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
ENGINEERSENGINEERSINDIA LIMITEDINDIA LIMITED
EPC and Total Solutions EPC and Total Solutions Consultancy OrganizationConsultancy Organization
Pipeline Design
Slide Number - 3 of 77 Engineers India Ltd – Delivering excellence through people
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 OFFICESEIL OFFICES
Pipeline Design
Slide Number - 5 of 77 Engineers India Ltd – Delivering excellence through people
PIPELINE DESIGNPIPELINE 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 DESIGNPIPELINE 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 DESIGNPIPELINE DESIGN
DESCRIPTIONDESCRIPTION CLIENTCLIENT YEARYEAR SIZESIZE LENGTH LENGTH (KM)(KM)
SERVICESSERVICES
HAZIRA-BIJAIPUR-HAZIRA-BIJAIPUR-JAGDISHPUR (HBJ)JAGDISHPUR (HBJ)
GAILGAIL 19891989 36“/30”/24”/18”36“/30”/24”/18” 18001800 NATURAL GASNATURAL GAS
MAQTA-AL-AIN PIPELINEMAQTA-AL-AIN PIPELINE ADNOCADNOC 19921992 30 ”/12”30 ”/12” 166166 NATURAL GASNATURAL GAS
KANDLA-BHATINDAKANDLA-BHATINDA IOCLIOCL 19961996 22”/14”/10”22”/14”/10” 14431443 MULTIPRODUCTMULTIPRODUCT
GAS REHABILITATION & GAS REHABILITATION & EXPANSION PROJECT EXPANSION PROJECT (GREP)(GREP)
GAILGAIL 19981998 36 ”36 ” 505505 NATURAL GASNATURAL GAS
MUMBAI – MANMADMUMBAI – MANMAD BPCLBPCL 19981998 18 ”18 ” 260260 MULTIPRODUCTMULTIPRODUCT
VIZAG-VIJAYWADAVIZAG-VIJAYWADA HPCLHPCL 19981998 18 ”18 ” 360360 MULTIPRODUCTMULTIPRODUCT
JAMNAGAR-LONI LPG JAMNAGAR-LONI LPG PIPELINEPIPELINE
GAILGAIL 20012001 16”/14”/12”/16”/14”/12”/8”/68”/6
12351235 LPG (LIQUIFIED LPG (LIQUIFIED PETROLIUM GAS)PETROLIUM GAS)
COCHIN – KARUR PIPELINECOCHIN – KARUR PIPELINE PETRONETPETRONET 20012001 18 ”/14 ”18 ”/14 ” 289289 MULTIPRODUCTMULTIPRODUCT
Major Onshore Projects (Completed)
Pipeline Design
Slide Number - 8 of 77 Engineers India Ltd – Delivering excellence through people
PIPELINE DESIGNPIPELINE DESIGN
DESCRIPTIONDESCRIPTION CLIENTCLIENT YEARYEAR SIZESIZE LENGTH LENGTH (KM)(KM)
SERVICESSERVICES
VIZAG – SECUNDERABAD LPG VIZAG – SECUNDERABAD LPG PIPELINEPIPELINE
GAILGAIL 20022002 12”/10”12”/10” 600600 LPG (LEQUIFIED LPG (LEQUIFIED PETROLEUM GAS)PETROLEUM GAS)
MANMAD-MANGALAYA PIPELINEMANMAD-MANGALAYA PIPELINE BPCLBPCL 20032003 14 ”14 ” 358358 MULTIPRODUCTMULTIPRODUCT
