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PIPELINE DESIGN

Delivering excellence through people

Pipeline Design

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ENGINEERSENGINEERS

INDIA LIMITEDINDIA LIMITED

EPC and Total Solutions EPC and Total Solutions

Consultancy OrganizationConsultancy Organization

Pipeline Design


Engineers India Ltd – Delivering excellence through people

Petroleum Refineries

PetrochemicalsPetrochemicals

Pipelines

Offshore Platforms

Gas Processing

Metallurgy

Pipeline Design



Metallurgy

Ports & Terminals

Highways and Airports

HEAD OFFICE NEW DELHI

REGIONAL OFFICES VADODARA, CHENNAI

EIL OFFICESEIL OFFICES

REGIONAL OFFICES VADODARA, CHENNAI

KOLKATA

PROCUREMENT OFFICES MUMBAI

SITE OFFICES 29 LOCATIONS (INDIA)

9 LOCATIONS (OVERSEAS)

INSPECTION OFFICE 10 LOCATIONS

Pipeline Design



OVERSEAS OFFICES LONDON, LIBYA ABU DHABI,

ITALY, SAUDI ARABIA , QATAR,

KUWAIT

PIPELINE DESIGNPIPELINE DESIGN

SERVICES OFFERED BY EILProject Implementation Services

� Feasibility Studies

� Project Management

Specialist Services

� Heat & Mass Transfer Equipment

Design� Project Management

� Planning & Scheduling

� Process Design

� Detailed Engineering

� Procurement Services

� Construction Management

Design

� Environment Engineering

� Information Technology Services

� Specialist Materials and

Maintenance Services

� Plant Operation & Safety

Pipeline Design



� Commissioning and Plant

Start-up Assistance

� Risk Analysis

� Advanced Control & Optimization


EIL EXPERIENCE

1975 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

Pipeline Design



for GAIL

Over 40 major pipeline projects completed.


DESCRIPTIONDESCRIPTION CLIENTCLIENT YEARYEAR SIZESIZE LENGTH LENGTH

(KM)(KM)

SERVICESSERVICES

HAZIRAHAZIRA--BIJAIPURBIJAIPUR--

JAGDISHPUR (HBJ)JAGDISHPUR (HBJ)

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

Major Onshore Projects (Completed)

JAGDISHPUR (HBJ)JAGDISHPUR (HBJ)

MAQTAMAQTA--ALAL--AIN PIPELINEAIN PIPELINE ADNOCADNOC 19921992 30 ”/12”30 ”/12” 166166 NATURAL GASNATURAL GAS

KANDLAKANDLA--BHATINDABHATINDA 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 MUMBAI –– MANMADMANMAD BPCLBPCL 19981998 18 ”18 ” 260260 MULTIPRODUCTMULTIPRODUCT

VIZAGVIZAG--VIJAYWADAVIJAYWADA HPCLHPCL 19981998 18 ”18 ” 360360 MULTIPRODUCTMULTIPRODUCT

Pipeline Design



VIZAGVIZAG--VIJAYWADAVIJAYWADA HPCLHPCL 19981998 18 ”18 ” 360360 MULTIPRODUCTMULTIPRODUCT

JAMNAGARJAMNAGAR--LONI LPG LONI LPG

PIPELINEPIPELINE

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

66

12351235 LPG (LIQUIFIED LPG (LIQUIFIED

PETROLIUM GAS)PETROLIUM GAS)

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



(KM)(KM)

SERVICESSERVICES

VIZAG VIZAG –– SECUNDERABAD LPG SECUNDERABAD LPG

PIPELINEPIPELINE

GAILGAIL 20022002 12”/10”12”/10” 600600 LPG (LEQUIFIED LPG (LEQUIFIED

PETROLEUM GAS)PETROLEUM GAS)

Major Onshore Projects (..contd) (Completed)

