Pipeline Design

(1)

(2)

ENGINEERS

INDIA LIMITED

EPC and Total Solutions

Consultancy Organization

(3)

Petroleum Refineries

Petrochemicals

Pipelines

Offshore Platforms

Gas Processing

Metallurgy

Ports & Terminals

(4)

HEAD OFFICE

NEW DELHI

REGIONAL OFFICES

VADODARA, CHENNAI

EIL OFFICES

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

(5)

PIPELINE DESIGN

SERVICES OFFERED BY EIL

Project Implementation Services

Feasibility Studies

Project Management

Specialist Services

Heat & Mass Transfer Equipment

Design

Project Management

Planning & Scheduling

Process Design

Detailed Engineering

Procurement Services

Construction Management

Design

Environment Engineering

Information Technology Services

Specialist Materials and

Maintenance Services

Plant Operation & Safety

Commissioning and Plant

Start-up Assistance

Risk Analysis

(6)

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

(7)

PIPELINE DESIGN

DESCRIPTION

DESCRIPTION CLIENTCLIENT YEARYEAR SIZESIZE LENGTH LENGTH (KM) (KM) SERVICES SERVICES HAZIRA HAZIRA--BIJAIPUR BIJAIPUR--JAGDISHPUR (HBJ) JAGDISHPUR (HBJ) GAIL

GAIL 19891989 36“/30”/24”/18”36“/30”/24”/18” 18001800 NATURAL GASNATURAL GAS

Major Onshore Projects (Completed)

JAGDISHPUR (HBJ) JAGDISHPUR (HBJ)

MAQTA

MAQTA--ALAL--AIN PIPELINEAIN PIPELINE ADNOCADNOC 19921992 30 ”/12”30 ”/12” 166166 NATURAL GASNATURAL GAS KANDLA

KANDLA--BHATINDABHATINDA IOCLIOCL 19961996 22”/14”/10”22”/14”/10” 14431443 MULTIPRODUCTMULTIPRODUCT

GAS REHABILITATION & GAS REHABILITATION & EXPANSION PROJECT EXPANSION PROJECT (GREP)

(GREP)

GAIL

GAIL 19981998 36 ”36 ” 505505 NATURAL GASNATURAL GAS

MUMBAI

MUMBAI –– MANMADMANMAD BPCLBPCL 19981998 18 ”18 ” 260260 MULTIPRODUCTMULTIPRODUCT VIZAG

VIZAG--VIJAYWADAVIJAYWADA HPCLHPCL 19981998 18 ”18 ” 360360 MULTIPRODUCTMULTIPRODUCT VIZAG

VIZAG--VIJAYWADAVIJAYWADA HPCLHPCL 19981998 18 ”18 ” 360360 MULTIPRODUCTMULTIPRODUCT JAMNAGAR JAMNAGAR--LONI LPG LONI LPG PIPELINE PIPELINE GAIL GAIL 20012001 16”/14”/12”/8”/16”/14”/12”/8”/ 66 1235 1235 LPG (LIQUIFIED LPG (LIQUIFIED PETROLIUM GAS) PETROLIUM GAS) COCHIN

(8)

PIPELINE DESIGN

DESCRIPTION

DESCRIPTION CLIENTCLIENT YEARYEAR SIZESIZE LENGTH LENGTH (KM) (KM)

SERVICES SERVICES

VIZAG

VIZAG –– SECUNDERABAD LPG SECUNDERABAD LPG PIPELINE

PIPELINE

GAIL

GAIL 20022002 12”/10”12”/10” 600600 LPG (LEQUIFIED LPG (LEQUIFIED PETROLEUM GAS) PETROLEUM GAS)

Major Onshore Projects (..contd) (Completed)

