Pipeline Design
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Pipeline Design...
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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
Pipeline Design Slide Number - 2 of 77
Petroleum Refineries Petrochemicals Pipelines Offshore Platforms Gas Processing Metallurgy Ports & Terminals Highways and Airports Engineers India Ltd – Delivering excellence through people
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EIL OFFICES HEAD OFFICE
NEW DELHI
REGIONAL OFFICES
VADODARA, CHENNAI KOLKATA
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
Engineers India Ltd – Delivering excellence through people
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PIPELINE DESIGN SERVICES OFFERED BY EIL Project Implementation Services
Specialist Services
Feasibility Studies
Heat & Mass Transfer Equipment
Project Management
Design
Planning & Scheduling
Environment Engineering
Process Design
Information Technology Services
Detailed Engineering
Specialist Materials and
Procurement Services
Maintenance Services
Construction Management
Plant Operation & Safety
Commissioning and Plant
Risk Analysis
Start-up Assistance
Advanced Control & Optimization
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Pipeline Design Slide Number - 5 of 77
PIPELINE DESIGN EIL EXPERIENCE 1975
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. Engineers India Ltd – Delivering excellence through people
Pipeline Design Slide Number - 6 of 77
PIPELINE DESIGN Major Onshore Projects (Completed) DESCRIPTION
CLIENT
YEAR
SIZE
LENGTH (KM)
GAIL
1989
36“/30”/24”/18”
1800
NATURAL GAS
ADNOC
1992
30 ”/12”
166
NATURAL GAS
KANDLA--BHATINDA KANDLA
IOCL
1996
22”/14”/10”
1443
MULTIPRODUCT
GAS REHABILITATION & EXPANSION PROJECT (GREP)
GAIL
1998
36 ”
505
NATURAL GAS
MUMBAI – MANMAD
BPCL
1998
18 ”
260
MULTIPRODUCT
VIZAG--VIJAYWADA VIZAG
HPCL
1998
18 ”
360
MULTIPRODUCT
JAMNAGAR-LONI LPG JAMNAGARPIPELINE
GAIL
2001
16”/14”/12”/8”/ 6
1235
LPG (LIQUIFIED PETROLIUM GAS)
PETRONET
2001
18 ”/14 ”
289
MULTIPRODUCT
HAZIRA-BIJAIPURHAZIRABIJAIPURJAGDISHPUR (HBJ) MAQTA--AL MAQTA AL--AIN PIPELINE
COCHIN – KARUR PIPELINE
Engineers India Ltd – Delivering excellence through people
SERVICES
Pipeline Design Slide Number - 7 of 77
PIPELINE DESIGN Major Onshore Projects (..contd) (Completed) DESCRIPTION
CLIENT
YEAR
SIZE
LENGTH (KM)
VIZAG – SECUNDERABAD LPG PIPELINE
GAIL
2002
12”/10”
600
LPG (LEQUIFIED PETROLEUM GAS)
MANMAD--MANGALAYA PIPELINE MANMAD
BPCL
2003
14 ”
358
MULTIPRODUCT
MANGALORE--BANGLORE MANGALORE
HPCL
2003
24 ”/20”
364
MULTIPRODUCT
DAHEJ – VIJAIPUR PIPELINE
GAIL
2003
42”
610
REGASIFIED LNG
TAKREER
2004
10” 12” 16”
230 230 208
NAPHTHA, MULTIPRODUCT & SRR
MANGALAYA-BIJWASAN MANGALAYAPIPELINE
BPCL
2006
16”/8”
775
MULTIPRODUCT
MUNDRA--DELHI PIPELINE MUNDRA
HPCL
2006
18”/16”
1050
MULTIPRODUCT
INTER REFINERIES PIPELINES PROJECT, ABU DHABI
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SERVICES
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PIPELINE DESIGN Major Onshore Projects (7contd) (Completed) DESCRIPTION
CLIENT
YEAR
SIZE
LENGTH (KM)
PUNE SOLAPUR PIPELINE
HPCL
2007
14 ”/ 12”
182 / 161
MULTIPRODUCT
DABHOL PANVEL PIPELINE PROJECT (PH(PH-I)
GAIL
2007
30”
187
REGASIFIED LNG
DABHOL PANVEL PIPELINE PROJECT (PH(PH-II)
GAIL
2007
30”
120
REGASIFIED LNG
Engineers India Ltd – Delivering excellence through people
SERVICES
