B. D.

Yadav
GM (Operations) IOCL- PL- HO

Demand Projections for Petroleum Products

(MMT)
180 160 160 140 120 100 80 60 40 20 0 2006-07 2009-10 * 2010-11 2011-12 2016-17 120 122 127 132

Source: Report of Working Group on P&NG Sector for the XI Plan

Year

Refining Scenario- India

(MMT)
350

302
300

250

235

200

149
150

100

70

50

1998-99

2006-07

2011-12

2016-17

(Actual)

Year
Source: Report of Working Group on P&NG Sector for the XI Plan

Supply Chain

Crude evaluation & Procurement ?

What and How to Feed ?

What & Where To Make ?

Demand Forecast ?

Distribution Planning ?

What & where to Store and from where ?

Pipelines

Railways

Modes of Product Transportation

Water Ways Road
5

Typical Mode-wise Transportation of Petroleum Products INDIA*

Rail 30% Road/ Coastal 31% Coastal
25%

USA**
Rail
3%

Road
4%

68%

Pipelines 39%
* Source : PPAC

Pipelines

** Source : Association of Oil Pipelines, 2006

http://www.aopl.org/posted/888/Shift_Report_1984_2004.126714.pdf

Pipeline System
Pipeline systems are the safest and the most environment friendly mode of transportation of crude petroleum, refined products and natural gas
Being a closed system, minimal handling and transit losses as compared to other means of transportation, hence most efficient Safety & Reliability minimum disruptions

Modes for Transportation of Petroleum A Comparison

Head Energy cost Operating cost Pollution Movement congestion Handling loss Safety Hazards Reliability Road Very High Very High High High High High Low Rail High High Low Low Low Low Low Pipeline Low Low Nil Nil Negligible Negligible 100%

Introduction of Pipelines in Oil Transportation

The first cross country oil pipeline was laid in Pennsylvania (USA) in 1879 from Bradford to Allen town, about 109 miles long and 6 in diameter

In India after 1960, most of the refineries were installed in land-locked locations and then crude / product pipelines were laid. During 1960-63, Oil India Limited laid the first trunk crude oil pipeline, 1156 km long from Naharkatiya and Moran oil fields to the refineries at Guwahati and Barauni
The first cross country product pipeline was laid by IOCL during 1962-64 to transport products from Guwahati refinery to Siliguri Pipeline industry has grown in parallel with the development of oil

Liquid Petroleum Pipeline Network Industry

(Length in km)

Company
IOCL
HPCL BPCL

Crude
4,366
11 -

Product
6,286
2,134 1,389

Total
10,652
2,145 1,389

GAIL
PIL OIL ONGC TOTAL

1193 6106 11,676

1,850
946 12,605

1,850
946 1193 6106 24,281

Figs as on 01.4.2010

Source: Petroleum & Planning Analysis Cell

Oil Pipelines
Jalandhar
Bhatinda Sangrur Panipat

Network in India
Ambala Roorkee Najibabad Meerut Delhi Loni Mathura Shahjahanpur

Rewari Sanganer Ajmer Jodhpur Chaksu Tundla Kanpur Kot Chittaurgarh Sidhpur Ahmedabad Kandla Ratlam Navagam Mundra Jamnagar Koyali Indore Vadinar Dahej Ankleshwar Hazira Mumbai High Manmad

Nahorkatiya Siliguri Bongaigaon Guwahati

Tinsukia

Lucknow Jagdishpur
Barauni Rajbandh Budge Maurigram Budge Haldia Paradip Vizag

Digboi Numaligarh

Mumbai Pune Secunderabad Uran Hazarwadi Pakni Vijayawada Mangalore Bangalore Chennai Sankari Karur Coimbatore Kochi Asanur Trichy Madurai

IOCs Pipelines (Existing) Product Crude Oil IOCs Pipelines (On-going) Product Crude Oil Other Companies Pipelines(Existing) Product Crude Oil LPG

11

Network of Gas Pipelines in India

NANGAL

BHATINDA DELHI

GURGAUN MATHANIA AGRA

BAREILLY AURAIYA LUCKNOW

JAGDISHPUR KANPUR

DISPUR PATNA GAYA

DAHEJ 10 mmtpa*
MUNDRA 6.5 mmtpa

BARMER GWALIOR

PHOOLPUR

KOTA
RAJKOT UJJAIN
AHMEDABAD

JHANSI VIJAYPUR BHOPAL

VARANASI

AGARTALA

LNG

BOKARO

Existing
KOLKATA CUTTACK

HAZIRA 2.5 mmtpa

BHARUCH BARODA SURAT

Upcoming
DAMRA BHUBANESHWAR

Transmission Pipelines
Existing GAILs Planned Pipeline RILs East West Pipeline RILs Planned Pipeline GSPCs Planned Pipeline

