Pipeline Design

A-PDF PPT TO PDF DEMO: Purchase from www.A-PDF.com to remove the watermark

PIPELINE DESIGN

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

ENGINEERS INDIA LIMITED EPC and Total Solutions Consultancy Organization

Engineers India Ltd – Delivering excellence through people

Pipeline Design Slide Number - 2 of 77

Petroleum Refineries Petrochemicals Pipelines Offshore Platforms Gas Processing Metallurgy Ports & Terminals Highways and Airports Engineers India Ltd – Delivering excellence through people


EIL OFFICES 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



PIPELINE DESIGN SERVICES OFFERED BY EIL Project Implementation Services

Specialist Services

Feasibility Studies

Heat & Mass Transfer Equipment

Project Management

Design

Planning & Scheduling

Environment Engineering

Process Design

Information Technology Services

Detailed Engineering

Specialist Materials and

Procurement Services

Maintenance Services

Construction Management

Plant Operation & Safety

Commissioning and Plant

Risk Analysis

Start-up Assistance

Advanced Control & Optimization



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. Engineers India Ltd – Delivering excellence through people


PIPELINE DESIGN Major Onshore Projects (Completed) DESCRIPTION

CLIENT

YEAR

SIZE

LENGTH (KM)

GAIL

1989

36“/30”/24”/18”

1800

NATURAL GAS

ADNOC

1992

30 ”/12”

166

NATURAL GAS

KANDLA--BHATINDA KANDLA

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 VIZAG

HPCL

1998

18 ”

360

MULTIPRODUCT

JAMNAGAR-LONI LPG JAMNAGARPIPELINE

GAIL

2001

16”/14”/12”/8”/ 6

1235

LPG (LIQUIFIED PETROLIUM GAS)

PETRONET

2001

18 ”/14 ”

289

MULTIPRODUCT

HAZIRA-BIJAIPURHAZIRABIJAIPURJAGDISHPUR (HBJ) MAQTA--AL MAQTA AL--AIN PIPELINE

COCHIN – KARUR PIPELINE


SERVICES


PIPELINE DESIGN Major Onshore Projects (..contd) (Completed) DESCRIPTION

CLIENT

YEAR

SIZE

LENGTH (KM)

VIZAG – SECUNDERABAD LPG PIPELINE

GAIL

2002

12”/10”

600

LPG (LEQUIFIED PETROLEUM GAS)

MANMAD--MANGALAYA PIPELINE MANMAD

BPCL

2003

14 ”

358

MULTIPRODUCT

MANGALORE--BANGLORE MANGALORE

HPCL

2003

24 ”/20”

364

MULTIPRODUCT

DAHEJ – VIJAIPUR PIPELINE

GAIL

2003

42”

610

REGASIFIED LNG

TAKREER

2004

10” 12” 16”

230 230 208

NAPHTHA, MULTIPRODUCT & SRR

MANGALAYA-BIJWASAN MANGALAYAPIPELINE

BPCL

2006

16”/8”

775

MULTIPRODUCT

MUNDRA--DELHI PIPELINE MUNDRA

HPCL

2006

18”/16”

1050

MULTIPRODUCT

INTER REFINERIES PIPELINES PROJECT, ABU DHABI


SERVICES


PIPELINE DESIGN Major Onshore Projects (7contd) (Completed) DESCRIPTION

CLIENT

YEAR

SIZE

LENGTH (KM)

PUNE SOLAPUR PIPELINE

HPCL

2007

14 ”/ 12”

182 / 161

MULTIPRODUCT

DABHOL PANVEL PIPELINE PROJECT (PH(PH-I)

GAIL

2007

30”

187

REGASIFIED LNG

DABHOL PANVEL PIPELINE PROJECT (PH(PH-II)

GAIL

2007

30”

120

REGASIFIED LNG


SERVICES


PIPELINE DESIGN Major Offshore Projects (Completed) DESCRIPTION

CLIENT

YEAR

SIZE

LENGTH (KM)

SERVICES

BOMBAY HIGH URAN TRUNKLINE (BUT)