MANGALORE-BANGLOREMANGALORE-BANGLORE HPCLHPCL 20032003 24 ”/20”24 ”/20” 364364 MULTIPRODUCTMULTIPRODUCT
DAHEJ – VIJAIPUR PIPELINEDAHEJ – VIJAIPUR PIPELINE GAILGAIL 20032003 42”42” 610610 REGASIFIED LNGREGASIFIED LNG
INTER REFINERIES PIPELINES INTER REFINERIES PIPELINES PROJECT, ABU DHABIPROJECT, ABU DHABI TAKREERTAKREER 20042004
10” 10”
12”12”
16”16”
230230
230230
208208
NAPHTHA, NAPHTHA, MULTIPRODUCT & SRRMULTIPRODUCT & SRR
MANGALAYA-BIJWASAN MANGALAYA-BIJWASAN PIPELINEPIPELINE
BPCLBPCL 20062006 16”/8”16”/8” 775775 MULTIPRODUCTMULTIPRODUCT
MUNDRA-DELHI PIPELINEMUNDRA-DELHI PIPELINE HPCLHPCL 20062006 18”/16”18”/16” 10501050 MULTIPRODUCTMULTIPRODUCT
Major Onshore Projects (..contd) (Completed)
Pipeline Design
Slide Number - 9 of 77 Engineers India Ltd – Delivering excellence through people
DESCRIPTIONDESCRIPTION CLIENTCLIENT YEARYEAR SIZESIZE LENGTH LENGTH (KM)(KM)
SERVICESSERVICES
PUNE SOLAPUR PIPELINEPUNE SOLAPUR PIPELINE HPCLHPCL 20072007 14 ”/ 12”14 ”/ 12” 182 / 161182 / 161 MULTIPRODUCTMULTIPRODUCT
DABHOL PANVEL PIPELINE DABHOL PANVEL PIPELINE PROJECT (PH-I)PROJECT (PH-I)
GAILGAIL 20072007 30”30” 187187 REGASIFIED LNGREGASIFIED LNG
DABHOL PANVEL PIPELINE DABHOL PANVEL PIPELINE PROJECT (PH-II)PROJECT (PH-II)
GAILGAIL 20072007 30”30” 120120 REGASIFIED LNGREGASIFIED LNG
PIPELINE DESIGNPIPELINE DESIGNMajor Onshore Projects (…contd)
(Completed)
Pipeline Design
Slide Number - 10 of 77 Engineers India Ltd – Delivering excellence through people
DESCRIPTIONDESCRIPTION CLIENTCLIENT YEARYEAR SIZESIZE LENGTH LENGTH (KM)(KM)
SERVICESSERVICES
BOMBAY HIGH URAN TRUNKLINEBOMBAY HIGH URAN TRUNKLINE
(BUT)(BUT)
ONGCONGC 19791979 30”/26”30”/26” 200 x 2200 x 2 CRUDE, GASCRUDE, GAS
SOUTH BASSEIN HAZIRA SOUTH BASSEIN HAZIRA TRUNKLINETRUNKLINE
ONGCONGC 19861986 36”36” 220220 GASGAS
HEERA-URAN TRUNK LINEHEERA-URAN TRUNK LINE ONGCONGC 19961996 26 ”/24 ”26 ”/24 ” 85 x 285 x 2 CRUDE, GASCRUDE, GAS
ICP - HEERA TRUNKLINEICP - HEERA TRUNKLINE ONGCONGC 19961996 30”/22”30”/22” 145145 CRUDECRUDE
SECOND BASSEIN HAZIRA SECOND BASSEIN HAZIRA TRUNKLINETRUNKLINE
ONGCONGC 19951995 42”42” 245245 GASGAS
MUMBAI HIGH URAN TRUNKLINEMUMBAI HIGH URAN TRUNKLINE
(MUT)(MUT)
ONGCONGC 20052005 30”/28”30”/28”
12” to 22”12” to 22”
205 x 2205 x 2
100100
CRUDE, GASCRUDE, GAS
IN-FIELD PIPELINES OF BOMBAY-HIGH, BASSEIN, HEERA, NEELAM, PANNA, MUKTA.
