Pipeline Laying proceedure

45
PIPELINE ACTIVITIES BY V.BHANU CHANDER V.BHANU CHANDER TIRUPATI, INDIA

description

this presentation describes the basic pipeline laying proceedure.

Transcript of Pipeline Laying proceedure

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PIPELINE ACTIVITIES

BY V.BHANU CHANDERV.BHANU CHANDERTIRUPATI,INDIA

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Pi liPi liPipe line :Pipe line :

TransportationTransportation ofof liquidsliquids andand gasesgases fromfrom oneoneplaceplace toto anotheranother placeplaceplaceplace toto anotheranother placeplace..

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Survey

Pipe line activity :

Unloading & stocking of pipes at site

Marking

Trench excavation

Blastingcontd…

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Sand bedding

Pi l iPipe lowering

Laying, joining

Back filling

Sand encasing

S i l fi iSpecials fixing

contd…

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Pedestals, thrust blocks & valve chambers

Hydro testing

i i iCommissioning

Final measurement

Reconciliation

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TYPE OF PIPES

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Mild steel (MS)

Glass reinforcement plastic (GRP)Glass reinforcement plastic (GRP)

Ductile iron (DI)( )

Cast iron (CI)

High density poly ethylene (HDPE)

Poly vinyl chloride (PVC)

ContdContd…

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Pre stressed concrete (PSC)

Reinforcement cement concrete (RCC)

Asbestos cement pressure (AC)Asbestos cement pressure (AC)

Bar wrapped steel cylinder (BWSC)pp y ( )

Galvanized iron (GI)

Low alloy pipe (LA)

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PVC pipe MS pipe GI pipe

GRP pipe BWSC pipe CI pipeGRP pipe BWSC pipe CI pipe

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HDPE i RCC i DI iHDPE pipe RCC pipe DI pipe

LA pipe PSC pipe AC pipeLA pipe PSC pipe AC pipe

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TRENCH EXCAVATION

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Obtain work permit before starting excavation work.

Marking is to be made

Excavate trench up to required level with free working

The side slopes of cutting shall generally have the followingThe side slopes of cutting shall generally have the following slopes for stability.

slope for excavation inslope for excavation in 1:1 clay, muram & boulders etc1:2 hard muram

NOTE: Slope not required for soft & hard rock

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TRANSPORTATION TRANSPORTATION

OF

MATERIAL TO SITE

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Pipes shall be transported to the site of laying and stacked along the routealong the route

Padding shall be placed between coated pipes and timber toPadding shall be placed between coated pipes and timber to avoid damage to the coating

Suitable gap during pipe stacking should be left at proper intervals to permit access from one side to the other

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Unloading & stocking of material :Unloading & stocking of material :

Each pipe & special should be properly stacked at site in such a manner so as not to distort their circularity orsite in such a manner so as not to distort their circularity or cause any damage to their outer coating.

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PIPE HANDLING

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manual pipe handling :B f h dli th iBefore handling the pipe,work men should wear helmet and gloveshelmet and gloves

1. Ropes used to lift the material must be in good condition, p g ,and it should not be let over sharp edges

2. Ensure that the persons are moved away from the pit while placing the pipe (if it is heavy)

3. while handling materials in the wet season, ensure that the materials are free from slush as it may cause slipping.

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Pipe handling by machinery

Slings should be in good condition and free from defects,

Ensure proper clamping of slings, these are provided on same direction on free lengthg

Ensure proper visibility for the crane.p p y

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C.I & D.I PIPES

LOWERING, LAYING &JOINING

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Pipes should be lowered slowly in to the trench by means of chain pulley block and tripod stand or cranes or with the p y phelp of ropes.

Rubber gaskets shall be inserted into the groove in theRubber gaskets shall be inserted into the groove in thesocket. Spigot end shall be lubricated with good quality ofgrease or oil, then the spigot shall be slipped into socket bymeans of jack on the other endmeans of jack on the other end.

Spigot ends of all pipes shall face up stream irrespective of p g p p p pthe direction of water flow.

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GRP PIPESGRP PIPES

LOWERING, LAYING

AND

JOININGJOINING

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Lowering and laying :Pi h ll b l id i d diti d d i tPipe shall be laid in dry condition and under no circumstancesthey shall rest on sludgy bedding. Pipes shall rest continuouslyon the bottom of the trench.

Clearance of approximately 100mm in depth and width equall h f h ll l 30 b h id h ll bto length of the collar plus 30mm on both sides shall be

provided at the joint which shall be refilled from sides after thejoint is made.j

The pipe should be lowered in to the trenches either by pulleyor by means of two ropes. For road crossing or river crossingthe pipe shall laid 2.0mtr. Below the bed level. The pipeshould be encased with 300mm thick sand.