MANMAD

MANMAD--MANGALAYA PIPELINEMANGALAYA PIPELINE BPCLBPCL 20032003 14 ”14 ” 358358 MULTIPRODUCTMULTIPRODUCT

MANGALORE

MANGALORE--BANGLOREBANGLORE HPCLHPCL 20032003 24 ”/20”24 ”/20” 364364 MULTIPRODUCTMULTIPRODUCT DAHEJ

DAHEJ –– VIJAIPUR PIPELINEVIJAIPUR PIPELINE GAILGAIL 20032003 42”42” 610610 REGASIFIED LNGREGASIFIED LNG

INTER REFINERIES PIPELINES INTER REFINERIES PIPELINES PROJECT, ABU DHABI

PROJECT, ABU DHABI _TAKREER_TAKREER ₂₀₀₄₂₀₀₄

10” 10” 12” 12” 16” 16” 230 230 230 230 208 208 NAPHTHA, NAPHTHA, MULTIPRODUCT & SRR MULTIPRODUCT & SRR 16” 16” 208208 MANGALAYA MANGALAYA--BIJWASAN BIJWASAN PIPELINE PIPELINE BPCL BPCL 20062006 16”/8”16”/8” 775775 MULTIPRODUCTMULTIPRODUCT MUNDRA

(9)

DESCRIPTION

PUNE SOLAPUR PIPELINE

PUNE SOLAPUR PIPELINE HPCLHPCL 20072007 14 ”/ 12”14 ”/ 12” 182 / 161182 / 161 MULTIPRODUCTMULTIPRODUCT

PIPELINE DESIGN

Major Onshore Projects (7contd)

(Completed)

DABHOL PANVEL PIPELINE DABHOL PANVEL PIPELINE PROJECT (PH

PROJECT (PH--I)I)

GAIL

GAIL 20072007 30”30” 187187 REGASIFIED LNGREGASIFIED LNG

DABHOL PANVEL PIPELINE DABHOL PANVEL PIPELINE PROJECT (PH

PROJECT (PH--II)II)

GAIL

(10)

DESCRIPTION

BOMBAY HIGH URAN TRUNKLINE BOMBAY HIGH URAN TRUNKLINE (BUT)

(BUT)

ONGC

ONGC 19791979 30”/26”30”/26” 200 x 2200 x 2 CRUDE, GASCRUDE, GAS

PIPELINE DESIGN

Major Offshore Projects

(Completed)

(BUT) (BUT)

SOUTH BASSEIN HAZIRA SOUTH BASSEIN HAZIRA TRUNKLINE

TRUNKLINE

ONGC

ONGC 19861986 36”36” 220220 GASGAS

HEERA

HEERA--URAN TRUNK LINEURAN TRUNK LINE ONGCONGC 19961996 26 ”/24 ”26 ”/24 ” 85 x 285 x 2 CRUDE, GASCRUDE, GAS

ICP

ICP -- HEERA TRUNKLINEHEERA TRUNKLINE ONGCONGC 19961996 30”/22”30”/22” 145145 CRUDECRUDE

SECOND BASSEIN HAZIRA SECOND BASSEIN HAZIRA TRUNKLINE

TRUNKLINE

ONGC

ONGC 19951995 42”42” 245245 GASGAS TRUNKLINE

TRUNKLINE

MUMBAI HIGH URAN TRUNKLINE MUMBAI HIGH URAN TRUNKLINE (MUT) (MUT) ONGC ONGC 20052005 30”/28”30”/28” 12” to 22” 12” to 22” 205 x 2 205 x 2 100 100 CRUDE, GAS CRUDE, GAS

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DESCRIPTION

VIJIPUR DADRI BAWANA PIPELINE VIJIPUR DADRI BAWANA PIPELINE (VDBPL) (VDBPL) GAIL GAIL 20092009 48”/ 36”/ 48”/ 36”/ 20” 20” 500/ 38/ 55 500/ 38/ 55 REGASIFIED LNGREGASIFIED LNG

PIPELINE DESIGN

Major Onshore Projects

(Current)

(VDBPL)

(VDBPL) 20”20”

MUNDRA BATHINDA PIPELINE MUNDRA BATHINDA PIPELINE (MBPL)

(MBPL)

