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Pipeline Design
Slide Number - 2 of 77
Engineers India Ltd – Delivering excellence through people
ENGINEERS
INDIA LIMITED
EPC and Total Solutions
Consultancy Organization
Pipeline Design
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Petroleum Refineries
Petrochemicals
Pipelines
Offshore Platforms
Gas Processing
Metallurgy
Ports & Terminals
Highways and Airports
Pipeline Design
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HEAD OFFICE NEW DELHI
REGIONAL OFFICES VADODARA, CHENNAI KOLKATA
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 OFFICES
Pipeline Design
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PIPELINE DESIGN
SERVICES OFFERED BY EIL
Project Implementation Services
� Feasibility Studies
� Project Management
� Planning & Scheduling
� Process Design
� Detailed Engineering
� Procurement Services
� Construction Management
� Commissioning and Plant
Start-up Assistance
Specialist Services
� Heat & Mass Transfer Equipment
Design
� Environment Engineering
� Information Technology Services
� Specialist Materials and
Maintenance Services
� Plant Operation & Safety
� Risk Analysis
� Advanced Control & Optimization
Pipeline Design
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PIPELINE DESIGN
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
for GAIL
Over 40 major pipeline projects completed.
Pipeline Design
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PIPELINE DESIGN
DESCRIPTION CLIENT YEAR SIZE LENGTH
(KM)
SERVICES
HAZIRA-BIJAIPUR-
JAGDISHPUR (HBJ)
GAIL 1989 36“/30”/24”/18” 1800 NATURAL GAS
MAQTA-AL-AIN PIPELINE ADNOC 1992 30 ”/12” 166 NATURAL GAS
KANDLA-BHATINDA IOCL 1996 22”/14”/10” 1443 MULTIPRODUCT
GAS REHABILITATION &
EXPANSION PROJECT
(GREP)
GAIL 1998 36 ” 505 NATURAL GAS
MUMBAI – MANMAD BPCL 1998 18 ” 260 MULTIPRODUCT
VIZAG-VIJAYWADA HPCL 1998 18 ” 360 MULTIPRODUCT
JAMNAGAR-LONI LPG
PIPELINE
GAIL 2001 16”/14”/12”/8”/
6
1235 LPG (LIQUIFIED
PETROLIUM GAS)
COCHIN – KARUR PIPELINE PETRONET 2001 18 ”/14 ” 289 MULTIPRODUCT
Major Onshore Projects (Completed)
Pipeline Design
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PIPELINE DESIGN
DESCRIPTION CLIENT YEAR SIZE LENGTH
(KM)
SERVICES
VIZAG – SECUNDERABAD LPG
PIPELINE
GAIL 2002 12”/10” 600 LPG (LEQUIFIED
PETROLEUM GAS)
MANMAD-MANGALAYA PIPELINE BPCL 2003 14 ” 358 MULTIPRODUCT
MANGALORE-BANGLORE HPCL 2003 24 ”/20” 364 MULTIPRODUCT
DAHEJ – VIJAIPUR PIPELINE GAIL 2003 42” 610 REGASIFIED LNG
INTER REFINERIES PIPELINES
PROJECT, ABU DHABI TAKREER 2004
10”
12”
16”
230
230
208
NAPHTHA,
MULTIPRODUCT & SRR
MANGALAYA-BIJWASAN
PIPELINE
BPCL 2006 16”/8” 775 MULTIPRODUCT
MUNDRA-DELHI PIPELINE HPCL 2006 18”/16” 1050 MULTIPRODUCT
Major Onshore Projects (..contd) (Completed)
Pipeline Design
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DESCRIPTION CLIENT YEAR SIZE LENGTH
(KM)
SERVICES
PUNE SOLAPUR PIPELINE HPCL 2007 14 ”/ 12” 182 / 161 MULTIPRODUCT
DABHOL PANVEL PIPELINE
PROJECT (PH-I)
GAIL 2007 30” 187 REGASIFIED LNG
DABHOL PANVEL PIPELINE
PROJECT (PH-II)
GAIL 2007 30” 120 REGASIFIED LNG
PIPELINE DESIGN Major Onshore Projects (8contd)
(Completed)
Pipeline Design
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DESCRIPTION CLIENT YEAR SIZE LENGTH
(KM)
SERVICES
BOMBAY HIGH URAN TRUNKLINE
(BUT)
ONGC 1979 30”/26” 200 x 2 CRUDE, GAS
SOUTH BASSEIN HAZIRA
TRUNKLINE
ONGC 1986 36” 220 GAS
HEERA-URAN TRUNK LINE ONGC 1996 26 ”/24 ” 85 x 2 CRUDE, GAS
ICP - HEERA TRUNKLINE ONGC 1996 30”/22” 145 CRUDE
SECOND BASSEIN HAZIRA
TRUNKLINE
ONGC 1995 42” 245 GAS
MUMBAI HIGH URAN TRUNKLINE
(MUT)
ONGC 2005 30”/28”
12” to 22”
205 x 2
100
CRUDE, GAS
IN-FIELD PIPELINES OF BOMBAY-HIGH, BASSEIN, HEERA, NEELAM, PANNA, MUKTA.
