INTEGRITY MANAGEMENT SYSTEM MANUAL- … · Web viewPipeline integrity management is a process for assessing and mitigating pipeline risks in order to reduce both the likelihood and

INTEGRITY MANAGEMENT SYSTEM DOCUMENT

GAIL (India) LimitedRamgarh, Jaisalmer

Doc. No. : RAMGARH/IMS/2013

Issue No. : 01

Issue Date : 1ST July, 2013

Revision control sheetDocument title Date Page no. Description

IMS document 01.07.13 New issue Issue no-01

ISSUE NO.: 01 DT: JULY 1, 2013REVISION NO.:02DT: DEC 14, 2014

PIPELINE INTEGRITY MANAGEMENT SYSTEM FOR RAMGARH NATURAL GAS PIPELINE SYSTEM

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IMS document 28.10.13 Amendments inPage nos-4, 12, 17to 30, 38,39,43,46,52,5357,59,61,68,69,70,71, 72, 73, 74,116,117.

Issue no-02

IMS Document 14.12.2014

12 Correction for No. of GTG (3.0)


17 Para. Added for ROU details (3.1.2)


18 Para added for solar power battery system.(3.1.3)


19 Para added for pig launcher details (3.1.4)


24 Para added for detail of fire fighting equipments(3.1.5)


37 Para added for control station details (3.1.8)


38 Para added for base line data of pipeline (5.0)


61-62 Para added for Management of Change procedure(6.4)


83 Para added for details of battery bank (appendix-VI)


111 Para added for details of solar powered battery system (annexure-IX)

APPROVAL AND ISSUE



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The Integrated Management System document is developed for operating and maintaining the Natural gas pipeline network under Ramgarh base as per the Regulation issued by PNGRB vide F. NO.- Infra/IM/NGPL/1/2012 dated:- 05.11.2012.

The IMS document is prepared covering the schedules1 to 8 laid out in the said regulation.

The document is hereby approved & issued for its compliance.

Date: 12th Dec.-2014

Prepared By Reviewed by Approved By

B.L.Meena P.S. Khinchi S.N. Kumar

Dy.Manager DGM (O&M) GM (O&M), Jaipur

Table of contents

S.NO Content details Page no.

Integrity management system of Ramgarh Pipeline

5

1 Integrity Management System for natural gas 8



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pipelines2 Introduction to the Integrity Management System

(IMS)9

3 Description of Ramgarh Natural Gas Pipeline system

10

4 Selection of appropriate Integrity Management System 375 Methods for Integrity Assessment and tools 386 Designing applicable Integrity Management

System for natural gas pipelines47

7 Approval of Integrity Management System (IMS) 688 Implementation schedule of the Integrity

Management System68

9 Review of the Integrity Management System 6910 Adequacy of Manpower positioned at Ramgarh

Station70

11 Appendix-I 7212 Appendix-II 7313 Appendix-III 7414 Appendix-IV 7615 Appendix-V 7716 Appendix-VI 8017 Appendix-VII 8718 Appendix-VIII 9019 Appendix-IX 9320 Appendix-X 12221 Appendix-XI 12422 Appendix-XII 125

INTEGRITY MANAGEMENT SYSTEM OF RAMGARH PIPELINE:

Ramgarh natural gas pipeline network has developed its Pipeline Integrity Management System document in response to Petroleum and Natural Gas Regulatory Board (Integrity Management System for Natural gas pipelines) Regulations – 2012.

DEFINITIONS AS REFERRED IN THIS DOCUMENT:



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“Act” means the Petroleum and Natural Gas Regulatory Board Act, 2006;

“Board” means the Petroleum and Natural Gas Regulatory Board established under sub-section (1) of section 3 of the Act;

“natural gas pipeline” means the pipeline as defined under the Petroleum and Natural Gas Regulatory Board (Authorizing Entities to Lay, Build, Operate or Expand Natural gas pipelines) Regulations, 2008;

“operator” means an entity that operates natural gas pipeline network with the authorization of the Board;

“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;

“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;

“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;

“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;

“spur-line” means a pipeline as defined in the Petroleum and Natural Gas Regulatory Board (Determining Capacity of Petroleum and Petroleum Products and Natural Gas Pipeline) Regulations, 2010;

“Subject Matter Expert (SME)” means an individual who possesses knowledge and experience in the process or discipline he represents as per ASME B 31Q;

“right of use (ROU) or right of way (ROW)” means the area or portion of land within which the pipeline operator or owner has acquired the right through the relevant provisions of law or in accordance with the agreement with the land owner or agency having jurisdiction over the land to lay and operate the natural gas pipelines;

“Integrated surveillance system” means the pipeline surveillance for third party encroachment activities along ROU. This may use optical fibre cable, microwaves and satellite as communication systems and could be integrated with SCADA’s data



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Words and expressions used and not defined in these regulations, but defined in the Act or in the rules or regulations made there under, shall have the meanings respectively assigned to them in the Act or in the rules or regulations, as the case may be.APPLICABILITY & SCOPE:

The scope of this document is development and implementation of an effective pipeline integrity management system based on available industry best practices and processes for Ramgarh pipeline network covering all the existing and new natural gas transmission pipelines. This includes associated facilities required for transportation of natural gas through pipelines i.e. metering units, storage facilities at originating, enroute and delivery points, tap off points (TOT), Sectionalizing Valve (SV), Despatch terminals (DT), Receipt terminals (RT) etc., 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. The materials, specifications and processes followed at Ramgarh pipeline system shall be in accordance with Petroleum & Natural Gas Regulatory Board (Technical Standards and Specifications including Safety Standards for Natural gas pipeline) Regulations, 2009. Further, GAIL the owner of the Ramgarh Pipeline System as a principal employer shall ensure the implementation of the Integrity Management System.REQUIREMENT UNDER OTHER STATUTORY BODIES:

Ramgarh pipeline system shall comply with all statutory rules, regulations and Acts in force as applicable and requisite approvals have been obtained from the relevant competent authorities for the Natural Gas Pipelines.



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1.0 INTEGRITY MANAGEMENT SYSTEM FOR NATURAL GAS 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 Natural Gas for its transportation without interruptions and also minimizing business risks associated with accidents and loss of products.

ii) Since the Natural Gas 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 IMS in Ramgarh pipeline 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 Ramgarh integrity plans and programs; and

Increasing the publics & stakeholders general confidence in the safe operation of Ramgarh pipeline network.

Optimizing the life of the pipelines with 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



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new pipelines. These are important assets transporting hazardous Natural Gas 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 Ramgarh pipeline system requires development of an integrated and efficient integrity management system. The basic IMS of Ramgarh has considered the following elements :

i) Administrative components of IMPii) The processes used to assess and make decisions about risks in

the operation of the Natural Gas pipeline system so as to minimize incidents.

iii) Threat identifications process.iv) Monitoring system. Ongoing process that monitors the condition

of the pipeline system assesses threats to their integrity and recommends actions to mitigate the risks.

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

vi) Implementation schedulevii) 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.

viii) Organization & Control. Structure, Accountabilities and Responsibilities, Organization, Relationships with Other Groups/Bodies, Communication Systems.

ix) 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.

x) Performance evaluation of IMP: This is a mechanism to monitor the effectiveness of integrity management plan adopted and for further improvement.



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xi) Communication Plan: This covers a structured plan to regulate information and data exchange within and amongst the internal and external environment.

xii) 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.

xiii) 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 RAMGARH NATURAL GAS PIPELINE SYSTEM:

HISTORICAL BACKGROUND: GAIL (India) Ltd., India's principal gas transmission and marketing company, was set up by the Government of India in August 1984 to create gas sector infrastructure for sustained development of the natural gas sector in the country.GAIL’s Ramgarh pipeline system has a gas receiving terminal at Ramgarh in Jaisalmer region. Gas receiving terminal is located inside the RRVUNL (Rajasthan Rajya Vidyut Utpadan Nigam Limited) Ramgarh premises. There are three gas suppliers and one customer in the region. GAIL is receiving the gas from gas suppliers and supplying the same to the customer for generation of electricity.(Ref Fig -1).

Suppliers:

1. OIL India Ltd.

2. ONGC

3. Focus Energy

Customer:

1. RRVUNL Ramgarh

GAIL has two different pipeline networks in the region for supplying gas to the customer.

1. Dandewala-Gamnewala-Ramgarh



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2. Langtala-Ramgarh

Dandewala-Gamnewala-Ramgarh pipeline network is for supply of OIL/ONGC gas. The pipeline network was commissioned in the year 1994-1995. The size of the pipeline is 12 inch and the length of the network is 67 Kms. From OIL India the gas is received at Dandewala, and from ONGC the gas is received at Gamnewala. The gas supplied though this network is approx 7,50,000 SCM per day (7,00,000 SCM from OIL India and 50,000 SCM from ONGC). Gas supply is likely to be further enhanced by OIL/ONGC.

Langtala-Ramgarh pipeline network is for supply of gas from Focus Energy. The pipeline network has been recently commissioned in July 2010. The size of the pipeline is 10 inch and the length of the network is 87 Kms. The gas supplied though this network is approx 2,00,000 SCM per day presently and shall be further increased to 9,50,000 SCM per day .

Design details of both pipelines are attached in Appendix- X.

Gas received at Ramgarh from above two pipeline networks, is passed through filtration units to remove any dust/ dirt present in the gas. After filtration, gas volume measured through the metering unit, is supplied to RRVUNL for power generation. RRVUNL has three gas turbines and two steam turbine for electricity generation. The capacity of these turbines is as under:

GT-I 35.5 MW

GT-II 37.5 MW

STG-I 37.5 MW

GT-III 110 MW

STG-II 50 MW

Total Installed capacity 270.5 MW



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FIGURE-1



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Tele-supervisory system has been provided for central monitoring and control of pipeline system in Ramgarh. There is a dedicated telecommunication network to provide a highly reliable voice and data communication. Pipeline system has incorporated most modern built-in safety and security systems.

Transportation through the pipeline has not only reduced the load on the roads and rail networks but also helped us to sustain our valuable environment. To ensure uninterrupted and safe transportation of natural gas, proper system orientation of pipeline and associated operations are essential. The challenges in this task were also unique due to non-uniform hazard management system and sheer population densities. The onus for its safe operation and hazard management system thus lies completely on the O&M team.

A key element in the Safe, Environment friendly and Qualitative Operation of the system rests in its well thought of and conceived system of integrated implementation of ISO 9001:2008, ISO 14001:2004 & OHSAS 18001:2007.

Using enriched expertise and experience of Pipe Liners, a uniform procedure and practice for O&M has been developed; this integrated Quality, Environment and Safety Standards (ISO 9001, ISO14001 & OHSAS 18001) will definitely increase the effectiveness of O&M of the Ramgarh Pipeline System.

To make Continual Improvement in O&M the existing system is being continually reviewed. ERP-SAP system has been introduced in GAIL. ERP-SAP adoption is further reinforcing standardization and harmonization of the best practices in line with GAIL’s vision & policy. It reaffirm for implementation of the Quality, Environment & Safety policy and common objective and targets at the installations of Ramgarh.

3.1 BRIEF DESCRIPTION OF VARIOUS SYTEMS IN RAMGARH PIPELINE SYSTEM

O&M Ramgarh consists of the following



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3.1.1 Dispatch terminal.

