2017

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ANNUAL REPORT: 2016-17 PIPELINE DEPARTMENT

Commissioned in 1962, the 1157 KM long fully automated crude oil pipeline is the lifeline of

OIL. Along with an additional network of 63 Km, OIL Pipelines operates a total network of

1220 Km of Crude Oil Pipelines. At present the main pipeline has two segments, one

segment of 401 km, 406 mm (16”) with built in capacity of 5.38 MMTPA for NE crude oil,

both from OIL and ONGCL. The second segment of 756 km, 356 mm (14”) has a built in

capacity of 3.0 MMTPA in the reverse direction from Barauni to Bongaigaon. In addition to

above, 0.65 MMTPA of OIL’s crude is transported from Duliajan field to Digboi refinery

through 200 mm diameter 30 km long pipeline. The system has a network of 11 crude oil

pumping stations and 18 repeater stations.

This 5.38 MMTPA capacity pipeline transports crude oil produced from oilfields in Upper

Assam to the public sector refineries at Numaligarh, Guwahati and Bongaigaon. The pipeline

runs through the states of Assam, West Bengal and Bihar traversing hostile terrain, dense

forests and cuts across 78 rivers including the mighty Brahmaputra.

The 600 KM pipeline segment between Bongaigaon and Barauni has been re-engineered to

enable oil flow in either direction and is now transporting imported crude from Barauni to

Bongaigaon.

A 660 km long 406 mm diameter cross country Pipeline was constructed by Oil India Limited

for evacuation of 1.72 MMTPA of products from Numaligarh Refinery in Assam to Siliguri

terminal in west Bengal at a project cost of Rs. 469 crores.

The department has carried out various activities during the year to achieve its desired goal

and few of them are summarised below:

i) Round the clock operation and maintenance of crude oil Pipeline Operation including

support services like electrical, telecommunication, instrumentation etc.

ii) Round the clock operation and maintenance of product pipeline to evacuate product

from Numaligarh Refinery to Marketing terminal at Rangapani.

iii) Customer satisfaction through timely delivery of crude oil under strict quality control

and also product delivery.

iv) Compliance of all statutory, safety rules and practices, implementation of new safety

recommendations made by relevant bodies.

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v) Liaison with external bodies like IOCL, NRL, CCoE, PESO, Oil Industry Safety Directorate

(OISD), authorities for implementation of Factories Act, State Administration of Assam,

West Bengal and Bihar etc.

vi) Training of students from Engineering Colleges, Institutes & Universities, Apprentice

trainees etc. and training of own employees through internal trainers.

vii) Periodic medical examination of all the employees of the department as per schedule.

viii) The ISO/ OHSAS certification under ISO9001, ISO14001: and OHSAS 18001 which was

valid up to 03.09.2016 was revalidated/re-certified by M/s BV, Kolkata. Now ISO 9001

& ISO 14001 is valid up to 14.09.2018 and OHSAS 18001 is valid up to 03.09.2019

II. PIPELINE OPERATIONS, UPLIFTMENT AND DELIVERY:

During the period overview, OIL’s Crude Oil Pipeline transported a total of 6.56 MMT

out of which Naharkatia-Bongaingaon sector transported 3.21 MMT of OIL crude and

0.94 MMT of ONGC crude. Barauni-Bongaigaon sector transported 2.41 MMT of

Imported Crude.

We have transported 1.78MMT of products through NSPL with Pipeline utilization

103.42%

The total deliveries of OIL & ONGC crude oil vis-à-vis off take are given below:

OFF TAKE

(in tonnes)

Delivery to

Refineries in

tonnes

Crude oil consumed

by pump engines &

generators

(in Pump-stations)

Percentage of

Achievement

OIL + JVC 3262761 3244544 3060 `99.44

ONGC 930856 939741 - 100.95

TOTAL 4193617 4184285 3060 99.78

The total IMPORTED crude oil delivery vis-à-vis off take is shown below:

Offtake of

Imported crude

oil at Barauni

(Wet tonnes)

Delivery of

Imported crude

oil at BRPL

(wet tonnes)

Line stock of

Imported crude

oil in the line

(tonnes)