PIPELINE DESIGNPIPELINE DESIGNMajor Offshore ProjectsMajor Offshore Projects
(Completed)
Pipeline Design
Slide Number - 11 of 77 Engineers India Ltd – Delivering excellence through people
DESCRIPTIONDESCRIPTION CLIENTCLIENT YEARYEAR SIZESIZE LENGTH LENGTH (KM)(KM)
SERVICESSERVICES
VIJIPUR DADRI BAWANA PIPELINEVIJIPUR DADRI BAWANA PIPELINE
(VDBPL)(VDBPL)
GAILGAIL 20092009 48”/ 36”/ 48”/ 36”/ 20”20”
500/ 38/ 55500/ 38/ 55 REGASIFIED LNGREGASIFIED LNG
MUNDRA BATHINDA PIPELINE MUNDRA BATHINDA PIPELINE (MBPL)(MBPL)
HMPLHMPL 20092009 28”/ 30”28”/ 30” 424/ 590424/ 590 CRUDE OILCRUDE OIL
BINA KOTA PIPELINEBINA KOTA PIPELINE BPCLBPCL 20092009 18”18” 257257 MULTI PRODUCTMULTI PRODUCT
VADINAR BINA PIPELINEVADINAR BINA PIPELINE BORLBORL 20092009 24”24” 935935 CRUDE OILCRUDE OIL
NUMALIGARH SILIGURI PIPELINENUMALIGARH SILIGURI PIPELINE OILOIL 20092009 16”16” 400400 MULTI PRODUCTMULTI PRODUCT
COMPRESSOR STATIONSCOMPRESSOR STATIONS GAILGAIL ------ ------ ------ REGASIFIED LNGREGASIFIED LNG
IN-FIELD PIPELINES OF BOMBAY-HIGH, BASSEIN, HEERA, NEELAM, PANNA, MUKTA.
PIPELINE DESIGNPIPELINE DESIGNMajor Onshore ProjectsMajor Onshore Projects
(Current)
Pipeline Design
Slide Number - 12 of 77 Engineers India Ltd – Delivering excellence through people
PIPELINE DESIGNPIPELINE DESIGN
SECTION-1
Pipeline Design
Slide Number - 13 of 77 Engineers India Ltd – Delivering excellence through people
PIPELINE DESIGNPIPELINE 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 DESIGNPIPELINE 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 DESIGNPIPELINE DESIGN
Pipeline Design
Slide Number - 16 of 77 Engineers India Ltd – Delivering excellence through people
PIPELINE DESIGNPIPELINE 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 DESIGNPIPELINE 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 DESIGNPIPELINE 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 TRANSPORTATIONECONOMICS 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 DESIGNPIPELINE 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 DESIGNPIPELINE 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 DESIGNPIPELINE 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 DESIGNPIPELINE DESIGN
Marine Offloading Terminal
Pipeline Design
Slide Number - 24 of 77 Engineers India Ltd – Delivering excellence through people
PIPELINE DESIGNPIPELINE DESIGN
Open sea Jetty
Pipeline Design
Slide Number - 25 of 77 Engineers India Ltd – Delivering excellence through people
PIPELINE DESIGNPIPELINE 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 DESIGNPIPELINE DESIGN
Major Pipelines in India
Pipeline Design
Slide Number - 27 of 77 Engineers India Ltd – Delivering excellence through people
PIPELINE DESIGNPIPELINE DESIGN
Pipeline Construction Video
Video for Mangalore Bangalore Pipeline
Pipeline Design
Slide Number - 28 of 77 Engineers India Ltd – Delivering excellence through people
PIPELINE DESIGNPIPELINE DESIGN
SECTION-2
PIPELINE DESIGN CODES AND STANDRADSPIPELINE DESIGN CODES AND STANDRADS
Pipeline Design
Slide Number - 29 of 77 Engineers India Ltd – Delivering excellence through people
PIPELINE DESIGNPIPELINE DESIGN
Stages of Pipeline Project
ConceptualizationConceptualization Establish RequirementEstablish Requirement Evaluate AlternativesEvaluate Alternatives Finalize the ConceptFinalize the Concept
Feasibility StudyFeasibility Study Pipeline Route Study and SelectionPipeline Route Study and Selection Hydraulic Studies and OptimizationHydraulic Studies and Optimization Establish Project CostEstablish Project Cost Project Implementation SchemeProject Implementation Scheme Environmental Impact Assessment & Risk AnalysisEnvironmental Impact Assessment & Risk Analysis
Pipeline Design
Slide Number - 30 of 77 Engineers India Ltd – Delivering excellence through people
PIPELINE DESIGNPIPELINE DESIGN
Stages of Pipeline Project
Basic EngineeringBasic Engineering Process Design and SizingProcess Design and Sizing Optimization StudiesOptimization Studies Route Surveys and InvestigationsRoute Surveys and Investigations
