National and Cross border pipelines:

Progress and Challenges

127th April 2016

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Natural Gas Scenario in India*

The estimated reserves of natural gas in India is around 1400 billion

cubic meters (BCM).

The Gross Production of Natural Gas in India during 2015-16 is 32,249

MMSCM.

Total LNG Import in India is 18,535 MMSCM during 2014-15.

Total NG Consumption during 2014-15 was around 51.23 BCM.

Import dependency during 2014-15 was around 36%.

* Source: Snapshot of India’s Oil and Gas Data of PPAC

Pipeline Transportation

• Uninterrupted Fuel – 365 days – 24 / 7 supply

• Supply over a long distance covering miles

• Door Delivery

• No Storage

• Minimal Pollution in transportation

• Safe Handling

• No Logistics

Advantages of Pipeline Transportation

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Existing Natural Gas Pipeline Network Strength

Sr No. Transporter Length (in KM) Capacity(MMSCM)

(% share)

1 GAIL 11077 206 68.95%

2 RGTIL 1469 80 9.14%

3 GSPL 2355 43 14.66%

4 AGCL/OIL/DNPL 1000 6 6.23%

5 IOCL 140 9.5 0.87%

6 ONGC 24 6 0.15%

Total 16065 350.50 100%

* Snapshot of India’s Oil and Gas Data of PPAC

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Pipeline Projects under Construction

NETWORK/REGION Entity Length in Kms Design Capacity (mmscmd)

Kochi - Kottanad - Bangalure - Mangalore GAIL(India) Ltd. 1104.00 16.00

Surat - Paradip* GAIL(India) Ltd. 2112.00 76.81

Jagdishpur- Haldia (Phase-1 (755 KM), 7.44 MMSCMD capacity

GAIL(India) Ltd. 1860.00 32.00

Mallavaram - Bhilwada GSPL India Transco Ltd. 2035.00 78.25

Mehsana - Bhatinda GSPL India Gasnet Ltd. 2052.00 77.11

Bhatinda -Srinagar GSPL India Gasnet Ltd. 725.00 42.42

Kakinada - Srikakulam A P Gas Distribution Corporation 391.00 90.00

Total 10279.00

* Snapshot of India’s Oil and Gas Data of PPAC

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Cross Country Pipeline Project: TAPI

It is proposed to lay a 56-inch diameter 1800

KM pipeline with design capacity of 90

MMSCMD of natural gas.

Construction on the project started in

Turkmenistan on 13 December 2015. The

pipeline is expected to be operational by

2019.

The Turkmenistan–Afghanistan–Pakistan–India Pipeline (TAPI), also known as

Trans-Afghanistan Pipeline, is a natural gas pipeline from Turkmenistan to India.

The pipeline will transport Caspian Sea natural gas.

GAIL’s PRESENCE IN INDIA

Operating around 11,000 Km of Natural Gas

Pipeline having capacity of about 206

MMSCMD.

Also operating around 2000 KM of LPG

pipelines having capacity of about 3.8

MMTPA.

Having stake in RGPPL with installed capacity

of around 2000 MW and also having installed

capacity in renewable energy sector (Solar &

Wind Power ) of more than 125 MW .

GAIL ( India ) Limited, the youngest Maharatna of India

GAIL’s PRESENCE IN INDIA

Having operational Petrochemical production

capacity of more than 400,000 TPA which is

recently expanded to more than 800,000 TPA.

Having participation in 30 E & P BLOCKS,

including two overseas blocks (Myanmar &

Shale Gas in USA).

Involved in LNG business through JV in

Petronet LNG (17.5 MMTPA) and RGPPL

Dhabol Terminal (5 MMTPA).

Operating City Gas Networks & CNG Stations,

through GAIL GAS Ltd & JVs across country.

GAIL ( India ) Limited, the youngest Maharatna of India

GAIL’s PIPELINE NETWORK

COMMON CARRIER+DEDICATED

SN NETWORK/REGION LENGTH IN KM

1 HVJ-GREP-DVPL 4658

2 GREP DVPL Upgradation 1119

3 DUPL-DPPL 875

4 TRIPURA 61

5 GUJARAT 671

6 MUMBAI 129

7 KG BASIN 881

8 CAUVERY BASIN 278

9 ASSAM 8

10 CJHPL 265

11 DBNPL 835

12 DHABOL-BANGALORE PIPELINE 1097

13 KKBMPL 41

14 JAISELMER REGION 151

GRAND TOTAL(NATURAL GAS PIPELINES) 11070

COMMON CARRIER

11 JAMNAGAR - LONI PIPELINE 1414

12 VIZAG - SECUND. PIPELINE 618

DEDICATED PIPELINES

13 GPU VIJAIPUR TO IOCL PLANT 4

14 GPU GANDHAR TO IOCL PLANT 2

GRAND TOTAL(LPG PIPELINES) 2038

13107

OPERATIONAL NATURAL GAS PIPELINES

OPERATIONAL LPG PIPELINES

Phases - Pipeline Project

Project

Conceptualization/ 1st

Stage Clearance

Investment

Approval

RoU, Statutory Permission, Permanent

Land Acquisition (12 M)

