at 33 KV level from

RSEB through independent feeder from 132 KV GSS at Aburoad. It has 1 no. of 1700 KVA DG set, and

second one is under installation stage as a backup of RSEB supply to ensure continuation of pumping in the

event of failure of RSEB power. The main electrical equipment of IPS Aburoad is given below:


60-CF-101A, B & C : Aux. Lube Oil Pump Motor (1.1 kW)

60-CF-101A, B & C : Aux. Lube Oil Fan Motor (0.37 kW)

60-CF-101A, B & C : Lube Oil Heater (1.5 kW)

GENERATORS

DG–007/ DG-008 :1700 KVA Diesel Generators

DG-012 : 250 KVA Emergencies D.G.

BOREWELL & DIESEL TRANSFER PUMP

BORE WELL 1, 2&3 : Bore well Pump Motor (7.5 HP)

60-PM-CF-111 : Diesel Transfer Pump Motor (3.7 kW)

PANELS

VSD Panel–101A/B/C : Variable Speed Drive Panel for ML Pumps

HT-205&206 : 33KV HT Panel


PMCC-306 : 415 V LT distribution Panel

HVAC

HVAC-2041 A & B : Compressor Motor (66.16 kW)

60-HVAC-2042 A & B : Air Blower Motor (7.5 kW)

60-HVAC-2044 : Air Handling Unit Motor (15 kW)

TRANSFORMERS

TR-029/TR-030 : Transformer 33/ 6.6 kV (3300 kVA)

TR-031/ TR-032 : Transformer 6.6/ 0.433 kV (630 kVA)

TR-IP-101A/ B/ C : Transformer 6.6/ 0.69 kV (1135 kVA)

TR-OP-101A/ B/ C : Transformer 0.613/ 3.3 kV (1275 kVA)

UPS

UPS-708 1-Ph, 230 Vac, (25 kVA) with 48 Vdc & 24 Vdc : Supplies for Telecom loads




DC BATTERY CHARGERS

DC-707 : 110 V DC Battery Charger (400 AH)

DC-DG-007/ DC-DG-008 : 24 V DC Battery Charger (180 AH)

Fire Water pump 103/ 104 : 24 V DC Battery Charger (180 AH)

BATTERY BANKS

UPS-708 :150 AH

DG-007/ DG-008 :180 AH

DCDB SWGR DC-707 :400 AH

Fire water pump 103/ 104 :180 AH

IPS NASIRABAD: This station is third booster station in JLPL It receives power at 33 KV level from

RSEB through single feeder It has2 nos. of 1350 KVA DG set as a backup of RSEB supply to ensure

continuation of pumping in the event of failure of RSEB power. The main electrical equipment of IPS

Nasirabad are given below:


70-CF-101A, B & C : Main Line Pumps (690KW, 3.3KV)

70-CF-101A, B & C : Aux. Lube Oil pump motor (1.1 kW)

70-CF-101A, B & C : Aux. Lube Oil Fan Motor (0.37 kW)

70-CF-101A, B & C : Lube Oil Heater (1.5 kW)

GENERATORS

DG–009/ DG-010 :1350 kVA, 6.6 KV Diesel Generators

DG-013 : 250 KVA, 415V Emergency D.G.

BOREWELL & DIESEL TRANSFER PUMP

BORE WELL 1, 2&3 : Bore well Pump Motor (7.5 HP)

70-PM-CF-111 : Diesel Transfer Pump Motor (3.7 kW)

PANELS


HT-208&209 :33KV HT Panel

HT-210 :6.6 kV HT distribution Panel

PMCC-307 :415 V LT distributions Panel

HVAC

HVAC-2041 A & B : Compressor Motor (62 kW)

70-HVAC-2042 A & B : Air Blower Motor (7.5 kW)


TRANSFORMERS

TR-033/TR-034 : Transformer 33/ 6.6 kV (2800 kVA)

TR-035/ TR-036 : Transformer 6.6/ 0.433 kV (630 kVA)

TR-IP-101A/ B/ C : Transformer 6.6/ 0.69 kV (876 kVA)

TR-OP-101A/ B/ C : Transformer 0.613/ 3.3 kV (872 kVA)

UPS




UPS 710 30 KVA, 1 Phase, 230V AC with 48v & 24Vdc : supplies for Telecom loads

DC BATTERY CHARGERS

DC-709 :110 V DC Battery Charger (400 AH)

DC-DG-009/ DC-DG-010 :24 V DC Battery Charger (180 AH)

Fire Water pump 70PM-103/ 104 :24 V DC Battery Charger (180 AH)

