Pipeline Coatings

PIPELINE COATINGS / FIELD JOINT COATING EXTERNAL

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TYPE OF MAIN LINE COATINGS

3 LPE (2 to 3.5mm thk)

FBE (0.45mm thk)

3 LPP (2 to 3.5mm thk)

DFBE (0.7mm thk) 2

PIPELINE COATINGS

DFBE ANTI CORROSION COATING HDPU THERMAL INSULATION (90mm thk) HDPE JACKET 5mm thk CTE COATING – 4.8mm thk

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BASIS OF SELECTION OF MAIN LINE COATINGS (NEW)

 PIPELINE OPERATING TEMPERATURE  PIPELINE DESIGN LIFE  PIPELINE DIAMETER  TYPE OF SOIL  AMBIENT TEMPERATURE  ROW CONDITIONS

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CONSTRUCTION PERFORMANCE

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BASIS OF SELECTION OF MAIN LINE COATING – OPERATING TEMPERATURE

 Polyethylene Coatings – 800C  Fusion Bond Epoxy Coatings – 1100C ~ 1400C

 Polypropylene Coatings – 1200C  Polymeric Tape Coatings - 600C

 Liquid Epoxy Coating - 1500C 5

THREE LAYER POLYETHYLENE COATING

DIN-30670 – “POLYETHYLENE COATING FOR STEEL PIPES & FITTINGS.

ISO-21809-1 – “ PETROLEUM & NATURAL GAS INDUSTRIES – EXTERNAL COATINGS FOR BURIED AND SUBMEREGED PIPELINES USED IN PIPELINES TRANSPORTATION SYSTEM PART-1 (3 LAYER PE & 3 LAYER PP) CAN/CAZ-Z245.21-06 – “EXTERNAL POLYETHYLENE COATING FOR PIPES.

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3LPE COATING PROCESS

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THREE LAYER POLYETHYLENE COATING DESIGNATION / COATING CLASSIFICATION DIN-30670

ISO-21809-1

CAN/CAZ.2451-06

DIN-30670 - N-n

Class-A

System-B1

DIN-30670 - N-v

Class-B

System-B2

DIN-30670 - S-n

Class-C

DIN-30670 - S-v Coating classes are based on N-Normal expected field duty - Operating Temperature S-Special - Transport -Handling n- normal thickness -Layer conditions - Operating conditions v- reinforced thickness - Soil Conditions - Expected Environmental Conditions

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THREE LAYER POLYETHYLENE COATING FUNCTIONAL PROPERTIES DIN-30670 Peel Strength(N/mm) @23°c

N-n 3.5

Tmax (Pull speed 10N/mm)

Impact Strength J/mm @ 23°c Indentation -23°c - Tmax Cathodic disbondment 65°C/24hrs(-3.5V) 20°C/28 days(-15V) 65°C/28days(-1.5V)

ISO-21809-1

S-n 3.5

A 10

1.5 (50°c)

2.5 (70°c)

2 (60°c)

N-n 5

S-n 5

N-n ≤ 0.2mm ≤ 0.3mm (50°c)

S-n 0.2mm ≤ 0.3mm (70°c)

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A 5

B 15

3 (80°c)

B 7

C 23

B1 6

4 (90°c)

-

C 10

A B C ≤ 0.3mm ≤ 0.2mm ≤ 0.1mm ≤ 0.3mm ≤ 0.2mm ≤ 0.1mm

≤ 7mm ≤ 7mm ≤ 15mm

CAS-Z245.21-06

B1 3 -

≤ 12mm

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THREE LAYER POLYETHYLENE COATING OPERATING TEMPERATURES

DIN-30670

ISO-21809-1

CAN/CAZ.2451-06

Class-A : (– )20°C to (+) 60°C DIN-30670- N up to 50° C

(LDPE) Class-B : (– )40° C to (+) 80 °C

(MDPE/HDPE) DIN-30670- S up to 70° C

Not Clearly Specified. However, the purchaser has to specify the max design temp.

Class-C ; (– )20°C to (+)110°C (PP)

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VIPUL KUMAR, PEng, Deputy General ManagerEngineering

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M 1 Infield Pipeline Pressure Class Length Kms  Power Fluid Lines 1500# 10  Water Injection Lines 900# 10  Production Fluid Lines 600# 53 R1 Infield Pipeline 600# 7 MR Pipeline  Gas Line 12” API 5LX60 PSL2 300# 90  Condensate Line 4” API 5LX 65 600# 90 T Pipeline  Water Supply Line 20” API 5LX 65 PSL2 20 Total Pipeline Length

280 Vipul Kumar, PEng

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Innovative Techniques Four Cluster of Well pads created to save on Flow lines cost from 18 individual well pads to M Field  Trunk lines laid for Power Fluid & Water Injection in pipeline corridor & connecting well pads to Trunk lines thus saving cost on lines from individual well pads to MPT. 

