The document discusses the safety of cross-country pipelines. It provides details about Petronet CCK Limited, a subsidiary of BPCL that has laid a 292 km petroleum product pipeline from Cochin to Karur via Coimbatore. It describes the design, facilities, operational safety features, emergency preparedness measures, mutual aid agreements, and emergency response and disaster management plan of the pipeline to ensure safety during transportation of products.

1. SAFETY OF CROSS COUNTRY PIPELINESSAFETY OF CROSS COUNTRY PIPELINES

2. SAFETY OF CROSS COUNTRYSAFETY OF CROSS COUNTRY
PIPELINESPIPELINES

3. Pipelines
Road Tankers
Rail Tankers
Water Carriers

4. ADVANTAGES OF TRANSPORTATION BY PIPELINESADVANTAGES 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-productTransportation

6. 6
Oil Pipelines in South India

7. PETRONET CCK LIMITED
Corporate Office – Irimpanam, Cochin
Petronet CCK Limited, a subsidiary of M/s. Bharat Petroleum Corporation Limited,
has laid a petroleum product pipeline from BPCL Irimpanam Terminal to Karur via
Coimbatore for transportation and downstream distribution of petroleum products MS, SKO
and HSD.

8. 8
PCCK- Milestones
PIPE LINE LAYING STARTED DECEMBER 1999
MECHANICAL COMPLETION FEBRUARY 2002
PROJECT PERIOD (ACTUAL) 3 YEARS 8 MONTHS
TRIAL RUNS MARCH 2002
COMMERCIAL OPERATION SEPTEMBER2002

9. 9
Pipes being laid along the route Work in river
Horizontal Directional Drilling across the Periyar Foundation setting for pump

10. 10
WELL BEGUN IS HALF DONE
Appropriate engineering design
Adopting state of the art technology
Ensuring quality in men, material and methods
Strict adherence to standard practices
Building a strong organizational safety culture

11. 
FACILITIES – DESIGN
PCCKL
LENGTH OF PIPELINE 292 KM
SIZE OF PIPELINE
o
COCHIN TO IRUGUR 450 MM (18”)
o
IRUGUR TO KARUR 350 MM (14”)
GRADE AND THICKNESS
(a) 18” API 5L Gr. X 65 of thick. 6.4, 7.9, 9.5, 12.7 mm
(b) 14” API 5L Gr. B of Thick. 6.4, 7.9 mm
THROUGHPUT 3.3 MMTPA in Phase – 1 and
4.0 MMTPA in Phase – 2
PRODUCTS HANDLED MS / HSD / SKO
PUMPING STREAM HOURS 8000 Hrs Per Annum

12. 
FACILITIES
DESPATCH TERMINAL IRIMPANAM
RECEIVING TERMINAL KARUR
TAP OFF POINTS IRUGUR
SV STATIONS
12 MOV STATIONS ( 10 IN C-I SECTION AND 2 IN I-K SECTION)
5 HOV STATIONS IN C-I SECTION
ROU WIDTH
18 M (in cross country portion)
Have restricted ROU's at select locations and forest areas.

13. 
FACILITIES AT PETRONET
Main Pumping Station at Cochin.
Receipt Terminal at Karur and tap off at Coimbatore.
182.500 Kms 18” underground Pipeline from Cochin
to Coimbatore.
110.000 Kms 14” underground Pipeline from
Coimbatore to Karur.
12 Motor operated Sectionalising Valve Stations and
5 Hand Operated Valve (HOV) Stations along the
Pipeline route.
300 Kms dedicated Optic Fiber Communication System.

