II Pipeline Design Codes and Standards-MSG

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
Petroleum Refineries Petrochemicals Pipelines Offshore Platforms Gas Processing Metallurgy Ports & Terminals Highways and Airports
EIL OFFICES
HEAD OFFICE REGIONAL OFFICES NEW DELHI VADODARA, CHENNAI KOLKATA MUMBAI 29 LOCATIONS (INDIA) 9 LOCATIONS (OVERSEAS) 10 LOCATIONS LONDON, LIBYA ABU DHABI, ITALY, SAUDI ARABIA , QATAR, KUWAIT
PROCUREMENT OFFICES SITE OFFICES
INSPECTION OFFICE OVERSEAS OFFICES
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
EIL EXPERIENCE
1975 1979 First major project Crude Oil Loop Line for Oil India Ltd. First major overseas project 150 km Multi Product Pipeline for Abu Dhabi National Oil Company First major high pressure Gas Pipeline Project - 1800 km Gas Transmission Network for GAIL
1984
Over 40 major pipeline projects completed.

PIPELINE DESIGN
Major Onshore Projects (Completed)
DESCRIPTION HAZIRA-BIJAIPURHAZIRA-BIJAIPURJAGDISHPUR (HBJ) MAQTA-ALMAQTA-AL-AIN PIPELINE KANDLAKANDLA-BHATINDA GAS REHABILITATION & EXPANSION PROJECT (GREP) MUMBAI MANMAD VIZAGVIZAG-VIJAYWADA JAMNAGARJAMNAGAR-LONI LPG PIPELINE COCHIN KARUR PIPELINE CLIENT GAIL ADNOC IOCL GAIL YEAR 1989 1992 1996 1998 SIZE 36/30/24/18 30 /12 22/14/10 36 LENGTH (KM) 1800 166 1443 505 SERVICES NATURAL GAS NATURAL GAS MULTIPRODUCT NATURAL GAS
BPCL HPCL GAIL PETRONET
1998 1998 2001 2001
18 18 16/14/12/8/ 6 18 /14
260 360 1235 289
MULTIPRODUCT MULTIPRODUCT LPG (LIQUIFIED PETROLIUM GAS) MULTIPRODUCT
PIPELINE DESIGN
Major Onshore Projects (..contd) (Completed)
DESCRIPTION VIZAG SECUNDERABAD LPG PIPELINE MANMADMANMAD-MANGALAYA PIPELINE MANGALOREMANGALORE-BANGLORE DAHEJ VIJAIPUR PIPELINE INTER REFINERIES PIPELINES PROJECT, ABU DHABI MANGALAYAMANGALAYA-BIJWASAN PIPELINE MUNDRAMUNDRA-DELHI PIPELINE CLIENT GAIL BPCL HPCL GAIL YEAR 2002 2003 2003 2003 SIZE 12/10 14 24 /20 42 10 12 16 16/8 18/16 LENGTH (KM) 600 358 364 610 230 230 208 775 1050 SERVICES LPG (LEQUIFIED PETROLEUM GAS) MULTIPRODUCT MULTIPRODUCT REGASIFIED LNG NAPHTHA, MULTIPRODUCT & SRR MULTIPRODUCT MULTIPRODUCT
TAKREER BPCL HPCL
2004 2006 2006
PIPELINE DESIGN
Major Onshore Projects (contd) (Completed)
DESCRIPTION PUNE SOLAPUR PIPELINE DABHOL PANVEL PIPELINE PROJECT (PH-I) (PHDABHOL PANVEL PIPELINE PROJECT (PH-II) (PHCLIENT HPCL GAIL GAIL YEAR 2007 2007 2007 SIZE 14 / 12 30 30 LENGTH (KM) 182 / 161 187 120 SERVICES MULTIPRODUCT REGASIFIED LNG REGASIFIED LNG
PIPELINE DESIGN
Major Offshore Projects (Completed)
DESCRIPTION BOMBAY HIGH URAN TRUNKLINE (BUT) SOUTH BASSEIN HAZIRA TRUNKLINE HEERAHEERA-URAN TRUNK LINE ICP - HEERA TRUNKLINE SECOND BASSEIN HAZIRA TRUNKLINE MUMBAI HIGH URAN TRUNKLINE (MUT) CLIENT ONGC ONGC ONGC ONGC ONGC ONGC YEAR 1979 1986 1996 1996 1995 2005 SIZE 30/26 36 26 /24 30/22 42 30/28 12 to 22 LENGTH (KM) 200 x 2 220 85 x 2 145 245 205 x 2 100 SERVICES CRUDE, GAS GAS CRUDE, GAS CRUDE GAS CRUDE, GAS
IN-FIELD PIPELINES OF BOMBAY-HIGH, BASSEIN, HEERA, NEELAM, PANNA, MUKTA.
PIPELINE DESIGN
Major Onshore Projects (Current)
DESCRIPTION VIJIPUR DADRI BAWANA PIPELINE (VDBPL) MUNDRA BATHINDA PIPELINE (MBPL) BINA KOTA PIPELINE VADINAR BINA PIPELINE NUMALIGARH SILIGURI PIPELINE COMPRESSOR STATIONS CLIENT GAIL HMPL BPCL BORL OIL GAIL YEAR 2009 2009 2009 2009 2009 --SIZE 48/ 36/ 20 28/ 30 18 24 16 --LENGTH (KM) 500/ 38/ 55 424/ 590 257 935 400 --SERVICES REGASIFIED LNG CRUDE OIL MULTI PRODUCT CRUDE OIL MULTI PRODUCT REGASIFIED LNG
IN-FIELD PIPELINES OF BOMBAY-HIGH, BASSEIN, HEERA, NEELAM, PANNA, MUKTA.
PIPELINE DESIGN
SECTION-1
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 (ONGC, OIL, CAIRN, RIL) GAS 115 MMSCMD 33 MMTPA
(ONGC, GAIL, OIL, GSPC, RIL)
PIPELINE DESIGN
Refining Scenario- India
350
Capacity - 2006-07 NOC 105.5 MMT Others- 43.5 MMT

