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Pipeline Design

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PIPELINE DESIGN

Pipeline Design


Engineers India Ltd – Delivering excellence through people

ENGINEERS

INDIA LIMITED

EPC and Total Solutions

Consultancy Organization

Pipeline Design



Petroleum Refineries

Petrochemicals

Pipelines

Offshore Platforms

Gas Processing

Metallurgy

Ports & Terminals

Highways and Airports

Pipeline Design



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

EIL OFFICES

Pipeline Design



PIPELINE DESIGN

SERVICES OFFERED BY EIL

Project Implementation Services

� Feasibility Studies

� Project Management

� Planning & Scheduling

� Process Design

� Detailed Engineering

� Procurement Services

� Construction Management

� Commissioning and Plant

Start-up Assistance

Specialist Services

� Heat & Mass Transfer Equipment

Design

� Environment Engineering

� Information Technology Services

� Specialist Materials and

Maintenance Services

� Plant Operation & Safety

� Risk Analysis

� Advanced Control & Optimization

Pipeline Design



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.

Pipeline Design



PIPELINE DESIGN

DESCRIPTION CLIENT YEAR SIZE LENGTH

(KM)

SERVICES

HAZIRA-BIJAIPUR-

JAGDISHPUR (HBJ)

GAIL 1989 36“/30”/24”/18” 1800 NATURAL GAS

MAQTA-AL-AIN PIPELINE ADNOC 1992 30 ”/12” 166 NATURAL GAS

KANDLA-BHATINDA 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 HPCL 1998 18 ” 360 MULTIPRODUCT

JAMNAGAR-LONI LPG

PIPELINE

GAIL 2001 16”/14”/12”/8”/

6

1235 LPG (LIQUIFIED

PETROLIUM GAS)

COCHIN – KARUR PIPELINE PETRONET 2001 18 ”/14 ” 289 MULTIPRODUCT

Major Onshore Projects (Completed)

Pipeline Design



PIPELINE DESIGN


(KM)

SERVICES

VIZAG – SECUNDERABAD LPG

PIPELINE

GAIL 2002 12”/10” 600 LPG (LEQUIFIED

PETROLEUM GAS)

MANMAD-MANGALAYA PIPELINE BPCL 2003 14 ” 358 MULTIPRODUCT

MANGALORE-BANGLORE HPCL 2003 24 ”/20” 364 MULTIPRODUCT

DAHEJ – VIJAIPUR PIPELINE GAIL 2003 42” 610 REGASIFIED LNG

INTER REFINERIES PIPELINES

PROJECT, ABU DHABI TAKREER 2004

10”

12”

16”

230

230

208

NAPHTHA,

MULTIPRODUCT & SRR

MANGALAYA-BIJWASAN

PIPELINE

BPCL 2006 16”/8” 775 MULTIPRODUCT

MUNDRA-DELHI PIPELINE HPCL 2006 18”/16” 1050 MULTIPRODUCT

Major Onshore Projects (..contd) (Completed)

Pipeline Design




(KM)

SERVICES

PUNE SOLAPUR PIPELINE HPCL 2007 14 ”/ 12” 182 / 161 MULTIPRODUCT

DABHOL PANVEL PIPELINE

PROJECT (PH-I)

GAIL 2007 30” 187 REGASIFIED LNG

DABHOL PANVEL PIPELINE

PROJECT (PH-II)

GAIL 2007 30” 120 REGASIFIED LNG

PIPELINE DESIGN Major Onshore Projects (8contd)

(Completed)

Pipeline Design




(KM)

SERVICES

BOMBAY HIGH URAN TRUNKLINE

(BUT)

ONGC 1979 30”/26” 200 x 2 CRUDE, GAS

SOUTH BASSEIN HAZIRA

TRUNKLINE

ONGC 1986 36” 220 GAS

HEERA-URAN TRUNK LINE ONGC 1996 26 ”/24 ” 85 x 2 CRUDE, GAS

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

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

PIPELINE DESIGN Major Offshore Projects

(Completed)

Pipeline Design




(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.

