Cross Country Pipeline

8/20/2019 Cross Country Pipeline

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CONSTRUCTION OF CROSS COUNTRY PIPELINES

Slide Number- 1 of 50Delivering excellence through people

CONSTRUCTIONCONSTRUCTIONOFOF

CROSS COUNTRYCROSS COUNTRYPIPELINESPIPELINES

By: G. K. IYER (AGM.)




Slide Number - 2 of 50Engineers India Ltd – Delivering excellence through people

CROSS COUNTRY PIPELINE WORKSCROSS COUNTRY PIPELINE WORKS

OVERVIEWOVERVIEWMAIN PURPOSEMAIN PURPOSE

TRANSPORTATION OF MATERIAL/PRODUCTTRANSPORTATION OF MATERIAL/PRODUCT-- PIPELINE FOR GAS E.G. NATURAL GAS; LPG; LNG ETC.PIPELINE FOR GAS E.G. NATURAL GAS; LPG; LNG ETC.-- PIPELINE FOR LIQUIDS E.G. CRUDE OIL / PETROLEUM PRODUCT; WATERPIPELINE FOR LIQUIDS E.G. CRUDE OIL / PETROLEUM PRODUCT; WATER ETC.ETC.-- PIPELINE FOR SOLIDS E.G. IRON ORE ETC.PIPELINE FOR SOLIDS E.G. IRON ORE ETC.

TYPES OF PIPELINETYPES OF PIPELINE

-- OFFSHORE SUBMARINE PIPELINE: LAID ON SEAOFFSHORE SUBMARINE PIPELINE: LAID ON SEA --BEDBED

-- ONSHORE CROSS COUNTRY PIPELINE: LAID 1MTR UNDERGROUNDONSHORE CROSS COUNTRY PIPELINE: LAID 1MTR UNDERGROUND

SOME MAJOR ADVANTAGESSOME MAJOR ADVANTAGES

-- LOW COST OF TRANSPORTATION & ACCESSIBILITY TO REMOTE AREASLOW COST OF TRANSPORTATION & ACCESSIBILITY TO REMOTE AREAS-- LESS TIME TAKEN FOR TRANSPORATIONLESS TIME TAKEN FOR TRANSPORATION

SOME DISADVANTAGESSOME DISADVANTAGES

-- HIGH INITIAL COSTHIGH INITIAL COST

-- DEAD STOCK / INVENTORY IN PIPELINEDEAD STOCK / INVENTORY IN PIPELINE







CROSS COUNTRY PIPELINE WORKSCROSS COUNTRY PIPELINE WORKSVADINAR – BINA CRUDE PIPELINE PROJECT : 24” DIA x 931 KMS., API – 5L X70 GR., CAPACITY - 6 MMPTA






DT-VADINAR

IP1 -SIDHASAR

IPS1- THAMNA

IPS2- BEWARI

IP2-SANDAVATA

RT- BINA

SP1-160 KMS.

SP2-199 KMS.

SP3-145 KMS.

SP4-219 KMS.

SP5-208 KMS.

VADINAR – BINA CRUDE PIPELINE PROJECT : 24” DIA x 931 KMS., API – 5L X70 GR., CAPACITY - 6 MMPTA






I.I. CONSTRUCTION METHODOLOGYCONSTRUCTION METHODOLOGY

II.II. TYPE OF CONSTRUCTION EQUIPMENTSTYPE OF CONSTRUCTION EQUIPMENTS

III.III. TYPES OF CONTRACTORS REQUIRED FORTYPES OF CONTRACTORS REQUIRED FORCONSTRUCTION OF PIPELINESCONSTRUCTION OF PIPELINES






I.I. CONSTRUCTION METHODOLOGYCONSTRUCTION METHODOLOGY

QA/QC, CODES, SPECN., & HSE REQUIREMENTSQA/QC, CODES, SPECN., & HSE REQUIREMENTS

LINEPIPES COATING AT YARD & DUMPSITELINEPIPES COATING AT YARD & DUMPSITE

LAYING OF PIPELINELAYING OF PIPELINE






QA/QC IN PIPELINEQA/QC IN PIPELINE

Review & Approval of Contractor Review & Approval of Contractor ’’s QAP for all activitiess QAP for all activities

