II Pipeline Design Codes and Standards-MSG

PIPELINE DESIGN
Delivering excellence through people

Pipeline Design Slide Number - 1 of 77
ENGINEERS INDIA LIMITED

EPC and Total Solutions Consultancy Organization
Engineers India Ltd Delivering excellence through people
Petroleum Refineries
Petrochemicals
Pipelines Offshore Platforms Gas Processing Metallurgy Ports & Terminals Highways and Airports
EIL OFFICES
HEAD OFFICE NEW DELHI
REGIONAL OFFICES
PROCUREMENT OFFICES
VADODARA, CHENNAI KOLKATA

MUMBAI
SITE OFFICES
INSPECTION OFFICE OVERSEAS OFFICES
29 LOCATIONS (INDIA) 9 LOCATIONS (OVERSEAS)

10 LOCATIONS LONDON, LIBYA ABU DHABI, ITALY, SAUDI ARABIA , QATAR, KUWAIT
PIPELINE DESIGN
SERVICES OFFERED BY EIL
Project Implementation Services
Feasibility Studies Project Management Planning & Scheduling Process Design Detailed Engineering Procurement Services Specialist Services Heat & Mass Transfer Equipment
Design
Environment Engineering Information Technology Services Specialist Materials and Maintenance Services Plant Operation & Safety Risk Analysis
Construction Management
Commissioning and Plant Start-up Assistance
Advanced Control & Optimization
PIPELINE DESIGN
EIL EXPERIENCE
1975
1979
First major project Crude Oil Loop Line for Oil India Ltd.
First major overseas project 150 km Multi Product Pipeline for Abu Dhabi National Oil Company First major high pressure Gas Pipeline Project - 1800 km Gas Transmission Network for GAIL
1984
Over 40 major pipeline projects completed.

PIPELINE DESIGN
Major Onshore Projects (Completed)
DESCRIPTION HAZIRA-BIJAIPURJAGDISHPUR (HBJ) MAQTA-AL-AIN PIPELINE KANDLA-BHATINDA GAS REHABILITATION & EXPANSION PROJECT (GREP) MUMBAI MANMAD VIZAG-VIJAYWADA JAMNAGAR-LONI LPG PIPELINE CLIENT GAIL ADNOC IOCL GAIL YEAR 1989 1992 1996 1998 SIZE 36/30/24/18 30 /12 22/14/10 36 LENGTH (KM) 1800 166 1443 505 SERVICES NATURAL GAS NATURAL GAS MULTIPRODUCT NATURAL GAS
BPCL HPCL GAIL
1998 1998 2001
18 18 16/14/12/8/ 6
260 360 1235
MULTIPRODUCT MULTIPRODUCT LPG (LIQUIFIED PETROLIUM GAS)
COCHIN KARUR PIPELINE
PETRONET
2001
18 /14
289
MULTIPRODUCT
PIPELINE DESIGN
Major Onshore Projects (..contd) (Completed)
DESCRIPTION VIZAG SECUNDERABAD LPG PIPELINE CLIENT GAIL YEAR 2002 SIZE 12/10 LENGTH (KM) 600 SERVICES LPG (LEQUIFIED PETROLEUM GAS)
MANMAD-MANGALAYA PIPELINE
MANGALORE-BANGLORE
BPCL
HPCL
2003
2003
14
24 /20
358
364
MULTIPRODUCT
MULTIPRODUCT
DAHEJ VIJAIPUR PIPELINE

