This document summarizes a presentation on safety and integrity measures for natural gas pipelines in India. It discusses the importance of gas pipelines, existing pipeline infrastructure in India, and safety considerations in pipeline design and operations. It focuses on GAIL's pipeline network and safety practices, including following national and international design standards, installing remotely operated valves and pressure safety valves, corrosion protection, emergency response planning, and 24/7 monitoring of pipelines.

1. Safety & Integrity Measures for NG pipelines-
Practices in India
13rd ENGI Conference- 2017
.
Dr. Narendra Kumar
GAIL (India) Ltd.

2. Areas Covered
23rd ENGI Conference- 2017
1.Importance of Gas Pipelines
2.Natural Gas Infrastructure in India
3.GAIL Infrastructure
4.Safety Considerations in Design &
operations
5.Technology
6.Education and Leanings
7.Conclusion

3. Natural Gas – Pipeline System
 Consists of a strong carbon steel material covered with a
specialized coating engineered based on robust design to meet
vigorous national & international standards
 Compressor Stations: To ensure the natural gas remains
pressurized, it must be compressed periodically along the
pipeline
 Valves & Metering Stations
 Control Rooms & SCADA
 Safest and Most Reliable, Economical and Eco -friendly Mode of
Product Transportation
3rd ENGI Conference- 2017

4. Pipeline Systems
4
Benefits of Transportation by Pipelines
 Safer mode of transportation
 Environment friendly
 Least energy requirement
 Lowest maintenance costs
 Minimal impact on land use pattern
 Negligible loss of product in transit
 High reliability
 Multi-product Transportation
3rd ENGI Conference- 2017

5. Pipeline Systems
5
Threats and Challenges in Pipeline Operations
 Ageing Assets and Complex Operations
 Third party intrusion/ miscreant activities
 Lack of online monitoring and control
 Inadequate Supervision
 Old technologies in some of pipelines
 Deterioration of Coatings of the pipelines
 AC/DC Interference in CP System
 Pilferage
 RoU Encroachments
 Natural Calamities
3rd ENGI Conference- 2017

6. NG Pipeline System- Safety Hazards
3rd ENGI Conference- 2017
 Highly flammable material transported at high pressure often
covering areas of high population or high environmental
sensitivity
 Provision of protective measures are essential for safe
operation of NG Pipeline system. The requirement is based on
 Hazardous properties of Natural Gas
 Quantity of Natural Gas, which could be released incase of leak/rupture and its effect
 Probable causes of accidents in NG Pipelines
 From the pipeline: External & Internal Corrosion
 From the third party: The pipeline system runs through agricultural area, community area,
along highway, and thus any disturbing third party activity may cause accident
 From natural disaster: Earthquake, Flood, etc

7. Existing Gas Pipelines in India
3rd ENGI Conference- 2017

8. Gas Pipelines in India
Name of the Company Length (km) Capacity (MMSCMD)
Existing Pipelines
GAIL 11,070 206
RGTIL 1,469 80
GSPL 2,600 43
AGCL/OIL 811 3
IOCL 140 9.5
ONGC 24 6
Sub Total 16,114 347.5
Under Construction
GAIL 6029 139
GSPL 4819 198
APGDC 391 90
Reliance Gas Pipelines Ltd. 312 3.50
Gas Transmission India Pvt. Ltd. 250 36
IOCL 1385 85
H-Energy Pvt. Ltd. 635 17
Sub Total 13,821 568.5
Grand Total 29,935 916
3rd ENGI Conference- 2017