Review & Approval of Contractor Review & Approval of Contractor ’’s Inspection & Test Plans (ITPs Inspection & Test Plans (ITP ’’s)s)with reference to standard ITPwith reference to standard ITP ’’s of EIL before start of works of EIL before start of work

Review & Approval of Job Procedures & Inspection FormatsReview & Approval of Job Procedures & Inspection Formatsbased on ITPbased on ITP ’’s for all Pipeline activitiess for all Pipeline activities

Quality Audits & Resolution of Non Conformances (NCQuality Audits & Resolution of Non Conformances (NC ’’s)s)observed during execution of work & quality auditsobserved during execution of work & quality audits





CROSS COUNTRY PIPELINE WORKSCROSS COUNTRY PIPELINE WORKSCODES & STANDARDSCODES & STANDARDS

Following are the reference/codes followed during LineFollowing are the reference/codes followed during Line --pipe Coating & Laying of Pipeline:pipe Coating & Laying of Pipeline:

1.1. DIN 30670DIN 30670 :: 3LPE Coating of Line3LPE Coating of Line --pipespipes

2.2. AWWA 203 AWWA 203 : Coal Tar Enamel Coating of Line: Coal Tar Enamel Coating of Line --pipespipes

3.3. API 1104 API 1104 : Welding of Pipeline & Related Activities: Welding of Pipeline & Related Activities

4.4. API 1105 API 1105 : Construction Practices for Oil & Products Pipelines: Construction Practices for Oil & Products Pipelines

5.5. ASME B 31.4 ASME B 31.4 : Pipeline Transportation System for Liquid Hydrocarbon: Pipeline Transportation System for Liquid Hydrocarbon

6.6. ASME B 31.8 ASME B 31.8 : Gas Transmission and Distribution Piping System: Gas Transmission and Distribution Piping System

7.7. OISD B 141OISD B 141 : Design and construction requirements for cross: Design and construction requirements for cross --countrycountryHydroHydro --carbon Pipelinescarbon Pipelines





CROSS COUNTRY PIPELINE WORKSCROSS COUNTRY PIPELINE WORKSRELEVANT EIL SPECN. & STANDARDSRELEVANT EIL SPECN. & STANDARDS

Following are the relevant EIL Specification & Standards for CoaFollowing are the relevant EIL Specification & Standards for Coa ting & Laying of Pipeline:ting & Laying of Pipeline:

1.1. 66 --7171 --00010001 : Standard specification for Line pipes, Valves, Fittings,: Standard specification for Line pipes, Valves, Fittings,to 6to 6 --7171 --0040 Scrapper Launcher / Receiver, Pig signaller etc.0040 Scrapper Launcher / Receiver, Pig signaller etc.

2.2. 66 --7171 --00410041 : Standard specification for 3LPE Coating: Standard specification for 3LPE Coating3.3. 66 --7171 --00420042 : Standard specification for CTE Coating Onshore Pipeline.: Standard specification for CTE Coating Onshore Pipeline.4.4. 66 --7171 --00440044 : Standard specification for Field Jt. Coating Onshore Pipel: Standard specification for Field Jt. Coating Onshore Pipel ine.ine.5.5. 66 --7171 --00460046 : Standard specification for Conc. Coating Onshore Pipeline.: Standard specification for Conc. Coating Onshore Pipeline.

6.6. 66 --7171 --00510051 : Standard specification for Pipeline Construction (Onshore): Standard specification for Pipeline Construction (Onshore)7.7. 66 --7171 --00520052 : Standard specification for Pipeline Construction, Road, Ra: Standard specification for Pipeline Construction, Road, Ra il,il,

Minor Water CrossingsMinor Water Crossings8.8. 66 --7171 --00530053 : Standard specification for Major Water Crossings (Conventi: Standard specification for Major Water Crossings (Conventi onal)onal)9.9. 66 --7171 --00540054 : Standard specification for Pipeline River Crossings by HDD: Standard specification for Pipeline River Crossings by HDD10.10. 66 --7171 --00550055 : Standard specification for Hydro: Standard specification for Hydro --testing of Onshore Pipelinestesting of Onshore Pipelines11.11. 66 --7171 --00570057 : Standard specification for Pipeline Markers: Standard specification for Pipeline Markers12.12. 66 --8282 --1901 : Standard Inspection & Test Plans (ITP1901 : Standard Inspection & Test Plans (ITP ’’s) for Pipeline Activitiess) for Pipeline Activities

to 6to 6 --8282 --19251925





HSE IN PIPELINEHSE IN PIPELINE

Review of contractorsReview of contractors ’’ HSE plan & documents with reference toHSE plan & documents with reference toEIL specification no. 6EIL specification no. 6 --8282 --0001, Rev0001, Rev --4.4.

