Delivering excellence through people Pipeline Design Slide Number - 1 of 77 PIPELINE DESIGN

Delivering excellence through peoplePipeline Design

Slide Number - 1 of 77

PIPELINE DESIGN

Pipeline Design

Slide Number - 2 of 77 Engineers India Ltd – Delivering excellence through people

ENGINEERSENGINEERSINDIA LIMITEDINDIA LIMITED

EPC and Total Solutions EPC and Total Solutions Consultancy OrganizationConsultancy Organization

Pipeline Design


Petroleum Refineries

PetrochemicalsPipelinesOffshore PlatformsGas ProcessingMetallurgyPorts & TerminalsHighways and Airports

Pipeline Design


HEAD OFFICE NEW DELHI

REGIONAL OFFICES VADODARA, CHENNAIKOLKATA

PROCUREMENT OFFICES MUMBAI

SITE OFFICES 29 LOCATIONS (INDIA) 9 LOCATIONS (OVERSEAS)

INSPECTION OFFICE 10 LOCATIONS

OVERSEAS OFFICES LONDON, LIBYA ABU DHABI, ITALY, SAUDI ARABIA , QATAR, KUWAIT

EIL OFFICESEIL OFFICES

Pipeline Design


PIPELINE DESIGNPIPELINE DESIGN

SERVICES OFFERED BY EILProject 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

Pipeline Design



EIL EXPERIENCE1975 First major project

Crude Oil Loop Line for Oil India Ltd.

1979 First major overseas project 150 km Multi Product Pipeline for Abu Dhabi National Oil Company

1984 First major high pressure Gas Pipeline Project - 1800 km Gas Transmission Network for GAIL

Over 40 major pipeline projects completed.

Pipeline Design



DESCRIPTIONDESCRIPTION CLIENTCLIENT YEARYEAR SIZESIZE LENGTH LENGTH (KM)(KM)

SERVICESSERVICES

HAZIRA-BIJAIPUR-HAZIRA-BIJAIPUR-JAGDISHPUR (HBJ)JAGDISHPUR (HBJ)

GAILGAIL 19891989 36“/30”/24”/18”36“/30”/24”/18” 18001800 NATURAL GASNATURAL GAS

MAQTA-AL-AIN PIPELINEMAQTA-AL-AIN PIPELINE ADNOCADNOC 19921992 30 ”/12”30 ”/12” 166166 NATURAL GASNATURAL GAS

KANDLA-BHATINDAKANDLA-BHATINDA IOCLIOCL 19961996 22”/14”/10”22”/14”/10” 14431443 MULTIPRODUCTMULTIPRODUCT

GAS REHABILITATION & GAS REHABILITATION & EXPANSION PROJECT EXPANSION PROJECT (GREP)(GREP)

GAILGAIL 19981998 36 ”36 ” 505505 NATURAL GASNATURAL GAS

MUMBAI – MANMADMUMBAI – MANMAD BPCLBPCL 19981998 18 ”18 ” 260260 MULTIPRODUCTMULTIPRODUCT

VIZAG-VIJAYWADAVIZAG-VIJAYWADA HPCLHPCL 19981998 18 ”18 ” 360360 MULTIPRODUCTMULTIPRODUCT

JAMNAGAR-LONI LPG JAMNAGAR-LONI LPG PIPELINEPIPELINE

GAILGAIL 20012001 16”/14”/12”/16”/14”/12”/8”/68”/6

12351235 LPG (LIQUIFIED LPG (LIQUIFIED PETROLIUM GAS)PETROLIUM GAS)

COCHIN – KARUR PIPELINECOCHIN – KARUR PIPELINE PETRONETPETRONET 20012001 18 ”/14 ”18 ”/14 ” 289289 MULTIPRODUCTMULTIPRODUCT

Major Onshore Projects (Completed)

Pipeline Design




SERVICESSERVICES

VIZAG – SECUNDERABAD LPG VIZAG – SECUNDERABAD LPG PIPELINEPIPELINE

GAILGAIL 20022002 12”/10”12”/10” 600600 LPG (LEQUIFIED LPG (LEQUIFIED PETROLEUM GAS)PETROLEUM GAS)