Crude oil

consumed in the

pump stations

(tonnes)

Percentage

of

achievements

%

2407349 2398468 45663 4493 99.63

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The deliveries to the four refineries against yearly allocation are given below:

REFINERIES/

CAPACITY

ACTUAL DELIVERY

(TONNES)

MoPNG

Allocation

MMT (16-

17)

%AGE OF

ACHIEVEMENT

(wrt MoPNG)

OCC

Allocation

MMT

(2016-17)

%Age of

Achievement

(w.r.t. OCC)

DIGBOI

0.65 MMT

EX/PL:479709

D/FLD+JVC: 49263

TOTAL: 528972

0.643 82.27 0.489 108.17

NRL

3.00 MMT

OIL: 2044006

ONGC: 706587

TOTAL: 2750593

2.968 92.67 2.769 99.34

GUWAHATI

1.MMT

OIL: 620957

ONGC: 232139

TOTAL: 835479

0.989 84.48 0.806 103.66

BONGAIGAON

0.497 MMT

(Assam Crude)

OIL: 50611

ONGC: 18632

TOTAL: 69243

NIL N/A 0.24

288.51

Delivery to Numaligarh, Bongaigoan and Digboi Refinery was less than the allocation

due non-availability of sufficient crude.

RECONCILIATION DIFFERENCE:

The reconciliation difference in the main line and the Duliajan-Digboi line for the

period 2015-16 to 2016-17 is given below:

YEAR MAIN LINE

DLJ-DIG 8” DEL/DIFF OIL (Ton) ONGC (Ton) TOTAL (Ton)

2015-16

Del 2687411 930048 3617459 511822

Diff 10804 3720 14524 4549

%Diff 0.40 0.40 0.40 0.88

2016-17

Del 2715572 939741 3655313 479709

Diff 6788 2349 9138 222

%Diff 0.25 0.25 0.25 0.046

Delivered quantity of OIL & ONGCL crude and transported quantity of IMPORTED

crude are comparatively shown below:

DESCRIPTION OF SERVICE

2011-12

(MMT)

2012-13

(MMT)

2013-14

(MMT)

2014-15

(MMT)

2015-16

(MMT)

2016-17

(MMT)

OIL CRUDE

DELLIVERED 3.80 3.62 3.42 3.40 3.20

3.20

ONGC CRUDE

DELLIVERED 1.19 1.18 1.20 1.08 0.93

0.94

IMP. CRUDE

TRANSPORTED 1.64 1.52 1.96 2.33 2.23

2.41

TOTAL 6.63 6.32 6.58 6.81 6.36 6.55

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PIPELINE STOCK:

The inventory of crude oil in the pipeline at 0700 hrs on 01/04/2017 was 39245

tonnes of OIL crude out of which 1003 tones was in the DIGBOI line. The total ONGC

stock with OIL is 19072 tones. The total line stock of imported crude oil in the 14”

sector is 45663 tonnes.

NSPL:

The NSPL line operated smoothly during the period. Below product wise quantities

dispatch from Numaligarh and Received at Rangapani Terminal are shown.

Despatch from Receipt at

Numaligarh Rangapani Terminal

MS 03 287684 306823

SKO 01 61261 48072

HSD 03 880835 926453

HSD 04 427309 390466

MS 04 115621 109723

HSD 02 8048 -

TOTAL 1780758 1781537

III. ACHIEVEMENTS AND HIGHLIGHTS:

The department earned revenue of about Rs. 367.67 crores during the financial

year from Crude Oil and Product transportation.

Out of 605 Nos. of safety recommendation given by OISD through their external

safety audits, so far 495 Nos. of recommendations have been completed. The

percentage of completion at the end of the year was 81.82%.

Monthly departmental safety meetings, monthly central safety meetings, annual

internal safety inspection of pump and repeater stations, tool box meetings, pit

level safety meetings, weekly fire drill in Pipeline department etc. were regularly

carried out with adequate attention to safety standard upgradation.