Basic / Detail Engineering (12 M)

Detail

Survey

(6 M)

Tendering / Ordering (9 M)

Manufacturing/Delivery (12 M)

Construction,

Commissioning (9 M)

Closeout

Typical timeline for 36-42 month project

3 M

9 M

Phases-Pipeline Projects

1. Ministry / Marketing Requirement/ Strategic Requirement

2. Identification of Gas Supply, Demand through market survey

3. Pre-Feasibility Study either In House / Consultant incorporating

4. Bidding Route (P&NGRB Guidelines)

5. Review of Proposal

6. Management approval for Pre-Project Activities.

Project Conceptualization & Initial Clearances

ROU and Land AcquisitionReconnaissance Survey, Detailed Engineering & PDI Survey, Soil Investigation ,

Corrosion & Cadastral Survey

• 6(i) Gazette notification though MOP&NG

• Hearing of Objection after minimum 21 days notice

ROU Acquisition

Permanent Land Acquisition

• Plot Identification

• Submission of proposal to concerned authority for acquisition & Publication of 4(i)

gazette notification.

• Notice Servicing , Hearing of Objection & 6(i) Gazette notification.

• Declaration of award & Possession & Registration of land.

Obstacle Crossings are identified during detail engineering survey & incorporates the

permission for the following crossings:

• Railways

• Roads : NH/SH/Other Roads

• Water bodies: Canal/ River/ Nalas etc.

• Forest : Protected/ Reserve/Social

• Sensitive areas like Wild Life Sanctuary / National Parks

• Defense area

• Foreign Pipeline

• Other types of crossings

Obstacle Crossing Permission

NoC is required to be obtained from respective State Pollution Control Boards as per

the requirement of EPA 1986. The steps involved are:

NoC from SPCB (04-06 month)

i. Submission of application to SPCB

ii. Public Hearing at each district

iii. Recommendation by district authorities based on the minutes of public hearing

iv. Issue of NoC

MoE&F Clearance(03-04 month)

Submission of application to MoE&F along with SPCB NoCs

i. Expert Committee meeting & presentation

ii. Issue of MoE&F Clearance

Required NoCs

i. Hiring of Project Management Consultant (PMC)

ii. Hiring of Third Party Inspection Agency (TPIA)

iii. Finalization of Project Schedule WBS wise

iv. Basic Engineering, Design Basis & Detail Engineering

v. Preparation of Specifications, Material Requisition & Tender Document

vi. Tendering & Ordering for all procurement & works package

vii. Manufacturing, Inspection & Delivery for all ordered items

viii. Setting up of Infrastructure for pipeline construction:Camps/Vehicles/Communication facilities etc.

ix. Deployment of Construction Manpower

x. Construction & Commissioning

Execution Stages

1. RoU Handing Over (Panchnama)

2. Grading

3. Stringing

4. Trenching

5. Welding (mainline, crossing / tie-in)

6. Inspection ( NDT/ UT/ X-ray)

7. Joint Coating

8. Concrete Coating

9. Lowering

10. Tie-In Joints

11. HDPE Duct Laying

12. Backfilling & Warning Mat

13. Crossings

14. TCP

15. Hydrotesting

16. Dewatering

17. Pigging (Foam, Gauge,

Magnetic & EGP)

18. Drying & Inertization

19. Gas-In

20. Restoration.

21. Terminal Construction.

22. Installation of GAS Metering

system.

23. Installation of Mechanical

Equipments / Telecom / SCADA

.

Pipeline Construction Stages

• Political risk.

• Socio-economical risk

• Technical risk

• Organizational risk

• Natural catastrophic risk

• Financial risk (investment risk)

• Safety and security risk

• Environment risk

Prospective Risks

Risk Analysis

• Selection of Technologies.

• Managing Schedule

• Route Survey

• Statutory Permissions

• Tendering & Award of Contract.

• Timely Procurement of high Values items- line pipe, valves etc.

• Analysis of Risk.

• ROU Opening & Permanent Land Acquisitions.

• Constructions Aspects

Major Challenges in Construction phase

Major Challenges in Operational Phase1. Asset Management

Health Monitoring of Assets

Regular Monitoring of Parameters

Pipeline Inspection and Defect Assessment

Integrity of Non-Piggable Pipelines

RoU Monitoring

Harsh Terrain

Pipeline Exposure and Leakages

Encroachment

Corrosion Management

a) Gas Source Quality Monitoring

b) Cathodic Protection System

c) Corrosion Rate Assessment

2. Stakeholder Management : Customer Satisfaction, Compliance of statutory norms, Boundary

Management, Supply –Chain Coordination.

