PIPELINE DESIGN

Delivering excellence through people

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ENGINEERS INDIA LIMITED

EPC and Total Solutions Consultancy Organization

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Petroleum Refineries Petrochemicals Pipelines Offshore Platforms Gas Processing Metallurgy Ports & Terminals Highways and Airports
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EIL OFFICES
HEAD OFFICE REGIONAL OFFICES NEW DELHI VADODARA, CHENNAI KOLKATA MUMBAI 29 LOCATIONS (INDIA) 9 LOCATIONS (OVERSEAS) 10 LOCATIONS LONDON, LIBYA ABU DHABI, ITALY, SAUDI ARABIA , QATAR, KUWAIT

PROCUREMENT OFFICES SITE OFFICES

INSPECTION OFFICE OVERSEAS OFFICES

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PIPELINE DESIGN
SERVICES OFFERED BY EIL
Project Implementation Services  Feasibility Studies  Project Management  Planning & Scheduling  Process Design  Detailed Engineering  Procurement Services  Construction Management  Commissioning and Plant Start-up Assistance Specialist Services  Heat & Mass Transfer Equipment Design  Environment Engineering  Information Technology Services  Specialist Materials and Maintenance Services  Plant Operation & Safety  Risk Analysis  Advanced Control & Optimization

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PIPELINE DESIGN
EIL EXPERIENCE
1975 1979 First major project Crude Oil Loop Line for Oil India Ltd. First major overseas project 150 km Multi Product Pipeline for Abu Dhabi National Oil Company First major high pressure Gas Pipeline Project - 1800 km Gas Transmission Network for GAIL

1984

Over 40 major pipeline projects completed.

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PIPELINE DESIGN
Major Onshore Projects (Completed)
DESCRIPTION HAZIRA-BIJAIPURHAZIRA-BIJAIPURJAGDISHPUR (HBJ) MAQTA-ALMAQTA-AL-AIN PIPELINE KANDLAKANDLA-BHATINDA GAS REHABILITATION & EXPANSION PROJECT (GREP) MUMBAI MANMAD VIZAGVIZAG-VIJAYWADA JAMNAGARJAMNAGAR-LONI LPG PIPELINE COCHIN KARUR PIPELINE CLIENT GAIL ADNOC IOCL GAIL YEAR 1989 1992 1996 1998 SIZE 36/30/24/18 30 /12 22/14/10 36 LENGTH (KM) 1800 166 1443 505 SERVICES NATURAL GAS NATURAL GAS MULTIPRODUCT NATURAL GAS

BPCL HPCL GAIL PETRONET

1998 1998 2001 2001

18 18 16/14/12/8/ 6 18 /14

260 360 1235 289

MULTIPRODUCT MULTIPRODUCT LPG (LIQUIFIED PETROLIUM GAS) MULTIPRODUCT

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PIPELINE DESIGN
Major Onshore Projects (..contd) (Completed)
DESCRIPTION VIZAG SECUNDERABAD LPG PIPELINE MANMADMANMAD-MANGALAYA PIPELINE MANGALOREMANGALORE-BANGLORE DAHEJ VIJAIPUR PIPELINE INTER REFINERIES PIPELINES PROJECT, ABU DHABI MANGALAYAMANGALAYA-BIJWASAN PIPELINE MUNDRAMUNDRA-DELHI PIPELINE CLIENT GAIL BPCL HPCL GAIL YEAR 2002 2003 2003 2003 SIZE 12/10 14 24 /20 42 10 12 16 16/8 18/16 LENGTH (KM) 600 358 364 610 230 230 208 775 1050 SERVICES LPG (LEQUIFIED PETROLEUM GAS) MULTIPRODUCT MULTIPRODUCT REGASIFIED LNG NAPHTHA, MULTIPRODUCT & SRR MULTIPRODUCT MULTIPRODUCT