PIPELINE DESIGN Major Offshore Projects
(Completed)
Pipeline Design
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DESCRIPTION CLIENT YEAR SIZE LENGTH
(KM)
SERVICES
VIJIPUR DADRI BAWANA PIPELINE
(VDBPL)
GAIL 2009 48”/ 36”/
20”
500/ 38/ 55 REGASIFIED LNG
MUNDRA BATHINDA PIPELINE
(MBPL)
HMPL 2009 28”/ 30” 424/ 590 CRUDE OIL
BINA KOTA PIPELINE BPCL 2009 18” 257 MULTI PRODUCT
VADINAR BINA PIPELINE BORL 2009 24” 935 CRUDE OIL
NUMALIGARH SILIGURI PIPELINE OIL 2009 16” 400 MULTI PRODUCT
COMPRESSOR STATIONS GAIL --- --- --- REGASIFIED LNG
IN-FIELD PIPELINES OF BOMBAY-HIGH, BASSEIN, HEERA, NEELAM, PANNA, MUKTA.
PIPELINE DESIGN Major Onshore Projects
(Current)
Pipeline Design
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PIPELINE DESIGN
SECTION-1
Pipeline Design
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PIPELINE DESIGN
CONTENTS
INTRODUCTION
� Modes of Transportation � Benefits of Pipelines
PIPELINE DESIGN
� Stages of Pipeline Project � Codes and Standards � Design � Installation, Testing & Commissioning
Pipeline Design
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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
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Refining Scenario- India
70
149
235
302
0
50
100
150
200
250
300
350
1998-99 2006-07 2011-12 2016-17
(MMT)
Source: Report of Working Group on P&NG Sector for the XI Plan
(Actual) Year
Capacity - 2006-07
NOC – 105.5 MMT
Others- 43.5 MMT
PIPELINE DESIGN
Pipeline Design
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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
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PIPELINE DESIGN
Benefits of Transportation by Pipelines
� Safer mode of transportation
� Environment friendly
� Least energy requirement
� Lowest maintenance costs
� Minimal impact on land use pattern
� Negligible loss of product in transit
� High reliability
� Multi-product Transportation
Pipeline Design
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PIPELINE DESIGN
Energy Savings
Energy Intensity for Various Modes
0.8
0.51
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
Energy Consumption in % of energy
Transported
Pipelines are the most energy efficient modes of transportation
Pipeline Design
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ECONOMICS OF PIPELINE TRANSPORTATION
Transmission losses
0 0.1 0.2 0.3 0.4 0.5
% Loss of Total Volume Transported
Pipelines
Rail/Road
Losses During Transportation
Transmission losses are lowest in Pipelines
Pipeline Design
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PIPELINE DESIGN
Products Transported
� Crude Oil
� Petroleum Products (MS, HSD, ATF, SKO)
� Water & Effluents
� LPG
� Natural Gas
� Slurries
Pipeline Design
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PIPELINE DESIGN
Types of Pipelines
ONSHORE (LAND) & OFFSHORE
(SUBMARINE) PIPELINES
� Trunk Pipelines
� Spur/ Branch Pipelines
� Marine Offloading Terminals & Outfalls
Pipeline Design
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PIPELINE DESIGN
Capital cost: Typical breakup
Liquid Lines Gas Lines
1 Su rv ey, ROW & Compen sa t io n 2 % 1 %
2 Lin e Pip e St ee l Co st 33 % 4 5 %
3 Main lin e ma teria ls 2 % 3 %
4 Coa t in g o f Pip es 11 % 6 %
5 Main lin e Con st ru c t io n 33 % 2 5 %
6 Cath od ic Pro t ect io n 1 % 1 %
7 Telecommun ica t io n , SCA DA and RCPs 5 % 2 %
8 Pump / Comp res so r Sta t io n s 5 % 1 2 %
9 Deliv e ry Termin a l fac ilit ie s 2 % 1 %
10 Pro jec t M an agemen t 5 % 4 %
11 S ubTotal 100% 100%
Item D e scriptionS r No.Percentage of Cap i ta l Cos t.
