OISD-STD-141.pdf

OISD/DOC/06/2024/01 OIL INDUSTRY SAFETY DIRECTORATE क्रॉस कं ट्री द्रव्य हाइड्रोकार्बन पाइपलाइन e...

OISD/DOC/06/2024/01 OIL INDUSTRY SAFETY DIRECTORATE क्रॉस कं ट्री द्रव्य हाइड्रोकार्बन पाइपलाइन e at ओ आई एस डी - मानक - 141 or ct CROSS COUNTRY LIQUID HYDROCARBON PIPELINE ire OISD-STD-141 D ty fe Inception April 1990 Sa Amended Edition September 2001 1st Revision September 2003 ry 2nd Revision July 2012 st 3rd Revision June 2024 du In il O FOR RESTRICTED CIRULATION ONLY OIL INDUSTRY SAFETY DIRECTORATE Government of India Ministry of Petroleum & Natural Gas 8th Floor, OIDB Bhavan, Plot No. 2, Sector – 73, Noida – 201301 (U.P.) Website: https://www.oisd.gov.in Tele: 0120-2593833  OISD/DOC/06/2024/01 e at or ct ire D ty fe Sa ry st du In il O This page is intentionally left blank  OISD/DOC/06/2024/01 PREFACE Indian petroleum industry is the energy lifeline of the nation and its continuous performance is essential for prosperity of the country. As the industry deals with inherently inflammable substances throughout its value chain – upstream, midstream and downstream – Safety is of paramount importance to this industry as safe performance at all times can ensure optimum return of these national assets and resources including sustainability. To ensure proper implementation of the various aspects of safety in the oil & gas industry, the e Government of India, vide Resolution No. R-13013/4/84-OR-1 dated 10th January, 1986 set at up a Safety Council at the apex, under the administrative control of the Ministry of Petroleum & Natural Gas (MoP&NG). To assist the Safety Council, a technical directorate, namely the or Oil Industry Safety Directorate (OISD) under the aegis of MoP&NG, has been entrusted with the responsibility of formulating standards, overseeing its implementation through safety ct audits to enhance safety level in the oil & gas industry. ire OISD has developed a rigorous, multi-layer, iterative and participative approach for D development of standards. OISD develops and revises Standards, Guidelines & Recommended Practices for the oil and gas sector through a participative process involving ty all the stakeholders, drawing inputs from national and international standards and adapting them by leveraging the experience of the functional committee. These standards cover inbuilt fe design safety, asset integrity and best operating practices in the field of production, processing, storage and transport of petroleum. Sa The participative process followed in standard formulation has resulted in excellent level of compliance by the industry. It also goes to prove the old adage that self-regulation is the best ry regulation. The quality and relevance of OISD standards had been further endorsed by their st adoption/ reference in various statutory rules and regulations of the land. du OISD and industry together strive to achieve nil incident in the entire hydrocarbon value chain. We at OISD, are confident that the provisions of this standard, when implemented in totality, In would go a long way in ensuring safe operation in the oil and gas industry. il O Executive Director Oil Industry Safety Directorate  OISD/DOC/06/2024/01 Page No. II NOTE Oil Industry Safety Directorate (OISD) publications are prepared by the Oil and Gas industry under the Ministry of Petroleum & Natural Gas. This standard is a property of Oil Industry Safety Directorate (OISD) and shall not be reproduced or copied and loaned or exhibited to others without written consent from OISD. OISD standards are published to facilitate sound engineering, operating practices and aimed to supplement the information to the oil and gas industry, however this may be used e by anyone desiring to do so and are not intended to obviate the need for applying sound at engineering judgement regarding when and where these standards should be utilized. The formulation and publication of OISD standard is not intended in any way to inhibit anyone or from using any other practices and not to replace the prevailing statutory requirements, which must be followed as applicable. ct ire Wherever Acts/ Rules/ Regulation and National/ International Standards are mentioned in the standard, the same relates to in-vogue version of such documents. Whenever there is D any difference between the statutory norm and OISD standard, more stringent requirement should be followed. However, in case of any difference in the requirement between OISD ty standards, the requirement as specified in the standard released at a later stage shall prevail. fe The industry has to carry out gap analysis and make necessary changes in their system in Sa line with the revised standard and the requirement should be implemented within a time frame of 1 year (from the date of release of revised standard). ry Though every effort has been made to assure the accuracy and reliability of the information contained in these documents, OISD hereby expressly disclaims any liability or st responsibility for loss or damage resulting from the use of OISD standard. du The standards would be reviewed periodically based on the decision in the Steering Committee/ Safety Council, industry request, technological development, recommendations In of high level committee and accident investigation reports. Generally, OISD standards are reviewed and revised, reaffirmed or withdrawn at least every ten years. il O Suggestions for revision are invited from the oil and gas industry and should be submitted to OISD at [email protected].  OISD/DOC/06/2024/01 Page No. III CURRENT FUNCTIONAL COMMITTEE NAME DESIGNATION ORGANISATION LEADER Dr. Saumitra Shankar Gupta Advisor (Technical) Centre for High Technology MEMBERS Himanshu Pant Group General Manager Oil and Natural Gas Corporation J. K. Rai Chief General Manager Indian Oil Corporation Ltd. e at Shiv Shanker Verma General Manager Gail India Ltd. or Abhijeet S. Pathare Regional Manager Bharat Petroleum Corporation Ltd. Mohit Krishna Dy. General Manager Hindustan Petroleum Corporation Ltd. ct Neeraj Rai Dy. General Manager Engineers India Ltd. ire Dumendra Kumar Thakur Dy. General Manager D Indian Oil Corporation Ltd. Sunil Somnath Khode Dy. General Manager Indian Oil Corporation Ltd. ty Prashil Islania Dy. General Manager Nayara Energy Ltd. fe Dhiraj Bora Chief Engineer Oil India Ltd. Sa Jamunalal Rout Dy. Director (Technical) PNGRB Abhishek Srivastava Joint Director (Pipeline) Oil Industry Safety Directorate ry MEMBERCOORDINATOR st Mohit Vasudeva Addl. Director (Pipeline) Oil Industry Safety Directorate du OISD also recognizes the support & cooperation of several other experts from industry, who contributed to the preparation, review and finalization of this document. In il O  OISD/DOC/06/2024/01 Page No. IV TABLE OF CONTENT PART-I: CROSS COUNTRY LIQUID HYDROCARBON PIPELINE SL.NO CONTENT PAGE NO. 1.0 INTRODUCTION 1 2.0 SCOPE 1 3.0 DEFINITIONS 2 4.0 STATUTORY ACTS AND REGULATIONS 6 5.0 DESIGN 6 6.0 SAFETY INSTRUMENTED SYSTEM 20 7.0 COMMUNICATION 23 8.0 PUMP STATION 23 e 9.0 MATERIALS 26 at 10.0 CORROSION CONTROL 28 11.0 CONSTRUCTION 32 or 12.0 TESTING AND COMMISSIONING 41 13.0 SAFETY AND FIRE PROTECTION SYSTEM 44 ct 14.0 OPERATION AND MAINTENANCE 47 15.0 MANAGEMENT OF CHANGE 52 ire 16.0 DEFECT DETECTION, ASSESSMENT AND MITIGATION 53 17.0 PIPELINE INTEGRITY MANAGEMENT 53 18.0 PIPELINE REPAIR D 54 19.0 REMAINING LIFE ASSESSMENT 56 20.0 CHANGE IN SERVICE CONDITIONS 57 ty 21.0 STATIC LEAK TEST 58 22.0 ABANDONMENT OF PIPELINE 58 fe 23.0 MOTHBALLING OF PIPELINE SYSTEM 58 24.0 DOCUMENTATION FOR OPERATION AND MAINTENANCE 59 Sa 25.0 AUDITS 59 26.0 REFERENCES 59 27.0 ABBREVIATIONS 61 28.0 ANNEXURES ry ANNEXURE I – SCOPE OUTLINE OF THE STANDARD 64 ANNEXURE-II- STATUTORY ACTS AND REGULATIONS 65 st ANNEXURE III - MINIMUM INTERDISTANCES FOR PIPELINE 66-68 INSTALLATION FACILITIES du ANNEXURE IV - PROCEDURE FOR SAFETY INSTRUMENTED 69-70 SYSTEM ANNEXURE V - LIST OF ENGINE MONITORING AND PROTECTION 71 In INSTRUMENTATION ANNEXURE VI - ADDITIONAL REQUIREMENTS FOR ELECTRIC 72-73 il WELDED PIPES O ANNEXURE VII - LIST OF SPECIFICATIONS OF PIPING MATERIALS 74-75 USED IN LIQUID HYDROCARBON PIPELINES ANNEXURE VIII – SCHEMATIC INDICATING EARTHING DURING 76 MAINTENANCE ANNEXURE IX - INDICATIVE LIST OF BASIC EQUIPMENT FOR 77 EMERGENCY HANDLING / PIPELINE MAINTENANCE ANNEXURE X - INDICATIVE DRAWINGS