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PIPELINE DESIGN Major Offshore Projects (Completed) DESCRIPTION
CLIENT
YEAR
SIZE
LENGTH (KM)
SERVICES
BOMBAY HIGH URAN TRUNKLINE (BUT)
ONGC
1979
30”/26”
200 x 2
SOUTH BASSEIN HAZIRA TRUNKLINE
ONGC
1986
36”
220
HEERA--URAN TRUNK LINE HEERA
ONGC
1996
26 ”/24 ”
85 x 2
ICP - HEERA TRUNKLINE
ONGC
1996
30”/22”
145
CRUDE
SECOND BASSEIN HAZIRA TRUNKLINE
ONGC
1995
42”
245
GAS
MUMBAI HIGH URAN TRUNKLINE (MUT)
ONGC
2005
30”/28” 12” to 22”
205 x 2 100
CRUDE, GAS GAS CRUDE, GAS
CRUDE, GAS
IN-FIELD PIPELINES OF BOMBAY-HIGH, BASSEIN, HEERA, NEELAM, PANNA, MUKTA.
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Pipeline Design Slide Number - 10 of 77
PIPELINE DESIGN Major Onshore Projects (Current) DESCRIPTION
CLIENT
YEAR
SIZE
LENGTH (KM)
SERVICES
VIJIPUR DADRI BAWANA PIPELINE (VDBPL)
GAIL
2009
48”/ 36”/ 20”
500/ 38/ 55
REGASIFIED LNG
MUNDRA BATHINDA PIPELINE (MBPL)
HMPL
2009
28”/ 30”
424/ 590
CRUDE OIL
BINA KOTA PIPELINE
BPCL
2009
18”
257
MULTI PRODUCT
VADINAR BINA PIPELINE
BORL
2009
24”
935
CRUDE OIL
NUMALIGARH SILIGURI PIPELINE
OIL
2009
16”
400
MULTI PRODUCT
COMPRESSOR STATIONS
GAIL
---
---
---
REGASIFIED LNG
IN-FIELD PIPELINES OF BOMBAY-HIGH, BASSEIN, HEERA, NEELAM, PANNA, MUKTA.
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PIPELINE DESIGN SECTION-1
INTRODUCTION
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PIPELINE DESIGN CONTENTS INTRODUCTION
Modes of Transportation Benefits of Pipelines
PIPELINE DESIGN
Stages of Pipeline Project Codes and Standards Design Installation, Testing & Commissioning
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Pipeline Design Slide Number - 13 of 77
PIPELINE DESIGN Oil and Gas Production in India
OIL
33 MMTPA
(ONGC, OIL, CAIRN, RIL)
GAS
115 MMSCMD
(ONGC, GAIL, OIL, GSPC, RIL)
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Pipeline Design Slide Number - 14 of 77
PIPELINE DESIGN Refining Scenario- India 350
Capacity - 2006-07 NOC – 105.5 MMT Others- 43.5 MMT 302
(MMT)
300
235
250
200
149 150
100
70
50
0
1998-99
2006-07
2011-12
2016-17
(Actual) Year Engineers India of LtdWorking – Delivering excellence through people Source: Report Group on P&NG Sector for the XI Plan
Pipeline Design Slide Number - 15 of 77
PIPELINE DESIGN Modes of Hydrocarbon Transportation - India 35% 30%
Pipelines Road Tankers
32%
25%
32%
20%
Pipelines Road Tankers Rail Tankers Water Carriers
15%
Rail Tankers
26%
Water Carriers
10%
10% 5% 0% % Share
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Pipeline Design Slide Number - 16 of 77
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
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Pipeline Design Slide Number - 17 of 77
PIPELINE DESIGN Energy Savings 4 3.2
3.5 Transported
Energy Consumption in % of energy
Energy Intensity for Various M ode s
3 2.5
2
2 1.5 1 0.5
0.8 0.5
0.8
1.1
1
0 LiquidPipelines
LiquidCoastal
LiquidTrains
LiquidTrucks
CoalTrains
CoalCoastal
N.GasPipelines
Pipelines are the most energy efficient modes of transportation Engineers India Ltd – Delivering excellence through people
Pipeline Design Slide Number - 18 of 77
ECONOMICS OF PIPELINE TRANSPORTATION
Transmission losses Losses During Transportation
Rail/Road
Pipelines
0
0.1
0.2
0.3
0.4
0.5
% Loss of Total Volum e Transported
Transmission losses are lowest in Pipelines Engineers India Ltd – Delivering excellence through people
Pipeline Design Slide Number - 19 of 77
PIPELINE DESIGN Products Transported