Construction hazards identification & mitigation measuresConstruction hazards identification & mitigation measures

Ensuring compliance to HSE requirements by contractorsEnsuring compliance to HSE requirements by contractors

FirstFirst -- Aid & Fire fighting facilities Aid & Fire fighting facilities

HSE promotion activitiesHSE promotion activities

HSE Reporting including statisticsHSE Reporting including statistics

HSE Audits & Resolution of NonHSE Audits & Resolution of Non --conformancesconformances






CROSS COUNTRY PIPELINE WORKSCROSS COUNTRY PIPELINE WORKSLINEPIPE COATING AT YARDLINEPIPE COATING AT YARD

TYPES OF EXTERNAL YARD COATINGTYPES OF EXTERNAL YARD COATING

-- 3 LAYER POLYETHELENE (3LPE) COATING / FBE COATING3 LAYER POLYETHELENE (3LPE) COATING / FBE COATING

-- COAL TAR ENAMEL (CTE) COATINGCOAL TAR ENAMEL (CTE) COATING

3LPE COATING / ONE LAYER FBE COATING3LPE COATING / ONE LAYER FBE COATING--11 stst LAYER: FUSION BONDED EPOXYLAYER: FUSION BONDED EPOXY – – 50 MICRONS (200 TO 300 MICRONS50 MICRONS (200 TO 300 MICRONS -- FBE COATING)FBE COATING)

-- 22 ndnd LAYER: SIDE EXTRUSION ADHESIVE (LDPE)LAYER: SIDE EXTRUSION ADHESIVE (LDPE) – – 200 TO 300 MICRONS200 TO 300 MICRONS--33 rdrd LAYER: SIDE EXTRUSION POLYETHELENE (LDPE / MDPE / HDPE)LAYER: SIDE EXTRUSION POLYETHELENE (LDPE / MDPE / HDPE) -- > 2 MM> 2 MM

CTE COATING (HOT APPLIED)CTE COATING (HOT APPLIED)-- 11 stst COAT: COAL TAR PRIMERCOAT: COAL TAR PRIMER – – 50 TO 75 MICRONS50 TO 75 MICRONS

-- 22 ndnd COAT: 1COAT: 1 stst HOT COAL TAR ENAMEL LAYER WITH INNER WRAPHOT COAL TAR ENAMEL LAYER WITH INNER WRAP – – > 1 MM> 1 MM-- 33 rdrd COAT: 2COAT: 2 ndnd HOT COAL TAR ENAMEL LAYER WITH INNER WRAPHOT COAL TAR ENAMEL LAYER WITH INNER WRAP – – > 1 MM> 1 MM-- FINAL COAT: COAL TAR IMPREGNATED OUTER WRAPFINAL COAT: COAL TAR IMPREGNATED OUTER WRAP – – 600 TO 750 MICRONS600 TO 750 MICRONS





CROSS COUNTRY PIPELINE WORKSCROSS COUNTRY PIPELINE WORKSLINEPIPE COATING AT YARD ContdLINEPIPE COATING AT YARD Contd ……

COATING PROCESS:COATING PROCESS:

1)1) BARE PIPES VISUAL INSPECTIONBARE PIPES VISUAL INSPECTION 2)2) SHOTBLASTING AND VISUAL INSPECTIONSHOTBLASTING AND VISUAL INSPECTION

-- PIPE NO., HEAT NO., LENGTH, DIA, THK ETC.PIPE NO., HEAT NO., LENGTH, DIA, THK ETC. -- ROUGHNESS CHECK ON BODYROUGHNESS CHECK ON BODY