14. An Operating Manual has been drawn up in consultation
with BPCL based on the provisions made in the Off Take
Agreement
It describes the activities and responsibilities of all terminals of
PCCKL and BPCL on the following
Planning and Scheduling
Product Quality
Operational Activities at Cochin, Irugur and Karur.
Product Quality Certification
Batch Reconciliation
Slop Management
Product Loss Management
Operating Manual

15. 
FACILITIES AT PETRONETFACILITIES AT PETRONET

16. 
FACILITIES AT PETRONET

17. 
FACILITIES AT PETRONET

18. PIPELINE PROFILE (ELEVATION)PIPELINE PROFILE (ELEVATION)
PCCKLPCCKL
0
25
50
75
100
125
150
175
200
225
250
275
300
325
350
375
400
425
450
0
4
8
12
16
20
24
28
32
36
40
44
48
52
56
60
64
68
72
76
80
84
88
92
96
100
104
108
112
116
120
124
128
132
136
140
144
148
152
156
160
164
168
172
176
180
183
187
191
195
199
203
207
211
215
219
223
227
231
235
239
243
247
251
255
259
263
267
271
275
279
283
287
291
Cochin (5m)
Irugur
(375m)
Karur
(150m)
0kms
182 kms 292 kms
415m
Peak(415m)
Kuthiran (150m)
80 kms

19. Five Characteristics of World Class Safety Management System
Leadership - Lead by example (promote risk awareness,
encourage the team, ensure compliance and involve)
Integrated system approach - Integrating safety into all
functions of the organization
Performance measurement - Continuous monitoring to
promote safety performance
Alignment to core organizational goals - Aligning safety
along with organizational goals, objectives and values
Off the job safety - Extending safety efforts to employees
and community outside the work

20. Petronet CCK Ltd. has implemented the Integrated
Management System – IMS with effect from 01st
October 2008 consisting the following standards:
ISO 9001:2008-Quality Management System (QMS),
ISO 14001:2004-Environmental Management System
(EMS) and OHSAS 18001:2007.
The certification was done by M/s Det Norske Veritas
(DNV) Certification B.V., The Netherlands.

21. IMS POLICY AT PCCKL

22. 
Real time data acquisition and monitoring through SCADA system
Application software including Leak Detection System - LDS
Emergency Shutdown System - ESD
12 numbers of motorised remotely operated Sectionalizing Valves
IP based day/night Video Surveillance System
OPERATIONAL SAFETY FEATURES AT PETRONET

23. 
Daily line patrolling by Line Patroller's
Internal Inspection of Pipeline using PIGS
Cathodic Protection by ICCP and Galvanic Protection
Operational Control Procedures - OCP
Work Permit and audit system
Fire Hydrant System, Foam Trolleys, Fire Extinguishers, MCP’s, Fire Alarm
System.
OPERATIONAL SAFETY FEATURES AT PETRONET

24. PREPAREDNESS MEASURESPREPAREDNESS MEASURES
As part of emergency preparedness, following measures are adoptedAs part of emergency preparedness, following measures are adopted::
Emergency Drills and Mock Exercises
The effectiveness and thoroughness of ERDMP is evaluated through regular
table top exercises covering all potential scenarios on rotation basis in safety
meetings. Safety meetings are held at a frequency of once in a month
Training
Training on basis / advanced firefighting is extended to all employees on
yearly basis. The guards & LPMs, are also provided with fire and safety
training on a yearly basis.
Mutual aid associations are in place at Cochin, Coimbatore and Karur with
nearby units of oil PSUs and other major industrial units. The mutual aid
members meet on quarterly basis and discuss common areas of interest and
also participate in the DCMP drills of each unit.
Mutual Aid

25. The Inspector of Factories and Boilers suggested
in the mutual aid meeting held on 30/05/2011
at Petronet CCK Limited that the Mutual Aid
Group of Irimpanam should have a name
and it was unanimously decided that the group
shall be named as “ IMAG –IMAG –
Irimpanam Mutual Aid GroupIrimpanam Mutual Aid Group”.

26. Irimpanam Mutual Aid group (IMAG) has been
formulated and an agreement signed with the
neighboring oil companies like BPCL, IOCL, HPCL, HP Gas
and IOC LPG bottling plant as members.
IMAG members meet once in a quarter to discuss on
common issues among the oil companies and also the
safety of the public in the nearby areas.
The motive of IMAG is to mutually assist the members
by sharing resources during an emergency.