MANMADMANMAD--MANGALAYA PIPELINEMANGALAYA PIPELINE BPCLBPCL 20032003 14 ”14 ” 358358 MULTIPRODUCTMULTIPRODUCT

MANGALOREMANGALORE--BANGLOREBANGLORE HPCLHPCL 20032003 24 ”/20”24 ”/20” 364364 MULTIPRODUCTMULTIPRODUCT

DAHEJ DAHEJ –– VIJAIPUR PIPELINEVIJAIPUR 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

Pipeline Design



16”16” 208208

MANGALAYAMANGALAYA--BIJWASAN BIJWASAN

PIPELINEPIPELINE

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

MUNDRAMUNDRA--DELHI PIPELINEDELHI PIPELINE HPCLHPCL 20062006 18”/16”18”/16” 10501050 MULTIPRODUCTMULTIPRODUCT


(KM)(KM)

SERVICESSERVICES

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

PIPELINE DESIGNPIPELINE DESIGNMajor Onshore Projects (7contd)

(Completed)

DABHOL PANVEL PIPELINE DABHOL PANVEL PIPELINE

PROJECT (PHPROJECT (PH--I)I)

GAILGAIL 20072007 30”30” 187187 REGASIFIED LNGREGASIFIED LNG

DABHOL PANVEL PIPELINE DABHOL PANVEL PIPELINE

PROJECT (PHPROJECT (PH--II)II)

GAILGAIL 20072007 30”30” 120120 REGASIFIED LNGREGASIFIED LNG

Pipeline Design




(KM)(KM)

SERVICESSERVICES

BOMBAY HIGH URAN TRUNKLINEBOMBAY HIGH URAN TRUNKLINE

(BUT)(BUT)

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

PIPELINE DESIGNPIPELINE DESIGNMajor Offshore ProjectsMajor Offshore Projects

(Completed)

(BUT)(BUT)

SOUTH BASSEIN HAZIRA SOUTH BASSEIN HAZIRA

TRUNKLINETRUNKLINE

ONGCONGC 19861986 36”36” 220220 GASGAS

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

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

SECOND BASSEIN HAZIRA SECOND BASSEIN HAZIRA

TRUNKLINETRUNKLINE

ONGCONGC 19951995 42”42” 245245 GASGAS

Pipeline Design



TRUNKLINETRUNKLINE

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.


(KM)(KM)

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

PIPELINE DESIGNPIPELINE DESIGNMajor Onshore ProjectsMajor Onshore Projects

(Current)

(VDBPL)(VDBPL) 20”20”

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

Pipeline Design



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

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


SECTION-1

INTRODUCTIONINTRODUCTION

Pipeline Design




CONTENTS

INTRODUCTION

� Modes of TransportationBenefits of Pipelines� Benefits of Pipelines

PIPELINE DESIGN

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

Pipeline Design



� Installation, Testing & Commissioning


Oil and Gas Production in India

� OIL 33 MMTPA� OIL 33 MMTPA

(ONGC, OIL, CAIRN, RIL)

� GAS 115 MMSCMD

Pipeline Design



(ONGC, GAIL, OIL, GSPC, RIL)

Refining Scenario- India

302300

350

Capacity - 2006-07

NOC – 105.5 MMT

Others- 43.5 MMT


70

149

235

100

150

200

250

300

(MMT)