HMPL

HMPL 20092009 28”/ 30”28”/ 30” 424/ 590424/ 590 CRUDE OILCRUDE OIL

BINA KOTA PIPELINE

BINA KOTA PIPELINE BPCLBPCL 20092009 18”18” 257257 MULTI PRODUCTMULTI PRODUCT

VADINAR BINA PIPELINE

VADINAR BINA PIPELINE BORLBORL 20092009 24”24” 935935 CRUDE OILCRUDE OIL

NUMALIGARH SILIGURI PIPELINE

NUMALIGARH SILIGURI PIPELINE OILOIL 20092009 16”16” 400400 MULTI PRODUCTMULTI PRODUCT

COMPRESSOR STATIONS

COMPRESSOR STATIONS GAILGAIL ------ ------ ------ REGASIFIED LNGREGASIFIED LNG

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PIPELINE DESIGN

SECTION-1

INTRODUCTION

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PIPELINE DESIGN

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

Oil and Gas Production in India

OIL

33 MMTPA

OIL

33 MMTPA

(ONGC, OIL, CAIRN, RIL)

GAS

115 MMSCMD

(15)

Refining Scenario- India

302 300 350

Capacity - 2006-07

NOC – 105.5 MMT

Others- 43.5 MMT

PIPELINE DESIGN

70 149 235 100 150 200 250 300

(M

M

T

)

0 50 1998-99 2006-07 2011-12 2016-17

(Actual)

_Year

(16)

PIPELINE DESIGN

Modes of Hydrocarbon Transportation - India

30% 35%

Pipelines

32%

Road Tankers

32%

Rail Tankers

26%

Water Carriers

10%

0% 5% 10% 15% 20% 25% 30% % Share Pipelines Road Tankers Rail Tankers Water Carriers % Share

(17)

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

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PIPELINE DESIGN

Energy Savings

Ene rgy Inte nsity for Various M ode s

4 E n e rg y C o n s u m p ti o n i n % o f e n e rg y 0.8 0.5 1 3.2 0.8 1.1 2 0 0.5 1 1.5 2 2.5 3 3.5 4 E n e rg y C o n s u m p ti o n i n % o f e n e rg y T ra n s p o rt e d 0 Liquid-Pipelines Liquid-Coastal Liquid-Trains Liquid-Trucks Coal-Trains Coal-Coastal N.Gas-Pipelines E n e rg y C o n s u m p ti o n i n % o f e n e rg y

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ECONOMICS OF PIPELINE TRANSPORTATION

Transmission losses

Losses During Transportation

Pipelines Rail/Road

0 0.1 0.2 0.3 0.4 0.5

% Loss of Total Volum e Transported

(20)

PIPELINE DESIGN

Products Transported

Crude Oil

Petroleum Products (MS, HSD, ATF, SKO)

Water & Effluents

LPG

Natural Gas

(21)

PIPELINE DESIGN

Types of Pipelines

ONSHORE (LAND) & OFFSHORE

(SUBMARINE) PIPELINES

Trunk Pipelines

Spur/ Branch Pipelines

(22)

PIPELINE DESIGN

Capital cost: Typical breakup

Liqui d Li ne s Gas Line s

1 Su rv e y , RO W & Co mp e n s a tio n 2 % 1 %

Ite m D e s criptio n

S r o.

P e r c e ntag e of C a p ita l C os t.

1 Su rv e y , RO W & Co mp e n s a tio n 2 % 1 %

2 Lin e Pip e Ste e l Co s t 3 3 % 4 5 %

3 M a in lin e ma te ria ls 2 % 3 %

4 Co a tin g o f Pip e s 1 1 % 6 %

5 M a in lin e Co n s tru c tio n 3 3 % 2 5 %

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 D A a n d RCPs 5 % 2 %

8 Pu mp / Co mp re s s o r Sta tio n s 5 % 1 2 %

9 D e 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 %

1 1 S ubTotal 1 0 0 % 1 0 0 %

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PIPELINE DESIGN

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PIPELINE DESIGN

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PIPELINE DESIGN

UTTAR PRADESH

N

HBJ GAS PIPELINE NETWORK

KEY PLAN

RAJASTHAN DADRI JAGDISHPUR ANOLA SHAHJAHANPUR AURAIYA BABRALA ANTA BIJAIPUR

INDIA

GUJARAT DELHI N GADEPAN

LEGEND

MADHYA PRADESH JHABUA

COMPRESSOR STATION

RECEIVING TERMINAL

DESPATCH STATION

HAZIRA ARABIAN SEA

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PIPELINE DESIGN

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PIPELINE DESIGN

Pipeline Construction Video

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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

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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

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PIPELINE DESIGN

Major Codes & Standards

Code/Standard

Title

ASME B 31.8 (2003)