FOR PIPE SUPPORTS 78 ANNEXURE XI - SCHEMATIC DIAGRAM FOR CLEANING PIG 79 RECEIVING BARREL DURING CONSTRUCTION ANNEXURE XII - FLOWCHART FOR THE REMAINING LIFE 80 ASSESSMENT OF THE PIPELINE SYSTEM  OISD/DOC/06/2024/01 Page No. V PART-II: LIQUID HYDROCARBON JETTY PIPELINE SL. CONTENT PAGE NO. NO 1.0 INTRODUCTION 82 2.0 SCOPE 82 3.0 DEFINITIONS 82 4.0 STATUTORY ACTS AND REGULATIONS 82 5.0 COMPONENTS OF JETTY PIPELINES 83 6.0 INTERNAL CORROSION OF JETTY PIPELINES 83 7.0 EXTERNAL CORROSION OF JETTY PIPELINES 83 8.0 INSPECTION REQUIREMENTS OF JETTY PIPELINE SYSTEM 84 8.1 INSPECTION OF JETTY PIPELINE SYSTEM 84 e 8.2 INSPECTION OF BLOCK VALVE 87 8.3 INSPECTION OF MARINE HEADER 87 at 8.4 INSPECTION OF HOSE 87 8.5 INSPECTION OF JETTY EMBANKMENT/RCC SUPPORT/STAGING 87 or 8.6 INSPECTION OF EARTHING & ELECTRICAL SYSTEMS 87 8.7 INSPECTION OF FIRE FIGHTING EQUIPMENT 88 ct 8.8 PATROLLING 88 8.9 INSPECTION OF COLOR CODE 88 ire 8.10 INSPECTION OF COMMUNICATION SYSTEM 88 8.11 REPAIR OF THE PIPELINE / SECTIOND 88 8.12 ABANDONMENT AND MOTHBALLING OF JETTY PIPELINE 88 9.0 DOCUMENTATION 88 10.0 REFERENCES 88 ty MAJOR CHANGES IN REVISED EDITION 90-95 fe LIST OF PREVIOUS FUNCTIONAL COMMITTEE(S) 96-97 Sa ry st du In il O  OISD/DOC/06/2024/01 e at PART-I or ct ire CROSS COUNTRY LIQUID HYDROCARBON PIPELINE D ty fe Sa ry st du In il O  OISD/DOC/06/2024/01 OISD-STD-141 Page no. 1 CROSS COUNTRY LIQUID HYDROCARBON PIPELINE 1.0 INTRODUCTION Safety in petroleum installation and pipeline comes through continuous efforts at all stages and as such it can be ensured by observing that installations and pipelines are designed, constructed and tested as per recognised engineering standards and they are periodically inspected and maintained. The primary purpose of this standard is to establish minimum requirement for design, corrosion protection, material, construction, inspection during construction, testing, commissioning, operation, maintenance, modification, abandonment and safety of cross country liquid hydrocarbon steel pipeline and also for protection of employees, public, facilities and environment against the hazard associated with transportation of liquid hydrocarbon through pipeline. e at 2.0 SCOPE or 2.1 This standard shall cover minimum requirements for design, construction, operation, inspection ct and maintenance, modification, mothballing, abandonment, safety and related aspects of onshore cross country pipeline system and associated facilities that transports liquid ire hydrocarbons, including crude oil, liquid petroleum products between the following facilities. The details are shown in the scope outlined in Annexure-I. (a) D 1st valve at Land Fall Point of offshore pipeline and inlet manifold valve of onshore storage Tank(s). (b) Onshore storage Tank(s) outlet manifold (marine / rail / road terminal) to inlet manifold of ty Refinery / process plant storage tank(s). (c) Inlet manifold of cross-country pipeline pump station to inlet manifold of product / crude fe storage tanks(s) at delivery terminal/ refinery. (d) Gathering station including intermediate group gathering station to pump station and / or Sa manifold of bulk storage facilities of Tank farm / Refinery / process plant. (e) Liquid hydrocarbon Jetty Pipeline which is covered in Part-II of this standard. ry 2.1.1 Provisions of OISD-STD-108 shall be applicable to all crude oil / product storage tanks located inside pipeline installation irrespective of their capacity. Additionally, relevant clauses pertaining st to storage tanks as specified in this standard shall also be applicable. du Wherever there is variation between provisions of OISD-STD-108 and this standard (OISD-STD- 141), provision of this standard shall prevail. In 2.1.2 For storage tanks located outside pipeline installation, but inside POL/ Marketing terminal premises, OISD-STD-244 and applicable regulations shall be followed. il 2.2 This standard shall be applicable from the date of issuance mentioned on title page for all new O projects / extension or expansion of existing system. For new pipeline under construction and commissioning phase and also for existing pipelines and associated facilities under operation phase, the requirements related to safety & fire protection system, operation & maintenance, pipeline integrity management, defect detection, assessment & mitigation specified in this standard shall be applicable. It shall be obligatory on the part of Owner/Operator to implement/ comply these requirements within 1 year of issuance of this Standard for pipelines already in operation and within 1 year of commissioning of pipelines which are under construction phase. 2.3 This standard does not cover : i) The offshore portion of the onshore pipeline, if any, which shall be governed by OISD- STD-139. ii) Cross country pipeline transporting liquefied petroleum gas (LPG) and other high vapour pressure liquid pipeline, which is covered in OISD-STD-214. iii) Cross country pipeline transporting natural gas, which is covered in OISD-STD-226.  OISD/DOC/06/2024/01 OISD-STD-141 Page no. 2 CROSS COUNTRY LIQUID HYDROCARBON PIPELINE iv) Onshore Pipeline transporting fluid to/from well head, which is covered in OISD-STD-233. 3.0 DEFINITIONS All definition / explanatory notes mentioned herein below shall be used for this standard. 3.1 Authorized person A person or representative of the company trained and assigned to carry out a specific job. 3.2 Competent Authority Any person appointed / authorized by Central Government, by notification in the official Gazette to perform the functions of the competent authority under the PMP Act’1962 or any other Act as per the requirement. e 3.3 Competent person at A person recognized by Owner / Operator based on his proficiency, skill, appropriate education, training and experience. or 3.4 Cold Work It is an activity which does not produce sufficient heat to ignite a flammable mixture (mixture of ct flammable gas with an oxidizing agent) or a flammable substance. ire 3.5 Critical Consequence Area Location where a pipeline release might have a significant adverse effect on public safety and D property such as designated industrial, commercial, residential and environmentally sensitive areas. ty Note: The location and scope of critical consequence areas (CCA) will change over time as new population and environmental resource data becomes available. The pipeline segments in CCAs fe are of particular interest in risk assessment and integrity assessment evaluations and prioritizations. Sa 3.6 Cross country Pipeline: Cross country pipeline refers to a pipeline and its associated facilities situated beyond the boundary of an installation, meant for transportation of hydrocarbon from one location to another ry and traversing through private or Government land. st 3.7 Coating A material applied (externally or internally) to a pipeline / structure to separate it from the du environment for preventing corrosion. 3.8 Cathodic protection In A technique to control the corrosion of a metal surface by making that surface the cathode of an electrochemical cell. il 3.9 Cathodic disbondment: O The loss of adhesion between a coating and pipe surface caused by the products of cathodic reaction. 3.10 Chief Controller Means Chief Controller of Explosives. 3.11 Consequence Means impact on the public, employees, property and environment due to pipeline failure. 3.12 Design Factor It is the percentage factor of Specified Minimum Yield Strength (SMYS) of the material considered, for determining wall thickness of pipe based on location of the pipeline. 3.13 Design Pressure  OISD/DOC/06/2024/01 OISD-STD-141 Page no. 3 CROSS COUNTRY LIQUID HYDROCARBON PIPELINE The maximum internal pressure which the pipeline can be subjected to as determined by design procedure applicable to materials and locations involved. 3.14 Electrical bonding A metal piece having very little electrical resistance used for connecting two points on the same or different pipeline structure. 3.15 Earthing Earthing is provision of a safe path of electrical current to ground in order to protect structures, plant and equipment from the effects of stray electrical current and electrostatic discharges. 