EIL Cross Country Pipeline Presentation
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CONSTRUCTION OF CROSS COUNTRY PIPELINES By: G. K. IYER (AGM.)
CONSTRUCTION OF CROSS COUNTRY PIPELINES
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Slide Number- 1 of 50
CROSS COUNTRY PIPELINE WORKS
OVERVIEW
MAIN PURPOSE TRANSPORTATION OF MATERIAL/PRODUCT - PIPELINE FOR GAS E.G. NATURAL GAS; LPG; LNG ETC. - PIPELINE FOR LIQUIDS E.G. CRUDE OIL / PETROLEUM PRODUCT; WATER ETC. - PIPELINE FOR SOLIDS E.G. IRON ORE ETC.
TYPES OF PIPELINE - OFFSHORE SUBMARINE PIPELINE: LAID ON SEA-BED - ONSHORE CROSS COUNTRY PIPELINE: LAID 1MTR UNDERGROUND
SOME MAJOR ADVANTAGES - LOW COST OF TRANSPORTATION & ACCESSIBILITY TO REMOTE AREAS - LESS TIME TAKEN FOR TRANSPORATION
SOME DISADVANTAGES - HIGH INITIAL COST - DEAD STOCK / INVENTORY IN PIPELINE Engineers India Ltd – Delivering excellence through people
CONSTRUCTION OF CROSS COUNTRY PIPELINES Slide Number - 2 of 50
CROSS COUNTRY PIPELINE WORKS
SOME OF THE MAJOR PIPELINES UNDERTAKEN BY EIL 1. 2. 3. 4.
5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18.
1986 – 36”/18” x 1800 Kms: HBJ (HAZIRA-BIJAIPUR-JAGDISHPUR) GAS P/L OF M/s GAIL 1996 – 22”/14”/10” x 1450 Kms: KBPL (KANDLA-BHATINDA) PRODUCT P/L OF M/s IOCL 1997 – 36” x 505 Kms: GREP (HBJ UP-GRADATION) GAS P/L OF M/s GAIL 1998, 2003, 2007 – 18”/14” x ~1200 Kms: MMPL PH-1,2 &3 (MUMBAI-MANMAD-INDOREDELHI) PRODUCT P/L OF M/s BPCL 2000 – 16” x 1269 Kms: JLPL (JAMNAGAR-LONI) LPG P/L OF M/s GAIL 2002 – 16”/14” x 220 Kms: VSPL (VIJAIWADA-SECUNDRABAD) PRODUCT P/L OF M/s HPCL 2002 – 18”/14” x 289 Kms: CKPL (COCHIN-KARUR) PRODUCT P/L OF M/s PETRONET LTD. 2003 – 24”/24” x 380 Kms: MBPL (MANGLORE-BANGLORE) PRODUCT P/L OF M/s HPCL 2003 – 12”/10” x 600 Kms: VSPL (VIZAG-SECUNDRABAD) LPG P/L OF M/s GAIL 2004 – 42” x 610 Kms: DVPL (DAHEJ-VIJAIPUR) GAS P/L OF M/s GAIL 2006 – 18” x 1037 Kms: MDPL (MUNDRA-DELHI) PRODUCT P/L OF M/s HPCL 2006 – 14”/12” x 343 Kms: PSPL (PUNE-SHOLAPUR) PRODUCT P/L OF M/s HPCL 2007 – 16” x 401 Kms: NSPL (NUMALIGARH-SILIGURI) PRODUCT P/L OF M/s OIL DPPL PH-1&2 (DHABOL-PUNE) GAS P/L OF M/s GAIL PH-2 IN PROGRESS VBPL (VADINAR-BINA) CRUDE OIL P/L OF M/s BORL IN PROGRESS VDBPL (VIJAIPUR-DADRI-BAWANA) GAS P/L OF M/s GAIL IN PROGRESS MBPL (MUNDRA-BHATINDA) CRUDE OIL P/L OF M/s HMPL IN PROGRESS BKPL (BINA-KOTA) PRODUCT P/L OF M/s BPCL IN PROGRESS
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CONSTRUCTION OF CROSS COUNTRY PIPELINES Slide Number - 3 of 50
CROSS COUNTRY PIPELINE WORKS VADINAR – BINA CRUDE PIPELINE PROJECT : 24” DIA x 931 KMS., API – 5L X70 GR., CAPACITY - 6 MMPTA
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CONSTRUCTION OF CROSS COUNTRY PIPELINES Slide Number - 4 of 50
CROSS COUNTRY PIPELINE WORKS VADINAR – BINA CRUDE PIPELINE PROJECT : 24” DIA x 931 KMS., API – 5L X70 GR., CAPACITY - 6 MMPTA
RT- BINA
IP2-SANDAVATA IPS2- BEWARI IP1 -SIDHASAR
IPS1- THAMNA DT-VADINAR
SP1160 KMS.