Crude Oil Petroleum Products (MS, HSD, ATF, SKO) Water & Effluents LPG Natural Gas Slurries
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Pipeline Design Slide Number - 20 of 77
PIPELINE DESIGN
Types of Pipelines ONSHORE (LAND) & OFFSHORE (SUBMARINE) PIPELINES
Trunk Pipelines
Spur/ Branch Pipelines
Marine Offloading Terminals & Outfalls
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Pipeline Design Slide Number - 21 of 77
PIPELINE DESIGN
Capital cost: Typical breakup P e r c e ntag e of C a p ita l Cos t.
Ite m D e s cription
S r o.
Liquid Line s
Gas Line s
1
Su rv e y , ROW & Co mp e n s a tio n
2%
1%
2
Lin e Pip e Ste e l Co s t
33%
45%
3
M a in lin e ma te ria ls
2%
3%
4
Co a tin g o f Pip e s
11%
6%
5
M a in lin e Co n s tru c tio n
33%
25%
6
Ca th o d ic Pro te c tio n
1%
1%
7
T e le c o mmu n ic a tio n , SCA DA a n d RCPs
5%
2%
8
Pu mp / Co mp re s s o r Sta tio n s
5%
12%
9
De liv e ry T e rmin a l fa c ilitie s
2%
1%
10
Pro je c t M a n a g e me n t
5%
4%
11
S ubTotal
100%
100%
Pipes, prime-overs and construction constitute big ticket items Engineers India Ltd – Delivering excellence through people
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PIPELINE DESIGN Marine Offloading Terminal
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PIPELINE DESIGN Open sea Jetty
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PIPELINE DESIGN HBJ GAS PIPELINE NETWORK UTTAR PRADESH N
DELHI
RAJASTHAN
DADRI
ANOLA SHAHJAHANPUR
BABRALA
INDIA GADEPAN
ANTA
AURAIYA JAGDISHPUR
BIJAIPUR
GUJARAT JHABUA ARABIAN SEA
MADHYA PRADESH HAZIRA
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KEY PLAN LEGEND COMPRESSOR STATION RECEIVING TERMINAL DESPATCH STATION
Pipeline Design Slide Number - 25 of 77
PIPELINE DESIGN Major Pipelines in India
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PIPELINE DESIGN Pipeline Construction Video Video for Mangalore Bangalore Pipeline
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PIPELINE DESIGN SECTION-2
PIPELINE DESIGN
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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
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Pipeline Design Slide Number - 29 of 77
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
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Pipeline Design Slide Number - 30 of 77
PIPELINE DESIGN Major Codes & Standards Code/Standard
Title
ASME B 31.8 (2003)
Gas Transportation and Distribution Piping Systems
ASME B 31.4 (2006)
Pipeline Transportation Systems for Liquid Hydrocarbons and other Liquids
OISD--141 (2003) OISD
Design and Construction Requirements for Cross Cross--Country Hydrocarbon Pipelines
OISD--214 (2006) OISD
Cross Cross--Country LPG Pipelines
OISD--226 (2007) OISD
Natural Gas Transmission Pipelines and City Gas Distribution Networks
API 5L / ISO 3183 : 2007
Specification for Line Pipe
API RP1102
Recommended practice for Rail and Highway crossings
API 1104
Standard for welding pipeline and related facilities
API 6D / ISO 14313
Pipeline Valves
DNV OSOS-F101
Submarine pipeline systems
Other References
Applicable Standards / Specs of ASME, API, NACE, MSS, BS and DIN
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Pipeline Design Slide Number - 31 of 77
PIPELINE DESIGN Major Codes & Standards Type of Crossing ROU & Land Acquisition
Approval Authority Central/State Govt. as applicable (As per PMP Act 1962)
