The project envisages laying of 740 km long cross country pipeline from BPCL’s terminal at Manglya (Indore) to Piyala terminal which is proposed to be developed adjacent to the existing LPG bottling plant at Piyala in Haryana and a 54 km long feeder pipeline from Piyala to Bijwasan for the movement of MS, SKO and HSD from Mumbai refinery.

2.1 Project justification
The extension of Mumbai-Manglya pipeline to Piyala with a feeder line to Bijwasan shall ensure product availability to cater to the petroleum requirement in the Northern part of India. The following are the justifications outlined for implementing the proposed project:

The project will help BPL create better negotiating strengths for products/tariffs with oil marketing companies.

The project will be beneficial for meeting the petroleum product demand more competitively in the Northern Region.

The project will help in smooth evacuation of Mumbai Refinery

The project will reduce rail/road and reduce hazards of environmental pollution associated with transportation of products by road or rail.

Reduced consumption of petroleum products due to reduction in vehicular traffic once the transportation of petroleum product is ensured through pipeline.

2.2 Pipeline length, route and major crossings
The proposed pipeline route has been finalized after evaluation of several route alternatives. A schematic representation of the proposed pipeline route is presented in Fig. 1. The total length of the proposed pipeline is 740 km. Of this the length of main pipeline is 686 km and feeder pipeline is 54 km. The finalized route now recommended for lying of the pipeline would pass through the 15 districts in five states (Table 2.1 & Fig. 2).

Table 2.1 Pipeline route through different states and districts in India.

 The following are the major crossings along the pipeline route:

Railways - 17

National Highways - 10

State Highways - 23

Major River - 11

Canals - 33

 2.3 Pipeline design parameters

The following are the design specifications and parameters for the proposed pipeline:

The line pipe shall conform to API specification 5L. The grades and size of line pipe shall be API 5L Gr. X-60 and 16” NB for Manglya-Piyala section and API-5L Gr. B & 8” NB for Piyala-Bijwasan. Pipe wall thickness shall conform to ASME B31.4 and shall also meet the requirements of OISD 141. All pipeline materials downstream of the main line pumps, such as valves, flanges and fittings etc. shall be of Class 600# rating.

2.3.1 Location and design features of sectionalising valves and station block valves

The throughput estimates for the Phase-I of the project have been made for the year 2011-12 which is assumed as 2.2 MMTPA for Manglya to Piyala and 1.0 MMTPA from Piyala to Bijwasan. However, the pipeline optimization and selection of the size has been done considering the projected throughput of 3.5 MMTPA for 2019-20.
 

A pump configuration of one main & one standby pump at Manglya and one main and one standby pump at Intermediate Pumping Stations for particular pipeline size has been considered for the optimization study.

Adequate number of sectionalizing valves (27 nos.) and Station Block Valves shall be motor operated, All sectionalizing valves shall have provision for remote operation (ROV). The sectionalizing valves shall be buried and provided with stem extension. The mainline valves shall be full-bore type ball valves to allow smooth passage of scrapers or pigs through them. These valves shall conform to API-6D. In addition to the above, two sectionalizing valves shall be provided for segregation of feeder pipeline at strategic locations.

Pig Launching facilities at Manglya Terminal, Pig Launching and Receiving facilities at IP station, Mathura Installation & Kota and Pig receiving facilities at Piyala will be provided to facilitate effective monitoring of the pipeline condition to enhance safe operation of 16” diameter pipeline from Manglya to Piyala.

Pig launching facility and pumps at Piyala installation and Pig receiving facilities at Bijwasan installation shall be provided for 8” diameter feeder pipeline.

Pipeline and associated facilities shall be constructed in accordance with ASME B 31.4 and other applicable API standards. The pipeline shall be laid underground with minimum 1 m cover. Additional cover, wherever required, shall be provided in accordance with OISD 141. Welding shall be carried out as per API 1104. All welds shall be 100 % radio -graphed. After the installation is completed, the entire pipeline shall be hydrostatically tested. The hydrostatic test pressure at any test section shall be 1.5 times the design pressure. Hydrostatic testing of terminal piping shall be carried out separately.

2.4 Construction methodology
For the purpose of regulating planning and conducting detailed route alignment, and later for the purpose of project administration and supervision of construction and operation of the proposed pipeline project, the entire pipeline has been divided into the five spreads (Table 2.2).

Table 2.2 Different spreads of Manglya-Bijwasan pipeline.

The pipeline will be laid with a minimum cover of 1.0 m below the ground level and the land will be reinstated to its original land use after completion of laying the pipeline.