MANMAD-MANGALAYA PIPELINEMANMAD-MANGALAYA PIPELINE BPCLBPCL 20032003 14 ”14 ” 358358 MULTIPRODUCTMULTIPRODUCT

MANGALORE-BANGLOREMANGALORE-BANGLORE HPCLHPCL 20032003 24 ”/20”24 ”/20” 364364 MULTIPRODUCTMULTIPRODUCT

DAHEJ – VIJAIPUR PIPELINEDAHEJ – VIJAIPUR PIPELINE GAILGAIL 20032003 42”42” 610610 REGASIFIED LNGREGASIFIED LNG

INTER REFINERIES PIPELINES INTER REFINERIES PIPELINES PROJECT, ABU DHABIPROJECT, ABU DHABI TAKREERTAKREER 20042004

10” 10”

12”12”

16”16”

230230

230230

208208

NAPHTHA, NAPHTHA, MULTIPRODUCT & SRRMULTIPRODUCT & SRR

MANGALAYA-BIJWASAN MANGALAYA-BIJWASAN PIPELINEPIPELINE

BPCLBPCL 20062006 16”/8”16”/8” 775775 MULTIPRODUCTMULTIPRODUCT

MUNDRA-DELHI PIPELINEMUNDRA-DELHI PIPELINE HPCLHPCL 20062006 18”/16”18”/16” 10501050 MULTIPRODUCTMULTIPRODUCT

Major Onshore Projects (..contd) (Completed)

Pipeline Design



SERVICESSERVICES

PUNE SOLAPUR PIPELINEPUNE SOLAPUR PIPELINE HPCLHPCL 20072007 14 ”/ 12”14 ”/ 12” 182 / 161182 / 161 MULTIPRODUCTMULTIPRODUCT

DABHOL PANVEL PIPELINE DABHOL PANVEL PIPELINE PROJECT (PH-I)PROJECT (PH-I)

GAILGAIL 20072007 30”30” 187187 REGASIFIED LNGREGASIFIED LNG

DABHOL PANVEL PIPELINE DABHOL PANVEL PIPELINE PROJECT (PH-II)PROJECT (PH-II)

GAILGAIL 20072007 30”30” 120120 REGASIFIED LNGREGASIFIED LNG

PIPELINE DESIGNPIPELINE DESIGNMajor Onshore Projects (…contd)

(Completed)

Pipeline Design



SERVICESSERVICES

BOMBAY HIGH URAN TRUNKLINEBOMBAY HIGH URAN TRUNKLINE

(BUT)(BUT)

ONGCONGC 19791979 30”/26”30”/26” 200 x 2200 x 2 CRUDE, GASCRUDE, GAS

SOUTH BASSEIN HAZIRA SOUTH BASSEIN HAZIRA TRUNKLINETRUNKLINE

ONGCONGC 19861986 36”36” 220220 GASGAS

HEERA-URAN TRUNK LINEHEERA-URAN TRUNK LINE ONGCONGC 19961996 26 ”/24 ”26 ”/24 ” 85 x 285 x 2 CRUDE, GASCRUDE, GAS

ICP - HEERA TRUNKLINEICP - HEERA TRUNKLINE ONGCONGC 19961996 30”/22”30”/22” 145145 CRUDECRUDE

SECOND BASSEIN HAZIRA SECOND BASSEIN HAZIRA TRUNKLINETRUNKLINE

ONGCONGC 19951995 42”42” 245245 GASGAS

MUMBAI HIGH URAN TRUNKLINEMUMBAI HIGH URAN TRUNKLINE

(MUT)(MUT)

ONGCONGC 20052005 30”/28”30”/28”

12” to 22”12” to 22”

205 x 2205 x 2

100100

CRUDE, GASCRUDE, GAS

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

PIPELINE DESIGNPIPELINE DESIGNMajor Offshore ProjectsMajor Offshore Projects

(Completed)

Pipeline Design



SERVICESSERVICES

VIJIPUR DADRI BAWANA PIPELINEVIJIPUR DADRI BAWANA PIPELINE

(VDBPL)(VDBPL)

GAILGAIL 20092009 48”/ 36”/ 48”/ 36”/ 20”20”

500/ 38/ 55500/ 38/ 55 REGASIFIED LNGREGASIFIED LNG

MUNDRA BATHINDA PIPELINE MUNDRA BATHINDA PIPELINE (MBPL)(MBPL)