MUMBAI

PUNE
RAJAMUNDRY

KRISHNAPATNAM KAKINADA

DABHOL 5 mmtpa

SOLAPUR

KOLHAPUR GOA

HYDERABAD

VIJAYAWADA NELLORE HASAN

BANGLORE

CHENNAI

ENNORE 2.5 mmtpa

City Gas/ CNG

Existing Planned LNG Terminal

KANJIKKOD
COIMBTORE

TIRUCHCHIRAPALLI

KOCHI 5 mmtpa

TUTICORIN

Total Length = 11360 (Approx.) 12

Pipeline System
High Grade Steel Pipes (conforming to International Code API 5L) are used for constructing cross country Pipelines The typical sizes of the Pipes are as under:
Diameter - 4 inch 56 inch Pipe thickness - 0.219 inch 1 inch

Pipes are welded and inspected as per the most stringent international standards

Pipeline System
The flow in the pipeline is achieved using high

capacity pumps (liquid lines) & compressors (gas lines).

The normal flow in product pipeline is around

300-1000 KL/hr & for Crude Pipeline is around 1500-3400 KL/hr

The cross country pipelines are designed to

operate at very high pressures (upto 120 kg/cm2) to achieve throughput.

Pipeline System
To safeguard the Pipeline from external corrosion, the pipes are coated from the following type of materials
3LPE - Three Layer Polyethylene 3LPP - Three Layer Polypropylene DFBE - Dual Layer Fusion Bonded Epoxy Coal Tar Enamel

In addition to the anti-corrosion coating, the pipelines are also provided with custom designed Cathodic Protection systems

PIPELINE CONSTRUCTION

ROW Grading/Leveling

Trenching

PIPELINE CONSTRUCTION

Transportation of Pre-coated Pipes to Site

String of Pipes in ROW

PIPELINE CONSTRUCTION

Welding of Pipes in Progress

Joint after Welding

PIPELINE CONSTRUCTION

Coating of the Welded Joint

PIPELINE CONSTRUCTION

Lowering of the Pipeline

PIPELINE OPERATIONS

PIPELINE SYSTEM
CRUDE TRANSPORTATION
CRUDE OIL IN SHIPS OFFSHORE LINE OIL FIELDS

GATHERING STATION

JETTY/SPM SYSTEM
STORAGE TANKS UNDER BUOY HOSES

PUMPING UNITS
PIPELINE END MANIFOLD CROSS COUNTRY PIPELINE

DOCKLINES / OFFSHORE / ONSHORE PIPELINE

CRUDE OIL IN SHIPS

REFINERY TANKAGE

PUMPING STATION CUM TANK FARM

PIPELINE SYSTEM
PRODUCT TRANSPORTATION
REFINED PRODUCT FROM UNIT OF REFINERIES
REFINERYs PRODUCT TANKAGE IMPORTED / OTHER PRODUCT IN SHIP/OIL JETTY TANKAGES

PUMPING STATION

CROSS COUNTRY PIPELINE PUMPING CUM DELIVERY STATIONS

DELIVERY TERMINAL

Mathura - Jallandhar Pipeline

Delhi Pump cum delivery Station

Sonepat TPoint

Ambala PS/DS

Panipat PS/DS Mathura Pump station Meerut Terminal

Jallandhar Terminal

Product Pipeline Pump cum Delivery Station

28

Mainline pumping units

29

Typical Terminal Station

Madurai Terminal

Asanur TPoint

Chennai Pump station Sankari Terminal

Trichy Terminal

Interface Management
In multi-product pipelines, different products are
Product-A

pumped one after the other in a particular

sequence. This leads to generation of a mixture where two products meet. This mixture is called interface

Mixture volume

Interface generation is dependent on factors like

Pipeline diameter, velocity of the flow, topography of the land, turbulent flow conditions and the type of products

Product-B

LENGTH OF INTERFACE
The pipeline can not be operated precisely unless the length or the volume of the interface and its location can be known at any given time, once the length of interface is determined, it is easy to calculate its volume from line fill
The length of interface is given by the following formula. C = 11.75(D)0.5 (L)0.5 (Re)-0.1 where, C = length of interface (ft.) D = Inside diameter (ft.) L = distance of travel (ft.) Re =Reynolds number of 50 : 50 mixture The interface has to be absorbed by one of the products without affecting its quality. This necessitates product sequencing and batch

lenths based on product characteristics.

Requirement of Batch Scheduling

Meeting Product demand in market To match /balance production at Refinery and supply demand at ToPs including tankages capacity Avoiding/Minimizing Tanker demurrage Optimizing Pipeline Operating Cost (-Less consumption of power & fuel) How much --- Where ----- When

33

Cost Recovery in Pipelines

Earlier pipelines were operated under Administrated Price Mechanism (APM) and were re-imbursed based on cost plus formula

Presently pipeline tariff is fixed at 75% of railway freight

In future Petroleum & Natural Gas Regulatory Board (PNGRB) will fix tariff of individual pipeline based on common carrier principle

35

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