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PIPELINE DESIGN

Delivering excellence through people

Slide Number - 1 of 77

ENGINEERSINDIA LIMITED

EPC and Total SolutionsConsultancy Organization

Pipeline Design


Engineers India Ltd – Delivering excellence through people

Pipeline Design



Petroleum Refineries

Petrochemicals

PipelinesOffshore PlatformsGas ProcessingMetallurgyPorts & TerminalsHighways and Airports

EIL OFFICES

Pipeline Design



HEAD OFFICE

REGIONAL OFFICES

PROCUREMENT OFFICES

SITE OFFICES

INSPECTION OFFICE

OVERSEAS OFFICES

NEW DELHI

VADODARA, CHENNAIKOLKATA

MUMBAI

29 LOCATIONS (INDIA)9 LOCATIONS (OVERSEAS)

10 LOCATIONS

LONDON, LIBYA ABU DHABI,ITALY, SAUDI ARABIA , QATAR,KUWAIT

PIPELINE DESIGN

SERVICES OFFERED BY EIL

Pipeline Design



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 EXPERIENCE1975

1979

1984

First major projectCrude Oil Loop Line for Oil India Ltd.

First major overseas project150 km Multi Product Pipelinefor Abu Dhabi National Oil Company

First major high pressure Gas Pipeline

Pipeline Design



Project - 1800 km Gas Transmission Networkfor GAIL

Over 40 major pipeline projects completed.

DESCRIPTION CLIENT YEAR SIZE LENGTH(KM)

SERVICES

HAZIRAHAZIRA--BIJAIPUR--BIJAIPURJAGDISHPUR (HBJ)

GAIL 1989 36“/30”/24”/18”

1800 NATURAL GAS

MAQTAMAQTA--ALAL--AIN PIPELINE

ADNOC 1992 30 ”/12” 166 NATURAL GAS

KANDLAKANDLA--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

VIZAGVIZAG--VIJAYWADA

HPCL 1998 18 ” 360 MULTIPRODUCT

JAMNAGARJAMNAGAR--LONI LPGPIPELINE

GAIL 2001 16”/14”/12”/8”/6

1235 LPG (LIQUIFIEDPETROLIUM GAS)

COCHIN – KARUR PIPELINE

PETRONET

2001 18 ”/14 ” 289 MULTIPRODUCT

PIPELINE DESIGNMajor Onshore Projects (Completed)

Pipeline Design




SERVICES

VIZAG – SECUNDERABAD LPGPIPELINE

GAIL 2002 12”/10” 600 LPG (LEQUIFIEDPETROLEUM GAS)

MANMADMANMAD--MANGALAYA PIPELINE

BPCL 2003 14 ” 358 MULTIPRODUCT

MANGALOREMANGALORE--BANGLORE

HPCL 2003 24 ”/20” 364 MULTIPRODUCT

DAHEJ – VIJAIPUR PIPELINE

GAIL 2003 42” 610 REGASIFIED LNG

INTER REFINERIES PIPELINESPROJECT, ABU DHABI

TAKREER 2004 10”

12”

16”

230

230

208

NAPHTHA,MULTIPRODUCT & SRR

MANGALAYAMANGALAYA--BIJWASANPIPELINE

BPCL 2006 16”/8” 775 MULTIPRODUCT

MUNDRAMUNDRA--DELHI PIPELINE

HPCL 2006 18”/16” 1050 MULTIPRODUCT

PIPELINE DESIGNMajor Onshore Projects (..contd) (Completed)

Pipeline Design




SERVICES

PUNE SOLAPUR PIPELINE HPCL 2007 14 ”/ 12” 182 / 161 MULTIPRODUCT

DABHOL PANVEL PIPELINEPROJECT (PH-(PH-I)


DABHOL PANVEL PIPELINEPROJECT (PH-(PH-II)


PIPELINE DESIGNMajor Onshore Projects ( contd)

(Completed)

Pipeline Design




SERVICES

BOMBAY HIGH URAN TRUNKLINE

(BUT)

ONGC 1979 30”/26” 200 x 2 CRUDE, GAS

SOUTH BASSEIN HAZIRATRUNKLINE

ONGC 1986 36” 220 GAS

HEERAHEERA--URAN TRUNK LINE

ONGC 1996 26 ”/24 ” 85 x 2 CRUDE, GAS

ICP - HEERA TRUNKLINE ONGC 1996 30”/22” 145 CRUDE

SECOND BASSEIN HAZIRATRUNKLINE

ONGC 1995 42” 245 GAS

MUMBAI HIGH URAN TRUNKLINE

(MUT)