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Joining :

1. Spigot and socket and socket joint with double water tightbb i k t kirubber ring gasket packing

2. Double socket coupling joint with water tight rubber ring p g j g ggasket packing

3. Flanged joint is used for connecting the valves, the flanged joint is made from the same materials as the pipe

4. End pipes should not kept open, the ends shall be covered up either by suitable cap or plug or double layer of gunny bags.

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GRP joint with Spigot & socket end

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M.S PIPESLOWERING, LAYING, JOINING &

PAINTINGPAINTING

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Before Laying, M.S pipes should be coated with cement or PaintingPainting

1. surface cleaning :

The pipe should be cleaned before painting with specialepoxy thinner. This avoids oil, Greece marks on the pipe.Due to these marks the paint wasn't sticking. Inside dust canbe removed by using compressed airbe removed by using compressed air.

2. primary coating

After surface cleaning, first primer coating is necessary. Forthis purpose zinc phosphate primer is combined withactivator in 6:1 ratio. Zinc phosphate primer is component a& i i b& activator is component b, so

primer = component a + component

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3. Out side coating :After primary coating, out side of pipe painted with

l hi h i bi d i h i i 4 1epoxy coal tar which is combined with activator in 4:1ratio.

4. Inside :

d d d f i id i i iFood grade epoxy used for inside painting resistscorrosion, this is the combination of resin & cure in 1:1ratio.

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Lowering, laying and joining of MS pipes:Lowering, laying and joining of MS pipes:

Before welding the pipe faces shall be cleaned by scraping Before welding the pipe faces shall be cleaned by scraping by wire brushes by wire brushes

MS pipe provided with cement mortar / apoxy paintingMS pipe provided with cement mortar / apoxy paintingMS pipe provided with cement mortar / apoxy painting MS pipe provided with cement mortar / apoxy painting in lining and coatingin lining and coating

Th d f MS i h ll h b l d d f ldiTh d f MS i h ll h b l d d f ldiThe ends of MS pipes shall have beveled ends for weldingThe ends of MS pipes shall have beveled ends for welding

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While assembling the pipes shall be close to uniform gapWhile assembling the pipes shall be close to uniform gapWhile assembling, the pipes shall be close to uniform gap.While assembling, the pipes shall be close to uniform gap.(Gap depends up on thickness) electrodes shall be conform (Gap depends up on thickness) electrodes shall be conform to is 814to is 814--1991 i.e, e1991 i.e, e--60136013

MSMS pipespipes areare manufacturedmanufactured eithereither byby electroelectro resistanceresistanceweldingwelding oror submergedsubmerged arcarc weldingwelding processprocess longitudinallylongitudinally ororgg gg gg pp g yg yspirallyspirally weldedwelded

Manual metal arc welding with covered electrodesManual metal arc welding with covered electrodesManual metal arc welding with covered electrodes.Manual metal arc welding with covered electrodes.

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What is metal arc welding :In metal arc welding a metal rod is used as one

electrode during the welding operation this metal electrode ismelted by the heat of the arc and is fused with the base metal.Welding defects :1. Lack of penetration, 2. Slag inclusion,3. Under cut,4 P f i4. Poor fusion,5. Porosity,6 Weld crack6. Weld crack,7. Spatter,8. Wrapping & distortion.pp g

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HDPE PIPE

LAYING & JOINING

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FusionFusion weldingwelding isis commonlycommonly usedused inin HDPEHDPE andand isis aapermanentpermanent typetype ofof jointjoint

TheThe pipespipes shallshall bebe brushedbrushed throughthrough outout toto removeremove anyany soilsoildepositeddeposited oror stonestone theirtheir inin

PipesPipes shallshall bebe laidlaid inin drydry conditioncondition andand underunder nonocircumstancescircumstances theythey shallshall restrest onon slushyslushy beddingbeddingyy yy gg

ClearanceClearance ofof requiredrequired depthdepth && widthwidth onon bothboth sidessides shallshallbebe providedprovided atat thethe jointjoint whichwhich shallshall bebe refilledrefilled fromfrom sidessidesbebe provided,provided, atat thethe jointjoint whichwhich shallshall bebe refilledrefilled fromfrom sidessidesafterafter thethe jointjoint isis mademade

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ForFor roadroad crossingcrossing oror riverriver crossingcrossing thethe pipepipe shallshall bebe laidlaid 22metermeter belowbelow thethe bedbed levellevel andand encasingencasing shouldshould bebe donedonemetermeter belowbelow thethe bedbed levellevel andand encasingencasing shouldshould bebe donedone

PipePipe afterafter transportingtransporting toto thethe exactexact placeplace shouldshould bebe cutcut squaresquarebyby thethe hacksawhacksaw bladeblade

TThehe faceface ofof thethe pipepipe shouldshould bebe slightlyslightly scrappedscrapped priorprior toto thethep pp p g yg y pppp ppfusionfusion weldingwelding toto removeremove oxidizedoxidized layerlayer