PIPELINE DESIGN Major Onshore Projects

(Current)

Pipeline Design



PIPELINE DESIGN

SECTION-1

Pipeline Design



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



PIPELINE DESIGN

Oil and Gas Production in India

� OIL 33 MMTPA

(ONGC, OIL, CAIRN, RIL)

� GAS 115 MMSCMD

(ONGC, GAIL, OIL, GSPC, RIL)

Pipeline Design



Refining Scenario- India

70

149

235

302

0

50

100

150

200

250

300

350

1998-99 2006-07 2011-12 2016-17

(MMT)

Source: Report of Working Group on P&NG Sector for the XI Plan

(Actual) Year

Capacity - 2006-07

NOC – 105.5 MMT

Others- 43.5 MMT

PIPELINE DESIGN

Pipeline Design



PIPELINE DESIGN

Modes of Hydrocarbon Transportation - India

Pipelines 32%

Road Tankers 32%

Rail Tankers 26%

Water Carriers 10%

0%

5%

10%

15%

20%

25%

30%

35%

% Share

Pipelines

Road Tankers

Rail Tankers

Water Carriers

Pipeline Design



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



PIPELINE DESIGN

Energy Savings

Energy Intensity for Various Modes

0.8

0.51

3.2

0.81.1

2

0

0.5

1

1.5

2

2.5

3

3.5

4

Liquid-

Pipelines

Liquid-

Coastal

Liquid-

Trains

Liquid-

Trucks

Coal-

Trains

Coal-

Coastal

N.Gas-

Pipelines

Energy Consumption in % of energy

Transported

Pipelines are the most energy efficient modes of transportation

Pipeline Design



ECONOMICS OF PIPELINE TRANSPORTATION

Transmission losses

0 0.1 0.2 0.3 0.4 0.5

% Loss of Total Volume Transported

Pipelines

Rail/Road

Losses During Transportation

Transmission losses are lowest in Pipelines

Pipeline Design



PIPELINE DESIGN

Products Transported

� Crude Oil

� Petroleum Products (MS, HSD, ATF, SKO)

� Water & Effluents

� LPG

� Natural Gas

� Slurries

Pipeline Design



PIPELINE DESIGN

Types of Pipelines

ONSHORE (LAND) & OFFSHORE

(SUBMARINE) PIPELINES

� Trunk Pipelines

� Spur/ Branch Pipelines

� Marine Offloading Terminals & Outfalls

Pipeline Design



PIPELINE DESIGN

Capital cost: Typical breakup

Liquid Lines Gas Lines

1 Su rv ey, ROW & Compen sa t io n 2 % 1 %

2 Lin e Pip e St ee l Co st 33 % 4 5 %

3 Main lin e ma teria ls 2 % 3 %

4 Coa t in g o f Pip es 11 % 6 %

5 Main lin e Con st ru c t io n 33 % 2 5 %

6 Cath od ic Pro t ect io n 1 % 1 %

7 Telecommun ica t io n , SCA DA and RCPs 5 % 2 %

8 Pump / Comp res so r Sta t io n s 5 % 1 2 %

9 Deliv e ry Termin a l fac ilit ie s 2 % 1 %

10 Pro jec t M an agemen t 5 % 4 %

11 S ubTotal 100% 100%

Item D e scriptionS r No.Percentage of Cap i ta l Cos t.

Pipes, prime-overs and construction constitute big ticket items

Pipeline Design



PIPELINE DESIGN

Marine Offloading Terminal

Pipeline Design



PIPELINE DESIGN

Open sea Jetty

Pipeline Design



PIPELINE DESIGN

KEY PLAN

LEGEND

MADHYA PRADESH

RAJASTHAN

DADRI

JAGDISHPUR

UTTAR PRADESH

ANOLA

SHAHJAHANPUR

AURAIYA

BABRALA

ANTA

BIJAIPUR

JHABUA

INDIA

COMPRESSOR STATION

RECEIVING TERMINAL

DESPATCH STATION

GUJARAT

HAZIRA

DELHI

N

GADEPAN

ARABIAN SEA

HBJ GAS PIPELINE NETWORK

Pipeline Design



PIPELINE DESIGN

Major Pipelines in India

Pipeline Design



PIPELINE DESIGN

Pipeline Construction Video

Video for Mangalore Bangalore Pipeline

Pipeline Design



PIPELINE DESIGN

SECTION-2

PIPELINE DESIGN CODES AND STANDRADS

Pipeline Design



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



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



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) Design and Construction Requirements for Cross-Country Hydrocarbon Pipelines

OISD-214 (2006) Cross-Country LPG Pipelines

OISD-226 (2007) 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 OS-F101 Submarine pipeline systems

Other References Applicable Standards / Specs of ASME, API, NACE, MSS, BS and DIN