3.1.2 Pipeline

3.1.3 Sectionalizing Valve Stations

3.1.4 Pigging Facilities

3.1.5 Receipt Terminal

3.1.6 Pipeline Protection System against Corrosion (Cathodic Protection)

3.1.7 Telecommunication with IP based online camera and SCADA facilities

3.1.1Dispatch terminal (DT).

Dispatch terminal is location where GAIL receive Gas from Suppliers facilities .The natural gas received from various sources contains impurities, such as dirt, hydrocarbon condensate, water, solid particulars etc. These impurities need to be removed otherwise they will affect the health of the pipeline and as well as the Equipment. Besides, the efficiency of operation of the pipeline will also get adversely affected. In order to avoid the above problems, facilities are installed at gas Dispatch terminals of GAIL to remove these impurities before the gas is dispatched to the consumer.

In O&M Ramgarh there is three such dispatch terminals as follows:

Sr. Suppliers: DT Location

1. OIL India Ltd. –Dandewala DT

2. ONGC –Gamnewala DT

3. Focus Energy – Langtala DT

Old DT at Gamnewala & Dandewala equipped with pigging (only at Dandewala), pressure monitoring, cathodic protection, communication, Portable LEL detectors & associated facilities.



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Langtala DT having gas metering, Filtration, Gas Chromatograph, LEL & flame detection system & associated facilities.

List Of major Equipment at DT is mentioned in Appendix-V

3.1.2Pipeline

The pipeline route is selected after conducting a reconnaissance survey. The reconnaissance survey generally provides three to five alternate routes out of which the shortest one with minimum number of obstacles is selected. Subsequently detailed and cadastral surveys are carried out. The material of pipeline is Carbon steel and the thickness varies depending primarily on diameter, design pressure, class location etc. Pipeline has been sectionalized by providing mainline valves. External coating (mainly three layer polyethylene) is provided to prevent corrosion of the pipeline. Cathodic protection is also provided to supplement the coating to ensure full protection against corrosion. As mentioned old pipeline section Covering Dandewala Gamnewala- Ramgarh is approximately 67 inch long & 12 inch in size, it has one SV station (At Sadewala). New Pipeline from Langtala to Ramgarh is 10 inch 87 Km long, having Three SV station namely SV-1, 2, 3.

Right of Use (ROU): ROU means the area or portion of land within which the pipeline operator or owner has acquired the right through the relevant provisions of law or in accordance with the agreement with the land owner or agency having jurisdiction over the land to lay and operate the natural gas pipelines.

ROU width is 20 meters for Langtala-Ramgarh pipeline & 18 meters for Dandewala-Gamnewala-Ramgarh pipeline.

S/N

Name of the Pipeline

Size (“)

Length

(Km)

Wall Thicknes

s

(mm)

Grade of Steel

Design Pressure (Kg/cm2)

ROU width

(meter)

1Dandewala-Gamnewala-

Ramgarh Pipeline12” NB 65.3 6.4 API 5L Gr B 75 18



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2 Langtala-Ramgarh Pipeline

10” NB 86.2 6.4 API 5L Gr X42 70 20

List of major Equipment at Pipeline section is detailed out in Appendix-IX

3.1.3 Sectionalizing Valve Stations

The pipeline is sectionalized by providing mainline valves for the purpose of isolating the section of the pipeline system in case of maintenance or emergency of accident. The interval between sectionalizing valve stations vary depending on the population density in the area details mentioned below, river crossing etc. For major river crossings the SV stations shall be at upstream and downstream of the banks. The sectionalizing valves are full bore type to facilitate passage of pipeline pigs. Venting or blowing off facilities is also provided at these stations for safe venting of gas from pipeline to atmosphere.

Distance between the SVs as per the ASTM-B 31.8 on area classification:

Class I 32 Km Max

Class II 24 Km

Class III 16 Km

Class IV 08 Km

List of Sectionalizing valves stations and its distances along the pipeline under Ramgarh are mentioned in Table no-5 of Appendix-V. Pipeline sectionalizing valve stations having pressure, temperature monitoring facility .Powers are feed through solar powered battery bank (At SV-2, LRPL section & Dandewala terminal & Gamnewala terminal for DGRPL section). Details of solar powered battery system is provided in Appendix-IX

3.1.4Pigging Facilities

Pig launcher & Pig receiver are installed at DT-Langtala & RT-Ramgarh for LRPL respectively. Pig launcher & Pig receiver is



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installed at DT-Dandewala & RT-Ramgarh for DGRPL respectively to carry out pigging operation periodically. These launchers and receivers are provided with kicker lines and vent lines to facilitate pigging operation without causing interruption in gas supply to consumers. Details of Pig launchers & Pig receivers are provided in appendix-IX.

Pigging operation is to be carried out periodically for health monitoring, improve the efficiency and life of pipeline as per the OISD guide line and ISO procedure for pipeline maintenance. Pigs are cleaning devices launched in the pipe line for its cleaning and removal of solid and liquids. Various types of pigs used like brush pig, foam pig and cup pig made of different materials varying from rubber, polyurethane, foam and Steel.

List of Pig Launcher/Receiver. - Appendix-IX

3.1.5Receipt Terminal.

The natural gas received from ONGC/OIL or FOCUS ENERGY may contain impurities, such as dirt, hydrocarbon condensate, water, solid particulars etc. These impurities need to be removed otherwise they will affect the health of the pipeline and as well as the Equipment. Besides, the efficiency of operation of the pipeline will also get adversely affected. In order to avoid the above problems, facilities are installed at gas receiving terminals at Ramgarh to remove these impurities before the gas is dispatched to the consumer. During the transportation of the gas through the pipeline, the gas may get cooled due to low sub-soil temperatures which sometimes result in the formation of hydrocarbon condensate and water. Moreover, the pipeline system may contain dirt, dust, mill scale etc. which keep on getting transported with the gas. Since contractually the gas delivered to the consumer should be delivered at a particular pressure and temperature and must also be avoid of all impurities like dirt, dust and condensate. Hence Gas Receiving Terminals have been installed at consumer premises to treat and measure the gas before it is finally delivered to the consumer as per the agreement and required quality and quantity of gas.

The details of equipment are mentioned in Appendix-IX.



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Gas terminal at Ramgarh has the following facilities.

a) Pig Receiver

b) Scrubber & Filter.

c) Wet Gas Filter.

d) Dry Gas Filter.

e) Flow Control System

f) Pressure Control & Regulating system

g) Flow Measurement system.

h) Gas Chromatograph

i) Safety Features

j) Electrical & Cathodic Protection.

k) Instrumentation & Control.

a) PIG RECEIVER

Pig receivers are installed at receiving terminals to receive the pigs during the pigging operation periodically. These receivers are provided with kicker lines and vent lines to facilitate pigging operation without causing interruption in gas supply to consumers.

Dwg / DOC Ref: Appendix-IX

b) SCRUBBER (SC-101)

Cyclone type scrubbers have been installed where the carrier gas with suspended impurities enter tangentially into the cylindrical or conical body and ten spiral downward forcing the heavier suspended matter against the wall. Solids tend to slide down the wall while liquid particles wet the wall to form a running film and are removed at the bottom. Scrubbers remove liquid droplets and foreign matter of size 40 microns and higher.




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c) Wet Gas Filter (CF-101/102)

Filter separators are installed to remove liquid and foreign material up to 5 microns size from the feed gas. The filter separators contain filter coalescing elements capable of removing solids as well as liquid droplets. As the gas enters the filter separator, the velocity is decreased and large liquid droplets are removed by the mechanisms of gravity and impingement on the shell surfaces. The mist particles which were not separated by the gravity and shell impingement are carried with the gas into the cartridge element which is a fibrous pack. As the mist is passed into the pack, collection of the mist takes place by the interception, diffusion and inertial impaction of the droplets on the fibers. Some of the droplets are coalesced on the outside surface of the fibrous pack and are drained without entering the pad surface.

When the pressure drop across filter separator reaches 0.5 Kg/cm2, filter elements shall be cleaned or replaced.


(d) Dry Gas Filter

Filter separators are installed to remove liquid and foreign material up to 3 microns size from the feed gas. The filter separators contain filter coalescing elements capable of removing solids as well as liquid droplets. As the gas enters the filter separator, the velocity is decreased and large liquid droplets are removed by the mechanisms of gravity and impingement on the shell surfaces. The mist particles which were not separated by the gravity and shell impingement are carried with the gas into the cartridge element which is a fibrous pack. As the mist is passed into the pack, collection of the mist takes place by the interception, diffusion and inertial impaction of the droplets on the fibers. Some of the droplets are coalesced on the outside surface of the fibrous pack and are drained without entering the pad surface.

When the pressure drop across filter separator reaches 0.5 Kg/cm2, filter elements shall be cleaned or replaced.

Dwg/Doc No: Appendix –IX.



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e) FLOW CONTROL DEVICES

(i) Flow Control Valve

Flow control valves are installed in Ramgarh terminal to ensure that the consumer does not draw more gas than allocated quantity and that too at a controlled rate. Once the set point of the flow control valve is set, it starts comparing its set point with instantaneous flow rate figures available from the flow computer and whenever the rate of gas drawn exceeds the preset value, the valve starts to pinch the control the flow.

Tag No –FCV-201/202 (ONGC /OIL) ,RG-FCV-01(FOCUS GAS)

Dwg/Doc No: Appendix IX

(ii) Non-Return Valve

A non-return valve is installed before the custody transfer takes place with the consumer. This is done to prevent any back pressure due to sudden tripping of consumer plant.

f) PRESSURE CONTROL & REGULATING SYSTEM

(Covered under Instrumentation & Controls)

g) FLOW MEASUREMENT SYSTEM

(Covered under Instrumentation & Controls)

h) SAFETY FEATURES

Fire & safety system includes Fire extinguishers, Fire alarm system for control rooms, field mounted (open Path/Point type) as well as portable LEL detection system. Fire hydrants (for RT-Ramgarh) with pressurized fire water surrounded in field area of Ramgarh –RT.

Details of fire fighting equipments and other safety equipments available at terminals & SV stations are given in following table.

S.No. Location of Terminal/SV

DCP Ext.

DCP Ext.

DCP Ext.

DCP Ext.

CO2 Ext.

CO2 Ext.

CO2 Ext.

CO2 Ext.



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1Kg Capacity

2Kg Capacity

9Kg Capacity

75Kg Capacity

1Kg Capacity

2Kg Capacity

9Kg Capacity

22Kg Capacity

1 Ramgarh-RT 6 - 6 4 - 5 9 -

2 Langtala-DT - - 6 2 - - 7 -

3 SV-1 - - 4 - - - 1 2

4 SV-2 - - 6 - - - 5 -

5 SV-3 - - 4 - - - 1 2

6 Dandewala-DT

- - 4 2 2 1 - -

7 Gamnewala Terminal

2 2 1 1 2

External Safety Audit shall be carried out once in 2 years and Internal Safety Audit once in a Quarter.

(i) Remote Operated Terminal Inlet Valve

The terminal inlet valves are designed for remote operation from Local control room as well as from Master Control Room, Ramgarh. In case of emergency, gas supply can be stopped immediately by closing down these valves.

Tag No: Ref P&ID’s .

Dwg/Doc No: Annexure –IX

(ii) Pressure Safety Valves

The terminals have in-built safety design features such as PSVs of sufficient discharge capacity, on pressure vessels like Slug catcher, Scrubber, Filter separators etc., and on metering skid to protect the equipment against high pressure in case of plant tripping.

Tag No: Ref P&ID’s .