HMPLHMPL 20092009 28”/ 30”28”/ 30” 424/ 590424/ 590 CRUDE OILCRUDE OIL

BINA KOTA PIPELINEBINA KOTA PIPELINE BPCLBPCL 20092009 18”18” 257257 MULTI PRODUCTMULTI PRODUCT

VADINAR BINA PIPELINEVADINAR BINA PIPELINE BORLBORL 20092009 24”24” 935935 CRUDE OILCRUDE OIL

NUMALIGARH SILIGURI PIPELINENUMALIGARH SILIGURI PIPELINE OILOIL 20092009 16”16” 400400 MULTI PRODUCTMULTI PRODUCT

COMPRESSOR STATIONSCOMPRESSOR STATIONS GAILGAIL ------ ------ ------ REGASIFIED LNGREGASIFIED LNG

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

PIPELINE DESIGNPIPELINE DESIGNMajor Onshore ProjectsMajor Onshore Projects

(Current)

Pipeline Design



SECTION-1

Pipeline Design



CONTENTSINTRODUCTION Modes of Transportation Benefits of Pipelines

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

Pipeline Design



Oil and Gas Production in India

OIL 33 MMTPA

(ONGC, OIL, CAIRN, RIL)

GAS 115 MMSCMD

(ONGC, GAIL, OIL, GSPC, RIL)

Pipeline Design


Refining Scenario- India

70

149

235

302

0

50

100

150

200

250

300

350

1998-99 2006-07 2011-12 2016-17

(MM

T)

Source: Report of Working Group on P&NG Sector for the XI Plan

(Actual) Year

Capacity - 2006-07NOC – 105.5 MMTOthers- 43.5 MMT


Pipeline Design



Modes of Hydrocarbon Transportation - India

Pipelines 32%

Road Tankers 32%

Rail Tankers 26%

Water Carriers 10%0%

5%

10%

15%

20%

25%

30%

35%

% Share

Pipelines

Road Tankers

Rail Tankers

Water Carriers

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

Pipeline Design



Energy SavingsEnergy Intensity for Various Modes

0.80.5

1

3.2

0.81.1

2

0

0.5

1

1.5

2

2.5

3

3.5

4

Liquid-Pipelines

Liquid-Coastal

Liquid-Trains

Liquid-Trucks

Coal-Trains

Coal-Coastal

N.Gas-Pipelines

En

erg

y C

on

su

mp

tio

n in

% o

f en

erg

y

Tra

nsp

ort

ed

Pipelines are the most energy efficient modes of transportation

Pipeline Design


ECONOMICS OF PIPELINE TRANSPORTATIONECONOMICS OF PIPELINE TRANSPORTATION

Transmission losses

0 0.1 0.2 0.3 0.4 0.5

% Loss of Total Volume Transported

Losses During Transportation

Transmission losses are lowest in Pipelines

Pipeline Design



Products Transported

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

Pipeline Design



Types of Pipelines

ONSHORE (LAND) & OFFSHORE (SUBMARINE) PIPELINES

Trunk Pipelines

Spur/ Branch Pipelines

Marine Offloading Terminals & Outfalls

Pipeline Design



Capital cost: Typical breakup

Liquid Lines Gas Lines

1 Survey, ROW & Compensation 2% 1%

2 Line Pipe Steel Cost 33% 45%

3 Main line materials 2% 3%

4 Coating of Pipes 11% 6%

5 Mainline Construction 33% 25%

6 Cathodic Protection 1% 1%

7 Telecommunication, SCADA and RCPs 5% 2%

8 Pump / Compressor Stations 5% 12%

9 Delivery Terminal facilities 2% 1%

10 Project Management 5% 4%

11 SubTotal 100% 100%

Item DescriptionSr No.Percentage of Capital Cost.

E le c tric a l C o st V a ria tn - P u mp S ta tio n

0

0. 5

1

1. 5

0 0. 2 0. 4 0. 6 0. 8 1 1. 2

Pipes, prime-overs and construction constitute big ticket items

Pipeline Design



Marine Offloading Terminal

Pipeline Design



Open sea Jetty

Pipeline Design



KEY PLANLEGEND

MADHYA PRADESH

RAJASTHAN

DADRI

JAGDISHPUR

UTTAR PRADESH

ANOLA

SHAHJAHANPUR

AURAIYA

BABRALA

ANTA

BIJAIPUR

JHABUA

INDIA

COMPRESSOR STATION

RECEIVING TERMINAL

DESPATCH STATION

GUJARAT

HAZIRA

DELHI

N

GADEPAN

ARABIAN SEA

HBJ GAS PIPELINE NETWORK

Pipeline Design



Major Pipelines in India

Pipeline Design



Pipeline Construction Video

Video for Mangalore Bangalore Pipeline

Pipeline Design



SECTION-2

PIPELINE DESIGN CODES AND STANDRADSPIPELINE DESIGN CODES AND STANDRADS

Pipeline Design



Stages of Pipeline Project

ConceptualizationConceptualization Establish RequirementEstablish Requirement Evaluate AlternativesEvaluate Alternatives Finalize the ConceptFinalize the Concept

