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Delivering excellence through people Pipeline Design Slide Number - 1 of 77 PIPELINE DESIGN
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Delivering excellence through peoplePipeline Design
Slide Number - 1 of 77
PIPELINE DESIGN
Pipeline Design
Slide Number - 2 of 77 Engineers India Ltd – Delivering excellence through people
ENGINEERSINDIA LIMITED
EPC and Total Solutions Consultancy Organization
Pipeline Design
Slide Number - 3 of 77 Engineers India Ltd – Delivering excellence through people
ENGINEERS INDIA LTD. - AREAS OF OPERATION
Petroleum Refineries
PetrochemicalsPipelinesOffshore PlatformsGas ProcessingMetallurgyPorts & TerminalsHighways and Airports
Pipeline Design
Slide Number - 4 of 77 Engineers India Ltd – Delivering excellence through people
HEAD OFFICE NEW DELHI
REGIONAL OFFICES VADODARA, CHENNAIKOLKATA
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
Slide Number - 5 of 77 Engineers India Ltd – Delivering excellence through people
PIPELINE DESIGN
SERVICES OFFERED BY EILProject 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
Slide Number - 6 of 77 Engineers India Ltd – Delivering excellence through people
PIPELINE DESIGN
EIL EXPERIENCE1975 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
Slide Number - 7 of 77 Engineers India Ltd – Delivering excellence through people
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
Slide Number - 8 of 77 Engineers India Ltd – Delivering excellence through people
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”
230230208
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
Slide Number - 9 of 77 Engineers India Ltd – Delivering excellence through people
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 DESIGNMajor Onshore Projects (…contd)
(Completed)
Pipeline Design
Slide Number - 10 of 77 Engineers India Ltd – Delivering excellence through people
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 2100
CRUDE, GAS
IN-FIELD PIPELINES OF BOMBAY-HIGH, BASSEIN, HEERA, NEELAM, PANNA, MUKTA.
PIPELINE DESIGNMajor Offshore Projects
(Completed)
Pipeline Design
Slide Number - 11 of 77 Engineers India Ltd – Delivering excellence through people
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 DESIGNMajor Onshore Projects
(Current)
Pipeline Design
Slide Number - 12 of 77 Engineers India Ltd – Delivering excellence through people
PIPELINE DESIGN
SECTION-1
Pipeline Design
Slide Number - 13 of 77 Engineers India Ltd – Delivering excellence through people
PIPELINE DESIGN
CONTENTSINTRODUCTION Modes of Transportation Benefits of Pipelines
PIPELINE DESIGN Stages of Pipeline Project Codes and Standards Design Installation, Testing & Commissioning
Pipeline Design
Slide Number - 14 of 77 Engineers India Ltd – Delivering excellence through people
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
Slide Number - 15 of 77 Engineers India Ltd – Delivering excellence through people
Refining Scenario- India
70
149
235
302
0
50
100
150
200
250
300
350
1998-99 2006-07 2011-12 2016-17
(MM
T)
Source: Report of Working Group on P&NG Sector for the XI Plan
(Actual) Year
Capacity - 2006-07NOC – 105.5 MMTOthers- 43.5 MMT
PIPELINE DESIGN
Pipeline Design
Slide Number - 16 of 77 Engineers India Ltd – Delivering excellence through people
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
Slide Number - 17 of 77 Engineers India Ltd – Delivering excellence through people
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
Slide Number - 18 of 77 Engineers India Ltd – Delivering excellence through people
PIPELINE DESIGN
Energy SavingsEnergy Intensity for Various Modes
0.80.5
1
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
En
erg
y C
on
su
mp
tio
n in
% o
f en
erg
y
Tra
nsp
ort
ed
Pipelines are the most energy efficient modes of transportation
Pipeline Design
Slide Number - 19 of 77 Engineers India Ltd – Delivering excellence through people
ECONOMICS OF PIPELINE TRANSPORTATION
Transmission losses
0 0.1 0.2 0.3 0.4 0.5
% Loss of Total Volume Transported
Losses During Transportation
Transmission losses are lowest in Pipelines
Pipeline Design
Slide Number - 20 of 77 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
Slide Number - 21 of 77 Engineers India Ltd – Delivering excellence through people
PIPELINE DESIGN
Types of Pipelines
ONSHORE (LAND) & OFFSHORE (SUBMARINE) PIPELINES
Trunk Pipelines
Spur/ Branch Pipelines
Marine Offloading Terminals & Outfalls
Pipeline Design
Slide Number - 22 of 77 Engineers India Ltd – Delivering excellence through people
PIPELINE DESIGN
Capital cost: Typical breakup
Liquid Lines Gas Lines
1 Survey, ROW & Compensation 2% 1%
2 Line Pipe Steel Cost 33% 45%
3 Main line materials 2% 3%
4 Coating of Pipes 11% 6%
5 Mainline Construction 33% 25%
6 Cathodic Protection 1% 1%
7 Telecommunication, SCADA and RCPs 5% 2%
8 Pump / Compressor Stations 5% 12%
9 Delivery Terminal facilities 2% 1%
10 Project Management 5% 4%
11 SubTotal 100% 100%
Item DescriptionSr No.Percentage of Capital Cost.