ONGC

1979

30”/26”

200 x 2

SOUTH BASSEIN HAZIRA TRUNKLINE

ONGC

1986

36”

220

HEERA--URAN TRUNK LINE HEERA

ONGC

1996

26 ”/24 ”

85 x 2

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 GAS CRUDE, GAS

CRUDE, GAS

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



PIPELINE DESIGN Major Onshore Projects (Current) 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 SECTION-1

INTRODUCTION



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 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 350

Capacity - 2006-07 NOC – 105.5 MMT Others- 43.5 MMT 302

(MMT)

300

235

250

200

149 150

100

70

50

0

1998-99

2006-07

2011-12

2016-17

(Actual) Year Engineers India of LtdWorking – Delivering excellence through people Source: Report Group on P&NG Sector for the XI Plan


PIPELINE DESIGN Modes of Hydrocarbon Transportation - India 35% 30%

Pipelines Road Tankers

32%

25%

32%

20%

Pipelines Road Tankers Rail Tankers Water Carriers

15%

Rail Tankers

26%

Water Carriers

10%

10% 5% 0% % Share



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 Savings 4 3.2

3.5 Transported

Energy Consumption in % of energy

Energy Intensity for Various M ode s

3 2.5

2

2 1.5 1 0.5

0.8 0.5

0.8

1.1

1

0 LiquidPipelines

LiquidCoastal

LiquidTrains

LiquidTrucks

CoalTrains

CoalCoastal

N.GasPipelines

Pipelines are the most energy efficient modes of transportation Engineers India Ltd – Delivering excellence through people


ECONOMICS OF PIPELINE TRANSPORTATION

Transmission losses Losses During Transportation

Rail/Road

Pipelines

0

0.1

0.2

0.3

0.4

0.5

% Loss of Total Volum e Transported

Transmission losses are lowest in Pipelines Engineers India Ltd – Delivering excellence through people


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 P e r c e ntag e of C a p ita l Cos t.

Ite m D e s cription

S r o.

Liquid Line s

Gas Line s

1

Su rv e y , ROW & Co mp e n s a tio n

2%

1%

2

Lin e Pip e Ste e l Co s t

33%

45%

3

M a in lin e ma te ria ls

2%

3%

4

Co a tin g o f Pip e s

11%

6%

5

M a in lin e Co n s tru c tio n

33%

25%

6

Ca th o d ic Pro te c tio n

1%

1%

7

T e le c o mmu n ic a tio n , SCA DA a n d RCPs

5%

2%

8

Pu mp / Co mp re s s o r Sta tio n s

5%

12%

9

De liv e ry T e rmin a l fa c ilitie s

2%

1%

10

Pro je c t M a n a g e me n t

5%

4%

11

S ubTotal

100%

100%

Pipes, prime-overs and construction constitute big ticket items Engineers India Ltd – Delivering excellence through people


PIPELINE DESIGN Marine Offloading Terminal



PIPELINE DESIGN Open sea Jetty



PIPELINE DESIGN HBJ GAS PIPELINE NETWORK UTTAR PRADESH N

DELHI

RAJASTHAN

DADRI

ANOLA SHAHJAHANPUR

BABRALA

INDIA GADEPAN

ANTA

AURAIYA JAGDISHPUR

BIJAIPUR

GUJARAT JHABUA ARABIAN SEA

MADHYA PRADESH HAZIRA


KEY PLAN LEGEND COMPRESSOR STATION RECEIVING TERMINAL DESPATCH STATION


PIPELINE DESIGN Major Pipelines in India



PIPELINE DESIGN Pipeline Construction Video Video for Mangalore Bangalore Pipeline



PIPELINE DESIGN SECTION-2

PIPELINE DESIGN



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 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 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) OISD

Design and Construction Requirements for Cross Cross--Country Hydrocarbon Pipelines