Feasibility StudyFeasibility Study Pipeline Route Study and SelectionPipeline Route Study and Selection Hydraulic Studies and OptimizationHydraulic Studies and Optimization Establish Project CostEstablish Project Cost Project Implementation SchemeProject Implementation Scheme Environmental Impact Assessment & Risk AnalysisEnvironmental Impact Assessment & Risk Analysis

Pipeline Design



Stages of Pipeline Project

Basic EngineeringBasic Engineering Process Design and SizingProcess Design and Sizing Optimization StudiesOptimization Studies Route Surveys and InvestigationsRoute Surveys and Investigations

Detailed EngineeringDetailed Engineering Engineering Design BasisEngineering Design Basis Route Engineering and Engineering AnalysisRoute Engineering and Engineering Analysis Specifications and Job StandardsSpecifications and Job Standards Engineering for ProcurementEngineering for Procurement Installation Engineering and Construction ProceduresInstallation Engineering and Construction Procedures

Pipeline Design


PIPELINE DESIGNPIPELINE DESIGNMajor Codes & Standards

Code/StandardCode/Standard TitleTitleASME B 31.8 (2003)ASME B 31.8 (2003) Gas Transportation and Distribution Piping SystemsGas Transportation and Distribution Piping Systems

ASME B 31.4 (2006)ASME B 31.4 (2006) Pipeline Transportation Systems for Liquid Hydrocarbons and other Pipeline Transportation Systems for Liquid Hydrocarbons and other LiquidsLiquids

OISD-141 (2003)OISD-141 (2003) Design and Construction Requirements for Cross-Country Design and Construction Requirements for Cross-Country Hydrocarbon PipelinesHydrocarbon Pipelines

OISD-214 (2006)OISD-214 (2006) Cross-Country LPG PipelinesCross-Country LPG Pipelines

OISD-226 (2007)OISD-226 (2007) Natural Gas Transmission Pipelines and City Gas Distribution Natural Gas Transmission Pipelines and City Gas Distribution NetworksNetworks

API 5L / ISO 3183 : 2007API 5L / ISO 3183 : 2007 Specification for Line PipeSpecification for Line Pipe

API RP1102API RP1102 Recommended practice for Rail and Highway crossingsRecommended practice for Rail and Highway crossings

API 1104API 1104 Standard for welding pipeline and related facilitiesStandard for welding pipeline and related facilities

API 6D / ISO 14313API 6D / ISO 14313 Pipeline ValvesPipeline Valves

DNV OS-F101DNV OS-F101 Submarine pipeline systemsSubmarine pipeline systems

Other References Other References Applicable Standards / Specs of ASME, API, NACE, MSS, BS and Applicable Standards / Specs of ASME, API, NACE, MSS, BS and DINDIN

Pipeline Design


PIPELINE DESIGNPIPELINE DESIGNMajor Codes & Standards

Type of CrossingType of Crossing Approval AuthorityApproval Authority

ROU & Land AcquisitionROU & Land Acquisition Central/State Govt. as applicableCentral/State Govt. as applicable

(As per PMP Act 1962)(As per PMP Act 1962)

National Highway CrossingsNational Highway Crossings NHAINHAI

SH/ MDR/ ODR CrossingsSH/ MDR/ ODR Crossings PWDPWD

Railway Track crossings Railway Track crossings Indian RailwaysIndian Railways

Crossing through Forest landCrossing through Forest land Forest AuthorityForest Authority

River/Canal crossingsRiver/Canal crossings Irrigation/Canal AuthorityIrrigation/Canal Authority

Pipeline Design


CAESAR-IICAESAR-II AUTOPIPEAUTOPIPE IPMCSIPMCS MRPACKMRPACK SORPSSORPS PIPECALCPIPECALC OFFPIPEOFFPIPE PRISEPRISE PIPECROSSPIPECROSS

LIST OF SOFTWARES USED IN PIPELINE ENGINEERING

PIPELINE STUDIOPIPELINE STUDIO

TGNETTGNET

TLNETTLNET HYSISHYSIS

Pipeline Design


Optimal sizes of various capacities

Economy of scale


Pipeline Design



Route Selection

Routing Considerations Pipeline length Obstructions & Sensitive areas Installation Limitations Crossings