Pipeline Design



PIPELINE DESIGN

Major Codes & Standards

Type of Crossing Approval Authority

ROU & Land Acquisition 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

Pipeline Design



� CAESAR-II

� AUTOPIPE

� IPMCS

� MRPACK

� SORPS

� PIPECALC

� OFFPIPE

� PRISE

� PIPECROSS

LIST OF SOFTWARES USED IN PIPELINE

ENGINEERING

� PIPELINE STUDIO

TGNET

TLNET

� HYSIS

Pipeline Design



Optimal sizes of various capacities

Economy of scale

PIPELINE DESIGN

Pipeline Design



PIPELINE DESIGN

Route Selection

Routing Considerations

� Pipeline length

� Obstructions & Sensitive areas

� Installation Limitations

� Crossings

Surveys

� Topographical

� Geo-technical

� Population Density Index

� Soil Resistivity

� Cadastral

Pipeline Design



BHATINDACh . 101 2.67 km

1. P IPELINE ROUTE SHOWN IS INDICATIVE ONLY.

LEGEND:

PROPOSED MUNDRA-BHATINDA PIPELINE ( 28" NB)

RECEIPT TERMINAL

DESPATCH TERMINAL AND PUMPING STAT ION

NOTES:

PROPOSED PIPELINE

INTERMEDI AT E PIGGING STAT ION ( IP )

I NT ERM EDIAT E PUMPING STATION (IPS)

IPS-F

Ch . 226 .72 k m

JORAWARPURACh. 3 13.63 km

J UDCh . 593 .88 km

RANSISARCh. 855.01 km

MUNDRACh. 0.00 km

GAI LAWASCh. 527.87 km

2. CHAINAGES INDICATED ARE APPROXIMATE. J HEKDA

IPS-1

IPS-F

IPS-2

IP-1 & IPS-F

FUTURE PUMPING STATION (IPS-F)

PIPELINE DESIGN

Typical Pipeline Route Map

Pipeline Design



PIPELINE DESIGN

Pipeline Design



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

� Carbon Steel (CS)

� NACE Carbon Steel

� CRA Clad CS

� CS with internal

Coatings

� Non-Metallic

Materials

Pipeline Design



PIPELINE DESIGN

Design and Analysis

� Wall Thickness Calculations

� Anti-Buoyancy Measures

� Piping Stress Analysis

� Buried Pipeline Analysis

� Crossing Design

Pipeline Design



PIPELINE DESIGN

Steel Pipe Wall Thickness Calculation

LIQUID PIPELINE

(ASME B 31.4, Cl. 404.1.2)

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

GAS PIPELINE

(ASME B 31.8, Cl. 841.11)

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



PIPELINE DESIGN

Basic Design Factor for Gas Pipelines

LOCATION CLASS DESIGN FACTOR, F

Location Class 1 0.72




Location Class Classification

Location Class 1 : ≤≤≤≤ 10 buildings

Location Class 2 : > 10 and < 46 buildings

Location Class 3 : ≥≥≥≥ 46 buildings

Location Class 4 : Multistory buildings

Pipeline Design



PIPELINE DESIGN

Line Pipe Selection

Line Pipe Selection Parameters

� Thickness and Grade

Selection

� Handling and

Transportation (d/t ratio)

� Type of LinePipe

� Installation Requirements

Type of Line Pipes

� Seamless

� Electric Welded

� Longitudinal Seam

Submerged-Arc Welded

(LSAW)

� Helical Seam Submerged-

Arc Welded

(HSAW)

Pipeline Design



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”)

Pipeline Design



Manufacturing of Helical Pipes

PIPELINE DESIGN

Pipeline Design



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

� 3 Layer PE/ PP Coating (DIN 30670) � 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

� 600-800 micron thick dual layer coating

Pipeline Design



PIPELINE DESIGN

3 Layer PE Coating Application

Pipeline Design



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



PIPELINE DESIGN

Scraper traps

Pipeline Design



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)




LPG Pipelines

Industrial, 12 km (7.5 miles)

Commercial &

Residential Areas

Pipeline Design



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



PIPELINE DESIGN

Ball valves

Pipeline Design



PIPELINE DESIGN

Plug valve

Pipeline Design



PIPELINE DESIGN

Check valve

Pipeline Design



PIPELINE DESIGN

Major Engineering Deliverables

Design Reports

�Design Basis

�Route Selection Report

�Wall Thickness Report

�Seismic Design Report

�Crossing Design Report

Drawings

�Route Map

�Pipeline Schematic

�Alignment Sheets

�SV Station Layout

�Equipment Layout

�Piping General Arrangement Drawings

Pipeline Design



PIPELINE DESIGN

Typical Pipeline Alignment Sheet INTERSECTION POINTS(IP/TP )