Pipes, prime-overs and construction constitute big ticket items
Pipeline Design
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PIPELINE DESIGN
Marine Offloading Terminal
Pipeline Design
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PIPELINE DESIGN
Open sea Jetty
Pipeline Design
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PIPELINE DESIGN
KEY PLAN
LEGEND
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
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PIPELINE DESIGN
Major Pipelines in India
Pipeline Design
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PIPELINE DESIGN
Pipeline Construction Video
Video for Mangalore Bangalore Pipeline
Pipeline Design
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PIPELINE DESIGN
SECTION-2
PIPELINE DESIGN CODES AND STANDRADS
Pipeline Design
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PIPELINE DESIGN
Stages of Pipeline Project
� Conceptualization
� Establish Requirement
� Evaluate Alternatives
� Finalize the Concept
� Feasibility Study
� Pipeline Route Study and Selection
� Hydraulic Studies and Optimization
� Establish Project Cost
� Project Implementation Scheme
� Environmental Impact Assessment & Risk Analysis
Pipeline Design
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PIPELINE DESIGN
Stages of Pipeline Project
� Basic Engineering
� Process Design and Sizing
� Optimization Studies
� Route Surveys and Investigations
� Detailed Engineering
� Engineering Design Basis
� Route Engineering and Engineering Analysis
� Specifications and Job Standards
� Engineering for Procurement
� Installation Engineering and Construction Procedures
Pipeline Design
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PIPELINE DESIGN Major Codes & Standards
Code/Standard Title
ASME B 31.8 (2003) Gas Transportation and Distribution Piping Systems
ASME B 31.4 (2006) Pipeline Transportation Systems for Liquid Hydrocarbons and other Liquids
OISD-141 (2003) Design and Construction Requirements for Cross-Country Hydrocarbon Pipelines
OISD-214 (2006) Cross-Country LPG Pipelines
OISD-226 (2007) Natural Gas Transmission Pipelines and City Gas Distribution Networks
API 5L / ISO 3183 : 2007 Specification for Line Pipe
API RP1102 Recommended practice for Rail and Highway crossings
API 1104 Standard for welding pipeline and related facilities
API 6D / ISO 14313 Pipeline Valves
DNV OS-F101 Submarine pipeline systems
Other References Applicable Standards / Specs of ASME, API, NACE, MSS, BS and DIN
Pipeline Design
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PIPELINE DESIGN
Major Codes & Standards
Type of Crossing Approval Authority
ROU & Land Acquisition Central/State Govt. as applicable
(As per PMP Act 1962)
National Highway Crossings NHAI
SH/ MDR/ ODR Crossings PWD
Railway Track crossings Indian Railways
Crossing through Forest land Forest Authority
River/Canal crossings Irrigation/Canal Authority
Pipeline Design
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� CAESAR-II
� AUTOPIPE
� IPMCS
� MRPACK
� SORPS
� PIPECALC
� OFFPIPE
� PRISE
� PIPECROSS
LIST OF SOFTWARES USED IN PIPELINE
ENGINEERING
� PIPELINE STUDIO
TGNET
TLNET
� HYSIS
Pipeline Design
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Optimal sizes of various capacities