(iii) Fire Fighting Equipment

Sufficient no. of fire hydrants and monitors have installed around the terminal to tackle major fire incidents. Moreover all



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consumers got excellent fire fighting system and GAIL has mutual aid agreement with them to extend the facilities and assistance in case of major fire.

As per OISD Standard 116, sufficient number of Portable fire extinguishers have been provided at the terminals of sufficient numbers as per OISD Standard 116, have been provided at the terminals to handle minor fire and gas leakage. List of Fire Fighting equipment covered under F&S Manual ( Manual doc. no- GAIL/RG/FSM).

(iv) First Aid

First Aid medicines as per guidelines of Sub-section (I) of Section 45 have been made available at the terminals for minor injuries. List of First aiders are kept with F&S dept.

V) Pipeline Shut Down:

Emergency shutdown (ESD) access provided in SCADA system for single access shut down of whole P/L along with RT-Ramgarh to facilitate prompt action in case of emergency.

i) Electrical system

Terminal electrical system comprises of UPS & CP system. UPS is for supplying uninterrupted power to the critical system & CP system panels are installed for providing protection to pipeline. Detail provided in Concerned Electrical Maintenance Manual.

Dwg. /Doc ref: Ref Elect/CP Manual

Tag: Refer Elect /CP Manual for Tag nos.

j) INSTRUMENTATION & CONTROLS

1. Main activities of Instrumentation in O&M Ramgarh.

a) Operation and Maintenance of Instruments & Systems for Un-interrupted supply of Natural Gas to consumers at specified parameters as per contract and ISO system.



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b) Joint calibration of custody transfer metering with Consumers and Suppliers like ONGCL & OIL Focus Energy ,RRUVNL to ensure custody transfer metering uncertainty with in the tolerable limits as per contract and ISO system.

c) Calibration of Non-Custody Transfer Instruments.d) Procurement of Spares for Instruments & Systems.

2. Brief Description of Instruments & Systems

Brief description of Instruments and systems is given below:

3. Natural Gas Flow Metering System

Flow computers are used for measurement of Natural Gas supply to Consumers. At Ramgarh O&M DT Langtala& RT- Ramgarh (For Focus gas supply) USM based flow measurement as per AGA 9 ( ins done. However for ONGC/OIL section Turbine Flow meters following AGA 7 are installed. Flow Computers are interfaced with SCADA system through serial communication.

4. Control Room Panel mounted type Flow Computers

These types of Flow computers take input signals from the flow meters/ transmitters mounted in the field along with P/L data from Pressure Transmitters / Temperature Transmitters. Flo Boss S600 flow computers of make Daniel are employed for flow measurement.

Doc: Instrumentation maintenance Manual, Rev-00

Tag:RG- Refer P&ID’s for tag nos.

5. Electronic Pressure Transmitter

These are installed to measure the static pressures of Inlet / Outlet of Terminals custody / Non-custody pressure measurements of scrubbers and pipelines.

Dwg: P&ID for DT/RT

Tag: Refer P&ID’s for tag nos.

6. Temperature Transmitter



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These are installed to measure the static Temperature of Natural gas of Inlet / Outlet of Terminals, scrubbers and pipelines. These are Temperature sensitive instruments. These instruments are calibrated to required Temperature ranges. These transmitters convert Temperature signals into electrical signals (4ma-20ma) which are proportional to actual Temperature and are fed to computers / Records.

Dwg/Doc: Refer P&ID drawings and Instrumentation maint. manual.

Tag: Refer P&ID drawings.

7. LEL & Flame detection system .

Field mounted & portable LEL detectors are available for detecting hydrocarbon gas leakage of P/L locations like DT, RT,SVs .

For Field mounted catalytic & optical open path LEL detectors are sensing existence of hydrocarbon gas & in turrn send signal to control room LEL monitor & SCADA system generating 20 % & 60 % LEL alarm.

Flame detectors are UV/IR based flame sensors supposed to be mounted at RT & DT for sensing any hydrocarbon flame.

Dwg/Doc: Refer P&ID drawings and Instrumentation maint. manual.

Tag: Refer P&ID drawings

8. On-Line Gas Chromatographs

In O&M Ramgarh On-Line Gas Chromatographs are installed at terminals at RT Ramgarh (Dual Stream ) & DT-Langtala (Single Stream ).On-line Gas Chromatographs are used to analyze concentration of the following hydrocarbons present in the Natural Gas:

i. Methane

ii. Ethane

iii. Propane

iv. i Butane

v. n Butane



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vi. i Pentane

vii. n Pentane

viii. Hexane +

ix. Carbon dioxide

x. Nitrogen

Based on the concentration of the above hydrocarbons the following Natural Gas qualities are calculated:

i. Specific gravity

ii. Compressibility Factor

iii. Net Heating value (Kcal/m3)

iv. Gross Heating Value (Kcal/m3)

Specific gravity & Compressibility Factors are used for Flow Computations in Flow Computer and Net Calorific value is used for Calculation of Energy supplied to consumers for billing purpose.

Typical values of gas composition of supplier’s gas are attached in Appendix-XI.

Dwg/Doc: Refer P&ID drawings and Instrumentation maintenance manual.

Tag: Refer P&ID drawings.

9. Pressure control

Pressure control valves are self-actuated field mounted pilot operated valves. These valves are operated based on line condition & Customers pressure requirement (RRUVNL). Out let of these valves are controlled to pre-set pressure. For LRPL section of P/L in RT having two stages pressure control. Due to low supply pressure ONGC section does not have any pressure control system.

Ref: Appendix-IX,



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Tag: RG-PCV-101/102/103/104

10. Flow control

Flow control valves are utilized for controlling flow as per contracted requirement . Controllers for flow are in built in flow computers, installed in control room.

Dwg Ref: Appendix-IX.

Tag:FCV-101/102(ONGC &OIL), RG-FCV-01(Focus)

3.1.6 Pipe Line Protection & CP

Sub soil pipeline prone to damage due to exchange of charge/ion from metallic pipe. Cathodic protection is provided to Pipe line below ground to prevent such damage. System for Cathodic protection of part of Electrical maintenance for pipeline & Terminal. Detail regarding cathodic protection is mentioned in respective maint. Manual.

3.1.7 Telecommunication system with IP based CCTV & SCADA.

GAIL has dedicated telecommunication system for O&M Ramgarh through it’s own OFC network. Tele Phones are installed RT, DT,SV’s along the pipeline to have reliable communication. Also IP based PTZ CCTV cameras are installed in DT –Langtala, RT-Ramgarh, SV-2 for viewing real time pictures & keeping video footage for the same is essential for in Sensitive border area.

Same OFC network is used for state of art SCADA system (Yokogawa-Stardom) ,which is meant for capturing process information along pipeline(LRPL). Pipeline remote operation, ESD is envisaged in SCADA.

a. Equipment details are attached in Appendix-IX

b. Flow diagram of GAIL, Ramgarh is attached in Appendix-IX

c. SAFETY:-



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INBUILT SAFETY FEATURES AT RAMGARH

PIPELINE SAFETY SYSTEM

The Pipelines are laid as per national/International standards with inbuilt and operational safety features. The Safety features are as given below.

SOME OF THE SPECIFIC DESIGN SAFETY FEATURES PROVIDED INCLUDES:

Distance between the SVs as per the ASTM-B 31.8 on area classification: Class I 32 Km Max Class II 24 Km Class III 16 Km Class IV 08 Km

A hot tapping is carried out only after a detailed Job Safety Analysis and joint study by an expert group and closing out actions arising thereof prior to commencement of the hot tapping operation.

The entire pipeline is cathodically protected through a well engineered Cathodic Protection System.

All welded joints are subject to Automatic Ultrasonic and X-Ray Testing by approved agencies and procedures to very high quality standards. The use of X-rays or gamma-rays is restricted to safe locations not accessible by unauthorised persons.

Pipeline marking is an extremely important safety aspect and is essential to prevent unauthorized access to the pipeline and its hazards by members of the general public.



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Marking out the entire pipeline route will include: Pipeline warning signs Right of way boundary markers Kilometre Posts Ariel markers Directional markers

Pipeline Warning Sign are in general installed at National and state highway crossings Other road crossings Railway crossings Minor water crossings Valve stations And at all places deemed necessary Special care is taken in

urban areas and wherever the pipeline is laid in public areas. Reinforced concrete walls are provided around the process area in town areas and other areas of higher population.

Right of Way Boundary Markers are placed at regular distance on both side of the pipeline axis to mark out the width of the Right of Way or ROW.

Kilometre Posts are placed on the axis of the pipeline. Post indicates cumulative distance in Km from the reference point.

Aerial markers are placed at least every 5 km. Concrete slab is put on open cut crossings for higher integrity.

Foreign pipeline crossings or third party utility crossings are carried out as per GAIL’s laid out procedures mentioned in Final maintenance policy issued on SEP-2010.

Directional Markers shall be placed at every change in direction, two more directional markers shall be installed along pipeline alignment, one on either side of the turning point.

All markers will be located at suitable place preferably in public area and /or at property/plot limits boundaries.



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3 layer coating over the pipeline. The pipeline is laid at least 1.2 meter below Ground level. The warning tape is laid above 250mm of Pipeline. Above ground Pipelines Markers with contact nos. installed.

Safety in terminals:-

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 Pressure Safety Valves & Slam Shut Valves4. LEL detectors are installed in the process area to detect Natural Gas leak if any.5. Fire water network along with fire hydrants & monitors at major

terminals provided by consumers6. Manual Call Points (MCPs) at major terminals, provided by respective

consumersFIRE PROTECTION SYSTEM

Fire Protection and Safety System: Being Hydrocarbon Industry, Fire and Safety activities are very vital in nature. Ramgarh Gas Pipeline has been provided with Fire Protection System. All the Major Terminals have been protected with Fire Water Network provided by consumers.

Gas Detection System: Portable unit i.e., LEL detector is used to check any Gas leakage as and when required. Online LEL detection systems are provided at major terminals.Fire Water System: The system has been designed to take care of any outbreak of fire by means of availability of Fire Water, at all times, at sufficient pressure. Adequate no. of Fire Hydrants, Water Monitors, Fire Hoses, Hose boxes have been provided at Major Terminals. Main fire pumps above ground water storage tanks are maintained by CONSUMERS. Normally hydrant system is a part of Consumer’s Fire Water system. Testing and maintenance is carried out by the consumer. However the



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quarterly check of fire water hydrants & monitors is conducted by GAIL & records maintained. Adequate numbers of portable fire extinguishers are installed all over terminal area and installations.

First-Aid box is provided at all manned installations and monthly checking and replenishment of medicines is carried out and records maintained.

Procedure for Safe Work Practices: All the Statutory Rules and Regulations are observed during the execution of work. It is the responsibility of the supervisor to ensure that all jobs are properly planned and supervised to avoid accidents. All non-routine jobs of Maintenance, Construction, Modification, etc. are being carried out under work permit system.

Safety Committee: A safety committee consisting of members from Officers and Staff is constituted to look into all aspects of Safety. The Committee should meet once in a quarter and discuss various EHS issues relating to Personnel and Pipeline.

Personal Protective Equipments (PPE): All persons working in the Terminal operational area shall use safe clothing and proper personal Protective Equipments, as per the job requirement. All PPEs shall be properly maintained by BIC.

Safety Audit: Internal Safety Audit by multi-disciplinary group shall be carried out once in a quarter. External safety audit shall be carried out once in a three years and the same is arranged centrally by Corporate HSE Dept.