BATTERY BANKS

UPS-710 :200 AHDG-009/ DG-010 :180 AHDCDB SWGR DC-709 :400 AHFire water pump 70PM- 103/ 104 :180 AH IPS MANSARAMPURA: This station is fourth booster station in JLPL It receives power at 33 KV level

from RSEB through single feeder It has 1 nos. of 1475 KVA DG set as a backup of RSEB supply to ensure

continuation of pumping in the event of failure of RSEB power. The main electrical equipment of IPS

JAIPUR are given below:


80-PM-101A, B & C : Main HT Motor (630 kW)

GENERATORS

DG–017 :1475 KVA Diesel Generators

SERVICE PUMPS

80-P-101 & 102 : Jockey Pump (18.5 KW)

80-PM-CF-111 : Diesel Transfer Pump (3.7KW)

Drinking Water Pump A & B : Drinking Water Pump (3.7 KW)

PANELS


HT-223 & 224 : 33 KV HT I/C CB Panel


PCC-313 : 415 V LT distribution Panel

MCC-HVAC : 415 V LT distribution Panel – HVAC

HVAC

80- HVAC-2041 1,2,3 & 4 : Compressor Motor (14.5 kW)

80-HVAC-2042 1,2,3 & 4 : Condenser Fan Motor (4.5 kW)


TRANSFORMERS

TR-043/TR-044 :Transformer 33/ 6.6 kV (2500 KVA)

TR-045/ TR-046 :Transformer 6.6/ 0.433 kV (315 KVA)

TR-IP-101A/ B/ C :Transformer 6.6/ 0.635 kV (687 KVA)

UPS

UPS- 706 and UPS-718 1-Ph, 230 V AC, 24 KVA with 48 V DC & 24 V DC supplies for Telecom & INST. loads

DC BATTERY CHARGERS

DC-717 : 110 V DC Battery Charger (400 AH)




DC-DG-017 : 24 V DC Battery Charger (180 AH)

Fire Water Pump 103/ 104 : 24 V DC Battery Charger (180 AH)

IP-3 Battery Charger : 48 V, 200A Float cum Boost Charger

BATTERY BANKS

UPS-718 :200 AH

DG-017 :180 AH

6.6 KV SWGR DC717 :400 AH

Fire water pump 103/ 104 :180 AH

RECEIPT TERMINAL (RT): LPG is received at the Receipt Terminal from upstream stations and is

delivered to respective customer at required flow and pressure.

1) RT-AJMER (IOCL, HPCL & BPCL)

2) RT-SANGANER(IOCL)

3) RT-JAIPUR(BPCL)

4) RT-PIYALA(BPCL)

5) RT-GURGOAN (IOCL)

6) RT-MADANPUR KHADAR(IOCL)

7) RT-LONI (IOCL, HPCL & BPCL)

Each RT receives power at 415V from SEB’s or OMC. This power is used to cater various loads as given below.

The RT’s are identical as far as electrical equipments are concerned.

LIST OF ELECTRICAL EQUIPMENT AT EACH RT [TABLE-07]Sl.

No.Equipment Name Ratings Qty Remarks

1 LT Switchgear 415V,250A 01

2 Emergency Switchgear 415v, 100A 01

3 UPS 10 KVA, 230V

AC

01

4 Rectifier 600 W, 24V DC 01

5 Rectifier 1150W,48V DC 01

6 Rectifier 385W,110V DC 01

7 DG SET 50 / 100 KVA 01 Not available at RT, IOCL TABJI

8 MOV 03 At RT LONI total 09 Nos. MOVs for three

OMC

9 Central AC System 50 KW 01 Only at LONI RT

RESPONSIBILITY AND AUTHORITY: Each employee of Electrical Maintenance department is

responsible for ensuring that all the equipment and the total electrical system is well maintained as per

procedure described in this manual.

a) HOD (Elect.) is responsible to ensure that the procedures described in this manual are followed

and all the maintenance activities (Preventive, Predictive and Break-down etc.) of Electrical




Departments are carried out as per schedule and requirements by following good engineering

practices along with all statutory rules & regulations.

b) For all major jobs such as break down of motors, transformers, VSD panels or any modification,

import substitution etc. shall be the responsibility of electrical core Group however all such

activities shall be coordinated by HOD (Elect) of each station.

c) Common spares for Electrical system across JLPL: A list of items shall be prepared by HOD

(Elect.) of each Maintenance base and shall be forwarded to Core group leader for further

compilation and initiation of procurement action.

d) Core group constituted by GM (O&M) shall be responsible for engineering changes, imported

spares procurement, corrective & preventive action for all the stations along JLPL.

e) Exception/interpretation reports shall be prepared on the basis of scheduled

monitoring/maintenance reports by individual maintenance base and only the exception report

shall be sent to HOD (Elect.) at HQ. On the basis of the exception reports, HOD (Elect.) shall

ensure the corrective action(s) at all the maintenance bases in consultation with the Electrical

Core Group.

f) A list of critical spares for each equipment shall be prepared by HOD(Elect) and availability of

these shall be ensured by him.