302
300
(MMT)
250
235
200
149
150
100
70
50
1998-99
2006-07
2011-12
2016-17
(Actual) Year
Engineers India Ltd Delivering excellence through people Source: Report of Working Group on P&NG Sector for the XI Plan
PIPELINE DESIGN
Modes of Hydrocarbon Transportation - India
35% 30%
Pipelines Road Tankers Rail Tankers Water Carriers
32% 32% 26% 10%
25% 20% 15% 10% 5% 0% % Share Pipelines Road Tankers Rail Tankers Water Carriers
PIPELINE DESIGN
Benefits of Transportation by Pipelines
Safer mode of transportation Environment friendly Least energy requirement Lowest maintenance costs Minimal impact on land use pattern Negligible loss of product in transit High reliability Multi-product Transportation
PIPELINE DESIGN Energy Savings

Energy Inte nsity for Various M ode s
Energy Consumption in % of energy 4 3.5 Transported 3 2.5 2 1.5 1 0.5 0 LiquidPipelines LiquidCoastal LiquidTrains LiquidTrucks CoalTrains CoalCoastal N.GasPipelines 0.8 0.5 1 0.8 1.1 2 3.2
Pipelines are the most energy efficient modes of transportation

ECONOMICS OF PIPELINE TRANSPORTATION
Transmission losses
Losses During Transportation
Rail/Road
Pipelines
0.1
0.2
0.3
0.4
0.5
% Loss of Total Volum e Transported
Transmission losses are lowest in Pipelines

PIPELINE DESIGN
Products Transported
Crude Oil Petroleum Products (MS, HSD, ATF, SKO) Water & Effluents LPG Natural Gas Slurries
PIPELINE DESIGN
Types of Pipelines
ONSHORE (LAND) & OFFSHORE (SUBMARINE) PIPELINES