In general, the pipeline will be kept at a minimum distance of 100 m from any organized habitat to avoid rehabilitation and resettlement issues associated with the project as far as possible. The width of Right of Use (RoU) will be 18 m and will be reduced at places wherever restrictions dictate reduction in RoU. For the construction of main pipeline in different type of strata and installation of associated pipeline crossings, the following methodology has been considered:

Common land crossing
Where the pipeline route passes through the areas with black soil, the pipeline is interspread with murram and gravel. Conventional trenching and back filling using trenching machine is considered for laying of the pipeline in such areas. Wherever hard rock soil with murram, gravel and weathered rock are encountered en route (mostly in river crossing and protected forest areas), excavation shall be undertaken with the help of dozer/ripper and back-hoes. Mechanical equipment for rock excavation may also be used. A minimum of 150 mm thick layer of soft back-fill material will be provided all around the pipeline prior to back filling the trenches with excavated material in rocky terrain.

Rail
All railway lines shall be crossed by boring method. Approval of designs and construction methodology shall be obtained from concerned railway authorities. Pipeline at railway crossings shall be provided with casing pipe. The carrier pipe will be provided with casing pipe. The minimum clear cover at the crossing above top of pipeline will be 1.7 m. The railway crossings will comply with the requirements of API 1102 and Indian Railway Authorities. Casing insulators and end seals will be provided to isolate carrier and casing pipes.

Roads & canals
Road crossings shall comply with the requirements of API 1102 and the requirements of the concerned road authorities. Pipeline at national highway and states highway crossings shall be provided with the casing pipe. Metalled roads other than the national highways and state highways shall be crossed by open cut method. Irrigation canals shall be crossed by boring method wherever required by the statutory authorities. All other minor canals and nallas crossings shall be carried out with conventional open cut method unless directed otherwise by the concerned authorities. The canal crossings and other water crossings shall be provided with a minimum clear cover of 1.5 m.

Minor river crossing
Minor rivers crossings are considered to be crossed by conventional open cut method. Pipeline shall be installed approx. 1.5 m below the lowest bed level.

Major river crossing
Major river crossing i.e. Chambal would be carried out by Horizontal Directional Drilling (HDD) method. Pipeline shall be installed approx 2.5 m below the lowest bed level.

For river crossings, lowest bed level shall be calculated after giving due consideration to scour depth of such water crossings. The pipeline shall be concrete coated, if required, to provide sufficient negative buoyancy. Corrosion inhibitor will be used along with the products to be transported to protect internal corrosion.

2.5 Safety features and measures

Cathodic Protection System
For the proper functioning of cross-country pipeline system, both from the safety and economy points of view, the pipeline will be protected against corrosion, which also pose potential danger to the health of the pipeline.

External pipeline protection will be a combination of corrosion coating and cathodic protection techniques. During the construction phase, the pipeline will be protected by temporary cathodic protection using sacrificial anodes, with a design life of 2 years. Permanent cathodic protection system for the pipeline shall be by impressed current method, with a design life of 35 years.

A dedicated low capacity optical fiber cable link is envisaged to provide data communication and voice communication link between dispatch terminal, receiving terminal, en route Top of Points (TOP’s) and Sectionalizing Valve (SV) Stations. This shall be hooked up with the existing tele-communication system of Mumbai-Manglya pipeline.

Supervisory Control and Data Acquisition (SCADA)
The pipeline operating parameters (like pressure, temperature, flow rate, density) shall be constantly monitored at the existing MCS at Mumbai and also the status of cathodic protection system and SV valves will be checked through SCADA. Additional Remote Terminal Units (RTU) shall be procured for Manglya-Piyala and Piyala-Bijwasan section and hooked with Master Control Systems (MCS) of SCADA system already provided.

Leak detection
Software for accurate and timely detection of leak already provided for Mumbai-Manglya pipeline shall be utilized for Manglya-Piyala and Piyala-Bijwasan section. The selection of system is governed by instrument’s accuracies and statutory requirements.

Fire prevention and protection measures
For ensuring fire protection, marketing tunnel shall be fully covered by hydrant systems with hydrant and monitors located as per OISD/CCOE rules and design guidelines. Planned and non planned buildings and petroleum storage tanks and handling areas will have portable and wheeled fire extinguishers. There would be adequate facilities for installing fire water pumps, fixed water spray systems and foam systems.

2.6 Description of Piyala terminal and storage tanks
A new P/L receipt terminal shall be constructed on 43 acres of land near BPC’s existing LPG bottling plant at Piyala (Haryana). At Piyala, products received from pipeline shall be stored in respective storage tanks. Type of storage tanks considered for different products in the terminal are as follows:

MS : Floating roof

SKO : Floating roof

HSD : Floating roof

Slop : Cone roof

Four tanks each shall be provided for MS and HSD and 2 tanks for SKO. Two tanks each of MS/HSD shall be used for storing Bharat Stage II product which is required for feeding up all northern locations and balance two tanks each of MS/HSD shall be utilized for storage of Euro 3 equivalent specification product for feeding Delhi/NCR markets. Tank to tank transfer facility shall be provided using products transfer pumps.

Conclusions and Recommendations