EIL Cross Country Pipeline Presentation

CONSTRUCTION
OF
CROSS COUNTRY
PIPELINES
By: G. K. IYER (AGM.)
CONSTRUCTION OF CROSS COUNTRY PIPELINES

Delivering excellence through people
Slide Number- 1 of 50
CROSS COUNTRY PIPELINE WORKS
OVERVIEW
MAIN PURPOSE
TRANSPORTATION OF MATERIAL/PRODUCT
- PIPELINE FOR GAS E.G. NATURAL GAS; LPG; LNG ETC.
- PIPELINE FOR LIQUIDS E.G. CRUDE OIL / PETROLEUM PRODUCT; WATER ETC.
- PIPELINE FOR SOLIDS E.G. IRON ORE ETC.
TYPES OF PIPELINE
- OFFSHORE SUBMARINE PIPELINE: LAID ON SEA-BED
- ONSHORE CROSS COUNTRY PIPELINE: LAID 1MTR UNDERGROUND
SOME MAJOR ADVANTAGES

- LOW COST OF TRANSPORTATION & ACCESSIBILITY TO REMOTE AREAS
- LESS TIME TAKEN FOR TRANSPORATION
SOME DISADVANTAGES
- HIGH INITIAL COST
- DEAD STOCK / INVENTORY IN PIPELINE
Engineers India Ltd – Delivering excellence through people
Slide Number - 2 of 50
SOME OF THE MAJOR PIPELINES UNDERTAKEN BY EIL
1. 1986 – 36”/18” x 1800 Kms: HBJ (HAZIRA-BIJAIPUR-JAGDISHPUR) GAS P/L OF M/s GAIL
2. 1996 – 22”/14”/10” x 1450 Kms: KBPL (KANDLA-BHATINDA) PRODUCT P/L OF M/s IOCL
3. 1997 – 36” x 505 Kms: GREP (HBJ UP-GRADATION) GAS P/L OF M/s GAIL
4. 1998, 2003, 2007 – 18”/14” x ~1200 Kms: MMPL PH-1,2 &3 (MUMBAI-MANMAD-INDORE-
DELHI) PRODUCT P/L OF M/s BPCL
5. 2000 – 16” x 1269 Kms: JLPL (JAMNAGAR-LONI) LPG P/L OF M/s GAIL
6. 2002 – 16”/14” x 220 Kms: VSPL (VIJAIWADA-SECUNDRABAD) PRODUCT P/L OF M/s HPCL
7. 2002 – 18”/14” x 289 Kms: CKPL (COCHIN-KARUR) PRODUCT P/L OF M/s PETRONET LTD.
8. 2003 – 24”/24” x 380 Kms: MBPL (MANGLORE-BANGLORE) PRODUCT P/L OF M/s HPCL
9. 2003 – 12”/10” x 600 Kms: VSPL (VIZAG-SECUNDRABAD) LPG P/L OF M/s GAIL
10. 2004 – 42” x 610 Kms: DVPL (DAHEJ-VIJAIPUR) GAS P/L OF M/s GAIL
11. 2006 – 18” x 1037 Kms: MDPL (MUNDRA-DELHI) PRODUCT P/L OF M/s HPCL
12. 2006 – 14”/12” x 343 Kms: PSPL (PUNE-SHOLAPUR) PRODUCT P/L OF M/s HPCL
13. 2007 – 16” x 401 Kms: NSPL (NUMALIGARH-SILIGURI) PRODUCT P/L OF M/s OIL
14. DPPL PH-1&2 (DHABOL-PUNE) GAS P/L OF M/s GAIL PH-2 IN PROGRESS
15. VBPL (VADINAR-BINA) CRUDE OIL P/L OF M/s BORL IN PROGRESS
16. VDBPL (VIJAIPUR-DADRI-BAWANA) GAS P/L OF M/s GAIL IN PROGRESS
17. MBPL (MUNDRA-BHATINDA) CRUDE OIL P/L OF M/s HMPL IN PROGRESS
18. BKPL (BINA-KOTA) PRODUCT P/L OF M/s BPCL IN PROGRESS
VADINAR – BINA CRUDE PIPELINE PROJECT : 24” DIA x 931 KMS., API – 5L X70 GR., CAPACITY - 6 MMPTA