Trunk Pipelines Spur/ Branch Pipelines Marine Offloading Terminals & Outfalls
PIPELINE DESIGN
Capital cost: Typical breakup

Percentage of Capital Cost. Sr No. 1 2 3 4 5 6 7 8 9 10 11
Item Description
Liquid Lines Survey, ROW & Compensation Line Pipe Steel Cost Main line materials Coating of Pipes Mainline Construction Cathodic Protection Telecommunication, SCADA and RCPs Pump / Compressor Stations Delivery Terminal facilities Project Management SubTotal
2% 33% 2% 11% 33% 1% 5% 5% 2% 5% 100%
Gas Lines
1% 45% 3% 6% 25% 1% 2% 12% 1% 4% 100%
Pipes, prime-overs and construction constitute big ticket items

PIPELINE DESIGN
Marine Offloading Terminal
PIPELINE DESIGN
Open sea Jetty
PIPELINE DESIGN
HBJ GAS PIPELINE NETWORK
UTTAR PRADESH
N
DELHI
DADRI
ANOLA SHAHJAHANPUR
RAJASTHAN
GADEPAN ANTA
BABRALA
INDIA
AURAIYA JAGDISHPUR
GUJARAT
JHABUA ARABIAN SEA HAZIRA
BIJAIPUR
KEY PLAN LEGEND COMPRESSOR STATION RECEIVING TERMINAL DESPATCH STATION
MADHYA PRADESH
PIPELINE DESIGN
Major Pipelines in India
PIPELINE DESIGN
Pipeline Construction Video
Video for Mangalore Bangalore Pipeline
PIPELINE DESIGN
SECTION-2
PIPELINE DESIGN CODES AND STANDRADS

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
ASME B 31.8 (2003) ASME B 31.4 (2006) OISDOISD-141 (2003) OISDOISD-214 (2006) OISDOISD-226 (2007) API 5L / ISO 3183 : 2007 API RP1102 API 1104 API 6D / ISO 14313 DNV OS-F101 OSOther References
Title
Gas Transportation and Distribution Piping Systems Pipeline Transportation Systems for Liquid Hydrocarbons and other Liquids Design and Construction Requirements for Cross-Country CrossHydrocarbon Pipelines Cross-Country LPG Pipelines CrossNatural Gas Transmission Pipelines and City Gas Distribution Networks Specification for Line Pipe Recommended practice for Rail and Highway crossings Standard for welding pipeline and related facilities Pipeline Valves Submarine pipeline systems 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) NHAI
National Highway Crossings
SH/ MDR/ ODR Crossings Railway Track crossings Crossing through Forest land River/Canal crossings
PWD Indian Railways Forest Authority 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
PIPELINE DESIGN
Route Selection
Routing Considerations
Pipeline length Obstructions & Sensitive areas Installation Limitations Crossings
Surveys
Topographical Geo-technical Population Density Index Soil Resistivity Cadastral
PIPELINE DESIGN
Typical Pipeline Route Map
The drawing, design and details given on this format are the property of ENGINEERS INDIA LIMITED. They are merely loaned on the borrower's express agreement that they will not be reproduced, copied, exhibited or used, except in the limited w ay permitted by a written consent given by the lender to the borrower for the intended use.
BHATINDA
Ch. 1012.67 km
RANSISAR Ch. 855.01 km
IP-1 & IPS-F
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 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.
JORAWARPURA Ch. 313.63 km
IPS-1
JHEKDA Ch. 226.72 km
IPS-F
MUNDRA
Ch. 0.00 km
PROJECT : ENGINEERS INDIA LIMITED