ONGC 2005 30”/28”

12” to 22”

205 x 2

100

CRUDE, GAS

Pipeline Design



PIPELINE DESIGNMajor Offshore Projects

(Completed)

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


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

Pipeline Design



PIPELINE DESIGNMajor Onshore Projects

(Current)

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

PIPELINE DESIGN

SECTION-1

INTRODUCTION

Pipeline Design



PIPELINE DESIGN

CONTENTSINTRODUCTION

Modes of TransportationBenefits of Pipelines

PIPELINE DESIGN

Stages of Pipeline ProjectCodes and StandardsDesignInstallation, Testing & Commissioning

Pipeline Design



PIPELINE DESIGN

Oil and Gas Production in India

33 MMTPAOIL

(ONGC, OIL, CAIRN, RIL)

GAS 115 MMSCMD

Pipeline Design



(ONGC, GAIL, OIL, GSPC, RIL)

(MM

T)

Refining Scenario- India

302300

350

Capacity - 2006-07NOC – 105.5 MMTOthers- 43.5 MMT

PIPELINE DESIGN

70

149

235250

200

150

Pipeline Design


100

50

0

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

Source: India of –Working Group on P&NG peopleEngineersReport Ltd Delivering excellence throughSector for the XI Plan

(Actual) Year

PIPELINE DESIGN

Modes of Hydrocarbon Transportation - India

35%

30%

Pipelines 32%

Road Tankers

Rail Tankers

Water Carriers

32%

26%

10%

20%

15%

10%

5%

25%

0%% Share

Pipelines

Road Tankers

Rail Tankers

Water Carriers

Pipeline Design



Pipeline Design



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

En

ergy

Con

sum

pti

on in

% o

f en

ergy

Tra

nsp

orte

d

PIPELINE DESIGN

Energy SavingsEnergy Intensity for Various M ode s

4

0.8

0.51

3.2

0.81.1

2

0

1.5

1

0.5

3.5

3

2.5

2

Pipeline Design



Liquid-

Pipelines

Liquid-

Coastal

Liquid-

Trains

Liquid-

Trucks

Coal-

Trains

Coal-

Coastal

N.Gas-

Pipelines

Pipelines are the most energy efficient modes of transportation

ECONOMICS OF PIPELINE TRANSPORTATION

Transmission lossesLosses During Transportation

Rail/Road

Pipelines

Pipeline Design



0 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



PIPELINE DESIGN

Types of Pipelines

ONSHORE (LAND) & OFFSHORE(SUBMARINE) PIPELINES

Trunk Pipelines

Spur/ Branch Pipelines

Marine Offloading Terminals & Outfalls

Pipeline Design



Liquid Line s Gas Line sIte m D e s criptionSr o.

PIPELINE DESIGN

Capital cost: Typical breakupP e r c e ntag e of C a p ita l Cos t.

Pipeline Design



1

2

3

4

5

6

7

8

9

10

11

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

Lin e Pip e Ste e l Co s t

M a in lin e ma te ria ls

Co a tin g o f Pip e s

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

Ca th o d ic Pro te c tio n

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

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

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

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

S ubTotal

2%

33%

2%

11%

33%

1%

5%

5%

2%

5%

100%

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



PIPELINE DESIGN

Open sea Jetty

Pipeline Design



PIPELINE DESIGN

HBJ GAS PIPELINE NETWORK

UTTAR PRADESH

N

DADRI ANOLA

SHAHJAHANPUR

AURAIYA JAGDISHPUR

BABRALA

ANTA

INDIA

DELHI

RAJASTHAN

GADEPAN

BIJAIPUR

MADHYA PRADESH

JHABUA

KEY PLAN

LEGENDCOMPRESSOR STATION

RECEIVING TERMINAL

DESPATCH STATION

Pipeline Design


HAZIRA


GUJARAT

ARABIANSEA

PIPELINE DESIGN

Major Pipelines in India

Pipeline Design



PIPELINE DESIGN

Pipeline Construction Video

Video for Mangalore Bangalore Pipeline

Pipeline Design



PIPELINE DESIGN

SECTION-2

PIPELINE DESIGN

Pipeline Design



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



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

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 otherLiquids

OISDOISD--141 (2003) Design and Construction Requirements for CrossCross--CountryHydrocarbon Pipelines

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

OISDOISD--226 (2007) Natural Gas Transmission Pipelines and City Gas DistributionNetworks