TAKREER BPCL HPCL

2004 2006 2006

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PIPELINE DESIGN
Major Onshore Projects (contd) (Completed)
DESCRIPTION PUNE SOLAPUR PIPELINE DABHOL PANVEL PIPELINE PROJECT (PH-I) (PHDABHOL PANVEL PIPELINE PROJECT (PH-II) (PHCLIENT HPCL GAIL GAIL YEAR 2007 2007 2007 SIZE 14 / 12 30 30 LENGTH (KM) 182 / 161 187 120 SERVICES MULTIPRODUCT REGASIFIED LNG REGASIFIED LNG

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PIPELINE DESIGN
Major Offshore Projects (Completed)
DESCRIPTION BOMBAY HIGH URAN TRUNKLINE (BUT) SOUTH BASSEIN HAZIRA TRUNKLINE HEERAHEERA-URAN TRUNK LINE ICP - HEERA TRUNKLINE SECOND BASSEIN HAZIRA TRUNKLINE MUMBAI HIGH URAN TRUNKLINE (MUT) CLIENT ONGC ONGC ONGC ONGC ONGC ONGC YEAR 1979 1986 1996 1996 1995 2005 SIZE 30/26 36 26 /24 30/22 42 30/28 12 to 22 LENGTH (KM) 200 x 2 220 85 x 2 145 245 205 x 2 100 SERVICES CRUDE, GAS GAS CRUDE, GAS CRUDE GAS CRUDE, GAS

IN-FIELD PIPELINES OF BOMBAY-HIGH, BASSEIN, HEERA, NEELAM, PANNA, MUKTA.

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PIPELINE DESIGN
Major Onshore Projects (Current)
DESCRIPTION VIJIPUR DADRI BAWANA PIPELINE (VDBPL) MUNDRA BATHINDA PIPELINE (MBPL) BINA KOTA PIPELINE VADINAR BINA PIPELINE NUMALIGARH SILIGURI PIPELINE COMPRESSOR STATIONS CLIENT GAIL HMPL BPCL BORL OIL GAIL YEAR 2009 2009 2009 2009 2009 --SIZE 48/ 36/ 20 28/ 30 18 24 16 --LENGTH (KM) 500/ 38/ 55 424/ 590 257 935 400 --SERVICES REGASIFIED LNG CRUDE OIL MULTI PRODUCT CRUDE OIL MULTI PRODUCT REGASIFIED LNG

IN-FIELD PIPELINES OF BOMBAY-HIGH, BASSEIN, HEERA, NEELAM, PANNA, MUKTA.

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PIPELINE DESIGN
SECTION-1

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PIPELINE DESIGN
CONTENTS
INTRODUCTION
 

Modes of Transportation Benefits of Pipelines

PIPELINE DESIGN
   

Stages of Pipeline Project Codes and Standards Design Installation, Testing & Commissioning

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PIPELINE DESIGN
Oil and Gas Production in India
OIL (ONGC, OIL, CAIRN, RIL) GAS 115 MMSCMD 33 MMTPA

(ONGC, GAIL, OIL, GSPC, RIL)

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PIPELINE DESIGN
Refining Scenario- India
350

Capacity - 2006-07 NOC 105.5 MMT Others- 43.5 MMT

302

300

(MMT)

250

235

200

149
150

100

70

50

1998-99

2006-07

2011-12

2016-17

(Actual) Year
Engineers India Ltd Delivering excellence through people Source: Report of Working Group on P&NG Sector for the XI Plan
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PIPELINE DESIGN
Modes of Hydrocarbon Transportation - India
35% 30%

Pipelines Road Tankers Rail Tankers Water Carriers

32% 32% 26% 10%

25% 20% 15% 10% 5% 0% % Share Pipelines Road Tankers Rail Tankers Water Carriers

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PIPELINE DESIGN
Benefits of Transportation by Pipelines
Safer mode of transportation Environment friendly Least energy requirement Lowest maintenance costs Minimal impact on land use pattern Negligible loss of product in transit High reliability Multi-product Transportation

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PIPELINE DESIGN Energy Savings

Energy Inte nsity for Various M ode s
Energy Consumption in % of energy 4 3.5 Transported 3 2.5 2 1.5 1 0.5 0 LiquidPipelines LiquidCoastal LiquidTrains LiquidTrucks CoalTrains CoalCoastal N.GasPipelines 0.8 0.5 1 0.8 1.1 2 3.2