OISD--214 (2006) OISD

Cross Cross--Country LPG Pipelines

OISD--226 (2007) OISD

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 OSOS-F101

Submarine pipeline systems

Other References

Applicable Standards / Specs of ASME, API, NACE, MSS, BS and DIN



PIPELINE DESIGN Major Codes & Standards Type of Crossing ROU & Land Acquisition

Approval Authority 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



LIST OF SOFTWARES USED IN PIPELINE ENGINEERING

CAESAR-II CAESARAUTOPIPE IPMCS MRPACK SORPS PIPECALC OFFPIPE PRISE PIPECROSS

PIPELINE STUDIO TGNET TLNET HYSIS



PIPELINE DESIGN Optimal sizes of various capacities

Economy of scale Engineers India Ltd – Delivering excellence through people


PIPELINE DESIGN Route Selection Routing Considerations

Pipeline length Obstructions & Sensitive areas Installation Limitations Crossings

Surveys

Topographical Geo-technical Population Density Index Soil Resistivity Cadastral Engineers India Ltd – Delivering excellence through people


PIPELINE DESIGN Typical Pipeline Route Map BHATINDA Ch. 1012.67 km

IP-1 & IPS-F

RANSISAR Ch. 855.01 km

PROPOSED PIPELINE IPS-2

JUD Ch. 593.88 km

IPS-F

GAILAWAS Ch. 527.87 km

LEGEND: PROPOSED MUNDRA-BHATINDA PIPELINE (28" NB) DESPATCH TERMINAL AND PUMPING STATION RECEIPT TERMINAL

IPS-1

JORAWARPURA Ch. 313.63 km

INTERMEDIATE PUMPING STATION (IPS) INTERMEDIATE PIGGING STATION (IP) FUTURE PUMPING STATION (IPS-F) NOTES: 1. PIPELINE ROUTE SHOWN IS INDICATIVE ONLY. 2. CHAINAGES INDICATED ARE APPROXIMATE.

IPS-F

JHEKDA Ch. 226.72 km

MUNDRA Ch. 0.00 km



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

GAS PIPELINE

(ASME B 31.4, Cl. 404.1.2)

(ASME B 31.8, Cl. 841.11)

t = PiD 2.S

P = 2St FET D

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

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 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 : Location Class 2 : Location Class 3 : Location Class 4 :

≤ 10 buildings > 10 and < 46 buildings ≥ 46 buildings Multistory buildings



PIPELINE DESIGN Line Pipe Selection Line Pipe Selection Parameters

Type of Line Pipes

Thickness and Grade Selection

Seamless

Electric Welded

Handling and Transportation (d/t ratio)

Type of LinePipe

Longitudinal Seam Submerged--Arc Welded Submerged (LSAW)

Installation Requirements

Helical Seam SubmergedSubmergedArc Welded

(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 Pipes



PIPELINE DESIGN Anti-corrosive Coatings

Coal Tar Enamel Coating (BS 4164, AWWA C203)

3 Layer PE/ PP Coating (DIN 30670)

Primer Two layers of coal tar enamel & glass fibre Inner wrap One layer of coal tar impregnated outer wrap Coating thickness 4.7mm 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 350600--800 micron thick dual layer coating 600



PIPELINE DESIGN 3 Layer PE Coating Application



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 Scraper traps



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 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 Engineers India Ltd – Delivering excellence through people


PIPELINE DESIGN Ball valves



PIPELINE DESIGN Plug valve



PIPELINE DESIGN Check valve



PIPELINE DESIGN Major Engineering Deliverables Design Reports Design Route Wall

Basis

Selection Report

Thickness Report

Seismic

Design Report

Crossing

Design Report

Drawings Route

Map

Pipeline

Schematic

Alignment SV

Sheets

Station Layout

Equipment

Layout

Piping

General Arrangement Drawings



PIPELINE DESIGN Typical Pipeline Alignment Sheet TP50

INTERSECTION POINTS(IP/TP)

IP50/1 TP51

38°4'58''(R)

DEFLECTION ANGLE DISTANCE BETWEEN TP & IP's(m) DISTANCE AS PER GROUND PROFILE

IP51/1

TP52

29°8'20''(L)

TP53

TP54

5°18'55''(R) 8°2'3''(L)

TP55 TP56

37°0'54''(L)