VADINAR – BINA CRUDE PIPELINE PROJECT : 24” DIA x 931 KMS., API – 5L X70 GR., CAPACITY - 6 MMPTA
RT- BINA
IP2-SANDAVATA
IPS2- BEWARI
IP1 -SIDHASAR
IPS1- THAMNA SP5-

208 KMS.
SP4-
DT-VADINAR SP1- SP2- SP3- 219 KMS.
160 KMS. 199 KMS. 145 KMS.

I. CONSTRUCTION METHODOLOGY
II. TYPE OF CONSTRUCTION EQUIPMENTS
III. TYPES OF CONTRACTORS REQUIRED FOR

CONSTRUCTION OF PIPELINES

I. CONSTRUCTION METHODOLOGY
QA/QC, CODES, SPECN., & HSE REQUIREMENTS
LINEPIPES COATING AT YARD & DUMPSITE
LAYING OF PIPELINE

QA/QC IN PIPELINE
Review & Approval of Contractor’s QAP for all activities
Review & Approval of Contractor’s Inspection & Test Plans (ITP’s)

with reference to standard ITP’s of EIL before start of work
Review & Approval of Job Procedures & Inspection Formats

based on ITP’s for all Pipeline activities
Quality Audits & Resolution of Non Conformances (NC’s)

observed during execution of work & quality audits

CODES & STANDARDS
Following are the reference/codes followed during Line-pipe Coating & Laying of Pipeline:
1. DIN 30670 : 3LPE Coating of Line-pipes
2. AWWA 203 : Coal Tar Enamel Coating of Line-pipes
3. API 1104 : Welding of Pipeline & Related Activities
4. API 1105 : Construction Practices for Oil & Products Pipelines
5. ASME B 31.4 : Pipeline Transportation System for Liquid Hydrocarbon
6. ASME B 31.8 : Gas Transmission and Distribution Piping System
7. OISD B 141 : Design and construction requirements for cross-country

Hydro-carbon Pipelines

RELEVANT EIL SPECN. & STANDARDS
Following are the relevant EIL Specification & Standards for Coating & Laying of Pipeline:
1. 6-71-0001 : Standard specification for Line pipes, Valves, Fittings,
to 6-71-0040 Scrapper Launcher / Receiver, Pig signaller etc.
2. 6-71-0041 : Standard specification for 3LPE Coating
3. 6-71-0042 : Standard specification for CTE Coating Onshore Pipeline.
4. 6-71-0044 : Standard specification for Field Jt. Coating Onshore Pipeline.
5. 6-71-0046 : Standard specification for Conc. Coating Onshore Pipeline.
6. 6-71-0051 : Standard specification for Pipeline Construction (Onshore)
7. 6-71-0052 : Standard specification for Pipeline Construction, Road, Rail,
Minor Water Crossings
8. 6-71-0053 : Standard specification for Major Water Crossings (Conventional)
9. 6-71-0054 : Standard specification for Pipeline River Crossings by HDD
10. 6-71-0055 : Standard specification for Hydro-testing of Onshore Pipelines
11. 6-71-0057 : Standard specification for Pipeline Markers
12. 6-82-1901 : Standard Inspection & Test Plans (ITP’s) for Pipeline Activities
to 6-82-1925

HSE IN PIPELINE
Review of contractors’ HSE plan & documents with reference to

EIL specification no. 6-82-0001, Rev-4.
Construction hazards identification & mitigation measures
Ensuring compliance to HSE requirements by contractors
First-Aid & Fire fighting facilities
HSE promotion activities
HSE Reporting including statistics
HSE Audits & Resolution of Non-conformances

LINEPIPE COATING AT YARD
TYPES OF EXTERNAL YARD COATING

- 3 LAYER POLYETHELENE (3LPE) COATING / FBE COATING
- COAL TAR ENAMEL (CTE) COATING
3LPE COATING / ONE LAYER FBE COATING

-1st LAYER: FUSION BONDED EPOXY – 50 MICRONS (200 TO 300 MICRONS - FBE COATING)
- 2nd LAYER: SIDE EXTRUSION ADHESIVE (LDPE) – 200 TO 300 MICRONS
-3rd LAYER: SIDE EXTRUSION POLYETHELENE (LDPE / MDPE / HDPE) - > 2 MM
CTE COATING (HOT APPLIED)