INTER REFINERIES PIPELINES PROJECT, ABU DHABI
GAIL
2003
42
10 12 16
610
230 230 208
REGASIFIED LNG
NAPHTHA, MULTIPRODUCT & SRR
TAKREER
2004
MANGALAYA-BIJWASAN PIPELINE
MUNDRA-DELHI PIPELINE
BPCL
HPCL
2006
2006
16/8
18/16
775
1050
MULTIPRODUCT
MULTIPRODUCT
PIPELINE DESIGN
Major Onshore Projects (contd) (Completed)
DESCRIPTION PUNE SOLAPUR PIPELINE DABHOL PANVEL PIPELINE PROJECT (PH-I) DABHOL PANVEL PIPELINE PROJECT (PH-II) CLIENT HPCL GAIL GAIL YEAR 2007 2007 2007 SIZE 14 / 12 30 30 LENGTH (KM) 182 / 161 187 120 SERVICES MULTIPRODUCT REGASIFIED LNG REGASIFIED LNG
PIPELINE DESIGN
Major Offshore Projects (Completed)
DESCRIPTION BOMBAY HIGH URAN TRUNKLINE (BUT) SOUTH BASSEIN HAZIRA TRUNKLINE HEERA-URAN TRUNK LINE ICP - HEERA TRUNKLINE CLIENT ONGC ONGC ONGC ONGC YEAR 1979 1986 1996 1996 SIZE 30/26 36 26 /24 30/22 LENGTH (KM) 200 x 2 220 85 x 2 145 SERVICES CRUDE, GAS GAS CRUDE, GAS CRUDE
SECOND BASSEIN HAZIRA TRUNKLINE

MUMBAI HIGH URAN TRUNKLINE (MUT)
ONGC
ONGC
1995
2005
42
30/28 12 to 22
245
205 x 2 100
GAS
CRUDE, GAS
IN-FIELD PIPELINES OF BOMBAY-HIGH, BASSEIN, HEERA, NEELAM, PANNA, MUKTA.
PIPELINE DESIGN
Major Onshore Projects (Current)
DESCRIPTION VIJIPUR DADRI BAWANA PIPELINE (VDBPL) MUNDRA BATHINDA PIPELINE (MBPL) BINA KOTA PIPELINE VADINAR BINA PIPELINE NUMALIGARH SILIGURI PIPELINE COMPRESSOR STATIONS CLIENT GAIL HMPL BPCL BORL OIL GAIL YEAR 2009 2009 2009 2009 2009 --SIZE 48/ 36/ 20 28/ 30 18 24 16 --LENGTH (KM) 500/ 38/ 55 424/ 590 257 935 400 --SERVICES REGASIFIED LNG CRUDE OIL MULTI PRODUCT CRUDE OIL MULTI PRODUCT REGASIFIED LNG
IN-FIELD PIPELINES OF BOMBAY-HIGH, BASSEIN, HEERA, NEELAM, PANNA, MUKTA.
PIPELINE DESIGN
SECTION-1
PIPELINE DESIGN
CONTENTS
INTRODUCTION

Modes of Transportation Benefits of Pipelines
PIPELINE DESIGN

Stages of Pipeline Project Codes and Standards Design Installation, Testing & Commissioning
PIPELINE DESIGN
Oil and Gas Production in India
OIL
(ONGC, OIL, CAIRN, RIL)
33 MMTPA
GAS
115 MMSCMD
(ONGC, GAIL, OIL, GSPC, RIL)
PIPELINE DESIGN
Refining Scenario- India
350
Capacity - 2006-07 NOC 105.5 MMT Others- 43.5 MMT

302
300
(MMT)
250
235
200
149
150
100
70
50
1998-99
2006-07
2011-12
2016-17
(Actual) Year
Engineers India Ltd Delivering excellence through people Source: Report of Working Group on P&NG Sector for the XI Plan
PIPELINE DESIGN
Modes of Hydrocarbon Transportation - India
35% 30%
Pipelines Road Tankers Rail Tankers Water Carriers
32% 32% 26% 10%
25% 20% 15% 10% 5% 0% % Share Pipelines Road Tankers Rail Tankers Water Carriers
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
Energy Savings
Energy Intensity for Various M odes
Energy Consumption in % of energy Transported
4 3.5 3 2.5 2 1.5 1 0.5 0 LiquidPipelines LiquidCoastal LiquidTrains LiquidTrucks CoalTrains CoalCoastal N.GasPipelines 0.8 0.5 1 0.8 1.1 2 3.2
Pipelines are the most energy efficient modes of transportation

ECONOMICS OF PIPELINE TRANSPORTATION
Transmission losses
Losses During Transportation
Rail/Road
Pipelines
0.1
0.2
0.3
0.4
0.5
% Loss of Total Volume 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
Types of Pipelines
ONSHORE (LAND) & OFFSHORE (SUBMARINE) PIPELINES