-- BEVEL & BODY DAMAGESBEVEL & BODY DAMAGES E.G. DENTS, GOUGES ETC.E.G. DENTS, GOUGES ETC. -- BODY DENTS & GOUGESBODY DENTS & GOUGES

BARE PIPES STACKING YARD SHOT BLASTING OF PIPES







3)3) PREPRE --HEATING OF PIPES &HEATING OF PIPES & PRIMER / EPOXY APPLICATION (PIPES TO BE PREHEATED TO 200PRIMER / EPOXY APPLICATION (PIPES TO BE PREHEATED TO 200 00 C BYC BYINDUCTION COIL/ GAS OVEN)INDUCTION COIL/ GAS OVEN)

-- CHECK FOR PIPE TEMP BY DIGITAL TEMPERATURE GUAGE & UNIFORM SPRACHECK FOR PIPE TEMP BY DIGITAL TEMPERATURE GUAGE & UNIFORM SPRA Y OF EPOXY ON PIPEY OF EPOXY ON PIPE

BARE PIPES PRE HEATING







4)4) COATING APPLICATIONCOATING APPLICATION

-- CHECK TEMP OF EXTRUDERS, PE FILM, ADHESIVE FILM, COAL TAR ENAMECHECK TEMP OF EXTRUDERS, PE FILM, ADHESIVE FILM, COAL TAR ENAME L ETC.L ETC.

ADHESIVE & PE APPLICATION INNER/OUTER WRAP & COALTAR ENAMEL APPLICATION







5)5) COOLING OF COATED PIPES IN COOLING TUNNEL & VISUAL INSPECTION OFCOOLING OF COATED PIPES IN COOLING TUNNEL & VISUAL INSPECTION OF COATED PIPESCOATED PIPES

- CHECK COOLING WATER TEMP, VISUAL DAMAGE TO COATING, COATING THK. ETC.

COATED PIPE COOLING TUNNEL 3LPE COATING THICKNESS CHECK CTE COATING THICKNESS CHECK







6)6) HOLIDAY TESTING, REPAIR OF COATING & TESTINGHOLIDAY TESTING, REPAIR OF COATING & TESTING

-- CHECK FOR HOLIDAY AT 25KV FOR 3LPE COATING & 15KV FOR CTE COATICHECK FOR HOLIDAY AT 25KV FOR 3LPE COATING & 15KV FOR CTE COATI NGNG

-- MARK PIPES FOR TESTING E.G. PEEL TEST, AP TEST, IMPACT TEST ETCMARK PIPES FOR TESTING E.G. PEEL TEST, AP TEST, IMPACT TEST ETC . & COATING REPAIR. & COATING REPAIR

RING HOLIDAY TESTING MARKING OF TESTING







7)7) EXTERNAL PAINTING (IF REQD) AND STACKING IN YARDEXTERNAL PAINTING (IF REQD) AND STACKING IN YARD

- THK OF PAINT, MARKING ON COATING PIPES, COATING ACCEPTANCE NO., ROW HEIGHT ETC.

COATED PIPES EXTERNALPAINTING COATED PIPES STACKING YARD

CROSS COUNTRY PIPELINE WORKS





CROSS COUNTRY PIPELINE WORKSCROSS COUNTRY PIPELINE WORKSDUMP SITES FOR STORAGE OF COATED PIPESDUMP SITES FOR STORAGE OF COATED PIPES

ACQUIRING OF LAND & DEVELOPMENT OF DUMP SITEACQUIRING OF LAND & DEVELOPMENT OF DUMP SITE

-- GRADING OF LAND, PROVIDING TEMPORARY FENCING, BARRIER GATE , GUGRADING OF LAND, PROVIDING TEMPORARY FENCING, BARRIER GATE , GU ARD ROOM AND SECURITY ARD ROOM AND SECURITY

-- PROVIDING INTERNAL ROADS (WBM) FOR TRAILER MOVEMENT & AREA LIGHPROVIDING INTERNAL ROADS (WBM) FOR TRAILER MOVEMENT & AREA LIGH TING WITH DG SETTING WITH DG SET-- PROVIDING SAND ROWS FOR STACKING OF COATED PIPESPROVIDING SAND ROWS FOR STACKING OF COATED PIPES