Surveys Topographical Geo-technical Population Density Index Soil Resistivity Cadastral

Pipeline Design



Typical Pipeline Route Map

Pipeline Design



Pipeline Design



Material Selection & Corrosion Control

Assessment Nature of the Product Design Life Product Temperature

Corrosion Protection Material Chemistry Internal Coatings Product Conditioning Corrosion inhibitors Corrosion Allowance

Materials Carbon Steel (CS) NACE Carbon Steel CRA Clad CS CS with internal

Coatings Non-Metallic

Materials

Pipeline Design



Design and Analysis

Wall Thickness Calculations

Anti-Buoyancy Measures

Piping Stress Analysis

Buried Pipeline Analysis

Crossing Design

Pipeline Design



Steel Pipe Wall Thickness Calculation

LIQUID PIPELINE

(ASME B 31.4, Cl. 404.1.2)

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

GAS PIPELINE

(ASME B 31.8, Cl. 841.11)

P = 2St FET D

where P Design pressure S Specified minimum yield

strengthD Nominal OD of pipe t Nominal wall thickness F Design factorE Longitudinal joint factorT Temperature de-rating factor

Pipeline Design



Basic Design Factor for Gas PipelinesLOCATION CLASS DESIGN FACTOR, F

Location Class 1 0.72




Location Class Classification

Location Class 1 : 10 buildings

Location Class 2 : > 10 and < 46 buildings

Location Class 3 : 46 buildings

Location Class 4 : Multistory buildings

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 PipesType of Line Pipes

SeamlessSeamless

Electric WeldedElectric Welded

Longitudinal Seam Longitudinal Seam

Submerged-Arc Welded Submerged-Arc Welded

(LSAW)(LSAW)

Helical Seam Submerged-Helical Seam Submerged-

Arc Welded Arc Welded

(HSAW)(HSAW)

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”)

Pipeline Design


Manufacturing of Helical PipesManufacturing of Helical PipesPIPELINE DESIGNPIPELINE DESIGN

Pipeline Design



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

PrimerPrimer Two layers of coal tar enamel & glass fibre Inner wrapTwo layers of coal tar enamel & glass fibre Inner wrap One layer of coal tar impregnated outer wrapOne layer of coal tar impregnated outer wrap Coating thickness 4.7mmCoating thickness 4.7mm

3 Layer PE/ PP Coating (DIN 30670)3 Layer PE/ PP Coating (DIN 30670) First layer of Fusion bonded epoxyFirst layer of Fusion bonded epoxy Second layer of extruded adhesive Second layer of extruded adhesive Third layer of extruded PE/ PPThird layer of extruded PE/ PP Coating thickness 2.0 to 3.7 mmCoating thickness 2.0 to 3.7 mm

Fusion Bonded Epoxy Coating (CSA Z245.20)Fusion Bonded Epoxy Coating (CSA Z245.20) 350-500 micron thick single layer coating350-500 micron thick single layer coating 600-800 micron thick dual layer coating600-800 micron thick dual layer coating

Pipeline Design



3 Layer PE Coating Application

Pipeline Design



Major Pipeline Components

Line Pipe & CoatingsLine Pipe & Coatings Scraper Traps & Pig SignallersScraper Traps & Pig Signallers Long Radius (LR) BendsLong Radius (LR) Bends Insulating JointsInsulating Joints Flow TeesFlow Tees Sectionalizing ValvesSectionalizing Valves Pumps / CompressorsPumps / Compressors Filters & MetersFilters & Meters

Pipeline Design



Scraper traps

Pipeline Design



Sectionalizing ValveSpacing Spacing

ASME B 31.8 for Gas pipelines

ASME B 31.4 for Liquid Pipelines

LocationLocation Pollution Concerns Statutory Requirements Prevention of Inventory

Loss Approachability of Valve

Station

Gas PipelinesLocation Class 1 32 km (20 miles)

Location Class 2 24 km (15 miles)



LPG Pipelines

Industrial, 12 km (7.5 miles)

Commercial &

Residential Areas

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

Pipeline Design



Ball valves

Pipeline Design


PIPELINE DESIGNPIPELINE DESIGNPlug valve

Pipeline Design


PIPELINE DESIGNPIPELINE DESIGNCheck valve

Pipeline Design



Major Engineering Deliverables

Design ReportsDesign ReportsDesign BasisDesign BasisRoute Selection ReportRoute Selection ReportWall Thickness ReportWall Thickness ReportSeismic Design ReportSeismic Design ReportCrossing Design ReportCrossing Design Report