Emergency Response & Disaster Management Plan (ERDMP): ERDMP is prepared& vetted by PNGRB authorized agency (M/s TQ Services). Duties and responsibilities are distributed to all concerned. The plan shall be regularly updated and exercised. Mock drills shall be conducted quarterly. Proper records of such Mock Drills shall be maintained and analyzed for further improvements.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



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contained to a particular place and doesn’t affect the neighbourhood & surrounding places.Off Site Emergency: If the emergency becomes uncontrollable and leads to damage to life and property in the Installation and its neighbourhood 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.Refer- ERDMP document no GAIL/RG/ERDMP, issue no 2 dated 8.1.2013

3.1.8 Control Room Station: Control room for both pipeline networks (LRPL & DGRPL) is located at Ramgarh receipt terminal and is the centre for activities of operation and is manned on round the clock basis. Apart from this control room, the centralized monitoring is also available at National Gas Management Centre (NGMC), Noida. 4.0 SELECTION OF APPROPRIATE INTEGRITY MANAGEMENT SYSTEM:

a. Integrity Management System for natural gas pipelines could employ either a performance based Integrity Management System or a prescriptive type Integrity Management System. Whereas, natural gas pipeline industry has gathered a reasonably good experience of pipeline operations and as such pipeline industry is fairly mature, a performance based Integrity Management System are appreciated globally. However, where pipeline systems are in developing stage, a prescriptive type Integrity Management System is recommended. Whereas, the performance based Integrity Management System recognizes the experience of the entity which has been operating the pipeline but the prescriptive type Integrity Management System is more rigorous as it considers the worst case scenario of the failures in the pipeline systems and, therefore, worst case scenario for mitigation.

b. Though subsequent schedule in these regulations apply to both prescriptive and performance based type of Integrity Management System, present regulations mainly focus on prescriptive aspects in absence of adequate historical Integrity Management System data.

c. A prescriptive type of Integrity Management System mandates the implementation of an established process for addressing the risks, their consequences and proven methods for mitigation. It also mandates the



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in-house development of Integrity Management Plan and Management of Change pertaining to technical aspects. Based on the development of gas pipeline industry in India till date, the preparation of prescriptive type Integrity Management System has been considered for implementation to all natural gas pipelines in India. Further, as the natural gas pipeline industry matures and gathers sufficient records or data as per the requirements prescribed in the Petroleum and Natural Gas Regulatory Board (Technical Standards and Specifications Including Safety Standards for Natural gas pipelines) Regulations, 2009, a review mechanism may be considered by the Board for recommending a Performance Based Integrity Management System for Natural gas pipeline.

5.0 METHODS FOR INTEGRITY ASSESSMENT AND TOOLS:

The natural gas pipeline system Ramgarh has been using the following tools to achieve the IMS for pipeline system. Though baseline data for specific measurement is not available in case of old pipelines, it has been made mandatory to obtain baseline data for all upcoming pipelines since 2010: Initial baseline data of pipeline is available in documents pipe book and in post commissioning EGP/ILI run reports, CP monitoring records, CIPL/DCVG survey records, Pipeline patrolling records. Pipeline Baseline data thereafter checked and compared in subsequent baseline data measurement as per frequency given in chart of Appendix-III & as per T4S regulation (Technical Standards and Specifications including Safety Standards for Natural gas pipeline).The details of base line data available is as per Appendix-X5.1 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 are 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.



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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. The ILI is carried out as per ASME B31.8S (A1.3)Table-09: Details of ILI of Ramgarh Pipeline Sections

S/N

NAME OF THE PIPELINE

SIZE (“)

LENGTH (Km)

WALL THICK.

GRADE OF

STEEL

ILI inspecti

on month /

year

Next Due

1Langtala- Ramgarh pipeline

10” 86.2 6.4mm

API 5LGR-B

X42

Pipeline commissioned in Jul-2010

2020

2Dandewala- Gamnewala-

Ramgarh pipeline

12” 65 6.4mm

API 5L GR B

Aug-2013 2023

In addition the following is carried out:a. Pressure loss in the segment during pipeline operation through

SCADA monitoring system.b. Placing sensors for detecting gas leaks in a confined above ground

piping area such as DT/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:

Following Cathodic protection monitoring methods are being employed in Pipeline sections of Ramgarh:(i) Pipe to Soil Potential Survey.(ii) Closed Interval Potential Logging Survey (CIPL)/ Direct Current

Voltage Gradient survey.(DCVG).



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(iii) Transformer Rectifier Unit (CPTR)/ Cathodic Protection Power Supply Module(CPPSM) - current and voltage monitoring method.

(iv) Pipeline Interference Survey.

Cathodic Protection Monitoring Schedule S/N

Cathodic protection monitoring

methods

Time period/Frequency

1 PSP Survey Once in a quarter2 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 online

4 Coating Health Surveys (CPL & DCVG)

Immediate after commissioning and once in 5 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 crossings

Once in a year.

9 ON potential monitoring at all test stations

Once in a quarter

10 OFF potential monitoring at all test station

Once in a year

Details of CPL & DCVG of Ramgarh Trunk line sectionS/N

NAME OF THE PIPELINE SIZE (“)

LENGTH (Km)

WALL THICK.

GRADE OF STEEL

CPL/DCV

G insp

Next due



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ection

month/year

1 Langtala – Ramgarh pipeline 10 86.2 6.4 mm API 5L

GR.X42Apr-2010

Apr-2015

2 Dandewala- Gamnewala- RamgarhPipleine 12 65 6.4mm API 5L

GR.B 2010 Apr-2015

TOTAL =151.

2

CORROSION: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:Ramgarh Natural gas Pipeline utilizing Various effective surveillance methods are being used as direct integrity assessment tools. As per guide line laid for IMS one or more tools may be selected . Based experience and resource management following tools are being selected for Pipeline Section Ramgarh.

I. Patrolling / Ground Survey:-



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To safe guarding & risk assessment of the pipeline sections O&M Ramgarh maintains a structured pipelines patrolling . 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) Line Walk by the officials of the Ramgarh is being carried out at

least once in a year for entire length of pipeline; it is carried out after the monsoon. Also Monthly patrolling is done by security guards along the pipeline. 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. All records regarding patrolling & mitigation plan for any observations are being maintained and kept by pipeline dept of O&M.

II. Integrated Electronic surveillance system: The following electronic Detection System for Ramgarh is implemented

1. 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.

2. State of art dedicated SCADA and CCTV surveillance system is in place.

3. Flame & gas detection system at facilities along the pipeline.III. 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 issued in



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the form of pamphlets titled:- “EK NIVEDAN”. 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.Various programme for awareness enhancement for pipeline for stake holders are detailed in pipeline maintenance manual for O&M Ramgarh and GAIL’s Maintenance policy and guidelines issued on Sep-2010.

5.4 HYDRO TESTING :

Pipeline system covered under Ramgarh O&M Base are hydro tested for 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 pre-commissioning of pipelines as specified in the relevant standards ASME B31.4, OISD-214 or regulations issued by the Petroleum & Natural Gas Regulatory Board. Also hydro testing records are being kept as base line data.5.5 DIRECT ASSESSMENT AND EVALUATION

System are in place in Ramgarh Natural Gas pipeline system as apart direct assessment method including 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. 5.5.1 External Corrosion Direct Assessment (ECDA) is 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- By Continuous & Periodic CP monitoring or CPL etc survey compared with base line data available.

b) Identification - using either tools or calculations to flag possible corrosion sites, or calls, based on the evaluation or extrapolation of the database- Long term maintenance data (CIPL/DCVG) aligned with short term continuous or periodic incidental findings & compared with base line data available. This structured method is utilized for pin pointing problem area.



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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, examinations for threats other than that for external corrosion also (like mechanical and coating damages) assessment procedure taken care & further included in pipeline CAPA ( Corrective & Preventive action) as per ISO procedure .5.5.2 Internal Corrosion Direct Assessment (ICDA) is 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.

Procedure for pipeline internal corrosion direct assessment for O&M Ramgarh taken care are through various stages of pigging operation up to intelligent pigging. (Ref Section 5.1).5.5.3 Stress Corrosion Cracking Direct Assessment (SCCDA) :Can be used for determining integrity for the stress corrosion threat on pipeline segments . The SCCDA process having following 4 components

(a)Pre-assessment(b) Identifications(c) Examinations and evaluations(d) Post-assessment.

5.6 Thickness assessment and periodic review against baseline values

Thickness assessment for all the pipelines above ground, skids and pressure vessels and comparison to baseline values shall be done once every two years.



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Ramgarh pipeline section identified & listing of most risked /threat location & included for periodic thickness survey as per existing ISO procedure.

Ultrasonic thickness measurement in above ground pipelines is carried out once in two years and Bell hole thickness/coating survey is done on underground pipelines once in 10 years.

5.7 Pipeline equipment health monitoring

Various pipeline equipment line Sectionalising Valve (Remote & Locally Operated ), Pig launcher , Pig Receiver, Filtration , Metering Skids ,Pressure Reliving Devices are identified & proper checking & maintenance procedure being followed as per ISO maintenance manual.5.8 Review of existing pipeline class location

Before laying of pipeline location class survey was done as per design requirement .However pipeline surveillance system through periodic pipeline patrolling by GAIL & security agencies are being done including data compilation. Any changes in location type are time to time notified for further class review. Procedure is listed in respective pipeline manual.Also the details of integrity tools used in pipelines under Ramgarh base in summarized in Appendix no- X.6.0 DESIGNING APPLICABLE INTEGRITY MANAGEMENT SYSTEM

FOR NATURAL GAS PIPELINESRamgarh 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 Natural Gas pipelines. It is recognized that the comprehensive pipeline integrity management program is based on continuous exercise of extensive data collection, assimilation and analysis. Further, 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 PLAN All natural gas pipelines and associated facilities installed as a part of Ramgarh pipeline system shall be 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



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Yes

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 GAIL, Ramgarh 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. Operational and integrity assessment data will be continuously updated while performing various activities along the pipeline such as patrolling, aerial surveillance, Cathodic Protection (CP) monitoring, monthly maintenance of equipments, etc. and records maintained either hard or soft options.6.1.2 Threats Identification: Pipeline section of Ramgarh classified threats in line with Pipeline research Committee International (PRCI) which 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: However Appendix-III addressed all the possible threats respect to Ramgarh Pipeline.

No

Yes

Data Updation& integration

Mitigation and Responses

Integrity Assessment

Risk Assessment / Evaluation

Review of IMS as per ERDMP

Consequences & Impact Analysis

Whether all threats evaluated

Threat Identification

Initial data gathering and review for O&M

Ramgarh



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(I) Time Dependent Threats:

1) External Corrosion

2) Internal Corrosion

3) Stress Corrosion Cracking

(II) Stable Threats:

4) Manufacturing related defects

i. Defective pipe seamii. Defective pipe

5) Welding /fabrication related

i. Defective pipe girth weldii. Defective fabrication weldiii. Wrinkle bend or buckleiv. Stripped threads /broken pipe /coupling failure6) Equipment

i. Gasket O-ring failureii. Control/relief equipment malfunctioniii. Seal pump packing failureiv. 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:



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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 Hazardous events are identified for & risk analysis for analyse their consequences, i.e., estimate the magnitude of damage to the public, property and environment of all the identified threats done for GAIL Ramgarh pipeline section. Following consequences are considered ,included Risk Analysis report for the pipe line:(i) Leak(ii) Mass release / Continuous release(iii) Flash fire / Jet fire(iv) Explosion(v) Gas cloudRisk analysis & Hazop studies considers 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:

Risk management is the overall process by which management decides what actions to take, if any, to control or reduce existing or anticipated



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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. It has been carried out by third party expert consultant. List of HAZOP and Risk analysis of Ramgarh is being given below.