NEW DELHI
REV. OVERALL PIPELINE ROUTE MAP

AC REV. DA TE REV ISION BY RK CHK VM AP PROVED AP PROVED
CLIENT JOB NO
: M/s GGSRL : 6812
Pipeline Design
1-1641-0503 REV.0 A3-420x297
Slide Number - 36 of 77
PIPELINE DESIGN
PIPELINE DESIGN
Material Selection & Corrosion Control
Assessment
Nature of the Product Design Life Product Temperature
Materials
Carbon Steel (CS) NACE Carbon Steel CRA Clad CS CS with internal Coatings Non-Metallic Materials
Corrosion Protection
Material Chemistry Internal Coatings Product Conditioning Corrosion inhibitors Corrosion Allowance
PIPELINE DESIGN
Design and Analysis
Wall Thickness Calculations Anti-Buoyancy Measures Piping Stress Analysis Buried Pipeline Analysis Crossing Design
PIPELINE DESIGN
Steel Pipe Wall Thickness Calculation
LIQUID PIPELINE (ASME B 31.4, Cl. 404.1.2) 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 E Weld joint factor
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
Basic Design Factor for Gas Pipelines
LOCATION CLASS Location Class 1 Location Class 2 Location Class 3 Location Class 4 Location Class Classification Location Class 1 : Location Class 2 : Location Class 3 : Location Class 4 : DESIGN FACTOR, F 0.72 0.60 0.50 0.40 e 10 buildings > 10 and < 46 buildings u 46 buildings Multistory buildings
PIPELINE DESIGN
Line Pipe Selection
Line Pipe Selection Parameters Thickness and Grade Selection Handling and Transportation (d/t ratio) Type of LinePipe Installation Requirements Type of Line Pipes Seamless Electric Welded Longitudinal Seam SubmergedSubmerged-Arc Welded (LSAW) 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)
Manufacturing of Helical Pipes
PIPELINE DESIGN
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 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 350350-500 micron thick single layer coating 600600-800 micron thick dual layer coating
3 Layer PE/ PP Coating (DIN 30670)

Fusion Bonded Epoxy Coating (CSA Z245.20)

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 Location Class 2 Location Class 3 Location Class 4 LPG Pipelines Industrial, 12 km (7.5 miles) Commercial & Residential Areas 32 km (20 miles) 24 km (15 miles) 16 km (10 miles) 8 km (5 miles)
PIPELINE DESIGN
Type of Valves
Full Bore Ball Valves Through Conduit Gate Valves Plug and Check Valves Valve Standard : API 6D/ISO14313 Other Valve Standards: API 600, API 602, BS EN ISO 17292:2004, BS EN ISO 15761:2002, BS 5353
PIPELINE DESIGN
Ball valves
PIPELINE DESIGN Plug valve
PIPELINE DESIGN Check valve
PIPELINE DESIGN
Major Engineering Deliverables
Design Reports
Design Route Wall
Drawings
Route
Basis
Map Schematic Sheets Layout
Selection Report Design Report Design Report
Pipeline
Thickness Report
Alignment SV
Seismic
Station Layout
Crossing
Equipment Piping
General Arrangement Drawings
PIPELINE DESIGN
Typical Pipeline Alignment Sheet
INTERSECTION POINTS(IP/TP) DEFLECTION ANGLE DISTA NCE BETWEEN TP & IP's (m)
DISTANCE AS PER GROUND PROFILE TP50 IP5 0/1 TP51 2 98 '20''(L) 187.855 187.993 IP5 1/1 TP52 TP53 TP54 370'54''(L) 339.096 339.126 TP55 TP56 1354'57'' (R) 176.463 176.478 112 5'7''(L) 322.708 322.772 TP57 121'55''(L) 141.760 141.845 TP58 IP58/1 824'45''(R) 45.000 45.093 104.113 104.624 TP59 2 8'32''(L) 224.969 225.022 TP60 140'19''(R) 393.395 393.407 TP61 830'18''(L) 218.000 218.014 348.437 348.444 IP61/1 TP62 152 '57''(L) 326.642 326.679 TP63 104'42''(L) 237.677 237.707 TP64 1025'50'' (L) 65.521 65.728 90.164 90.390 IP64/1 TP65 518'12''(R) 3 84 '58''(R) 518'55''(R) 82'3'' (L) 76.544 76.618 67.046 25.199 85.000 67.049 25.200 85.284 38.749 38.853
STATE , DISTRICT AND MANDAL