E le c tric a l C o st V a ria tn - P u mp S ta tio n
0
0. 5
1
1. 5
0 0. 2 0. 4 0. 6 0. 8 1 1. 2
Pipes, prime-overs and construction constitute big ticket items
Pipeline Design
Slide Number - 23 of 77 Engineers India Ltd – Delivering excellence through people
PIPELINE DESIGN
Marine Offloading Terminal
Pipeline Design
Slide Number - 24 of 77 Engineers India Ltd – Delivering excellence through people
PIPELINE DESIGN
Open sea Jetty
Pipeline Design
Slide Number - 25 of 77 Engineers India Ltd – Delivering excellence through people
PIPELINE DESIGN
KEY PLANLEGEND
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
Slide Number - 26 of 77 Engineers India Ltd – Delivering excellence through people
PIPELINE DESIGN
Major Pipelines in India
Pipeline Design
Slide Number - 27 of 77 Engineers India Ltd – Delivering excellence through people
PIPELINE DESIGN
Pipeline Construction Video
Video for Mangalore Bangalore Pipeline
Pipeline Design
Slide Number - 28 of 77 Engineers India Ltd – Delivering excellence through people
PIPELINE DESIGN
SECTION-2
PIPELINE DESIGN CODES AND STANDRADS
Pipeline Design
Slide Number - 29 of 77 Engineers India Ltd – Delivering excellence through people
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
Slide Number - 30 of 77 Engineers India Ltd – Delivering excellence through people
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
Slide Number - 31 of 77 Engineers India Ltd – Delivering excellence through people
PIPELINE DESIGNMajor Codes & Standards
Code/Standard TitleASME 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
Slide Number - 32 of 77 Engineers India Ltd – Delivering excellence through people
PIPELINE DESIGNMajor 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
Slide Number - 33 of 77 Engineers India Ltd – Delivering excellence through people
CAESAR-II AUTOPIPE IPMCS MRPACK SORPS PIPECALC OFFPIPE PRISE PIPECROSS
LIST OF SOFTWARES USED IN PIPELINE ENGINEERING
PIPELINE STUDIO
TGNET
TLNET HYSIS
Pipeline Design
Slide Number - 34 of 77 Engineers India Ltd – Delivering excellence through people
Optimal sizes of various capacities
Economy of scale
PIPELINE DESIGN
Pipeline Design
Slide Number - 35 of 77 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
Pipeline Design
Slide Number - 36 of 77 Engineers India Ltd – Delivering excellence through people
6812M/s GGSRL:
:CLIENT
JOB NO
OVERALL PIPELINE ROUTE MAP
The
draw
ing,
des
ign
and
deta
ils g
iven
on th
is fo
rmat
are
the
prop
erty
of
ENG
INEE
RS IN
DIA
LIM
ITED
. Th
ey a
re m
erel
y lo
aned
on
the
borro
wer's
exp
ress
agr
eem
ent t
hat
they
will
not b
e re
prod
uced
, cop
ied,
exh
ibite
d or
use
d, e
xcep
t in
the
limite
d wa
y pe
rmitt
ed b
y a
writt
en c
onse
nt g
iven
by th
e len
der t
o th
e bo
rrowe
r for
the
inte
nded
use
.
REV.
APPROVEDCHKBYREVISIONDATEREV.