1. HAZOP for gas pipelines under Ramgarh is covered in Hazop report viz; Document no- 9587-01-HR-003, Rev—1,, dated:- 20.09.12

2. Risk assessment for Ramgarh Natural gas pipeline is done as per document no- 9587-28RA-002, Rev-1, dated:- 20.9.12

3. Emergency Response & Disaster Management Plan (ERDMP) for Ramgarh is available per PNGRB Guidelines accredited by M/s TQ Services. Certification No. TQ/EMP/011 Dated 10.01.2013. The plan is prepared and placed in document no- GAIL/RG/ERDMP, issue no-02, Rev-00, dated:- 08.1.2013.

4. As per PNGRB regulation, T4S audit was carried out for GAIL, Ramgarh as per audit report no- IN/MUM/IND/20110068 by SGS, Mumbai.

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 PNGRB (Technical Standards and Specifications including Safety Standards).

b) Inline inspection (ILI) as per OISD 226, PNGRB and GAIL Maintenance Policy & Guidelines-2010.

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



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d) Various forms of pipeline surveillance and monitoring e.g. foot patrolling, Integrated Electronic Surveillance System (IESS) etc.

GAIL, Ramgarh 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.Also Qualitative risk assessment for Ramgarh pipeline Integrity is developed and placed at Appendix-XII6.1.6MITIGATION & 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 ARE 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 havingi) 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 gauges.

v) Any near term failure indication



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(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 SMYSii) Mechanical damage with or without concurrent visible indentation

of the pipeiii) Dent with cracksiv) Dent that affect ductile girth or seam wells if the depth is in

excess of 2% of the nominal pipe diameterv) Dents of any depth that affect non ductile welds

* For more information on scheduled conditions,” Repair Procedures for Steel Pipelines” Para 851.40 of ASME B 31.8 to 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: Gas – High Consequential Areas Repair Conditions



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Immediate

Metal Loss> 80%Metal Loss predicted burst pressure ≤ 1.1 x MOPDent with metal loss, crack stress riserAnomaly that analyst believes to warrant immediate repair

1 Year

Dent (smooth) top of pipe > 6% (or > 0.50” if pipe diameter < 12”)Dent> 2% (or > 0.5” if pipe diameter < 12”) that affects pipe curvature at girth or seam weld

Monitored Conditions

Dent bottom pipe > 6% (or > 0.50” if pipe diameter < 12”)

Dent top of pipe > 6% (or > 0.50” if pipe diameter < 12”) and engineering analysis of the dent demonstrate critical strain levels are not exceeded

Dent > 2% (or > 0.25”if pipe diameter < 12”) that affects pipe curvature at girth or seam weld and engineering analysis of the dent demonstrate critical strain levels are not exceeded

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

Integrity assessment results

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

Critical activities or activities



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The plans for critical activities are reviewed periodically by In charge of O&M , address the resources (means) requirement and necessary changes in organizational and external factors affecting integrity management.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 EVALUATION PLAN:

GAIL, Ramgarh 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 anomalies3) Direct integrity measures e.g. No. of damages per km. of pipeline

lengthGAIL, Ramgarh conducts 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 Ramgarh’s pipeline integrity management and performance evaluation program:1) An integrated management ISO policy and program for all applicable

elements is in place. Refer Integrated SEQ APEX manual no. - RAMGARH/SEQM-APEX, Rev-00, Issue no-1. MR(controller) is Chief Manager (O&M), Mansarampura

Mitigation actions

evaluated?

Incorporate additional frequencies or include actions in subsequent Annual Maintenance Plans

Normally undertaken

ActivitiesRequiring special focus



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2) Written integrity management plan procedures and task descriptions are up to 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

document6) 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

6.2.1PERFORMANCE 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), Jaipur 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 goals on priorities & specific problems has been defined in its Appendix-1 and same has been reproduced here at Appendix-VI and X.

For performance measures relating to damage events, the following points have been documented in the Ramgarh’s Damage Prevention Report in maintenance manual:

The number of third party damage events and near misses.



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

Line walk 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 Ramgarh’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 & accidentse) Process enhancement / changes(MOC),f) Recommended changes for the IMS,g) Additional training requirements necessary to support IMS,h) Public awareness programi) Inspection tool performance(Whenever applicable)j) Inspection tool vendor performance k) Alternative repair methods,l) Staffing for inspections, testing and repairsm) 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



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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: GAIL, Ramgarh 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 procedure is in place in IMS (ISO 9001, ISO 14001, and OSHAS 18001) procedure, GAIL maintenance policy and OISD GDN-178 guidelines are being followed to identify and consider the impact of changes to pipeline systems and their integrity.Management of change (MOC) should be implemented to achieve higher efficiency, improve operability, safety, reliability, improvement of the plant machineries and equipment and to accommodate technical change. The management of changes may be arising due to various reasons like operational flexibility, energy conservation, capacity augmentation, improvement of product specification, yield improvement, compliance with statutory rules and regulations which shall be identified, reviewed, approved and communicated prior to the implementation of the changeBefore implementing any major modification, same shall be reviewed by formulating a cross functional team. The cross functional team should review the modification in totality including safety hazards, quality issues etc. The approving authority for these changes shall not be below the level of OIC.Any change in design basis, process or operational issue that can affect the risk rating has to be routed through Management of Change. A Management of change procedure shall follow as below:

Recognize change(s), record reasons for its requirement & initiate for MOC.

Review of change by cross functional team. HAZOP and risk analysis as per nature of change(s) required. Recommendation to OIC to approve the change Approval by OIC for executing the change(s) Communication to all concerned regarding change(s) carried out. Incorporation & Documentation of change(s) as appropriate. Feedback, Training & Review of change(s).



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6.5 QUALITY CONTROL PLAN:GAIL, Ramgarh has integrated ISO system of ISO 9001:2008 QMS, ISO 14001: 2004 EMS, and OHSAS 18001: 2007 and maintains documented procedure and records as per the requirement of this standard in Integrated SEQ APEX manual no- RAMGARH/SEQM-APEX, Rev-00, Issue no-1. MR(controller) is Chief Manager (O&M), Mansarampura . 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 CM(O&M), 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



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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.6.5.1 CONTROLS OVER INTEGRITY:GAIL –Ramgarh has in place various controls which put over at various stages, to achieve sound integrity management. The various stages are described below:

a. DESIGN: Integrity management of a pipeline starts with a sound design and construction of the pipeline. GAIL, Ramgarh 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. GAIL, Ramgarh maintains a document for Basis of Design, and all the pipelines laid by it and all other facilities.

b. PROCUREMENT & SUPPLY CHAIN: GAIL, Ramgarh ensures 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.



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c. FABRICATION, CONSTRUCTION, INSTALLATION & TESTING STAGE:

Ramgarh ensures 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, Ramgarh 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 specificationso Appropriate fabricatorso Quality control / assuranceo Construction documentationo Deviations / concessions recordedo Confirmation of integrity as appropriate (pressure testing / NDT

etc.)o Commissioning plans and procedure

d. SYSTEM HANDOVER / TAKEOVER: At corporate level policy and procedure has been circulated.

e. 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.

f. OPERATIONS: In SOP and ISO document Issue-01, Dt01.04.2012has established its operations philosophy and implement it by operations management procedures and controls developed by it. Through SOP Ramgarh 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



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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 actionsg. 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. Ramgarh 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



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a week basis.h. 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 failures2. Planning of repairs to ensure minimum disruption3. Monitoring for wear and tear and random failuresDetails of instrumentation and electrical systems under Ramgarh is

attached in Annexure- II.

i. 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 Natural Gas; purged of Natural Gas 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 Natural Gas 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 Natural Gas is installed in the line or somewhere along the assembly;

c) The terminal’s piping is physically disconnected from the Natural Gas supply and the open pipe ends sealed.

7.0 APPROVAL OF INTEGRITY MANAGEMENT SYSTEM (IMS): A Ramgarh Integrity Management System is a management plan in the



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form of a document that explains to Ramgarh’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 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.8.0 IMPLEMENTATION SCHEDULE OF THE INTEGRITY MANGEMENT SYSTEM:

Sr. No

Activity Time Schedule

1. Compliance with PNGRB (TS4) regulations-2009

Implemented.

2. Preparation of IMS document & Approval by Head of Operation Team

Implemented.

3. Conformity to IMS document by TPIA. Implemented.4. Submission of IMS document by

PNGRB.Implemented.

5. Approval for implementation By 31st Jan 2015.6 Start Of Implementation Immediately .7. Submission of Compliance statement By 31st Dec 2015.

9.0 REVIEW OF THE INTEGRITY MANGEMENT SYSTEM:

9.1 Periodicity: In line with PNGRB requirement Ramgarh shall review their existing IMS every 3 years based upon the:

(i) Revised Baseline data(ii) Critical Inputs from various departments



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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 Natural Gas pipelines

provided by PNGRB is carried out by the management of Ramgarh every year.

(b) External Audit (EA) by third party, approved by the Board, as per the methodology specified by the PNGRB every 3 years.

(c) Internal safety audits once in a quarter and External safety audit once in two years are carried out at GAIL, Ramgarh.

(d) Technical audit is being carried out once in 2 years. 10.0 Adequacy of Manpower positioned at Ramgarh Station:

GAIL Management and CO HR Department takes care of the requirement of manpower for different stage of project, namely: Design, construction, commissioning, operation and maintenance. In Ramgarh GAIL management has deployed manpower of the qualification in conformity to Appendix-IV. The GAIL, Ramgarh is having the detailed records of all manpower as posted to their station. The following is the manpower details at GAIL, Ramgarh:-

S.NO

Name of executive

Designation Educationalqualification

Experience in Gas industry

1 T.P. Yuvaraj Manager(Inst) DEIE, BE(I&C), MBA

11 years

2 Bhoora Lal Meena

Dy. Manager( Elect)

B.tech(ELE) 7 years

3 Parbat Singh Dy. Manager(Mech)

BE(Mech) 6 years

In addition to the above manpower, the technical and other supports are extended from HSE dept, Pipeline dept, Purchase, stores, Finance, HR etc from GAIL –Jaipur and Mansarampura.

Roles and responsibilities for activities like pipeline, CP, Instrumentation, Electrical, Mechanical, Fire and safety are defined through Organograms and Apex manual no- RAMGARH/SEQM-APEX, Rev-00, Issue no-1. MR (controller) is Chief Manager (O&M), Mansarampura



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In addition of above GAIL manpower, contract based manpower is available for assisting the operation and maintenance activities of Ramgarh pipeline system. 6 nos of ITI qualified technicians are deployed with experience ranging from 2 to 6 years.

11.TRAINING:-

Training is imparted to permanent employees of GAIL in the areas of pipeline operations and maintenance every year. Also training is extended to contract employees working under Ramgarh base on regular basis. Safety trainings are imparted quarterly basis to contract employees. Monthly safety campaigns are conducted at GAIL, Ramgarh to sensitize the importance of safety in pipeline and terminals. GAIL training institute(GTI) located at Noida conduct the trainings to GAIL executives as per Annual calendar schedule.