TO IRUVADA
PU M RA
TP65 CH. 14134.896m IP64/1 CH.14044.732m EARTHEN EMBANKMENT TP64 CH. 13979.211m
TBM W40 (RL 37.514m) TP50 CH. 10620.558m IP5 0/1 TP51 CH. 10712.803m IP5 1/1 CH. 10797.803m
10 IN 4.7 A 66 DR H.10 C m
TO PE
A ND
IT R M
TELEPHONE LINE CH.14134.896m METAL LED ROAD(ASPHALTIC) CH.14115.309m ELEC. LINE 440V CH.14132.231m
CH. 10687.604m RAIWADA LEFT CANAL (UNLINED) CH. 10691.604m TP52

DR A IN CH .1 1 8 2 4 .6 2 9 m
LOW LYING AREA
TP63 CH. 13741.534m
E LE C T RI CH .1 1 8 4 8 C L IN E .8 8 m
TP57
TP58 CH. 12080.978m TP59 IP58/1 CH. 12125.978m CH. 12230.091m
EARTHEN EMBANKMENT TP60 CH. 12455.060m TP61 CH. 12848.455m IP61/1 CH. 13066.455m DRAIN CH.12903.743m
K K
MA TC H L IN E FO R C ON T . R E FE R D WG NO .4 5 2 9 -1 0-1 6 -7 1 -9 00 5
CH. 10985.658m TP53
CH. 11939.218m
MA TC H L IN E FO R C ON T . R E FE R D WG NO .4 5 2 9 -1 0-1 6 -7 1 -9 00 3
IN TA TO CH
A GUTL GRAVEL ROAD CH.10787.022m
CH. 11062.202m TP55 CH. 11577.761m TP56 CH. 11616.510m HPCL CH. 15.00Km ELECTRIC LINE 440V CH.11018.117m TP54 CH. 11401.298m
K
SV-1 OF GAIL CH.11960.218 m
CH.12747.397m
TBM W49 (RL 25.138m) C A N AL C H 106 91.6m /R L 35.411m OPEN WELL 6m DIA 7.648m FROM C/L CH.11648.136m OPEN WELL 6m DIA 8m FROM C/L CH 11577.761m
VILLAGE BOUNDARY AMRUT APURAM IRUVADA
D R A IN C H 106 64.71m /RL 33. 366m
R O AD C H 107 87.02 m /RL 32 .587m
PUMP HOUSE 4m FROM C/L
SCALE: HORIZONTAL 1:5000 VERTICAL 1: 500
45 43 41 39 37 35 33 31 29 27 25 23 21 37.32 5
D R A IN C H 118 2 4.63m /RL 24.341m
R O AD C H 1 20 60.88m /RL 24.604m
3 2 .587
22 .175
D R A IN C H 121 15.34m /RL 22 .175m
3 2 .444
C A RT T RA CK C H 134 9 2. 61m /RL 33.622 m
39.741 4 2 .491
2 9.815
2 7.370
2 7.904
2 4.858
2 5.138
2 4.341 2 4.675
2 4.604 2 3.667
2 5.884
2 9.135
2 8.935
33.366 35.411 33.560
31.496
30.300
30.557
30.893
40.816
C A N AL C H 140 2 7.73m /RL 39. 741m R O AD C H 140 40. 2 7m /RL 42. 491m
196.96 2
2 48.9 2 9
141.5 22
2 99.2 54
14 2 .134
18 2 .117
1 2 1.660
22 4.969
2 17.539
2 37.676
198.636
176.463
114.747
166.780
2 6.894 2 1.199
90.34 2
44.15 2
48.5 2 1
74.2 19
2 4.2 46
1 2 .543
39.369
37.175
38.749
66.597
2 0.101 34.366
94.141
77.714
75.034
KAJU GARDEN
RICE FIELDS
10.6 2 1
10.665 10.69 2 10.713
11.0 2 5
11.06 2
11.8 2 5 11.849
11.939 11.960 11.97 2 11.984
13.74 2
14.0 2 8 14.040
11.2 59
1 2 .2 30
13.2 48
1 2 .061 1 2 .081
1 2 .115
1 2 .455
1 2 .754
1 2 .848
10.787
10.986
11.401
11.578
11.617
11.758
13.066
13.415
13.493
13.979
10.6 2 1
10.665 10.69 2 10.713
11.0 2 5
11.06 2
11.8 2 5 11.849
13.74 2
14.0 2 8 14.040
11.2 59
1 2 .2 30
13.2 48
1 2 .061 1 2 .081
1 2 .115
12 .455
12 .754
12 .848
10.787
10.986
11.401
11.578
11.617
11.758
11.939
13.066
13.415
13.493
13.979
14.115 14.135
14.115 14.135
19.588
43.684 43.034
2 5.362
2 4.82 8
2 9.2 19
33.622
37.2 19
C A RT T RA CK C H 141 15.31m /RL 43.684m
A T O PE ND A M RU TH AP UR AM
TBM W57(RL 42.533m) TP62 CH. 13414.892m
TO
ST AT
RAIWADA LEFT CANAL (UNLINED) CH.14027.732m GRAVEL ROAD CH.14040.275m TEMP. HUT ON C/L
HI GH W
AY -S A BB
AV A RA M
DRAIN CH.12115.344m TO AM RUTH APU RAM GRAVEL ROAD CH.12060.877m
HPCL CH. 16.00Km
HPCL CH. 17.00Km HIGH TENSION LINE 1 2.2m HIGH & 550KV
CK T TRA CAR 2.606m 349 CH.1
PIPELINE DESIGN Typical P&ID
PIPELINE DESIGN Typical GA DRAWING
PIPELINE DESIGN Major Engineering Deliverables