Pipelines are the most energy efficient modes of transportation

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ECONOMICS OF PIPELINE TRANSPORTATION

Transmission losses
Losses During Transportation

Rail/Road

Pipelines

0.1

0.2

0.3

0.4

0.5

% Loss of Total Volum e Transported

Transmission losses are lowest in Pipelines

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PIPELINE DESIGN
Products Transported
Crude Oil Petroleum Products (MS, HSD, ATF, SKO) Water & Effluents LPG Natural Gas Slurries

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PIPELINE DESIGN

Types of Pipelines
ONSHORE (LAND) & OFFSHORE (SUBMARINE) PIPELINES
  

Trunk Pipelines Spur/ Branch Pipelines Marine Offloading Terminals & Outfalls

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PIPELINE DESIGN

Capital cost: Typical breakup

Percentage of Capital Cost. Sr No. 1 2 3 4 5 6 7 8 9 10 11

Item Description
Liquid Lines Survey, ROW & Compensation Line Pipe Steel Cost Main line materials Coating of Pipes Mainline Construction Cathodic Protection Telecommunication, SCADA and RCPs Pump / Compressor Stations Delivery Terminal facilities Project Management SubTotal
2% 33% 2% 11% 33% 1% 5% 5% 2% 5% 100%

Gas Lines
1% 45% 3% 6% 25% 1% 2% 12% 1% 4% 100%

Pipes, prime-overs and construction constitute big ticket items

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PIPELINE DESIGN
Marine Offloading Terminal

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PIPELINE DESIGN
Open sea Jetty

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PIPELINE DESIGN
HBJ GAS PIPELINE NETWORK
UTTAR PRADESH
N

DELHI

DADRI

ANOLA SHAHJAHANPUR

RAJASTHAN
GADEPAN ANTA

BABRALA

INDIA
AURAIYA JAGDISHPUR

GUJARAT
JHABUA ARABIAN SEA HAZIRA

BIJAIPUR

KEY PLAN LEGEND COMPRESSOR STATION RECEIVING TERMINAL DESPATCH STATION

MADHYA PRADESH

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PIPELINE DESIGN
Major Pipelines in India

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PIPELINE DESIGN
Pipeline Construction Video
Video for Mangalore Bangalore Pipeline

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PIPELINE DESIGN
SECTION-2

PIPELINE DESIGN CODES AND STANDRADS

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PIPELINE DESIGN
Stages of Pipeline Project
Conceptualization
  

Establish Requirement Evaluate Alternatives Finalize the Concept

Feasibility Study
    

Pipeline Route Study and Selection Hydraulic Studies and Optimization Establish Project Cost Project Implementation Scheme Environmental Impact Assessment & Risk Analysis

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PIPELINE DESIGN
Stages of Pipeline Project
Basic Engineering
  

Process Design and Sizing Optimization Studies Route Surveys and Investigations

Detailed Engineering
    

Engineering Design Basis Route Engineering and Engineering Analysis Specifications and Job Standards Engineering for Procurement Installation Engineering and Construction Procedures

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PIPELINE DESIGN Major Codes & Standards

Code/Standard
ASME B 31.8 (2003) ASME B 31.4 (2006) OISDOISD-141 (2003) OISDOISD-214 (2006) OISDOISD-226 (2007) API 5L / ISO 3183 : 2007 API RP1102 API 1104 API 6D / ISO 14313 DNV OS-F101 OSOther References

Title
Gas Transportation and Distribution Piping Systems Pipeline Transportation Systems for Liquid Hydrocarbons and other Liquids Design and Construction Requirements for Cross-Country CrossHydrocarbon Pipelines Cross-Country LPG Pipelines CrossNatural Gas Transmission Pipelines and City Gas Distribution Networks Specification for Line Pipe Recommended practice for Rail and Highway crossings Standard for welding pipeline and related facilities Pipeline Valves Submarine pipeline systems Applicable Standards / Specs of ASME, API, NACE, MSS, BS and DIN
Pipeline Design Slide Number - 31 of 77

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PIPELINE DESIGN Major Codes & Standards