Trunk Pipelines Spur/ Branch Pipelines Marine Offloading Terminals & Outfalls
PIPELINE DESIGN
Capital cost: Typical breakup

Percentage of Capital Cost. Sr No. 1 2 3 4 5 6 7 8 9 10 11
1. 5
Item Description
Liquid Lines Survey, ROW & Compensation Line Pipe Steel Cost Main line materials Coating of Pipes Mainline Construction Cathodic Protection Telecommunication, SCADA and RCPs Pump / Compressor Stations Delivery Terminal facilities Project Management SubTotal
2% 33% 2% 11% 33% 1% 5% 5% 2% 5% 100%
Gas Lines
1% 45% 3% 6% 25% 1% 2% 12% 1% 4% 100%
1 0.5 0
Pipes, prime-overs and construction constitute big ticket items

0 0.2 0.4 0.6 0.8 1 1. 2
PIPELINE DESIGN
Marine Offloading Terminal
PIPELINE DESIGN
Open sea Jetty
PIPELINE DESIGN
HBJ GAS PIPELINE NETWORK
UTTAR PRADESH
N
DELHI
DADRI
ANOLA SHAHJAHANPUR
RAJASTHAN
GADEPAN
ANTA
BABRALA
INDIA
AURAIYA JAGDISHPUR
GUJARAT
JHABUA
ARABIAN SEA HAZIRA
BIJAIPUR
KEY PLAN LEGEND COMPRESSOR STATION RECEIVING TERMINAL DESPATCH STATION
MADHYA PRADESH
PIPELINE DESIGN
Major Pipelines in India
PIPELINE DESIGN
Pipeline Construction Video
Video for Mangalore Bangalore Pipeline
PIPELINE DESIGN
SECTION-2
PIPELINE DESIGN CODES AND STANDRADS

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
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 Major Codes & Standards

Code/Standard
ASME B 31.8 (2003) ASME B 31.4 (2006) OISD-141 (2003) OISD-214 (2006) OISD-226 (2007) API 5L / ISO 3183 : 2007 API RP1102 API 1104 API 6D / ISO 14313 DNV OS-F101 Other References
Title
Gas Transportation and Distribution Piping Systems Pipeline Transportation Systems for Liquid Hydrocarbons and other Liquids Design and Construction Requirements for Cross-Country Hydrocarbon Pipelines Cross-Country LPG Pipelines Natural Gas Transmission Pipelines and City Gas Distribution Networks Specification for Line Pipe Recommended practice for Rail and Highway crossings Standard for welding pipeline and related facilities Pipeline Valves Submarine pipeline systems Applicable Standards / Specs of ASME, API, NACE, MSS, BS and DIN
PIPELINE DESIGN Major Codes & Standards

Type of Crossing
ROU & Land Acquisition
Approval Authority
Central/State Govt. as applicable (As per PMP Act 1962) NHAI
National Highway Crossings
SH/ MDR/ ODR Crossings Railway Track crossings Crossing through Forest land
PWD Indian Railways Forest Authority
River/Canal crossings
Irrigation/Canal Authority
LIST OF SOFTWARES USED IN PIPELINE ENGINEERING
CAESAR-II AUTOPIPE IPMCS MRPACK SORPS PIPECALC OFFPIPE PRISE PIPECROSS
PIPELINE STUDIO TGNET TLNET HYSIS
PIPELINE DESIGN Optimal sizes of various capacities
Economy of scale
PIPELINE DESIGN
Route Selection
Routing Considerations

Pipeline length Obstructions & Sensitive areas Installation Limitations Crossings Topographical Geo-technical Population Density Index Soil Resistivity Cadastral
Surveys
PIPELINE DESIGN
Typical Pipeline Route Map
The drawing, design and details given on this format are the property of ENGINEERS INDIA LIMITED. They are merely loaned on the borrower's express agreement that they will not be reproduced, copied, exhibited or used, except in the limited way permitted by a written consent given by the lender to the borrower for the intended use.
BHATINDA
Ch. 1012.67 km
RANSISAR Ch. 855.01 km
IP-1 & IPS-F
PROPOSED PIPELINE
IPS-2
JUD Ch. 593.88 km
IPS-F
GAILAWAS Ch. 527.87 km
LEGEND:
PROPOSED MUNDRA-BHATINDA PIPELINE (28" NB) DESPATCH TERMINAL AND PUMPING STATION 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.
JORAWARPURA Ch. 313.63 km
IPS-1
JHEKDA Ch. 226.72 km
IPS-F
MUNDRA
Ch. 0.00 km
PROJECT : ENGINEERS INDIA LIMITED