9. Governance Mechanism & Framework
 PNGRB (Petroleum & Natural Gas regulatory Board):
 Technical Standards and Specifications Including Safety Standards for Natural
Gas Pipelines( T4S)
 Integrity Management System
 ASME
 Standard B31.8: Gas Transmission and Distribution Piping Systems
 Standard B31.8S: Managing System Integrity of Gas Pipelines
 OISD (Oil India Safety Directorate): Standard 226 – Natural Gas Transmission
Pipeline and City Gas Distribution Network
 Charter : Defining the Objective, Mission, Vision and Responsibilities
 Focus Areas for Functional Excellence: ‘S2OMES-TEA’
Safe & Secure O&M, Efficient Operation, Best Maintenance Practices,
Environment Management, Stakeholder Management,
Adopting state of art Technology, Education and Learning & Award and Appreciation
3rd ENGI Conference- 2017

10. GAIL an Integral part of India’s growth story....
75% of India’s gas travels through
GAIL’s network
More than half of India’s natural gas is
traded by GAIL
Operate more than 2/3rd of country’s
CNG stations through JVs
Produce 25% of India’s total poly-
ethylene
LPG in every 10th LPG cylinder in the
country is produced by GAIL
3rd ENGI Conference- 2017

11. GAIL’S MISSION & VISION
Formed in 1984
as Gas Authority
of India Limited
with
Changed name in 2002
as GAIL (India) Ltd
with
redefined
Mission
Vision
“TO ACCELERATE AND OPTIMIZE
THE EFFECTIVE AND ECONOMIC USE
OF NATURAL GAS AND ITS FRACTIONS
TO THE BENEFIT OF NATIONAL ECONOMY.”
“BE THE LEADING COMPANY IN NATURAL
GAS & BEYOND, WITH GLOBAL FOCUS,
COMMITTED TO CUSTOMER CARE,
VALUE CREATION FOR ALL STAKEHOLDERS
AND ENVIRONMENTAL RESPONSIBILITY”
Mission & Vision of GAIL
3rd ENGI Conference- 2017

12. JAGDISHPUR
PHOOLPUR
BHATINDA
BAREILLY
DISPUR
DELHI
AGARTALA
BARODA
LUCKNOW
PATNA
AHMEDABAD
RAJKOT
KOTA
MATHANIA
GWALIOR
UJJAIN
AGRA
KOLKATA
GAYA
BOKARO
VARANASI
JHANSI
DAHEJ I & II
10 MMTPA
(36 MMSCMD)
COIMBATORE
MANGALORE
BANGALORE
SOLAPUR
KAKINADA
DABHOL
5 MMTPA
(18 MMSCMD)
AURAIYA
CUTTACK
VIJAYPUR
KANPUR
NANGAL
GURGAUN
PUNE
BHARUCH
SURAT
HYDERABAD
RAJAMUNDRY
BHOPAL
BARMER
Hisar
Jhajjarr
KOCHI
5 MMTPA
(18 MMSCMD)
ENNORE
(CHENNAI)
DAMRA
JABALPUR
BHILAI
JAISALMER
IPI P/L
(30 MMSCMD)
TAPI P/L
(38 MMSCMD)
Surat - ParadipHAZIRA
3.6 MMTPA
(13 MMSCMD)
GAIL’s NG P/Ls
PARADIP
HALDIA
Existing Pipeline Network:
Pipeline Network – 11000 Km
States / UT’s covered – 17
Total Capacity – 206 MMSCMD
Jagdishpur - Haldia
ENNORE
5 MMTPA
(18 MMSCMD)
KAKINADA/
GANGAVARAM
3 & 3.5 MMTPA
(24 MMSCMD)
3rd ENGI Conference- 2017

13. HVJ – GREP-
DVPL P/L
KOTA
VIJAIPUR
JAGDISHPUR
AURAIYA
DADRI
KHERA
JHABUA
VAGHODI
A
DAHE
J
HAZIRA
DEWAS
PITAMPU
R
ANKOT
KELARAS
DAULPUR
MALANPUR
AGRA
FEROZABA
D
MATHURA
BABRALA
AONLA
SHAJAHAPU
R
GURGOAN
CHAINSAFARIDABAD
ANTA
KANPUR
LUCKNO
W
PHULPHUR
HVJ & SPURLINE : 1” -36”
TOTAL Length : ~ 2650 kms
DVPL : 42” x 610 km
48”x 610 ( upgradation)
Project Cost: 5186 Cr.
GREP : 36” x 505 km
48” x 505 km ( upgrade)
Project Cost: 5439 Cr.