13°54'57''(R)

TP57

11°25'7''(L)

TP58 IP58/1

1°21'55''(L)

TP59

8°24'45''(R)

TP60

2°8'32''(L)

TP61

14°0'19''(R)

IP61/1

TP62

8°30'18''(L)

TP63

15°2'57''(L)

TP64

10°4'42''(L)

67.046 25.199 85.000

187.855

76.544

339.096

176.463

38.749

322.708

141.760

45.000

104.113

224.969

393.395

218.000

348.437

326.642

67.049 25.200 85.284

187.993

76.618

339.126

176.478

38.853

322.772

141.845

45.093

104.624

225.022

393.407

218.014

348.444

326.679

IP64/1

TP65

10°25'50''(L)

5°18'12''(R)

237.677

65.521

90.164

237.707

65.728

90.390

STATE , DISTRICT AND MANDAL TO IRUVADA

TP65 CH. 14134.896m

M RA PU

IP64/1 CH.14044.732m

CH. 10985.658m TP53 CH. 11062.202m

CH. 12125.978m

ELECTRIC LINE 440V CH.11018.117m

SV-1 OF GAIL CH.11960.218 m

K

CH. 11401.298m

HIGH TENSIONLINE 12.2m HIGH& 550KV VILLAGE BOUNDARY AMRUTAPURAM IRUVADA

CH.12747.397m

40.816 48.521

237.676

248.929

37.219

CART TRACK CH 13492.61m/RL 33.622m 33.622

32.444 77.714

166.780

182.117

30.893

28.935

29.135

217.539

29.219 94.141

299.254

30.557

25.884 114.747

ROAD CH 12060.88m/RL 24.604m

DRAIN C H 12115.34m/RL 22.175m 22.175

24.604 23.667 20.101 34.366

121.660

90.342

24.341 24.675 66.597

ST AT E

HIG HW AY -SA BB AV AR AM

14.115 14.135

13.248 13.248

14.115 14.135

13.066 13.066

13.979

12.848 12.848

14.028 14.040

12.754 12.754

13.979

12.455 12.455

14.028 14.040

12.230 12.230

13.742

12.115

13.742

12.061 12.081 12.061 12.081

12.115

13.415

11.939 11.960 11.972 11.984 11.939

13.493

11.825 11.849 11.825 11.849

13.415

11.758 11.758


13.493

11.578

11.617

11.401 11.401

11.578

11.259 11.259

11.617

10.986

11.025

11.062

10.986

11.025

RICE FIELDS

11.062

10.787 10.787

25.138

24.858

141.522

27.904 38.749

176.463

142.134

25.362

27.370

29.815

196.962

30.300

31.496 39.369

37.175

198.636

10.665

10.692 10.713

10.665

10.692 10.713

KAJU GARDEN

24.828

DRAIN CH 11824.63m/RL 24.341m

OPEN WELL 6m DIA 8m FROM C/L CH11577.761m

24.246

CANAL CH 10691.6m/RL 35.411m

OPEN WELL 6m DIA 7.648mFROMC/L CH.11648.136m

PUMP HOUSE 4m FROMC/L

32.587

35.411 33.560

33.366

26.894 21.199

74.219

37.325 44.152

K TRAC CART 2.606m 49 CH.13

HPCLCH. 17.00Km

HPCL CH. 16.00Km

GRAVEL ROAD CH.12060.877m

25 23 21

10.621

K

TEMP. HUT ON C/L

31 29 27

10.621

CH. 13066.455m

CH. 12848.455m

DRAIN CH.12115.344m TO A MRUT HAPU RAM

TP54

K

ROAD CH 10787.02m/RL 32.587m

DRAIN CH 10664.71m/RL 33.366m

35 33

RAIWADA LEFT CANAL (UNLINED) CH.14027.732m GRAVEL ROAD CH.14040.275m

DRAIN CH.12903.743m

TBMW49 (RL 25.138m)