3.16 Functional Safety It is a part of the overall safety that depends on a system or equipment operating correctly in e response to its inputs. at 3.17 Hazard Analysis It is to Identify significant Hazards for equipment and any associated Control System in its or intended environment with probabilities of occurrence and impacts. ct 3.18 Hot work It is an activity which involves welding, burning, soldering, brazing, sand blasting, chipping by ire spark producing tools, use of power-driven tools, non-flame proof electrical work including other work which can produce sufficient energy to cause ignition where potential flammable mixture (mixture of flammable gas with an oxidizing agent) or a flammable substance exists. D 3.19 High Vapour Pressure liquid: ty Hydrocarbon or hydrocarbon mixture in liquid state with a vapour pressure more than 110 kpa (abs) at 38 degree Celsius determined by Reid method. fe 3.20 Installation: Sa Installation means station such as tank farm, marine terminal, refinery & petrochemical plant, processing plant, GGS, pump station, intermediate pigging station or consumer facilities. 3.21 Intermediate pigging station: ry An intermediate pigging station is an installation having facility for receiving and launching of pig for pipeline pigging operations and is located between originating and delivery station. st 3.22 Intermediate pump station du An intermediate pump station is any installation having facilities such as pumps etc. between originating pump station and intermediate pigging station and / or terminal station / receipt station for boosting the pressure of the liquid so that it reaches to next station. In 3.23 Intermediate delivery station / Tap off Station (TOP)/ Tap off Point An intermediate delivery station / Tap off station/ Point on the pipeline installation is an installation il having facility to deliver product to any industry(ies) / storage tanks through a tapping from the O mainline. 3.24 Jetty A Jetty is generally a structure built out into the sea or along the shore as a part of a port. Oil & Gas Ships/tankers dock here to load/off-load their partial/complete cargo. 3.25 Jetty Pipeline Jetty Pipeline is a pipeline located at the Jetty and the pipeline used for loading/unloading of crude oil/petroleum products to/from Refinery/Terminals from/to Ships/Barges through Jetty. The Jetty pipelines may be buried/ aboveground / subsea/ above sea (on a trestle structure located in the sea). 3.26 Kerb wall  OISD/DOC/06/2024/01 OISD-STD-141 Page no. 4 CROSS COUNTRY LIQUID HYDROCARBON PIPELINE A wall of appropriate height and size constructed of brick masonry/ concrete designed to contain the Oil spillage from facility and to direct it to ETP/OWS/ Oil collection chamber. 3.27 Land Fall Point A place on the land after the offshore area where a valve is installed to separate the offshore and onshore part of the pipeline. 3.28 Layers of Protection: Layers of protection are the systems or actions and devices that are capable of preventing a scenario from proceeding to undesired consequences. 3.29 Layers of Protection Analysis (LOPA) LOPA is a simplified semi-quantitative technique of risk analysis. It helps to assess what e independent protection layers (IPL) already exist or what are required for process safety. at 3.30 Marine Loading Arm A marine loading arm is alternative to direct hose hook ups and is useful for vessels which or transfers petroleum products at higher loading / unloading rates and pressures. Same arm may be used for loading or unloading. These arms are controlled manually or hydraulically. A loading ct arm employs swivel joints and it is designed to follow the movement of a moored vessel. ire 3.31 May May are to be considered desirable or good practices which are encouraged to implement but not necessary. D 3.32 Maximum Allowable Operating Pressure (MAOP) ty The maximum pressure at which the pipeline is allowed to operate. MAOP may be less than or equal to the design pressure. fe 3.33 Maximum Operating Pressure (MOP) Sa The highest pressure at which the pipeline is operated during a normal operating cycle corresponding to a declared pipeline capacity. 3.34 Mothballing of Pipeline ry Mothballing is the deactivation and preservation of pipeline for possible future use. st 3.35 Multiphase Fluids Multiphase fluids means oil, gas or water in any combination produced from one or more oil wells du or recombined oil well fluids that may have been separated in passing through treatment/processing facilities. For the purpose of this standard, multiphase fluids are considered to be low vapour pressure fluids. In 3.36 Nominal Pipe Size It indicates the standard pipe size when followed by a number. il O 3.37 Nominal wall thickness It is the thickness of the pipe used in design calculation. 3.38 Operating Pressure It is the pressure corresponding to a particular flow rate at which pipeline is operated. Operating pressure may be less than or equal to MAOP. 3.39 Offshore Areas beyond the line of ordinary high water, along that portion of the coast that is in direct contact with the open seas and beyond the line marking the seaward limit of inland coastal waters. 3.40 Onshore  OISD/DOC/06/2024/01 OISD-STD-141 Page no. 5 CROSS COUNTRY LIQUID HYDROCARBON PIPELINE Areas not covered by 'Offshore' as defined above forming scope of this standard. Feeder lines from Jetty or other storage point and spur lines will form part of the onshore pipeline. 3.41 Originating Station Originating station is the first installation in the cross country pipeline where the liquid hydrocarbon is received for further transportation. 3.42 Originating Pump Station: An originating pump station is the first installation in the cross country pipeline having pumps for boosting the pressure of the liquid hydrocarbon to be transported so that it reaches to next station in the cross country pipeline. e 3.43 Owner at Shall mean individual, partnership, corporation or public agency / organization or any other entity that owns the cross country pipeline. or 3.44 Operating Company/ Operator ct Shall mean individual, partnership, corporation or public agency / organization or any other entity that operates cross country pipeline. ire 3.45 Oil Water Separator (OWS): Oil water separator is a system designed to separate gross amount of oil and suspended solids D from the oily water effluent generated due to different activities/operations in petroleum Installations. ty Open Type OWS : OWS system having open oily water collection chamber / pit / tank or having fe open filters (gravity separation, multimedia, coalescer etc) or having sludge drying bed shall be considered as open type OWS system. Sa Closed Type OWS : OWS system having covered oily water collection chamber / pit / tank (covered either by chequered plate or RCC slabs) along with vapor vent & vessel mounted filters (multimedia, coalescer etc) but without sludge drying bed shall be considered as closed type ry OWS system. st 3.46 Pipeline Installation Installation with or without tank farm being operated and maintained by pipeline operating du company / operator. 3.47 Pipeline System In Means all pipelines as defined in para 2.0 of this standard transporting liquid hydrocarbons with associated safety systems, equipment, valves, tool, launchers or receivers, manifolds, corrosion protection system or other accessory equipment. il O 3.48 Purging It is the process of replacing the atmospheric air within a container (pipeline, vessels, filters etc) by an inert substance in such a manner so as to prevent the formation of explosive mixture. 3.49 Right-of–User (ROU) / Right-of-Way (ROW) The area or portion of land within which the pipeline operating company has acquired the right through PMP Act’1962 or in accordance with the agreement with the land owner or agency to lay and operate the cross country liquid hydrocarbon pipeline. 3.50 Safety Integrity Levels (SIL) This defines the Target Risk Reduction factor & Target average probability of Safety availability. The SIL as per IEC-61508 is given in clause 6.0. 3.51 Specified Minimum Yield Strength (SMYS)  OISD/DOC/06/2024/01 OISD-STD-141 Page no. 6 CROSS COUNTRY LIQUID HYDROCARBON PIPELINE It is the minimum yield strength specified by specification or standard under which material is purchased from the manufacturer. 3.52 Spur / Branch Pipeline Pipeline originating from cross country pipeline (also called as trunkline pipeline) for dedicated terminal and/or customer location(s). 