14. JLPL Route Map

15. LPG PIPELINE

16. Global Footprints
Egypt
 Equity in 2 Retail Gas Companies
Myanmar
 Partner in A1, A3 E&P Blocks
 Participation in Myanmar-China Gas
Pipeline
United States of America
 GAIL Global U.S. holds 20% stake in
producing Shale Asset in Eagle ford
China
 Equity Partner in China Gas (Retail
Gas Company)
 50:50 JV With China Gas
Singapore
 100% Subsidiary – GAIL Global
(Singapore) Pte. Limited –
Overseas investment & Trading /
Sourcing arm
3rd ENGI Conference- 2017

17.  Sizeable
contribution
 6 Plant across India
 Capacity ~1.4
MMTPA
 LPG Capacity ~1.1
MMTPA
LHC
 Significant Player (~
25%)
 Capacity 900 KTA
Polymers
 70% stake in BCPL (280
KTA) with 100%
Marketing rights
 17% stake in OPAL,
1400 KTAofPolymer
Petrochemicals
 Gas Marketing with
volume of 79
MMSCMD
 Covering 17 States
& UT across the
Country
Trading
 NG Transport
Capacity 206
MMSCMD (~11000
Kms.)
 LPG Transport
Capacity 3.8 MMTPA
(~2050 Kms.)
Transmission
Present Business Portfolio
3rd ENGI Conference- 2017

18.  Leveraging OFC
 Countrywide
Presence
 11000 KM – OFC
Network
GAILTel
 Securing Gas
Supply or Equity Oil
/ Gas
 30 Domestic
Blocks
 2 Overseas
(2Myanmar)
 20% working
interest in Shale
Gas Asset in U.S.A
E&P
 High Growth Area
 8 JVs
 Incorporated
wholly owned
subsidiary, GAIL
Gas Ltd.
(Meerut, Dewas,
Kota, Sonepat,
Bangalore )
Retail
 PLL - LNG
Dahej-10 MMT
Kochi-2.5 MMT
 Dabhol-5 MMT
 Renewables (wind-
118 MW, Solar-5
MW)
 RGPPL – Power
(2184 MW)
 GSEG – Power
(156 MW)
Diversification
Present Business Portfolio
3rd ENGI Conference- 2017

19. CGD JVs
IGL,
Delhi
GAIL Gas,
(Sonepat)
GGL,
Agra, Lucknow
CUGL,
Kanpur, Bareilly
TNGCL,
Tripura
GAIL Gas
(Kota)
BGL,
Hyd & VijaywadaMNGL,
Pune
MGL,
Mumbai
VGL,
Vadodara
AGL,
(Indore, Ujjain,
& Gwalior)
GAIL Gas
(Dewas)
GAIL Gas,
Bengaluru
GAIL Gas,
Haridwar
GAIL Gas North
Goa
GAIL Gas,
Taj
Trapezium
GAIL Gas,
(Meerut)

20. Design & Construction-Practices
 National & International Standards like OISD, PNGRB, ASME 31.8B, API etc. followed .
 Fulfilling Regulatory requirement eg. PNGRB Regulations
 P/L wall thickness according to the population class, design pressure, specified minimum
yield strength, dia of the pipe longitudinal joint factor and temperature de-rating factor as
per ANSI/ASME B 31.8.
 Additional corrosion allowance of design wall thickness considering 30 years pipeline
design life and moderate corrosion rate
 Proper External Coating like 3 layer polyethylene coating
 Installation of remotely operated sectionalizing valves at regular intervals of approximate
8-32 KM based on Location Class
 Provision of Intermediate pigging stations along with the pipeline route to meet the
pigging requirement of pipelines
3rd ENGI Conference- 2017