Economy of scale
PIPELINE DESIGN
Pipeline Design
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PIPELINE DESIGN
Route Selection
Routing Considerations
� Pipeline length
� Obstructions & Sensitive areas
� Installation Limitations
� Crossings
Surveys
� Topographical
� Geo-technical
� Population Density Index
� Soil Resistivity
� Cadastral
Pipeline Design
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BHATINDACh . 101 2.67 km
1. P IPELINE ROUTE SHOWN IS INDICATIVE ONLY.
LEGEND:
PROPOSED MUNDRA-BHATINDA PIPELINE ( 28" NB)
RECEIPT TERMINAL
DESPATCH TERMINAL AND PUMPING STAT ION
NOTES:
PROPOSED PIPELINE
INTERMEDI AT E PIGGING STAT ION ( IP )
I NT ERM EDIAT E PUMPING STATION (IPS)
IPS-F
Ch . 226 .72 k m
JORAWARPURACh. 3 13.63 km
J UDCh . 593 .88 km
RANSISARCh. 855.01 km
MUNDRACh. 0.00 km
GAI LAWASCh. 527.87 km
2. CHAINAGES INDICATED ARE APPROXIMATE. J HEKDA
IPS-1
IPS-F
IPS-2
IP-1 & IPS-F
FUTURE PUMPING STATION (IPS-F)
PIPELINE DESIGN
Typical Pipeline Route Map
Pipeline Design
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PIPELINE DESIGN
Pipeline Design
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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
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PIPELINE DESIGN
Design and Analysis
� Wall Thickness Calculations
� Anti-Buoyancy Measures
� Piping Stress Analysis
� Buried Pipeline Analysis
� Crossing Design
Pipeline Design
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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
strength
D Nominal OD of pipe
t Nominal wall thickness
F Design factor
E Longitudinal joint factor
T Temperature de-rating factor
Pipeline Design
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PIPELINE DESIGN
Basic Design Factor for Gas Pipelines
LOCATION CLASS DESIGN FACTOR, F
Location Class 1 0.72
Location Class 2 0.60
Location Class 3 0.50
Location Class 4 0.40
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
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PIPELINE DESIGN
Line Pipe Selection
Line Pipe Selection Parameters
� Thickness and Grade
Selection
� Handling and
Transportation (d/t ratio)
� Type of LinePipe
� Installation Requirements
Type of Line Pipes
� Seamless
� Electric Welded
� Longitudinal Seam
Submerged-Arc Welded
(LSAW)
� Helical Seam Submerged-
Arc Welded
(HSAW)
Pipeline Design
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PIPELINE DESIGN
Line Pipe Application
Submarine Pipelines
� Seamless Pipes
(upto & including 16”)
� LSAW Pipes
(18” & above)
Onshore Pipelines
� Seamless Pipes
(upto & including 8”)
� LSAW Pipes
(16” & above)
� HSAW Pipes
(18” & above)
� EW Pipes
(4” - 18”)
Pipeline Design
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Manufacturing of Helical Pipes
PIPELINE DESIGN
Pipeline Design
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PIPELINE DESIGN
Anti-corrosive Coatings � Coal Tar Enamel Coating (BS 4164, AWWA C203)
� Primer
� Two layers of coal tar enamel & glass fibre Inner wrap
� One layer of coal tar impregnated outer wrap
� Coating thickness 4.7mm
� 3 Layer PE/ PP Coating (DIN 30670) � First layer of Fusion bonded epoxy
� Second layer of extruded adhesive
� Third layer of extruded PE/ PP
� Coating thickness 2.0 to 3.7 mm
� Fusion Bonded Epoxy Coating (CSA Z245.20) � 350-500 micron thick single layer coating
� 600-800 micron thick dual layer coating
Pipeline Design
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PIPELINE DESIGN
3 Layer PE Coating Application
