Workshop on

Transportation of OIL & GAS through Pipelines

FLOW OF PRESENTATION
Over view of safety of pipeline

PRESENTATION ON

Design codes/standards/safety guidelines followed in Petroleum Pipelines

M.R.DWIBEDY SPJM(HSE),IOCL PL, NOIDA

Advantages of Pipeline Transportation

Lower cost of transportation Lower transit losses Lower energy intensiveness Economies of scale Safety and Reliability - minimum disruptions Environment friendliness Multi-product handling Stationary carrier Augmentation at low cost Minimal land costs Decongestion of surface transport systems

Codes / Standards / guidelines to be followed/to be complied in Oil/Gas pipeline

Codes & Standards being followed

Sl. No
01 02 03

Codes & Standards being followed

Sl. No
08

Standard

Description

Usage

Standard
API 610

Description
Centrifugal Pumps for Petroleum, Petrochemical and Natural Gas Industries Welded Steel Tanks for Oil Storage Reciprocating Internal Combustion Engines

Usages
MLPU, BPU

ANSI B31.4 OISD 118 OISD 117

Pipeline Transportation System for Liquid Hydrocarbons and other liquids Layouts for Oil & Gas Installation Fire Protection Facilities for Petroleum Depots, Terminals, Pipeline Installations and Lube Oil Installations Specification for Line Pipes

To Estblish Requirement for safe Design Lay out various blocks of station F/F Facility

09 10

API 650 BS 5355 API 6D API 600 BS 1868

Tanks Engines

04 05 06 07

API 5L ASTM A106 Gr.B ASTM A53 Gr.B IS 3589

M/L Pipe

11
Station Pipes

Pipeline Transportation Valves System -Pipeline Valves Gate Valves Swing Check Valves

12
Station Pipes

13
Station Pipes

Codes & Standards being followed

S.N.
14

Codes & Standards being followed

Sl. No
21 22

Std.

Description
Design ASME Section VIII, QOC- BS EN 10222 Door Closure BS PD 5500 Design ASME Section VIII Div-I Material- ASTM A 234 WPB, MSS SP 75 WPHY 52,65 Dimension- ANSI 16.25, MSS SP75 Inspection ANSI B16.9, MSS SP 75 Material- ASTM A 105, Mfg/Dimension- ANSI B16. 5, MSS SP 44, API 605 API 1589, API 1581 Material- ASTM A 216 WCB, Design- ANSI B16 104, ANSI B 16.5,

Usages
Barrels

Standard
API -1104 IS- 5120 BS- 5514 ASME Section VIII Div-I API Standard 601

Description
Welding of Pipeline and related Facilities Pump Design Engine Testing

Usages
Welding Fire Fighting Pumping Units Insulating Coupling

15 16

Sump Tank Fittings

23 24

17 18 19

Flanges Separator Filter Elements Control Valves 25 26 API Standard 526 ANSI/API Standard 602 API Standard 2510

Metallic Gasket for Raised-Face Pipe Flanges and Flanged Connections (Double-Jacketed Corrugated and spiral-wound) Flanged Steel Pressure Relief valves Steel Gate, Globe and Check Valves for sizes DN 100 and smaller for the petroleum and Natural gas Industries Design and Construction of LPG installations

Gaskets

Relief Valves

27

Codes & Standards being followed

Sl. No
28 29 30 31

Oil Industry Safety Directorate (OISD)

Standard
OISD-STANDARD214 ASME B 31.8-2003 API 520, 526, 527, ASME section VIII BS 1873

Description
Cross Country LPG Pipelines Gas Transmission and Distribution Piping System Pressure Relieving devices

Usages

TRVs Globe Valves

OISD (Oil industry safety directorate) , set up in 1986, is technical directorate under the Ministry of Petroleum and Natural gas that formulates and co-ordinates the implementation of a series of self regulatory measures aimed at enhancing the safety in the oil & gas industry in India.