21. Design & Construction-Practices
 Pressure safety valves at the Intermediate Pigging Stations provided to take care of excess
pressure
 Installation of casing pipes at all railway crossing and highway crossing as per
International Standards
 Pipeline markers like warning boards, kilo meter/aerial markers or boundary pillars along
the pipeline route
 Gas Detection System at Pipeline Installations area
 Automatic fire detection and suitable fire extinguishing system is installed at all
Installations
 Cathodic Protection System provided for pipeline against corrosion
 Corrosion sensing probes for monitoring external & internal corrosion rate
 Provision of SCADA to ensure effective and reliable control, management and supervision
of the pipeline
3rd ENGI Conference- 2017

22.  Behavior Based Safety
 Emergency Response and Disaster
Management Plan (ERDMP)
 Emergency Mock-Drills
 Foot Patrolling with GPS Tracker and LEL
Detector
 Aerial Patrolling
 Incident Reporting System
 Emergency Response Vehicles
 One Call System
 Next Level:
 RoU Patrolling through UAV (Drones) & Satellite
Imagery
 Pipeline Intrusion & Leak Detection System
Safety & security- Practices
3rd ENGI Conference- 2017

23.  Operation & Maintenance Policy & Guidelines
 Standard Operation Procedures (SOPs) for
Control System and Safety Interlocks
 24x7 Monitoring through Pipeline Control
Rooms
 Remote Operation & Auto Closure Facility of
Sectionalizing Valve (SVs)
 Source Monitoring-Online Moisture & H2S
Analyzers
 Component based Maintenance Systems &
Procedures
 Corrosion Inhibitor Injection
 Next Level:
 Odorization in Trunk Pipeline for leak detection
 Predictive Maintenance through Data Analytics
Operation & Maintenance- Practices
3rd ENGI Conference- 2017

24.  Cathodic Protection: PSP Monitoring, CIPL,
CAT / DCVG, AC/ DC Interference Surveys
and Modelling, etc.
 Corrosion Monitoring Probes
 Pipeline Integrity Management System
 Pigging of Pipelines
 Direct Assessment: ICDA/ ECDA
 Integrity Assessment through
 Magnetic Tomography Method (MTM)
 Contactless Magnetometric Diagnostics
method (CMDM)
 Next Level:
• ILI using Internal Eddy Current Tool & EMAT
technology
• Online risk based Pipeline Integrity
• Predictive maintenance instead of preventive/
shutdown maintenance based on analytics
Operation & Maintenance- Practices
3rd ENGI Conference- 2017

25.  PPP model i.e. Planet-People-Profit
 Sustainable Development through
Environmental Initiatives and
Developmental Projects
 Environmental Monitoring and Audits
 Green House Gas/ Methane emission
control/ accounting
 Online Monitoring of SOx/ NOx emission
 Utilization of LED Lights
 Clean energy initiatives such as wind and
solar
 Cleanness drive at various locations eg.
SWACHH BHARAT ABHIYAN
Environment Management- Practices
3rd ENGI Conference- 2017

26.  Demand & Supply Management of
Natural Gas
 Effective Encroachment Removal Policy
 Sahayogi Scheme
 Regular Customer and Vendor Meets
 Various CSR activities in the field of Health,
Education, Infrastructure etc
 Public Awareness Program on “PIPELINE
SAFETY”
 Model Terminals to be used for spreading
brand value
 Hand- Holding Initiative
Stakeholder Management- Practices
3rd ENGI Conference- 2017

27. How to ensure Pipeline Safety
27
Pipeline Safety can be ensured by having a
sound Pipeline Integrity Management
System.
3rd ENGI Conference- 2017

28.  Design & Construction Practices - To avoid
stable threats
 Operation and Maintenance Practices - To
avoid Time Dependent and Independent
Threat
Establishing Pipeline Integrity
283rd ENGI Conference- 2017