NEW DELHI
REV. OVERALL PIPELINE ROUTE MAP

AC RK VM REV. DATE REVISION BY CHK APPROVED APPROVED
CLIENT JOB NO
: M/s GGSRL : 6812
Pipeline Design
1-1641-0503 REV.0 A3-420x297
Slide Number - 36 of 77
PIPELINE DESIGN
PIPELINE DESIGN
Material Selection & Corrosion Control
Assessment

Materials

Nature of the Product Design Life Product Temperature Material Chemistry Internal Coatings Product Conditioning Corrosion inhibitors Corrosion Allowance
Corrosion Protection

Carbon Steel (CS) NACE Carbon Steel CRA Clad CS CS with internal Coatings Non-Metallic Materials
PIPELINE DESIGN
Design and Analysis

Wall Thickness Calculations Anti-Buoyancy Measures Piping Stress Analysis
Buried Pipeline Analysis

Crossing Design
PIPELINE DESIGN
Steel Pipe Wall Thickness Calculation
LIQUID PIPELINE (ASME B 31.4, Cl. 404.1.2)
GAS PIPELINE
(ASME B 31.8, Cl. 841.11)
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
P = 2St FET D
where P Design pressure S Specified minimum yield strength D Nominal OD of pipe t Nominal wall thickness F Design factor E Longitudinal joint factor T Temperature de-rating factor
PIPELINE DESIGN
Basic Design Factor for Gas Pipelines
LOCATION CLASS Location Class 1 Location Class 2 Location Class 3 DESIGN FACTOR, F 0.72 0.60 0.50
Location Class 4
Location Class Classification Location Class 1 : Location Class 2 : Location Class 3 : Location Class 4 :
0.40
10 buildings > 10 and < 46 buildings 46 buildings Multistory buildings
PIPELINE DESIGN
Line Pipe Selection
Line Pipe Selection Parameters
Type of Line Pipes

Thickness and Grade Selection

Handling and Transportation (d/t ratio) Type of LinePipe Installation Requirements
Seamless Electric Welded Longitudinal Seam Submerged-Arc Welded (LSAW) Helical Seam SubmergedArc Welded (HSAW)
PIPELINE DESIGN
Line Pipe Application
Submarine Pipelines

Onshore Pipelines

Seamless Pipes (upto & including 16) LSAW Pipes (18 & above)
Seamless Pipes (upto & including 8) LSAW Pipes (16 & above) HSAW Pipes (18 & above) EW Pipes (4 - 18)
PIPELINE DESIGN
Manufacturing of Helical Pipes
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
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 350-500 micron thick single layer coating 600-800 micron thick dual layer coating
3 Layer PE/ PP Coating (DIN 30670)

Fusion Bonded Epoxy Coating (CSA Z245.20)

PIPELINE DESIGN
3 Layer PE Coating Application
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
Sectionalizing Valve
Spacing 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 Pipelines Location Class 1 32 km (20 miles)
Location Class 2
Location Class 3 Location Class 4 LPG Pipelines
24 km (15 miles)
16 km (10 miles) 8 km (5 miles)
Industrial, 12 km (7.5 miles) Commercial & Residential Areas
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 Plug valve
PIPELINE DESIGN Check valve
PIPELINE DESIGN
Major Engineering Deliverables
Design Reports
Design Route Wall
Drawings
Route
Basis
Map Schematic Sheets Layout
Selection Report
Pipeline
Thickness Report
Alignment
Seismic
Design Report
Design Report
SV
Station Layout
Crossing
Equipment Piping
General Arrangement Drawings
PIPELINE DESIGN
Typical Pipeline Alignment Sheet
INTERSECTION POINTS(IP/TP) DEFLECTION ANGLE DISTANCE BETWEEN TP & IP's(m)
DISTANCE AS PER GROUND PROFILE TP50 IP50/1 TP51 298'20''(L) 187.855 187.993 IP51/1 TP52 TP53 TP54 370'54''(L) 339.096 339.126 TP55 TP56 1354'57''(R) 176.463 176.478 1125'7''(L) 322.708 322.772 TP57 121'55''(L) 141.760 141.845 TP58 IP58/1 824'45''(R) 45.000 45.093 104.113 104.624 TP59 28'32''(L) 224.969 225.022 TP60 140'19''(R) 393.395 393.407 TP61 830'18''(L) 218.000 218.014 348.437 348.444 IP61/1 TP62 152'57''(L) 326.642 326.679 TP63 104'42''(L) 237.677 237.707 TP64 1025'50''(L) 65.521 65.728 IP64/1 TP65 518'12''(R) 90.164 90.390 384'58''(R) 518'55''(R) 82'3''(L) 76.544 76.618 67.046 25.199 85.000 67.049 25.200 85.284 38.749 38.853
STATE , DISTRICT AND MANDAL