43 41 39 37

TO

TBMW57(RL42.533m) TP62 CH. 13414.892m

IP61/1

TP61

CH. 12230.091m

CH. 11616.510m HPCLCH. 15.00Km

45

SCALE: HORIZONTAL 1:5000 VERTICAL 1: 500

TP55 CH. 11577.761m TP56

CH. 12455.060m

TP59 IP58/1

224.969

MATCH LINE FOR CONT. REFER DWG NO.4529-10-16-71-9003

A GUTL GRAVEL ROAD INTA CH.10787.022m TO CH

TP57

CH. 11939.218m

TP63 CH. 13741.534m EARTHEN EMBANKMENT

TP60

R OAD C H 14040.27m/RL 42.491m

DRAIN C H.11824.629m

TP52

LOW LYING AREA

TP58 CH. 12080.978m

AM

0m .71 AIN 664 DR H.10 C

ELECTR CH.1184 IC LINE 8.88m

RAIWADA LEFT CANAL (UNLINED) CH. 10691.604m

CANAL CH 14027.73m/RL 39.741m

IP51/1 CH. 10797.803m

CART TRACK CH 14115.31m/RL 43.684m

CH. 10712.803m

UR THAP AMRU NDA

CH. 10687.604m

43.684 43.034

TO PE

IP50/1 TP51

MATCH LINE FOR CONT. REFER DWG NO.4529-10-16-71-9005

EARTHEN EMBANKMENT

TELEPHONE LINECH.14134.896m METALLED ROAD(ASPHALTIC) CH.14115.309m ELEC. LINE 440V CH.14132.231m

TP64 CH. 13979.211m

19.588

A

39.741 42.491

TO

CH. 10620.558m

PE

RIT AM

75.034

TP50

A ND

12.543

TBMW40 (RL 37.514m)


PIPELINE DESIGN Typical P&ID



PIPELINE DESIGN Typical GA DRAWING



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 Installation, Testing & Commissioning RoU Grading & Trenching

Stringing of Linepipe



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 Installation, Testing & Commissioning 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.



Boring Across Road crossings.



Boring Across Road crossings, showing Auger used for Boring



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 Schematic Diagram



PIPELINE DESIGN Pipeline Installation using Micro-tunnelling Long Distance Micro Tunnelling



PIPELINE DESIGN Overview of Micro tunneling



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

DRYING Swabbing Methanol Drying Super Dry Air Method Vacuum Drying COMMISSIONING Nitrogen Purging Product Charging

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



PIPELINE DESIGN Pigging Requirements

Types of Pigs

Pipeline Cleaning Displacement Internal Inspection Batching

Cleaning pigs

Gauge Pigs

Brush pigs Gauge Pigs Spheres Intelligent Pigs

Spheres


Intelligent Pig (MFL) Pipeline Design Slide Number - 72 of 77

PIPELINE DESIGN RECENT DEVELOPMENTS TECHNICAL IMPROVEMENTS

Automatic Welding & Automatic UT Micro--Tunneling for pipeline construction Micro

Internal flow coating on line pipes for gas pipelines 3LPP coating on High Temperature pipelines



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 1515-20%

Geometry

Controlled to the desired level with cold expansion

Controlled during forming only and no cold expansion is carried out



PIPELINE DESIGN Coating Comparison CTE

3LPE

3LPP

FBE

Upto 45

Upto 65

Upto 110

Upto 110

Resistance to Moisture

Good

Very Good

Excellent

Good

Cathodic Disbondment

Fair

Good

Good

Good

Good

Excellent

Excellent

Excellent

Service Conditions Temperature, o C

Anti--corrosion Properties Anti

Electrical Properties Coating Resistance




3LPE

3LPP

FBE

High

Low

Low

Low

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

-

Cathodic Protection Design Current Density

Mechanical Properties




3LPE

3LPP

FBE

Fair

Very Good

Very Good

Very Good

Long Term Ageing Heat & Light Ageing

Application & Field Repair Ease of Application

Easy

Relatively difficult



Damages during handling & transportation

High

Low

Low

High

Difficult

Easy for small repair, Cumbersome for larger repair



Ease of Field Repair



Thank You

www.engineersindia.com



Pipeline Design

Recommend Documents