Type of Crossing
ROU & Land Acquisition

Approval Authority
Central/State Govt. as applicable (As per PMP Act 1962) NHAI

National Highway Crossings

SH/ MDR/ ODR Crossings Railway Track crossings Crossing through Forest land River/Canal crossings

PWD Indian Railways Forest Authority Irrigation/Canal Authority

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LIST OF SOFTWARES USED IN PIPELINE ENGINEERING

        

CAESAR-II CAESARAUTOPIPE IPMCS MRPACK SORPS PIPECALC OFFPIPE PRISE PIPECROSS

PIPELINE STUDIO TGNET TLNET HYSIS

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PIPELINE DESIGN Optimal sizes of various capacities

Economy of scale
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PIPELINE DESIGN
Route Selection
Routing Considerations
Pipeline length Obstructions & Sensitive areas Installation Limitations Crossings

Surveys
Topographical Geo-technical Population Density Index Soil Resistivity Cadastral
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PIPELINE DESIGN
Typical Pipeline Route Map
The drawing, design and details given on this format are the property of ENGINEERS INDIA LIMITED. They are merely loaned on the borrower's express agreement that they will not be reproduced, copied, exhibited or used, except in the limited w ay permitted by a written consent given by the lender to the borrower for the intended use.

BHATINDA
Ch. 1012.67 km

RANSISAR Ch. 855.01 km

IP-1 & IPS-F

PROPOSED PIPELINE
IPS-2

JUD Ch. 593.88 km

IPS-F

GAILAWAS Ch. 527.87 km

LEGEND:
PROPOSED MUNDRA-BHATINDA PIPELINE (28" NB) DESPATCH TERMINAL AND PUMPING STATION RECEIPT TERMINAL INTERMEDIATE PUMPING STATION (IPS) INTERMEDIATE PIGGING STATION (IP) FUTURE PUMPING STATION (IPS-F) NOTES: 1. PIPELINE ROUTE SHOWN IS INDICATIVE ONLY. 2. CHAINAGES INDICATED ARE APPROXIMATE.

JORAWARPURA Ch. 313.63 km

IPS-1

JHEKDA Ch. 226.72 km

IPS-F

MUNDRA
Ch. 0.00 km

PROJECT : ENGINEERS INDIA LIMITED

NEW DELHI

REV. OVERALL PIPELINE ROUTE MAP

AC REV. DA TE REV ISION BY RK CHK VM AP PROVED AP PROVED

CLIENT JOB NO

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: M/s GGSRL : 6812

Pipeline Design
1-1641-0503 REV.0 A3-420x297

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PIPELINE DESIGN

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PIPELINE DESIGN
Material Selection & Corrosion Control
Assessment
Nature of the Product Design Life Product Temperature

Materials
Carbon Steel (CS) NACE Carbon Steel CRA Clad CS CS with internal Coatings Non-Metallic Materials

Corrosion Protection
Material Chemistry Internal Coatings Product Conditioning Corrosion inhibitors Corrosion Allowance
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PIPELINE DESIGN
Design and Analysis
Wall Thickness Calculations Anti-Buoyancy Measures Piping Stress Analysis Buried Pipeline Analysis Crossing Design

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PIPELINE DESIGN
Steel Pipe Wall Thickness Calculation
LIQUID PIPELINE (ASME B 31.4, Cl. 404.1.2) GAS PIPELINE (ASME B 31.8, Cl. 841.11)

t = PiD 2.S where Pi Internal design pressure S allowable stress = 0.72 x E x SMYS D Outside Diameter of pipe t pressure design wall thickness E Weld joint factor

P = 2St FET D where P Design pressure S Specified minimum yield strength D Nominal OD of pipe t Nominal wall thickness F Design factor E Longitudinal joint factor T Temperature de-rating factor

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PIPELINE DESIGN
Basic Design Factor for Gas Pipelines
LOCATION CLASS Location Class 1 Location Class 2 Location Class 3 Location Class 4 Location Class Classification Location Class 1 : Location Class 2 : Location Class 3 : Location Class 4 : DESIGN FACTOR, F 0.72 0.60 0.50 0.40 e 10 buildings > 10 and < 46 buildings u 46 buildings Multistory buildings