3.53 Sectionalizing Valve (SV) Valve (MOVs / HOVs) used in the cross-country pipeline system for isolation of a particular pipeline section, whenever required. This valve is also referred as Main Line Valve (MLV). e 3.54 Sectionalizing Valve station A facility containing sectionalizing Valve and associated equipment for electrical power supply, at communication, CP etc. or 3.55 Supplier Company The company or organization owning and operating pipeline system for delivery to various ct industry (ies) / oil marketing companies. ire 3.56 Sour liquid hydrocarbon A type of liquid hydrocarbon that contains H2S under partial pressure and / or presence of elemental sulphur 0.5% by weight. D 3.57 Sump tank ty An underground tank installed at pipeline station to store hazardous liquid which is released from pressure relief system / filters / scrapper barrels / piping of stations and subsequently re-injected fe to either the pipeline system and / or other storage tanks. Sa 3.58 Weight Coating Coating done on the pipeline for increasing the pipeline section specific gravity for the purpose of giving anti-buoyancy effect. ry 3.59 Shall ‘Shall’ indicates mandatory requirement. st 3.60 Should du ‘Should’ indicates that the provision is recommended as a good practice. 3.61 Terminal Station / Receiving Station / Receipt Terminal In Terminal / Receiving station / Receipt terminal is the last station on the pipeline used for receipt of liquid hydrocarbon. il 4.0 STATUTORY ACTS AND REGULATIONS O Liquid hydrocarbon pipeline and its associated facilities are covered under various acts / regulations and require specific approval from concerned authorities. Various acts / regulations, inter alia applicable are mentioned as Annexure-II.. 5.0 DESIGN The pipeline shall be designed in a manner that ensures adequate public safety under all conditions likely to be encountered during installation, testing, commissioning and operating conditions. All materials and equipment shall be selected to ensure safety and suitability for the condition of use. Design for pipeline system shall be based on the following evaluation of the properties and required flow rate of the liquid to be transported, together with the environment in which the pipeline is to be installed. (a) Sweet or sour liquid, single or multiphase flow conditions.  OISD/DOC/06/2024/01 OISD-STD-141 Page no. 7 CROSS COUNTRY LIQUID HYDROCARBON PIPELINE (b) Operating pressures and temperatures. (c) Services i.e., crude / single product / multi product. Design of liquid hydrocarbon pipeline system shall be in accordance with ASME B 31.4 unless specified otherwise. In case of variations /differences between this standard and ASME B31.4, whichever provision is more relevant and stringent, shall prevail. Section(s) of cross-country pipeline to be installed across estuaries and creeks etc. affected by tidal fluctuations, waves and currents and cannot be installed using conventional onshore equipment shall be designed in accordance with OISD-STD-139. 5.1 PIPELINE DESIGN e at 5.1.1 A design Life of minimum 25 years for pipeline system in general should be considered by the owner for designing various system and facilities. The life of pipeline can be extended beyond the design life subject to satisfying the comprehensive pipeline integrity assessment. or 5.1.2 All necessary calculations shall be carried out to verify structural integrity and stability of the ct pipeline for the combined effect of pressure, temperature, bending, soil/pipe interaction, external loads and other environmental parameters as applicable, during all phases of work from ire installation to operation. Such calculations shall include but not limited to the following: (a) Buoyancy control and stability analysis for pipeline section to be installed in areas D subjected to flooding/submergence, (b) Analysis of pipeline waterbody crossing and control measures for hydrotechnical threats ty such as flooding, channelling, scouring, erosions, creek area effects, river meandering, riverbed or bank movement. fe (c) Evaluation of potential for Geo-Hazards, earthquake occurrence across fault locations, carrying out requisite seismic analysis and requisite measures to ensure safety and Sa integrity of the pipeline system. (d) Evaluation of hazards/ interference due to high voltage AC/DC transmission lines/ cables/ lightening and requisite mitigation measures to ensure safety and integrity of the pipeline system. ry 5.1.3 While designing the pipeline system, the design engineer shall consider reasonable protection to prevent damage to the pipeline from unusual external conditions. Some of the protective st measures which the design engineer may provide are encasing with steel pipe of larger diameter, adding concrete protective coating, increasing the wall thickness of the pipe, lowering the du pipeline to a greater depth or indicating the presence of the pipeline with additional markers. In 5.1.4 Environmental Impact Assessment (EIA) and Risk Analysis (RA) study shall be carried for the pipeline and stations. Recommendations / findings from such studies to be taken into account while designing the pipeline system. il O 5.1.5 DESIGN TEMPERATURE The design temperature is the metal temperature expected in normal operation. Appropriate temperature range for design of pipeline / piping system shall be determined based on temperature of liquid hydrocarbon proposed to be transported through the pipeline, ambient / sub-soil temperature. 5.1.5.1 Maximum design temperature Maximum temperature for design of above ground section of pipeline / piping shall be the maximum expected metal / liquid temperature during operation or maximum ambient temperature whichever is higher. In no case maximum temperature for carbon steel pipeline shall be more than (+) 120oC. Maximum temperature for design of buried section of pipeline / piping shall be maximum expected liquid hydrocarbon temperature during operation or maximum sub-soil temperature whichever is higher.  OISD/DOC/06/2024/01 OISD-STD-141 Page no. 8 CROSS COUNTRY LIQUID HYDROCARBON PIPELINE 5.1.5.2 Minimum design temperature Minimum temperature for design shall be minimum expected metal / liquid temperature during operation or minimum ambient / sub-soil temperature whichever is lower. In no case minimum temperature for carbon steel pipeline shall be less than (-) 29oC. 5.1.5.3 When maximum liquid hydrocarbon temperature during operation is below 65 oC, thermal expansion and stresses in the above ground section of pipeline / piping shall be evaluated considering pipe skin temperature of 65 oC. 5.1.6 STRAIGHT PIPE 5.1.6.1 Pipe diameter NPS 4 and above shall be used for cross country pipeline. Pipe wall thickness less than 6.35 mm should not be used for cross country pipeline. e 5.1.6.2 The nominal wall thickness "tn" for the steel pipe shall be calculated in accordance with ASME B31.4 and is as under: at tn ≥ t + A. where, A = sum of allowance for threading & grooving, corrosion, erosion and increase in wall or thickness if used as protective measures in para 5.1.6.3 of this standard. ct The internal design pressure wall thickness “t” of steel pipe shall be calculated by the following equation: ire Pi D t = 2S D Where, D = outside diameter of pipe, in. Pi = Internal design gauge pressure, psi (Refer note ii below). ty S = applicable allowable stress value, psi = F x E x SMYS, psi fe F = Design Factor from Table-1 E = Longitudinal joint factor, which for electric welded (HFW), longitudinal Sa seam submerged arc welded (SAWL), helical seam submerged arc welded (SAWH) and seamless types of pipes, manufactured in accordance with API specification 5L and considered as 1; SMYS = Specified Minimum Yield Strength, psi ry Note: i) The above wall thickness design shall be considered applicable for metal temperature st between (-) 29°C and (+) 120°C. ii) The internal design pressure shall be at least equal to maximum steady state du operating pressure which shall be the sum of the static head pressure, pressure required to overcome friction losses, and required back pressure. In calculation of internal design pressure, credit may be given to external hydrostatic pressure In appropriately. il TABLE- 1 : Design Factor O Facility Design Factor Pipelines, mains, and service lines 0.72 Crossings of roads, railroads without casing: (a) Private roads, Unimproved Public Roads 0.72 (b) Roads, highways, public streets, with 0.60 # hard surface (c) Railroads 0.60 # Crossings of roads, railroads with casing 0.72 Parallel pipelines and mains roads / railroads within ROW of utility: (a) Private roads, Unimproved public roads 0.72 (b) Highways or public streets, with hard 0.60 surface and Railroads Pipelines on bridges 0.50  OISD/DOC/06/2024/01 OISD-STD-141 Page no. 9 CROSS COUNTRY LIQUID HYDROCARBON PIPELINE Facility Design Factor River Crossings 0.6 # Dispatch terminal, intermediate pumping & pigging station, receipt/ terminal piping & 0.72 other stations piping # At these locations, Engineering Assessment/ Stress analysis for additional external loads on account of traffic, overburden etc. must be performed and pipe of higher thickness may be considered over and above design factor, if required. 