National Highway Crossings
NHAI
SH/ MDR/ ODR Crossings
PWD
Railway Track crossings
Indian Railways
Crossing through Forest land
Forest Authority
River/Canal crossings
Irrigation/Canal Authority
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Pipeline Design Slide Number - 32 of 77
LIST OF SOFTWARES USED IN PIPELINE ENGINEERING
CAESAR-II CAESARAUTOPIPE IPMCS MRPACK SORPS PIPECALC OFFPIPE PRISE PIPECROSS
PIPELINE STUDIO TGNET TLNET HYSIS
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PIPELINE DESIGN Optimal sizes of various capacities
Economy of scale Engineers India Ltd – Delivering excellence through people
Pipeline Design Slide Number - 34 of 77
PIPELINE DESIGN Route Selection Routing Considerations
Pipeline length Obstructions & Sensitive areas Installation Limitations Crossings
Surveys
Topographical Geo-technical Population Density Index Soil Resistivity Cadastral Engineers India Ltd – Delivering excellence through people
Pipeline Design Slide Number - 35 of 77
PIPELINE DESIGN Typical Pipeline Route Map BHATINDA Ch. 1012.67 km
IP-1 & IPS-F
RANSISAR Ch. 855.01 km
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
IPS-1
JORAWARPURA Ch. 313.63 km
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.
IPS-F
JHEKDA Ch. 226.72 km
MUNDRA Ch. 0.00 km
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Pipeline Design Slide Number - 36 of 77
PIPELINE DESIGN
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Pipeline Design Slide Number - 37 of 77
PIPELINE 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
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Carbon Steel (CS) NACE Carbon Steel CRA Clad CS CS with internal Coatings Non-Metallic Materials
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PIPELINE DESIGN Design and Analysis
Wall Thickness Calculations
Anti-Buoyancy Measures
Piping Stress Analysis
Buried Pipeline Analysis
Crossing Design
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Pipeline Design Slide Number - 39 of 77
PIPELINE DESIGN Steel Pipe Wall Thickness Calculation LIQUID PIPELINE
GAS PIPELINE
(ASME B 31.4, Cl. 404.1.2)
(ASME B 31.8, Cl. 841.11)
t = PiD 2.S
P = 2St FET D
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
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
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Pipeline Design Slide Number - 40 of 77
PIPELINE DESIGN Basic Design Factor for Gas Pipelines LOCATION 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 : Location Class 2 : Location Class 3 : Location Class 4 :
≤ 10 buildings > 10 and < 46 buildings ≥ 46 buildings Multistory buildings
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PIPELINE DESIGN Line Pipe Selection Line Pipe Selection Parameters
Type of Line Pipes
Thickness and Grade Selection
Seamless
Electric Welded
Handling and Transportation (d/t ratio)
Type of LinePipe
Longitudinal Seam Submerged--Arc Welded Submerged (LSAW)
Installation Requirements
Helical Seam SubmergedSubmergedArc Welded
(HSAW)
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PIPELINE 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”)
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PIPELINE DESIGN Manufacturing of Helical Pipes
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PIPELINE DESIGN Anti-corrosive Coatings
Coal Tar Enamel Coating (BS 4164, AWWA C203)
3 Layer PE/ PP Coating (DIN 30670)
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