- 1st COAT: COAL TAR PRIMER – 50 TO 75 MICRONS
- 2nd COAT: 1st HOT COAL TAR ENAMEL LAYER WITH INNER WRAP– > 1 MM
- 3rd COAT: 2nd HOT COAL TAR ENAMEL LAYER WITH INNER WRAP– > 1 MM
- FINAL COAT: COAL TAR IMPREGNATED OUTER WRAP – 600 TO 750 MICRONS

LINEPIPE COATING AT YARD Contd…
COATING PROCESS:
1) BARE PIPES VISUAL INSPECTION 2) SHOTBLASTING AND VISUAL INSPECTION
- PIPE NO., HEAT NO., LENGTH, DIA, THK ETC. - ROUGHNESS CHECK ON BODY
- BEVEL & BODY DAMAGES E.G. DENTS, GOUGES ETC. - BODY DENTS & GOUGES
BARE PIPES STACKING YARD SHOT BLASTING OF PIPES

COATING PROCESS:
3) PRE-HEATING OF PIPES & PRIMER / EPOXY APPLICATION (PIPES TO BE PREHEATED TO 200 0 C BY
INDUCTION COIL/ GAS OVEN)
- CHECK FOR PIPE TEMP BY DIGITAL TEMPERATURE GUAGE & UNIFORM SPRAY
SPRAY OF EPOXY ON PIPE
BARE PIPES PRE HEATING

COATING PROCESS:
4) COATING APPLICATION
- CHECK TEMP OF EXTRUDERS, PE FILM, ADHESIVE FILM, COAL TAR ENAMEL
ENAMEL ETC.
INNER/OUTER WRAP & COAL

ADHESIVE & PE APPLICATION
TAR ENAMEL APPLICATION

COATING PROCESS:
5) COOLING OF COATED PIPES IN COOLING TUNNEL & VISUAL INSPECTION OF COATED PIPES
- CHECK COOLING WATER TEMP, VISUAL DAMAGE TO COATING, COATING THK. ETC.
COATED PIPE COOLING TUNNEL 3LPE COATING THICKNESS CHECK CTE COATING THICKNESS CHECK

COATING PROCESS:
6) HOLIDAY TESTING, REPAIR OF COATING & TESTING
- CHECK FOR HOLIDAY AT 25KV FOR 3LPE COATING & 15KV FOR CTE COATING
COATING
- MARK PIPES FOR TESTING E.G. PEEL TEST, AP TEST, IMPACT TEST ETC.
ETC. & COATING REPAIR
RING HOLIDAY TESTING MARKING OF TESTING

COATING PROCESS:
7) EXTERNAL PAINTING (IF REQD) AND STACKING IN YARD
- THK OF PAINT, MARKING ON COATING PIPES, COATING ACCEPTANCE NO., ROW HEIGHT ETC.
COATED PIPES EXTERNAL

COATED PIPES STACKING YARD
PAINTING

DUMP SITES FOR STORAGE OF COATED PIPES
ACQUIRING OF LAND & DEVELOPMENT OF DUMP SITE
- GRADING OF LAND, PROVIDING TEMPORARY FENCING, BARRIER GATE , GUARD
GUARD ROOM AND SECURITY
- PROVIDING INTERNAL ROADS (WBM) FOR TRAILER MOVEMENT & AREA LIGHTING
LIGHTING WITH DG SET
- PROVIDING SAND ROWS FOR STACKING OF COATED PIPES
HANDLING OF COATED PIPES

- ADEQUATE CRANES WITH PADDED HOOKS FOR UNLOADING / LOADING OF COATED
COATED PIPES IN TRAILERS
- STACKING OF COATED PIPES ON SAND ROWS
- HOLIDAY CHECK AND VISUAL CHECK INCLUDING GUAGE PLATE PULL TEST BEFORE DESPATCH TO SITE

PIPELINE LAYING ACTIVITIES:
ROU SURVEY
ROU CLEARING AND GRADING
STRINGING
TRENCHING
BENDING
WELDING
FIELD JOINT COATING
LOWERING
BACKFILLING
CROSSING
TIE-INS
HYDROTESTING
PIPELINE MARKERS, CLEAN UP & RESTORATION
STATION WORKS
MAGNETIC PIGGING & EGP – PRE COMMISSIONING ACTIVITY