DrawingsDrawingsRoute MapRoute MapPipeline SchematicPipeline SchematicAlignment SheetsAlignment SheetsSV Station LayoutSV Station LayoutEquipment LayoutEquipment LayoutPiping General Piping General

Arrangement DrawingsArrangement Drawings

Pipeline Design



Typical Pipeline Alignment SheetINTERSECTION POINTS(IP/TP)

DEFLECTION ANGLE

STATE , DISTRICT AND MANDAL

SCALE:HORIZONTAL 1:5000VERTICAL 1: 500

DISTANCE AS PER GROUND PROFILE

21

23

25

27

29

31

33

35

37

39

41

43

45

10.6

2137

.325

33.3

66

35.4

1133

.560

32.5

87

31.4

96

30.3

00

29.8

15

27.3

70

25.3

62

27.9

04

24.8

58

25.1

38

24.3

41

24.6

75

24.8

28

24.6

0423

.667

22.1

75

25.8

84

30.5

57

29.2

19

29.1

35

28.9

35

30.8

93

32.4

44

33.6

22

37.2

19

40.8

16

39.7

4142

.491

43.6

8443

.034

38°4'58''(R)

TP50 IP50/1

29°8'20''(L)

TP51 IP51/1

5°18'55''(R)

TP52

8°2'3''(L)

TP53

37°0'54''(L)

TP54

13°54'57''(R)

TP55

11°25'7''(L)

TP56

1°21'55''(L)

TP57

8°24'45''(R)

TP58 IP58/1

2°8'32''(L)

TP59

14°0'19''(R)

TP60

8°30'18''(L)

TP61 IP61/1

15°2'57''(L)

TP62

10°4'42''(L)

TP63

10°25'50''(L)

TP64 IP64/1

5°18'12''(R)

TP65

DRA

INC

H 10

664.

71m

/RL

33.3

66m

CAN

ALC

H 10

691.

6m/R

L 35

.411

m

RO

AD

CH

1078

7.02

m/R

L 32

.587

m

DRA

IN

CH

1182

4.63

m/R

L 24

.341

m

RO

AD

CH

1206

0.88

m/R

L 24

.604

m

DRA

IN

CH

1211

5.34

m/R

L 22

.175

m CAR

T TR

ACK

CH

1349

2.61

m/R

L 33

.622

m

CAN

ALC

H 14

027.

73m

/RL

39.7

41m

RO

ADC

H 14

040.

27m

/RL

42.4

91m

CAR

T TR

ACK

CH

1411

5.31

m/R

L 43

.684

m

CH. 12848.455m

HIGH TENSION LINE

TP57

CH.

1182

4.62

9m

CH. 11062.202m

CH. 11401.298m

TP54

CH.11018.117mELECTRIC LINE 440V CH.12115.344m

CH. 11577.761m

TP55

TP56

CH. 11616.510m

CH.12060.877mGRAVEL ROAD

CH. 11939.218m

DRA

IN

DRAIN

CH.12747.397m

CH. 10620.558m

MAT

CH

LINE

FO

R C

O NT.

REF

ER D

WG

NO.

4529

-10-

16-7

1-90

03

CH. 10985.658m

CH. 10797.803m

GRAVEL ROADCH.10787.022m

TP52

IP50/1

CH. 10687.604mTP51

CH. 10712.803mIP51/1

TP53

TP50

CH. 12080.978m

TP58

CH. 12455.060m

TP60

CH. 12230.091m

TP59

DRAINCH.12903.743m

TP61

TP62

CH. 13414.892m

CH. 13741.534m

TP63

CH.14027.732m

RAIWADA LEFT CANAL

TP65CH. 14134.896m

CH. 13979.211m

TP64

IP58/1

CH. 12125.978m CH. 13066.455m

IP61/1

IP64/1CH.14044.732m

KAJU GARDEN RICE FIELDS

VILLAGE BOUNDARY

AMRUTAPURAM IRUVADA

TBM W40 (RL 37.514m)

TBM W49 (RL 25.138m)

TEMP. HUT ON C/L

TBM W57(RL 42.533m)

HPCL CH. 15.00Km HPCL CH. 16.00KmHPCL CH. 17.00Km

RAIWADA LEFT CANAL(UNLINED)CH. 10691.604m

SV-1 OF GAILCH.11960.218 m

K

K

OPEN WELL 6m DIA7.648m FROM C/LCH.11648.136m

OPEN WELL 6m DIA8m FROM C/LCH 11577.761m

PUMP HOUSE 4m FROM C/L

12.2m HIGH & 550KV

EARTHEN EMBANKMENT

LOW LYING AREA

EARTHEN EMBANKMENT

K

(UNLINED)

GRAVEL ROAD CH.14040.275m

MAT

CH

LINE

FO

R C

O NT.