Fusion Bonded Epoxy Coating (CSA Z245.20)
350-500 micron thick single layer coating 350600--800 micron thick dual layer coating 600
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PIPELINE DESIGN 3 Layer PE Coating Application
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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
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PIPELINE DESIGN Scraper traps
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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
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
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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 Engineers India Ltd – Delivering excellence through people
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PIPELINE DESIGN Ball valves
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PIPELINE DESIGN Plug valve
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PIPELINE DESIGN Check valve
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PIPELINE DESIGN Major Engineering Deliverables Design Reports Design Route Wall
Basis
Selection Report
Thickness Report
Seismic
Design Report
Crossing
Design Report
Drawings Route
Map
Pipeline
Schematic
Alignment SV
Sheets
Station Layout
Equipment
Layout
Piping
General Arrangement Drawings
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PIPELINE DESIGN Typical Pipeline Alignment Sheet TP50
INTERSECTION POINTS(IP/TP)
IP50/1 TP51
38°4'58''(R)
DEFLECTION ANGLE DISTANCE BETWEEN TP & IP's(m) DISTANCE AS PER GROUND PROFILE
IP51/1
TP52
29°8'20''(L)
TP53
TP54
5°18'55''(R) 8°2'3''(L)
TP55 TP56
37°0'54''(L)
13°54'57''(R)
TP57
11°25'7''(L)
TP58 IP58/1
1°21'55''(L)
TP59
8°24'45''(R)
TP60
2°8'32''(L)
TP61
14°0'19''(R)
IP61/1
TP62
8°30'18''(L)
TP63
15°2'57''(L)
TP64
10°4'42''(L)
67.046 25.199 85.000
187.855
76.544
339.096
176.463
38.749
322.708
141.760
45.000
104.113
224.969
393.395
218.000
348.437
326.642
67.049 25.200 85.284
187.993
76.618
339.126
176.478
38.853
322.772
141.845
45.093
104.624
225.022
393.407
218.014
348.444
326.679
IP64/1
TP65
10°25'50''(L)
5°18'12''(R)
237.677
65.521
90.164
237.707
65.728
90.390
STATE , DISTRICT AND MANDAL TO IRUVADA
TP65 CH. 14134.896m
M RA PU
IP64/1 CH.14044.732m
CH. 10985.658m TP53 CH. 11062.202m
CH. 12125.978m
ELECTRIC LINE 440V CH.11018.117m
SV-1 OF GAIL CH.11960.218 m
K
CH. 11401.298m
HIGH TENSIONLINE 12.2m HIGH& 550KV VILLAGE BOUNDARY AMRUTAPURAM IRUVADA
CH.12747.397m
40.816 48.521
237.676
248.929
37.219
CART TRACK CH 13492.61m/RL 33.622m 33.622
32.444 77.714
166.780
182.117
30.893
28.935
29.135
217.539
29.219 94.141
299.254
30.557
25.884 114.747
ROAD CH 12060.88m/RL 24.604m
DRAIN C H 12115.34m/RL 22.175m 22.175
24.604 23.667 20.101 34.366
121.660
90.342
24.341 24.675 66.597
ST AT E
HIG HW AY -SA BB AV AR AM
14.115 14.135
13.248 13.248
14.115 14.135
13.066 13.066
13.979
12.848 12.848
14.028 14.040
12.754 12.754
13.979
12.455 12.455
14.028 14.040
12.230 12.230
13.742
12.115
13.742
12.061 12.081 12.061 12.081
12.115
13.415
11.939 11.960 11.972 11.984 11.939
13.493
11.825 11.849 11.825 11.849
13.415
11.758 11.758
Engineers India Ltd – Delivering excellence through people
13.493
11.578
11.617
11.401 11.401
11.578
11.259 11.259
11.617
10.986
11.025
11.062
10.986
11.025
RICE FIELDS
11.062
10.787 10.787
25.138
24.858
141.522
27.904 38.749
176.463
142.134
25.362
27.370
29.815
196.962
30.300
31.496 39.369
37.175