27. Organization
Emergency Contact
Number
Contact Person and
phone number
Terminal In charge and
phone number
Control Room
0484 2778145
9446427555
Ratheesh R
Engineering Executive
9495315882
Jalin K Thampi
Sr. Terminal Manager
9447640105
Control Room
0484 2778316
Tirumala Srinivas M
Asst. Manager (HSSE)
9447356143
Somasundaram M
Sr. Installation Manager
8547831573
Control Room
0484 2114327
Arun Anto
Asst. Manager (HSSE)
9645660823
R Kumar
Chief Terminal Manager
9447498266
Control Room
0484 2114847
Radha Krishnan
Sr. Officer(HSSE)
9847625470
K A Devan
Chief Installation Manager
9177443322
Control Room
0484 2775407
Deepak E D
Safety Officer
8156844411
Muhammed Tajib Sait
Sr. Plant Manager
9605001969
Control Room
0484 2791848/2458
Nibil P S
Officer (LPG - Safety)
9539711199
N Manoharan
Chief Plant Manager
9446312888
IMAG MEMBER LIST

28. MUTUAL AID AGREEMENTMUTUAL AID AGREEMENT
SIGNING CEREMONYSIGNING CEREMONY

29. EMERGENCY RESPONSE ANDEMERGENCY RESPONSE AND
DISASTER MANAGEMENT PLANDISASTER MANAGEMENT PLAN
 An elaborate ERDMPERDMP is in place describing various emergency scenarios
to assist all personnel engaged in the operation and maintenance of the
pipeline network to deal with emergencies of different kind.
 ERDMP also describe the on-site and off-site emergency plans and also
defines the roles and responsibilities of the Crisis Coordinators and
various other coordinators, line patrolling man, security guards, external
agencies like Police, Fire force, medical services, water & irrigation,
public works department, pollution control board etc…

30. MAINLINE EMERGENCY RESPONSEMAINLINE EMERGENCY RESPONSE
EQUIPMENTSEQUIPMENTS
 Emergency Rescue Vehicle-ERV.
 Oil Spill Care Equipment's.
 Skimmers.
 Booms.
 Oil Dispersants.
 Leak Clamps.

31. 1. Oil Spill Care Kits
2. ERV
3. Booms
MAINLINE EMERGENCY RESPONSE EQUIPMENTS

32. 1. Oil Skimmers
2. Leak Clamps
MAINLINE EMERGENCY RESPONSE EQUIPMENTS

33. WORK PERMIT SYSTEM
 Work Permit System in accordance with OISD 105 is
religiously in place.
 Hot Work Permit, Cold Work Permit, Electrical Isolation and
Energisation Permit is strictly issued by the authorized
personnel only.
 Trainings on Work Permit System is given to all employees,
contract staff, contractors and labourers, security guards and
line patrol man.
 Work Permits are issued, renewed and closed judiciously.
 Work permits are tracked and reviewed every morning.

34. AUDIT SYSTEMS AT PETRONET FOR
ENSURING SAFETY COMPLIANCE
Half yearly internal audits for the continual improvement
and maintenance of IMS system.
Yearly IMS audit by external third party agency.
Technical cum Safety audits done by qualified internal
auditors.
Third party safety audits done through NSC.
OISD audit.
Internal OISD standards review and GAP analysis.
Petroleum and Natural Gas Regulatory Authority
Compliance audit

35. SYSTEM OF ACCIDENT MONITORING,
INVESTIGATION AND CORRECTIVE ACTION
Any near miss, incident or accident shall be reported,
investigated by a constituted committee, corrective action to
be taken based on the committee recommendation to avoid
such near misses, incidents, accidents in future. Such incidents
and further corrective actions taken shall be communicated
down the line.
Any near miss, incidents or accidents should be reported to
the concerned TM/COO immediately. For all near miss
reported TM shall constitute a committee with two engineers
as members within 24 hours of the occurrence of the near miss
and the committee shall submit their report within 5 working
days to TM.

