EIL Cross Country Pipeline Presentation

CONSTRUCTION OF CROSS COUNTRY PIPELINES

Slide Number- 1 of 50Delivering excellence through people

CONSTRUCTION CONSTRUCTION OFOF

CROSS COUNTRY CROSS COUNTRY PIPELINESPIPELINES

By: G. K. IYER (AGM.)


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

CROSS COUNTRY PIPELINE WORKSCROSS COUNTRY PIPELINE WORKSOVERVIEWOVERVIEW

MAIN 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; WATER PIPELINE 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 AREAS LOW 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 WORKSSOME OF THE MAJOR PIPELINES UNDERTAKEN BY EILSOME OF THE MAJOR PIPELINES UNDERTAKEN BY EIL

1.1. 1986 1986 –– 3636””/18/18”” x 1800 Kms: HBJ (HAZIRAx 1800 Kms: HBJ (HAZIRA--BIJAIPURBIJAIPUR--JAGDISHPUR) GAS P/L OF M/s GAILJAGDISHPUR) GAS P/L OF M/s GAIL2.2. 1996 1996 –– 2222””/14/14””/10/10”” x 1450 Kms: KBPL (KANDLAx 1450 Kms: KBPL (KANDLA--BHATINDA) PRODUCT P/L OF M/s IOCLBHATINDA) PRODUCT P/L OF M/s IOCL3.3. 1997 1997 –– 3636”” x 505 Kms: GREP (HBJ UPx 505 Kms: GREP (HBJ UP--GRADATION) GAS P/L OF M/s GAILGRADATION) GAS P/L OF M/s GAIL4.4. 1998, 2003, 2007 1998, 2003, 2007 –– 1818””/14/14”” x ~1200 Kms: MMPL PHx ~1200 Kms: MMPL PH--1,2 &3 (MUMBAI1,2 &3 (MUMBAI--MANMADMANMAD--INDOREINDORE--

DELHI) PRODUCT P/L OF M/s BPCLDELHI) PRODUCT P/L OF M/s BPCL5.5. 2000 2000 –– 1616”” x 1269 Kms: JLPL (JAMNAGARx 1269 Kms: JLPL (JAMNAGAR--LONI) LPG P/L OF M/s GAIL LONI) LPG P/L OF M/s GAIL 6.6. 2002 2002 –– 1616””/14/14”” x 220 Kms: VSPL (VIJAIWADAx 220 Kms: VSPL (VIJAIWADA--SECUNDRABAD) PRODUCT P/L OF M/s HPCLSECUNDRABAD) PRODUCT P/L OF M/s HPCL7.7. 2002 2002 –– 1818””/14/14”” x 289 Kms: CKPL (COCHINx 289 Kms: CKPL (COCHIN--KARUR) PRODUCT P/L OF M/s PETRONET LTD.KARUR) PRODUCT P/L OF M/s PETRONET LTD.8.8. 2003 2003 –– 2424””/24/24”” x 380 Kms: MBPL (MANGLOREx 380 Kms: MBPL (MANGLORE--BANGLORE) PRODUCT P/L OF M/s HPCLBANGLORE) PRODUCT P/L OF M/s HPCL9.9. 2003 2003 –– 1212””/10/10”” x 600 Kms: VSPL (VIZAGx 600 Kms: VSPL (VIZAG--SECUNDRABAD) LPG P/L OF M/s GAILSECUNDRABAD) LPG P/L OF M/s GAIL10.10. 2004 2004 –– 4242”” x 610 Kms: DVPL (DAHEJx 610 Kms: DVPL (DAHEJ--VIJAIPUR) GAS P/L OF M/s GAILVIJAIPUR) GAS P/L OF M/s GAIL11.11. 2006 2006 –– 1818”” x 1037 Kms: MDPL (MUNDRAx 1037 Kms: MDPL (MUNDRA--DELHI) PRODUCT P/L OF M/s HPCL DELHI) PRODUCT P/L OF M/s HPCL 12.12. 2006 2006 –– 1414””/12/12”” x 343 Kms: PSPL (PUNEx 343 Kms: PSPL (PUNE--SHOLAPUR) PRODUCT P/L OF M/s HPCLSHOLAPUR) PRODUCT P/L OF M/s HPCL13.13. 2007 2007 –– 1616”” x 401 Kms: NSPL (NUMALIGARHx 401 Kms: NSPL (NUMALIGARH--SILIGURI) PRODUCT P/L OF M/s OILSILIGURI) PRODUCT P/L OF M/s OIL14.14. DPPL PHDPPL PH--1&2 (DHABOL1&2 (DHABOL--PUNE) GAS P/L OF M/s GAIL PUNE) GAS P/L OF M/s GAIL PHPH--2 IN PROGRESS2 IN PROGRESS15.15. VBPL (VADINARVBPL (VADINAR--BINA) CRUDE OIL P/L OF M/s BORL BINA) CRUDE OIL P/L OF M/s BORL IN PROGRESSIN PROGRESS16.16. VDBPL (VIJAIPURVDBPL (VIJAIPUR--DADRIDADRI--BAWANA) GAS P/L OF M/s GAIL BAWANA) GAS P/L OF M/s GAIL IN PROGRESSIN PROGRESS17.17. MBPL (MUNDRAMBPL (MUNDRA--BHATINDA) CRUDE OIL P/L OF M/s HMPL BHATINDA) CRUDE OIL P/L OF M/s HMPL IN PROGRESSIN PROGRESS18.18. BKPL (BINABKPL (BINA--KOTA) PRODUCT P/L OF M/s BPCL KOTA) PRODUCT P/L OF M/s BPCL IN PROGRESSIN PROGRESS