Strategy

Strategy

Advocacy for Policy Changes

Culture Change

Aligning with Global

Practices

Improving Contract

Management

Integrate Technology

& SafetyCompetence

Building

Focus Areas for Functional Excellence

SOMES (TEA)

Safety

Efficient Operation

Best Maintenance Practices

Environment Management

Stakeholder Management

Adopting state of art Technology

Education and Learning

Award and Appreciation

Smart Safety and Asset Management GIS Mapping of Pan India Pipeline Network

GAIL has taken an initiative to map its entire

pipeline network through GIS MAPPING

PROJECT.

The coverage of the Project is:• Capturing pipeline alignment & features in GIS database

• Capturing station boundaries & details of plants & stations

• Population density survey (200 m either side of ROU)

• Measurement Depth of cover (250 m interval & TP

correlated

with MSL for plotting pipeline profile).

• Collection / Conversion of Cadastral maps & data

• Development of web based solution for GIS maps & data

• Facility Management & Support Services (24 months)

Smart Safety and Asset Management

Integration of all pipeline Integrity assessment data in a common database and its

analysis

CPIMS is a GIS enabled computer application to maintain, align and analyses

various pipeline integrity survey with ability to facilitate risk assessment.

It is suite of different modules such as Feature Assessment module, Cathodic

protection module, Risk Assessment module etc.

GIS Based - Pipeline Integrity Management System (PIMS)

Smart Operation and MaintenanceMOBILE BASED APPLICATION

GAIL has developed a mobile based application software.

This facilitates accessibility of ready data based for pipeline parameters covering

more than 40 attributes from any location through GSM mobile having GPRS.

It provide live Data for pipelines and compressor, Generation of Work Permit as

well as enable the officer at site the Updation of Maintenance Data in SAP

Platform

Information Data Bank on major maintenance activities Enabling Maintenance Information through Mobile

Process MonitoringNATIONAL GAS MANAGEMENT CENTRE & RGMC

National Gas Management Centre (NGMC), state of art control system,

monitors all critical parameters/operations of the pipeline through an on-line

SCADA system

It monitors Real time data of all Pipeline

Parameters, Supply and Delivery

Conditions at all Sources and Major

Customer terminals through SCADA.

NGMC Coordinates with Regional Gas

Management Centers to handle any

upset in the process.

It acts as a Nodal center for crisis

management of GAIL installations.

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• Health assessment and integrity Audits for all Natural Gas and LPG pipelines

was concluded through reputed independent third party having expertise in

the field of corrosion, Inline Inspection, Cathodic Protection.

• In-line-inspection (Intelligent Pigging) programs are one of the most effective

means of obtaining data that can be used as a fundamental base for an

Integrity Management Program.

• GAIL has adopted the practice of mapping entire pipeline network by running

XYZ mapping tool along with TFI and CDP tool.

HEALTH MONITORING FOR PAN INDIA NETWORK

• GAIL has enhanced the frequency of ILI

of Wet Gas Pipelines to once in a 5 year

though Regulation require frequency of

once in a 10 year.

New Technology Integrity of Non-Piggable Pipelines

MTM is a non-intrusive pipeline inspection technology based on Magnetic

Tomography Method.

MTM evaluates the relative change in mechanical stress through the pipeline

magnetic field strength measurement. It helps to locate defects in metal &

weld joints, assess the state of corrosion & monitor the development of

corrosion.

Magnetic Tomography Method (MTM)

Contactless Magnetometric Diagnostics method (CMDM)

Contactless Magnetometric Diagnostics method is another tool that is used

for ensuring the Integrity of the Non-Piggable Pipeline.

This method comprises of acoustic emission, ultrasonic thickness gauging,

vibration diagnosis to enable the execution of check of the facility’s

technical state when in service on the basis of different NDT methods.

Surveillance of ROU/ROW

For monitoring of ROU, GAIL has started Foot

patrolling along its pipeline with GPS devices.

GAIL is in advanced stage of implementing use of

Unmanned Aerial Vehicle / Drone in surveillance of

pipelines at harsh locations.

Also, latest pipeline monitoring technology, namely

“High resolution low orbit satellite imaging”, is being

implemented in GAIL.

A pilot project on remote surveillance in DVPL

pipeline by R&D department of GAIL in collaboration

with National Remote Sensing Centre (NRSC).

Intrusion Detection System

Highly sensitive, distributed acoustic sensing system -utilizing fiber optic cables,

Sensing Probes for automated monitoring/measuring activities along linear

assets. Tendering in Progress for PIDS in sections of JLPL & VSPL.