IV. MAINTENANCE:

A: Mechanical:

During the year under review, the plant and machineries in all the Pump & Repeater

stations along the Pipeline were maintained in good running condition, and

uninterrupted pumping operation was maintained achieving 100% of the MOU

target of Crude delivery. The Preventive Maintenance schedules of the pumping and

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generating units were carried out as per plan as per availability of the units.

The overall achievement as against planned targets for scheduled maintenance of

pumping and generating units of all the three bases is as follows:

ALLEN-ALDRICH Pumping units: 115.56%

ALLEN alternator units: 88.46 %

DG set at repeater stations: 103.45 %

B: Telecom:

Telecommunication:

Average Link Availability OFC System: 99.76 %

Instrumentation:

16" Sector Instrumentation Availability: 99.31 %

14" Sector Instrumentation Availability: 99.84 %

NSPL Instrumentation Availability: 99.60 %

Telemetry:

16 inch Sector Telemetry Availability: 99.15 %

14 inch Sector Telemetry Availability: 96.88 %

NSPL Telemetry Availability: 98.78 %

C: Electrical:

Power Availability: The power supply to various installations was monitored

throughout the year. As a result over 99.8 % of power availability was maintained for

all the pump stations and over 98% for repeater stations below.

V. PROJECT JOBS:

A. TENGAKHAT-SHALMARI PIPELINE (TSPL):

Electronic Geometry Pigging (EGP) of TSPL Pipeline from Tengakhat PS to

Fetengbor (Shalmari) hook up point carried out successfully on 07.03.2015.

Preliminary report submitted reveals no reductions observed above 5% of pipe

ID during survey.

B. UP-GRADATION PROJECTS:

During the year 2016-17, the Pipeline Project section was primarily engaged for

managing 3 projects namely

UP-GRADATION OF PUMP STATIONS/TERMINALS (Phase I)

UP-GRADATION OF PUMP STATIONS/TERMINALS (Phase II)

PIPELINE REHABILITATION PROJECT (Phase I).

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The status of project activities being undertaken by Project section are given

below

UGPS (Phase-I)

Project Scope: Up-gradation Project for replacement and optimization of

eight (08) Pumping Stations and all Receipt Terminals including replacement of

50 years old Mainline Pumping units along with Engine drives and auxiliary

equipment’s.

Consultant: Engineers India Limited (EIL)

EIL Scope of Work: Engineering, Procurement, Tendering, Construction,

Management and Commissioning assistance

Date of Award: 14.12.2012

Project cost: Rs. 1200.00 Crore

Project key date:

- Effective start date: 14.12.2012

- Revised Schedule for Mechanical completion: 31.08.2015

- Revised schedule for Commissioning: 31.05.2017

Revised schedule for Project closure: 31.08.2017

Time elapsed: 51 ½ Months

Overall progress: 63.8%

C. DIGITIZED MAP OF TOWNSHIP:

For preparation of concept master plan of PHQ Township through School of

Planning and Architecture (SPA) the topographical survey of the township was

carried out by latest technology. A digitized map of the township has been

prepared on the basis of actual coordinate in reference to Survey on India and

Satellite data. With the help of this map one can easily find out the existing

properties, services, different facilities, installation, fire hydrant line, piping

network, electrical layout, contour lines etc. for planning and other development

purpose.

D. K.D. MALAVIYA NATIONAL OIL MUSEUM, GUWAHATI:

To showcase the involvement oil industry, an OIL Museum project at Guwahati is

being coordinated by Civil Engineering Section of PHQ. At this inception stage

liaising with the different PSUs of Petroleum Industries is being done for

preparing the detailed project report with the help of National Council of

Science Museums (NCSM).

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E. HOOK-UP OF MICRO-TUNNEL SECTIONS:

Haruaputa-Sankosh- Hookup (PLKM 629-632):

Diversion of Crude oil pipeline from the railway bridges to submerged mode by

laying approximately 4.2 km length of pipeline and Hook up with Micro-

Tunneling sections. Approximately 2000 m pipe laying was completed in July

2013 and 1200 m pipe laying completed in Jan 2015 (700 m in Assam side and

500 m in Bengal side). Laying of the remaining 1000 m pipeline and the hook-up

job could not be completed on schedule due to non-clearance of RoU land.