5.1.6.3 Additional Requirements for Nominal Wall Thickness “t n” in Para 5.1.6.2 (a) The minimum wall thickness ‘t’, required for pressure containment as determined by para 5.1.6.2 above, may not be adequate for other forces to which the pipeline may be subjected. e (b) Corrosion allowance to account for expected loss of wall thickness due to internal corrosion at that may be caused due to constituents of the liquid hydrocarbon and other service conditions shall be added to the calculated thickness unless other internal corrosion or mitigation measures are adopted. (c) In addition, the selected thickness shall also be checked to ensure that the diameter to ct nominal wall thickness (D/ tn) ratio does not exceed 100 in order to avoid damage to pipe during handling and transportation. ire 5.1.6.4 Other Loadings Other loadings such as those caused by scour, erosion, soil movement and landslides, D installation forces, wind loading, earthquake loading etc. shall be considered and provided for in accordance with sound engineering practices. ty Weight of water during hydrostatic testing and weight of product during operation shall also be fe considered. Consideration shall be given to the use of lower allowable design stress if there is likelihood of Sa repeated stress changes giving rise to fatigue conditions. 5.1.6.5 CALCULATION OF STRESSES ry 5.1.6.5.1 Stress from Thermal Expansion st (a) Restrained Pipe du Thermal expansion stress in restrained pipe is calculated as In where = moduli of elasticity il = thermal expansion stress, psi (MPa) O = temperature of the pipe at installation or completion of final tie-in, °F (°C) = operating temperature, °F (°C) = coefficient of thermal expansion, in./in./°F (mm/mm/°C) In the above equation, compressive stress is a negative value. (b) Unrestrained Pipe Calculations shall take into account flexibility and stress intensification factors of piping components. The stress range resulting from thermal expansion in pipe, fittings, and components in unrestrained pipeline is calculated as follows, using the modulus of elasticity at the installed temperature:  OISD/DOC/06/2024/01 OISD-STD-141 Page no. 10 CROSS COUNTRY LIQUID HYDROCARBON PIPELINE SE = where Sb = resultant bending stress, psi (MPa) St = torsional stress, psi (MPa) Thermal stress shall be calculated for the range of minimum and maximum operating temperatures. The resultant bending stress, Sb, is calculated as follows: Sb = where e ii = in-plane stress intensification factor in accordance with ASME B31.4. Note that ii is 1 for pipe. at io = out-of-plane stress intensification factor in accordance with ASME B31.4. Note that io is 1 for pipe. or Mi = in-plane bending moment, in.-lb (N·m) Mo = out-of-plane bending moment, in.-lb (N·m) Z = section modulus of the pipe or of the fitting outlet, as applicable, in. 3 (cm3) ct Resultant torsional stress, St, is calculated as ire S= where Mt = torsional moment, in.-lb (N·m) D ty 5.1.6.5.2 Longitudinal Stress (a) Restrained Pipe fe Longitudinal stress in restrained pipe is calculated as Sa ry where = metal area of nominal pipe cross section, in.2 (mm2) st = axial force, such as weight on a riser, lb (N) du = bending moment, in.-lb (N·m) = thermal expansion stress, psi (MPa) In = circumferential (hoop) stress due to internal pressure, psi (MPa) = section modulus of the pipe, in.3 (cm3) il = Poisson’s ratio O Examples of force, , are forces due to the differential pressure on a buried valve and frictional forces due to pipe movement through the soil. can be positive or negative, depending on the direction of the force. can be either a positive or negative value. Both positive and negative values of shall be considered in the analysis. Residual stresses from construction are often present for spanning, elastic bends, and differential settlement. Designers should determine if such stresses need to be evaluated. (b) Unrestrained Pipe The longitudinal stress from pressure and external loadings in unrestrained pipe is calculated as (U.S. Customary Units)  OISD/DOC/06/2024/01 OISD-STD-141 Page no. 11 CROSS COUNTRY LIQUID HYDROCARBON PIPELINE (Si Units) where = metal area of nominal pipe cross section, in.2(mm2) = outside diameter of pipe, in. (mm) = axial force, such as weight on a riser, lb (N) = component stress intensification in plane of loading (see Table 402.1-1 of ASME B31.4), limited by 0.75i ≥ 1. For straight pipe, = 1.0. M = bending moment across the nominal pipe cross section due to weight or seismic inertia e loading, in.-lb (N·m) = internal design gage pressure, psi (bar) at t = wall thickness of pipe, in. (mm) Z = section modulus of the pipe or of the fitting outlet, as applicable, in. 3 (cm3) or Longitudinal stress from pressure in an unrestrained line shall include consideration of bending ct stress or axial stress that may be caused by elongation of the pipe due to internal pressure and result in stress at bends and at connections and produce additional loads on equipment and on ire supports. 5.1.6.5.3 Combining of Stresses In restrained pipe, the longitudinal and circumferential stresses are combined in accordance D with the maximum shear stress theory as follows: ty = fe where = equivalent combined stress Sa = torsional stress, psi (MPa) When can be disregarded, the combined stress calculation can be reduced to the following: ry such that when , and when ) st where du = axial stress, psi (MPa) Alternatively, the stresses may be combined in accordance with the maximum distortion energy theory as follows: In = il O 5.1.6.5.4 Stresses from Road and Rail Traffic Loads The total effective stress due to internal design pressure, temperature change, and external loads (including sustained, occasional, and transient loads) in pipe installed under railroads or highways without use of casings shall be calculated in accordance with API RP 1102 or other calculation methods. Cyclic stress components shall be checked for fatigue. Where casings are used, the same methodology may be used for the design of the casing. 5.1.6.5.5 Allowable Values for Pipeline System Stresses Sum of Longitudinal Effective Stress for Internal and Allowable Additive Stresses From Equivalent Casing or Uncased External Pressure Expansion Longitudinal Sustained and Combined Pipe at Road or Location Stress, Stress, Stress, Occasional Loads Stress, Railroad Crossings  OISD/DOC/06/2024/01 OISD-STD-141 Page no. 12 CROSS COUNTRY LIQUID HYDROCARBON PIPELINE Restrained 0.72(E) 0.90 0.90 [Note (1)] 0.90 0.90 0.90 [Note (2)] pipeline Unrestrained 0.72(E) [Note (3)] 0.75 [Note (1)] 0.80 n/a 0.90 [Note (2)] pipeline GENERAL NOTES: (a) = specified minimum yield strength of pipe material, psi (MPa) (b) = weld joint factor (see Table 403.2.1-1 of ASME B31.4) (c) in the table above is the maximum allowable value for unrestrained piping calculated e in accordance with ASME B31.4. The maximum value of for restrained pipe is calculated in accordance with ASME B31.4. at NOTES: or i) Beam-bending stresses shall be included in the longitudinal stress for those portions of the restrained or unrestrained line that are supported aboveground. ct ii) Effective stress is the sum of the stress caused by temperature change and from circumferential, longitudinal, and radial stresses from internal design pressure and ire external loads in pipe installed under railroads or highways. 