TO IRUVADA
PU R M A
TP65 CH. 14134.896m IP64/1 CH.14044.732m TP64 CH. 13979.211m
R M
IT
TELEPHONE LINE CH.14134.896m METALLED ROAD(ASPHALTIC) CH.14115.309m ELEC. LINE 440V CH.14132.231m
MATC H LINE FOR C ONT. R EFER DWG NO.45 29-1 0-16 -71-9005
TBM W40 (RL 37.514m) TP50 CH. 10620.558m IP50/1 TP51 CH. 10712.803m IP51/1 CH. 10797.803m
.7 IN 4 A 6 R 06 D H.1 C 10 m
T O PE
D N
EARTHEN EMBANKMENT
ND TO PE
CH. 10687.604m RAIWADA LEFT CANAL (UNLINED) CH. 10691.604m TP52 CH. 10985.658m TP53
DRAIN C H.11824.629m
LOW LYING AREA
TP63 CH. 13741.534m EARTHEN EMBANKMENT
RU A AM TH AP
TO
ELEC TRIC LINE C H.11848.8 8m
TP57
TP58 CH. 12080.978m TP59 IP58/1 CH. 12125.978m CH. 12230.091m
TP60 CH. 12455.060m TP61 CH. 12848.455m IP61/1 CH. 13066.455m DRAIN CH.12903.743m
K K
TBM W57(RL 42.533m) TP62 CH. 13414.892m
ST AT E
CH. 11939.218m
MATC H LINE FOR C ONT. R EFER DWG NO.45 29-1 0-16 -71-9003
TO
CH
INTA
A GUTL
CH. 11062.202m GRAVEL ROAD CH.10787.022m TP55 CH. 11577.761m TP56 CH. 11616.510m HPCL CH. 15.00Km ELECTRIC LINE 440V CH.11018.117m TP54 CH. 11401.298m
K
SV-1 OF GAIL CH.11960.218 m
RAIWADA LEFT CANAL (UNLINED) CH.14027.732m GRAVEL ROAD CH.14040.275m TEMP. HUT ON C/L
HIG H
TBM W49 (RL 25.138m)