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



CROSS COUNTRY PIPELINE WORKSCROSS COUNTRY PIPELINE WORKS

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 FOR TYPES OF CONTRACTORS REQUIRED FOR CONSTRUCTION OF PIPELINESCONSTRUCTION OF PIPELINES




I.I. CONSTRUCTION METHODOLOGY CONSTRUCTION METHODOLOGY

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

LINEPIPES COATING AT YARD & DUMPSITE LINEPIPES COATING AT YARD & DUMPSITE

LAYING OF PIPELINE LAYING OF PIPELINE



CROSS COUNTRY PIPELINE WORKSCROSS COUNTRY PIPELINE WORKSQA/QC IN PIPELINEQA/QC IN PIPELINE

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

Review & Approval of ContractorReview & 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 Formats Review & Approval of Job Procedures & Inspection Formats based 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 203AWWA 203 : Coal Tar Enamel Coating of Line: Coal Tar Enamel Coating of Line--pipespipes

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

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

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

6.6. ASME B 31.8ASME 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--country country HydroHydro--carbon Pipelinescarbon Pipelines



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

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

1.1. 66--7171--0001 0001 : 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--0042 0042 : Standard specification for CTE Coating Onshore Pipeline.: Standard specification for CTE Coating Onshore Pipeline.4.4. 66--7171--0044 0044 : Standard specification for Field Jt. Coating Onshore Pipel: Standard specification for Field Jt. Coating Onshore Pipeline.ine.5.5. 66--7171--0046 0046 : Standard specification for Conc. Coating Onshore Pipeline.: Standard specification for Conc. Coating Onshore Pipeline.6.6. 66--7171--0051 0051 : Standard specification for Pipeline Construction (Onshore): Standard specification for Pipeline Construction (Onshore)7.7. 66--7171--0052 0052 : Standard specification for Pipeline Construction, Road, Ra: Standard specification for Pipeline Construction, Road, Rail, il,

Minor Water CrossingsMinor Water Crossings8.8. 66--7171--0053 0053 : Standard specification for Major Water Crossings (Conventi: Standard specification for Major Water Crossings (Conventional)onal)9.9. 66--7171--0054 0054 : Standard specification for Pipeline River Crossings by HDD: Standard specification for Pipeline River Crossings by HDD10.10. 66--7171--0055 0055 : Standard specification for Hydro: Standard specification for Hydro--testing of Onshore Pipelinestesting of Onshore Pipelines11.11. 66--7171--0057 0057 : 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 to HSE plan & documents with reference to EIL 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 facilitiesAid & 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--11stst LAYER: FUSION BONDED EPOXY LAYER: FUSION BONDED EPOXY –– 50 MICRONS (200 TO 300 MICRONS 50 MICRONS (200 TO 300 MICRONS -- FBE COATING)FBE COATING)-- 22ndnd LAYER: SIDE EXTRUSION ADHESIVE (LDPE) LAYER: SIDE EXTRUSION ADHESIVE (LDPE) –– 200 TO 300 MICRONS200 TO 300 MICRONS--33rdrd 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)-- 11stst COAT: COAL TAR PRIMER COAT: COAL TAR PRIMER –– 50 TO 75 MICRONS50 TO 75 MICRONS-- 22ndnd COAT: 1COAT: 1stst HOT COAL TAR ENAMEL LAYER WITH INNER WRAPHOT COAL TAR ENAMEL LAYER WITH INNER WRAP–– > 1 MM> 1 MM-- 33rdrd COAT: 2COAT: 2ndnd 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 WRAP FINAL 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 DAMAGES BEVEL & 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 200 PRIMER / EPOXY APPLICATION (PIPES TO BE PREHEATED TO 200 00 C BY C BY INDUCTION 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 SPRAY 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 ENAMEL ETC.L ETC.