HANDLING OF COATED PIPESHANDLING OF COATED PIPES

-- ADEQUATE CRANES WITH PADDED HOOKS FOR UNLOADING / LOADING OF C ADEQUATE CRANES WITH PADDED HOOKS FOR UNLOADING / LOADING OF C OATED PIPES IN TRAILERSOATED PIPES IN TRAILERS

-- STACKING OF COATED PIPES ON SAND ROWSSTACKING OF COATED PIPES ON SAND ROWS-- HOLIDAY CHECK AND VISUAL CHECK INCLUDING GUAGE PLATE PULL TESTHOLIDAY CHECK AND VISUAL CHECK INCLUDING GUAGE PLATE PULL TEST BEFORE DESPATCH TO SITEBEFORE DESPATCH TO SITE





Slide Number - ___of 50Engineers India Ltd – Delivering excellence through people

CROSS COUNTRY PIPELINE WORKSCROSS COUNTRY PIPELINE WORKSPIPELINE LAYING ACTIVITIES:PIPELINE LAYING ACTIVITIES:

ROU SURVEYROU CLEARING AND GRADINGSTRINGING

TRENCHINGBENDINGWELDINGFIELD JOINT COATING

LOWERINGBACKFILLINGCROSSINGTIE-INS

HYDROTESTINGPIPELINE MARKERS, CLEAN UP & RESTORATIONSTATION WORKSMAGNETIC PIGGING & EGP – PRE COMMISSIONING ACTIVITY






CROSS COUNTRY PIPELINE WORKSCROSS COUNTRY PIPELINE WORKSPIPELINE LAYING ACTIVITIES..Contd.:PIPELINE LAYING ACTIVITIES..Contd.:

ROU SURVEYROU SURVEYInstallation of Bench Marks, Turning PointsStake markers in center line of pipeline at a distance of max.100m for centre line and forhorizontal bends10 m. and reference point for same

Stake two ROU markers at least at every 100m, Painted in red and numbers in white indirection of flow.Chainage markers at every 250 m

ROU CLEARING & GRADINGROU CLEARING & GRADING Al l obstacles causing hindrance in construction / laying pipeline are removed.

Entire ROU is Graded for movement of equipments and vehicle.Temporary approaches/bridges, if required, are constructed for movement of equipments,vehicles & personnel’s

STRINGINGSTRINGINGStringing shall be done after blasting & trenching when ROU is in rocky area .Coated Pipes shall be strung on approved soft earth/sand filled bag and wedge in such away that bottom of coated Pipe remain above groundPipes shall be supported at minimum two locationsPipe number, Heat number, coat number & length shall be transferred and recorded inserial order






CROSS COUNTRY PIPELINE WORKSCROSS COUNTRY PIPELINE WORKSROU CLEARING & GRADING AND PIPELINE STRINGING ACTIVITY






CROSS COUNTRY PIPELINE WORKSCROSS COUNTRY PIPELINE WORKSPIPELINE LAYING ACTIVITIES ..Contd.:PIPELINE LAYING ACTIVITIES ..Contd.:

TRENCHINGTRENCHINGTrench excavation is carried out along staked centerline of PipelineThe width of excavation for trench shall be minimum (pipe diameter plus 200mm either side)Depth of trench shall be as specified (Normal= 1M; Road= 1.2M; River= 1.5M; Rly.= 1.7M etc)In case of trenching in rocky areas, blasting is performed with the guidelines /Safety Rulesof Chief Controller of explosives, Nagpur.In case where rock/gravel or murrum/hard soil is encountered in the bottom of trench,

padding material (minimum compacted thickness of 150 mm) shall be provided.When up-floating of the pipeline after backfilling is anticipated, antibuoyancy measures areprovided in such areas e.g. weighing by applying continuous concrete, installing saddleweights etc.