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-OS-F101 Submarine pipeline systems

Other References Applicable Standards / Specs of ASME, API, NACE, MSS, BS andDIN

PIPELINE DESIGNMajor Codes & Standards

Pipeline Design



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 DESIGNMajor Codes & Standards

Pipeline Design



LIST OF SOFTWARES USED IN PIPELINEENGINEERING

PIPELINE STUDIO

TGNET

TLNET

HYSIS

Pipeline Design



CAESAR--II

AUTOPIPE

IPMCS

MRPACK

SORPS

PIPECALC

OFFPIPE

PRISE

PIPECROSS

Pipeline Design



PIPELINE DESIGN

Optimal sizes of various capacities

Economy of scale

Pipeline Design



PIPELINE DESIGN

Route Selection

Routing ConsiderationsPipeline lengthObstructions & Sensitive areasInstallation LimitationsCrossings

SurveysTopographicalGeo-technicalPopulation Density IndexSoil ResistivityCadastral

Pipeline Design



PIPELINE DESIGN

Typical Pipeline Route Map

BHATINDACh. 1012.67 km

IP-1 & IPS-FRANSISARCh. 855.01 km

PROPOSED PIPELINE

IPS-2JUDCh. 593.88 km

IPS-FGAILAWASCh. 527.87 km

LEGEND:

PROPOSED MUNDRA-BHATINDA PIPELINE (28" NB)

DESPATCH TERMINAL AND PUMPING STATION

IPS-1JORAWARPURACh. 313.63 km

IPS-FJHEKDACh. 226.72 km

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.

MUNDRACh. 0.00 km

PIPELINE DESIGN

Pipeline Design



PIPELINE DESIGN

Material Selection & Corrosion Control

MaterialsCarbon Steel (CS)

NACE Carbon Steel

CRA Clad CS

CS with internalCoatings

Non-MetallicMaterials

Pipeline Design



AssessmentNature of the Product

Design Life

Product Temperature

Corrosion ProtectionMaterial 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



PIPELINE DESIGN

Steel Pipe Wall Thickness Calculation

LIQUID PIPELINE

(ASME B 31.4, Cl. 404.1.2)

t = PiD2.S

where

Pi Internal design pressureS allowable stress

= 0.72 x E x SMYSD Outside Diameter of pipet pressure design wall

thickness

GAS PIPELINE

(ASME B 31.8, Cl. 841.11)

P = 2St FETD

whereP Design pressureS Specified minimum yield

strengthD Nominal OD of pipet Nominal wall thickness

F Design factor

Pipeline Design



E Weld joint factor E Longitudinal joint factorT Temperature de-rating factor

LOCATION CLASS DESIGN FACTOR, F

Location Class 1 0.72




Location Class Classification

Location Class 1 : ≤10 buildingsLocation Class 2 : > 10 and < 46 buildings

Location Class 3 : ≥46 buildingsLocation Class 4 : Multistory buildings

PIPELINE DESIGN

Basic Design Factor for Gas Pipelines

Pipeline Design



PIPELINE DESIGN

Line Pipe Selection

Line Pipe Selection Parameters

Thickness and Grade

Selection

Handling and

Transportation (d/t ratio)

Type of LinePipe

Installation Requirements

Pipeline Design



Type of Line Pipes

Seamless

Electric Welded

Longitudinal Seam

Submerged-Arc Welded

(LSAW)

Helical Seam Submerged-

Arc Welded

(HSAW)

PIPELINE DESIGN

Line Pipe Application

Submarine Pipelines

Seamless Pipes(upto & including 16”)

LSAW Pipes(18” & above)

Pipeline Design



Onshore Pipelines

Seamless Pipes(upto & including 8”)

LSAW Pipes(16” & above)

HSAW Pipes(18” & above)

EW Pipes(4” - 18”)

Pipeline Design



PIPELINE DESIGNManufacturing of Helical Pipes

Pipeline Design



Pipeline Design



PIPELINE DESIGN

Anti-corrosive CoatingsCoal Tar Enamel Coating (BS 4164, AWWA C203)

PrimerTwo layers of coal tar enamel & glass fibre Inner wrapOne layer of coal tar impregnated outer wrapCoating thickness 4.7mm

3 Layer PE/ PP Coating (DIN 30670)First layer of Fusion bonded epoxySecond layer of extruded adhesiveThird layer of extruded PE/ PPCoating thickness 2.0 to 3.7 mm

Fusion Bonded Epoxy Coating (CSA Z245.20)350--500 micron thick single layer coating600--800 micron thick dual layer coating