Pipeline Design



0

50

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

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

(Actual) Year


Modes of Hydrocarbon Transportation - India

30%

35%

Pipelines 32%

Road Tankers 32%

Rail Tankers 26%

Water Carriers 10%0%

5%

10%

15%

20%

25%

30%

% Share

Pipelines

Road Tankers

Rail Tankers

Water Carriers

Pipeline Design



% Share


Benefits of Transportation by Pipelines

� Safer mode of transportation

� Environment friendly� Environment friendly

� Least energy requirement

� Lowest maintenance costs

� Minimal impact on land use pattern

� Negligible loss of product in transit

High reliability

Pipeline Design



� High reliability

� Multi-product Transportation


Energy Savings

Energy Intensity for Various Modes

4

Energy Consumption in % of energy

0.8

0.51

3.2

0.81.1

2

0

0.5

1

1.5

2

2.5

3

3.5

4


Transported

Pipeline Design



0

Liquid-

Pipelines

Liquid-

Coastal

Liquid-

Trains

Liquid-

Trucks

Coal-

Trains

Coal-

Coastal

N.Gas-

Pipelines


Pipelines are the most energy efficient modes of transportation

ECONOMICS OF PIPELINE TRANSPORTATIONECONOMICS OF PIPELINE TRANSPORTATION

Transmission losses

Losses During Transportation

Pipelines

Rail/Road

Pipeline Design



0 0.1 0.2 0.3 0.4 0.5

% Loss of Total Volume Transported

Transmission losses are lowest in Pipelines


Products Transported

� Crude Oil

� Petroleum Products (MS, HSD, ATF, SKO)� Petroleum Products (MS, HSD, ATF, SKO)

� Water & Effluents

� LPG

� Natural Gas

� Slurries

Pipeline Design




Types of Pipelines

ONSHORE (LAND) & OFFSHORE

(SUBMARINE) PIPELINES(SUBMARINE) PIPELINES

� Trunk Pipelines

� Spur/ Branch Pipelines

� Marine Offloading Terminals & Outfalls

Pipeline Design




Capital cost: Typical breakup

Liquid Lines Gas Lines

1 Su rv ey , ROW & Compen s atio n 2% 1%

Ite m D e scriptionS r �o.Percentag e of Cap ita l Cos t.

1 Su rv ey , ROW & Compen s atio n 2% 1%

2 Lin e Pip e Steel Co s t 33% 45%

3 M ain lin e materia ls 2% 3%

4 Coating o f Pip es 11% 6%

5 M ain lin e Con s tru ctio n 33% 25%

6 Cathod ic Pro tectio n 1% 1%

7 Telecommun ication , SCADA and RCPs 5% 2%

8 Pump / Compres s o r Station s 5% 12%

Pipeline Design



9 Deliv ery Terminal facilities 2% 1%

10 Pro ject M anag emen t 5% 4%

1 1 S ubTotal 100% 100%

Pipes, prime-overs and construction constitute big ticket items


Marine Offloading Terminal

Pipeline Design




Open sea Jetty

Pipeline Design




UTTAR PRADESHN

HBJ GAS PIPELINE NETWORK

KEY PLAN

RAJASTHAN

DADRI

JAGDISHPUR

ANOLA

SHAHJAHANPUR

AURAIYA

BABRALA

ANTA

BIJAIPUR

INDIA

GUJARAT

DELHI

N

GADEPAN

Pipeline Design



LEGEND

MADHYA PRADESH

JHABUA

COMPRESSOR STATION

RECEIVING TERMINAL

DESPATCH STATIONHAZIRA

ARABIAN

SEA


Major Pipelines in India

Pipeline Design




Pipeline Construction Video

Video for Mangalore Bangalore Pipeline

Pipeline Design




SECTION-2


Pipeline Design




Stages of Pipeline Project

�� ConceptualizationConceptualization

�� Establish RequirementEstablish Requirement�� 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

Pipeline Design



�� Establish Project CostEstablish Project Cost

�� Project Implementation SchemeProject Implementation Scheme

�� Environmental Impact Assessment & Risk AnalysisEnvironmental Impact Assessment & Risk Analysis


Stages of Pipeline Project

�� Basic EngineeringBasic Engineering

�� Process Design and SizingProcess Design and Sizing�� 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

Pipeline Design



�� Specifications and Job StandardsSpecifications and Job Standards

�� Engineering for ProcurementEngineering for Procurement

�� Installation Engineering and Construction ProceduresInstallation Engineering and Construction Procedures

PIPELINE DESIGNPIPELINE DESIGNMajor Codes & Standards

Code/StandardCode/Standard TitleTitle

ASME 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

OISDOISD--141 (2003)141 (2003) Design and Construction Requirements for CrossDesign and Construction Requirements for Cross--Country Country

Hydrocarbon PipelinesHydrocarbon Pipelines

OISDOISD--214 (2006)214 (2006) CrossCross--Country LPG PipelinesCountry LPG Pipelines