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PIPELINE DESIGN
Line Pipe Selection
Line Pipe Selection Parameters Thickness and Grade Selection Handling and Transportation (d/t ratio) Type of LinePipe Installation Requirements Type of Line Pipes Seamless Electric Welded Longitudinal Seam SubmergedSubmerged-Arc Welded (LSAW) Helical Seam SubmergedSubmergedArc Welded (HSAW)

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PIPELINE DESIGN
Line Pipe Application
Submarine Pipelines
Seamless Pipes (upto & including 16) LSAW Pipes (18 & above)

Onshore Pipelines
Seamless Pipes (upto & including 8) LSAW Pipes (16 & above) HSAW Pipes (18 & above) EW Pipes (4 - 18)

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Manufacturing of Helical Pipes

PIPELINE DESIGN

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PIPELINE DESIGN
Anti-corrosive Coatings
Coal Tar Enamel Coating (BS 4164, AWWA C203)
   

Primer Two layers of coal tar enamel & glass fibre Inner wrap One layer of coal tar impregnated outer wrap Coating thickness 4.7mm First layer of Fusion bonded epoxy Second layer of extruded adhesive Third layer of extruded PE/ PP Coating thickness 2.0 to 3.7 mm 350350-500 micron thick single layer coating 600600-800 micron thick dual layer coating

3 Layer PE/ PP Coating (DIN 30670)

   

Fusion Bonded Epoxy Coating (CSA Z245.20)

 

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PIPELINE DESIGN
3 Layer PE Coating Application

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PIPELINE DESIGN
Major Pipeline Components
Line Pipe & Coatings Scraper Traps & Pig Signallers Long Radius (LR) Bends Insulating Joints Flow Tees Sectionalizing Valves Pumps / Compressors Filters & Meters

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PIPELINE DESIGN
Scraper traps

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PIPELINE DESIGN
Sectionalizing Valve
Spacing  ASME B 31.8 for Gas pipelines  ASME B 31.4 for Liquid Pipelines Location  Pollution Concerns  Statutory Requirements  Prevention of Inventory Loss  Approachability of Valve Station Gas Pipelines Location Class 1 Location Class 2 Location Class 3 Location Class 4 LPG Pipelines Industrial, 12 km (7.5 miles) Commercial & Residential Areas 32 km (20 miles) 24 km (15 miles) 16 km (10 miles) 8 km (5 miles)

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PIPELINE DESIGN
Type of Valves
Full Bore Ball Valves Through Conduit Gate Valves Plug and Check Valves Valve Standard : API 6D/ISO14313 Other Valve Standards: API 600, API 602, BS EN ISO 17292:2004, BS EN ISO 15761:2002, BS 5353
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PIPELINE DESIGN
Ball valves

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PIPELINE DESIGN Plug valve

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PIPELINE DESIGN Check valve

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PIPELINE DESIGN
Major Engineering Deliverables
Design Reports
Design Route Wall

Drawings
Route

Basis

Map Schematic Sheets Layout

Selection Report Design Report Design Report

Pipeline

Thickness Report

Alignment SV

Seismic

Station Layout

Crossing

Equipment Piping

General Arrangement Drawings

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PIPELINE DESIGN
Typical Pipeline Alignment Sheet
INTERSECTION POINTS(IP/TP) DEFLECTION ANGLE DISTA NCE BETWEEN TP & IP's (m)
DISTANCE AS PER GROUND PROFILE TP50 IP5 0/1 TP51 2 98 '20''(L) 187.855 187.993 IP5 1/1 TP52 TP53 TP54 370'54''(L) 339.096 339.126 TP55 TP56 1354'57'' (R) 176.463 176.478 112 5'7''(L) 322.708 322.772 TP57 121'55''(L) 141.760 141.845 TP58 IP58/1 824'45''(R) 45.000 45.093 104.113 104.624 TP59 2 8'32''(L) 224.969 225.022 TP60 140'19''(R) 393.395 393.407 TP61 830'18''(L) 218.000 218.014 348.437 348.444 IP61/1 TP62 152 '57''(L) 326.642 326.679 TP63 104'42''(L) 237.677 237.707 TP64 1025'50'' (L) 65.521 65.728 90.164 90.390 IP64/1 TP65 518'12''(R) 3 84 '58''(R) 518'55''(R) 82'3'' (L) 76.544 76.618 67.046 25.199 85.000 67.049 25.200 85.284 38.749 38.853