Pipeline Design
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PIPELINE DESIGN
Major Pipeline Components
� Line Pipe & Coatings
� Scraper Traps & Pig Signallers
� Long Radius (LR) Bends
� Insulating Joints
� Flow Tees
� Sectionalizing Valves
� Pumps / Compressors
� Filters & Meters
Pipeline Design
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PIPELINE DESIGN
Scraper traps
Pipeline Design
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PIPELINE DESIGN
Sectionalizing Valve
Spacing
� ASME B 31.8 for Gas
pipelines
� ASME B 31.4 for Liquid
Pipelines
Location
� Pollution Concerns
� Statutory Requirements
� Prevention of Inventory
Loss
� Approachability of Valve
Station
Gas Pipelines
Location Class 1 32 km (20 miles)
Location Class 2 24 km (15 miles)
Location Class 3 16 km (10 miles)
Location Class 4 8 km (5 miles)
LPG Pipelines
Industrial, 12 km (7.5 miles)
Commercial &
Residential Areas
Pipeline Design
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PIPELINE DESIGN
Type of Valves
� Full Bore Ball Valves
� Through Conduit Gate
Valves
� Plug and Check Valves
� Valve Standard :
API 6D/ISO14313
Other Valve Standards:
API 600, API 602, BS EN
ISO 17292:2004, BS EN
ISO 15761:2002, BS 5353
Pipeline Design
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PIPELINE DESIGN
Ball valves
Pipeline Design
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PIPELINE DESIGN
Plug valve
Pipeline Design
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PIPELINE DESIGN
Check valve
Pipeline Design
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PIPELINE DESIGN
Major Engineering Deliverables
Design Reports
�Design Basis
�Route Selection Report
�Wall Thickness Report
�Seismic Design Report
�Crossing Design Report
Drawings
�Route Map
�Pipeline Schematic
�Alignment Sheets
�SV Station Layout
�Equipment Layout
�Piping General Arrangement Drawings
Pipeline Design
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PIPELINE DESIGN
Typical Pipeline Alignment Sheet INTERSECTION POINTS(IP/TP )
DEFLECT ION ANGLE
S TATE , DISTRICT AND MANDAL
SCALE:HORIZONTAL 1:5000
VERTICAL 1: 500
D ISTANCE AS PER GROUND PR OFILE
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
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)
T P62
10°4'42' '(L)
TP63
10°25'50'' (L)
TP64 IP64/1
5°18'12' '(R )
TP65
DRA
INCH 10664.71m/RL 33.366m
CANA
LCH
10691.6m
/RL 35.411m
ROA
D
CH 10787.02m/RL 32.587m
DRAIN
CH 11
824.6
3m/RL 2
4.341m
ROA
D
CH 12060.88m/RL 24.604m
DRA
IN
CH 12115.34m/RL 22.175m
CART
TRACK
CH 13
492.61m/RL
33.622m
CANA
LCH
14027.73m/RL
39.741m
ROA
DCH 14040.27m/RL 42.491m
CAR
T TRACK
CH 14115.31m/RL 43.684m
CH . 12848.455m
HIGH T ENSION LINE
T P57
CH.11848.8 8m
ELEC
TRIC LINE
CH.11824.629 m
C H. 11062. 202m
C H. 11401. 298m
TP54
CH .11018.117m
ELEC TRIC LINE 440V CH. 12115.344m
C H. 11577. 761m
TP55
TP56
CH . 11616.510m
C H.12060.877m
GRAVE L ROAD
C H. 11939. 218m
DRA
IN
DRA IN
CH. 12747. 397m
CH. 10620.558m
MATC
H LINE
FOR CON
T. REFER DW
G
NO.4529
-10-16
-71-9003
DRAIN
CH.106
64 .710m
CH. 10985.658m
CH. 10797. 803m
GRAVEL ROAD
CH. 10787.022m
TP52
IP50/ 1
CH. 10687. 604mTP51
CH. 10712.803m
IP51/ 1
T P53
TP50
CH . 12080.978m
TP58
C H. 12455. 060m
T P60
C H. 12230. 091m
T P59
DRAIN
CH. 12903. 743m
CH. 13492. 606mC ART TRACK
TP61
T P62
CH. 13414.892m
CH . 13741.534m
TP63
CH. 14027.732m
RAIWADA LEFT CANAL
TP65
CH. 14134. 896m
CH. 13979.211m
TP64
IP58/ 1
CH . 12125.978m C H. 13066. 455m
IP61/1
IP64/1CH .14044.732m