OISDOISD--226 (2007)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

Pipeline Design



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 OSDNV OS--F101F101 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


Major 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)(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

Pipeline Design



Crossing through Forest landCrossing through Forest land Forest AuthorityForest Authority

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

�� CAESARCAESAR--IIII

�� AUTOPIPEAUTOPIPE

LIST OF SOFTWARES USED IN PIPELINE

ENGINEERING

�� PIPELINE STUDIOPIPELINE STUDIO�� AUTOPIPEAUTOPIPE

�� IPMCSIPMCS

�� MRPACKMRPACK

�� SORPSSORPS

�� PIPECALCPIPECALC

OFFPIPEOFFPIPE

TGNETTGNET

TLNETTLNET

�� HYSISHYSIS

Pipeline Design



�� OFFPIPEOFFPIPE

�� PRISEPRISE

�� PIPECROSSPIPECROSS

Optimal sizes of various capacities


Pipeline Design



Economy of scale


Route Selection

Routing Considerations

� Pipeline length

� Obstructions & Sensitive areas� Obstructions & Sensitive areas

� Installation Limitations

� Crossings

Surveys

� Topographical

� Geo-technical

Pipeline Design



� Geo-technical

� Population Density Index

� Soil Resistivity

� Cadastral

BHATINDACh. 1012.67 km


Typical Pipeline Route Map

LEGEND:

PROPOSED PIPELINE

JUDCh. 593.88 km

RANSISARCh. 855.01 km

GAILAWASCh. 527.87 km

IPS-F

IPS-2

IP-1 & IPS-F

Pipeline Design



1. PIPELINE ROUTE SHOWN IS INDICATIVE ONLY.

LEGEND:

PROPOSED MUNDRA-BHATINDA PIPELINE (28" NB)

RECEIPT TERMINAL

DESPATCH TERMINAL AND PUMPING STATION

NOTES:

INTERMEDIATE PIGGING STATION (IP)

INTERMEDIATE PUMPING STATION (IPS)

IPS-F

Ch. 226.72 km

JORAWARPURACh. 313.63 km

MUNDRACh. 0.00 km

2. CHAINAGES INDICATED ARE APPROXIMATE. JHEKDA

IPS-1

FUTURE PUMPING STATION (IPS-F)


Pipeline Design




Material Selection & Corrosion Control

Assessment

� Nature of the Product

Materials

� Carbon Steel (CS)

� Design Life

� Product Temperature

Corrosion Protection

� Material Chemistry

� Internal Coatings

� NACE Carbon Steel

� CRA Clad CS

� CS with internal

Coatings

� Non-Metallic

Materials

Pipeline Design



� Product Conditioning

� Corrosion inhibitors

� Corrosion Allowance

Materials


Design and Analysis

� Wall Thickness Calculations

� Anti-Buoyancy Measures

� Piping Stress Analysis

� Buried Pipeline Analysis

� Crossing Design

Pipeline Design



� Crossing 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

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

Pipeline Design



thickness

E Weld joint factor

F Design factor

E Longitudinal joint factor

T Temperature de-rating factor


Basic Design Factor for Gas Pipelines

LOCATION CLASS DESIGN FACTOR, F

Location Class 1 0.72

Location Class 2 0.60Location Class 2 0.60



Location Class Classification

Location Class 1 : ≤≤≤≤ 10 buildings

Location Class 2 : > 10 and < 46 buildings

Location Class 3 : ≥≥≥≥ 46 buildings

Pipeline Design



Location Class 3 : ≥≥≥≥ 46 buildings

Location Class 4 : Multistory buildings


Line Pipe Selection

Line Pipe Selection Parameters

� Thickness and Grade

Type of Line PipesType of Line Pipes

�� SeamlessSeamless� Thickness and Grade

Selection

� Handling and

Transportation (d/t ratio)

� Type of LinePipe

� Installation Requirements

�� SeamlessSeamless

�� Electric WeldedElectric Welded

�� Longitudinal Seam Longitudinal Seam

SubmergedSubmerged--Arc Welded Arc Welded

(LSAW)(LSAW)