NEW DELHI
ENGINEERS INDIA LIMITED
1-1641-0503 REV.0 A3-420x297
APPROVED
:PROJECT
RK VMAC
BHATINDACh. 1012.67 km
1. PIPELINE ROUTE SHOWN IS INDICATIVE ONLY.
LEGEND:
PROPOSED MUNDRA-BHATINDA PIPELINE (28" NB)
RECEIPT TERMINAL
DESPATCH TERMINAL AND PUMPING STATION
NOTES:
PROPOSED PIPELINE
INTERMEDIATE PIGGING STATION (IP)
INTERMEDIATE PUMPING STATION (IPS)
IPS-FCh. 226.72 km
JORAWARPURACh. 313.63 km
JUDCh. 593.88 km
RANSISARCh. 855.01 km
MUNDRACh. 0.00 km
GAILAWASCh. 527.87 km
2. CHAINAGES INDICATED ARE APPROXIMATE. JHEKDA
IPS-1
IPS-F
IPS-2
IP-1 & IPS-F
FUTURE PUMPING STATION (IPS-F)
PIPELINE DESIGN
Typical Pipeline Route Map
Pipeline Design
Slide Number - 37 of 77 Engineers India Ltd – Delivering excellence through people
PIPELINE DESIGN
Pipeline Design
Slide Number - 38 of 77 Engineers India Ltd – Delivering excellence through people
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
Slide Number - 39 of 77 Engineers India Ltd – Delivering excellence through people
PIPELINE DESIGN
Design and Analysis
Wall Thickness Calculations
Anti-Buoyancy Measures
Piping Stress Analysis
Buried Pipeline Analysis
Crossing Design
Pipeline Design
Slide Number - 40 of 77 Engineers India Ltd – Delivering excellence through people
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
strengthD Nominal OD of pipe t Nominal wall thickness F Design factorE Longitudinal joint factorT Temperature de-rating factor
Pipeline Design
Slide Number - 41 of 77 Engineers India Ltd – Delivering excellence through people
PIPELINE DESIGN
Basic Design Factor for Gas PipelinesLOCATION 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 ClassificationLocation Class 1 : 10 buildingsLocation Class 2 : > 10 and < 46 buildingsLocation Class 3 : 46 buildingsLocation Class 4 : Multistory buildings
Pipeline Design
Slide Number - 42 of 77 Engineers India Ltd – Delivering excellence through people
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
Slide Number - 43 of 77 Engineers India Ltd – Delivering excellence through people
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
Slide Number - 44 of 77 Engineers India Ltd – Delivering excellence through people
Manufacturing of Helical PipesPIPELINE DESIGN
Pipeline Design
Slide Number - 45 of 77 Engineers India Ltd – Delivering excellence through people
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
Slide Number - 46 of 77 Engineers India Ltd – Delivering excellence through people
PIPELINE DESIGN
3 Layer PE Coating Application
Pipeline Design
Slide Number - 47 of 77 Engineers India Ltd – Delivering excellence through people
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
Slide Number - 48 of 77 Engineers India Ltd – Delivering excellence through people
PIPELINE DESIGN
Scraper traps
Pipeline Design
Slide Number - 49 of 77 Engineers India Ltd – Delivering excellence through people
PIPELINE DESIGN
Sectionalizing ValveSpacing
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 PipelinesLocation 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
Slide Number - 50 of 77 Engineers India Ltd – Delivering excellence through people
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
Slide Number - 51 of 77 Engineers India Ltd – Delivering excellence through people
PIPELINE DESIGN
Ball valves
Pipeline Design
Slide Number - 52 of 77 Engineers India Ltd – Delivering excellence through people
PIPELINE DESIGNPlug valve
Pipeline Design
Slide Number - 53 of 77 Engineers India Ltd – Delivering excellence through people
PIPELINE DESIGNCheck valve
Pipeline Design
Slide Number - 54 of 77 Engineers India Ltd – Delivering excellence through people
PIPELINE DESIGN
Major Engineering Deliverables
Design ReportsDesign BasisRoute Selection ReportWall Thickness ReportSeismic Design ReportCrossing Design Report
DrawingsRoute MapPipeline SchematicAlignment SheetsSV Station LayoutEquipment LayoutPiping General
Arrangement Drawings
Pipeline Design
Slide Number - 55 of 77 Engineers India Ltd – Delivering excellence through people
PIPELINE DESIGN
Typical Pipeline Alignment SheetINTERSECTION POINTS(IP/TP)
DEFLECTION ANGLE
STATE , DISTRICT AND MANDAL
SCALE:HORIZONTAL 1:5000VERTICAL 1: 500
DISTANCE AS PER GROUND PROFILE
21
23
25
27
29
31
33
35
3739
41
43
45
10.6
2137
.325
33.3
66
35.4
1133
.560
32.5
87
31.4
96
30.3
00
29.8
15
27.3
70
25.3
62
27.9
04
24.8
58
25.1
38
24.3
4124
.675
24.8
28
24.6
0423
.667
22.1
75
25.8
84
30.5
57
29.2
19
29.1
35
28.9
35
30.8
93
32.4
44
33.6
22
37.2
19
40.8
16
39.7
4142
.491
43.6
8443
.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)
TP62
10°4'42''(L)
TP63
10°25'50''(L)
TP64 IP64/1
5°18'12''(R)
TP65
DRA
INC
H 10
664.
71m
/RL
33.3
66m
CAN
ALC
H 10
691.
6m/R
L 35
.411
m
RO
AD
CH
1078
7.02
m/R
L 32
.587
m
DRA
IN
CH
1182
4.63
m/R
L 24
.341
m
RO
AD
CH
1206
0.88
m/R
L 24
.604
m
DRA
IN
CH
1211
5.34
m/R
L 22
.175
m CAR
T TR
ACK
CH
1349
2.61
m/R
L 33
.622
m
CAN
ALC
H 14
027.
73m
/RL
39.7
41m
RO
ADC
H 14
040.