ASME B 31.8 (2003) Gas Transportation and Distribution Piping SystemsGas Transportation and Distribution Piping Systems

ASME B 31.4 (2006)

ASME B 31.4 (2006) Pipeline Transportation Systems for Liquid Hydrocarbons and other Pipeline Transportation Systems for Liquid Hydrocarbons and other

Liquids Liquids OISD

OISD--141 (2003)141 (2003) Design and Construction Requirements for CrossDesign and Construction Requirements for Cross--Country Country

Hydrocarbon Pipelines Hydrocarbon Pipelines OISD

OISD--214 (2006)214 (2006) CrossCross--Country LPG PipelinesCountry LPG Pipelines

OISD

OISD--226 (2007)226 (2007) Natural Gas Transmission Pipelines and City Gas Distribution Natural Gas Transmission Pipelines and City Gas Distribution

Networks Networks API 5L / ISO 3183 : 2007

API 5L / ISO 3183 : 2007 Specification for Line PipeSpecification for Line Pipe

API RP1102

API RP1102 Recommended practice for Rail and Highway crossingsRecommended practice for Rail and Highway crossings

API 1104

API 1104 Standard for welding pipeline and related facilitiesStandard for welding pipeline and related facilities

API 6D / ISO 14313

API 6D / ISO 14313 Pipeline ValvesPipeline Valves

DNV OS

DNV OS--F101F101 Submarine pipeline systemsSubmarine pipeline systems

Other References

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

DIN DIN

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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

(33)

CAESAR

CAESAR--II

II

AUTOPIPE

LIST OF SOFTWARES USED IN PIPELINE

ENGINEERING

PIPELINE STUDIO

AUTOPIPE

IPMCS

MRPACK

SORPS

PIPECALC

OFFPIPE

TGNET

TLNET

HYSIS

OFFPIPE

PRISE

PIPECROSS

(34)

Optimal sizes of various capacities

PIPELINE DESIGN

(35)

PIPELINE DESIGN

Route Selection

Routing Considerations

Pipeline length

Obstructions & Sensitive areas

Installation Limitations

Crossings

Surveys

Topographical

Geo-technical

Population Density Index

Soil Resistivity

(36)

BHATINDA

Ch. 1012.67 km

PIPELINE DESIGN

Typical Pipeline Route Map

LEGEND: PROPOSED PIPELINE JUD Ch. 593.88 km RANSISAR Ch. 855.01 km GAILAWAS Ch. 527.87 km IPS-F IPS-2

IP-1 & IPS-F

1. PIPELINE ROUTE SHOWN IS INDICATIVE ONLY.

LEGEND:

PROPOSED MUNDRA-BHATINDA PIPELINE (28" NB)

RECEIPT TERMINAL

DESPATCH TERMINAL AND PUMPING STATION

NOTES:

INTERMEDIATE PIGGING STATION (IP) INTERMEDIATE PUMPING STATION (IPS)

IPS-F Ch. 226.72 km JORAWARPURA Ch. 313.63 km MUNDRA Ch. 0.00 km

2. CHAINAGES INDICATED ARE APPROXIMATE. JHEKDA

IPS-1

(37)

PIPELINE DESIGN

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PIPELINE DESIGN

Material Selection & Corrosion Control

Assessment

Nature of the Product

Materials

Carbon Steel (CS)

Design Life

Product Temperature

Corrosion Protection

Material Chemistry

Internal Coatings

NACE Carbon Steel

CRA Clad CS

CS with internal

Coatings

Non-Metallic

Materials

Product Conditioning

Corrosion inhibitors

Corrosion Allowance

Materials

(39)

PIPELINE DESIGN

Design and Analysis

Wall Thickness Calculations

Anti-Buoyancy Measures

Piping Stress Analysis

Buried Pipeline Analysis

Crossing Design

(40)

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 = P

_i

D

2.S

where

P

_i

Internal design pressure

S

allowable stress

= 0.72 x E x SMYS

D

Outside Diameter of pipe

t

pressure

design

wall

thickness

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

thickness

E

Weld joint factor

F

Design factor

E

Longitudinal joint factor

(41)

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 2

0.60 Location Class 3

0.50 Location Class 4

0.40 Location Class Classification

Location Class 1 :