�� Helical Seam SubmergedHelical Seam Submerged--

Pipeline Design



� Installation RequirementsArc Welded Arc Welded

(HSAW)(HSAW)


Line Pipe Application

Submarine Pipelines Onshore Pipelines

� Seamless Pipes

(upto & including 16”)

� LSAW Pipes

(18” & above)

� Seamless Pipes

(upto & including 8”)

� LSAW Pipes

(16” & above)

� HSAW Pipes

(18” & above)

� EW Pipes

Pipeline Design



� 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�� 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

Pipeline Design



�� Fusion Bonded Epoxy Coating (CSA Z245.20)Fusion Bonded Epoxy Coating (CSA Z245.20)�� 350350--500 micron thick single layer coating500 micron thick single layer coating

�� 600600--800 micron thick dual layer coating800 micron thick dual layer coating


3 Layer PE Coating Application

Pipeline Design




Major Pipeline Components

�� Line Pipe & CoatingsLine Pipe & Coatings

�� Scraper Traps & Pig SignallersScraper Traps & Pig Signallers�� 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

Pipeline Design



�� Pumps / CompressorsPumps / Compressors

�� Filters & MetersFilters & Meters


Scraper traps

Pipeline Design




Sectionalizing Valve

Spacing Spacing

� ASME B 31.8 for Gas

pipelines

Gas Pipelines

Location Class 1 32 km (20 miles)

Location Class 2 24 km (15 miles)pipelines

� ASME B 31.4 for Liquid

Pipelines

LocationLocation

� Pollution Concerns

� Statutory Requirements

� Prevention of Inventory

Loss




LPG Pipelines

Industrial, 12 km (7.5 miles)

Commercial &

Pipeline Design



Loss

� Approachability of Valve

Station

Residential Areas


Type of Valves

� Full Bore Ball Valves

� Through Conduit Gate

Valves

� Plug and Check Valves

� Valve Standard :

API 6D/ISO14313

Other Valve Standards:

Pipeline Design



API 600, API 602, BS EN

ISO 17292:2004, BS EN

ISO 15761:2002, BS 5353


Ball valves

Pipeline Design




Plug valve

Pipeline Design




Check valve

Pipeline Design




Major Engineering Deliverables

Design ReportsDesign Reports

��Design BasisDesign Basis

DrawingsDrawings

��Route MapRoute Map��Design BasisDesign Basis

��Route Selection ReportRoute Selection Report

��Wall Thickness ReportWall Thickness Report

��Seismic Design ReportSeismic Design Report

��Crossing Design ReportCrossing Design Report

��Route MapRoute Map

��Pipeline SchematicPipeline Schematic

��Alignment SheetsAlignment Sheets

��SV Station LayoutSV Station Layout

��Equipment LayoutEquipment Layout

Piping General Piping General

Pipeline Design



��Piping General Piping General

Arrangement DrawingsArrangement Drawings


Typical Pipeline Alignment SheetINTERSECTION POINTS(IP/TP)

DEFLECTION ANGLE

STATE , DISTRICT AND MANDAL

DISTANCE AS PER GROUND PROFILE

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

CH. 10620.558m

CH.10664.710m

CH. 10797.803m

IP50/1

CH. 10687.604mTP51

CH. 10712.803mIP51/1

TP50

TP58 TP60

CH. 13741.534m

TP63

TP65

CH. 14134.896m

CH. 13979.211m

TP64

IP64/1

CH.14044.732m

TBM W40 (RL 37.514m)

TBM W57(RL 42.533m)

RAIWADA LEFT CANAL

(UNLINED)

CH. 10691.604m

TO PENDA AMRITA PURAM

TO PENDA AMRUTHAPURAM

EARTHEN EMBANKMENT

LOW LYING AREA

EARTHEN EMBANKMENT

MATCH LINE FOR CONT. REFER DWG

NO.4529-10-16-71-9005

METALLED ROAD(ASPHALTIC)