36. Integrity checks
of pipelines to
ensure all round
safety

37. 
 Intelligent PIG Survey
 Close Interval Potential Survey (CIPS)
 Current Attenuation Testing (CAT)
 Direct Current Voltage Gradient Method (DCVG)
 Soil Resistivity Survey
 Cover Survey
PIPELINE INTEGRITY MANAGEMENT SYSTEM

38. Requirements
 Pipeline Cleaning
 Displacement
 Internal Inspection
 Batching
Types of Pigs
 Brush pigs
 Gauge Pigs
 Spheres
 Intelligent Pigs
Cleaning pigs Gauge Pigs Spheres
Intelligent Pig
(MFL)

40.  Intelligent pigging provides a method of evaluating the
performance/effectiveness of the pipe line and helps to
determine the healthiness of a pipeline.
 The main advantage of IPS is that a pipeline can be
assessed to its full length without interrupting the
pipeline operation. It further serves as the foundation
for a pro-active maintenance program to safeguard
against the consequences of failures.
 Intelligent Pigging can determine pipeline ovality,
dents, Surface pitting and corrosion, as well as cracks
and weld defects in steel/ferrous pipelines.

41. 1. MFL PIG
2. Caliper PIG

44.  Close Interval Potential survey (CIPS)
To determine level of cathodic polarisation along the pipeline
and to identify suspected holiday spots
 Current Attenuation Testing (CAT)
Method to locate faults and poor coating that is draining the
current, resulting in improved potentials and minimizing
damaging side effects.
Direct Current Voltage Gradient (DCVG)
Carried out for verification of the Coating defects identified
during Close Interval Potential Logging Survey and Current
Attenuation Test.
CIPS / CAT / DCVG SURVEYCIPS / CAT / DCVG SURVEY

45. LINE WALKSLINE WALKS
Also GPS based personnel tracking system in place
at PCCKL for close monitoring of LPM and integrity
of line walking.
Line walks are done by the employees at frequent
intervals in the ROU to ensure safety and security
of the pipeline and to avoid encroachment in the
ROU of mainline.

48. 
Technological Advancements in pipelineTechnological Advancements in pipeline
monitoringmonitoring
GPS based personnel tracking system has put in place at PCCKL
for close monitoring of LPM and to ensure integrity of line
walking.

49. SAFETY COMMITTEESAFETY COMMITTEE
Safety Committee is headed by the Sr. Terminal Manager
as Chairman and a nominated Engineering Executive as
Safety Officer and one Operator as Worker
Representative and all technical staff as its members.
Safety meetings are done once in a month for reviewing
different safety related issues and requirements.
Near miss incidents as well as identification of risks are done
and discussed in detail in the meeting.
The deliberations are minuted and time bound action is
initiated to close the same.

50. Safety Awards are distributed to all members
annually to encourage accident free working.
Various kinds of safety awareness programs/trainings are
conducted periodically for employees, contract labours,
security guards, line patroller’s like industrial safety,
home safety, road safety etc.
Reward based safety suggestion scheme is in place to
motivate the employees to identify work related hazards
and mitigate them.
Safety week is observed every year and competitions
like safety poster design, safety slogans, safety quiz,
essay writing etc… are held among employees
along with their families to create awareness
on safety at work as well as home.

51. SAFETY COMMITTEE MEETINGS
FIRE & SAFETY TRAININGS
ONSITE AND OFFSITE MOCK DRILLS
SAFETY WEEK CELEBRATIONS
ENVIRONMENT DAY CELEBRATIONS
PROGRAMMES CONDUCTED BY
SAFETY COMMITTEE

52. SAFETY COMMITTEE MEETINGS
Safety meetings are done once in a month to review
and discuss issues related to safety and implement the
suggested improvements.
Safety committee is headed by the Sr. Terminal
Manager as chairman and a nominated Engineering
Executive as safety officer and one Operator as worker
representative and all technical staff as its members.