F. HDD IN 10 RIVER CROSSINGS:

GOURANG River HDD (PLKM- 590):

Diversion of Crude oil pipeline from suspension crossing to underground mode

by HDD: Out of 1300 m new pipeline construction, fabrication and hydro-testing

of HDD string and railway track crossing string as well as fabrication of 450 m

string for normal terrain completed. Wrapping/coating of 350 m length in D/S

site with cold applied tape completed and lowered. Fabrication and hydro-test of

the 350m HDD segment completed; fabrication and coating of 100m Segment for

normal terrain completed in June 2015. Pilot boring started on 10.12.2016.

Pulling of 438 m of 3LPE pipe completed on 29.12.2016. Boring under railway

track started on 23.01.2017. PRs has been processed for HDD jobs for river

locations, namely, MAHANANDA-I, MAHANANDA-II, KOSI, BURIGANDHAK,

BURIDIHING & DHANSIRI. Work commencement is expected during the financial

year 2017-18

Status of Remaining 8 River Locations:

Necessary permissions from River Body authorities of Assam, West Bengal Bihar

as well as from NF Railway and East Central Railway obtained. Procurement of

land except river Donk completed.

G. 65 KM COATING REBURBISHMENT UNDER SR BUDGET:

● 15 km coating refurbishment: Starting date as per Work Order is 6.03.2015.

Total coating refurbishment done as on 31.03.2017 is 7837.87 meter.

50 km coating refurbishment: Starting date as per Work Order is 1.11.2015.

Total Coating refurbishment done as on 31.03.2017 is 45232.6 meter

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VI. TECHNOLOGY UP-GRADATION:

Post-Earthquake study of storage tanks: Chief Scientist, CMERI, Durgapur

visited PS3 on 28.06.2015 for preliminary seismic study of the and delivered one

presentation on seismic excitation of storage tanks on 02.07.2015 at PHQ. LOA

has been issued to CMERI for Post-Earthquake study of storage tanks from PS-3

to PS-5 in Phase-I as per directives of Ministry of Petroleum and Natural Gas,

Govt. of India.

Mutual aid agreement has been signed between OIL Pipeline Department;

IOCL, Guwahati Refinery and NRL on 00.03.2017. This will cover Pipeline and

its Installations from PS3 to PS6.

After prolonged study and trial through field use, Butyle rubber Polyethylene

cold applied tape has been inducted as the coating material for pipeline and Coal

Tar Enamel has been phased out. Coating refurbishment with Cold applied tape

and visco-elastic material carried out at different locations.

New methodology for strengthening of the live pipeline by application of cold

applied composite material has been inducted.

New state-of-the art insulating flange joint kit has been inducted and effectively

applied in repairing shorted insulating flanges.

Digitized MAP of Township:

For preparation of concept master plan of PHQ Township through School of

Planning and Architecture (SPA) the topographical survey of the township was

carried out by latest technology.

Establishment of GIS based pipeline assets management system:

With an objective for better management of OIL’s Pipeline asset from Duliajan to

Barauni, it was decided to develop a Geographic Information System (GIS) based

asset management by preparation of a Pipeline base map encompassing the

entire RoW of OIL with Geo-referencing and overlaying the pipeline asset details

over the map so that the entire network could be viewed and managed

efficiently on one platform. The system should also be able to track the line

walkers with the help of Global Positioning System (GPS).

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VII. GENERATION, CONSUMPTION AND SALE OF ELECTRICITY:

Power Generation:

A total of 8257570 KWh of energy was generated in the Pump Stations and Repeater

Stations along the pipeline.

LOCATION 2014 - 15 2015 - 16 2016-17

Pump Stations 7,848,394 7,581,250 7,783,713

Repeater Stations 517199 501,155 473,857

TOTAL(KWh) 8,365,593 8,082,405 8257570

Energy Consumption

The power consumption in all the installations in the last three years is shown below

LOCATION 2014- 15 2015- 16 2016 – 17

Pump Stations 16,813,172 16,1,79,907 16,670,605

Repeater Stations 545,519 515,315 473,857

TOTAL(KWH) 17,358,691 16,695,222 17,144,462

Power Sale to other Organization:

The total units of power supplied to other organizations in the FY 2016-17

amounted to 47,553 KWh. Organization wise break-up for the last three years is

shown in the following table.

