Navghar Terminal

October – 2017
Presentation prepared by: Shivaji Shivekar
 Pipeline Safety

• Which OISD is applicable for our lines?

• Related OISD’s and documents.

• Integrity threat Classification:

 External Corrosion
 Internal Corrosion
 Stress corrosion cracking

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Stress corrosion cracking

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 Types of Damaging Agents

1. Third-Party Damage
2. Corrosion Related
3. Equipment
4. Incorrect Operation
5. Weather related
6. Manufacture
7. Construction
8. Environment

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Types of Failures

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 PIPELINE INTEGRITY MANAGEMENT SYSTEM

Objectives of pipeline integrity management system are:

• To maintain integrity of cross country pipelines.

• At all times to ensure public safety

• Protect environment and

• Ensure continuous availability of pipeline for transportation

without interruptions, thereby minimizing the business risks
and throughput loss.

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Pipeline Integrity

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 Categories of piggable/ non-piggable lines

From pigging point of view there are four categories of

pipelines :

• Piggable lines in which regular cleaning pigging is carried out.

• Piggable lines in which cleaning pigging is not carried out.

• Non-piggable pipelines such as well flow lines/ jetty lines.

• SPM / sub-sea lines having no loop.

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 Basic concern for piggable pipelines

Piggable lines in which regular cleaning pigging is carried

out.

• Pig residue analysis is not carried out regularly.

• Proper statistical analysis is not carried out to establish trend of

internal corrosion.

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 Basic concern for piggable pipelines

Piggable lines in which cleaning pigging is not carried out.

• Basic details about the health of the pipeline are not available

• Periodicity for maintenance is not followed or ignored

• Since commissioning proper cleaning pigging has not been done.

High apprehension of condensate and wax deposition cannot be

over ruled

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 Basic concern for non-piggable pipelines

Non-piggable pipelines such as flow lines/ jetty lines

• There is no focused attention on these pipelines.

• There is no cathodic protection for some underground pipelines.

• Monitoring system not in place in line with oisd-gdn-233.

• In some pipelines it has been observed that even corrosion probes/

coupons are not used.

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 Challenges for monitoring internal corrosion of non-
piggable pipelines

Spm / sub-sea lines having no loop

• Fit for purpose subject to various conditions is not a solution.

• Awareness about various techniques available for assessing

internal corrosion such as direct assessment.

• Exploring possibility of pigging the line by using modern

technology.

• Exploring possibility of converting the line to a piggable line

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 DUPL - Incident

River Incident: on 25thAugust 2013, there was explosion in

the DUPL natural gas pipeline of GAIL and breakage in the

26” gas pipeline of RIL. This was followed by incident of oil

leakage in the ONGC pipeline on 28thAugust 2013.

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LOCATION MAP NARMADA SITE
.

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Schematic view of the Narmada river site

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 Total no. Of pipelines passing through Narmada river

Sr. no. Pipeline Operator Pipe Size Remarks

Reliance (RGTIL) 48” OD x 1.000” WT (25.4 mm),

(1) Line is intact.
Natural Gas API 5L X70 Gr.

GAIL India 30” OD x 19.1/11.9 mm WT, API

(2) Snapped & burst
Natural Gas 5L X 70 Gr.

Reliance Industries Limited (RIL) Snapped & burst. Pipe has

26” OD x 0.500” WT, API 5L X 60
(3) Ch. 29.150 KM (NG) got stuck in the nearby
Gr.
Natural Gas electrical tower

Reliance Industries Limited (RIL)(NG) 24” OD x 0.500” WT API 5L X 60

(4) Snapped & burst.
Ch. 29.150 KM Gr.

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 Total no. Of pipelines passing through Narmada river

Sr. no. Pipeline Operator Pipe Size Remarks

(5) Gujarat State Petronet Ltd., (GSPL – NG) 24” OD x 0.688” (17.5 mm) WT, About 100 m pipeline is
Ch. 17.000 KM API 5L X 60 Gr. exposed.

(6) 8.625” OD x 0.375” (9.53 mm)

ONGC (Ch. 14.200 KM) CRUDE OIL Leakage in line
WT, API 5L X 46 Gr.

(7) 12.75” OD x 0.219” WT, API 5L X

IOCL (Amod Hazira Pipeline) Line is intact
60 Gr.

(8) ONGC (OPAL) 12.75” OD x 0.25” WT, API 5L X

Under construction
Naptha 46 Gr.

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 Root cause of Incident

Sr. no. Cause of the Incident.

IT WAS A NATURAL CALAMITY. UNPRECEDENTED SUDDEN FLOODS DUE TO HEAVY RAINS AND LARGE
(1)
QUANTITY OF DISCHARGE OF WATER FROM SARDAR SAROVAR DAM.

(2) THE RIVER BANK (SOUTH SIDE) WAS NOT REINFORCED, WHICH RESULTED IN HEAVY SOIL EROSION.

REMOVAL OF PLANTS AND VEGETATION DURING THE CONSTRUCTION OF ELECTRICAL TRANSMISSION

(3) TOWER OF TORRENT POWER CLOSE TO THE RIVER BANK, WHICH HAS RESULTED IN LOOSENING OF
THE PARENT SOIL.

IRRIGATION DEPT. DID NOT PROVIDE ANY PRIOR WARNING BEFORE RELEASE OF ABRUPT WATER
(4)
DISCHARGE IN SUCH A LARGE QUANTITY.

SOIL EROSION IS A GRADUAL PROCESS, WHICH TAKES NUMBER OF YEARS. PIPELINE OPERATORS
(5) SHOULD CLOSELY MONITOR SUCH BEHAVIOR OF THE RIVER COURSE AND THE ADJOINING BANKS ON A
REGULAR BASIS.

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 Major lapses noted of-late in the pipeline industry on the
basis of some major accidents

• Inadequate line-patrolling.

• Changing design service without proper technical analysis or

without proper management of change process.

• Not learning from past failures & not carrying out proper root cause

analysis.

• Not carrying out proper cleaning pigging & intelligent pigging

survey; not implementing recommendations of IPS survey in time.

• High dependency on third party agencies without proper control.

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 Pipeline integrity management system

Rigorous integrity management system provides

framework for :

1. Management leadership, commitment and accountability

2. Risk assessment and management
3. Facilities design & construction – specs, codes, standards
4. Information / documentation
5. Personnel & training
6. Operations & maintenance
7. Management of change
8. Third party services
9. Incident investigation & analysis
10. Community awareness & emergency preparedness
11. Operations integrity assessment and improvement

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Failures are Preventable

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 Conclusion

 Pipes laid underground cannot speak, it is our duty to

care for the pipe & give either pain or pleasure. Need of
the hour is to have a sensitivity towards pipe.

 Pipeline integrity must consider all aspects of design,

construction & operation phases.

 Pipeline integrity requires adopting a “failures are

preventable” mindset.

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 Plot No. 101, Sector 1,NH4B,
Dronagiri Node, Navghar,

Thank You Navi Mumbai - 400 707

Ph No: 022-65161591

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