5.1.6.5.6 Other stresses D Other stresses as applicable, shall also be considered as per ASME B31.4. ty 5.1.7 PRE – OPERATIONAL STRESSES It is desirable to limit stresses during pre-operational manipulation of the pipe so as to avoid fe damage that might impair the operability of the line. The designer shall ensure that pre- operational stresses are controlled and that they are non-injurious to the pipe. Consideration Sa shall be given to, but not restricted to, the effect of the following pre-operational loads: (a) Transportation and stockpiling of the pipe; (b) Stringing, coating and wrapping, and laying; ry (c) Backfilling; (d) Loads imparted by construction traffic; st (e) Field bending; (f) Pulling load during horizontal directional drilling. du (g) Frictional load during jacking and boring. (h) Hydrostatic test pressure loads (particularly when the pipeline is constructed as an above ground installation or is buried in unstable soils). In 5.1.8 SURGE ANALYSIS A detailed surge analysis shall be carried out during design stage considering the following il condition: O i) Closure of sectionalizing motor operated valve (MOV) on the mainline. ii) Closure of inlet MOV/ ROSOV / ROV of the storage Tanks during receipt. iii) Closure of any MOV in the delivery pipeline. iv) Stoppage of Pump(s) at originating / Intermediate pump station. v) Closure of valves during emergency shutdown. vi) Combination of the above vii) Any other condition which can generate surge pressure. Based on surge analysis, adequate engineering controls and protective equipment shall be provided in case the pressure rise due to surges and other variations from normal operations exceeds the internal design pressure at any point in the piping system and equipment by more than 10%. Surge analysis shall also be carried out before undertaking any modification involving change in operational parameters and change in configuration.  OISD/DOC/06/2024/01 OISD-STD-141 Page no. 13 CROSS COUNTRY LIQUID HYDROCARBON PIPELINE 5.1.9 ANTI-BUOYANCY MEASURE Pipeline crossing water bodies, marshy areas, swamps and areas with high water table shall be checked for buoyancy and if required suitable anti-buoyancy measures such as continuous concrete weight coating or gravel filled geotextile bags, anchors etc. shall be provided. The specific gravity of the anti-buoyancy measures with pipeline under empty/ installation conditions shall be minimum 1.1. 5.1.10 EXTERNAL CORROSION All underground pipes and its component shall be protected against external corrosion using suitable external anti-corrosion coating and cathodic protection system. All above ground piping and its component shall be protected against external corrosion by e providing suitable anti-corrosion coating / painting. at 5.2 LOCATION AND LAYOUT OF PIPELINE INSTALLATION or 5.2.1 LOCATION Originating, intermediate and terminal facilities of cross-country pipeline such as Originating ct Pump Station, Intermediate pump / pigging Station, Tap-off Station and Sectionalizing Valve Stations etc. shall be located considering following aspects: ire i) Functional and pipeline hydraulic requirements. ii) Environmental consideration based on Environmental Impact Assessment (EIA) and Risk D Analysis (RA) study for the pipeline and installations/stations including sectionalizing valve stations. iii) HIRA, HAZOP and QRA. ty iv) The availability of space for future augmentation of facilities. v) Approachability, water table and flood level and natural drainage. fe vi) Availability of electric power/ alternate powers like Solar, DG. Sa In addition to above, pipeline installations should be located at such clear distances from adjacent property not under control of the pipeline owner / operator so as to minimize the hazard of propagation of fire to the pump station from structures on adjacent property. ry 5.2.2 LAYOUT st The following aspects shall be considered while establishing station layout. du i) Station equipment including sump tank. ii) P&I diagram for the station. iii) Utility requirement including other storage tanks like HSD for power generation etc. In iv) Storm water drainage system, Oil water separation system v) Operation & maintenance philosophy of station equipment. il vi) Fire station & allied facility wherever required. O vii) Overhead power lines should not be allowed above station equipment / buildings. viii) HT Pole structure, Transformers, Breaker and MCC room etc. to be located in non- hazardous area. ix) Requirement of space and access around the pump (including engine / motor) house/ shed / building and other equipment to permit the free movement of firefighting equipment. 5.2.3 SEPARATION DISTANCES Control room should be located far away from potential leak source as far as practicable. Inter- distance between various station facilities and utilities shall be as per Annexure- III and in line with OISD-STD-118/ applicable regulations. 5.2.4 PIPING LAYOUT Wherever possible station piping should be installed above ground. Where station piping is buried, necessary corrosion control measures shall be provided. All buried station piping should  OISD/DOC/06/2024/01 OISD-STD-141 Page no. 14 CROSS COUNTRY LIQUID HYDROCARBON PIPELINE be at least 2 m away from the boundary wall (above ground portion) inside the station. Buried piping inside the terminal area shall have a minimum cover of 1.2 m from top of pipe to finished ground level. At internal storm water drains, underground piping shall be provided with a minimum cover of 300 mm with additional concrete slab extending at least 500mm on either side of the edge of the drain. The coated portion of the buried piping shall extend overground at least up to 600 mm above finished ground level and sealed against entry of moisture. Platforms and crossovers with appropriate handrails shall be provided for accessibility, ease of operation and maintenance of above ground piping where required. Whenever mainline pipe is e laid below the boundary wall in any pipeline installation, suitable concrete plinth beam design at shall be followed for boundary wall, so that load of wall is transferred to plinth beam and not to mainline pipe. or 5.3 PROTECTION OF FACILITIES ct 5.3.1 Properly laid out roads around various facilities shall be provided within the installation for smooth access of fire tenders/other emergency vehicles etc. ire 5.3.2 The boundary wall around the installation shall be constructed as per the directives of the D Ministry of Home Affairs or any other Government directive. In any case, the boundary wall shall be of minimum 3 M height from both side of boundary wall. Additionally 600 mm diameter concertina coil on top of the wall shall be provided. ty 5.3.3 Emergency exit (to a safe place) with proper gate(s) shall be provided at all installations such as fe pump station, intermediate pump station, intermediate pigging station, pump station with tank farm, delivery / terminal station. Emergency exit gate shall be away from main gate and always Sa be available for use of personnel evacuation during emergency. 5.3.4 At intermediate pigging station and sectionalizing valve station, Close Circuit Television (CCTV) camera and / or intrusion alarm system should be provided. At pump station, delivery / terminal ry station CCTV camera shall be installed at the security gate and at other operationally critical locations like storage tank, pump house area, Scraper barrel, filters, manifold, SLV etc and as st decided by operating company. Monitoring of CCTVs shall be done from control room of respective station/ jurisdiction. The CCTV data shall be stored for a minimum period of 90 days du or in line with prevailing MHA/IB norms. In 5.3.5 All cross country pipeline system shall be equipped with Supervisory Control and Data Acquisition (SCADA) system for pipeline length of 50 KM and above or line fill of 5000 KL and above. SCADA system shall also be provided for all pipelines laid in critical consequence areas il (CCA). O In case of short pipeline networks (less than pipeline length of 50 KM or line fill less than 5000 KL) suitable alternative arrangement shall be provided to facilitate monitoring and control of the pipeline which inter alia should include at least monitoring of pressure, temperature, flow open/close status of valves etc. of entire pipeline system. 