_≤

_{≤ 10 buildings}

Location Class 2 :

> 10 and < 46 buildings

Location Class 3 :

_≥

_{≥ 46 buildings}

Location Class 3 :

_≥

_{≥ 46 buildings}

(42)

PIPELINE DESIGN

Line Pipe Selection

Line Pipe Selection Parameters

Thickness and Grade

Type of Line Pipes

Seamless

Thickness and Grade

Selection

Handling and

Transportation (d/t ratio)

Type of LinePipe

Installation Requirements

Seamless

Electric Welded

Longitudinal Seam

Submerged

Submerged--Arc Welded

Arc Welded

(LSAW)

Helical Seam Submerged

Helical Seam

Submerged--

Installation Requirements

Arc Welded

(HSAW)

(43)

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”)

(44)

(45)

Manufacturing of Helical Pipes

PIPELINE DESIGN

(46)

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)

350 350--500 micron thick single layer coating

500 micron thick single layer coating

(47)

PIPELINE DESIGN

(48)

PIPELINE DESIGN

Major Pipeline Components

Line Pipe & Coatings

Scraper Traps & Pig Signallers

Long Radius (LR) Bends

Insulating Joints

Flow Tees

Sectionalizing Valves

Pumps / Compressors

(49)

PIPELINE DESIGN

(50)

PIPELINE DESIGN

Sectionalizing Valve

Spacing

ASME B 31.8 for Gas

pipelines

Gas Pipelines

Location Class 1

32 km (20 miles)

Location Class 2

24 km (15 miles)

pipelines

ASME B 31.4 for Liquid

Pipelines

Location

Pollution Concerns

Statutory Requirements

Prevention of Inventory

Loss

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 &

Loss

Approachability of Valve

Station

Residential Areas

(51)

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

(52)

PIPELINE DESIGN

(53)

PIPELINE DESIGN

(54)

PIPELINE DESIGN

(55)

PIPELINE DESIGN

Major Engineering Deliverables

Design Reports

Design Basis

Drawings

Route Map

Design Basis

Route Selection Report

Wall Thickness Report

Seismic Design Report

Crossing Design Report

Route Map

Pipeline Schematic

Alignment Sheets

SV Station Layout

Equipment Layout

Piping General

Arrangement Drawings

(56)

PIPELINE DESIGN

Typical Pipeline Alignment Sheet

INTERSECTION POINTS(IP/TP) DEFLECTION ANGLE STATE , DISTRICT AND MANDAL

DISTANCE AS PER GROUND PROFILE 38°4'58''(R) TP50IP50/1 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) TP62 10°4'42''(L) TP63 10°25'50''(L) TP64 IP64/1 5°18'12''(R) TP65 CH. 10620.558m CH.1 0664 .710m CH. 10797.803m IP50/1 CH. 10687.604m TP51 CH. 10712.803m IP51/1 TP50 TP58 TP60 CH. 13741.534m TP63 TP65 CH. 14134.896m CH. 13979.211m TP64 IP64/1 CH.14044.732m TBM W40 (RL 37.514m) TBM W57(RL 42.533m) RAIWADA LEFT CANAL

(UNLINED) CH. 10691.604m TO PEND A A MRITA PUR AM T O PEN D A AM RU TH APUR A M EARTHEN EMBANKMENT LOW LYING AREA

EARTHEN EMBANKMENT M A T C H L IN E F O R C O N T . R E F E R D W G N O .4 5 2 9 -1 0 -1 6 -7 1-9 0 0 5 METALLED ROAD(ASPHALTIC) CH.14115.309m TO_ST AT_{E H} IG_HW AY_-SA BB_AV AR_AM TO IRUVADA ELEC. LINE 440V CH.14132.231m TELEPHONE LINE CH.14134.896m