STATE , DISTRICT AND MANDAL

TO IRUVADA
PU M RA

TP65 CH. 14134.896m IP64/1 CH.14044.732m EARTHEN EMBANKMENT TP64 CH. 13979.211m

TBM W40 (RL 37.514m) TP50 CH. 10620.558m IP5 0/1 TP51 CH. 10712.803m IP5 1/1 CH. 10797.803m
10 IN 4.7 A 66 DR H.10 C m
TO PE

A ND

IT R M

TELEPHONE LINE CH.14134.896m METAL LED ROAD(ASPHALTIC) CH.14115.309m ELEC. LINE 440V CH.14132.231m

CH. 10687.604m RAIWADA LEFT CANAL (UNLINED) CH. 10691.604m TP52

DR A IN CH .1 1 8 2 4 .6 2 9 m

LOW LYING AREA

TP63 CH. 13741.534m

E LE C T RI CH .1 1 8 4 8 C L IN E .8 8 m

TP57

TP58 CH. 12080.978m TP59 IP58/1 CH. 12125.978m CH. 12230.091m

EARTHEN EMBANKMENT TP60 CH. 12455.060m TP61 CH. 12848.455m IP61/1 CH. 13066.455m DRAIN CH.12903.743m
K K

MA TC H L IN E FO R C ON T . R E FE R D WG NO .4 5 2 9 -1 0-1 6 -7 1 -9 00 5

CH. 10985.658m TP53

CH. 11939.218m

MA TC H L IN E FO R C ON T . R E FE R D WG NO .4 5 2 9 -1 0-1 6 -7 1 -9 00 3

IN TA TO CH

A GUTL GRAVEL ROAD CH.10787.022m

CH. 11062.202m TP55 CH. 11577.761m TP56 CH. 11616.510m HPCL CH. 15.00Km ELECTRIC LINE 440V CH.11018.117m TP54 CH. 11401.298m
K

SV-1 OF GAIL CH.11960.218 m

CH.12747.397m

TBM W49 (RL 25.138m) C A N AL C H 106 91.6m /R L 35.411m OPEN WELL 6m DIA 7.648m FROM C/L CH.11648.136m OPEN WELL 6m DIA 8m FROM C/L CH 11577.761m