Cairn India – 2010 Technical Forum (October 20th & 21st) Celebrating Our Technical Achievements

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Initial Design Concept Heavy design on Anchor Flanges and Anchor Blocks  Anchor Block Estimated Quantity of RCC=24000 Cum 

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Innovative Efforts Improvisation on Basic Design of Anchor Flanges & Blocks  Added bends to reduce total applicable force  Anchor flanges on downstream of Water and gas lines eliminated after review  Above resulted in to Reduction of RCC to 10000 Cum(i.e. reduction of 58 %) 

Vipul Kumar, PEng

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ANCHOR FLANGE/ BLOCK DESIGN

Cairn India – 2010 Technical Forum (October 20th & 21st) Celebrating Our Technical Achievements

Vipul Kumar, PEng

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Reinstatement of Flow-lines Prior to Re-Start Oil in flow lines likely to congeal in black out/ shut down condition.  Original design envisaged tapping at every 500 meters for flushing congealed oil with hot water.  On design review the arrangement considered of high risk. 

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INNOVATIVE TECHNIQUE 

On power black out/ shut down displace oil in flowlines with water to ensure oil will not stay in flow lines.

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Installed diesel driven high capacity pump at MPT end itself. Vipul Kumar, PEng

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Thumbli Main Header 

Originally header design concept • Horizontal header on sloped graded area • Header of uniform size pipes

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Design Review Sloped header to match graded slope  Header of Multiple sizes matching with flow requirement 

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Advantages Saving on concrete cost  Saving on pipe cost 

Vipul Kumar, PEng

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Sectionalizing Valve Location 

As per ASME B 31.8 Sectionalizing valves provided as per location Class

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Original design provided for installation of vents and drains along with Sectionalizing valves. However, various constraints were not permitting this feasible.

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On design review, risk assessment and proper interpretation of OISD 141 recommended design was modified to eliminate drains and vents. Cairn India – 2010 Technical Forum (October 20th & 21st) Celebrating Our Technical Achievements

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Gas and Condensate lines from MPT to RGT(90 Kms) passing through villages and populated area Considered high safety and Security Risks Intrusion detection system introduced 

Multifunctional120 Core Optical Fiber cable • Intrusion Detection System • Access control system • Data Network • Hotline • PAGA System Vipul Kumar, PEng

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ZINC RIBBON CONFIGURATION IN CASING

Cairn India – 2010 Technical Forum (October 20th & 21st) Celebrating Our Technical Achievements

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Anti-buoyancy Method  

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Innovative Technique 

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Original design concept for concrete coating Recommended in coating yard to achieve desired density

Geo text bags filled with gravel material used

Advantages  

Saving on time Saving in logistics Vipul andKumar, cost PEng

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OPTIONS CONSIDERED All 14 Pipelines on Steel / Concrete structure Bridge  Horizontal Directional Drilling  Bury below soil erosion point 

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TECHNO-COMMERCIAL FEASIBLE OPTION IMPLEMENTED 1200 X 25 X 6 meters open excavation  Pipe-layers, cranes, trailers, welding sets etc lowered in excavated trench  All 14 pipelines laid & trench backfilled 

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ADAVANTAGES ACCRUED 

Saving on time and cost Vipul Kumar, PEng

Launcher and Receiver skids matching Hot bends and Cold bends Inclusion of Magnetic Pigging TCP and PCP System MIJs GOC OFC Hydro-testing Drying with Compressor Magnetic pigging Nitrogen Packing of Pipelines Vipul Kumar, PEng

Launcher and Receiver skids matching Hot bends and Cold bends Inclusion of Magnetic Pigging TCP and PCP System MIJs GOC OFC Hydro-testing Drying with Compressor Magnetic pigging Nitrogen Packing of Pipelines Vipul Kumar, PEng

Vipul Kumar, PEng

Vipul Kumar, PEng

Cairn India – 2010 Technical Forum (October 20th & 21st) Celebrating Our Technical Achievements

Cairn India – 2010 Technical Forum (October 20th & 21st) Celebrating Our Technical Achievements