Slide Number - ___of 50
PIPELINE LAYING ACTIVITIES..Contd.:
ROU SURVEY
Installation of Bench Marks, Turning Points
Stake markers in center line of pipeline at a distance of max.100m for centre line and for
horizontal bends10 m. and reference point for same
Stake two ROU markers at least at every 100m, Painted in red and numbers in white in
direction of flow.
Chainage markers at every 250 m
ROU CLEARING & GRADING
All obstacles causing hindrance in construction / laying pipeline are removed.
Entire ROU is Graded for movement of equipments and vehicle.
Temporary approaches/bridges, if required, are constructed for movement of equipments,
vehicles & personnel’s
STRINGING
Stringing shall be done after blasting & trenching when ROU is in rocky area .
Coated Pipes shall be strung on approved soft earth/sand filled bag and wedge in such a
way that bottom of coated Pipe remain above ground
Pipes shall be supported at minimum two locations
Pipe number, Heat number, coat number & length shall be transferred and recorded in
serial order
ROU CLEARING & GRADING AND PIPELINE STRINGING ACTIVITY

PIPELINE LAYING ACTIVITIES ..Contd.:
TRENCHING
Trench excavation is carried out along staked centerline of Pipeline
The width of excavation for trench shall be minimum (pipe diameter plus 200mm either side)
Depth of trench shall be as specified (Normal= 1M; Road= 1.2M; River= 1.5M; Rly.= 1.7M etc)
In case of trenching in rocky areas, blasting is performed with the guidelines /Safety Rules
of Chief Controller of explosives, Nagpur.
In case where rock/gravel or murrum/hard soil is encountered in the bottom of trench,
padding material (minimum compacted thickness of 150 mm) shall be provided.
When up-floating of the pipeline after backfilling is anticipated, antibuoyancy measures are
provided in such areas e.g. weighing by applying continuous concrete, installing saddle
weights etc.
BENDING
For changes in vertical & horizontal alignment, pre-fabricated cold field bends are provided
Over-bends are made in a manner that centre of bend clears the highest point of trench
bottom. Sag bends shall fit the bottom of the trench. Side bends shall have specified
clearance to the outside wall of trench.
The radius of cold field bends shall not be more than 40 times the dia. of pipe (for 18” inch
and above) and 30 times the dia. of pipe (for 18” inch below).
Pipes with longitudinal welds are bent a way that weld lies in the plane passing through the
neutral axis of bend
PIPELINE TRENCHING ACTIVITY

PIPELINE BENDING ACTIVITY

PIPELINE LAYING ACTIVITIES.. Contd.:
WELDING
Welding Procedure Specification (WPS) to be followed for the welding is qualified and the
Procedure qualification record (PQR) is approved before start of welding. Approved brand of
electrodes are used for welding. Physical properties of the weld produced by an electrode
shall not be less than minimum value of base metal. Electrode qualification and batch record
are maintained.
Each pipe shall be thoroughly checked internally & externally for visual defect/ damage and
cleaned internally by compressed air blowing.
Damaged end shall be cut and re-bevelled with beveling machine. All new bevels shall be 100%
dye penetrant /MPI tested and Ultrasonically tested for any lamination.
Use of internal clamp is mandatory for pipe dia.> 10”. Except tie in joints, fitting etc. In such
case external clamps are used.
Each joint shall bear an identification number which shall be followed for NDT
The number of welders, and welding sequence, speed etc. should be similar to that of adopted
in approved welding procedure
Radiography examination of 100 % girth weld is carried out. Weld shall meet the requirement
of API 1104. In addition 100% ultrasonic inspection is required for critical weld joints i.e. tie in,
welding of valves etc. joints which have not undergone pressure testing i.e. GOLDEN TIE-Ins.
Repair is limited to maximum 30% of the weld length. Weld containing cracks shall be cut and
re-bevelled to make a joint.
Destructive testing of weld joints are done for 0.1% of the total numbers of welds completed.
PIPELINE MAINLINE WELDING ACTIVITY

AUTOMATIC WELDING CREW FOR MAINLINE JOINT MANUAL WELDING OF MAINLINE JOINT
AUTOMATIC WELDING OF MAINLINE JOINT AUTO UT OF MAINLINE JOINT

FIELD JOINT COATING
The cut-back areas of Coated Pipes where weld joints are made are to be Coated by Field
Joint Coating.
Field joint coating material is heat shrinkable wraparound sleeve used as anticorrosion
coating of buried onshore pipeline.
Sleeve consist of radiation cross-linked, thermally stabilized, ultraviolet resistant semi-
rigid polyolefin backing with a uniform thickness of high shear strength thermoplastic/co-
melt adhesive
The joint coating system shall consist of a solvent free epoxy primer applied to the pipe
surface prior to sleeve application. The surface area is blast cleaned to SA-2.5 followed by
Pre-heating of pipe surface, application of epoxy primer and application of sleeve by heat
shrinking.
Each sleeve joint is inspected by means of a full circle holiday detector set to DC voltage
at 25 KV (Pipe surface temperature below 50 degree Celsius) and thickness of sleeve
checked.
One out of 50 joints coating or one coating out of every day production shall be tested to
establish peel strength on steel and factory applied coating.