SP2199 KMS.
SP3145 KMS.
SP4219 KMS.
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SP5208 KMS.
CONSTRUCTION OF CROSS COUNTRY PIPELINES Slide Number - 5 of 50
CROSS COUNTRY PIPELINE WORKS
I.
CONSTRUCTION METHODOLOGY
II.
TYPE OF CONSTRUCTION EQUIPMENTS
III. TYPES
OF CONTRACTORS REQUIRED FOR CONSTRUCTION OF PIPELINES Engineers India Ltd – Delivering excellence through people
CONSTRUCTION OF CROSS COUNTRY PIPELINES Slide Number - 6 of 50
CROSS COUNTRY PIPELINE WORKS
I.
CONSTRUCTION METHODOLOGY
QA/QC, CODES, SPECN., & HSE REQUIREMENTS
LINEPIPES COATING AT YARD & DUMPSITE
LAYING OF PIPELINE
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CONSTRUCTION OF CROSS COUNTRY PIPELINES Slide Number - 7 of 50
CROSS COUNTRY PIPELINE WORKS
QA/QC IN PIPELINE
Review & Approval of Contractor’s QAP for all activities
Review & Approval of Contractor’s Inspection & Test Plans (ITP’s) with reference to standard ITP’s of EIL before start of work
Review & Approval of Job Procedures & Inspection Formats based on ITP’s for all Pipeline activities
Quality Audits & Resolution of Non Conformances (NC’s) observed during execution of work & quality audits
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CONSTRUCTION OF CROSS COUNTRY PIPELINES Slide Number - 8 of 50
CROSS COUNTRY PIPELINE WORKS
CODES & STANDARDS
Following are the reference/codes followed during Line-pipe Coating & Laying of Pipeline: 1.
DIN 30670
: 3LPE Coating of Line-pipes
2.
AWWA 203
: Coal Tar Enamel Coating of Line-pipes
3.
API 1104
: Welding of Pipeline & Related Activities
4.
API 1105
: Construction Practices for Oil & Products Pipelines
5.
ASME B 31.4
: Pipeline Transportation System for Liquid Hydrocarbon
6.
ASME B 31.8
: Gas Transmission and Distribution Piping System
7.
OISD B 141
: Design and construction requirements for cross-country Hydro-carbon Pipelines
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CONSTRUCTION OF CROSS COUNTRY PIPELINES Slide Number - 9 of 50
CROSS COUNTRY PIPELINE WORKS
RELEVANT EIL SPECN. & STANDARDS
Following are the relevant EIL Specification & Standards for Coating & Laying of Pipeline: 1.
2. 3. 4. 5. 6. 7.
8. 9. 10. 11. 12.
6-71-0001 to 6-71-0040 6-71-0041 6-71-0042 6-71-0044 6-71-0046 6-71-0051 6-71-0052 6-71-0053 6-71-0054 6-71-0055 6-71-0057 6-82-1901 to 6-82-1925
: Standard specification for Line pipes, Valves, Fittings, Scrapper Launcher / Receiver, Pig signaller etc. : Standard specification for 3LPE Coating : Standard specification for CTE Coating Onshore Pipeline. : Standard specification for Field Jt. Coating Onshore Pipeline. : Standard specification for Conc. Coating Onshore Pipeline. : Standard specification for Pipeline Construction (Onshore) : Standard specification for Pipeline Construction, Road, Rail, Minor Water Crossings : Standard specification for Major Water Crossings (Conventional) : Standard specification for Pipeline River Crossings by HDD : Standard specification for Hydro-testing of Onshore Pipelines : Standard specification for Pipeline Markers : Standard Inspection & Test Plans (ITP’s) for Pipeline Activities
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CROSS COUNTRY PIPELINE WORKS
HSE IN PIPELINE
Review of contractors’ HSE plan & documents with reference to EIL specification no. 6-82-0001, Rev-4.