Tenders

Survey Tender Pipe Coating Tender Pipeline Installation Tender Line Pipes Valves & Actuators Scraper Traps, QOEC, Pig Signallers Flow Tees & Insulating Joints Induction Bends Flow meters Pumps & Compressors OFC cables
Material Procurement

PIPELINE DESIGN
Installation, Testing & Commissioning
RoU Grading & Trenching Stringing of Linepipe
PIPELINE DESIGN
Welding & NDT :

Edge Preparation Internal / External Line-up Clamps Manual / Automatic Welding NDT (X-Ray / UT / MPI etc.)
PIPELINE DESIGN
Field Joint Coating
Heat Shrink Sleeves Cold applied tapes
Lowering & Backfilling
PIPELINE DESIGN
Pipeline Crossings
Crossing Installation
Crossings River, Canal, Road & Rail Utility Crossing Methodologies Open-Cut Method Trench-less Method Horizontal Directional Drilling Jacking and Boring Micro tunneling
PIPELINE DESIGN
The conventional HDD operations for river crossings.
PIPELINE DESIGN
Pipeline Installation using Micro-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 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
ADVANTAGES:

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

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
PIPELINE DESIGN Pigging

Requirements

Types of Pigs

Pipeline Cleaning Displacement Internal Inspection Batching
Brush pigs Gauge Pigs Spheres Intelligent Pigs
Cleaning pigs
Gauge Pigs
Spheres
Intelligent Pig (MFL)

PIPELINE DESIGN
RECENT DEVELOPMENTS
TECHNICAL IMPROVEMENTS

Automatic Welding & Automatic UT MicroMicro-Tunneling for pipeline construction

Internal flow coating on line pipes for gas pipelines 3LPP coating on High Temperature pipelines
PIPELINE DESIGN Comparison of LSAW & HSAW Pipes