PIPELINE DESIGN

3 Layer PE Coating Application

Pipeline Design



Pipeline Design



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



PIPELINE DESIGN

Sectionalizing ValveSpacing Gas Pipelines

ASME B 31.8 for GaspipelinesASME B 31.4 for LiquidPipelines

Location

Location Class 1

Location Class 2

Location Class 3

Location Class 4

32 km (20 miles)

24 km (15 miles)

16 km (10 miles)

8 km (5 miles)

Pipeline Design



Pollution ConcernsStatutory RequirementsPrevention of InventoryLossApproachability of ValveStation

LPG Pipelines

Industrial, 12 km (7.5 miles)

Commercial &

Residential Areas

Pipeline Design



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



PIPELINE DESIGNPlug valve

Pipeline Design



PIPELINE DESIGNCheck valve

Pipeline Design



PIPELINE DESIGN

Major Engineering Deliverables

Design Reports

Design Basis

Route Selection Report

Wall Thickness Report

Seismic Design Report

Crossing Design Report

Pipeline Design



Drawings

Route Map

Pipeline Schematic

Alignment Sheets

SV Station Layout

Equipment Layout

Piping GeneralArrangement Drawings

MA

TC

H L

INE

FO

R C

ON

T. R

EFE

R D

WG

NO

.452

9-10

-16-

71-9

005

TO

TO

PE

UR

TH

AP

AM

RU

ND

A

EL

EC

TR

CH

.118

4IC

LIN

E

8.88

m

DR

AIN C

H.1

182 4

. 62 9

m

MA

TC

HL

I NE

F OR

CO

NT

.RE

FER

DW

G

NO

.452

9 -1 0

-16-

71-9

0 03

CA

NA

LC

H 1

0691

.6m

/RL

35.

411m

RO

AD

CH

107

87.0

2m/R

L 3

2.58

7m

CA

RT

TR

AC

K

CH

134

92.6

1m/R

L 3

3.62

2m

DR

AIN

CH

106

64.7

1m/R

L 3

3.36

6m

DR

AIN

CH

118

24.6

3m/R

L 2

4.34

1m

RO

AD

CH

120

60.8

8m/R

L 2

4.60

4m

33.3

66

35.4

11

33.5

60

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

41

24.6

75

24.8

28

24.6

04

23.6

67

22.1

75D

RA

IN

C H

121

15.3

4m/R

L 2

2.17

5m

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

CA

NA

LC

H 1

4027

.73m

/RL

39.

741m

R O

AD

C H

140

40.2

7m/R

L 4

2.49

1m

7 5. 0

3 4

37.3

25

1 98 .

6 36

1 96 .

9 62

1 42 .

1 34

1 76 .

4 63

1 14 .

7 47

1 41 .

5 22

1 21 .

6 60

2 24 .

9 69

2 99 .

2 54

2 17 .

5 39

1 82 .

1 17

1 66 .

7 80

2 48 .

9 29

2 37 .