29. A Time-Dependent I External corrosion
II Internal corrosion
III Stress corrosion cracking
B Stable IV Manufacturing-related defects (a) defective pipe seam
(b) defective pipe
V Welding/fabrication related (a) defective pipe girth weld (circumferential)
(b) defective fabrication weld
(c) wrinkle bend or buckle
(d) stripped threads/broken pipe/coupling failure
VI Equipment (a) gasket O-ring failure
(b) control/relief equipment malfunction
(c) seal/pump packing failure
(d) miscellaneous
C Time-Independent VII Third party/mechanical damage (a) damage inflicted by first, second, or third parties
(b) previously damaged pipe (such as dents / gouges)
(c) vandalism
VIII Incorrect operational procedure
XI Weather-related and outside force (a) cold weather
(b) lightning
(c) heavy rains or floods
(d) earth movements
D UNKNOWN
Pipeline Threat Matrix
29
3rd ENGI Conference- 2017

30. Stable Threat
AXIAL GROOVE CAVERN
CIRCUMFERENCIAL GROOVE ABNORMAL GIRTH WELD 30
3rd ENGI Conference- 2017

31. Time Dependent Threat
Corrosion in Pipelines
Stress Corrosion Colonies & cracks 31
3rd ENGI Conference- 2017

32. Time Independent Threat
MECHANICAL DAMAGE MECHANICALLY DAMAGED PIPELINE
32
3rd ENGI Conference- 2017

33. Types of Failures
33
24
6
24
26
20
Types of Failures
Non-adherence to SOP
&Permit system / Gap in
supervision 24%
Natural Calamity 6%
Equipment failure 24%
3rd Party Damage/
Miscreant activity 26%
Corrosion failure/
Pipeline Rupture 20%
Source: OISD
3rd ENGI Conference- 2017

34.  Adopting state of art Technology- “SMART
UTILITY COMPANY”
 Centralized Asset Management: GIS based
Pipeline Information System which is helpful
in
 Centralized Maintenance of Health Records of
Pipelines on the GIS map
 Cadastral & other land records of Pipelines on
the GIS map
 Seamless Integration between field data &
Gas Management System through SCADA
 Next Level:
 OT – IT Integration
 Data Analytics for taking business decision
Technology
3rd ENGI Conference- 2017

35.  Training to pipeline officers through NACE,
ASME, etc. to create Cadre Based Team
 Organizing Pipeline Operators Meet &
Technical Seminars for discussions on various
pipeline operation & maintenance issues
 Participation in various National and
International Seminars like CORCON, ICEPIM,
NCCI, etc.
 Next Level:
 E- Learning System for imparting knowledge
digitally
 “DELTA Project” - the delta change or positive
uplift required for improvement in efficiency
of People, Process & Plants
Education & Learning
3rd ENGI Conference- 2017

36.  Awards: Recognizing the extra ordinary
efforts made by Team members
 Best Model Terminal Trophy
 Corrosion Awards- Recognizing the excellent
work done in Monitoring & Mitigating
Corrosion Threats in Pipelines
 Gratitude And Appreciation Day on 7th day
of each month
 To express Gratitude and Appreciate good
things that come to our day to day lives
 Creates strong positive emotions not only in
the recipient but also in one who performs
this act
 Helps in improving our relationship with
others
Education & Learning
3rd ENGI Conference- 2017

37. Conclusion
ASSET INTEGRITY : BUSINESS CONTINUITY
 An effective Surveillance Regime covering all aspects of
Operation and Maintenance is an important factor to ensure
Integrity of pipeline assets
 Pipeline Integrity requires adopting a mind set “ Failures are
Preventable”
 Adoption of Corrosion Management best Practices can
improve overall performance of Pieline Operations
373rd ENGI Conference- 2017

38. THANK YOU
38
3rd ENGI Conference- 2017
Safety & Integrity Measures for NG pipelines: Practices in India