198.636
10.665
10.692 10.713
10.665
10.692 10.713
KAJU GARDEN
24.828
DRAIN CH 11824.63m/RL 24.341m
OPEN WELL 6m DIA 8m FROM C/L CH11577.761m
24.246
CANAL CH 10691.6m/RL 35.411m
OPEN WELL 6m DIA 7.648mFROMC/L CH.11648.136m
PUMP HOUSE 4m FROMC/L
32.587
35.411 33.560
33.366
26.894 21.199
74.219
37.325 44.152
K TRAC CART 2.606m 49 CH.13
HPCLCH. 17.00Km
HPCL CH. 16.00Km
GRAVEL ROAD CH.12060.877m
25 23 21
10.621
K
TEMP. HUT ON C/L
31 29 27
10.621
CH. 13066.455m
CH. 12848.455m
DRAIN CH.12115.344m TO A MRUT HAPU RAM
TP54
K
ROAD CH 10787.02m/RL 32.587m
DRAIN CH 10664.71m/RL 33.366m
35 33
RAIWADA LEFT CANAL (UNLINED) CH.14027.732m GRAVEL ROAD CH.14040.275m
DRAIN CH.12903.743m
TBMW49 (RL 25.138m)
43 41 39 37
TO
TBMW57(RL42.533m) TP62 CH. 13414.892m
IP61/1
TP61
CH. 12230.091m
CH. 11616.510m HPCLCH. 15.00Km
45
SCALE: HORIZONTAL 1:5000 VERTICAL 1: 500
TP55 CH. 11577.761m TP56
CH. 12455.060m
TP59 IP58/1
224.969
MATCH LINE FOR CONT. REFER DWG NO.4529-10-16-71-9003
A GUTL GRAVEL ROAD INTA CH.10787.022m TO CH
TP57
CH. 11939.218m
TP63 CH. 13741.534m EARTHEN EMBANKMENT
TP60
R OAD C H 14040.27m/RL 42.491m
DRAIN C H.11824.629m
TP52
LOW LYING AREA
TP58 CH. 12080.978m
AM
0m .71 AIN 664 DR H.10 C
ELECTR CH.1184 IC LINE 8.88m
RAIWADA LEFT CANAL (UNLINED) CH. 10691.604m
CANAL CH 14027.73m/RL 39.741m
IP51/1 CH. 10797.803m
CART TRACK CH 14115.31m/RL 43.684m
CH. 10712.803m
UR THAP AMRU NDA
CH. 10687.604m
43.684 43.034
TO PE
IP50/1 TP51
MATCH LINE FOR CONT. REFER DWG NO.4529-10-16-71-9005
EARTHEN EMBANKMENT
TELEPHONE LINECH.14134.896m METALLED ROAD(ASPHALTIC) CH.14115.309m ELEC. LINE 440V CH.14132.231m
TP64 CH. 13979.211m
19.588
A
39.741 42.491
TO
CH. 10620.558m
PE
RIT AM
75.034
TP50
A ND
12.543
TBMW40 (RL 37.514m)
Pipeline Design Slide Number - 56 of 77
PIPELINE DESIGN Typical P&ID
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Pipeline Design Slide Number - 57 of 77
PIPELINE DESIGN Typical GA DRAWING
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Pipeline Design Slide Number - 58 of 77
PIPELINE DESIGN Major Engineering Deliverables Tenders
Survey Tender Pipe Coating Tender Pipeline Installation Tender
Material Procurement
Line Pipes Valves & Actuators Scraper Traps, QOEC, Pig Signallers Flow Tees & Insulating Joints Induction Bends Flow meters Pumps & Compressors OFC cables
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Pipeline Design Slide Number - 59 of 77
PIPELINE DESIGN Installation, Testing & Commissioning RoU Grading & Trenching
Stringing of Linepipe
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Pipeline Design Slide Number - 60 of 77
PIPELINE DESIGN Installation, Testing & Commissioning Welding & NDT :
Edge Preparation Internal / External Line-up Clamps Manual / Automatic Welding NDT (X-Ray / UT / MPI etc.)
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Pipeline Design Slide Number - 61 of 77
PIPELINE DESIGN Installation, Testing & Commissioning Field Joint Coating
Lowering & Backfilling
Heat Shrink Sleeves Cold applied tapes
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Pipeline Design Slide Number - 62 of 77
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
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Pipeline Design Slide Number - 63 of 77
PIPELINE DESIGN The conventional HDD operations for river crossings.
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Pipeline Design Slide Number - 64 of 77
Boring Across Road crossings.