CH.14115.309m

TO STATE HIGHWAY-SABBAVARAM

TO IRUVADA

ELEC. LINE 440VCH.14132.231m

TELEPHONE LINE CH.14134.896m

DISTANCE BETWEEN TP & IP's(m)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

SCALE:

HORIZONTAL 1:5000

VERTICAL 1: 500

21

23

25

27

29

31

33

35

37

39

41

43

45

10.621

37.325

33.366

35.411

33.560

32.587

31.496

30.300

29.815

27.370

25.362

27.904

24.858

25.138

24.341

24.675

24.828

24.604

23.667

22.175

25.884

30.557

29.219

29.135

28.935

30.893

32.444

33.622

37.219

40.816

39.741

42.491

43.684

43.034

DRAIN

CH 10664.71m/RL 33.366m

CANAL

CH 10691.6m/RL 35.411m

ROAD

CH 10787.02m/RL 32.587m

DRAIN

CH 11824.63m/RL 24.341m

ROAD

CH 12060.88m/RL 24.604m

DRAIN

CH 12115.34m/RL 22.175m

CART TRACK

CH 13492.61m/RL 33.622m

CANAL

CH 14027.73m/RL 39.741m

ROAD

CH 14040.27m/RL 42.491m

CART TRACK

CH 14115.31m/RL 43.684m

CH. 12848.455m

HIGH TENSION LINE

TP57

CH.11848.88m

ELECTRIC LINE

CH.11824.629m

CH. 11062.202m

CH. 11401.298m

TP54

CH.11018.117m

ELECTRIC LINE 440V CH.12115.344m

CH. 11577.761m

TP55

TP56

CH. 11616.510m

CH.12060.877m

GRAVEL ROAD

CH. 11939.218m

DRAI N

DRAIN

CH.12747.397m

MATCH LINE FOR C

ONT. REFER DWG

NO.4529-10-16-71-9003

DRAIN

CH.10664.710m

CH. 10985.658m

GRAVEL ROAD

CH.10787.022m

TP52

TP53

CH. 12080.978m

TP58

CH. 12455.060m

TP60

CH. 12230.091m

TP59

DRAIN

CH.12903.743m

CH.13492

.606mCART TR

ACK

TP61

TP62

CH. 13414.892m

CH.14027.732m

RAIWADA LEFT CANAL IP58/1

CH. 12125.978m CH. 13066.455m

IP61/1

KAJU GARDEN RICE FIELDS

VILLAGE BOUNDARY

AMRUTAPURAM IRUVADATBM W49 (RL 25.138m)

TEMP. HUT ON C/L

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

TO CHIN

TA GUTL

A

SV-1 OF GAIL

CH.11960.218 m

TO PENDA AMRUTHAPURAM

TO AMRUTHAPURAM

K

K

OPEN WELL 6m DIA

7.648m FROM C/L

CH.11648.136m

OPEN WELL 6m DIA

8m FROM C/L

CH 11577.761m

PUMP HOUSE 4m FROM C/L

12.2m HIGH & 550KV

K

(UNLINED)

GRAVEL ROAD

CH.14040.275m

MATCH LINE FOR CONT. REFER DWG

NO.4529-10-16-71-9005

TO STATE HIGHWAY-SABBAVARAM

10.665

44.152

10.692

26.894

10.713

21.199

10.787

74.219

10.986

198.636

11.025

39.369

11.062

37.175

11.259

196.962

11.401

142.134

11.578

176.463

11.617

38.749

11.758

141.522

11.825

66.597

11.849

24.246

11.939

90.342

12.061

121.660

12.081

20.101

12.115

34.366

12.230

114.747

12.455

224.969

12.754

299.254

12.848

94.141

13.066

217.539

13.248

182.117

13.415

166.780

13.493

77.714

13.742

248.929

13.979

237.676

14.028

48.521

14.040

12.543

14.115

75.034

14.135

19.588

10.621

10.665

10.692

10.713

10.787

10.986

11.025

11.062

11.259

11.401

11.578

11.617

11.758

11.825

11.849

11.939

12.061

12.081

12.115

12.230

12.455

12.754

12.848

13.066

13.248

13.415

13.493

13.742

13.979

14.028

14.040

14.115

14.135

11.960

11.972

11.984

Pipeline Design



Typical P&ID


Pipeline Design



PIPELINE DESIGNPIPELINE DESIGNTypical GA DRAWING

Pipeline Design




Major 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 Scraper Traps, QOEC, Pig SignallersSignallers