BENDINGBENDINGFor changes in vertical & horizontal alignment, pre-fabricated cold field bends are providedOver-bends are made in a manner that centre of bend clears the highest point of trench

bottom. Sag bends shall fit the bottom of the trench. Side bends shall have specifiedclearance to the outside wall of trench.The radius of cold f ield bends shall not be more than 40 times the dia. of pipe (for 18” inchand above) and 30 times the dia. of pipe (for 18” inch below).Pipes with longitudinal welds are bent a way that weld lies in the plane passing through theneutral axis of bend






CROSS COUNTRY PIPELINE WORKSCROSS COUNTRY PIPELINE WORKSPIPELINE TRENCHING ACTIVITY

CROSS COUNTRY PIPELINE WOCROSS COUNTRY PIPELINE WO RKSRKS





CROSS COUNTRY PIPELINE WOCROSS COUNTRY PIPELINE WO RKSRKS

PIPELINE BENDING ACTIVITY






CROSS COUNTRY PIPELINE WORKSCROSS COUNTRY PIPELINE WORKSPIPELINE LAYING ACTIVITIES.. Contd.:PIPELINE LAYING ACTIVITIES.. Contd.:

WELDINGWELDINGWelding Procedure Specification (WPS) to be followed for the welding is qualified and theProcedure qualification record (PQR) is approved before start of welding. Approved brand ofelectrodes are used for welding. Physical properties of the weld produced by an electrodeshall not be less than minimum value of base metal. Electrode qualification and batch recordare maintained.Each pipe shall be thoroughly checked internally & externally for visual defect/ damage andcleaned internally by compressed air blowing.Damaged end shall be cut and re-bevelled with beveling machine. All new bevels shall be 100%dye penetrant /MPI tested and Ultrasonically tested for any lamination.Use of internal clamp is mandatory for pipe dia.> 10” . Except tie in joints, fitting etc. In suchcase external clamps are used.Each joint shall bear an identification number which shall be followed for NDTThe number of welders, and welding sequence, speed etc. should be similar to that of adoptedin approved welding procedureRadiography examination of 100 % gir th weld is carried out. Weld shall meet the requirementof API 1104. In addition 100% ultrasonic inspection is required for cri tical weld joints i.e. tie in,welding of valves etc. joints which have not undergone pressure testing i.e. GOLDEN TIE-Ins.Repair is limited to maximum 30% of the weld length. Weld containing cracks shall be cut andre-bevelled to make a joint.Destructive testing of weld joints are done for 0.1% of the total numbers of welds completed.






CROSS COUNTRY PIPELINE WORKSCROSS COUNTRY PIPELINE WORKSPIPELINE MAINLINE WELDING ACTIVITY






CROSS COUNTRY PIPELINE WORKSCROSS COUNTRY PIPELINE WORKSMANUAL WELDING OF MAINLINE JOINT AUTOMATIC WELDING CREW FOR MAINLINE JOINT

AUTO UT OF MAINLINE JOINT AUTOMATIC WELDING OF MAINLINE JOINT







PIPELINE LAYING ACTIVITIES.. Contd.:PIPELINE LAYING ACTIVITIES.. Contd.:

FIELD JOINT COATINGFIELD JOINT COATING

The cut-back areas of Coated Pipes where weld joints are made are to be Coated by FieldJoint Coating.Field joint coating material is heat shrinkable wraparound sleeve used as anticorrosioncoating of buried onshore pipeline.Sleeve consist of radiation cross-linked, thermally stabilized, ultraviolet resistant semi-rigid polyolefin backing with a uniform thickness of high shear strength thermoplastic/co-melt adhesiveThe joint coating system shall consist of a solvent free epoxy primer applied to the pipesurface prior to sleeve application. The surface area is blast cleaned to SA-2.5 followed byPre-heating of pipe surface, application of epoxy primer and application of sleeve by heatshrinking.Each sleeve joint is inspected by means of a full circle holiday detector set to DC voltage

at 25 KV (Pipe surface temperature below 50 degree Celsius) and thickness of sleevechecked.One out of 50 joints coating or one coating out of every day production shall be tested toestablish peel strength on steel and factory applied coating.






CROSS COUNTRY PIPELINE WORKSCROSS COUNTRY PIPELINE WORKSPIPELINE FIELD JOINT COATING ACTIVITY








LOWERINGLOWERING

Lowering shall commence after inspection of trench. Trench bottom shall be free frompipe supports, stones, roots, debris, stakes, and rigid material. Padding shall be providedin rocky/ murram area.