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Pipeline Design Slide Number - 65 of 77
Boring Across Road crossings, showing Auger used for Boring
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Pipeline Design Slide Number - 66 of 77
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
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Pipeline Design Slide Number - 67 of 77
PIPELINE DESIGN Schematic Diagram
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Pipeline Design Slide Number - 68 of 77
PIPELINE DESIGN Pipeline Installation using Micro-tunnelling Long Distance Micro Tunnelling
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Pipeline Design Slide Number - 69 of 77
PIPELINE DESIGN Overview of Micro tunneling
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Pipeline Design Slide Number - 70 of 77
PIPELINE DESIGN Testing & Commissioning TESTING
Gauging and Pigging Test Pressure Test Medium
TEST PRESSURE LIQUID PIPELINES Ref. ASME B 31.4 : 437.4.1 1.25 times design pressure
DRYING Swabbing Methanol Drying Super Dry Air Method Vacuum Drying COMMISSIONING Nitrogen Purging Product Charging
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
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Pipeline Design Slide Number - 71 of 77
PIPELINE DESIGN Pigging Requirements
Types of Pigs
Pipeline Cleaning Displacement Internal Inspection Batching
Cleaning pigs
Gauge Pigs
Brush pigs Gauge Pigs Spheres Intelligent Pigs
Spheres
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Intelligent Pig (MFL) Pipeline Design Slide Number - 72 of 77
PIPELINE DESIGN RECENT DEVELOPMENTS TECHNICAL IMPROVEMENTS
Automatic Welding & Automatic UT Micro--Tunneling for pipeline construction Micro
Internal flow coating on line pipes for gas pipelines 3LPP coating on High Temperature pipelines
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Pipeline Design Slide Number - 73 of 77
PIPELINE DESIGN Comparison of LSAW & HSAW Pipes Description
LSAW
HSAW
Method of Manufacture
UOE/COE/JCO/3 roll bending
Formed by Twisting of Coil
Weld Length
Equal to pipe joint length
Approximately 1.5 to 2 times the length of pipe joint
Position of weld
Longitudinal – positioned in upper quadrant during construction
Spiral – present all around the pipe
Corrosion Coating
Specified thickness throughout entire body. Weld seam is tracked to ensure coating thickness on weld seam
Thickness normally increased all over the body, resulting in proportional increase in coating cost by 1515-20%
Geometry
Controlled to the desired level with cold expansion
Controlled during forming only and no cold expansion is carried out
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Pipeline Design Slide Number - 74 of 77
PIPELINE DESIGN Coating Comparison CTE
3LPE
3LPP
FBE
Upto 45
Upto 65
Upto 110
Upto 110
Resistance to Moisture
Good
Very Good
Excellent
Good
Cathodic Disbondment
Fair
Good
Good
Good
Good
Excellent
Excellent
Excellent
Service Conditions Temperature, o C
Anti--corrosion Properties Anti
Electrical Properties Coating Resistance
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Pipeline Design Slide Number - 75 of 77
PIPELINE DESIGN Coating Comparison CTE
3LPE
3LPP
FBE
High
Low
Low
Low
Resistance to Impact
Fair
Excellent
Superior to PE
Fair
Resistance to Indentation
Poor
Very Good
Excellent
Fair
Resistance to Peel
Fair
Excellent
Superior than PE
-
Resistance to Soil Stresses
Fair
Excellent
Excellent
Excellent
Elongation
Fair
Excellent
Excellent
-
Cathodic Protection Design Current Density
Mechanical Properties
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Pipeline Design Slide Number - 76 of 77
PIPELINE DESIGN Coating Comparison CTE
3LPE
3LPP
FBE
Fair
Very Good
Very Good
Very Good
Long Term Ageing Heat & Light Ageing
Application & Field Repair Ease of Application
Easy
Relatively difficult
Relatively difficult
Relatively difficult
Damages during handling & transportation
High
Low
Low
High
Difficult
Easy for small repair, Cumbersome for larger repair
Easy for small repair, Cumbersome for larger repair
Easy for small repair, Cumbersome for larger repair
Ease of Field Repair
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Pipeline Design Slide Number - 77 of 77
Thank You
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Pipeline Design Slide Number - 78 of 77
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