KAJU GAR DEN RIC E FIELDS
V ILLAGE B OUNDARY
AMR UTAPUR AM IRUVADA
TB M W40 (RL 37.514m)
TB M W49 (RL 25.138m)
TEMP. HUT ON C/L
TBM W57(RL 42.533m)
H PCL C H. 15.00Km HPCL C H. 16.00KmHPCL CH. 17. 00Km
R AIWADA LE FT CANAL
(UNL INED )C H. 10691. 604m
TO PENDA A MR
ITA PURAM
TO C HIN TA GUTLA
SV-1 OF GA IL
CH. 11960. 218 m
TO PEN
DA AM
R UT H
AP URA
M
TO AMRUTHA PURAM
K
K
OPEN WE LL 6m DIA
7.648m FR OM C/ L
CH.11648.136m
OPEN WELL 6m D IA
8m FROM C/ L
CH 11577. 761m
PUMP HOUSE 4m FR OM C/L
12. 2m H IGH & 550KV
EARTHEN EMB ANKMENT
L OW LYING AREA
EARTHEN EMB ANKMENT
K
(UNLINED)
GRAVEL ROAD
CH. 14040. 275m
MATC
H LINE
FOR CON
T. REFER DW
G
NO.4529-10-16-71-9005
MET ALLE D R OAD (ASPHALTIC)
CH. 14115.309m
TO STATE HI GHWAY-SABBAVARAM
TO IR UVADA
ELEC . LIN E 440VC H.14132.231m
TELE PHONE LIN E CH .14134.896m
D ISTANCE BE TWEE N TP & IP' s(m)
10.665
44.15
2
10.692
26.894
10.713
21.199
10.787
74.21
9
10.986
198.6
36
11.025
39.36
9
11.062
37.17
5
11.259
196.9
62
11.401
142.1
34
11.578
176.4
63
11.617
38.74
9
11.758
141.5
22
11.825
66.59
7
11.849
24.24
6
11.939
90.34
2
12.061
121.6
60
12.081
20.10
1
12.115
34.36
6
12.230
114.7
47
12.455
224.9
69
12.754
299.2
54
12.848
94.14
1
13.066
217.5
39
13.248
182.1
17
13.415
166.7
80
13.493
77.71
4
13.742
248.9
29
13.979
237.6
76
14.028
48.52
1
14.040
12.54
3
14.115
75.03
4
14.135
19.58
8
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
10.621
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
Slide Number - 56 of 77
Engineers India Ltd – Delivering excellence through people
Typical P&ID
PIPELINE DESIGN
Pipeline Design
Slide Number - 57 of 77
Engineers India Ltd – Delivering excellence through people
PIPELINE DESIGN Typical GA DRAWING
Pipeline Design
Slide Number - 58 of 77
Engineers India Ltd – Delivering excellence through people
PIPELINE DESIGN
Major Engineering Deliverables
Tenders
� Survey Tender � Pipe Coating Tender
� Pipeline Installation Tender
Material Procurement
� Line Pipes � Valves & Actuators
� Scraper Traps, QOEC, Pig Signallers
� Flow Tees & Insulating Joints
� Induction Bends
� Flow meters � Pumps & Compressors
� OFC cables
Pipeline Design
Slide Number - 59 of 77
Engineers India Ltd – Delivering excellence through people
PIPELINE DESIGN
Installation, Testing & Commissioning
RoU Grading & Trenching Stringing of Linepipe
Pipeline Design
Slide Number - 60 of 77
Engineers India Ltd – Delivering excellence through people
PIPELINE DESIGN
Installation, Testing & Commissioning
Welding & NDT : � Edge Preparation
� Internal / External Line-up Clamps
� Manual / Automatic Welding
� NDT (X-Ray / UT / MPI etc.)
Pipeline Design
Slide Number - 61 of 77
Engineers India Ltd – Delivering excellence through people
PIPELINE DESIGN
Installation, Testing & Commissioning
Field Joint Coating Lowering & Backfilling � Heat Shrink Sleeves
� Cold applied tapes
Pipeline Design
Slide Number - 62 of 77
Engineers India Ltd – Delivering excellence through people
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
Slide Number - 63 of 77
Engineers India Ltd – Delivering excellence through people
PIPELINE DESIGN
The conventional HDD operations for river crossings.
Pipeline Design
Slide Number - 64 of 77
Engineers India Ltd – Delivering excellence through people
PIPELINE DESIGN
Pipeline Installation using Micro-tunnelling MICRO-TUNNELLING: � Micro Tunneling process uses a Micro Tunnel Boring Machine
(MTBM) combined with pipe jacking technique.
� Pipe jacking from launch shaft to reception shaft.