C ANAL C H 10691.6m/RL 35.411m
UR AM
AMRUTAPURAM
IRUVADA
DRAIN C H 10664.71m/RL 33.366m
C H 10787.02m/RL 32.587m
PUMP HOUSE 4m FROM C/L
45 43 41
SCALE: HORIZONTAL 1:5000 VERTICAL 1: 500
35 33 31 29 27 25 23 21
37.325
33.366
35.411
33.560
32.587
31.496
30.300
29.815
27.370
25.362
27.904
24.858
25.138
24.341
24.675
24.828
24.604 23.667
22.175
C H 12115.34m/RL 22.175m
R OAD
39 37
C H 11824.63m/RL 24.341m
DRAIN
C H 12060.88m/RL 24.604m
R OAD
DRAIN
25.884
30.557
29.219
29.135
28.935
30.893
32.444
33.622
C ART TRACK
OPEN WELL 6m DIA 8m FROM C/L CH 11577.761m
C H 13492.61m/RL 33.622m
OPEN WELL 6m DIA 7.648m FROM C/L CH.11648.136m
37.219
40.816
39.741 42.491
198.636
196.962
142.134
176.463
141.522
121.660
114.747
224.969
299.254
217.539
182.117
166.780
248.929
237.676
26.894
44.152
21.199
74.219
39.369
37.175
38.749
66.597
24.246
90.342
20.101
34.366
94.141
77.714
48.521
12.543
75.034
KAJU GARDEN
RICE FIELDS
10.621
10.665
10.692
10.713
10.787
10.986
11.025
11.062
11.259
11.401
11.578
11.617
11.758
11.825
11.849
11.939 11.960 11.972 11.984
12.061 12.081
12.115
12.230
12.455
12.754
12.848
13.066
13.248
13.415
13.493
13.742
13.979
14.028 14.040
10.621
10.665
10.692
10.713
10.787
10.986
11.025
11.062
11.259
11.401
11.578
11.617
11.758
11.825
11.849
11.939
12.061 12.081
12.115
12.230
12.455
12.754
12.848
13.066
13.248
13.415
13.493
13.742
13.979
14.028 14.040
14.115 14.135
14.115 14.135
19.588
43.684 43.034
C ART TRACK
GRAVEL ROAD CH.12060.877m
C ANAL C H 14027.73m/RL 39.741m
CH.12747.397m
VILLAGE BOUNDARY
R OAD C H 14040.27m/RL 42.491m
C H 14115.31m/RL 43.684m
UR AM
W A
Y-S A
BB
AV
AR
AM
DRAIN CH.12115.344m TO AM RUTH AP
HPCL CH. 16.00Km HIGH TENSION LINE 12.2m HIGH & 550KV
HPCL CH. 17.00Km
K TRAC m CART 492.606 CH.13
PIPELINE DESIGN Typical P&ID
PIPELINE DESIGN Typical GA DRAWING
PIPELINE DESIGN Major Engineering Deliverables

Tenders
Survey Tender Pipe Coating Tender Pipeline Installation Tender Line Pipes Valves & Actuators Scraper Traps, QOEC, Pig Signallers Flow Tees & Insulating Joints Induction Bends Flow meters Pumps & Compressors OFC cables
Material Procurement

PIPELINE DESIGN
Installation, Testing & Commissioning
RoU Grading & Trenching Stringing of Linepipe
PIPELINE DESIGN
Welding & NDT :

Edge Preparation Internal / External Line-up Clamps Manual / Automatic Welding NDT (X-Ray / UT / MPI etc.)
PIPELINE DESIGN
Field Joint Coating

Lowering & Backfilling
Heat Shrink Sleeves Cold applied tapes
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
The conventional HDD operations for river crossings.
PIPELINE DESIGN
Pipeline Installation using Micro-tunnelling
MICRO-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
Pipeline Installation using Micro-tunnelling
Long Distance Micro Tunnelling
PIPELINE DESIGN
Overview of Micro tunneling
PIPELINE DESIGN
Testing & Commissioning
TESTING

Gauging and Pigging Test Pressure Test Medium
DRYING Swabbing Methanol Drying Super Dry Air Method Vacuum Drying COMMISSIONING Nitrogen Purging Product Charging
TEST PRESSURE
LIQUID PIPELINES Ref. ASME B 31.4 : 437.4.1 1.25 times design pressure GAS PIPELINES Ref. ASME B 31.8 : Table 841.322(f) Class 1 and 2: 1.25 * des pr Class 3 and 4: 1.4 * des pr
PIPELINE DESIGN Pigging

Requirements
Types of Pigs
Pipeline Cleaning Displacement Internal Inspection Batching
Brush pigs Gauge Pigs Spheres Intelligent Pigs
Cleaning pigs
Gauge Pigs
Spheres
Intelligent Pig (MFL)

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 Comparison of LSAW & HSAW Pipes