OISD : Function
Formulation of New Standards & Upgrading the existing standards OISD constitutes number of functional committees comprising of experts nominated from industry to draw up standards various topics like layout of installations, design, engineering, maintenance, operations etc. There are more than100 standards. Training & Development- Workshops, Seminar & Publications etc External Safety Audit- Safety Audit of various facilities in upstream and down stream oil sector Safety Performance Evaluation/Safety Awards OISD safety awards were instituted in order to inculcate competitiveness among oil companies to improve their safety performance. Safety performance is evaluated considering total loss concept i.e, fatalities, fires, lost time, direct & indirect losses etc. And also the hazard potentials.

OISD : Function
Safety Performance Evaluation/Safety Awards OISD safety awards were instituted in order to inculcate competitiveness among oil companies to improve their safety performance. Safety performance is evaluated considering total loss concept i.e, fatalities, fires, lost time, direct & indirect losses etc. And also the hazard potentials. Assisting Safety Council of MOP&NG - Appraisal on monitoring of implementation of ESA recommendation, Safety performance evaluation, Accident reporting, Investigation & analysis, Training programs/workshops, Ratification of amendments of standards, Adoption of standards etc. Steering Committee meeting with principal panellistAmendments of standards, Identification of subjects for preparation of standards, monitoring of implementation ESA recommendation,Various items for Industry

OISD : Function
Assisting Safety Council of MOP&NG - Appraisal on monitoring of implementation of ESA recommendation, Safety performance evaluation, Accident reporting, Investigation & analysis, Training programs/workshops, Ratification of amendments of standards, Adoption of standards etc. Steering Committee meeting with principal panellist- Amendments of standards, Identification of subjects for preparation of standards, monitoring of implementation ESA recommendation,

OISD Standards (Applicable for Pipelines)

STANDARDS OISD -Std-105 OISD -GDN-115 OISD -Std-117 OISD -Std-118 OISD -Std-130 OISD -Std-132 OISD -Std-137 OISD -Std-138 OISD -Std-139 OISD -Std-140 OISD -Std-141 OISD -Std-142 OISD -GDN-145 SUBJECT Work Permit System Guideline for fire fighting equipment Fire Protection Facilities for Petroleum Depots and Terminals Layouts for Oil and Gas Installations Inspection pipes, valves and fittings Inspection of pressure relieving devices Inspection of electrical equipment Inspection of cross country pipelines Onshore Inspection of pipelines Offshore Inspection of jetty pipelines Design and Construction requirements for cross country hydrocarbon pipelines Inspection of fire fighting equipments and systems Guidelines on Internal Safety Audits (Procedures and Checklist)

OISD Standards (Applicable for Pipelines)

STANDARDS OISD -Std-149 OISD -Std-154 OISD -Std-155 SUBJECT Design aspects for safety in electrical systems Safety aspects in functional training Personnel Protective Equipment Part I Non-respiratory equipment Part II Respiratory Equipment Guidelines for Occupational Health Monitoring in Oil and Gas Industry Fire Protection System for Electrical Installations Safety practice during construction Guidelines for development of contingency plan for oil Spill Response Guidelines on Safety Management System in Petroleum Industry. Guidelines on Environmental Audit (Internal) in down stream petroleum sector

OISD Standards(Incorporated in Petroleum Rules, 2002)

Standards OISD-STD-105 OISD-STD-116 OISD-STD-117 OISD-STD-118 OISD-STD-141 OISD-STD-156 Subjects Work permit system Fire protection facilities for petroleum refineries and oil/gas processing plants Fire protection facilities for petroleum depots, terminals and pipeline Layout of oil & gas installations Design & Construction requirements for Cross Country hydrocarbon pipeline Fire fighting facilities for Port Oil Terminals

OISD -GDN-166 OISD -Std-173 OISD -GDN-192 OISD -GDN-200 OISD-GDN-206 OISD GDN 212

More OISD standards may be included in Act / Rules

OISD-STD-117:

Fire protection facilities for petroleum Depots, Terminals and Pipeline

OISD-STD-117:

Fire protection facilities for petroleum Depots, Terminals and Pipeline

Scope : Fire protection facilities in petroleum Depots, Terminals and

Pipeline installation with or without storage Central Tank Farms (CTF). Lube Oil Installations, Grease Manufacturing & Filling Facilities. Design criteria: One single largest risk for installation with storage capacity up to 30000 kl and Double fire Risk for storage capacity more than 30000 kl.
Fire water distribution net work Hydrants and Monitors Material Specifications Fixed Water Spray System Foam system

Fire water system

Flow rate Header Pressure Storage Fire Pumps Jockey pumps

Halon protection system First Aid fire fighting equipment Hoses, nozzles & Accessories Mobile fire equipments Communication Fire Safety Training

OISD-STD-118: Layouts for Oil and Gas Installations Scope :

OISD-STD-118: Layouts for Oil and Gas Installations

Minimum requirements of layouts within the plant boundary for petroleum refineries, oil/ gas production and processing plant.

Lay out of Blocks/Facilities

General considerations Inter distances

Plant Layout Philosophy: Basic information Blocks Roads Erection and maintenance

Layout of Process Units

Process Equipment Control Room and Sub station Equipment Spacing within process units

Layout of Storage tanks

Dyked enclosures Grouping Fire Walls Inter - Distances for Tanks/Offsite facilities

MINIMUM INTERDISTANCES BETWEEN BLOCKS/FACILITIES

S.No. From \ To
S.No. 1. 2. 3. 4. 5. 6. 7. 8. 9. From \ To 1 36 *** 30 45 30 2 *** ** 45 30 60 90 150 45 30 3 30 ** T3 & T5 T3 & T5 T3 & T5 30 90 150 30 60 4 45 45 T3 & T5 T3 & T5 T3 & T5 30 90 150 30 60 5 30 30 T3 & T5 T3 & T5 T3 & T5 30 90 150 30 60 6 60 60 30 30 30 T7 90 150 30 90 7 90 90 90 90 90 90 90 150 90 90 8 150 150 150 150 150 150 150 150 150 9 45 45 30 30 30 30 90 150 10 60 30 60 60 60 90 90 150 11 45 30 90 90 90 90 90 150 30 30 12 30 30 30 30 30 90 150 13 60 30 T6 T6 T6 T8 90 150 14 60 15 60 30 30 45 90 150 15 30 30 30 30 30 30 90 150 30 30 16 90 30 50 50 50 60 90 150 50 90 Process Units Process Control Room Storage Tank Class A Storage Tank Class B Storage Tank Class C

1 45

2 30

3 90

4 90

5 90

6 90

9 30

10 30

11 -

12 15

13 50

14 30

15 30

16 90

11. Boiler House/ heaters 12. Rail spur

90 150

30

30 15 30

30 T6 60 30

30 T6 30 30

30 T6 30 30

30 T8 45 30

90 150

T7

30

15 50 30 30

30 6 15

30 6 30

6 6 30

15 30 30 -

50 50 50 15

13. Boundary fence 60 around installation 14. Service buildings 60 15. Cooling towers, water storage, nitrogen plant 16. API Separators/ oil sludge pit 30

90 150 T6/T7 12 90 150 90 150 60 30 12 30

Storage Vessels 60 (Pressure) LPG/Other Flares-elevated Flares-ground Bulk loading racks (rail/road) LPG/POL 90 150 45 60

T7 90/60

T7 T6/T760 30 12 12

90

30

50

50

50

60

90 150

50

90

90

50

50

50

15

10. Fire stations/ First aid centre

150 90/60

TABLE-2 MINIMUM INTERDISTANCES BETWEEN EQUIPMENTS WITHIN PROCESS UNIT

This table could be used by the oil companies as a guideline for their projects. These could be suitably modified as required to suit space constraints and relevant engineering practices. NOTE 1
S.No.