ADHESIVE & PE APPLICATION INNER/OUTER WRAP & COAL TAR 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 COATING NG -- 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 EXTERNAL PAINTING COATED PIPES STACKING YARD



CROSS COUNTRY PIPELINE WORKSCROSS COUNTRY PIPELINE WORKSDUMP SITES FOR STORAGE OF COATED PIPESDUMP SITES FOR STORAGE OF COATED PIPESACQUIRING 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 , GUARD ROOM AND SECURITY ARD ROOM AND SECURITY -- PROVIDING INTERNAL ROADS (WBM) FOR TRAILER MOVEMENT & AREA LIGHPROVIDING INTERNAL ROADS (WBM) FOR TRAILER MOVEMENT & AREA LIGHTING 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 CADEQUATE CRANES WITH PADDED HOOKS FOR UNLOADING / LOADING OF COATED 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 50 Engineers India Ltd – Delivering excellence through people

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

ROU SURVEYROU CLEARING AND GRADING STRINGINGTRENCHINGBENDINGWELDINGFIELD JOINT COATINGLOWERING BACKFILLINGCROSSINGTIE-INSHYDROTESTINGPIPELINE 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 SURVEY

Installation of Bench Marks, Turning PointsStake markers in center line of pipeline at a distance of max.100m for centre line and for horizontal bends10 m. and reference point for sameStake two ROU markers at least at every 100m, Painted in red and numbers in white in direction of flow.Chainage markers at every 250 m

ROU CLEARING & GRADINGROU CLEARING & GRADINGAll 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 a way that bottom of coated Pipe remain above ground Pipes shall be supported at minimum two locationsPipe number, Heat number, coat number & length shall be transferred and recorded in serial 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.:TRENCHINGTRENCHING

Trench excavation is carried out along staked centerline of Pipeline The 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 Rules of 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 are provided in such areas e.g. weighing by applying continuous concrete, installing saddle weights etc.

BENDING BENDING For changes in vertical & horizontal alignment, pre-fabricated cold field bends are provided Over-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 specified clearance to the outside wall of trench. The radius of cold field bends shall not be more than 40 times the dia. of pipe (for 18” inch and 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 the neutral axis of bend



CROSS COUNTRY PIPELINE WORKSCROSS COUNTRY PIPELINE WORKSPIPELINE TRENCHING ACTIVITY



CROSS COUNTRY PIPELINE WOCROSS COUNTRY PIPELINE WORKSRKSPIPELINE 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 the Procedure qualification record (PQR) is approved before start of welding. Approved brand of electrodes are used for welding. Physical properties of the weld produced by an electrode shall not be less than minimum value of base metal. Electrode qualification and batch record are maintained. Each pipe shall be thoroughly checked internally & externally for visual defect/ damage and cleaned 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 such case external clamps are used.Each joint shall bear an identification number which shall be followed for NDT The number of welders, and welding sequence, speed etc. should be similar to that of adopted in approved welding procedureRadiography examination of 100 % girth weld is carried out. Weld shall meet the requirement of API 1104. In addition 100% ultrasonic inspection is required for critical 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 and re-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 JOINTAUTOMATIC WELDING CREW FOR MAINLINE JOINT

AUTO UT OF MAINLINE JOINTAUTOMATIC WELDING OF MAINLINE JOINT



CROSS COUNTRY PIPELINE WORKSCROSS COUNTRY PIPELINE WORKSPIPELINE 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 Field Joint Coating. Field joint coating material is heat shrinkable wraparound sleeve used as anticorrosion coating 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 adhesive The joint coating system shall consist of a solvent free epoxy primer applied to the pipe surface prior to sleeve application. The surface area is blast cleaned to SA-2.5 followed by Pre-heating of pipe surface, application of epoxy primer and application of sleeve by heat shrinking. 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 sleeve checked.One out of 50 joints coating or one coating out of every day production shall be tested to establish 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 from pipe supports, stones, roots, debris, stakes, and rigid material. Padding shall be provided in rocky/ murram area.

Lowering shall commence as soon as possible after completion of joint coating, Before lowering in, complete check by a full circle holiday detector for pipe coating and field joint coating 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 section available

Ends of the lowered pipeline section shall be closed with night cap to prevent ingress of water, 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.:BACKFILLINGBACKFILLING

Backfilling shall be carried out immediately after pipeline lowering in trench after inspection, so as to provide a natural anchorage for the pipeline, thus avoiding long exposure of coating to high temperature, damaging action of adverse weather conditions, sliding down of trench sides and pipeline movement in the trench. Backfill material shall not contain any extraneous material or hard lumps of soil which can damage pipeline or coating or leave the voids in backfilled trench. After placing of initial backfill, proper compaction shall be done. The surplus material shall be crowned (300 mm) directly over trench and adjacent excavated area on both side of trench. If trench are excavated in steep area where the slope is more than 10%, slope breakers shall be installed to prevent erosion of backfill. Stabilization of backfill shall be done in sandy area to have consolidated cover over the pipeline.