Lowering shall commence as soon as possible after completion of joint coating, Beforelowering in, complete check by a full ci rcle holiday detector for pipe coating and field jointcoating at 15 KV is carried out (Speed 300mm /sec). Any damage shall be repaired.Support/ skid points shall be thoroughly checked.

The pipeline must be laid without interruption for the whole or the length of sectionavailable

Ends of the lowered pipeline section shall be closed with night cap to prevent ingress ofwater, mud etc.






CROSS COUNTRY PIPELINE WORKSCROSS COUNTRY PIPELINE WORKSPIPELINE HOLIDAY AND LOWERING ACTIVITY






CROSS COUNTRY PIPELINE WORKSCROSS COUNTRY PIPELINE WORKSPIPELINE LAYING ACTIVITIES.. Contd.:PIPELINE LAYING ACTIVITIES.. Contd.:

BACKFILLINGBACKFILLINGBackfilling shall be carried out immediately after pipeline lowering in trench afterinspection, so as to provide a natural anchorage for the pipeline, thus avoiding longexposure of coating to high temperature, damaging action of adverse weather conditions,sliding down of trench sides and pipeline movement in the trench.

Backfil l material shall not contain any extraneous material or hard lumps of soil which candamage pipeline or coating or leave the voids in backfilled trench. After placing of initial backfill, proper compact ion shall be done. The surplus mater ialshall be crowned (300 mm) directly over trench and adjacent excavated area on both s ideof trench.If trench are excavated in steep area where the slope is more than 10%, slope breakersshall be installed to prevent erosion of backfill. Stabilization of backfill shall be done insandy area to have consolidated cover over the pipeline.

CROSSINGSCROSSINGSCased & Un-cased crossings for Roads & Railways

Open cut & Horizontal Directional Drill ing (HDD) for Minor & Major River CrossingTIETIE --INsINs

The unconnected sections of the lowered pipeline sections at various locations have to bewelded, coated and backfi lled to make the sections ready for post installation hydro test .If a pup piece cannot be avoided for tie in, the minimum 1.0 m length shall be added.






CROSS COUNTRY PIPELINE WORKSBOARING FOR CASED CROSSINGPADDING & BACKFILLING

TIE-IN IN PROGRESS

TIE-IN WELDING IN PROGRESS







HYDROHYDRO --TESTINGTESTING

Hydrostatic test is performed on entire length of the pipeline. The maximum permitted lengthis 50 Kms. Hydrostatic test diagrams indicating number of test sections and minimum andmaximum test pressure in each test section are prepared before performing hydrostatic test.

Hydrostatic test commence only after completion of all welding works so as to avoid/minimize untested hydro-test joints/ Golden joints.

Hydro test includes all those sections which are tested earlier for Road, rail road crossings,major water c rossings etc.

Duration of hydrostatic test is minimum 24 hours after thermal stabilization. Hydro-static testpressure for pipeline handling hydrocarbon in gaseous phase is 1.25 times the designpressure in pipeline located in Class-1 & 2 locations and 1.4 times the design pressure ifpipeline located in Class-3 & 4 locations.

Before water filling, pipeline shall be cleaned with air driven pigs with spring loaded brushesand chiseled to remove all mill scale, rust, sand etc. from the internal pipe section.

After successful c leaning and acceptance, gauging is carr ied out using gauging pig.







HYDROHYDRO --TESTING..ContdTESTING..Contd ,,

After acceptance of gauging operation, un-inhabited water is pumped into the section usingfour cup batching pigs which are launched at specific intervals.

After water filling operation, thermal equilibrium between pipel ine and environment shal l bechecked with thermocouples installed on the pipeline.

After thermal stabi lization pressur ization is carried out in cycles of 50% test pressure & 75%test pressure and held for 1 hour at each test pressure and depressurized to zero pressure andthen pressurized to final test pressure. During each test pressure, two test shall be carried outfor calculation of air volume in the pipeline under test and on acceptance of air volume test thesection is held for 24 hours at Final test pressure and pressure and temperature recorded onchart.

The hydrostatic test shall be considered positive if pressure has kept a constant valuethroughout the test duration, except for change due to temperature effects. The pressure value

thus added shall be compared with initial value and the test shall be considered as acceptableif the difference is less than or equal to 0.3 bar.