Detailed EngineeringDetailed Engineering Engineering Design BasisEngineering Design Basis Route Engineering and Engineering AnalysisRoute Engineering and Engineering Analysis Specifications and Job StandardsSpecifications and Job Standards Engineering for ProcurementEngineering for Procurement Installation Engineering and Construction ProceduresInstallation Engineering and Construction Procedures
Pipeline Design
Slide Number - 31 of 77 Engineers India Ltd – Delivering excellence through people
PIPELINE DESIGNPIPELINE DESIGNMajor Codes & Standards
Code/StandardCode/Standard TitleTitleASME B 31.8 (2003)ASME B 31.8 (2003) Gas Transportation and Distribution Piping SystemsGas Transportation and Distribution Piping Systems
ASME B 31.4 (2006)ASME B 31.4 (2006) Pipeline Transportation Systems for Liquid Hydrocarbons and other Pipeline Transportation Systems for Liquid Hydrocarbons and other LiquidsLiquids
OISD-141 (2003)OISD-141 (2003) Design and Construction Requirements for Cross-Country Design and Construction Requirements for Cross-Country Hydrocarbon PipelinesHydrocarbon Pipelines
OISD-214 (2006)OISD-214 (2006) Cross-Country LPG PipelinesCross-Country LPG Pipelines
OISD-226 (2007)OISD-226 (2007) Natural Gas Transmission Pipelines and City Gas Distribution Natural Gas Transmission Pipelines and City Gas Distribution NetworksNetworks
API 5L / ISO 3183 : 2007API 5L / ISO 3183 : 2007 Specification for Line PipeSpecification for Line Pipe
API RP1102API RP1102 Recommended practice for Rail and Highway crossingsRecommended practice for Rail and Highway crossings
API 1104API 1104 Standard for welding pipeline and related facilitiesStandard for welding pipeline and related facilities
API 6D / ISO 14313API 6D / ISO 14313 Pipeline ValvesPipeline Valves
DNV OS-F101DNV OS-F101 Submarine pipeline systemsSubmarine pipeline systems
Other References Other References Applicable Standards / Specs of ASME, API, NACE, MSS, BS and Applicable Standards / Specs of ASME, API, NACE, MSS, BS and DINDIN
Pipeline Design
Slide Number - 32 of 77 Engineers India Ltd – Delivering excellence through people
PIPELINE DESIGNPIPELINE DESIGNMajor Codes & Standards
Type of CrossingType of Crossing Approval AuthorityApproval Authority
ROU & Land AcquisitionROU & Land Acquisition Central/State Govt. as applicableCentral/State Govt. as applicable
(As per PMP Act 1962)(As per PMP Act 1962)
National Highway CrossingsNational Highway Crossings NHAINHAI
SH/ MDR/ ODR CrossingsSH/ MDR/ ODR Crossings PWDPWD
Railway Track crossings Railway Track crossings Indian RailwaysIndian Railways
Crossing through Forest landCrossing through Forest land Forest AuthorityForest Authority
River/Canal crossingsRiver/Canal crossings Irrigation/Canal AuthorityIrrigation/Canal Authority
Pipeline Design
Slide Number - 33 of 77 Engineers India Ltd – Delivering excellence through people
CAESAR-IICAESAR-II AUTOPIPEAUTOPIPE IPMCSIPMCS MRPACKMRPACK SORPSSORPS PIPECALCPIPECALC OFFPIPEOFFPIPE PRISEPRISE PIPECROSSPIPECROSS
LIST OF SOFTWARES USED IN PIPELINE ENGINEERING
PIPELINE STUDIOPIPELINE STUDIO
TGNETTGNET
TLNETTLNET HYSISHYSIS
Pipeline Design
Slide Number - 34 of 77 Engineers India Ltd – Delivering excellence through people
Optimal sizes of various capacities
Economy of scale
PIPELINE DESIGNPIPELINE DESIGN
Pipeline Design
Slide Number - 35 of 77 Engineers India Ltd – Delivering excellence through people
PIPELINE DESIGNPIPELINE 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
PIPELINE DESIGNPIPELINE DESIGN
Typical Pipeline Route Map
Pipeline Design
Slide Number - 37 of 77 Engineers India Ltd – Delivering excellence through people
PIPELINE DESIGNPIPELINE DESIGN
Pipeline Design
Slide Number - 38 of 77 Engineers India Ltd – Delivering excellence through people
PIPELINE DESIGNPIPELINE 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 DESIGNPIPELINE 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 DESIGNPIPELINE 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 DESIGNPIPELINE 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 Classification
Location Class 1 : 10 buildings
Location Class 2 : > 10 and < 46 buildings
Location Class 3 : 46 buildings
Location Class 4 : Multistory buildings
Pipeline Design