PIPELINE FIELD JOINT COATING ACTIVITY

LOWERING
Lowering shall commence after inspection of trench. Trench bottom shall be free from
pipe supports, stones, roots, debris, stakes, and rigid material. Padding shall be provided
in rocky/ murram area.
Lowering shall commence as soon as possible after completion of joint coating, Before
lowering in, complete check by a full circle holiday detector for pipe coating and field joint
coating at 15 KV is carried out (Speed 300mm /sec). Any damage shall be repaired.
Support/ skid points shall be thoroughly checked.
The pipeline must be laid without interruption for the whole or the length of section
available
Ends of the lowered pipeline section shall be closed with night cap to prevent ingress of
water, mud etc.

PIPELINE HOLIDAY AND LOWERING ACTIVITY

BACKFILLING
Backfilling shall be carried out immediately after pipeline lowering in trench after
inspection, so as to provide a natural anchorage for the pipeline, thus avoiding long
exposure of coating to high temperature, damaging action of adverse weather conditions,
sliding down of trench sides and pipeline movement in the trench.
Backfill material shall not contain any extraneous material or hard lumps of soil which can
damage pipeline or coating or leave the voids in backfilled trench.
After placing of initial backfill, proper compaction shall be done. The surplus material
shall be crowned (300 mm) directly over trench and adjacent excavated area on both side
of trench.
If trench are excavated in steep area where the slope is more than 10%, slope breakers
shall be installed to prevent erosion of backfill. Stabilization of backfill shall be done in
sandy area to have consolidated cover over the pipeline.
CROSSINGS
Cased & Un-cased crossings for Roads & Railways
Open cut & Horizontal Directional Drilling (HDD) for Minor & Major River Crossing
TIE-INs
The unconnected sections of the lowered pipeline sections at various locations have to be
welded, coated and backfilled to make the sections ready for post installation hydro test .
If a pup piece cannot be avoided for tie in, the minimum 1.0 m length shall be added.
PADDING & BACKFILLING BOARING FOR CASED CROSSING
TIE-IN IN PROGRESS
TIE-IN WELDING IN PROGRESS

HYDRO-TESTING
Hydrostatic test is performed on entire length of the pipeline. The maximum permitted length
is 50 Kms. Hydrostatic test diagrams indicating number of test sections and minimum and
maximum test pressure in each test section are prepared before performing hydrostatic test.
Hydrostatic test commence only after completion of all welding works so as to avoid/
minimize untested hydro-test joints/ Golden joints.
Hydro test includes all those sections which are tested earlier for Road, rail road crossings,
major water crossings etc.
Duration of hydrostatic test is minimum 24 hours after thermal stabilization. Hydro-static test
pressure for pipeline handling hydrocarbon in gaseous phase is 1.25 times the design
pressure in pipeline located in Class-1 & 2 locations and 1.4 times the design pressure if
pipeline located in Class-3 & 4 locations.
Before water filling, pipeline shall be cleaned with air driven pigs with spring loaded brushes
and chiseled to remove all mill scale, rust, sand etc. from the internal pipe section.
After successful cleaning and acceptance, gauging is carried out using gauging pig.