APPENDIX-I

REFERENCES



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REFERENCE STANDARDS, CODE OF PRACTICE & GUIDELINES:

1) PNGRB (Technical Standards and specifications including safety standards for Natural gas pipelines) Regulations, 2009.

2) PNGRB(codes of practices for Emergency response and disaster management plan) Regulations , 2010

3) ASME B31.8- Gas Transmission and Distribution Piping Systems

4) ASME B31 Q- Pipeline personnel qualification.

5) ASME B31 G- Manual for determining the remaining strength of corroded pipelines

6) ASME B 31.8S Managing System Integrity of Gas.

7) Gas Research Institute- 00/0189- A model for sizing high consequence areas associated with Natural gas pipelines.

8) NACE Standard RP0502–2002

- AS 2885.1-1997 Pipelines - Gas and liquid petroleum - Design and construction

- AS 2885.2-1995 Pipelines - Gas and liquid petroleum – Welding

9) Gas Research Institute- 00/0193 – Natural gas transmission pipeline ; Pipeline integrity – prevention, detection, and mitigation practices.

APPENDIX-II

LIST OF CRITICAL ACTIVITIES IMPLEMENTATION SCHEDULE

Sr. No.

Critical infrastructure/ activity/ processes

Time period for implementati

Implementation plan in Ramgarh



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on

1Cathodic Protection survey to ensure an integrated CP system

6 months for survey

Since commissioning it is being carried out.

2 Intelligent Pigging 10 YearsIt is being done as per frequency in the OISD-226.

3 SurveillanceAs per PNGRB regulation 2009


4 Coating surveyAs per PNGRB regulation 2009


5 Hydro-testingAs per PNGRB regulation 2009

Being carried out as per regulations.

6 Leak detection system implementation 6 months

New leak detection system will be ready by Jan-2015

7 Preparation of IMS 1 Year *Can be submitted in stages as per schedule -8

8 GIS mapping implementation 2 years Target -2015

APPENDIX - III

Suggestive Chart for selection of Integrity Assessment method with respect to specific threat

Threat Group ThreatPreferred Integrity

Assessment / Assurance Method

Assessment interval

Time-Dependent



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External Corrosion Inline inspection, ECDA, Bell hole inspection

Max.10 year**

Internal Corrosion Inline inspection, ICDA, Bell hole inspection

Max.10 year**

Stress Corrosion cracking

Inline inspection, Direct Assessment, bell hole inspection

Max.10 year**

Stable

a) Manufacturing related defects

Defective Pipe Seam Hydro-test (Post Construction), Inline inspection

Before commissioning or as and when requiredDefective Pipe

b) Welding /

Fabrication related

Defective Pipe Girth Weld

Defective fabrication Weld

Wrinkle bend or buckle

Caliper pigging / EGP

Stripped threads/broken pipe

Visual Examination / Gas Leakage Survey

c) Equipment Gasket / O-ring Failure


Control / Relief equipment malfunction


Time-Independent

a)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,

Monthly /quarterly



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IESS

Previously damaged pipe (delayed failure mode)

Above + Leakage Survey, Rehabilitation

Vandalism All above

b)Incorrect Operations

Incorrect Operational procedure

Compliance Audits

c) Weather Related and Outside Forces

Weather related Leakage survey, Surveillance, patrolling

Monthly and Annually

Shifting Sand dunes P/L patrolling

Lightning Surge diverters

Heavy rains or floods Anti-buoyancy inspection, Surveillance

Earth Movements Strain monitoring, patrolling , 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-IV

Minimum Qualification & Experience for Field Personnel in Project Phase as well as O&M Stage

S.N Name of Designation Educational Experience in Gas



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O executive qualification industry1 T.P. Yuvaraj Manager(Inst) DEIE, BE(I&C),

MBA11 years

2 Bhoora Lal Meena

Dy. Manager( Elect)

B.Tech(ELE) 7 years

3 Parbat Singh Dy. Manager(Mech)

BE(Mech) 6 years

Note: 1) 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.2) Pipeline, Mechanical and operations are looked after by Dy. Manager(Mech). Electrical, CP maintenance are looked after by Dy. Manager( ELE). Manager(I) is having overall operation and maintenance activity control of Ramgarh base in addition to the instrumentation related jobs.

APPENDIX-V

1.1 PHYSICAL DESCRIPTION OF RAMGARH :

DESIGN CAPACITY

Design capacity details are available in Operation manual, doc no- GAIL/RG/OM, Dated:- 1.04.2013, issue no- 01



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DESIGN CODES

GAIL gas pipeline systems are primarily designed in accordance with ASME B 31.8 and OISD 138 & 141 standards. And various guidelines under API, DIN, BS, Canadian Standards, NACE, NFPA etc. are also followed.

TABLE-01: DETAILS OF MAIN PIPELINE

GAIL has two different pipeline networks in the region for supplying gas to the customer.

3. Dandewala-Gamnewala-Ramgarh

4. Langtala-Ramgarh

Dandewala-Gamnewala-Ramgarh pipeline network is for supply of OIL/ONGC gas. The pipeline network was commissioned in the year 1994-1995. The size of the pipeline is 12 inch and the length of the network is 67 Kms. From OIL India the gas is received at Dandewala, and from ONGC the gas is received at Gamnewala. The gas supplied though this network is approx 7,50,000 SCM per day (7,00,000 SCM from OIL India and 50,000 SCM from ONGC). Gas supply is likely to be further enhanced by OIL/ONGC.

Langtala-Ramgarh pipeline network is for supply of gas from Focus Energy. The pipeline network has been recently commissioned in July 2010. The size of the pipeline is 10 inch and the length of the network is 87 Kms. The gas supplied though this network is approx 2,00,000 SCM per day presently and shall be further increased to 9,50,000 SCM per day

1.1.2 STORAGE FACILITIES: No Natural Gas storage.

1.1.3 SECTIONALISING VALVE (SV) STATIONS:

To isolate the pipeline segment Sectionalizing Valves are installed at an average distance of 20 km all along the trunk pipelines. Mainline valves of full bore ball valve type are installed for isolating different sections of pipeline in case of leak/burst etc. At



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SV/IP/Tap-off/Tap-in 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:

TABLE-05:

S/N IP / SV / TAP-OFF / TAP-IN

CHAINAGE (Km)

ADDRESS MANUAL REMOTE

S.V.STATIONS

1 SV-01(LRPL) 32.0 GAIL, SV-1 station

Shahgarh

Manual

2 SV-02(LRPL) 58.0 GAIL, SV-02, 5RMSM, Ramgarh

Remote

3 SV-03(LRPL) 80.0 GAIL, SV-03, Ramgarh Manual

4 Sv-Sadewala 17.0 Sadewala village Manual

5 Gamnewala 33.0 Gamnewala Manual

1.1.5 RECEIPT TERMINALS / DISPATCH TERMINALS

Dispatch terminal is location where GAIL receive Gas from Suppliers facilities .The natural gas received from various sources contains impurities, such as dirt, hydrocarbon condensate, water, solid particulars etc. These impurities need to be removed otherwise they will affect the health of the pipeline and as well as the Equipments. Besides, the efficiency of operation of the pipeline will also get adversely affected. In order to avoid the above problems, facilities are installed at



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gas Dispatch terminals of GAIL to remove these impurities before the gas is dispatched to the consumer.

In O&M Ramgarh there are three such dispatch terminal as follows:

Sr. Suppliers: DT Location

1 OIL India Ltd. – Dandewala DT

2 ONGC – Gamnewala DT

3 Focus Energy – Langtala DT

Old DT at Gamnewala & Dandewala equipped with pigging(only at Dandewala), pressure monitoring, Cathodic protection, communication, Portable LEL detectors & associated facilities.

Langtala DT having gas metering, Filtration, Gas Chromatograph, LEL & flame detection system & associated facilities.

Receipt terminals are those to deliver filtered & uninterrupted Natural Gas at specified pressure & flow to consumers. GAIL, Ramgarh is only receipt terminal under this pipeline network.

APPENDIX-VI

2.1 INSTRUMENTATION & ELECTRICAL SYSTEMS:

2.1.1 Main activities of Instrumentation in Ramgarh

a) Operation and Maintenance of Instruments & Systems for Un-interrupted supply of Natural Gas to consumers at specified parameters as per contract and ISO system.



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b) Joint calibration of custody transfer metering with Consumers and Suppliers like Focus Energy, OIL India and ONGCL to ensure custody transfer metering uncertainty with in the tolerable limits as per contract and ISO system.

c) Calibration of Non-Custody Transfer Instruments.

d) Procurement of Spares for Instruments & Systems as per our ISO system.

2.1.2 Brief Description of Instruments & Systems

Brief description of Instruments and systems is given below:

Natural Gas Flow Metering System

Flow computers connected to flow meters are used for measurement of Natural Gas supply to Consumers. In Ramgarh, Ultrasonic type flow meters (AGA-9, AGA-10) are used at Langtala and Ramgarh terminals along the Focus energy pipeline. Turbine meter type Flow measurement system (AGA- 7) is also used at Ramgarh terminal for supplying gas to consumer from ONGCL and OIL India. Flow Computers are interfaced with SCADA system through serial communication.

Control Room Panel mounted type Flow Computers

These types of Flow computers take input signals from the transmitters mounted in the field like Differential Pressure Transmitters / Pressure Transmitters / Temperature Transmitters.

Electronic Pressure Transmitter

These are installed to measure the static pressures of Inlet / Outlet of Terminals custody / Non-custody pressure measurements of scrubbers and pipelines. These are pressure sensitive instruments. These instruments are calibrated to required pressure ranges. These transmitter converts pressure signals into electrical signals (4ma-20ma) which are proportional to actual pressures and are fed to computers / Recorders. The custody transfer pressure transmitters are calibrated as per IM-05 to check the performance, linearity and repeatability of the instrument...The non-custody transmitters calibrations are checked as per IM-11



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Temperature Transmitter

These are installed to measure the static Temperature of Natural gas of Inlet / Outlet of Terminals, scrubbers and pipelines. These are Temperature sensitive instruments. These instruments are calibrated to required Temperature ranges. These transmitters convert Temperature signals into electrical signals (4ma-20ma) which are proportional to actual Temperature and are fed to computers / Records. These are calibrated as per IM-05 to check the performance, linearity and repeatability of the instrument for custody transfer instruments. The non-custody transmitter calibrations are checked as per IM-11

OTHER INSTRUMENTS:-

Details of other instruments are provided in Instrumentation maintenance manual , issue no- 01, dated:- 01.04.2012.

RESPONSIBILITY AND AUTHORITY :

The responsibility for carrying out calibration of measuring test instruments / equipment lies with Works In-charge, Ramgarh.WIC-Ramgarh is responsible to ensure that Calibration procedure is implemented effectively and efficiently within their area of jurisdiction. The person who will be actually carrying out the Calibration shall ensure the use of Calibrated Test equipment.

ELECTRICAL SYSTEM AND ITS COMPONENTS

All the cross-country underground pipelines of Ramgarh Pipeline are protected from external corrosion by three-layer coating. Apart from coating, the pipelines is also protected from external corrosion through Impressed Current Cathodic Protection system using external power supply through CPPSM, TR Units, Battery Banks, GPRS, Anode Ground Bed, ALJB, Earthing system, Grounding Cells, Permanent Reference Cells etc.



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Equipment / Systems installed along Pipeline / ROW i.e., Manual Test Stations, Corrosion Sensing Probes, Grounding Cells, Sacrificial Anodes, casings, Insulating Joints etc..