Slide Number - 42 of 77 Engineers India Ltd – Delivering excellence through people
PIPELINE DESIGNPIPELINE 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 PipesType of Line Pipes
SeamlessSeamless
Electric WeldedElectric Welded
Longitudinal Seam Longitudinal Seam
Submerged-Arc Welded Submerged-Arc Welded
(LSAW)(LSAW)
Helical Seam Submerged-Helical Seam Submerged-
Arc Welded Arc Welded
(HSAW)(HSAW)
Pipeline Design
Slide Number - 43 of 77 Engineers India Ltd – Delivering excellence through people
PIPELINE DESIGNPIPELINE 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 PipesManufacturing of Helical PipesPIPELINE DESIGNPIPELINE DESIGN
Pipeline Design
Slide Number - 45 of 77 Engineers India Ltd – Delivering excellence through people
PIPELINE DESIGNPIPELINE DESIGN
Anti-corrosive Coatings Coal Tar Enamel Coating (BS 4164, AWWA C203)Coal Tar Enamel Coating (BS 4164, AWWA C203)
PrimerPrimer Two layers of coal tar enamel & glass fibre Inner wrapTwo layers of coal tar enamel & glass fibre Inner wrap One layer of coal tar impregnated outer wrapOne layer of coal tar impregnated outer wrap Coating thickness 4.7mmCoating thickness 4.7mm
3 Layer PE/ PP Coating (DIN 30670)3 Layer PE/ PP Coating (DIN 30670) First layer of Fusion bonded epoxyFirst layer of Fusion bonded epoxy Second layer of extruded adhesive Second layer of extruded adhesive Third layer of extruded PE/ PPThird layer of extruded PE/ PP Coating thickness 2.0 to 3.7 mmCoating thickness 2.0 to 3.7 mm
Fusion Bonded Epoxy Coating (CSA Z245.20)Fusion Bonded Epoxy Coating (CSA Z245.20) 350-500 micron thick single layer coating350-500 micron thick single layer coating 600-800 micron thick dual layer coating600-800 micron thick dual layer coating
Pipeline Design
Slide Number - 46 of 77 Engineers India Ltd – Delivering excellence through people
PIPELINE DESIGNPIPELINE DESIGN
3 Layer PE Coating Application
Pipeline Design
Slide Number - 47 of 77 Engineers India Ltd – Delivering excellence through people
PIPELINE DESIGNPIPELINE DESIGN
Major Pipeline Components
Line Pipe & CoatingsLine Pipe & Coatings Scraper Traps & Pig SignallersScraper Traps & Pig Signallers Long Radius (LR) BendsLong Radius (LR) Bends Insulating JointsInsulating Joints Flow TeesFlow Tees Sectionalizing ValvesSectionalizing Valves Pumps / CompressorsPumps / Compressors Filters & MetersFilters & Meters
Pipeline Design
Slide Number - 48 of 77 Engineers India Ltd – Delivering excellence through people
PIPELINE DESIGNPIPELINE DESIGN
Scraper traps
Pipeline Design
Slide Number - 49 of 77 Engineers India Ltd – Delivering excellence through people
PIPELINE DESIGNPIPELINE DESIGN
Sectionalizing ValveSpacing Spacing
ASME B 31.8 for Gas pipelines
ASME B 31.4 for Liquid Pipelines
LocationLocation 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 DESIGNPIPELINE 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 DESIGNPIPELINE DESIGN
Ball valves
Pipeline Design
Slide Number - 52 of 77 Engineers India Ltd – Delivering excellence through people
PIPELINE DESIGNPIPELINE DESIGNPlug valve
Pipeline Design
Slide Number - 53 of 77 Engineers India Ltd – Delivering excellence through people
PIPELINE DESIGNPIPELINE DESIGNCheck valve
Pipeline Design
Slide Number - 54 of 77 Engineers India Ltd – Delivering excellence through people
PIPELINE DESIGNPIPELINE DESIGN
Major Engineering Deliverables
Design ReportsDesign ReportsDesign BasisDesign BasisRoute Selection ReportRoute Selection ReportWall Thickness ReportWall Thickness ReportSeismic Design ReportSeismic Design ReportCrossing Design ReportCrossing Design Report
DrawingsDrawingsRoute MapRoute MapPipeline SchematicPipeline SchematicAlignment SheetsAlignment SheetsSV Station LayoutSV Station LayoutEquipment LayoutEquipment LayoutPiping General Piping General
Arrangement DrawingsArrangement Drawings
Pipeline Design
Slide Number - 55 of 77 Engineers India Ltd – Delivering excellence through people
PIPELINE DESIGNPIPELINE 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
37
39
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
41
24.6
75
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.