From \ To

9 10 11 12 13 14 15 16 17 18 19 15 1516/30 15 4 2 2 3 16 3 20 3 20 - 18 15 5 15 3 15 3 15 4 15 3 15 6 30 15 3 15 15 3 15 15 3 15 15 3 20 15 - 15 15 - 15 15 - 15 15

20 15 3 3 3 7.5 15 -

TABLE - 2 (Contd...)
S.No.From \ To
15. Pressure Vessel/ Drums (Hydrocarbon) 16. Fire water hydrants/monitors 17. Pipe rack (main) 18. Blow down facility (pumps, drums, stacks) 19. Water spray Deluge valve 20. Structural main (Technological platforms)

1. Fired heaters/ any fired equip. 2. Reactors 3. Distillation columns 4. Accumulators (Hydrocarbon) 5. Gas compressors (Hydrocarbon) 6. Hot oil transfer pumps 7. Fuel Oil Day tank 8. Pump for Class A & all products above auto-ignition temp. 9. Pumps - other Hydrocarbon 10. Heat Exchanger Hydrocarbon 11. Air Fin CoolersHydrocarbon 12. Control room 13. Snuffing/purging steam isolation valve 14. Fired heaters control panel (local)

- 15 15 15 22.5 15 15 20 15 15 15 15 22.5 15 2 2 6 2 3 4 6 8 7 15 5 15 5 15 7 5 4 7 5 4

1
18

2
5

3
3

4
3

5
4

8
3

9 10 11 12 13 14 15 16 17 18 19
3 2 2 16 2 10 2 15 3 15 15

20
2

- 15 - 15 - 15 - 15 - 15

4 7.5 2 8 8

3 15

15 15 15 15 15 15 15 15 15 15 15 6 3 3 3 3 - 2

- 15 15 -

- 15 15 - 15 15 - 15

15

8 7.5 7 5

3 7.5 15 7.5 7.5 7.5 7.5 16 1 7.51 1 1 2 2 16

5 7.5

- 16

3 15

30 15 15 15 20 15 15 15 15 15 15 16 15 15 15 15 15

15 15 15 15 15 7.5 20 7 5 4 7.5

2 15 15 15 15 16 1 1 2 2 16

- 15 15 15 - 15 3 15

1 15

15 15 15 15 15 15 15 15 15 15 15 15 3 3 3 7.5 - 15 -

5 15 15 5 2

- 15 15 - 15 -

15 15 15

7 4 3

5 2 3

4 7.5 2 7.5 3 7.5

1 15 2 15 2 15

1 2 2

1 2 2

2 2 2

2 16 2 16 - 16

- 15 - 15 - 15

3 15 2 15 2 15

- 15 15 2 15 15 - 15 15

2 16 -

2 16

16/30 16 20 20 16 16 16 16 16 16 16 15 -

- 16 20 16 2

- 16 16 5 - 15 5

- 16

- 15 15 15 15 15 15 15 15 15 15 20

- 10 15

- 15 15

Layout for oil and Gas Installation

control room
Control room should be located distinctly in the process block and should at a safe distance where protection to instrument and personal is ensured.. It should have alternate means of exist with doors opening to outside. Door should be of fire proof materials Control should occupancy. be designed to cater minimum

Layout for oil and Gas Installation Storage tanks Dyked enclosure Petroleum storage tanks shall be located in dyked enclosure with road al around the enclosure Aggregate capacity of tanks located in one dyked enclosure shall not exceed the following values for group of floating tanks - 120,000 CU.M. for group of fixed roof tanks - 60,000 CU.M. If a group of tanks contain both fixed and floating roof tanks then it shall be trated as a group of fixed roof tank for the purpose of above limits.

Transformer should be located on open area on the rear side of sub station. Each transformer shall be isolated from other by a brick wall.. Approach road should be made to facilitate crane movement for maintenance and erection.

Layout for oil and Gas Installation - Storage tanks

INTERDISTANCES BETWEEN STORAGE TANKS/OFFSITE FACILITIES

Dyked enclosure should be able to contain the complete contents of the largest tank in the tank farm in case of emergency Enclosure capacity shall be calculated after deducting the volume of the tanks( other than the largest tank ) up to the height of the enclosure. A free board of 200 mm above the calculated liquid level shall be considered for fixing the height of the dyke. Smoking Booth Smoking booths shall be located at least 30mt away from any hydrocarbon sources/ facility and preferably upwind.

S.No.