Description
Method of Manufacture Weld Length Position of weld
LSAW
UOE/COE/JCO/3 roll bending Equal to pipe joint length Longitudinal positioned in upper quadrant during construction Specified thickness throughout entire body. Weld seam is tracked to ensure coating thickness on weld seam Controlled to the desired level with cold expansion
HSAW
Formed by Twisting of Coil Approximately 1.5 to 2 times the length of pipe joint Spiral present all around the pipe Thickness normally increased all over the body, resulting in proportional increase in coating cost by 15-20% 15Controlled during forming only and no cold expansion is carried out
Corrosion Coating
Geometry
PIPELINE DESIGN
Coating Comparison
CTE
Service Conditions
Temperature, o C Upto 45 Upto 65 Upto 110 Upto 110
3LPE
3LPP
FBE
AntiAnti-corrosion Properties
Resistance to Moisture Good Very Good Excellent Good
Cathodic Disbondment
Fair
Good
Good
Good
Electrical Properties
Coating Resistance Good Excellent Excellent Excellent
PIPELINE DESIGN
Coating Comparison
CTE
Cathodic Protection Design
Current Density High Low Low Low
3LPE
3LPP
FBE
Mechanical Properties
Resistance to Impact Fair Poor Excellent Superior to PE Fair Fair -
Resistance to Indentation Resistance to Peel
Very Good
Excellent
Fair Fair
Excellent
Superior than PE
Resistance to Soil Stresses Elongation
Excellent
Excellent
Excellent
Fair
Excellent
Excellent
PIPELINE DESIGN
Coating Comparison
CTE
Long Term Ageing
Heat & Light Ageing Fair Very Good Very Good Very Good
3LPE
3LPP
FBE
Application & Field Repair

Ease of Application Easy Relatively difficult Relatively difficult Relatively difficult
Damages during handling & transportation Ease of Field Repair
High
Low
Low
High
Difficult
Easy for small repair, Cumbersome for larger repair
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II Pipeline Design Codes and Standards-MSG

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II Pipeline Design Codes and Standards-MSG

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PIPELINE DESIGN

Delivering excellence through people

ENGINEERS INDIA LIMITED

Engineers India Ltd Delivering excellence through people

Pipeline Design Slide Number - 2 of 77

PROCUREMENT OFFICES SITE OFFICES

INSPECTION OFFICE OVERSEAS OFFICES

Engineers India Ltd Delivering excellence through people

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Engineers India Ltd Delivering excellence through people

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Over 40 major pipeline projects completed.

BPCL HPCL GAIL PETRONET

1998 1998 2001 2001

260 360 1235 289

MULTIPRODUCT MULTIPRODUCT LPG (LIQUIFIED PETROLIUM GAS) MULTIPRODUCT

Engineers India Ltd Delivering excellence through people

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TAKREER BPCL HPCL

2004 2006 2006

Engineers India Ltd Delivering excellence through people

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Engineers India Ltd Delivering excellence through people

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

Engineers India Ltd Delivering excellence through people

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

Engineers India Ltd Delivering excellence through people

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Engineers India Ltd Delivering excellence through people

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Modes of Transportation Benefits of Pipelines

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(ONGC, GAIL, OIL, GSPC, RIL)

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

Pipelines Road Tankers Rail Tankers Water Carriers

32% 32% 26% 10%

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Engineers India Ltd Delivering excellence through people

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PIPELINE DESIGN Energy Savings

Pipelines are the most energy efficient modes of transportation

ECONOMICS OF PIPELINE TRANSPORTATION

% Loss of Total Volum e Transported

Transmission losses are lowest in Pipelines

Engineers India Ltd Delivering excellence through people

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Engineers India Ltd Delivering excellence through people

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Capital cost: Typical breakup

Pipes, prime-overs and construction constitute big ticket items

Engineers India Ltd Delivering excellence through people

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Engineers India Ltd Delivering excellence through people

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KEY PLAN LEGEND COMPRESSOR STATION RECEIVING TERMINAL DESPATCH STATION

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