1182
4.62
9m
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
DRA
IN
DRAIN
CH.12747.397m
CH. 10620.558m
MAT
CH
LINE
FO
R C
O NT.
REF
ER D
WG
NO.
4529
-10-
16-7
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
LINE
FO
R C
O NT.
REF
ER D
WG
NO.
4529
-10-
16-7
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
25
11.8
49
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 DESIGNPIPELINE DESIGN
Pipeline Design
Slide Number - 57 of 77 Engineers India Ltd – Delivering excellence through people
PIPELINE DESIGNPIPELINE DESIGNTypical GA DRAWING
Pipeline Design
Slide Number - 58 of 77 Engineers India Ltd – Delivering excellence through people
PIPELINE DESIGNPIPELINE DESIGNMajor Engineering Deliverables
TendersTenders Survey TenderSurvey Tender Pipe Coating TenderPipe Coating Tender Pipeline Installation TenderPipeline Installation Tender
Material Procurement Material Procurement Line PipesLine Pipes Valves & ActuatorsValves & Actuators Scraper Traps, QOEC, Pig SignallersScraper Traps, QOEC, Pig Signallers Flow Tees & Insulating JointsFlow Tees & Insulating Joints Induction BendsInduction Bends Flow metersFlow meters Pumps & CompressorsPumps & Compressors OFC cablesOFC cables
Pipeline Design
Slide Number - 59 of 77 Engineers India Ltd – Delivering excellence through people
PIPELINE DESIGNPIPELINE 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 DESIGNPIPELINE 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 DESIGNPIPELINE 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 DESIGNPIPELINE 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 DESIGNPIPELINE DESIGN
The conventional HDD operations for river crossings.
Pipeline Design
Slide Number - 64 of 77 Engineers India Ltd – Delivering excellence through people
PIPELINE DESIGNPIPELINE 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 DESIGNPIPELINE DESIGN
Pipeline Installation using Micro-tunnelling
Long Distance Micro TunnellingLong Distance Micro Tunnelling
Pipeline Design
Slide Number - 66 of 77 Engineers India Ltd – Delivering excellence through people
PIPELINE DESIGNPIPELINE DESIGN
Overview of Micro tunneling
Pipeline Design
Slide Number - 67 of 77 Engineers India Ltd – Delivering excellence through people
PIPELINE DESIGNPIPELINE 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 DESIGNPIPELINE 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 DESIGNPIPELINE DESIGN
RECENT DEVELOPMENTS
TECHNICAL IMPROVEMENTSTECHNICAL IMPROVEMENTS Automatic Welding & Automatic UTAutomatic Welding & Automatic UT Micro-Tunneling for pipeline constructionMicro-Tunneling for pipeline construction Internal flow coating on line pipes for gas pipelinesInternal flow coating on line pipes for gas pipelines 3LPP coating on High Temperature pipelines3LPP coating on High Temperature pipelines
Pipeline Design
Slide Number - 70 of 77 Engineers India Ltd – Delivering excellence through people
PIPELINE DESIGNPIPELINE DESIGN
Comparison of LSAW & HSAW Pipes
DescriptionDescription LSAWLSAW HSAWHSAW
Method of Method of ManufactureManufacture
UOE/COE/JCO/3 roll bendingUOE/COE/JCO/3 roll bending Formed by Twisting of CoilFormed by Twisting of Coil
Weld LengthWeld Length Equal to pipe joint lengthEqual to pipe joint length Approximately 1.5 to 2 times the Approximately 1.5 to 2 times the length of pipe jointlength of pipe joint
Position of weldPosition of weld Longitudinal – positioned in Longitudinal – positioned in upper quadrant during upper quadrant during constructionconstruction
Spiral – present all around the Spiral – present all around the pipepipe
Corrosion Coating Corrosion Coating Specified thickness throughout Specified thickness throughout entire body. entire body.