�� Flow Tees & Insulating JointsFlow Tees & Insulating Joints

Pipeline Design



�� Flow Tees & Insulating JointsFlow Tees & Insulating Joints

�� Induction BendsInduction Bends

�� Flow metersFlow meters

�� Pumps & CompressorsPumps & Compressors

�� OFC cablesOFC cables


Installation, Testing & Commissioning

RoU Grading & Trenching Stringing of Linepipe

Pipeline Design





Welding & NDT :� Edge Preparation

� Internal / External Line-up Clamps� 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� Cold applied tapes

Pipeline Design




Pipeline Crossings

Crossing Installation

CrossingsCrossings

� River, Canal, Road & Rail

� Utility Crossing

Methodologies

� Open-Cut Method

� Trench-less Method

� Horizontal

Directional Drilling

Pipeline Design



Directional Drilling

� Jacking and Boring

� Micro tunneling


The conventional HDD operations for river crossings.

Pipeline Design



Boring Across Road crossings.

Pipeline Design



Boring Across Road crossings, showing Auger used for Boring

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.� 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

Pipeline Design



� Installation of more than one pipe in the tunnel

� Precise installation and Minimum space at both ends

� Can be done in curved path also


Schematic DiagramSchematic Diagram

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

DRYING

� Swabbing

� Methanol Drying� Test Medium

TEST PRESSURE

LIQUID PIPELINES

Ref. ASME B 31.4 : 437.4.1

1.25 times design pressure

GAS PIPELINES

� Methanol Drying

� Super Dry Air

Method

� Vacuum Drying

COMMISSIONING

� Nitrogen Purging

� Product Charging

Pipeline Design



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


Pigging

Requirements

� Pipeline Cleaning

� Displacement

Types of Pigs

� Brush pigs

� Gauge Pigs� Displacement

� Internal Inspection

� Batching

� Gauge Pigs

� Spheres

� Intelligent Pigs

Pipeline Design



Cleaning pigs Gauge Pigs Spheres Intelligent Pig

(MFL)


RECENT DEVELOPMENTS

TECHNICAL IMPROVEMENTSTECHNICAL IMPROVEMENTS

�� Automatic Welding & Automatic UTAutomatic Welding & Automatic UT�� Automatic Welding & Automatic UTAutomatic Welding & Automatic UT

�� MicroMicro--Tunneling for pipeline constructionTunneling 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 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 Longitudinal –– positioned in positioned in

upper quadrant during upper quadrant during

constructionconstruction

Spiral Spiral –– present all around the 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 15cost by 15--20%20%

Pipeline Design



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


CTECTE 3LPE3LPE 3LPP3LPP FBEFBE

Coating Comparison


Service ConditionsService Conditions

Temperature, Temperature, oo CC Upto 45Upto 45 Upto 65Upto 65 Upto 110Upto 110 Upto 110Upto 110

AntiAnti--corrosion Propertiescorrosion Properties

Resistance to MoistureResistance to Moisture GoodGood Very GoodVery Good ExcellentExcellent GoodGood

Cathodic DisbondmentCathodic Disbondment FairFair GoodGood GoodGood GoodGood

Pipeline Design



Cathodic DisbondmentCathodic Disbondment FairFair GoodGood GoodGood GoodGood

Electrical Properties Electrical Properties

Coating ResistanceCoating Resistance GoodGood ExcellentExcellent ExcellentExcellent ExcellentExcellent



Cathodic Protection DesignCathodic Protection Design

Coating Comparison

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 --

Pipeline Design



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 --



Long Term AgeingLong Term Ageing

Coating Comparison

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

Pipeline Design



transportationtransportation

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,



Thank YouThank YouThank YouThank You

Pipeline Design



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