27m
/RL
42.4
91m
CAR
T TR
ACK
CH
1411
5.31
m/R
L 43
.684
m
CH. 12848.455m
HIGH TENSION LINE
TP57
CH
.118
24.6
29m
CH. 11062.202m
CH. 11401.298m
TP54
CH.11018.117mELECTRIC LINE 440V CH.12115.344m
CH. 11577.761m
TP55
TP56
CH. 11616.510m
CH.12060.877mGRAVEL ROAD
CH. 11939.218m
DR
AIN
DRAIN
CH.12747.397m
CH. 10620.558m
MAT
CH
LIN E
FO
R C
ONT.
REF
ER D
WG
NO.
4529
-10-
1 6-7
1-90
03
CH. 10985.658m
CH. 10797.803m
GRAVEL ROADCH.10787.022m
TP52
IP50/1
CH. 10687.604mTP51
CH. 10712.803mIP51/1
TP53
TP50
CH. 12080.978m
TP58
CH. 12455.060m
TP60
CH. 12230.091m
TP59
DRAINCH.12903.743m
TP61
TP62
CH. 13414.892m
CH. 13741.534m
TP63
CH.14027.732m
RAIWADA LEFT CANAL
TP65CH. 14134.896m
CH. 13979.211m
TP64
IP58/1
CH. 12125.978m CH. 13066.455m
IP61/1
IP64/1CH.14044.732m
KAJU GARDEN RICE FIELDS
VILLAGE BOUNDARY
AMRUTAPURAM IRUVADA
TBM W40 (RL 37.514m)
TBM W49 (RL 25.138m)
TEMP. HUT ON C/L
TBM W57(RL 42.533m)
HPCL CH. 15.00Km HPCL CH. 16.00KmHPCL CH. 17.00Km
RAIWADA LEFT CANAL(UNLINED)CH. 10691.604m
SV-1 OF GAILCH.11960.218 m
K
K
OPEN WELL 6m DIA7.648m FROM C/LCH.11648.136m
OPEN WELL 6m DIA8m FROM C/LCH 11577.761m
PUMP HOUSE 4m FROM C/L
12.2m HIGH & 550KV
EARTHEN EMBANKMENT
LOW LYING AREA
EARTHEN EMBANKMENT
K
(UNLINED)
GRAVEL ROAD CH.14040.275m
MAT
CH
LIN E
FO
R C
ONT.
REF
ER D
WG
NO.
4529
-10-
1 6-7
1-90
05
METALLED ROAD(ASPHALTIC)CH.14115.309m
ELEC. LINE 440VCH.14132.231m
TELEPHONE LINE CH.14134.896m
DISTANCE BETWEEN TP & IP's(m)
10.6
65
44.1
52
10.6
9226
.894
10.7
1321
.199
10.7
87
74.2
19
10.9
86
198.
636
11.0
25
39.3
69
11.0
6237
.175
11.2
59
196.
962
11.4
01
142.
134
11.5
78
176.
463
11.6
17
38.7
49
11.7
58
141.
522
11.8
25
66.5
97
11.8
4924
.246
11.9
39
90.3
42
12.0
61
121.
660
12.0
8120
.101
12.1
1534
.366
12.2
30
114.
747
12.4
55
224.
969
12.7
54
299.
254
12.8
48
94.1
41
13.0
66
217.
539
13.2
48
182.
117
13.4
15
166.
780
13.4
93
77.7
14
13.7
42
248.
929
13.9
79
237.
676
14.0
28
48.5
21
14.0
4012
.543
14.1
15
75.0
34
14.1
3519
.588
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
10.6
21
10.6
65
10.6
9210
.713
10.7
87
10.9
86
11.0
25
11.0
62
11.2
59
11.4
01
11.5
78
11.6
17
11.7
58
11.8
2511
.849
11.9
39
12.0
6112
.081
12.1
15
12.2
30
12.4
55
12.7
54
12.8
48
13.0
66
13.2
48
13.4
15
13.4
93
13.7
42
13.9
79
14.0
2814
.040
14.1
1514
.135
11.9
6011
.972
11.9
84
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 DESIGNTypical GA DRAWING
Pipeline Design
Slide Number - 58 of 77 Engineers India Ltd – Delivering excellence through people
PIPELINE DESIGNMajor 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-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. 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-tunnellingLong 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 & CommissioningTESTING
Gauging and Pigging Test Pressure Test Medium
TEST PRESSURE
LIQUID PIPELINESRef. ASME B 31.4 : 437.4.11.25 times design pressure
GAS PIPELINESRef. ASME B 31.8 : Table 841.322(f)Class 1 and 2: 1.25 * des prClass 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 DESIGNPigging
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 HSAWMethod 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
Pipeline Design
Slide Number - 74 of 77 Engineers India Ltd – Delivering excellence through people
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