Construction hazards identification & mitigation measures
Ensuring compliance to HSE requirements by contractors
First-Aid & Fire fighting facilities
HSE promotion activities
HSE Reporting including statistics
HSE Audits & Resolution of Non-conformances
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CONSTRUCTION OF CROSS COUNTRY PIPELINES Slide Number - 11 of 50
CROSS COUNTRY PIPELINE WORKS
LINEPIPE COATING AT YARD TYPES OF EXTERNAL YARD COATING - 3 LAYER POLYETHELENE (3LPE) COATING / FBE COATING - COAL TAR ENAMEL (CTE) COATING 3LPE COATING / ONE LAYER FBE COATING -1st LAYER: FUSION BONDED EPOXY – 50 MICRONS (200 TO 300 MICRONS - FBE COATING) - 2nd LAYER: SIDE EXTRUSION ADHESIVE (LDPE) – 200 TO 300 MICRONS -3rd LAYER: SIDE EXTRUSION POLYETHELENE (LDPE / MDPE / HDPE) - > 2 MM
CTE COATING (HOT APPLIED) - 1st COAT: COAL TAR PRIMER – 50 TO 75 MICRONS - 2nd COAT: 1st HOT COAL TAR ENAMEL LAYER WITH INNER WRAP– > 1 MM - 3rd COAT: 2nd HOT COAL TAR ENAMEL LAYER WITH INNER WRAP– > 1 MM - FINAL COAT: COAL TAR IMPREGNATED OUTER WRAP – 600 TO 750 MICRONS
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CROSS COUNTRY PIPELINE WORKS
LINEPIPE COATING AT YARD Contd…
COATING PROCESS: 1) BARE PIPES VISUAL INSPECTION - PIPE NO., HEAT NO., LENGTH, DIA, THK ETC. - BEVEL & BODY DAMAGES E.G. DENTS, GOUGES ETC.
2) SHOTBLASTING AND VISUAL INSPECTION - ROUGHNESS CHECK ON BODY - BODY DENTS & GOUGES
BARE PIPES STACKING YARD
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SHOT BLASTING OF PIPES
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CROSS COUNTRY PIPELINE WORKS
LINEPIPE COATING AT YARD Contd…
COATING PROCESS: 3) PRE-HEATING OF PIPES & PRIMER / EPOXY APPLICATION (PIPES TO BE PREHEATED TO 200 0 C BY INDUCTION COIL/ GAS OVEN)
- CHECK FOR PIPE TEMP BY DIGITAL TEMPERATURE GUAGE & UNIFORM SPRAY SPRAY OF EPOXY ON PIPE BARE PIPES PRE HEATING
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CONSTRUCTION OF CROSS COUNTRY PIPELINES Slide Number - 14 of 50
CROSS COUNTRY PIPELINE WORKS
LINEPIPE COATING AT YARD Contd…
COATING PROCESS: 4) COATING APPLICATION - CHECK TEMP OF EXTRUDERS, PE FILM, ADHESIVE FILM, COAL TAR ENAMEL ENAMEL ETC.
ADHESIVE & PE APPLICATION
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INNER/OUTER WRAP & COAL TAR ENAMEL APPLICATION CONSTRUCTION OF CROSS COUNTRY PIPELINES Slide Number - 15 of 50
CROSS COUNTRY PIPELINE WORKS
LINEPIPE COATING AT YARD Contd…
COATING PROCESS: 5) COOLING OF COATED PIPES IN COOLING TUNNEL & VISUAL INSPECTION OF COATED PIPES - CHECK COOLING WATER TEMP, VISUAL DAMAGE TO COATING, COATING THK. ETC.