ORGANISATION LOCATION 2014 – 15 2015 - 16 2016 – 17

ONGC PS-3 10,775 15660 `13604

IOC PS-7 12,891 14969 15118

Contractors PS-5 -- 351 4715

Contractors PS-8 -- 58,389 27720

TOTAL(KWH) 23,666 89,369 47,553

VIII. Highlights of Cathodic Protection Jobs:

Pipeline 65 Km refurbishment work (PS9-RS16 & RS4-RS5) - Carried out Holiday

testing of the 2ply/3ply Tape coating work and installation of 1 Km TLPs.

ON-OFF PSP survey of all pipelines in OIL ROW/ROU is carried out

CAT survey of mainline from PS1 to PS5 carried out

CIPL survey of NSPL between NDT-RS3, RS5-PS5 and RS9-508.4km carried out.

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NEW PROJECTS AND INFRASTRUCTURE

20KWp PV Solar Power Plant at RS-14, Kishanganj:

20KWp P V Solar Power Plant has been installed & commissioned at RS-14,

Kishanganj on 27th May, 2015 as another achievement in the field of renewable

energy by Pipeline Department of Oil India Limited. In addition to the above, RS-8,

RS-10, RS-11, RS-15 & RS-16 is being taken up for installation of Solar Power Plants of

20 KW capacity each.

ENERGY CONSERVATION AND ENVIRONMENTAL PROTECTION MEASURES

Measures adopted

Efficient maintenance & operation of 20 KWp Solar PV Power Plants installed &

commissioned at RS-5 (Jagiroad) & RS-14 (Kishanganj) is considered as a major

step towards use of renewable energy, thereby serving the cause of energy

conservation.

Replaced high energy consuming street light fitting with energy efficient &

environment friendly 25W LED light which results not only in better illumination

but also saves energy considerably & helps protecting the environment. It helps

saving energy up to 6789 units.

Replacing old electromechanical/hybrid type energy meters with new technology

digital multi-function meter. Replacing existing BC lamps, damaged 20W/40W

tube light fittings with CFL of 9W& 15W results in savings of energy up to 25754

units.

Installation of 5 KWp Solar PV system for RS-6 & RS-7(BG Hills) replacing Diesel

generator is under progress (technical scrutiny completed) and once implemented

it will save considerable amount of energy as well as help protecting the

environment.

Installation & commissioning of 20KWp Solar PV system in 5 nos. repeater station

is in progress. (materials received at RS-8, Dhramapur & others are in transit)

Impact on Energy Consumption

Efficient operation of the solar plants at RS-5 (Jagiroad) & RS-14 (Kishanganj) has led

to a total HSD Fuel savings of 34 KL (appx.) which is equivalent to ₹28,40,229/- in

monetary terms.

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Contribution to Environmental Protection

By employment of solar energy, it has been possible to reduce the carbon footprint

under CDM (Clean Development Mechanism) with avoidance of good amount of CO2

(approximately 86 Tons). This type of clean energy project will help in achieving

carbon credits by OIL.

IX. ORGANIZATION:

The executive manpower strength of the department as on 31.03.2017 is as follows:

Board sanction : 157 (+12 against manning of MB Lal &

UGPS project)

Permanent Executive : 139 (Including 3 ET’s)

The work person manpower strength of the department as on 31.03.2017 is as

follows:

Sanctioned Strength (PL) : 470

Existing employees against sanctioned strength : 274

Separations during the year 2016-17:

X. TRAINING/ SEMINAR:

Diploma Holders, sponsored by Directorate of Technical Education and Trade

Apprentices had undergone training at PHQ during the year as follows:

Diploma Apprentices : 10

Trade Apprentices : 17

Students were imparted Training, in Both Summer and Winter Season:

Mechanical Stream : 78

Electronics, Telecom and Instrumentation Stream : 37

Electrical Stream : 0

HR Stream : 10

Civil Engineering Stream : 14

Moreover, 21 Company Employees attended various Training Programmes, both In-House and In-Country. On the Executive front, 52 Executives attended In-Country Training Programmes, In-House Programmes and 8 executives attended overseas training.