From \ To
Storage tank for petroleum class A Storage tank for petroleum class B Storage tank for petroleum class C Storage / filling shed for petroleum class A or class B Storage/filling shed for petroleum class C Tank vehicle loading/ unloading area for petroleum class A or B Tank vehicle loading/ unloading area for petroleum class C Flame proof electric pump motor Non-flame proof electric pump motor

1
T5 T5 T5 15

2
T5 T5 T5 15

3
T5 T5 T5 15

4
15 15 15 -

5
15 15 8

6
15 15 8 15

7
15 15 15

8
8 8 8

9
15 15 15

1. 2. 3. 4.

5. 6.

15 15

15 15

8 15

8 -

15

7.

15

15

15

8. 9.

8 15

8 15

8 15

8 15

8 -

INTERDISTANCES BETWEEN STORAGE TANKS

Sl. Item No. Floating Roof Fixed Roof Class C Tanks Tanks (Class Petroleum A & B Petroleum
(D + D) / 4 (D + d) / 4 (D + d) / 4 (D + d) / 3 (D + d) / 6 (D + d) / 4
S.No.

DISTANCES FROM BOUNDARY FENCING

Minimum Distance from Boundary fencing around Installation ** ** ** 15 10 20 10

Installation

1. 2.

Storage tank for Petroleum Class A Storage tank for Petroleum Class B Storage tank for Petroleum Class C Storage/filling shed for Petroleum Class A or Class B Storage/filling shed for Petroleum Class C Tank vehicle loading/unloading area for class A & B petroleum Tank vehicle loading/unloading area for class C petroleum

1.

All tanks with diameters upto 50 metres All tanks with diameters exceeding 50 metres

3. 4. 5. 6. 7.

2.

INTERDISTANCES FOR LPG FACILITIES

S.No.
1. 2.

From \ To
LPG Storage vessels Boundary/property line/ group of buildings, not associated with LPG plant Shed-LPG/Cold repair shed/ cylinder evacuation facilities Tank Wagon Gantry Tank Truck Gantry Rail spurs Pump house/Comp. house(LPG) Fire Pump house

1
* T8

2
T8 -

3
30 30

4
30 30

5
30 30

6
15 30

7
60 **

INTERDISTANCES BETWEEN LPG STORAGE VESSELS AND BOUNDARY / PROPERTY LINE / GROUP OF BUILDINGS NOT ASSOCIATED WITH LPG FACILITIES
Capacity of Each Vessel (Cum.M. of water)

3.

30

30

15

30

30

15

60

S.No.

Distance

4. 5. 6. 7.
Notes :
1.

30 30 15 60

30 30 30 **

30 30 15 60

50 50 30 60

50 50 30 60

30 30 60

60

1.
60

10 - 20 21 - 40 41. 350 351 - 450 451 - 750 751 - 3800

15 20 30 40 60 90

2.
60

3.
-

4. 5.

2.

3.

All distances are in metres. Notation: T8 Refer Table - 8 * 1/4 of sum of diameters of adjacent vessels or half the diameter of the larger of the two adjacent vessels whichever is greater. ** Any distance for operational convenience. Distance of stabling line shall be as per minimum Railway Standards.

6.

OISD-STD-141: Design and construction requirements for

cross country hydrocarbon pipelines

Contd.
Valves Bends

Scope :Minimum requirements for design, materials, construction,

assembly, inspection, testing and safety aspects of operation and maintenance.

Design
Dynamic effects Weight effects Zone location Allowable stress value Corrosion Pressure design

Materials Construction, Welding and Assembly

Location Bends Handling, hauling, Stringing and Storing Ditching Installation of pipe in ditch Special Crossing

Contd Block valves and Isolating valves Pump station, Tank farm and Terminal construction. Inspection and Testing
Type and Extent of Examination required Testing

Advantages of Pipeline Transportation

Lower cost of transportation Lower transit losses Lower energy intensiveness Economies of scale Safety and Reliability - minimum disruptions Environment friendliness Multi-product handling Stationary carrier Augmentation at low cost Minimal land costs Decongestion of surface transport systems

Commissioning Operation and Maintenance procedures Corrosion control

Protective coating Cathodic protection system