COATED PIPE COOLING TUNNEL
3LPE COATING THICKNESS CHECK
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CTE COATING THICKNESS CHECK
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CROSS COUNTRY PIPELINE WORKS
LINEPIPE COATING AT YARD Contd…
COATING PROCESS: 6) HOLIDAY TESTING, REPAIR OF COATING & TESTING - CHECK FOR HOLIDAY AT 25KV FOR 3LPE COATING & 15KV FOR CTE COATING COATING - MARK PIPES FOR TESTING E.G. PEEL TEST, AP TEST, IMPACT TEST ETC. ETC. & COATING REPAIR
RING HOLIDAY TESTING
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MARKING OF TESTING CONSTRUCTION OF CROSS COUNTRY PIPELINES Slide Number - 17 of 50
CROSS COUNTRY PIPELINE WORKS
LINEPIPE COATING AT YARD Contd…
COATING PROCESS: 7) EXTERNAL PAINTING (IF REQD) AND STACKING IN YARD - THK OF PAINT, MARKING ON COATING PIPES, COATING ACCEPTANCE NO., ROW HEIGHT ETC.
COATED PIPES EXTERNAL PAINTING
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COATED PIPES STACKING YARD CONSTRUCTION OF CROSS COUNTRY PIPELINES Slide Number - 18 of 50
CROSS COUNTRY PIPELINE WORKS
DUMP SITES FOR STORAGE OF COATED PIPES
ACQUIRING OF LAND & DEVELOPMENT OF DUMP SITE - GRADING OF LAND, PROVIDING TEMPORARY FENCING, BARRIER GATE , GUARD GUARD ROOM AND SECURITY - PROVIDING INTERNAL ROADS (WBM) FOR TRAILER MOVEMENT & AREA LIGHTING LIGHTING WITH DG SET - PROVIDING SAND ROWS FOR STACKING OF COATED PIPES
HANDLING OF COATED PIPES - ADEQUATE CRANES WITH PADDED HOOKS FOR UNLOADING / LOADING OF COATED COATED PIPES IN TRAILERS - STACKING OF COATED PIPES ON SAND ROWS - HOLIDAY CHECK AND VISUAL CHECK INCLUDING GUAGE PLATE PULL TEST BEFORE DESPATCH TO SITE
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CROSS COUNTRY PIPELINE WORKS
PIPELINE LAYING ACTIVITIES:
ROU SURVEY ROU CLEARING AND GRADING STRINGING TRENCHING BENDING WELDING FIELD JOINT COATING LOWERING BACKFILLING CROSSING TIE-INS HYDROTESTING PIPELINE MARKERS, CLEAN UP & RESTORATION STATION WORKS MAGNETIC PIGGING & EGP – PRE COMMISSIONING ACTIVITY
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PIPELINE LAYING ACTIVITIES..Contd.:
ROU SURVEY
ROU CLEARING & GRADING
Installation of Bench Marks, Turning Points Stake markers in center line of pipeline at a distance of max.100m for centre line and for horizontal bends10 m. and reference point for same Stake two ROU markers at least at every 100m, Painted in red and numbers in white in direction of flow. Chainage markers at every 250 m All obstacles causing hindrance in construction / laying pipeline are removed. Entire ROU is Graded for movement of equipments and vehicle. Temporary approaches/bridges, if required, are constructed for movement of equipments, vehicles & personnel’s
STRINGING
Stringing shall be done after blasting & trenching when ROU is in rocky area . Coated Pipes shall be strung on approved soft earth/sand filled bag and wedge in such a way that bottom of coated Pipe remain above ground Pipes shall be supported at minimum two locations Pipe number, Heat number, coat number & length shall be transferred and recorded in serial order Engineers India Ltd – Delivering excellence through people
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CROSS COUNTRY PIPELINE WORKS ROU CLEARING & GRADING AND PIPELINE STRINGING ACTIVITY
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CROSS COUNTRY PIPELINE WORKS
PIPELINE LAYING ACTIVITIES ..Contd.:
TRENCHING
Trench excavation is carried out along staked centerline of Pipeline The width of excavation for trench shall be minimum (pipe diameter plus 200mm either side) Depth of trench shall be as specified (Normal= 1M; Road= 1.2M; River= 1.5M; Rly.= 1.7M etc) In case of trenching in rocky areas, blasting is performed with the guidelines /Safety Rules of Chief Controller of explosives, Nagpur. In case where rock/gravel or murrum/hard soil is encountered in the bottom of trench, padding material (minimum compacted thickness of 150 mm) shall be provided. When up-floating of the pipeline after backfilling is anticipated, antibuoyancy measures are provided in such areas e.g. weighing by applying continuous concrete, installing saddle weights etc.