Brief description of these equipment is as given below:

a) CPPSM

This controls the voltage and current applied on pipeline for corrosion protection by ICCP method. The CPPSM works on auto (constant PSP) or manual mode (constant voltage / current).

b) Transformer Rectifier Units

These are installed at various locations and at terminals as a part of the Impressed Current Cathodic Protection system for corrosion protection of pipeline. The TR unit works on auto (constant PSP) or manual mode (constant voltage / current).

c) Battery Banks

As a back-up to the main power source i.e. CCVTs, Battery banks of different capacities are installed at CP stations. Monitoring and maintenance of Battery banks of CP installations will be done as per Format in the P-4. This is the responsibility of the BIC/WIC. Details of battery bank is provided in Appendix-IX

d) Ground Bed / Anode Lead Junction Box

The current required for CP of pipeline is fed by CPPSM/TR Unit. The -ve of CPPSM / TR unit is connected to P/L while +ve is connected to anode ground bed. Anode ground bed consists of individual anodes in direct contact with earth. Tail cables of each individual anode are brought into the Anode Lead Junction Box (ALJB) where they are connected to main header cable. One shunt and one variable resistance are connected in series with each individual anode for measurement and adjustment of current passing through each anode.

e) Earthing System



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This is installed for earthing of various installations / equipment for safety purposes. Earthing system of CP installations will be monitored as per the ISO format.

f) Grounding Cells / Surge DivertersGrounding cells are buried in ground and connected across insulating joints to protect against high voltage surges. Each cell consist of two high purity Zn anodes strapped together, separated by insulating spacers, with low resistivity back fill and connecting cables. Now a days Semi conductor type Surge diverters are more often used across Insulation Joints due to less maintenance and ease in Installation.

g) Polarization Cells

The Polarization cell consists of multiple pair of stainless steel sheets immersed in a potassium hydroxide (KOH) aqueous solution. DC flow through the cell causes a gas film to develop on the steel plates, offering a high resistance to low voltage DC current. As the applied voltage across the cell increases, current flow across the cell also increases causing the thickness of the polarization gas film to increase. The blocking voltage of a Polarization cell is in the range of 1.2 V – 1.7 V. When the leakage threshold is exceeded, the film starts to breakdown, consequently the cell resistance decreases quickly as the applied voltage increases. Thus the AC voltages and higher DC voltages see a Polarization cell as a “dead short”.

h) Permanent Reference Cells

These are high reliability Copper - Copper Sulphate reference cells permanently buried adjacent to the underground structure to measure structure to soil potential.

i) Manual Test Station

These are installed along pipeline ROU for monitoring PSP, current and other parameters related to health of the C.P. system.

j) Corrosion Sensing Probes

(a) External Corrosion Sensing probes: These are installed at aggressive soil locations. This probe is laid adjacent to pipeline. Probe consists of two elements - ref. element and test element. Both elements are made of material same as that of pipe. Ref. element is coated with bitumen paint and test element is connected to pipe via T.S. As the test element corrodes its resistance increases. This resistance is measured by ER meter



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which gives corrosion in terms of MILS. The CSP does not give the corrosion rate of pipeline directly, but gives the information about the corrosiveness of environment.

(b) Internal Corrosion Sensing probes: These are installed inside the pipeline in contact with the flow of the gas. By using the ER probe reader corrosion rate of the pipeline can be calculated. Based on the readings the corrosion rate will be classified based on the mils / year corrosion values obtained as shown below. If the corrosion rate is found to be high, suitable investigation and remedial action will be carried out

MILS/PER YEAR

LOW COROSION RATE < 1.0

MILD < 1.0 – 4.9

HIGH < 5 – 10

SEVERE > 10

These are installed inside the pipeline in contact with the flow of the gas. Coupon material will be same as the material of the parent pipeline material. By measuring the weight loss over a particular period the rate of corrosion of the pipeline in Mils/year can be calculated.

k) Sacrificial Anodes

Sacrificial Anodes have been installed for protection of Ramgarh Pipeline network.

Monitoring & Maintenance of Cathodic Protection System is carried out from Regional office / various maintenance bases.

l) Procedure

Monitoring of CP System

C.P. System shall be monitored as below.



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i. Monitoring Pipe to Soil Potentials and other related parameters, along the pipeline.

ii. Monitoring of systems / equipments installed at permanent installations.

Monitoring of installations & equipments installed along ROW of pipeline

Details of the CP Units installed for the Cathodic Protection of the Ramgarh Pipeline Network is provided in CP maintenance manual, issue no- 01, dated:- 01.04.2013 available in soft and hard copy at Ramgarh base.

APPENDIX-VII

The 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 drawings



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11) 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,



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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 - VIII

ANNUAL HEALTH CHECK-UP REPORT

Name of the Plant/Pipeline/Region: GAIL, Ramgarh Year:2013S. No. Parameter Details Status



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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.

Being complied

2. Uninterrupted Avail. Of P/L

Pipeline availability in percentage(details of any interruption to be attached)

100 %

3. Status of CP

1. Pipeline protection Index

2. Pipe to soil potential3. Power source

working(Grid/TEG)4. CP System working

(TR/CPPSM)

100 (%)OkOkOk

4. Maintenance status

1. Exception w.r.to Annual preventive maintenance schedule (pending more than a month)

2. Critical equipment (GTG/GTC/DEG/IA Comp/FWP (%) (for plants only) (for plants only)

Nil

NA

5. Safety Index 1. Overall safety Index2. Internal safety Audit

100 %3/4



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(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

1/1

1/1

0 % loss

OK

6. Performance Index

1. Unaccounted Gas: by energy

2. Performance vs. MOU (please attach reasons in case of performance less than “Excellent” MOU)

1) Nil2) Excellent

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

YES

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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APPENDIX -IX

Equipment List and details

Equipment details of DT-Dandewala /Gamnewala (DGRPL)

1. Pig launcher:

Make : Multitex Filtration Engineers Pvt. Ltd

Tag no : SL 202

Sr no : 1482

Year : 1994

Design Pressure : 50 kg/cm2

Design Temp : 60 deg cen

Code : ANSI B 31.8

Test pressure : 75 kg/cm2

Date of test : 12.08.1994

Radiography : Full 100%

Heat treatment : nil

Fluid : NG

Total weight (Empty) : 1050 kg

Control : DNV



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Equipment details of DT Langtala (LRPL Section).

2. Wet Gas Filters:

Description Loop – A Loop - B

Make Flash point equipment pvt. Ltd

Flash point equipment pvt. Ltd

Item no FPE-598 FPE-598

Sl no FPE 598 / FPFILV2-22-8” A 600-11-01

FPE 598 / FPFILV2-22-8” A 600-11-02

Year of Fabrication 2009-2010 2009-2010

Code ASME SEC VIII DIV 1 2004 ADD 05

ASME SEC VIII DIV 1 2004 ADD 05

Design Pressure 92 kg / cm2 92 kg / cm2

Design Temp -20 to 65 deg cen -20 to 65 deg cen

Test Pressure 138 kg / cm2 138 kg / cm2

Date of test 30.12.2009 30.12.2009

Inspected by FPEPL / DNV FPEPL / DNV

Radiography 100% 100%

Heat treatment As per ASME As per ASME

Capacity 1.2 MMSCMD 1.2 MMSCMD

Corrosion allow 2.0 mm 2.0 mm

Total weight(empty) 1600 kg 1600 kg

3. Dry Gas Filters:



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4.

USM

Description Loop – A(SG-FT-01) Loop – B(SG-FT-02)



PAGE 78 OF 124


Make Flash point equipments pvt. Ltd

Flash point equipments pvt. Ltd


Tag no SG-CF – 01 SG-CF - 02

Sl no FPE 598 / FPFILV2-22-8” A 600-11-01

FPE 598 / FPFILV2-22-8” A 600-11-02

Year of Fabrication

2009-2010 2009-2010




Design Temp -20 to 65 °C -20 to 65 °C


Date of test 30.12.2009 30.12.2009




Capacity 1.2 mscmd 1.2 mscmd


Total weight(empty)

1600 kg 1600 kg

Make Daniel Daniel

Model 3400 3400

Sl no 09-360466 09-360467

Sl no (Electronics) 09-410625 09-410621

Class 1, Group D 1, Group D

Temp code T4A T4A

Voltage 10.4 to 36 v dc, 15 w

10.4 to 36 v dc, 15 w

Ambient Op. Temp -40 to 65 °C -40 to 65 °C

5. Gas chromatograph (Field unit) (SG-AI-01)

Make : Daniel

Model : 500 Analyser

Sl no : 9009891

Rating temp : -18 to 55 °C

In put : 120 / 230 v AC

Out put : 4 – 20 ma

Class : 1, Groups C & D

Temp code : T3B (165 deg cen)

6. Pig Launcher :

Make : Control Plus Oil & Gas Solutions Pvt. Ltd

Item : Pig Launcher

Fluid : NG

Tag no : Y – 0201



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Operating pressure : 56.88 bar

Design Pressure : 68.66 bar

Design Temp : -20 to 65 °C

Year : 2009 -2010

Rating : 600 #

Corrosion allowance: 1.6 mm

Operating Temp : 0 – 60 °C

Equipment details of RT Ramgarh (ONGC/OIL section)

7. Scrubber:

Make : Flash point equipment°C pvt. Ltd

Item no : FPE-598

Sl no : FPE 598 / FPV-30-12”A 300-10-01

Year of Fab : 2009-2010

Code : ASME SEC VIII DIV 1 2004 ADD 05

Design Pressure : 49 bar

Design Temp : 0-65 °C

Test Pressure : 73.5 bar

Date of test : 07.03.2010

Inspected by : FPEPL / ABS

Radiography : 100%

Heat treatment : As per ASME

Corrosion allow : 3.0 mm

Total weight : 3000 kg

Model no : FPV-30-12 x 12A 300 – 10



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8. Wet gas filters:


Make Flash point Equipments Pvt. Ltd

Flash point Equipments Pvt. Ltd


Tag no CF 101 CF 102

Sl no FPE 598 / FPFILV2-SH-33-12A 300-10-01

FPE 598 / FPFILV2-SH-33-12A 300-10-02

Year of Fab 2009-2010 2009-2010



Design Pressure

49 kg / cm2 49 kg / cm2

Design Temp 0-65 deg cen 0-65 deg cen

Test Pressure 73.5 kg / cm2 73.5 kg / cm2

Date of test 02.02.2010 02.02.2010

Inspected by FPEPL / ABS FPEPL / ABS


Heat treatment

As per ASME As per ASME


Corrosion allow

3.0 mm 3.0 mm

Total weight(empty)

2780 kg 2780 kg

Model no FPFILV2-SH-33-12-A 300 FPFILV2-SH-33-12-A 300



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-10 FG 536 / 11 / QD -10 FG 536 / 11 / QD

9. Dry gas filters:


Make Flash point Equipments pvt. Ltd

Flash point Equipments pvt. Ltd


Tag no CF 201 CF 202

Sl no FPE 598 / FPFILV1- 33-12A 300-10-01

FPE 598 / FPFILV1- 33-12A 300-10-02

Year of Fab 2009-2010 2009-2010



Design Pressure

49 kg / cm2 49 kg / cm2

Design Temp 0-65 °C 0-65 °C

Test Pressure 73.5 kg / cm2 73.5 kg / cm2

Date of test 29.01.2010 29.01.2010

Inspected by FPEPL / ABS FPEPL / ABS





Total weight(empty)