REF

ER D

WG

NO.

4529

-10-

16-7

1-90

05

METALLED ROAD(ASPHALTIC)CH.14115.309m

ELEC. LINE 440VCH.14132.231m

TELEPHONE LINE CH.14134.896m

DISTANCE BETWEEN TP & IP's(m)

10.6

65

44.1

52

10.6

9226

.894

10.7

1321

.199

10.7

87

74.2

19

10.9

86

198.

636

11.0

25

39.3

69

11.0

6237

.175

11.2

59

196.

962

11.4

01

142.

134

11.5

78

176.

463

11.6

17

38.7

49

11.7

58

141.

522

11.8

25

66.5

97

11.8

4924

.246

11.9

39

90.3

42

12.0

61

121.

660

12.0

8120

.101

12.1

1534

.366

12.2

30

114.

747

12.4

55

224.

969

12.7

54

299.

254

12.8

48

94.1

41

13.0

66

217.

539

13.2

48

182.

117

13.4

15

166.

780

13.4

93

77.7

14

13.7

42

248.

929

13.9

79

237.

676

14.0

28

48.5

21

14.0

4012

.543

14.1

15

75.0

34

14.1

3519

.588

67.046

67.049

25.199

25.200

85.000

85.284

187.855

187.993

76.544

76.618

339.096

339.126

176.463

176.478

38.749

38.853

322.708

322.772

141.760

141.845

45.000

45.093

104.113

104.624

224.969

225.022

393.395

393.407

218.000

218.014

348.437

348.444

326.642

326.679

237.677

237.707

65.521

65.728

90.164

90.390

10.6

21

10.6

65

10.6

9210

.713

10.7

87

10.9

86

11.0

25

11.0

62

11.2

59

11.4

01

11.5

78

11.6

17

11.7

58

11.8

25

11.8

49

11.9

39

12.0

6112

.081

12.1

15

12.2

30

12.4

55

12.7

54

12.8

48

13.0

66

13.2

48

13.4

15

13.4

93

13.7

42

13.9

79

14.0

2814

.040

14.1

1514

.135

11.9

6011

.972

11.9

84

Pipeline Design


Typical P&ID


Pipeline Design


PIPELINE DESIGNPIPELINE DESIGNTypical GA DRAWING

Pipeline Design


PIPELINE DESIGNPIPELINE DESIGNMajor Engineering Deliverables

TendersTenders Survey TenderSurvey Tender Pipe Coating TenderPipe Coating Tender Pipeline Installation TenderPipeline Installation Tender

Material Procurement Material Procurement Line PipesLine Pipes Valves & ActuatorsValves & Actuators Scraper Traps, QOEC, Pig SignallersScraper Traps, QOEC, Pig Signallers Flow Tees & Insulating JointsFlow Tees & Insulating Joints Induction BendsInduction Bends Flow metersFlow meters Pumps & CompressorsPumps & Compressors OFC cablesOFC cables

Pipeline Design



Installation, Testing & Commissioning

RoU Grading & Trenching Stringing of Linepipe

Pipeline Design




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

Pipeline Design




Field Joint Coating Lowering & Backfilling Heat Shrink Sleeves Cold applied tapes

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

Pipeline Design



The conventional HDD operations for river crossings.

Pipeline Design



Pipeline Installation using Micro-tunnellingMICRO-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

ADVANTAGES: 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

Pipeline Design



Pipeline Installation using Micro-tunnelling

Long Distance Micro TunnellingLong Distance Micro Tunnelling

Pipeline Design



Overview of Micro tunneling

Pipeline Design



Testing & CommissioningTESTING

Gauging and Pigging Test Pressure Test Medium

TEST PRESSURE

LIQUID PIPELINESRef. ASME B 31.4 : 437.4.11.25 times design pressure

GAS PIPELINESRef. ASME B 31.8 : Table 841.322(f)Class 1 and 2: 1.25 * des prClass 3 and 4: 1.4 * des pr