BENDING
For changes in vertical & horizontal alignment, pre-fabricated cold field bends are provided Over-bends are made in a manner that centre of bend clears the highest point of trench bottom. Sag bends shall fit the bottom of the trench. Side bends shall have specified clearance to the outside wall of trench. The radius of cold field bends shall not be more than 40 times the dia. of pipe (for 18” inch and above) and 30 times the dia. of pipe (for 18” inch below). Pipes with longitudinal welds are bent a way that weld lies in the plane passing through the neutral axis of bend Engineers India Ltd – Delivering excellence through people
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CROSS COUNTRY PIPELINE WORKS PIPELINE TRENCHING ACTIVITY
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CROSS COUNTRY PIPELINE WORKS PIPELINE BENDING ACTIVITY
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CROSS COUNTRY PIPELINE WORKS
PIPELINE LAYING ACTIVITIES.. Contd.:
WELDING
Welding Procedure Specification (WPS) to be followed for the welding is qualified and the Procedure qualification record (PQR) is approved before start of welding. Approved brand of electrodes are used for welding. Physical properties of the weld produced by an electrode shall not be less than minimum value of base metal. Electrode qualification and batch record are maintained. Each pipe shall be thoroughly checked internally & externally for visual defect/ damage and cleaned internally by compressed air blowing. Damaged end shall be cut and re-bevelled with beveling machine. All new bevels shall be 100% dye penetrant /MPI tested and Ultrasonically tested for any lamination. Use of internal clamp is mandatory for pipe dia.> 10”. Except tie in joints, fitting etc. In such case external clamps are used. Each joint shall bear an identification number which shall be followed for NDT The number of welders, and welding sequence, speed etc. should be similar to that of adopted in approved welding procedure Radiography examination of 100 % girth weld is carried out. Weld shall meet the requirement of API 1104. In addition 100% ultrasonic inspection is required for critical weld joints i.e. tie in, welding of valves etc. joints which have not undergone pressure testing i.e. GOLDEN TIE-Ins. Repair is limited to maximum 30% of the weld length. Weld containing cracks shall be cut and re-bevelled to make a joint. Destructive testing of weld joints are done for 0.1% of the total numbers of welds completed.
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CONSTRUCTION OF CROSS COUNTRY PIPELINES Slide Number - ___of 50
CROSS COUNTRY PIPELINE WORKS PIPELINE MAINLINE WELDING ACTIVITY
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CROSS COUNTRY PIPELINE WORKS AUTOMATIC WELDING CREW FOR MAINLINE JOINT
AUTOMATIC WELDING OF MAINLINE JOINT
MANUAL WELDING OF MAINLINE JOINT
AUTO UT OF MAINLINE JOINT
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PIPELINE LAYING ACTIVITIES.. Contd.:
FIELD JOINT COATING
The cut-back areas of Coated Pipes where weld joints are made are to be Coated by Field Joint Coating. Field joint coating material is heat shrinkable wraparound sleeve used as anticorrosion coating of buried onshore pipeline. Sleeve consist of radiation cross-linked, thermally stabilized, ultraviolet resistant semirigid polyolefin backing with a uniform thickness of high shear strength thermoplastic/comelt adhesive The joint coating system shall consist of a solvent free epoxy primer applied to the pipe surface prior to sleeve application. The surface area is blast cleaned to SA-2.5 followed by Pre-heating of pipe surface, application of epoxy primer and application of sleeve by heat shrinking. Each sleeve joint is inspected by means of a full circle holiday detector set to DC voltage at 25 KV (Pipe surface temperature below 50 degree Celsius) and thickness of sleeve checked. One out of 50 joints coating or one coating out of every day production shall be tested to establish peel strength on steel and factory applied coating.