2300 kg 2300 kg

Model no FPFILV1-SH-33-12x12 - A 300 -10 FG 536 / 08 – QD

FPFILV1-SH-33-12x12 - A 300 -10 FG 536 / 08 - QD



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10. Turbine Meters:


Make RMG Messtechnik Gmbh, Germany

RMG Messtechnik Gmbh, Germany

Sl no 34656 34659

Type TRZ 03 TRZ 03

DN 300 300

G G 4000 G 4000

Rating ANSI 300 ANSI 300

Qmax / Qmin 6500 / 320 m3/hr 6500 / 320 m3/hr

Pmax 50 bar 50 bar

11. PCV – A:


Make Masoneilan Dresser Valve India Pvt. Ltd

Masoneilan Dresser Valve India Pvt. Ltd

Model 37-41325 2010 37-41325 2010

Size body 12” 12”

Cv 1260 EQ% 1260 EQ%

Action Air to close Air to close

Range 3 -14 psi 3 -14 psi

Supply 29 psi 29 psi

Body WCB WCB



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Stem 316 316

Matel Plug 316 HF Seat 316 HF Seat

Rating 300 RF ANSI 300 RF ANSI

Sl no I-10-910351-001-1 I-10-101807-001

Tag / Item no FCV FCV

12. Pig receiver:

Make : Multitex Filtration Engineers Pvt. Ltd

Tag no : SR 202

Sr no : 1483

Year : 1994

Design Pressure : 50 kg/cm2

Design Temp : 60 °C

Code : ANSI B 31.8

Test pressure : 75 kg/cm2

Date of test : ---

Radiography : Full 100%

Heat treatment : nil

Fluid : NG

Capacity : ---

Total weight (Empty): 1315 kg

Control : DNV



PAGE 84 OF 124

13. Gas chromatograph (Field unit):

Make : Daniel

Model : 500 Analyser

Sl no : 9009891

Rating temp : -18 to 55°CC

In put : 120 / 230 v AC

Out put : 4 – 20 ma

Class : 1, Groups C & D

Temp code : T3B (165 deg cen)

Equipment details of O&M Ramgarh (LRPL Section).

14. Filters:


Make Flash point equipmentspvt. Ltd

Flash point equipmentspvt. Ltd


Tag no RG-CF – 01 RG-CF - 02

Sl no FPE 598 / FPFILV2-22-8” A 600-11-01

FPE 598 / FPFILV2-22-8” A 600-11-02



PAGE 85 OF 124

Year of Fabrication

2009-2010 2009-2010




Design Temp -20 to 65 °C -20 to 65 °C


Date of test 30.12.2009 30.12.2009




Capacity 1.2 mscmd 1.2 mscmd


Total weight(empty)

1600 kg 1600 kg

15. USM Meters:

Description Loop – A(RG-FT-01)

Loop – B(RG-FT-02)

Make Daniel Daniel

Model 3400 3400

Sl no 09-360466 09-360467

Sl no (Electronics) 09-410625 09-410621

Class 1, Group D 1, Group D

Temp code T4A T4A



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Voltage 10.4 to 36 v dc, 15 w

10.4 to 36 v dc, 15 w

Ambient Op. Temp -40 to 65 °C -40 to 65 °C

16. SDVs:


Make Tartarini Tartarini

Sl no NO24460 NO24461

Tag no RG-SDV-01 RG-SDV-02

Year 2010 2010

Fluid group 1 1

Cg 18375 18375

Ps / Body 100 bar 100 bar

Device type BM 5 /150 BM 5 /150

DN 1 150 ANSI 600 RF 150 ANSI 600 RF

DN 2 150 ANSI 600 RF 150 ANSI 600 RF

Wa --- ---

Wao --- ---

Pt 1.5 bar 1.5 bar



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17. PCVs:

Description

PCV - 1 PCV – 2 PCV - 3 PCV - 4

Make Tartarini Tartarini Tartarini Tartarini

Sl no LO 48943 LO 48944 LO 48945 LO 48946

Tag no RG-PCV-01 RG-PCV-02 RG-PCV-03 RG-PCV-04

Year 2009 2009 2009 2009

Fluid group 1 1 1 1

Cg 8050 8050 8050 8050

Ps / Body 100 bar 100 bar 100 bar 100 bar

Device type

FL / 100 SR FL / 100 SR FL / 100 SR FL / 100 SR

DN 1 100 ANSI 600 RF

100 ANSI 600 RF

100 ANSI 600 RF

100 ANSI 600 RF

DN 2 100 ANSI 600 RF

100 ANSI 600 RF

100 ANSI 600 RF

100 ANSI 600 RF

Wa --- --- --- ---

Wao --- --- --- ---

Pt 1.5 bar 1.5 bar 1.5 bar 1.5 bar

18. Pilots:

Description

PCV - 1 PCV – 2 PCV - 3 PCV - 4

Make Tartarini Tartarini Tartarini Tartarini

Sl. no Z 204828 Z 204829 Z 204830 Z 204831



PAGE 88 OF 124

Year 2009 2009 2009 2009

Fluid group 1 1 1 1

Ps / Body 100 bar 100 bar 100 bar 100 bar

Device type

PS / 80 PS / 80 PS / 79 PS / 79

Wa 25 – 30 bar 25 – 30 bar 25 – 30 bar 25 – 30 bar

Wao --- --- --- ---

19. FCV:

Description Loop - A

Make Masoneilan Dresser Valve India Pvt. Ltd

Model 87-41325 - 2010

Size body 8”

Cv 575 EQ%

Action Air to close

Range 3 -14 psi

Supply 33 psi

Body WCB

Stem 17 – 4 PH

Metal Plug disc 17 – 4 PH

Seat 410

Rating ANSI 600# RF

Sl. no I-10-910341-001



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Tag / Item no FCV1 / 001

20. Pig receiver:

Make : Control Plus Oil & Gas Solutions Pvt. Ltd

Item : Pig receiver

Fluid : NG

Tag no : Y – 0601

Operating pressure : 56.88 bar

Design Pressure : 68.66 bar

Design Temp : -20 to 65°C

Year : 2009 -2010

Rating : 600 #

Corrosion allowance : 1.6 mm

Operating Temp : 0 – 60°C

Detail of Solar PV system & Battery bank

Solar PV system along with battery bank is installed at SV-2 of Langtala-Ramgarh pipeline and Dandewala & Gamnewala terminal of Dandewala-Gamnewala pipeline for captive power requirement.

Solar PV system at SV-2:Solar PV array:-

Module capacity : 75 WpTotal No. of modules : 160 nos.Array Capacity : 12 K WpMake : SunTechnics

Battery Bank:-Capacity : 96 Volts, 853Ah



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No. of battery bank : 02 Nos.Nos. of cells/ battery bank : 80 Nos.Type : Ni-Cd BatteryMake : HBL

Solar PV system at Gamnewala Terminal:Solar PV array:

Module capacity : 35 WpTotal No. of modules : 60 nos.Array Capacity : 2100 WpMake : REIL

Battery Bank:Capacity : 24 Volts, 600AhNos. of cells : 12 nos.No. of battery bank : 01 no.Type : VRLAMake : Amaraja

Solar PV system at Dandewala Terminal:Solar PV array:

Module capacity : 35 WpTotal No. of modules : 60 nos.Array Capacity : 2100 Wp

Battery Bank:Capacity : 24 Volts, 600AhNos. of battery : 12 nos.No. of battery bank : 01 no.Type : VRLA

Details of Battery Banks at GAIL – Ramgarh O&M base

S/N

LocationBattery Bank Make

Type ModelCells in Each Bank

No. of Bank

svoltage

Ah Capacity

1 Ramgarh Terminal HBL Ni-CadKBL 390P

177 2 210 390

2 Ramgarh Terminal HBL Lead Acid VRLA 24 1 48 300

3 GamnewalaAMARAJA

Lead Acid VRLA 12 1 24 600

4 DandewalaAMARAJA

Lead Acid VRLA 12 1 24 600



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5 SV-2 HBL Ni-CadKGL 853P

80 2 110 853

6 Langtala Terminal HBL Ni-CadKBL 200P

175 2 210 200

7 Langtala Terminal HBL Lead Acid VRLA 24 1 48 300

SCADA:

The monitoring and control of Ramgarh pipeline network is done through SCADA System which has been commissioned in June 2010. It provides useful data to the operator for the effective and efficient running of the pipeline. In the Regional SCADA system, for the purpose of monitoring the Ramgarh Pipeline Network, two servers cum work station have been installed in hot standby redundant configuration at Ramgarh. These servers poll the RTUs and in many case directly the Flow Computers and Gas Chromatographs.To provide data to the operators in Control rooms, Server cum workstation have been provided at Ramgarh. This data (primarily comprising of Yesterday’s Volume, GCV and NCV) is sent to the Gas Management System (GMS SAP) for automatic billing and invoicing. For this, the data is first received by Regional Server located in NGMC which is further integrated with Centralized SCADA system and finally to GMS. 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, valve monitoring etc.RTUs are installed in the SV/IP station and act as an interface between the field facilities and the SCADA servers. The data of the field parameters comes to the RTU in the form of analog (4-20mA) signals and digital (NO/NC) signals. Total 3 nos. of RTU are installed in Ramgarh region. Telecom channels/E1 links have been extended from SCADA server to the RTU for TCP/ IP based polling wherever possible. RTUs, Flow Computers and Gas Chromatographs are also polled using low speed channels, High speed (E1 link) link, serial communication and Dial up (PSTN) Modem. Multiple types of RTU protocols like, DNP3, over serial and TCP/IP, Modbus over serial and TCP/IP and AB DF1 over serial and TCP/IP are supported by the Ramgarh SCADA system. Any RTU supporting these protocols can be integrated in the SCADA system for future pipeline expansion.



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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 gas suppliers and buyers can also be presented to them after suitable authorizations.The new SCADA system supports E-mail and SMS. It supports auto-generation of SMS and sending to concerned pipeline engineers on occurrence of critical alarms. It also supports generation of multiple types of reports related to pipeline operations, gas receipt and dispatch, PSP, gas pressure, calorific values etc. and sending 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.

CLEANING PIGGING: The frequency of de-scaling/cleaning of pipelines transporting Natural Gas shall be once in 3 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 Ramgarh pipeline Sections

S/N

NAME OF THE PIPELINE SIZE (“)

LENGTH (Km)

WALL THICK.

GRADE OF STEEL

Cleaning Pigging month/year

Next due



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1 Langtala – Ramgarh pipeline 10 86.2 6.4 mm API5L GR.

X42MAY-2013

MAY-2016

2 Dandewala- Gamnewala- Ramgarh pipeline 12 65 6.4mm API 5L GR.

BOct -2012

Oct-2015

TOTAL = 151.2



PAGE 94 OF 124



PAGE 95 OF 124

FLOW DIAGRAM FOR O&M RAMGARH

DT-Langtala

RT- RAMGARH (LRPL) 1/2



PAGE 96 OF 124

RT- RAMGARH (LRPL) 2/2

DT-DANDEWALA (DGRPL)



PAGE 97 OF 124



PAGE 98 OF 124

RT- RAMGARH (ONGC/OIL)-DGRPL

GAMNEWALA-TERMINAL(DGRPL)



PAGE 99 OF 124

Documents

INTEGRITY MANAGEMENT SYSTEM MANUAL- … · Web viewPipeline integrity management is a process for assessing and mitigating pipeline risks in order to reduce both the likelihood and