APPENDIX-III

REFERENCESREFERENCE STANDARDS, CODE OF PRACTICE & GUIDELINES:

1) ASME B31.4- PIPELINE TRANSPORTATION SYSTEMS FOR LIQUID

HYDROCARBONS AND OTHER LIQUIDS.

2) ASME B31 Q- PIPELINE PERSONNEL QUALIFICATION.

3) ASME B31 G- MANUAL FOR DETERMINING THE REMAINING STRENGTH OF

CORRODED PIPELINES

4) API STANDARD 1160- MANAGING SYSTEM INTEGRITY FOR

HAZARDOUS LIQUID PIPELINES

5) NACE Standard RP0502–2002

6) AS 2885.1-1997 Pipelines - Gas and liquid petroleum - Design and

construction

7) AS 2885.2-1995 Pipelines - Gas and liquid petroleum – Welding




APPENDIX-IV

List of CRITICAL ACTIVITIES IMPLEMENTATION SCHEDULE

Sr. No.

Critical infrastructure/ activity/ processes

Time period for implementation Implementation plan in JLPL

1 Cathodic Protection survey to ensure an integrated CP system 6 months for survey Since commission it is being

carried out.

2 Intelligent Pigging 2 Years It is being done as per frequency in the OISD-214.

3 GIS mapping 2 years Implementation plan to be prepared.

4 Leak detection system implementation 6 months New leak detection system will be ready by Jan-2013

5 Baseline Data for IMS 6 months6 Preparation of IMS 1 Year * Can be submitted in stages

7Conformity of IMS(A company of ISO-18000 may have a certification from CEO)

1 ½ Years Can be submitted in stages




Appendix-VSuggestive Chart for selection of Integrity Assessment method with respect to specific threat

Threat Group ThreatPreferred Integrity

Assessment / Assurance Method

Assessment interval

Time-DependentExternal Corrosion Inline inspection, ECDA Max.10 year**Internal Corrosion Inline inspection, ICDA, Max.10 year**Stress Corrosion cracking Inline inspection, Direct

AssessmentMax.10 year**

Stablea) Manufacturing related defects

Defective Pipe Seam Hydro-test (Post Construction), Inline inspection

Before commissioning or as and when required

Defective Pipeb) Welding / Fabrication related

Defective Pipe Girth WeldDefective fabrication WeldWrinkle bend or buckle Caliper pigging / EGPStripped threads/broken pipe

Visual Examination / Gas Leakage Survey

c) Equipment Gasket / O-ring Failure Visual Examination / Gas Leakage Survey

Control / Relief equipment malfunction

Visual Examination / Gas Leakage Survey

Time-Independenta)Third Party / Mechanical Damage

Damage inflicted by first, second, or third parties (Instantaneous / Immediate failure)

Public Education (See Communication Plan & preventive actions), Patrolling, ROW maintenance, External Protection, IESS

Monthly /quarterly

Previously damaged pipe (delayed failure mode)

Above + Leakage Survey, Rehabilitation

Vandalism All aboveb)Incorrect Operations

Incorrect Operational procedure

Compliance Audits

c) Weather Related and Outside Forces

Weather related Leakage survey, Surveillance

NA

Lightning Surge divertersHeavy rains or floods Anti-buoyancy inspection,

SurveillanceEarth Movements Strain monitoring, Leakage

survey.




1) Note: * Some of the important Integrity Assessment Methods have been briefed in Schedule-5 of these regulations.

2) ** Inline inspection frequency to be as per PNGRB (Technical Standards and specifications including Safety Standards for Petroleum & Petroleum Product Pipelines) Regulations as and when notified by the Board.

3) Abbreviations: ECDA – External Corrosion Direct Assessment

ICDA – Internal Corrosion Direct Assessment

ILI – In Line Inspection (Intelligent Pigging)

Appendix-VI

Minimum Qualification & Experience for Field Personnel in Project Phase as well as O&M Stage