CROSSINGSCROSSINGSCased & Un-cased crossings for Roads & RailwaysOpen cut & Horizontal Directional Drilling (HDD) for Minor & Major River Crossing

TIETIE--INs INs The unconnected sections of the lowered pipeline sections at various locations have to be welded, coated and backfilled 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 WORKSCROSS COUNTRY PIPELINE WORKSBOARING FOR CASED CROSSINGPADDING & BACKFILLING

TIE-IN IN PROGRESS

TIE-IN WELDING IN PROGRESS



CROSS COUNTRY PIPELINE WORKSCROSS COUNTRY PIPELINE WORKSPIPELINE LAYING ACTIVITIES.. Contd.:PIPELINE LAYING ACTIVITIES.. Contd.:HYDROHYDRO--TESTINGTESTING

Hydrostatic test is performed on entire length of the pipeline. The maximum permitted length is 50 Kms. Hydrostatic test diagrams indicating number of test sections and minimum and maximum 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 crossings etc.

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

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

After successful cleaning and acceptance, gauging is carried out using gauging pig.




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

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

After water filling operation, thermal equilibrium between pipeline and environment shall be checked with thermocouples installed on the pipeline.

After thermal stabilization pressurization 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 and then pressurized to final test pressure. During each test pressure, two test shall be carried out for calculation of air volume in the pipeline under test and on acceptance of air volume test the section is held for 24 hours at Final test pressure and pressure and temperature recorded on chart.

The hydrostatic test shall be considered positive if pressure has kept a constant value throughout 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 acceptable if the difference is less than or equal to 0.3 bar.

After positive test results, test shall be terminated . The pipeline shall be depressurized at constant rate. Dewatering shall be carried out by using four cup pigs driven by compressed air. Foam pigs shall be passed to complete the dewatering.



CROSS COUNTRY PIPELINE WORKSCROSS COUNTRY PIPELINE WORKSPIPELINE ACTIVITIES Contd.:PIPELINE ACTIVITIES Contd.:PIPELINE MARKERS, CLEANPIPELINE MARKERS, CLEAN--UP AND RESTORATIONUP AND RESTORATION

Following type of markers shall be fabricated and installed along the pipeline route such that they do not cause any hindrance to the regular land user or traffic

− Aerial Markers : At every 5 Kms. − Kilometer Markers : At every 1 Km. & as per Alignment sheet− Pipeline Warning Markers : At Road / Railway / River Crossings & Stations / 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 sites used for construction of pipeline , water crossing and other structures shall be restored as per satisfaction of authority having jurisdiction over it.Damages to roads, bridges, fences etc. damaged during construction shall be restored to original. 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 condition as may be reasonably consistent with the condition of the ROU prior to laying the pipeline. The release note from the land owner s regarding satisfactory indemnification and restoration of land shall be obtained from land owner.




PIPELINE ACTIVITIES Contd.:PIPELINE ACTIVITIES Contd.:

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 isolate pipeline section during emergencies like leakage in pipeline as per statutory requirements. An SV station is installed at such locations having a unmanned control room with a guard room and boundary wall. A lockable grill cage is provided over the Sectionalizing Valve installation including piping and instrumentation to prevent tampering by unauthorized persons and ensuring safety of pipeline operations.

Intermediate Pigging (IP) stations are installed at regular intervals (as per design ~ 150 Kms.) having a Pig Launcher and a Pig Receiver with Control room, Sump tank, Basket Filters, guard room, boundary wall etc. to facilitate pigging of pipeline during routine Operation 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 the product through the pipeline. It comprises of Pig Launcher / Pig Receiver with Control room, Mainline & Booster Pumps (DT/PS), Sump tank, Basket Filters, guard room, Firewater system, boundary wall etc.



CROSS COUNTRY PIPELINE WORKSCROSS COUNTRY PIPELINE WORKSTYPICAL SECTIONALIZING VALVE (SV) STATION




PIPELINE ACTIVITIES Contd.:PIPELINE ACTIVITIES Contd.:

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

This is a part of pre-commissioning activity, which ensures that there is no deformity in pipeline. This is done prior to filling the line with product.

Magnetic PIG loaded with high capacity magnets spread uniformly with high density polythene four cup PIG is launched to remove ferrous debris, mill scale, electrode pieces etc. 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 specific length 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 mounted with battery operated battery device, which gives the reduction in pipeline Dia. at specific location in electronic form.

Any defect /deformity more than 3% of internal diameter of pipe (dent or ovality) is physically verified at site. Defect of more than 5% internal diameter of pipe are repaired by cutting the suitable length of pipe and re-welding and accepted after radiography.

Documents

EIL Cross Country Pipeline Presentation