EnsureEnsure thethe levelingleveling ofof pipespipes isis maintainedmaintained atat thethe timetime ofof fusionfusionEnsureEnsure thethe levelingleveling ofof pipespipes isis maintainedmaintained atat thethe timetime ofof fusionfusionweldingwelding

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TheThe heatingheating mirrormirror // panpan shouldshould bebe heatedheated upup toto 200200 degdeg.. ccandand thethe surfacesurface ofof thethe panpan shouldshould bebe 210210 ++ oror –– 55 degdeg.. CC

TheThe heatingheating panpan shouldshould bebe metallicmetallic plateplate whichwhich isis heatedheated upuptoto thethe requiredrequired temperaturetemperature eithereither byby electricalelectrical coilcoil embeddedembeddedtoto thethe requiredrequired temperaturetemperature eithereither byby electricalelectrical coilcoil embeddedembeddedinsideinside oror byby blowblow torchtorch

TheThe fusionfusion weldingwelding ofof pipepipe shouldshould bebe heldheld inin eithereither sideside ofofTheThe fusionfusion weldingwelding ofof pipepipe shouldshould bebe heldheld inin eithereither sideside ofofthethe heatingheating mirrormirror // panpan withwith TeflonTeflon paperpaper onon eacheach sideside

TheThe contactcontact pressurepressure ofof 00..22 kg/cmkg/cm22 inin eithereither sideside ifif thethe pipepipeshouldshould bebe maintainedmaintained

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InitialInitial heatingheating timetime forfor achievingachieving thethe moltenmolten rim,rim, variesvaries fromfrom11 toto 55 minmin dependingdepending onon thethe pipepipe wallwall thickthick && sizesize..

PipesPipes shouldshould bebe removedremoved fromfrom thethe heatingheating mirrormirror // pan,pan, whenwhenPipesPipes shouldshould bebe removedremoved fromfrom thethe heatingheating mirrormirror // pan,pan, whenwhenthethe rimrim ofof thethe moltenmolten materialmaterial isis formedformed andand ensureensure thatthat thethe rimrimformationformation isis notnot excessiveexcessive..

ImmediateImmediate jointjoint shouldshould bebe mademade byby thethe applicationapplication ofofmoderatemoderate pressurepressure ofof approxapprox.. 11 toto 22 kg/cmkg/cm22 forfor 22 toto 33 secsec..

whilewhile joining,joining, thethe pressurepressure shouldshould bebe maintainedmaintained untiluntil thethejointjoint isis lukeluke warmwarm..jointjoint isis lukeluke warmwarm..

AfterAfter thethe pressurepressure isis relieved,relieved, thethe jointjoint shouldshould bebe allowedallowed totocoolcool completelycompletelycoolcool completelycompletely

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Back Filling :Back Filling :Back Filling :Back Filling :

BackBack fillfill withwith excavatedexcavated soilsoil shouldshould bebe freefree fromfromi di d hh ll ff bbi hbbi h t blt bl iicinders,cinders, ashes,ashes, slag,slag, refuse,refuse, rubbish,rubbish, vegetablevegetable oror organicorganic

metal,metal, lumpylumpy oror frozenfrozen metal,metal, bouldersboulders rocks,rocks, otherother materialsmaterialswhichwhich inin thethe opinionopinion ofof anyany authority,authority, isis deleteriousdeleterious..

Concrete slabs over pipes :Concrete slabs over pipes :

whenwhen pipespipes areare laidlaid belowbelow roadsroads (which(which maymay bebesubjectedsubjected toto heavyheavy traffictraffic loads),loads), trenchestrenches shouldshould bebe coveredcovered

ithith i f di f d tt l bl bwithwith reinforcedreinforced concreteconcrete slabsslabs

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GRP Lamination Details

Materials used in the process:Materials used in the process:

1. Grinding wheels, (machine)2. Surface,3. Robin,4. Matt, ,5. Resin, 6. Hardener,7 Aerosol powder7. Aerosol powder,

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L i ti PLamination Process :

1. First, grind the damaged portion with grinding wheel. , g g p g g

2. After that , mix the aerosol powder with hardener, this mixture has to be put on damaged portion hardener ismixture has to be put on damaged portion, hardener is used to set quickly that joint.

3. Surface is very soft material, this has to put on that portion & paste with resin which is used for sticking & hardening.

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4. Matt & robin are the strength of that lamination process these both used one by one on damaged portion.

5. The robin & matt used up to 7 times6. Resin pour on robin & matt

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Hydro Testing:

1. After Completion of each section of pipeline, it shall be

tested for water tightness before being covered intested for water tightness before being covered in.

2. This can be done by closing each end by means of

valve, blank flange, cap or plug and filling the pipe with

water.

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3. The pressure shall be raised gradually by means of a hydro testing pump till the pressure is at least one and half timesth kithe working pressure.

4. A pressure to be specified by the authority for a duration of one hour.

NOTE : In the test pressure drops after one hour

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