DISTANCE BETWEEN TP & IP's(m) 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 SCALE: HORIZONTAL 1:5000 VERTICAL 1: 500 21 23 25 27 29 31 33 35 37 39 41 43 45 1 0 .6 2 1 3 7 .3 2 5 3 3 .3 6 6 3 5 .4 1 1 3 3 .5 6 0 3 2 .5 8 7 3 1 .4 9 6 3 0 .3 0 0 2 9 .8 1 5 2 7 .3 7 0 2 5 .3 6 2 2 7 .9 0 4 2 4 .8 5 8 2 5 .1 3 8 2 4 .3 4 1 2 4 .6 7 5 2 4 .8 2 8 2 4 .6 0 4 2 3 .6 6 7 2 2 .1 7 5 2 5 .8 8 4 3 0 .5 5 7 2 9 .2 1 9 2 9 .1 3 5 2 8 .9 3 5 3 0 .8 9 3 3 2 .4 4 4 3 3 .6 2 2 3 7 .2 1 9 4 0 .8 1 6 3 9 .7 4 1 4 2 .4 9 1 4 3 .6 8 4 4 3 .0 3 4 D R A IN C H 1 06 6 4 .7 1m /R L 3 3 .3 6 6 m C A N A L C H 1 0 6 9 1.6 m /R L 3 5 .4 1 1 m R O A D C H 1 0 7 8 7 .0 2 m /R L 3 2.5 8 7 m D R A IN C H 1 1 8 2 4 .6 3 m /R L 2 4.3 4 1 m R O A D C H 1 2 0 6 0.8 8 m /R L 2 4 .6 0 4m D R A IN C H 1 21 1 5 .3 4 m /R L 2 2 .1 7 5 m C A R T T R A C K C H 1 3 4 9 2.6 1 m /R L 3 3 .6 2 2 m C A N A L C H 1 40 2 7 .7 3 m /R L 3 9 .7 4 1 m R O A D C H 1 4 0 40 .2 7 m /R L 4 2 .4 9 1m C A R T T R A C K C H 1 4 1 1 5 .3 1 m /R L 4 3 .6 8 4 m CH. 12848.455m HIGH TENSION LINE TP57 C H.11 848.88 m E LECT R IC L INE C H .1 1 8 24 .6 2 9 m CH. 11062.202m CH. 11401.298m TP54 CH.11018.117m ELECTRIC LINE 440V CH.12115.344m CH. 11577.761m TP55 TP56 CH. 11616.510m CH.12060.877m GRAVEL ROAD CH. 11939.218m D R A IN DRAIN CH.12747.397m M A T C H L IN E F O R C O N T . R E FE R D W G N O .4 5 2 9 -1 0 -1 6 -7 1 -9 0 0 3 DRAI N CH.1 0664 .710m CH. 10985.658m GRAVEL ROAD CH.10787.022m TP52 TP53 CH. 12080.978m TP58 CH. 12455.060m TP60 CH. 12230.091m TP59 DRAIN CH.12903.743m CH.13492.606m CART TRACK TP61 TP62 CH. 13414.892m CH.14027.732m RAIWADA LEFT CANAL IP58/1

CH. 12125.978m CH. 13066.455m IP61/1

KAJU GARDEN RICE FIELDS

VILLAGE BOUNDARY AMRUTAPURAM IRUVADA TBM W49 (RL 25.138m) TEMP. HUT ON C/L HPCL CH. 15.00Km HPCL CH. 16.00Km HPCL CH. 17.00Km TO CHINTA GUTLA SV-1 OF GAIL CH.11960.218 m T O PEN D A AM RU TH APUR A M TO AM_RUTHAP URAM K K