Discipline Tier-I Tier-II Tier-III

Supervisor Level Operator Level

Mechanical Degree In Mechanical Engineering

Diploma In Mechanical Engineering + at least 1

year of Experience

ITI with at least 1 year experience in the relevant

field of operation

Chemical Degree In Chemical Engineering

Diploma In Chemical Engineering + at least 1

year of Experience


field of operation

Instrumentation & Control

Degree In I&C Engineering

Diploma In I&C + at least 1 year of Experience


field of operation

Electronics & Communication

Degree In Electronics & Communication

Engineering

Diploma In Electronics & Communication

Engineering + at least 1 year of Experience in

SCADA


field of operation

Electrical Degree In Electrical Engineering

Diploma In Electrical Engineering+ at least 1

year of Experience


field of operation

Fire & Safety Equivalent Degree In F&S Engineering

Diploma In F&S Engineering+ at least 1

year of Experience


field of operation

Civil Degree In Civil Engineering

Diploma In Civil Engineering+ at least 1

year of Experience





field of operation

Note: Each Petroleum and Petroleum Product Pipeline shall have SME (Subject Matter Expert) having qualification in any of the discipline mentioned above with minimum 5 year of relevant experience.

Appendix-VIIThe following records shall be maintained by the pipeline operators for all new pipelines constructed after the issue of these recommended practice.1) Design & Engineering documents 2) Construction inspection reports3) Material certification, performance and functional reports.4) A complete pipe book 5) Pressure test records including location of leaks or failures, if any, and description of repair under taken6) Record of Calliper survey, if carried out 7) Complete asset of each location with identification8) As-built drawings including pipeline route maps, alignment sheets, crossings drawings, Piping and

Instrumentation Diagrams, station layouts, piping isometric, earthing grid, single line diagrams, instrument and cable layouts, loop diagrams, etc.

9) Equipment manuals supplied by manufacturers10) Approved Vendor drawings11) NDT records of welds12) Cleaning and swabbing report13) Geometric survey reports/EGP Survey to be done and repairs, if any, carried out. 14) Statutory Clearances15) Calibration records of instruments, measuring, metering and test equipment.16) Pre-commissioning Audit compliance report17) Details of ROW / Rou Owners, pending court cases pertaining to acquisition of ROW / RoU.18) Operation daily logs 19) Pipeline patrolling records20) Encroachment Records21) Pearson survey records/Continuous Interval Potential Logging (CIPL to be done once in 5 years) or

Continuous Potential logging (CPL) or / Direct Current Voltage Gradient (DCVG), or Current Attenuation Test (CAT) surveys etc.

22) Pipeline pigging recordsa) Scrapper pigging through foam pig or four cup pig once in a year.b) Intelligent pigging as per the provisions of relevant standards.

23) Records and maps showing the location of CP facilities and piping.24) CP monitoring report, test and survey reports. 25) Leak , burst & repair and test records 26) Records pertaining to inspections, such as external or internal line conditions




27) Near miss, minor and major incidents28) Integrity assessment data29) Various pilferages and chainage (location village reference), date of event (on pilferage carried out),

precautionary measures / steps, taken30) Soil resistivity reading or soil sample test on ROU after every 10 years, or any major change in the ground

profile due to industrial effluents or new water bodies.

Appendix-VIIIANNUAL HEALTH CHECK-UP REPORT

Name of the Plant/Pipeline/Region: Year:

S. No. Parameter Details Status

1. Status of ROU/Pipeline

1. Encroachment Status:(Nos at the beginning of the year)(Nos at the end of the year)(Status of pending encroachments to be attached)

2. Exception points of any of P/L integrity survey such as Intelligent pigging etc.

2. Uninterrupted Avail. Of P/L Pipeline availability in percentage(details of any interruption to be attached) %

3. Status of CP

1. Pipeline protection Index2. Pipe to soil potential3. Power source working(Grid/TEG)4. CP System working (TR/CPPSM)

(%)OK/NOT OKOK/NOT OK

OK/NOT OK

4. Maintenance status

1. Exception w.r.to Annual preventive maintenance schedule (pending more than a month)

2. Critical equipment availability (M/L LPG Pumps / Booster Pumps / DEG / F.W.P. / Fire Tender) (%) (for plants only)

Details

%

5. Safety Index

1. Overall safety Index2. Internal safety Audit (Remaining/Total

para)3. External safety audits (Remaining/Total

para)4. QMS Audits (Remaining/Total Points)5. No. of Mandays lost (As a % of the

total Mandays Available)6. Fire alarm system working

%Number

Number

Number

%

OK/NOT OK

6. Performance Index

1. Unaccounted Gas: by energy2. Performance vs. MOU (please attach

reasons in case of performance less than “Excellent” MOU)

%Details




7. Statutory clearances

1. All statutory clearance (Factory license / pollution clearance / CCOE license etc.)

2. Revalidation of all statutory clearances as per prescribed frequency

YES/NO

YES/NO

Note: 1. above status is with respect to the jurisdiction of the undersigned.2. Exception and other details have been enclosed as annexure.



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