Provides following key surveillance/operational functionalities

• Mechanical/Manual digging

• Personnel Movement

• Vehicle Movement

• Pig tracking Fiber Optic – upto ~40 KM length

(~4,000 measurement points of 10 mtr each)

Pipeline Intrusion Detection System (PIDS)

Leak Detection System GAIL has implemented Centralized Application Software

(APPS) System for modelling its entire Natural Gas and

LPG Pipeline Network.

GAIL has conducted a study regarding the feasibility of

usage of odorization in Natural Gas cross-country

pipelines which are passing through city or in the vicinity of

the city locations. Odorization is being done in one of the

pipeline on pilot basis.

GAIL has also taken an initiative to install RMLD-Remote

Methane Leak Detector. It quickly and efficiently detects

leaks up to one hundred feet away allowing remote

detection of hard-to-reach areas and difficult terrains

External Corrosion Management

Coatings (3-LPE), supplemented by Cathodic Protection.

Coating provides a electrical barrier and maximum protection & Cathodic

protection supplements it at coating holidays.

Making all cathodic sites potentials more electronegative to reach the

potential of anodic site on the metal surface, through external means.

Two types of CP systems:

(a) Sacrificial/Galvanic

(b) Impressed Current Cathodic Protection(ICCP)

Two systems work together augmenting each other and ensuring protection

& adequacy of protective current requirement. 32

External Corrosion Monitoring

CP Monitoring Mechanism:

On Line Portal for CP data upload in the GAIL server directly by the sites

3- stage review of CP data by each Pipeline Maintenance base In-charges,

Regional CP coordinators followed by CIMG.

Development of guidance documents by CIMG for various CP activities

uniformly by the sites.

SCADA connectivity of CPSM/TR Units with feeding PSP data.

Focus on AC Interference survey with simulation study & DC Interference.

Internal Corrosion Management

GAIL is monitoring H2S and Moisture at most of the source locations using

advanced Tunable Laser diode based Online Analyzers.

GAIL has installed Gas Dehydration facilities with ONGCL. Significantimprovements in water dew point and hydrocarbon dew point have beenobserved for the sources where GDU has become functional.

GAIL is chemically treating the in the Pipeline. Chemical treatment includes theuse of Corrosion Inhibitor, Biocides and Hydrate control with methanol.

GAIL has engaged The Energy Research Institute (TERI) for detailed

analysis of fluid samples from pig runs.

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GAIL has engaged Subject Matter Experts to review existing Maintenance

Practices and thus comparing them with world’s best practices and thereby

recommending modification for improvisation.

The hiring of expert advice from the reputed consultant/agency re-assure the

effectiveness of our existing practices/policies.

It also ensure the safety and health of persons and the environment by the

reduction of hazards and risks to a level as low as reasonably practical in

normal operating conditions or in an emergency.

Following subjects matter have been hired by GAIL:• Inline Inspection and Cathodic Protection : Mr. Jim Marr

• Metallurgy and Welding : Mr. V R Krishnan

• Corrosion : Mr. Patrick J Teevens

• Coating : Mr. Sidney A Taylor

ENGAGEMENT OF SMEs

Professional Excellence GAIL has taken the initiative to give training to GAIL pipeline officers

through NACE and ASME to create the required Cadre Based Team.

The NACE agency has been hired to give training on:

• Direct Assessment

• Cathodic Protection Level-2

GAIL, on regular basis, has organized Pipeline Operators Meet for

discussions on various pipeline operation & maintenance issues where

pipeline operators like M/s IOCL, M/s BPCL, M/s OIL, M/s RGTIL, M/s

Cairn Energy and M/s HPCL participated.

GAIL executives are nominated to participate in various National and

International Seminars like ICEPIM, NCCI etc.

Professional Excellence GAIL in collaboration with NIGIS has conducted Technical Seminars on Internal

Corrosion of pipelines JANG SE JANG-I & JANG SE JANG-II (Battle With

corrosion-II .The representative from industries- GAIL, RIL, RGTIL, IOCL,

BPCL, HPCL, VOLT, EIL, MECON,TRACTABLE, CEIL IGL,MGL, OISD,

experts from M/s NACE international, CIMG(Central Integrity management

group), RIMG (Regional Integrity management group) and personnel of GAIL

from sites has participated.

Moving Ahead

Transforming GAIL to a Smart Utility Company.

Balance approach towards performance and health.

Competency development at all levels.

Strengthening of systems and procedures including Monitoring, Controlling

& Reporting Practices.

Continual learning through periodic capturing of lessons learnt.

Brand management of GAIL through association with global best

companies.

Employee Engagement

Thank You