After positive test results , test shal l be terminated . The pipel ine shall be depressur ized atconstant rate. Dewatering shall be carried out by using four cup pigs dr iven by compressed air.Foam pigs shall be passed to complete the dewatering.






PIPELINE ACTIVITIES Contd.:PIPELINE ACTIVITIES Contd.:

PIPELINE MARKERS, CLEANPIPELINE MARKERS, CLEAN --UP AND RESTORATIONUP AND RESTORATIONFollowing type of markers shall be fabricated and installed along the pipeline route suchthat they do not cause any hindrance to the regular land user or traffic

− Aer ial Markers : At every 5 Kms.− Kilometer Markers : At every 1 Km. & as per Alignment sheet

− Pipel ine Warning Markers : At Road / Rai lway / River Crossings & Stat ions / Terminals− ROU Boundary Markers : At every 750 Mtrs. & as per Alignment sheet− Direction Markers : At significant turning points− Navigational Markers : At bank of Navigational Course− OFC Markers : At OFC Joints

ROU and all si tes used for construction of pipeline , water crossing and other structuresshall be restored as per satisfaction of authority having jurisdiction over it.Damages to roads, bridges, fences etc. damaged during construction shall be restored tooriginal.The bed of water course shall be restore to the original level. The banks and any

excavated area shall be restored to original levels . The banks shall also be stabilized.On completion of clean-up, the ROU shall be restored to such stable and usable conditionas may be reasonably consistent with the condition of the ROU prior to laying thepipeline. The release note from the land owner s regarding satisfactory indemnificationand restoration of land shall be obtained from land owner.







SV / IP / DT, PS & RT STATION WORKSSV / IP / DT, PS & RT STATION WORKS

Sectionalizing Valve (SV) are installed at regular intervals (around 25 to 40 Kms.) to isolatepipeline section during emergencies like leakage in pipeline as per statutory requirements.

An SV station is instal led at such locations having a unmanned control room with a guardroom and boundary wall. A lockable grill cage is provided over the Sectionalizing Valveinstallation including piping and instrumentation to prevent tampering by unauthorizedpersons and ensuring safety of pipeline operations.

Intermediate Pigging (IP) stations are installed at regular intervals (as per design ~ 150Kms.) having a Pig Launcher and a Pig Receiver with Control room, Sump tank, BasketFilters, guard room, boundary wall etc. to facilitate pigging of pipeline during routineOperation and Maintenance.

Dispatch Terminal (DT), Pump Station (PS) & Receipt Terminals are provided at start,

intermediate & end locations of the Pipeline to facilitate handling and pumping of theproduct through the pipeline. It comprises of Pig Launcher / Pig Receiver with Controlroom, Mainl ine & Booster Pumps (DT/PS), Sump tank, Basket Filters, guard room, Firewatersystem, boundary wall etc.






TYPICAL SECTIONALIZING VALVE (SV) STATION







MAGNETIC PIGGING & ELECTRONIC GEOMETRY PIGGING (EGP):MAGNETIC PIGGING & ELECTRONIC GEOMETRY PIGGING (EGP):Pre Commissioning ActivityPre Commissioning Activity

This is a part of pre-commissioning activi ty, which ensures that there is no deformity inpipeline. This is done prior to fil ling the line with product.

Magnetic PIG loaded with high capacity magnets spread uniformly with high densitypolythene four cup PIG is launched to remove ferrous debris, mill scale, electrode piecesetc. The accumulated weight of this ferrous debris is checked after running the PIG through

pipeline section. When the collected weight of ferrous debris is within limit for specificlength of pipeline section, the line is ready for launching EGP tool .

After successful completion of magnetic pig run EGP tool is launched. This tool is mountedwith battery operated battery device, which gives the reduction in pipeline Dia. at specificlocation in electronic form.

Any defect /deformity more than 3% of internal diameter of pipe (dent or ovali ty) isphysically verified at site. Defect of more than 5% internal diameter of pipe are repaired bycutt ing the suitable length of pipe and re-welding and accepted after radiography.

Documents

Cross Country Pipeline