Description
Method of Manufacture Weld Length Position of weld
LSAW
UOE/COE/JCO/3 roll bending Equal to pipe joint length Longitudinal positioned in upper quadrant during construction
HSAW
Formed by Twisting of Coil Approximately 1.5 to 2 times the length of pipe joint Spiral present all around the pipe
Corrosion Coating
Specified thickness throughout entire body. Weld seam is tracked to ensure coating thickness on weld seam
Controlled to the desired level with cold expansion
Thickness normally increased all over the body, resulting in proportional increase in coating cost by 15-20%
Controlled during forming only and no cold expansion is carried out
Geometry
PIPELINE DESIGN
Coating Comparison
CTE
Service Conditions
Temperature, o C Upto 45 Upto 65 Upto 110 Upto 110
3LPE
3LPP
FBE
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
PIPELINE DESIGN
Coating Comparison
CTE
Cathodic Protection Design
Current Density High Low Low Low
3LPE
3LPP
FBE
Mechanical Properties
Resistance to Impact Fair Excellent Superior to PE Fair
Resistance to Indentation Resistance to Peel
Poor
Very Good
Excellent
Fair
Fair
Excellent
Superior than PE
Resistance to Soil Stresses Elongation
Fair
Excellent
Excellent
Excellent
Fair
Excellent
Excellent
PIPELINE DESIGN
Coating Comparison
CTE
Long Term Ageing
Heat & Light Ageing Fair Very Good Very Good Very Good
3LPE
3LPP
FBE
Application & Field Repair

Ease of Application Easy Relatively difficult Relatively difficult Relatively difficult
Damages during handling & transportation Ease of Field Repair
High
Low
Low
High
Difficult
Easy for small repair, Cumbersome for larger repair
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II Pipeline Design Codes and Standards-MSG

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PIPELINE DESIGN

Delivering excellence through people

ENGINEERS INDIA LIMITED

Engineers India Ltd Delivering excellence through people

Pipeline Design Slide Number - 2 of 77

VADODARA, CHENNAI KOLKATA

29 LOCATIONS (INDIA) 9 LOCATIONS (OVERSEAS)

Engineers India Ltd Delivering excellence through people

Pipeline Design Slide Number - 4 of 77

Advanced Control & Optimization

Engineers India Ltd Delivering excellence through people

Pipeline Design Slide Number - 5 of 77

Over 40 major pipeline projects completed.

BPCL HPCL GAIL

1998 1998 2001

260 360 1235

MULTIPRODUCT MULTIPRODUCT LPG (LIQUIFIED PETROLIUM GAS)

COCHIN KARUR PIPELINE

Engineers India Ltd Delivering excellence through people

Pipeline Design Slide Number - 7 of 77

DAHEJ VIJAIPUR PIPELINE

Engineers India Ltd Delivering excellence through people

Pipeline Design Slide Number - 8 of 77

Engineers India Ltd Delivering excellence through people

Pipeline Design Slide Number - 9 of 77

SECOND BASSEIN HAZIRA TRUNKLINE

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

Engineers India Ltd Delivering excellence through people

Pipeline Design Slide Number - 10 of 77

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

Engineers India Ltd Delivering excellence through people

Pipeline Design Slide Number - 11 of 77

Engineers India Ltd Delivering excellence through people

Pipeline Design Slide Number - 12 of 77

Modes of Transportation Benefits of Pipelines

Engineers India Ltd Delivering excellence through people

Pipeline Design Slide Number - 13 of 77

(ONGC, GAIL, OIL, GSPC, RIL)

Engineers India Ltd Delivering excellence through people

Pipeline Design Slide Number - 14 of 77

Capacity - 2006-07 NOC 105.5 MMT Others- 43.5 MMT

Pipelines Road Tankers Rail Tankers Water Carriers

32% 32% 26% 10%

Engineers India Ltd Delivering excellence through people

Pipeline Design Slide Number - 16 of 77

Engineers India Ltd Delivering excellence through people

Pipeline Design Slide Number - 17 of 77

Pipelines are the most energy efficient modes of transportation

ECONOMICS OF PIPELINE TRANSPORTATION

% Loss of Total Volume Transported

Transmission losses are lowest in Pipelines

Engineers India Ltd Delivering excellence through people

Pipeline Design Slide Number - 20 of 77

Engineers India Ltd Delivering excellence through people

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Capital cost: Typical breakup

Pipes, prime-overs and construction constitute big ticket items

Engineers India Ltd Delivering excellence through people

Pipeline Design Slide Number - 22 of 77

Engineers India Ltd Delivering excellence through people