DRYING Swabbing Methanol Drying Super Dry Air

Method Vacuum Drying

COMMISSIONING Nitrogen Purging Product Charging

Pipeline Design


PIPELINE DESIGNPIPELINE DESIGNPigging

Requirements Pipeline Cleaning Displacement Internal Inspection Batching

Types of Pigs Brush pigs Gauge Pigs Spheres Intelligent Pigs

Cleaning pigs Gauge Pigs Spheres Intelligent Pig (MFL)

Pipeline Design



RECENT DEVELOPMENTS

TECHNICAL IMPROVEMENTSTECHNICAL IMPROVEMENTS Automatic Welding & Automatic UTAutomatic Welding & Automatic UT Micro-Tunneling for pipeline constructionMicro-Tunneling for pipeline construction Internal flow coating on line pipes for gas pipelinesInternal flow coating on line pipes for gas pipelines 3LPP coating on High Temperature pipelines3LPP coating on High Temperature pipelines

Pipeline Design



Comparison of LSAW & HSAW Pipes

DescriptionDescription LSAWLSAW HSAWHSAW

Method of Method of ManufactureManufacture

UOE/COE/JCO/3 roll bendingUOE/COE/JCO/3 roll bending Formed by Twisting of CoilFormed by Twisting of Coil

Weld LengthWeld Length Equal to pipe joint lengthEqual to pipe joint length Approximately 1.5 to 2 times the Approximately 1.5 to 2 times the length of pipe jointlength of pipe joint

Position of weldPosition of weld Longitudinal – positioned in Longitudinal – positioned in upper quadrant during upper quadrant during constructionconstruction

Spiral – present all around the Spiral – present all around the pipepipe

Corrosion Coating Corrosion Coating Specified thickness throughout Specified thickness throughout entire body. entire body.

Weld seam is tracked to ensure Weld seam is tracked to ensure coating thickness on weld seamcoating thickness on weld seam

Thickness normally increased all Thickness normally increased all over the body, resulting in over the body, resulting in proportional increase in coating proportional increase in coating cost by 15-20%cost by 15-20%

GeometryGeometry Controlled to the desired level Controlled to the desired level with cold expansionwith cold expansion

Controlled during forming only Controlled during forming only and no cold expansion is carried and no cold expansion is carried outout

Pipeline Design



CTECTE 3LPE3LPE 3LPP3LPP FBEFBE

Service ConditionsService Conditions

Temperature, Temperature, oo C C Upto 45Upto 45 Upto 65Upto 65 Upto 110Upto 110 Upto 110Upto 110

Anti-corrosion PropertiesAnti-corrosion Properties

Resistance to MoistureResistance to Moisture GoodGood Very GoodVery Good ExcellentExcellent GoodGood

Cathodic DisbondmentCathodic Disbondment FairFair GoodGood GoodGood GoodGood

Electrical Properties Electrical Properties

Coating ResistanceCoating Resistance GoodGood ExcellentExcellent ExcellentExcellent ExcellentExcellent

Coating Comparison

Pipeline Design




Cathodic Protection DesignCathodic Protection Design

Current DensityCurrent Density HighHigh LowLow LowLow LowLow

Mechanical PropertiesMechanical Properties

Resistance to ImpactResistance to Impact FairFair ExcellentExcellent Superior to PESuperior to PE FairFair

Resistance to Resistance to IndentationIndentation

PoorPoor Very GoodVery Good ExcellentExcellent FairFair

Resistance to PeelResistance to Peel FairFair ExcellentExcellent Superior than PESuperior than PE --

Resistance to Soil Resistance to Soil StressesStresses

FairFair ExcellentExcellent ExcellentExcellent ExcellentExcellent

ElongationElongation FairFair ExcellentExcellent ExcellentExcellent --

Coating Comparison

Pipeline Design




Long Term AgeingLong Term Ageing

Heat & Light AgeingHeat & Light Ageing FairFair Very GoodVery Good Very GoodVery Good Very GoodVery Good

Application & Field RepairApplication & Field Repair

Ease of ApplicationEase of Application Easy Easy Relatively difficultRelatively difficult Relatively difficultRelatively difficult Relatively difficultRelatively difficult

Damages during Damages during handling & handling & transportationtransportation

HighHigh LowLow LowLow HighHigh

Ease of Field RepairEase of Field Repair DifficultDifficult Easy for small repair,Easy for small repair,

Cumbersome for Cumbersome for larger repairlarger repair

Easy for small repair,Easy for small repair,


Easy for small repair,Easy for small repair,


Coating Comparison

Pipeline Design


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