53. ∗ Fire & Safety workshops are conducted in house as well as
by external agencies like IFAST, BPCL-Kochi Refinery
Fire & Safety department.
∗ Separate training sessions are provided to employees as well
as contract staff, LPM’s and Security guards.
FIRE & SAFETY TRAININGSFIRE & SAFETY TRAININGS

54. FIRE & SAFETY TRAINING GIVEN TO EMPLOYEES

55. FIRE & SAFETY TRAINING GIVEN TO EMPLOYEES

57. 
Training programme on First-Aid, CPR and
Basic Disaster Management

58. MOCK DRILLS
 On-site mock drills are carried out periodically.
 Off-Site emergency mock drills are conducted once in a year involving
external agencies and other statutory authorities like factory
inspectorate, police, fire force, local panchayats etc…

59. OFFSITE MOCK DRILLS SCENARIOSOFFSITE MOCK DRILLS SCENARIOS
 Water logged area scenario.
 Open field scenario.
 Valve station scenario.

60. OFF-SITE MOCK DRILL ATAT WATER LOGGEDWATER LOGGED
AREAAREA

61. OFF-SITE MOCK DRILL AT WATER LOGGED AREAOFF-SITE MOCK DRILL AT WATER LOGGED AREA

62. OFF-SITE MOCK DRILL AT WATER LOGGED AREAOFF-SITE MOCK DRILL AT WATER LOGGED AREA

63. OFF-SITE MOCK DRILL AT WATER LOGGED AREAOFF-SITE MOCK DRILL AT WATER LOGGED AREA

69. OFF-SITE MOCK DRILL AT VALVE STATIONAT VALVE STATION

70. OFF-SITE MOCK DRILL AT VALVE STATIONOFF-SITE MOCK DRILL AT VALVE STATION

71. OFF-SITE MOCK DRILL AT VALVE STATIONOFF-SITE MOCK DRILL AT VALVE STATION

72. OFF-SITE MOCK DRILL AT VALVE STATIONOFF-SITE MOCK DRILL AT VALVE STATION

80. ENVIRONMENT DAY CELEBRATIONSENVIRONMENT DAY CELEBRATIONS
PROTECTING NATURE

81. TREE PLANTATION AT CUSAT CAMPUS

86. Following CSR schemes implemented in Kerala during the year 2015-16 & 2016-17:
• Renovation of one number of anganwadi center and distribution of indoor play
equipments for 31 numbers of aganwadis in Parakkadavu, Ernakulam.
• Renovation of three numbers of anganwadi centers and distribution of indoor play
equipments for 31 numbers of aganwadis in Annamanada, Thrissur.
• Rehab on wheels with RIPMR at Thrissur.
• Electrification of six class rooms and completion of parapet wall in Govt. Girls High
School, Alathur in Palakkad District.
• Potable water (water purifier) to six Government Lower Primary Schools in
Pudussery Panchayat.
• Sanitation & Potable water (water purifier) to Government primary health centre,
Kanjikode in Pudussery Panchayat.
• Computers to six Government Lower Primary Schools in Pudussery Panchayat.
• Quality improvement project of assembly/play area at Govt. lower primary school,
Kanjikode.

87. DISTRIBUTION OF TOYS TO ANGANWADIS IN ANNAMANADA GRAMA PANCHAYAT

88. RENOVATED ANGANWADI CENTER IN ANNAMANADA GRAMA PANCHAYAT

89. Rehab on Wheels

90. SAFETY ACHIEVEMENTS
eceived Outstanding Safety Performance AwardOutstanding Safety Performance Award from ….National
Safety Council - Kerala Chapter for the last ….five
years (2012, 2013, 2014, 2015 & 2016)
eceived Outstanding Safety Performance AwardOutstanding Safety Performance Award
….from Factories and Boilers Department - Kerala for the
….year 2012 , 2014 & 2016

91. RECEIVING SAFETY AWARD - 2016 FROM NATIONAL SAFETY COUNCIL
FOR OUTSTANDING SAFETY PERFORMANCE
RECEIVING SAFETY AWARD -
2014 FROM DEPARTMENT OF
FACTORIES AND BOILERS,
FOR OUTSTANDING SAFETY
PERFORMANCE

92. The industry’s safety record is a demonstration of our
members’ steadfast commitment to operating the
pipeline systems in a way that safeguards workers,
the public and the environment.
Safety is our industry’s highest priority, and will always
lie at the core of everything we do.