HYDRO-TESTING..Contd,
After acceptance of gauging operation, un-inhabited water is pumped into the section using
four cup batching pigs which are launched at specific intervals.
After water filling operation, thermal equilibrium between pipeline and environment shall be
checked with thermocouples installed on the pipeline.
After thermal stabilization pressurization is carried out in cycles of 50% test pressure & 75%
test pressure and held for 1 hour at each test pressure and depressurized to zero pressure and
then pressurized to final test pressure. During each test pressure, two test shall be carried out
for calculation of air volume in the pipeline under test and on acceptance of air volume test the
section is held for 24 hours at Final test pressure and pressure and temperature recorded on
chart.
The hydrostatic test shall be considered positive if pressure has kept a constant value
throughout the test duration, except for change due to temperature effects. The pressure value
thus added shall be compared with initial value and the test shall be considered as acceptable
if the difference is less than or equal to 0.3 bar.
After positive test results, test shall be terminated . The pipeline shall be depressurized at
constant rate. Dewatering shall be carried out by using four cup pigs driven by compressed air.
Foam pigs shall be passed to complete the dewatering.
PIPELINE ACTIVITIES Contd.:
PIPELINE MARKERS, CLEAN-UP AND RESTORATION
Following type of markers shall be fabricated and installed along the pipeline route such
that they do not cause any hindrance to the regular land user or traffic
− Aerial Markers : At every 5 Kms.
− Kilometer Markers : At every 1 Km. & as per Alignment sheet
− Pipeline Warning Markers : At Road / Railway / River Crossings & Stations / Terminals
− ROU Boundary Markers : At every 750 Mtrs. & as per Alignment sheet
− Direction Markers : At significant turning points
− Navigational Markers : At bank of Navigational Course
− OFC Markers : At OFC Joints
ROU and all sites used for construction of pipeline , water crossing and other structures
shall be restored as per satisfaction of authority having jurisdiction over it.
Damages to roads, bridges, fences etc. damaged during construction shall be restored to
original.
The bed of water course shall be restore to the original level. The banks and any
excavated area shall be restored to original levels . The banks shall also be stabilized.
On completion of clean-up, the ROU shall be restored to such stable and usable condition
as may be reasonably consistent with the condition of the ROU prior to laying the
pipeline. The release note from the land owner s regarding satisfactory indemnification
and restoration of land shall be obtained from land owner.

SV / IP / DT, PS & RT STATION WORKS
Sectionalizing Valve (SV) are installed at regular intervals (around 25 to 40 Kms.) to isolate
pipeline section during emergencies like leakage in pipeline as per statutory requirements.
An SV station is installed at such locations having a unmanned control room with a guard
room and boundary wall. A lockable grill cage is provided over the Sectionalizing Valve
installation including piping and instrumentation to prevent tampering by unauthorized
persons and ensuring safety of pipeline operations.
Intermediate Pigging (IP) stations are installed at regular intervals (as per design ~ 150
Kms.) having a Pig Launcher and a Pig Receiver with Control room, Sump tank, Basket
Filters, guard room, boundary wall etc. to facilitate pigging of pipeline during routine
Operation and Maintenance.
Dispatch Terminal (DT), Pump Station (PS) & Receipt Terminals are provided at start,
intermediate & end locations of the Pipeline to facilitate handling and pumping of the
product through the pipeline. It comprises of Pig Launcher / Pig Receiver with Control
room, Mainline & Booster Pumps (DT/PS), Sump tank, Basket Filters, guard room, Firewater
system, boundary wall etc.

TYPICAL SECTIONALIZING VALVE (SV) STATION

MAGNETIC PIGGING & ELECTRONIC GEOMETRY PIGGING (EGP):
Pre Commissioning Activity
This is a part of pre-commissioning activity, which ensures that there is no deformity in
pipeline. This is done prior to filling the line with product.
Magnetic PIG loaded with high capacity magnets spread uniformly with high density
polythene four cup PIG is launched to remove ferrous debris, mill scale, electrode pieces
etc. The accumulated weight of this ferrous debris is checked after running the PIG through
pipeline section. When the collected weight of ferrous debris is within limit for specific
length of pipeline section, the line is ready for launching EGP tool.
After successful completion of magnetic pig run EGP tool is launched. This tool is mounted
with battery operated battery device, which gives the reduction in pipeline Dia. at specific
location in electronic form.
Any defect /deformity more than 3% of internal diameter of pipe (dent or ovality) is
physically verified at site. Defect of more than 5% internal diameter of pipe are repaired by
cutting the suitable length of pipe and re-welding and accepted after radiography.


EIL Cross Country Pipeline Presentation

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CONSTRUCTION

By: G. K. IYER (AGM.)