DEFLECT ION ANGLE

S TATE , DISTRICT AND MANDAL

SCALE:HORIZONTAL 1:5000

VERTICAL 1: 500

D ISTANCE AS PER GROUND PR OFILE

21

23

25

27

29

31

33

35

37

39

41

43

45

10.621

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

25.884

30.557

29.219

29.135

28.935

30.893

32.444

33.622

37.219

40.816

39.741

42.491

43.684

43.034

38°4'58' '(R )

TP50 IP50/ 1

29°8'20' '(L)

TP51 IP51/ 1

5°18' 55''(R)

TP52

8°2' 3''(L)

TP53

37°0' 54' '(L)

TP54

13°54' 57' '(R)

TP55

11°25' 7''(L)

TP56

1°21'55' '(L)

TP57

8°24'45''(R)

TP58 IP58/1

2°8'32'' (L)

TP59

14°0'19' '(R )

TP60

8°30' 18' '(L)

TP61 IP61/1

15°2'57'' (L)

T P62

10°4'42' '(L)

TP63

10°25'50'' (L)

TP64 IP64/1

5°18'12' '(R )

TP65

DRA

INCH 10664.71m/RL 33.366m

CANA

LCH

10691.6m

/RL 35.411m

ROA

D

CH 10787.02m/RL 32.587m

DRAIN

CH 11

824.6

3m/RL 2

4.341m

ROA

D

CH 12060.88m/RL 24.604m

DRA

IN

CH 12115.34m/RL 22.175m

CART

TRACK

CH 13

492.61m/RL

33.622m

CANA

LCH

14027.73m/RL

39.741m

ROA

DCH 14040.27m/RL 42.491m

CAR

T TRACK

CH 14115.31m/RL 43.684m

CH . 12848.455m

HIGH T ENSION LINE

T P57

CH.11848.8 8m

ELEC

TRIC LINE

CH.11824.629 m

C H. 11062. 202m

C H. 11401. 298m

TP54

CH .11018.117m

ELEC TRIC LINE 440V CH. 12115.344m

C H. 11577. 761m

TP55

TP56

CH . 11616.510m

C H.12060.877m

GRAVE L ROAD

C H. 11939. 218m

DRA

IN

DRA IN

CH. 12747. 397m

CH. 10620.558m

MATC

H LINE

FOR CON

T. REFER DW

G

NO.4529

-10-16

-71-9003

DRAIN

CH.106

64 .710m

CH. 10985.658m

CH. 10797. 803m

GRAVEL ROAD

CH. 10787.022m

TP52

IP50/ 1

CH. 10687. 604mTP51

CH. 10712.803m

IP51/ 1

T P53

TP50

CH . 12080.978m

TP58

C H. 12455. 060m

T P60

C H. 12230. 091m

T P59

DRAIN

CH. 12903. 743m

CH. 13492. 606mC ART TRACK

TP61

T P62

CH. 13414.892m

CH . 13741.534m

TP63

CH. 14027.732m

RAIWADA LEFT CANAL

TP65

CH. 14134. 896m

CH. 13979.211m

TP64

IP58/ 1

CH . 12125.978m C H. 13066. 455m

IP61/1

IP64/1CH .14044.732m

KAJU GAR DEN RIC E FIELDS

V ILLAGE B OUNDARY

AMR UTAPUR AM IRUVADA

TB M W40 (RL 37.514m)

TB M W49 (RL 25.138m)

TEMP. HUT ON C/L

TBM W57(RL 42.533m)

H PCL C H. 15.00Km HPCL C H. 16.00KmHPCL CH. 17. 00Km

R AIWADA LE FT CANAL

(UNL INED )C H. 10691. 604m

TO PENDA A MR

ITA PURAM

TO C HIN TA GUTLA

SV-1 OF GA IL

CH. 11960. 218 m

TO PEN

DA AM

R UT H

AP URA

M

TO AMRUTHA PURAM

K

K

OPEN WE LL 6m DIA

7.648m FR OM C/ L

CH.11648.136m

OPEN WELL 6m D IA

8m FROM C/ L

CH 11577. 761m

PUMP HOUSE 4m FR OM C/L

12. 2m H IGH & 550KV

EARTHEN EMB ANKMENT

L OW LYING AREA

EARTHEN EMB ANKMENT

K

(UNLINED)