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CROSS COUNTRY PIPELINE WORKS PIPELINE FIELD JOINT COATING ACTIVITY
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PIPELINE LAYING ACTIVITIES.. Contd.:
LOWERING
Lowering shall commence after inspection of trench. Trench bottom shall be free from pipe supports, stones, roots, debris, stakes, and rigid material. Padding shall be provided in rocky/ murram area.
Lowering shall commence as soon as possible after completion of joint coating, Before lowering in, complete check by a full circle holiday detector for pipe coating and field joint coating at 15 KV is carried out (Speed 300mm /sec). Any damage shall be repaired. Support/ skid points shall be thoroughly checked.
The pipeline must be laid without interruption for the whole or the length of section available
Ends of the lowered pipeline section shall be closed with night cap to prevent ingress of water, mud etc.
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CROSS COUNTRY PIPELINE WORKS PIPELINE HOLIDAY AND LOWERING ACTIVITY
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PIPELINE LAYING ACTIVITIES.. Contd.:
BACKFILLING
CROSSINGS
Backfilling shall be carried out immediately after pipeline lowering in trench after inspection, so as to provide a natural anchorage for the pipeline, thus avoiding long exposure of coating to high temperature, damaging action of adverse weather conditions, sliding down of trench sides and pipeline movement in the trench. Backfill material shall not contain any extraneous material or hard lumps of soil which can damage pipeline or coating or leave the voids in backfilled trench. After placing of initial backfill, proper compaction shall be done. The surplus material shall be crowned (300 mm) directly over trench and adjacent excavated area on both side of trench. If trench are excavated in steep area where the slope is more than 10%, slope breakers shall be installed to prevent erosion of backfill. Stabilization of backfill shall be done in sandy area to have consolidated cover over the pipeline. Cased & Un-cased crossings for Roads & Railways Open cut & Horizontal Directional Drilling (HDD) for Minor & Major River Crossing
TIE-INs
The unconnected sections of the lowered pipeline sections at various locations have to be welded, coated and backfilled to make the sections ready for post installation hydro test . If a pup piece cannot be avoided for tie in, the minimum 1.0 m length shall be added. Engineers India Ltd – Delivering excellence through people
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CROSS COUNTRY PIPELINE WORKS PADDING & BACKFILLING
BOARING FOR CASED CROSSING
TIE-IN IN PROGRESS
TIE-IN WELDING IN PROGRESS Engineers India Ltd – Delivering excellence through people
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PIPELINE LAYING ACTIVITIES.. Contd.:
HYDRO-TESTING
Hydrostatic test is performed on entire length of the pipeline. The maximum permitted length is 50 Kms. Hydrostatic test diagrams indicating number of test sections and minimum and maximum test pressure in each test section are prepared before performing hydrostatic test.
Hydrostatic test commence only after completion of all welding works so as to avoid/ minimize untested hydro-test joints/ Golden joints.
Hydro test includes all those sections which are tested earlier for Road, rail road crossings, major water crossings etc.
Duration of hydrostatic test is minimum 24 hours after thermal stabilization. Hydro-static test pressure for pipeline handling hydrocarbon in gaseous phase is 1.25 times the design pressure in pipeline located in Class-1 & 2 locations and 1.4 times the design pressure if pipeline located in Class-3 & 4 locations.
Before water filling, pipeline shall be cleaned with air driven pigs with spring loaded brushes and chiseled to remove all mill scale, rust, sand etc. from the internal pipe section.
After successful cleaning and acceptance, gauging is carried out using gauging pig.
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PIPELINE LAYING ACTIVITIES.. Contd.:
HYDRO-TESTING..Contd,
After acceptance of gauging operation, un-inhabited water is pumped into the section using four cup batching pigs which are launched at specific intervals.
After water filling operation, thermal equilibrium between pipeline and environment shall be checked with thermocouples installed on the pipeline.
After thermal stabilization pressurization is carried out in cycles of 50% test pressure & 75% test pressure and held for 1 hour at each test pressure and depressurized to zero pressure and then pressurized to final test pressure. During each test pressure, two test shall be carried out for calculation of air volume in the pipeline under test and on acceptance of air volume test the section is held for 24 hours at Final test pressure and pressure and temperature recorded on chart.