OPEN WELL 6m DIA 7.648m FROM C/L CH.11648.136m OPEN WELL 6m DIA 8m FROM C/L CH 11577.761m PUMP HOUSE 4m FROM C/L

12.2m HIGH & 550KV K (UNLINED) GRAVEL ROAD CH.14040.275m M A T C H L IN E F O R C O N T . R E F E R D W G N O .4 5 2 9 -1 0 -1 6 -7 1-9 0 0 5 TO_ST AT_{E H} IG_HW AY_-SA BB_AV AR_AM 1 0 .6 6 5 44 .1 5 2 1 0 .6 9 2 2 6 .8 9 4 1 0 .7 1 3 2 1 .1 9 9 1 0 .7 8 7 74 .2 1 9 1 0 .9 8 6 19 8 .6 3 6 1 1 .0 2 5 39 .3 6 9 1 1 .0 6 2 37 .1 7 5 1 1 .2 5 9 19 6 .9 6 2 1 1 .4 0 1 14 2 .1 3 4 1 1 .5 7 8 17 6 .4 6 3 1 1 .6 1 7 38 .7 4 9 1 1 .7 5 8 14 1 .5 2 2 1 1 .8 2 5 66 .5 9 7 1 1 .8 4 9 24 .2 4 6 1 1 .9 3 9 90 .3 4 2 1 2 .0 6 1 12 1 .6 6 0 1 2 .0 8 1 20 .1 0 1 1 2 .1 1 5 34 .3 6 6 1 2 .2 3 0 11 4 .7 4 7 1 2 .4 5 5 22 4 .9 6 9 1 2 .7 5 4 29 9 .2 5 4 1 2 .8 4 8 94 .1 4 1 1 3 .0 6 6 21 7 .5 3 9 1 3 .2 4 8 18 2 .1 1 7 1 3 .4 1 5 16 6 .7 8 0 1 3 .4 9 3 77 .7 1 4 1 3 .7 4 2 24 8 .9 2 9 1 3 .9 7 9 23 7 .6 7 6 1 4 .0 2 8 48 .5 2 1 1 4 .0 4 0 12 .5 4 3 1 4 .1 1 5 75 .0 3 4 1 4 .1 3 5 19 .5 8 8 10 .6 2 1 10 .6 6 5 10 .6 9 2 10 .7 1 3 10 .7 8 7 10 .9 8 6 11 .0 2 5 11 .0 6 2 11 .2 5 9 11 .4 0 1 11 .5 7 8 11 .6 1 7 11 .7 5 8 11 .8 2 5 11 .8 4 9 11 .9 3 9 12 .0 6 1 12 .0 8 1 12 .1 1 5 12 .2 3 0 12 .4 5 5 12 .7 5 4 12 .8 4 8 13 .0 6 6 13 .2 4 8 13 .4 1 5 13 .4 9 3 13 .7 4 2 13 .9 7 9 14 .0 2 8 14 .0 4 0 14 .1 1 5 14 .1 3 5 1 1 .9 6 0 1 1 .9 7 2 1 1 .9 8 4

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Typical P&ID

PIPELINE DESIGN

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PIPELINE DESIGN

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PIPELINE DESIGN

Major Engineering Deliverables

Tenders

Survey Tender

Pipe Coating Tender

Pipeline Installation Tender

Material Procurement

Line Pipes

Valves & Actuators

Scraper Traps, QOEC, Pig

Scraper Traps, QOEC, Pig Signallers

Signallers

Flow Tees & Insulating Joints

Induction Bends

Flow meters

Pumps & Compressors

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PIPELINE DESIGN

Installation, Testing & Commissioning

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PIPELINE DESIGN

Installation, Testing & Commissioning

Welding & NDT :

Edge Preparation

Internal / External Line-up Clamps

Manual / Automatic Welding

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PIPELINE DESIGN

Installation, Testing & Commissioning

Field Joint Coating Lowering & Backfilling

Heat Shrink Sleeves

Cold applied tapes

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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

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PIPELINE DESIGN

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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

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PIPELINE DESIGN

Schematic Diagram

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PIPELINE DESIGN

Pipeline Installation using Micro-tunnelling

Long Distance Micro Tunnelling

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PIPELINE DESIGN

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PIPELINE DESIGN

Testing & Commissioning

TESTING

Gauging and Pigging

Test Pressure

Test Medium

DRYING

Swabbing

Methanol Drying

Test Medium

TEST PRESSURE

LIQUID PIPELINES

Ref. ASME B 31.4 : 437.4.1

1.25 times design pressure

GAS PIPELINES

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

Pigging

Requirements

Pipeline Cleaning

Displacement

Types of Pigs

Brush pigs

Gauge Pigs

Displacement

Internal Inspection

Batching

Gauge Pigs

Spheres

Intelligent Pigs

Cleaning pigs

_{Gauge Pigs}

_Spheres

_{Intelligent Pig}

(MFL)