5.3.6 A system for real time leak detection based on techniques such as Real time transient model (RTTM) / negative pressure wave/ Statistical Analysis alongwith an OFC based distributed acoustic / temperature sensor should be provided. The system should have sufficient accuracy to limit the loss of containment. Provision for Leak detection system is mandatory for pipeline length of 50 KM and above or line fill of 5000 KL and above and also for all pipelines laid in critical consequence areas (CCA). 5.3.7 Pipeline intrusion detection system for real time monitoring and detection of third party activities to avoid unauthorised intrusion on the pipeline ROU shall be installed in all cross country  OISD/DOC/06/2024/01 OISD-STD-141 Page no. 15 CROSS COUNTRY LIQUID HYDROCARBON PIPELINE pipelines of length 50 KM and above and for all pipelines laid in CCA, to ensure public safety and security of pipeline. In pipelines of length less than 50 KM also, provision for installation of similar system is recommended. 5.4 SCADA REQUIREMENTS 5.4.1 Pipeline system equipped with SCADA system provided in line with clause 5.3.5 above shall be monitored and controlled from SCADA to ensure effective and reliable control, management and supervision of the pipeline with an objective for: e (a) Real Time monitoring of various pipeline parameters like Pressure, Temperature, Flow, Status of equipment. at (b) Leak detection reporting and alarm. (c) Remote control operations for Open / Close of valves during emergency shutdown. or 5.4.2 Originating Pump Stations, Intermediate Pump Station, Intermediate Pigging Stations, ct Intermediate Delivery Station and Receiving / terminal Stations, Sectionalizing Valve stations with remote operation capabilities as well as Telecom Repeater Stations / Cathodic Protection ire Stations (in case located independent of other facilities) should have suitable field signals’ connectivity with the control system. 5.4.3 D The SCADA system should be adequate (without adding any hardware to the system at Master Station and remote workstations) to accommodate future expansion without any limitations and ty without affecting the various system performance parameters. fe 5.4.4 The Communication protocol with RTU’s should conform to IEC 60870-5-101 or IEC 60870-5- 104 or DNP3 or DNP3 SA or DNP3 over TCP / IP or Modbus/ TCP or any other available Sa protocol as per government guidelines. 5.4.5 Master Station (MS) shall have the complete SCADA database and integrated alarm and event summary for overall operations management and control of the entire pipeline network. Backup ry Master Station shall be provided at geographically separate location/station which shall act as hot standby for the primary master station and act so, in case of non-availability of master station due st to any issues. All SCADA database and Integrated alarm and event summary of the entire pipeline network shall be maintained for at least 180 days. du SCADA server history back up shall be maintained for minimum 3 years in any cold storage device. The history back up shall be available in any storage media (CD, hard disk etc.) which In shall be available for retrieving as and when required. 5.4.6 Control Station (CS) / RCP (Repeater cum Cathodic Protection) station / SV station location il should not be located in low lying areas prone to flooding. O 5.4.7 The various process control and telemetry systems shall derive the time reference data from Network Time Protocol (NTP) Server of National Informatics Centre (NIC) or National Physical Laboratory (NPL) or with NTP servers traceable to these NTP servers, for synchronisation of all their systems clocks. Entities having ICT (Information and communications technology) infrastructure spanning multiple geographies may also use accurate and standard time source other than NPL and NIC, however it is to be ensured that their time source shall not deviate from NPL and NIC. Entities may also use the time reference from IRNSS system also. 5.4.8 The pipeline Operating company/ Operator shall have its cybersecurity policy document for security, routine check and maintenance of Operational technologies (OT) system installed in pipelines (e.g. risk analysis of OT system, minimum baseline security, firewall policy, antivirus, its checks and records etc).  OISD/DOC/06/2024/01 OISD-STD-141 Page no. 16 CROSS COUNTRY LIQUID HYDROCARBON PIPELINE The cyber security guidelines such as CERT-IN guidelines, government notifications and relevant national standards shall be followed to address cyber security risk of Operational technologies (OT) system. The international standards such as IEC 62443 may also be referred. 5.5 PIPELINE / STATION VALVES 5.5.1 STATION VALVES Station isolation valves shall be provided at the inlet and at the outlet on each pipeline passing through the pumping station/ intermediate pigging station / terminal station / delivery station piping with remote shut off provision from the control room to isolate the pipeline from station e facilities in case of emergency at station. at In addition, Station limit valve shall be considered at entry and exit of pipeline stations near boundary as per clause no. 5.5.5.1. or 5.5.2 STATION BYE PASS ct Station bye pass system shall be provided to facilitate flow of liquid hydrocarbon in the pipeline bypassing the pumping facilities inside the station premises. ire 5.5.3 CHECK VALVES/ NON RETURN VALVE (NRV) Check Valves/ NRV shall be installed to provide automatic blockage of reverse flow in the piping D system, within the station, wherever required. Check valves/ NRV, when provided in the mainline to minimise pipeline backflow, at locations appropriate for the terrain features (e.g., hills, steep ty slopes, etc.), shall be suitable for passage of all types of pigs including instrumented pigs. fe 5.5.4 FLOW/PRESSURE CONTROL VALVE Design of control valves in stations shall meet the requirement of part I of API 550 / API-RP-553, Sa ISA (Instrument Society of America) S- 75.01 -75.03, IEC -79 and IEC-529 5.5.5 SECTIONALIZING VALVE (SV)/ MAINLINE VALVE (MLV) / STATION LIMIT VALVE (SLV) ry 5.5.5.1 MLV/SLV/SV shall be provided for isolating sections of pipeline and station to: st (a) Limit the hazard and damage from accidental discharge from pipeline. (b) Facilitate repair / maintenance of pipeline. du Station limit valve (SLV) shall be provided at the entry and the exit of pipeline stations near boundary wall or at suitable safe location away from process area (inter distances as per In Annexure-III). All SLV shall have remote shut off provision from the control room to isolate the pipeline (mainline) from station facilities in case of emergency. il 5.5.5.2 Sectionalizing valves shall be installed wherever required for operation and maintenance and O control of emergencies. Factors such as topography of the location, ease of operation and maintenance including requirements for section line fill shall be taken into consideration in deciding the location of the valves. In critical consequence areas, inter-distance between sectionalizing valves shall be decided based on Risk assessment outcome. Also if there is significant difference of hydraulic gradient in pipeline such as steep slope or hilly terrain, provision of additional sectionalizing valve should be considered or as decided by operating company. However, in any case the distance between two consecutive sectionalizing valves shall not be more than 50 KM. 5.5.5.3 Sectionalizing valves shall be installed on upstream and downstream of perennial/ major river crossings and public water supply reservoirs (for drinking purpose). Location of such valves on either side of the water bodies shall be decided based on factors such as topography of the location, ease of operation and maintenance and section line fill. These upstream/downstream  OISD/DOC/06/2024/01 OISD-STD-141 Page no. 17 CROSS COUNTRY LIQUID HYDROCARBON PIPELINE sectionalizing valve shall be as close to water body as far as feasible, but should not be more than 6 KM from edge of perennial / major river crossings and public water supply reservoirs. 