� Hydraulic Jacks used to push Jacking pipes behind a tunnel boring
machine
� Carrier pipe inserted in jacking pipe
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
Slide Number - 65 of 77
Engineers India Ltd – Delivering excellence through people
PIPELINE DESIGN
Pipeline Installation using Micro-tunnelling
Long Distance Micro Tunnelling
Pipeline Design
Slide Number - 66 of 77
Engineers India Ltd – Delivering excellence through people
PIPELINE DESIGN
Overview of Micro tunneling
Pipeline Design
Slide Number - 67 of 77
Engineers India Ltd – Delivering excellence through people
PIPELINE DESIGN
Testing & Commissioning TESTING
� Gauging and Pigging
� Test Pressure
� Test Medium
TEST PRESSURE LIQUID PIPELINES
Ref. ASME B 31.4 : 437.4.1 1.25 times design pressure
GAS PIPELINES Ref. ASME B 31.8 : Table 841.322(f)
Class 1 and 2: 1.25 * des pr Class 3 and 4: 1.4 * des pr
DRYING
� Swabbing
� Methanol Drying
� Super Dry Air
Method
� Vacuum Drying
COMMISSIONING
� Nitrogen Purging
� Product Charging
Pipeline Design
Slide Number - 68 of 77
Engineers India Ltd – Delivering excellence through people
PIPELINE DESIGN
Pigging
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
Slide Number - 69 of 77
Engineers India Ltd – Delivering excellence through people
PIPELINE DESIGN
RECENT DEVELOPMENTS
TECHNICAL IMPROVEMENTS
� Automatic Welding & Automatic UT
� Micro-Tunneling for pipeline construction
� Internal flow coating on line pipes for gas pipelines
� 3LPP coating on High Temperature pipelines
Pipeline Design
Slide Number - 70 of 77
Engineers India Ltd – Delivering excellence through people
PIPELINE DESIGN
Comparison of LSAW & HSAW Pipes
Description LSAW HSAW
Method of
Manufacture
UOE/COE/JCO/3 roll bending Formed by Twisting of Coil
Weld Length Equal to pipe joint length Approximately 1.5 to 2 times the
length of pipe joint
Position of weld Longitudinal – positioned in
upper quadrant during
construction
Spiral – present all around the
pipe
Corrosion Coating Specified thickness throughout
entire body.
Weld seam is tracked to ensure
coating thickness on weld seam
Thickness normally increased all
over the body, resulting in
proportional increase in coating
cost by 15-20%
Geometry Controlled to the desired level
with cold expansion
Controlled during forming only
and no cold expansion is carried
out
Pipeline Design
Slide Number - 71 of 77
Engineers India Ltd – Delivering excellence through people
PIPELINE DESIGN
CTE 3LPE 3LPP FBE
Service Conditions
Temperature, o C Upto 45 Upto 65 Upto 110 Upto 110
Anti-corrosion Properties
Resistance to Moisture Good Very Good Excellent Good
Cathodic Disbondment Fair Good Good Good
Electrical Properties
Coating Resistance Good Excellent Excellent Excellent
Coating Comparison
Pipeline Design
Slide Number - 72 of 77
Engineers India Ltd – Delivering excellence through people
PIPELINE DESIGN
CTE 3LPE 3LPP FBE
Cathodic Protection Design
Current Density High Low Low Low
Mechanical Properties
Resistance to Impact Fair Excellent Superior to PE Fair
Resistance to Indentation
Poor Very Good Excellent Fair
Resistance to Peel Fair Excellent Superior than PE -
Resistance to Soil Stresses
Fair Excellent Excellent Excellent
Elongation Fair Excellent Excellent -
Coating Comparison
Pipeline Design
Slide Number - 73 of 77
Engineers India Ltd – Delivering excellence through people
PIPELINE DESIGN
CTE 3LPE 3LPP FBE
Long Term Ageing
Heat & Light Ageing Fair Very Good Very Good Very Good
Application & Field Repair
Ease of Application Easy Relatively difficult Relatively difficult Relatively difficult
Damages during handling &
transportation
High Low Low High
Ease of Field Repair Difficult Easy for small repair,
Cumbersome for
larger repair
Easy for small repair,
Cumbersome for
larger repair
Easy for small repair,
Cumbersome for
larger repair
Coating Comparison