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PIPELINE DESIGN

RECENT DEVELOPMENTS

TECHNICAL IMPROVEMENTS

Automatic Welding & Automatic UT

Micro

Micro--Tunneling for pipeline construction

Tunneling for pipeline construction

Internal flow coating on line pipes for gas pipelines

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PIPELINE DESIGN

Comparison of LSAW & HSAW Pipes

Description

LSAW

HSAW

Method of Method of Manufacture Manufacture

UOE/COE/JCO/3 roll bending

UOE/COE/JCO/3 roll bending Formed by Twisting of CoilFormed by Twisting of Coil Weld Length

Weld Length Equal to pipe joint lengthEqual to pipe joint length Approximately 1.5 to 2 times the Approximately 1.5 to 2 times the Weld Length

Weld Length Equal to pipe joint lengthEqual to pipe joint length Approximately 1.5 to 2 times the Approximately 1.5 to 2 times the length of pipe joint

length of pipe joint Position of weld

Position of weld Longitudinal Longitudinal –– positioned in positioned in upper quadrant during

upper quadrant during construction

construction

Spiral

Spiral –– present all around the present all around the pipe

pipe Corrosion Coating

Corrosion Coating Specified thickness throughout Specified thickness throughout entire body.

entire body.

Weld seam is tracked to ensure Weld seam is tracked to ensure coating thickness on weld seam coating thickness on weld seam

Thickness normally increased all Thickness normally increased all over the body, resulting in

over the body, resulting in

proportional increase in coating proportional increase in coating cost by 15

cost by 15--20%20% Geometry

Geometry Controlled to the desired level Controlled to the desired level with cold expansion

with cold expansion

Controlled during forming only Controlled during forming only and no cold expansion is carried and no cold expansion is carried out

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PIPELINE DESIGN

CTE

3LPE

3LPP

FBE

Coating Comparison

CTE

3LPE

3LPP

FBE

Service Conditions Service Conditions

Temperature,

Temperature, oo _C_C _{Upto 45}_{Upto 45} _{Upto 65}_{Upto 65} _{Upto 110}_{Upto 110} _{Upto 110}_{Upto 110}

Anti

Anti--corrosion Propertiescorrosion Properties

Resistance to Moisture

Resistance to Moisture GoodGood Very GoodVery Good ExcellentExcellent GoodGood

Cathodic Disbondment

Cathodic Disbondment FairFair GoodGood GoodGood GoodGood Cathodic Disbondment

Cathodic Disbondment FairFair GoodGood GoodGood GoodGood

Electrical Properties Electrical Properties

Coating Resistance

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PIPELINE DESIGN

CTE

3LPE

3LPP

FBE

Cathodic Protection Design Cathodic Protection Design

Coating Comparison

Cathodic Protection Design Cathodic Protection Design

Current Density

Current Density HighHigh LowLow LowLow LowLow

Mechanical Properties Mechanical Properties

Resistance to Impact

Resistance to Impact FairFair ExcellentExcellent Superior to PESuperior to PE FairFair

Resistance to Resistance to Indentation Indentation

Poor

Poor Very GoodVery Good ExcellentExcellent FairFair

Resistance to Peel

Resistance to Peel FairFair ExcellentExcellent Superior than PESuperior than PE --Resistance to Peel

Resistance to Peel FairFair ExcellentExcellent Superior than PESuperior than PE

--Resistance to Soil Resistance to Soil Stresses

Stresses

Fair

Fair ExcellentExcellent ExcellentExcellent ExcellentExcellent

Elongation

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--PIPELINE DESIGN

PIPELINE DESIGN

CTE

3LPE

3LPP

FBE

Long Term Ageing Long Term Ageing

Coating Comparison

Long Term Ageing Long Term Ageing

Heat & Light Ageing

Heat & Light Ageing FairFair Very GoodVery Good Very GoodVery Good Very GoodVery Good

Application & Field Repair Application & Field Repair

Ease of Application

Ease of Application Easy Easy Relatively difficultRelatively difficult Relatively difficultRelatively difficult Relatively difficultRelatively difficult

Damages during Damages during handling & handling & transportation transportation High

High LowLow LowLow HighHigh

transportation transportation

Ease of Field Repair

Ease of Field Repair DifficultDifficult Easy for small repair,Easy for small repair, Cumbersome for Cumbersome for

larger repair larger repair

Easy for small repair, Easy for small repair,

Cumbersome for Cumbersome for

Easy for small repair, Easy for small repair,

Cumbersome for Cumbersome for

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