No of executives retired 07

No of additional executives retired 02

No of executives expired -

No of executive resigned 01

No of ETs resigned 01

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XI. PROMOTION A total number of 22 executives have been promoted in Pipeline Department during the above period. ET s inducted in Grade B as probationary Officers: 3 Joining: 03

Transfer: 29 XII. AWARDS & PAPERS PUBLISHED:

● सितम्‍फय,‍ 2016‍िे‍ 30‍ सितम्‍फय,‍ 2016‍तक‍ विसबन्‍न‍्रतितमगिततओं ‍ के‍िओ ‍ िनन्‍ ी भओन‍िभओयगन‍कओ‍िपरतओ‍ऩिूवक‍आमगजन‍ककमओ‍तमओ‍।‍ऩओइऩरओइन‍भखु्‍मओरम,‍तिुओनओटी‍के‍िओ -िओ ‍ऩ ऩ‍स्‍टेशन न‍न ‍3‍जगयनओट‍एि ‍ऩ ऩ‍स्‍टेशन न‍‍न ‍8‍िगनओऩयु‍भें‍बी‍िनन्‍ ी‍भओन‍के‍ ौयओन‍कओमवक्रभों‍कओ‍आमगजन‍ककमओ‍तमओ‍।‍

● सितभ ‍‍फय,‍ 2016‍कग‍ ऩओइऩरओइन‍भखु्‍मओरम,‍ रईुतऩओय‍ क्‍रफ‍ ‍िबओतओय‍ भें‍ ‍ ‘’राजभाषा हिन् दी र का ा ति‍ ’’ शन ीर्वक‍ ऩय‍ यओजबओर्ओ‍ ि तगष्‍ठी‍ कओ‍आमगजन‍ ककमओ‍ तमओ‍ ।‍ तिुओनओटी‍नतय‍यओजबओर्ओ‍कओमओवन्‍िमन‍िसभित‍(उऩक्रभ)‍द्िओयओ‍यओजबओर्ओ‍भें‍उत्‍कृष्‍ट‍्रत शन वन‍नेत‍ुऩओइऩरओइन‍भखु्‍मओरम‍कग‍16‍ि िम्‍फय,‍2016‍कग‍्रतशन स्स्त‍ऩत्र‍्रत ओन‍ककमओ‍तमओ‍।‍ ऑमर‍ ्रतफ धन‍ सुरमओजओन‍ द्िओयओ‍ ऩओइऩरओइन‍ भखु्‍मओरम‍ कग‍ यओजबओर्ओ‍ िनन्‍ ी‍ के‍कओमओवन्‍िमन‍भें‍ ककम‍ेतमे‍ििवशे्रष्‍ठ‍्रत शन वन‍ नेत‍ु30‍सितम्‍फय‍2016‍कग‍्रत भ‍यओजबओर्ओ‍शन ील्‍ड‍ िे‍ निओजओ‍ तमओ।‍ विि त‍ नग‍ ऩओइऩरओइन‍ भखु्‍मओरम‍कग‍ िनयन्‍तय‍ 13िी ‍ फओय‍ मन‍शन ील्‍ड‍्रतओप्‍त‍नुआ‍।

XIII ACKOWLEDGEMENT I offer my sincere thanks and appreciation to all the Executives, Employees and other personnel of Pipeline Department for their invaluable contribution towards the smooth functioning of the department. On behalf of the OIL management I offer my heartfelt appreciation for their active cooperation in achieving the high standard of operation, maintenance and successful completion of all the on- going projects, in a safe and environment friendly manner. I also take this opportunity to acknowledge humbly the encouragement and guidance received from Chairman and Managing Director and all the other functional directors of OIL as well as support from Field Headquarters Duliajan which had greatly contributed to our achievements during the year. I also thank all the Sections for submitting their Annual Reports on time and also to the Planning and Coordinating Section for compiling and presenting it in such a Comprehensive manner.

(B. K. Mishra) General Manager (Pipeline Services)