6 76

4 4. 1

5 2

2 6. 8

9 4

2 1. 1

9 9

7 4. 2

1 9

3 9. 3

6 9

3 7. 1

7 5

3 8. 7

4 9

9 0. 3

4 2

6 6. 5

9 7

2 4. 2

4 6

2 0. 1

0 1

3 4. 3

6 6

9 4. 1

4 1

7 7. 7

1 4

4 8. 5

2 1

10.6

21

1 0. 6

6 5

1 1. 9

3 91 1

. 96 0

1 1. 9

7 21 1

. 98 4

1 0. 6

9 2

1 0. 7

1 3

1 0. 7

8 7

1 0. 9

8 6

1 1. 0

2 5

1 1. 0

6 2

1 1. 2

5 9

1 1. 4

0 1

1 1. 5

7 8

1 1. 6

1 7

1 2. 2

3 0

1 2. 0

6 1

1 2. 0

8 1

1 1. 8

2 5

1 1. 8

4 9

1 2. 1

1 5

1 2. 4

5 5

1 1. 7

5 8

1 2. 7

5 4

1 2. 8

4 8

1 3. 0

6 6

1 3. 2

4 8

1 3. 4

1 5

1 3. 4

9 3

1 3. 7

4 2

1 3. 9

7 9

1 2. 5

4 3

1 0. 6

2 1

1 0. 6

6 5

1 0. 6

9 2

1 0. 7

1 3

1 0. 7

8 7

1 0. 9

8 6

1 1. 0

2 5

1 1. 0

6 2

1 1. 2

5 9

1 1. 4

0 1

1 1. 5

7 8

1 1. 6

1 7

1 1. 7

5 8

1 1. 8

2 5

1 1. 8

4 9

1 1. 9

3 9

1 2. 0

6 1

1 2. 0

8 1

1 2. 1

1 5

1 2. 2

3 0

1 2. 4

5 5

1 2. 7

5 4

1 2. 8

4 8

1 3. 0

6 6

1 3. 2

4 8

1 3. 4

1 5

1 3. 4

9 3

1 3. 7

4 2

1 3. 9

7 9

1 4. 0

2 81 4

. 04 0

1 4. 1

1 51 4

. 13 5

1 4. 1

1 51 4

. 13 5

1 4. 0

2 81 4

. 04 0

1 9. 5

8 843

.684

43.0

34

CA

RT

TR

AC

K

CH

141

15.3

1m/R

L 4

3.68

4m

AM

ND

RA

.71

DR H.10

TO CH

GUTL

AT

-SA

TO AMRUT

RAM

TRAC

PIPELINE DESIGN

Typical Pipeline Alignment SheetINTERSECTION POINTS(IP/TP)

DEFLECTION ANGLE38°4'58''(R)

TP50

29°8'20''(L)

IP50/1 TP51 IP51/1 TP52

5°18'55''(R) 8°2'3''(L)

TP53

37°0'54''(L)

TP54

13°54'57''(R) 11°25'7''(L)

TP55 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)

IP64/1TP64

5°18'12''(R)

TP65

0m

IP50/1

TP51

CH. 10712.803m

CH. 10687.604m

IP51/1

TP63

CH. 13741.534m

TP65

CH. 14134.896m

IP64/1

CH.14044.732m

TP64

CH. 13979.211m

TBMW40 (RL37.514m)

TP50

CH. 10620.558m

RAIWADALEFT CANAL

TOPE

A

RIT

AM

APU

M

EARTHENEMBANKMENT

LOW LYINGAREA

TOST

EHIG

HWAY

BBAV

ARAM

STATE, DISTRICT ANDMANDAL

TO IRUVADA

TELEPHONE LINECH.14134.896m

METALLED ROAD(ASPHALTIC)

CH.14115.309m

ELEC. LINE440VCH.14132.231m

DISTANCE BETWEENTP& IP's(m)

DISTANCE AS PER GROUNDPROFILE

67.046 25.199 85.000

67.049 25.200 85.284

187.855

187.993

76.544

76.618

339.096

339.126

176.463

176.478

38.749

38.853

322.708

322.772

141.760

141.845

45.000

45.093

104.113

104.624

224.969

225.022

393.395

393.407

218.000

218.014

348.437

348.444

326.642

326.679

237.677

237.707

65.521

65.728

90.164

90.390

SCALE:HORIZONTAL 1:5000VERTICAL 1: 500

37

35

33

31

29

27

25

23

21

45

43

41

39

TP54

CH. 11401.298mELECTRICLINE 440V

CH.11018.117m

TP55

CH. 11577.761m

TP56

CH. 11616.510m

AIN 664

C

(UNLINED)

CH. 10691.604m

TP52

CH. 10985.658mTP53

CH. 11062.202m

TP60

CH. 12455.060m

K

CART 492.606mCH.13

TP61

CH. 12848.455m

TP62

CH. 13414.892m

TP58

CH. 12080.978m

IP58/1

CH. 12125.978m

EARTHEN EMBANKMENT

IP61/1

CH. 13066.455m

KAJUGARDEN RICEFIELDS

TBMW49 (RL25.138m)

TEMP. HUT ONC/L

HPCLCH. 15.00Km HPCLCH. 16.00Km

HPCLCH. 17.00Km

VILLAGEBOUNDARY

AMRUTAPURAM IRUVADA

INTA

CH. 10797.803m

A GRAVEL ROAD

CH.10787.022m

TP57

CH. 11939.218m

SV-1 OF GAIL

CH.11960.218 m

DRAIN

CH.12115.344m

HAPU

TP59

CH. 12230.091m

K

K

GRAVEL ROAD

CH.12060.877mOPEN WELL 6mDIA

7.648mFROMC/L

CH.11648.136m

OPEN WELL 6mDIA

8mFROMC/L

CH11577.761m

PUMP HOUSE 4mFROMC/L

HIGH TENSIONLINE

12.2m HIGH& 550KV

CH.12747.397m

DRAIN

CH.12903.743m

K

TBMW57(RL42.533m)