GRAVEL ROAD

CH. 14040. 275m

MATC

H LINE

FOR CON

T. REFER DW

G

NO.4529-10-16-71-9005

MET ALLE D R OAD (ASPHALTIC)

CH. 14115.309m

TO STATE HI GHWAY-SABBAVARAM

TO IR UVADA

ELEC . LIN E 440VC H.14132.231m

TELE PHONE LIN E CH .14134.896m

D ISTANCE BE TWEE N TP & IP' s(m)

10.665

44.15

2

10.692

26.894

10.713

21.199

10.787

74.21

9

10.986

198.6

36

11.025

39.36

9

11.062

37.17

5

11.259

196.9

62

11.401

142.1

34

11.578

176.4

63

11.617

38.74

9

11.758

141.5

22

11.825

66.59

7

11.849

24.24

6

11.939

90.34

2

12.061

121.6

60

12.081

20.10

1

12.115

34.36

6

12.230

114.7

47

12.455

224.9

69

12.754

299.2

54

12.848

94.14

1

13.066

217.5

39

13.248

182.1

17

13.415

166.7

80

13.493

77.71

4

13.742

248.9

29

13.979

237.6

76

14.028

48.52

1

14.040

12.54

3

14.115

75.03

4

14.135

19.58

8

67. 046

67. 049

25.199

25.200

85. 000

85. 284

187.855

187.993

76.544

76.618

339.096

339.126

176. 463

176. 478

38. 749

38. 853

322.708

322.772

141.760

141.845

45.000

45.093

104. 113

104. 624

224. 969

225. 022

393.395

393.407

218.000

218.014

348.437

348.444

326. 642

326. 679

237.677

237.707

65.521

65.728

90.164

90.390

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

11.960

11.972

11.984

Pipeline Design



Typical P&ID

PIPELINE DESIGN

Pipeline Design



PIPELINE DESIGN Typical GA DRAWING

Pipeline Design



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

Pipeline Design



PIPELINE DESIGN

Installation, Testing & Commissioning

RoU Grading & Trenching Stringing of Linepipe

Pipeline Design



PIPELINE DESIGN


Welding & NDT : � Edge Preparation

� Internal / External Line-up Clamps

� Manual / Automatic Welding

� NDT (X-Ray / UT / MPI etc.)

Pipeline Design



PIPELINE DESIGN


Field Joint Coating Lowering & Backfilling � Heat Shrink Sleeves

� Cold applied tapes

Pipeline Design



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



PIPELINE DESIGN

The conventional HDD operations for river crossings.

Pipeline Design



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 DESIGN

Pipeline Installation using Micro-tunnelling

Long Distance Micro Tunnelling

Pipeline Design



PIPELINE DESIGN

Overview of Micro tunneling

Pipeline Design



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

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

DRYING

� Swabbing

� Methanol Drying

� Super Dry Air

Method

� Vacuum Drying

COMMISSIONING

� Nitrogen Purging

� Product Charging

Pipeline Design



PIPELINE DESIGN

Pigging

Requirements

� Pipeline Cleaning

� Displacement

� Internal Inspection

� Batching

Types of Pigs

� Brush pigs

� Gauge Pigs

� Spheres

� Intelligent Pigs

Cleaning pigs Gauge Pigs Spheres Intelligent Pig

(MFL)

Pipeline Design



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



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 15-20%

Geometry Controlled to the desired level

with cold expansion

Controlled during forming only

and no cold expansion is carried

out

Pipeline Design



PIPELINE DESIGN

CTE 3LPE 3LPP FBE

Service Conditions

Temperature, o C Upto 45 Upto 65 Upto 110 Upto 110

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

Coating Comparison

Pipeline Design



PIPELINE DESIGN

CTE 3LPE 3LPP FBE

Cathodic Protection Design

Current Density High Low Low Low

Mechanical Properties

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 -

Coating Comparison

Pipeline Design



PIPELINE DESIGN

CTE 3LPE 3LPP FBE

Long Term Ageing

Heat & Light Ageing Fair Very Good Very Good Very Good

Application & Field Repair

Ease of Application Easy Relatively difficult Relatively difficult Relatively difficult

Damages during handling &

transportation

High Low Low High

Ease of Field Repair 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

Coating Comparison

Pipeline Design



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