Weld seam is tracked to ensure Weld seam is tracked to ensure coating thickness on weld seamcoating thickness on weld seam
Thickness normally increased all Thickness normally increased all over the body, resulting in over the body, resulting in proportional increase in coating proportional increase in coating cost by 15-20%cost by 15-20%
GeometryGeometry Controlled to the desired level Controlled to the desired level with cold expansionwith cold expansion
Controlled during forming only Controlled during forming only and no cold expansion is carried and no cold expansion is carried outout
Pipeline Design
Slide Number - 71 of 77 Engineers India Ltd – Delivering excellence through people
PIPELINE DESIGNPIPELINE DESIGN
CTECTE 3LPE3LPE 3LPP3LPP FBEFBE
Service ConditionsService Conditions
Temperature, Temperature, oo C C Upto 45Upto 45 Upto 65Upto 65 Upto 110Upto 110 Upto 110Upto 110
Anti-corrosion PropertiesAnti-corrosion Properties
Resistance to MoistureResistance to Moisture GoodGood Very GoodVery Good ExcellentExcellent GoodGood
Cathodic DisbondmentCathodic Disbondment FairFair GoodGood GoodGood GoodGood
Electrical Properties Electrical Properties
Coating ResistanceCoating Resistance GoodGood ExcellentExcellent ExcellentExcellent ExcellentExcellent
Coating Comparison
Pipeline Design
Slide Number - 72 of 77 Engineers India Ltd – Delivering excellence through people
PIPELINE DESIGNPIPELINE DESIGN
CTECTE 3LPE3LPE 3LPP3LPP FBEFBE
Cathodic Protection DesignCathodic Protection Design
Current DensityCurrent Density HighHigh LowLow LowLow LowLow
Mechanical PropertiesMechanical Properties
Resistance to ImpactResistance to Impact FairFair ExcellentExcellent Superior to PESuperior to PE FairFair
Resistance to Resistance to IndentationIndentation
PoorPoor Very GoodVery Good ExcellentExcellent FairFair
Resistance to PeelResistance to Peel FairFair ExcellentExcellent Superior than PESuperior than PE --
Resistance to Soil Resistance to Soil StressesStresses
FairFair ExcellentExcellent ExcellentExcellent ExcellentExcellent
ElongationElongation FairFair ExcellentExcellent ExcellentExcellent --
Coating Comparison
Pipeline Design
Slide Number - 73 of 77 Engineers India Ltd – Delivering excellence through people
PIPELINE DESIGNPIPELINE DESIGN
CTECTE 3LPE3LPE 3LPP3LPP FBEFBE
Long Term AgeingLong Term Ageing
Heat & Light AgeingHeat & Light Ageing FairFair Very GoodVery Good Very GoodVery Good Very GoodVery Good
Application & Field RepairApplication & Field Repair
Ease of ApplicationEase of Application Easy Easy Relatively difficultRelatively difficult Relatively difficultRelatively difficult Relatively difficultRelatively difficult
Damages during Damages during handling & handling & transportationtransportation
HighHigh LowLow LowLow HighHigh
Ease of Field RepairEase of Field Repair DifficultDifficult Easy for small repair,Easy for small repair,
Cumbersome for Cumbersome for larger repairlarger repair
Easy for small repair,Easy for small repair,
Cumbersome for Cumbersome for larger repairlarger repair
Easy for small repair,Easy for small repair,
Cumbersome for Cumbersome for larger repairlarger repair
Coating Comparison
Pipeline Design
Slide Number - 74 of 77 Engineers India Ltd – Delivering excellence through people
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