CONSTRUCTION OF CROSS COUNTRY PIPELINES

 SOME MAJOR ADVANTAGES

CONSTRUCTION OF CROSS COUNTRY PIPELINES

IPS1- THAMNA SP5-

CONSTRUCTION OF CROSS COUNTRY PIPELINES

II. TYPE OF CONSTRUCTION EQUIPMENTS

III. TYPES OF CONTRACTORS REQUIRED FOR

CONSTRUCTION OF CROSS COUNTRY PIPELINES

 QA/QC, CODES, SPECN., & HSE REQUIREMENTS

 LINEPIPES COATING AT YARD & DUMPSITE

CONSTRUCTION OF CROSS COUNTRY PIPELINES

 Review & Approval of Contractor’s QAP for all activities

 Review & Approval of Contractor’s Inspection & Test Plans (ITP’s)

 Review & Approval of Job Procedures & Inspection Formats

 Quality Audits & Resolution of Non Conformances (NC’s)

CONSTRUCTION OF CROSS COUNTRY PIPELINES

1. DIN 30670 : 3LPE Coating of Line-pipes

2. AWWA 203 : Coal Tar Enamel Coating of Line-pipes

3. API 1104 : Welding of Pipeline & Related Activities

4. API 1105 : Construction Practices for Oil & Products Pipelines

5. ASME B 31.4 : Pipeline Transportation System for Liquid Hydrocarbon

6. ASME B 31.8 : Gas Transmission and Distribution Piping System

7. OISD B 141 : Design and construction requirements for cross-country

CONSTRUCTION OF CROSS COUNTRY PIPELINES

CONSTRUCTION OF CROSS COUNTRY PIPELINES

 Review of contractors’ HSE plan & documents with reference to

 Construction hazards identification & mitigation measures

 Ensuring compliance to HSE requirements by contractors

 First-Aid & Fire fighting facilities

 HSE promotion activities

 HSE Reporting including statistics

 HSE Audits & Resolution of Non-conformances

CONSTRUCTION OF CROSS COUNTRY PIPELINES

 TYPES OF EXTERNAL YARD COATING

 3LPE COATING / ONE LAYER FBE COATING

 CTE COATING (HOT APPLIED)

CONSTRUCTION OF CROSS COUNTRY PIPELINES

BARE PIPES STACKING YARD SHOT BLASTING OF PIPES

CONSTRUCTION OF CROSS COUNTRY PIPELINES

BARE PIPES PRE HEATING

CONSTRUCTION OF CROSS COUNTRY PIPELINES

INNER/OUTER WRAP & COAL

CONSTRUCTION OF CROSS COUNTRY PIPELINES

CONSTRUCTION OF CROSS COUNTRY PIPELINES

RING HOLIDAY TESTING MARKING OF TESTING

CONSTRUCTION OF CROSS COUNTRY PIPELINES

COATED PIPES EXTERNAL

CONSTRUCTION OF CROSS COUNTRY PIPELINES

 HANDLING OF COATED PIPES

CONSTRUCTION OF CROSS COUNTRY PIPELINES

CONSTRUCTION OF CROSS COUNTRY PIPELINES

CONSTRUCTION OF CROSS COUNTRY PIPELINES

CONSTRUCTION OF CROSS COUNTRY PIPELINES

CONSTRUCTION OF CROSS COUNTRY PIPELINES

CONSTRUCTION OF CROSS COUNTRY PIPELINES

AUTOMATIC WELDING OF MAINLINE JOINT AUTO UT OF MAINLINE JOINT

CONSTRUCTION OF CROSS COUNTRY PIPELINES

CONSTRUCTION OF CROSS COUNTRY PIPELINES

CONSTRUCTION OF CROSS COUNTRY PIPELINES

CONSTRUCTION OF CROSS COUNTRY PIPELINES

CONSTRUCTION OF CROSS COUNTRY PIPELINES

TIE-IN WELDING IN PROGRESS

SOME MAJOR ADVANTAGES

QA/QC, CODES, SPECN., & HSE REQUIREMENTS

LINEPIPES COATING AT YARD & DUMPSITE

Review & Approval of Contractor’s QAP for all activities

Review & Approval of Contractor’s Inspection & Test Plans (ITP’s)

Review & Approval of Job Procedures & Inspection Formats

Quality Audits & Resolution of Non Conformances (NC’s)

Review of contractors’ HSE plan & documents with reference to

Construction hazards identification & mitigation measures

Ensuring compliance to HSE requirements by contractors

First-Aid & Fire fighting facilities

HSE promotion activities

HSE Reporting including statistics

HSE Audits & Resolution of Non-conformances

TYPES OF EXTERNAL YARD COATING

3LPE COATING / ONE LAYER FBE COATING

CTE COATING (HOT APPLIED)

HANDLING OF COATED PIPES