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PIPELINE ACTIVITIES
BY
TIRUPATI,INDIA
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pe ne :pe ne :
TransportationTransportation ofof liquidsliquids andand gasesgases fromfrom oneone
..
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Survey
Pipe line activity :
Unloading & stocking of pipes at site
Marking
Trench excavation
Blasting
contd
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Sand bedding
pe ower ng
Laying, joining
Back filling
Sand encasing
pec a s x ng
contd
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Pedestals, thrust blocks & valve chambers
Hydro testing
Commissioning
Final measurement
Reconciliation
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TYPE OF PIPES
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Mild steel (MS)
ass re n orcemen p as c
Ductile iron DI
Cast iron (CI)
High density poly ethylene (HDPE)
Poly vinyl chloride (PVC)
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Pre stressed concrete (PSC)
Reinforcement cement concrete (RCC)
Bar wra ed steel c linder (BWSC)
Galvanized iron (GI)
Low alloy pipe (LA)
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PVC pipe MS pipe GI pipe
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p pe p pe p pe
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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
slopes for stability.
1:1 clay, muram & boulders etc1:2 hard muram
NOTE: Slope not requiredfor soft & hard rock
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TRANSPORTATIONRANSPORTATION
OF
MATERIAL TO SITE
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Pipes shall be transported to the site of laying and stacked
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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Each pipe & special should be properly stacked at
cause any damage to their outer coating.
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PIPE HANDLING
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manual pipe handling :
e ore an ng t e p pe,
work men should wear
1. Ro es used to lift the material must be in ood condition
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 len th
Ensure ro er visibilit for the crane.
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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 ofchain ulle block and tri od standor cranes or with thehelp of ropes.
socket. Spigot end shall be lubricated with good quality of
grease or oil, then the spigot shall be slipped into socket by.
S i ot ends of all i es shall face u stream irres ective of
the direction of water flow.
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GRP PIPESRP PIPES
LOWERING, LAYING
AND
JOININGOINING
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Lowering and laying :
pe s a e a n ry con t on an un er no c rcumstancesthey shall rest on sludgy bedding. Pipes shall rest continuously
on the bottom of the trench.
Clearance of approximately100mm in depth and width equal
to engt o t e co ar p us mm on ot s es s a e
provided at the joint which shall be refilled from sides after the
oint is made.
The pipe should be lowered in to the trenches either by pulley
or by means of two ropes. For road crossing or river crossingthe pipe shall laid 2.0mtr. Below the bed level. The pipe
should be encased with300mm thicksand.
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Joining :
1. Spigot and socket and socket joint with double water tight
ru er r ng gas e pac ng
2. Double socket cou lin oint with water ti ht rubber rin
gasket 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 PIPES
LOWERING, LAYING, JOINING
PAINTINGAINTING
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Before Laying, M.S pipes should be coated with cement or
Paintin
1. surface cleaning :
The pipe should be cleaned before painting with special
epoxy thinner. This avoids oil, Greece marks on the pipe.Due to these marks the paint wasn't sticking. Inside dust can
.
2. primary coating
After surface cleaning, firstprimer coating is necessary. Forthis purpose zinc phosphate primer is combined withactivator in 6:1 ratio. Zinc phosphate primer is component a
act vator s component , so
primer = component a + component
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3. Out side coating :
After primary coating, out side of pipe painted with
epoxy coa tarw c s com ne w t act vator n 4:1
ratio.
4. Inside :
Foo gra e epoxy used for inside painting resistscorrosion, this is the combination ofresin & 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 scrapingBefore welding the pipe faces shall be cleaned by scraping
by wire brushesby wire brushes
in lining and coatingin lining and coating
e en s o p pes s a ave eve e en s or we nge en s o p pes s a ave eve e en s or we ng
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, ., .(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 resistanceresistanceweldinweldin or or submer edsubmer ed arcarc weldinweldin rocessrocess lon itudinalllon itudinall or or
spirallyspirally weldedwelded
. .
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What is metal arc welding :
In metal arc welding a metal rod is used as oneelectrode 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,
. oor us on,
5. Porosity,
. ,
7. Spatter,
8. Wra in & distortion.
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HDPE PIPE
LAYING JOINING
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FusionFusion weldingwelding isis commonlycommonly usedused inin HDPEHDPE andand isis aa
permanentpermanent 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 under under nono
circumstancescircumstances thethe shallshall restrest onon slushslush beddinbeddin
ClearanceClearance ofof requiredrequired depthdepth && widthwidth onon bothboth sidessides shallshall
,,
afterafter thethe jointjoint isis mademade
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ForFor roadroad crossingcrossing oror riverriver crossingcrossing thethe pipepipe shallshall bebe laidlaid 22
PipePipe afterafter transportingtransporting toto thethe exactexact placeplace shouldshould bebe cutcut squaresquare
byby thethe hacksawhacksaw bladeblade
TThehe faceface ofof thethe i ei e should should bebe sli htlsli htl scra ed scra ed rior rior toto thethefusionfusion weldingwelding toto removeremove oxidizedoxidized layerlayer
weldingwelding
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TheThe heatingheating mirrormirror // panpan shouldshould bebe heatedheated upup toto 200200 degdeg.. cc
andand thethe surfacesurface ofof thethe panpan shouldshould bebe 210210 ++ oror 55 degdeg.. CC
TheThe heatingheating panpan shouldshould bebe metallicmetallic plateplate whichwhich isis heatedheated upuptoto thethe re uiredre uired tem eraturetem erature eithereither bb electricalelectrical coilcoil embeddedembedded
insideinside oror byby blowblow torchtorch
thethe 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 fromfrom
11 toto 55 minmin dependingdepending onon thethe pipepipe wallwall thickthick && sizesize..
Pi esPi es shouldshould bebe removedremoved fromfrom thethe heatinheatin mirrormirror // anan whenwhen
thethe rimrim ofof thethe moltenmolten materialmaterial isis formedformed andand ensureensure thatthat thethe rimrimformationformation isis notnot excessiveexcessive..
ImmediateImmediate jointjoint shouldshould bebe mademade byby thethe applicationapplication ofof
moderatemoderate pressurepressure ofof approxapprox..11 toto 22 kg/cmkg/cm22 forfor 22 toto 33 secsec..
whilewhile joining,joining, thethe pressurepressure shouldshould bebe maintainedmaintained untiluntil thethe
ointoint isis lukeluke warmwarm..
AfterAfter thethe pressurepressure isis relieved,relieved, thethe jointjoint shouldshould bebe allowedallowed toto
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BackBack fillfill withwith excavatedexcavated soilsoil shouldshould bebe freefree fromfrom
c n ers,c n ers, as es,as es, s ag,s ag, re use,re use, ru s ,ru s , vege a evege a e or or organ corgan c
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 laid laid belowbelow roadsroads (which(which maymay bebe
subjectedsubjected toto heavyheavy traffictraffic loads),loads), trenchestrenches shouldshould bebe coveredcovered
ww re n orcere n orce concre econcre e s a ss a s
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GRP Lamination Details
1. Grinding wheels, (machine)
2. Surface,
3. Robin,
4. Matt5. Resin,
6. Hardener,
. ,
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am na on rocess :
1. First rindthe dama ed ortion with rindin wheel.
2. After that , mix the aerosol powderwith hardener, this
m x ure as o e pu on amage por on, ar ener s
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. Resinpour on robin & matt
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Hydro Testing:
1. After Completion of each section of pipeline, it shall be
es e or wa er g ness e ore e ng covere n.
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 times
t e wor ng 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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THANK U.....
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