RAIWADALEFT CANAL

(UNLINED)

CH.14027.732mGRAVEL ROAD

CH.14040.275m

Pipeline Design



PIPELINE DESIGN

Typical P&ID

Pipeline Design



PIPELINE DESIGNTypical GA DRAWING

Pipeline Design



Pipeline Design



PIPELINE DESIGNMajor Engineering Deliverables

TendersSurvey TenderPipe Coating TenderPipeline Installation Tender

Material ProcurementLine PipesValves & ActuatorsScraper Traps, QOEC, Pig SignallersFlow Tees & Insulating JointsInduction BendsFlow metersPumps & CompressorsOFC cables

PIPELINE DESIGN

Installation, Testing & Commissioning

RoU Grading & Trenching Stringing of Linepipe

Pipeline Design



PIPELINE DESIGN


Welding & NDT :Edge PreparationInternal / External Line-up ClampsManual / Automatic WeldingNDT (X-Ray / UT / MPI etc.)

Pipeline Design



PIPELINE DESIGN


Lowering & BackfillingField Joint CoatingHeat Shrink SleevesCold applied tapes

Pipeline Design



Pipeline Design



PIPELINE DESIGN

Pipeline Crossings

Crossing Installation

CrossingsRiver, Canal, Road & RailUtility Crossing

MethodologiesOpen-Cut MethodTrench-less Method

HorizontalDirectional DrillingJacking and BoringMicro tunneling

PIPELINE DESIGN

The conventional HDD operations for river crossings.

Pipeline Design



Boring Across Road crossings.

Pipeline Design



Boring Across Road crossings, showing Auger used for Boring

Pipeline Design



Pipeline Design



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 boringmachineCarrier pipe inserted in jacking pipe

ADVANTAGES:Micro-tunnelling can be used wherever HDD cannot be doneCrossing of Rivers with gravels, cobbles & bouldersInstallation of more than one pipe in the tunnelPrecise installation and Minimum space at both endsCan be done in curved path also

PIPELINE DESIGN

Schematic Diagram

Pipeline Design



PIPELINE DESIGN

Pipeline Installation using Micro-tunnellingLong Distance Micro Tunnelling

Pipeline Design



PIPELINE DESIGN

Overview of Micro tunneling

Pipeline Design



PIPELINE DESIGN

Testing & CommissioningTESTING

Gauging and PiggingTest PressureTest Medium

DRYINGSwabbingMethanol DryingSuper Dry AirMethodVacuum Drying

COMMISSIONINGNitrogen PurgingProduct Charging

Pipeline Design



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

PIPELINE DESIGNPigging

RequirementsPipeline Cleaning

Displacement

Internal Inspection

Batching

Types of PigsBrush pigs

Gauge Pigs

Spheres

Intelligent Pigs

Pipeline Design



Cleaning pigs Gauge Pigs Spheres Intelligent Pig(MFL)

PIPELINE DESIGN

RECENT DEVELOPMENTS

TECHNICAL IMPROVEMENTSAutomatic 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



Description LSAW HSAW

Method ofManufacture

UOE/COE/JCO/3 roll bending Formed by Twisting of Coil

Weld Length Equal to pipe joint length Approximately 1.5 to 2 times thelength of pipe joint

Position of weld Longitudinal – positioned inupper quadrant duringconstruction

Spiral – present all around thepipe

Corrosion Coating Specified thickness throughoutentire body.

Weld seam is tracked to ensurecoating thickness on weld seam

Thickness normally increased allover the body, resulting inproportional increase in coatingcost by 15-15-20%

Geometry Controlled to the desired levelwith cold expansion

Controlled during forming onlyand no cold expansion is carriedout

PIPELINE DESIGN

Comparison of LSAW & HSAW Pipes

Pipeline Design



CTE 3LPE 3LPP FBE

Service Conditions

oTemperature, C Upto 45 Upto 65 Upto 110 Upto 110

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

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 toIndentation

Poor Very Good Excellent Fair

Resistance to Peel Fair Excellent Superior than PE -

Resistance to SoilStresses

Fair Excellent Excellent Excellent

Elongation Fair Excellent Excellent -

PIPELINE DESIGN

Coating Comparison

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 duringhandling &transportation

High Low Low High

Ease of Field Repair Difficult Easy for small repair,

Cumbersome forlarger repair

Easy for small repair,


Easy for small repair,


PIPELINE DESIGN

Coating Comparison

Pipeline Design



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