The hydrostatic test shall be considered positive if pressure has kept a constant value throughout the test duration, except for change due to temperature effects. The pressure value thus added shall be compared with initial value and the test shall be considered as acceptable if the difference is less than or equal to 0.3 bar.
After positive test results, test shall be terminated . The pipeline shall be depressurized at constant rate. Dewatering shall be carried out by using four cup pigs driven by compressed air. Foam pigs shall be passed to complete the dewatering. Engineers India Ltd – Delivering excellence through people
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PIPELINE ACTIVITIES Contd.:
PIPELINE MARKERS, CLEAN-UP AND RESTORATION
Following type of markers shall be fabricated and installed along the pipeline route such that they do not cause any hindrance to the regular land user or traffic − − − − − − −
Aerial Markers Kilometer Markers Pipeline Warning Markers ROU Boundary Markers Direction Markers Navigational Markers OFC Markers
: At every 5 Kms. : At every 1 Km. & as per Alignment sheet : At Road / Railway / River Crossings & Stations / Terminals : At every 750 Mtrs. & as per Alignment sheet : At significant turning points : At bank of Navigational Course : At OFC Joints
ROU and all sites used for construction of pipeline , water crossing and other structures shall be restored as per satisfaction of authority having jurisdiction over it. Damages to roads, bridges, fences etc. damaged during construction shall be restored to original. The bed of water course shall be restore to the original level. The banks and any excavated area shall be restored to original levels . The banks shall also be stabilized. On completion of clean-up, the ROU shall be restored to such stable and usable condition as may be reasonably consistent with the condition of the ROU prior to laying the pipeline. The release note from the land owner s regarding satisfactory indemnification and restoration of land shall be obtained from land owner. Engineers India Ltd – Delivering excellence through people
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CROSS COUNTRY PIPELINE WORKS
PIPELINE ACTIVITIES Contd.:
SV / IP / DT, PS & RT STATION WORKS
Sectionalizing Valve (SV) are installed at regular intervals (around 25 to 40 Kms.) to isolate pipeline section during emergencies like leakage in pipeline as per statutory requirements. An SV station is installed at such locations having a unmanned control room with a guard room and boundary wall. A lockable grill cage is provided over the Sectionalizing Valve installation including piping and instrumentation to prevent tampering by unauthorized persons and ensuring safety of pipeline operations.
Intermediate Pigging (IP) stations are installed at regular intervals (as per design ~ 150 Kms.) having a Pig Launcher and a Pig Receiver with Control room, Sump tank, Basket Filters, guard room, boundary wall etc. to facilitate pigging of pipeline during routine Operation and Maintenance.
Dispatch Terminal (DT), Pump Station (PS) & Receipt Terminals are provided at start, intermediate & end locations of the Pipeline to facilitate handling and pumping of the product through the pipeline. It comprises of Pig Launcher / Pig Receiver with Control room, Mainline & Booster Pumps (DT/PS), Sump tank, Basket Filters, guard room, Firewater system, boundary wall etc.
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CROSS COUNTRY PIPELINE WORKS TYPICAL SECTIONALIZING VALVE (SV) STATION
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PIPELINE ACTIVITIES Contd.:
MAGNETIC PIGGING & ELECTRONIC GEOMETRY PIGGING (EGP): Pre Commissioning Activity
This is a part of pre-commissioning activity, which ensures that there is no deformity in pipeline. This is done prior to filling the line with product.
Magnetic PIG loaded with high capacity magnets spread uniformly with high density polythene four cup PIG is launched to remove ferrous debris, mill scale, electrode pieces etc. The accumulated weight of this ferrous debris is checked after running the PIG through pipeline section. When the collected weight of ferrous debris is within limit for specific length of pipeline section, the line is ready for launching EGP tool.
After successful completion of magnetic pig run EGP tool is launched. This tool is mounted with battery operated battery device, which gives the reduction in pipeline Dia. at specific location in electronic form.
Any defect /deformity more than 3% of internal diameter of pipe (dent or ovality) is physically verified at site. Defect of more than 5% internal diameter of pipe are repaired by cutting the suitable length of pipe and re-welding and accepted after radiography.
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