5.5.5.4 The valve stations shall be located at a readily accessible location such as near roads and shall be provided with an access road from the nearest all weather metalled road. The facilities within valve station shall be secured by providing a suitable boundary wall / fencing around the installation with a gate. 5.5.5.5 For unmanned sectionalizing valve stations, provision for remote operation of valve shall be available. Considering the requirement of ESD for entire pipeline as per clause 6.2.1, the provision of remote operation of valve should be available for manned SV stations as well. Additionally, hydrocarbon detectors (HCD) shall be provided near sectionalizing valve at e unmanned SV stations. At manned SV station, operator may provide HCD at SV as per their operation philosophy. at 5.5.5.6 Sectionalising valve and Station limit valve shall preferably be buried and provided with a stem or extension in such a way that the centre of wheel / actuator is at approximately 1.0 m above the ground level for ease of operation. Sectionalizing valve on the main pipeline shall be of full bore ct type conforming to the minimum requirements of API 6D “Specification for Pipeline and Piping Valves”. Isolation of earthing of actuator to be done to avoid interference in CP. ire 5.5.5.7 Pipeline sectionalizing valve may be manually / electrically / pneumatically or hydraulically operated. In order to minimize potential leak sources, valves used in mainline shall be with butt- D weld ends. Valves used in buried portion shall be with butt weld joints only, except at the locations where hot tapping operation is to be carried out for which, buried flanged end valve may ty be provided. Valve surface shall be applied with suitable corrosion protection coating. fe 5.5.5.8 All joints between the mainline pipe and the Station limit valve shall be butt welded. Valves at Scrapper barrel and at barrel T-point can be welded or flanged end type. Sa 5.5.5.9 Pressure transmitters on both side of sectionalizing valve in mainline should be provided to monitor pipeline pressure. ry 5.6 PIGGING FACILITIES st 5.6.1 All cross-country pipelines of size ≥ NPS 4 and ≥ 10 KM long shall be provided with pigging facilities. For pipelines not falling in this category, it is recommended that these cross country du pipelines should also be made suitable for pigging. In case of space constraints for pig barrels, temporary pig barrels or three way full bore pigging valve should be considered for cleaning pigging and Intelligent pigging. While using temporary pig launching/receiving barrel / three way In valve, Job safety analysis to be carried out before pigging. 5.6.2 Distance between consecutive pigging stations shall be determined based on the diameter of il pipeline, type of product, elevation profile, cleaning efficiency, nature of pigging operation and O capability of the pigs. 5.6.3 Access to Pigging stations shall be provided with all-weather road. 5.6.4 Pigging facilities should be designed to be suitable for: (a) access to the pig traps; (b) handling of pigs; (c) isolation requirements necessary for pig launching and receiving; (d) draining of carried over muck / condensate during pigging operation; (e) direction of pigging including bi-directional pigging; (f) minimum permissible bend radius and the distances between bends/fittings; (g) variation in pipe diameter and wall thickness; (h) pig signallers.  OISD/DOC/06/2024/01 OISD-STD-141 Page no. 18 CROSS COUNTRY LIQUID HYDROCARBON PIPELINE The safety of access routes and adjacent facilities shall be considered when determining the orientation of pig traps. 5.6.5 PIG TRAPS / PIG BARRELS 5.6.5.1 Pig traps shall be capable of handling all types of pig including intelligent pig. Diameter of pig barrel shall be suitable for handling all type of pigs. Diameter of major barrel for launcher/receiver should be minimum 2 size higher than mainline pipe size. The pig barrel shall be provided with quick opening end closures equipped with safety locking device. Pig traps shall be designed as per ASME B31.4 and quick opening end closure shall be designed in compliance with ASME section VIII of Boiler & Pressure vessel code. 5.6.5.2 Suitable arrangements for safe launching, retraction, handling and lifting of pigs should be e provided at the pigging station. Vents, drains and pressure indicators shall be provided on both minor and major barrels for monitoring and release of residual pressure. Facility for nitrogen at purging / water flushing of the barrel should be provided for safe retrieval of pig. or 5.6.5.3 Pig signallers with local indication as well as signal in control room shall be installed on the pipeline and minor pig barrel to track the passage of pig. ct 5.6.5.4 Centreline elevation of pig barrel shall be such as to allow easy insertion / retraction of pigs and ire operation of quick opening closure. Elevation of approximately 1.0m above finished grade / pavement level is recommended. Necessary provision / pit should be provided to divert remaining liquid from the barrel to the sump tank / OWS. D 5.7 BENDS ty The minimum radius of Cold Field Bend shall be as per Table -2 below. Use of Mitre bend shall not be permitted. Factory made bend of bend radius less than 3D shall not be permitted. fe TABLE - 2 Sa Minimum Bend Radius Nominal Pipe Minimum Bend Size Radius 12 and Smaller 18D ry 14 21D 16 24 D st 18 27D du 20 and larger 30 D Where ‘D’ is the outside diameter of the steel pipe. In 5.8 INSULATING/ ISOLATING JOINT Insulating joints shall be provided to electrically isolate the buried pipeline from the above ground il pipeline to prevent the CP current drainage. Insulating joints shall be monolithic type and shall O allow smooth passage of pigs. Insulating joints separating buried and above ground pipeline shall be installed in above ground portion of pipeline, immediately after the buried /above ground transition point. Each insulating joint shall be provided with surge diverters and shall have provision for checking integrity of the insulating joint. The insulating joint shall be provided with Surge Diverter of appropriate rating and in case the pipeline monitoring indicates evidence of AC interference, the CP protected side of the IJ shall be grounded through zinc anode or de-coupler. On the unprotected side, the connected piping shall be grounded through station grounding grid as minimum subject to the condition that the maximum resistance of the earthing system is in accordance with IS 3043. Branch tapping of TT/ PT fittings from Mainline shall be electrically isolated by using insulating joint/ equivalent isolation system to ensure that CP current is not getting drained from TT/ PT. 5.9 BRANCH CONNECTION  OISD/DOC/06/2024/01 OISD-STD-141 Page no. 19 CROSS COUNTRY LIQUID HYDROCARBON PIPELINE 5.9.1 Branch connections of size below NPS 2 are not recommended in buried pipeline section. 5.9.2 All branch connections from mainline shall be provided with a weld end isolation valve located at a minimum possible distance from the main pipeline. 5.9.3 All branch connections or side tap on the piggable section of the pipeline having diameter equal to or exceeding 40 percent of the main pipe diameter, shall be made using flow tee/ barred tee in order to enable smooth passage of all types of pigs. Such flow tee / barred tee shall comply with the requirements of ASME B 16.9, MSS-SP-75 or equivalent. 5.10 SUPPORTS FOR ABOVE GROUND STATION PIPING 5.10.1 Piping supports shall be designed in a manner such that excessive local stresses, axial or lateral e friction forces are not generated in the pipe. Due consideration shall be given to the effect of such supports on possible fatigue failures, corrosion and local stress concentrations. at 5.10.2 Wherever non integral attachments, such as pipe clamps and ring girders are used, adequate or precautions shall be taken to prevent corrosion at or near the contact points. ct 5.10.3 A minimum ground clearance of 300 mm should be maintained for all above ground piping to prevent corrosion. ire 5.10.4 If a pipeline is designed to operate at Hoop stress of more than 20% of the specified minimum yield strength of the pipe, support if welded to the pipe shall be made to a separate cylindrical D member which completely encircles the pipe and this encircling member shall be welded to the pipe by continuous circumferential welds at both ends. Indicative drawings for pipe supports are ty attached as Annexure-X. fe 5.11 FLANGED OR THREADED JOINTS, BOLTS, NUTS, GASKET AND OTHER FITTINGS Sa 5.11.1 Threaded joints shall not b