VILLAGE BOUNDARY AMRUT APURAM IRUVADA

D R A IN C H 106 64.71m /RL 33. 366m

R O AD C H 107 87.02 m /RL 32 .587m

PUMP HOUSE 4m FROM C/L

SCALE: HORIZONTAL 1:5000 VERTICAL 1: 500

45 43 41 39 37 35 33 31 29 27 25 23 21 37.32 5

D R A IN C H 118 2 4.63m /RL 24.341m

R O AD C H 1 20 60.88m /RL 24.604m

3 2 .587

22 .175

D R A IN C H 121 15.34m /RL 22 .175m

3 2 .444

C A RT T RA CK C H 134 9 2. 61m /RL 33.622 m

39.741 4 2 .491

2 9.815

2 7.370

2 7.904

2 4.858

2 5.138

2 4.341 2 4.675

2 4.604 2 3.667

2 5.884

2 9.135

2 8.935

33.366 35.411 33.560

31.496

30.300

30.557

30.893

40.816

C A N AL C H 140 2 7.73m /RL 39. 741m R O AD C H 140 40. 2 7m /RL 42. 491m

196.96 2

2 48.9 2 9

141.5 22

2 99.2 54

14 2 .134

18 2 .117

1 2 1.660

22 4.969

2 17.539

2 37.676

198.636

176.463

114.747

166.780

2 6.894 2 1.199

90.34 2

44.15 2

48.5 2 1

74.2 19

2 4.2 46

1 2 .543

39.369

37.175

38.749

66.597

2 0.101 34.366

94.141

77.714

75.034

KAJU GARDEN

RICE FIELDS

10.6 2 1

10.665 10.69 2 10.713

11.0 2 5

11.06 2

11.8 2 5 11.849

11.939 11.960 11.97 2 11.984

13.74 2

14.0 2 8 14.040

11.2 59

1 2 .2 30

13.2 48

1 2 .061 1 2 .081

1 2 .115

1 2 .455

1 2 .754

1 2 .848

10.787

10.986

11.401

11.578

11.617

11.758

13.066

13.415

13.493

13.979

10.6 2 1

10.665 10.69 2 10.713

11.0 2 5

11.06 2

11.8 2 5 11.849

13.74 2

14.0 2 8 14.040

11.2 59

1 2 .2 30

13.2 48

1 2 .061 1 2 .081

1 2 .115

12 .455

12 .754

12 .848

10.787

10.986

11.401

11.578

11.617

11.758

11.939

13.066

13.415

13.493

13.979

14.115 14.135

14.115 14.135

19.588

43.684 43.034

2 5.362

2 4.82 8

2 9.2 19

33.622

37.2 19

C A RT T RA CK C H 141 15.31m /RL 43.684m

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A T O PE ND A M RU TH AP UR AM

TBM W57(RL 42.533m) TP62 CH. 13414.892m

TO

ST AT

RAIWADA LEFT CANAL (UNLINED) CH.14027.732m GRAVEL ROAD CH.14040.275m TEMP. HUT ON C/L

HI GH W

AY -S A BB

AV A RA M

DRAIN CH.12115.344m TO AM RUTH APU RAM GRAVEL ROAD CH.12060.877m

HPCL CH. 16.00Km

HPCL CH. 17.00Km HIGH TENSION LINE 1 2.2m HIGH & 550KV

CK T TRA CAR 2.606m 349 CH.1

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PIPELINE DESIGN Typical P&ID

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PIPELINE DESIGN Typical GA DRAWING

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Pipeline Design Slide Number - 57 of 77

PIPELINE DESIGN Major Engineering Deliverables

Tenders
  

Survey Tender Pipe Coating Tender Pipeline Installation Tender Line Pipes Valves & Actuators Scraper Traps, QOEC, Pig Signallers Flow Tees & Insulating Joints Induction Bends Flow meters Pumps & Compressors OFC cables
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Material Procurement
       

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PIPELINE DESIGN
Installation, Testing & Commissioning
RoU Grading & Trenching Stringing of Linepipe

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Pipeline Design Slide Number - 59 of 77

PIPELINE DESIGN
Installation, Testing & Commissioning
Welding & NDT :
   

Edge Preparation Internal / External Line-up Clamps Manual / Automatic Welding NDT (X-Ray / UT / MPI etc.)

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Pipeline Design Slide Number - 60 of 77

PIPELINE DESIGN
Installation, Testing & Commissioning
Field Joint Coating
Heat Shrink Sleeves Cold applied tapes

Lowering & Backfilling

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Pipeline Design Slide Number - 61 of 77

PIPELINE DESIGN
Pipeline Crossings
Crossing Installation
Crossings  River, Canal, Road & Rail  Utility Crossing Methodologies  Open-Cut Method  Trench-less Method  Horizontal Directional Drilling  Jacking and Boring  Micro tunneling

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Pipeline Design Slide Number - 62 of 77

PIPELINE DESIGN
The conventional HDD operations for river crossings.

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Pipeline Design Slide Number - 63 of 77

PIPELINE DESIGN
Pipeline Installation using Micro-tunnelling
MICRO-TUNNELLING:
  

Micro Tunneling process uses a Micro Tunnel Boring Machine (MTBM) combined with pipe jacking technique. Pipe jacking from launch shaft to reception shaft. Hydraulic Jacks used to push Jacking pipes behind a tunnel boring machine Carrier pipe inserted in jacking pipe Micro-tunnelling can be used wherever HDD cannot be done Crossing of Rivers with gravels, cobbles & boulders Installation of more than one pipe in the tunnel Precise installation and Minimum space at both ends Can be done in curved path also

ADVANTAGES:
    

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Pipeline Design Slide Number - 64 of 77

PIPELINE DESIGN
Pipeline Installation using Micro-tunnelling
Long Distance Micro Tunnelling

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Pipeline Design Slide Number - 65 of 77

PIPELINE DESIGN
Overview of Micro tunneling

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Pipeline Design Slide Number - 66 of 77

PIPELINE DESIGN
Testing & Commissioning
TESTING
  

Gauging and Pigging Test Pressure Test Medium

DRYING Swabbing Methanol Drying Super Dry Air Method  Vacuum Drying COMMISSIONING  Nitrogen Purging  Product Charging
  

TEST PRESSURE
LIQUID PIPELINES Ref. ASME B 31.4 : 437.4.1 1.25 times design pressure GAS PIPELINES Ref. ASME B 31.8 : Table 841.322(f) Class 1 and 2: 1.25 * des pr Class 3 and 4: 1.4 * des pr

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Pipeline Design Slide Number - 67 of 77

PIPELINE DESIGN Pigging

Requirements
   

Types of Pigs
   

Pipeline Cleaning Displacement Internal Inspection Batching

Brush pigs Gauge Pigs Spheres Intelligent Pigs

Cleaning pigs

Gauge Pigs

Spheres

Intelligent Pig (MFL)

Pipeline Design Slide Number - 68 of 77

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PIPELINE DESIGN
RECENT DEVELOPMENTS
TECHNICAL IMPROVEMENTS
 

Automatic Welding & Automatic UT MicroMicro-Tunneling for pipeline construction

 

Internal flow coating on line pipes for gas pipelines 3LPP coating on High Temperature pipelines

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Pipeline Design Slide Number - 69 of 77

PIPELINE DESIGN Comparison of LSAW & HSAW Pipes

Description
Method of Manufacture Weld Length Position of weld

LSAW
UOE/COE/JCO/3 roll bending Equal to pipe joint length Longitudinal positioned in upper quadrant during construction Specified thickness throughout entire body. Weld seam is tracked to ensure coating thickness on weld seam Controlled to the desired level with cold expansion

HSAW
Formed by Twisting of Coil Approximately 1.5 to 2 times the length of pipe joint Spiral present all around the pipe Thickness normally increased all over the body, resulting in proportional increase in coating cost by 15-20% 15Controlled during forming only and no cold expansion is carried out

Corrosion Coating

Geometry

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Pipeline Design Slide Number - 70 of 77

PIPELINE DESIGN
Coating Comparison
CTE
Service Conditions
Temperature, o C Upto 45 Upto 65 Upto 110 Upto 110

3LPE

3LPP

FBE

AntiAnti-corrosion Properties
Resistance to Moisture Good Very Good Excellent Good

Cathodic Disbondment

Fair

Good

Good

Good

Electrical Properties
Coating Resistance Good Excellent Excellent Excellent

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Pipeline Design Slide Number - 71 of 77

PIPELINE DESIGN
Coating Comparison
CTE
Cathodic Protection Design
Current Density High Low Low Low

3LPE

3LPP

FBE

Mechanical Properties
Resistance to Impact Fair Poor Excellent Superior to PE Fair Fair -

Resistance to Indentation Resistance to Peel

Very Good

Excellent

Fair Fair

Excellent

Superior than PE

Resistance to Soil Stresses Elongation

Excellent

Excellent

Excellent

Fair

Excellent

Excellent

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PIPELINE DESIGN
Coating Comparison
CTE
Long Term Ageing
Heat & Light Ageing Fair Very Good Very Good Very Good

3LPE

3LPP

FBE

Application & Field Repair

Ease of Application Easy Relatively difficult Relatively difficult Relatively difficult

Damages during handling & transportation Ease of Field Repair

High

Low

Low

High

Difficult

Easy for small repair, Cumbersome for larger repair

Easy for small repair, Cumbersome for larger repair

Easy for small repair, Cumbersome for larger repair

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Pipeline Design Slide Number - 73 of 77

Thank You

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Pipeline Design Slide Number - 74 of 77

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