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PIPELINE DESIGN

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Delivering excellence through people
Pipeline Design

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ENGINEERS
INDIA LIMITED

EPC and Total Solutions


Consultancy Organization

Pipeline Design
Engineers India Ltd – Delivering excellence through people
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Petroleum Refineries
Petrochemicals
Pipelines
Offshore Platforms
Gas Processing
Metallurgy
Ports & Terminals
Highways and Airports

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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

Pipeline Design
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

Pipeline Design
Engineers India Ltd – Delivering excellence through people
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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
Engineers India Ltd – Delivering excellence through people
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PIPELINE DESIGN
Major Onshore Projects (Completed)

DESCRIPTION CLIENT YEAR SIZE LENGTH SERVICES


(KM)

HAZIRA-BIJAIPUR-
HAZIRA- BIJAIPUR- GAIL 1989 36“/30”/24”/18” 1800 NATURAL GAS
JAGDISHPUR (HBJ)

MAQTA--AL
MAQTA AL--AIN PIPELINE ADNOC 1992 30 ”/12” 166 NATURAL GAS
KANDLA--BHATINDA
KANDLA IOCL 1996 22”/14”/10” 1443 MULTIPRODUCT

GAS REHABILITATION & GAIL 1998 36 ” 505 NATURAL GAS


EXPANSION PROJECT
(GREP)
MUMBAI – MANMAD BPCL 1998 18 ” 260 MULTIPRODUCT
VIZAG--VIJAYWADA
VIZAG HPCL 1998 18 ” 360 MULTIPRODUCT
JAMNAGAR-LONI LPG
JAMNAGAR- GAIL 2001 16”/14”/12”/8”/ 1235 LPG (LIQUIFIED
PIPELINE 6 PETROLIUM GAS)

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

Pipeline Design
Engineers India Ltd – Delivering excellence through people
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PIPELINE DESIGN
Major Onshore Projects (..contd) (Completed)
DESCRIPTION CLIENT YEAR SIZE LENGTH SERVICES
(KM)

VIZAG – SECUNDERABAD LPG GAIL 2002 12”/10” 600 LPG (LEQUIFIED


PIPELINE 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

INTER REFINERIES PIPELINES 10” 230 NAPHTHA,


PROJECT, ABU DHABI TAKREER 2004 12” 230 MULTIPRODUCT & SRR
16” 208
MANGALAYA-BIJWASAN
MANGALAYA- BPCL 2006 16”/8” 775 MULTIPRODUCT
PIPELINE

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

Pipeline Design
Engineers India Ltd – Delivering excellence through people
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PIPELINE DESIGN
Major Onshore Projects (7contd)
(Completed)
DESCRIPTION CLIENT YEAR SIZE LENGTH SERVICES
(KM)
PUNE SOLAPUR PIPELINE HPCL 2007 14 ”/ 12” 182 / 161 MULTIPRODUCT

DABHOL PANVEL PIPELINE GAIL 2007 30” 187 REGASIFIED LNG


PROJECT (PH-
(PH-I)
DABHOL PANVEL PIPELINE GAIL 2007 30” 120 REGASIFIED LNG
PROJECT (PH-
(PH-II)

Pipeline Design
Engineers India Ltd – Delivering excellence through people
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PIPELINE DESIGN
Major Offshore Projects
(Completed)
DESCRIPTION CLIENT YEAR SIZE LENGTH SERVICES
(KM)

BOMBAY HIGH URAN TRUNKLINE ONGC 1979 30”/26” 200 x 2 CRUDE, GAS
(BUT)
SOUTH BASSEIN HAZIRA ONGC 1986 36” 220 GAS
TRUNKLINE

HEERA--URAN TRUNK LINE


HEERA ONGC 1996 26 ”/24 ” 85 x 2 CRUDE, GAS

ICP - HEERA TRUNKLINE ONGC 1996 30”/22” 145 CRUDE

SECOND BASSEIN HAZIRA ONGC 1995 42” 245 GAS


TRUNKLINE

MUMBAI HIGH URAN TRUNKLINE ONGC 2005 30”/28” 205 x 2 CRUDE, GAS
(MUT) 12” to 22” 100
IN-FIELD PIPELINES OF BOMBAY-HIGH, BASSEIN, HEERA, NEELAM, PANNA, MUKTA.

Pipeline Design
Engineers India Ltd – Delivering excellence through people
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PIPELINE DESIGN
Major Onshore Projects
(Current)
DESCRIPTION CLIENT YEAR SIZE LENGTH SERVICES
(KM)

VIJIPUR DADRI BAWANA PIPELINE GAIL 2009 48”/ 36”/ 500/ 38/ 55 REGASIFIED LNG
(VDBPL) 20”

MUNDRA BATHINDA PIPELINE HMPL 2009 28”/ 30” 424/ 590 CRUDE OIL
(MBPL)

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
Engineers India Ltd – Delivering excellence through people
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PIPELINE DESIGN
SECTION-1

INTRODUCTION

Pipeline Design
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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

Pipeline Design
Engineers India Ltd – Delivering excellence through people
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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
Engineers India Ltd – Delivering excellence through people
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PIPELINE DESIGN

Refining Scenario- India Capacity - 2006-07


NOC – 105.5 MMT
350
Others- 43.5 MMT
302
300

235
(MMT)

250

200

149
150

100
70

50

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

(Actual) Year

Pipeline Design
Engineers
Source: India of
Report LtdWorking
– Delivering
Group on P&NG
excellence Sector
through for the XI Plan
people
Slide Number - 15 of 77
PIPELINE DESIGN
Modes of Hydrocarbon Transportation - India

35%
30%
Pipelines 32% 25%
Pipelines
20%
Road Tankers 32% Road Tankers
15% Rail Tankers
Rail Tankers 26% 10% Water Carriers
5%
Water Carriers 10%
0%
% Share

Pipeline Design
Engineers India Ltd – Delivering excellence through people
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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
Engineers India Ltd – Delivering excellence through people
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PIPELINE DESIGN
Energy Savings
Energy Intensity for Various M ode s
Energy Consumption in % of energy

4
3.5 3.2
3
Transported

2.5 2
2
1.5 1.1
0.8 0.8
1
0.5
0.5 1
0
Liquid- Liquid- Liquid- Liquid- Coal- Coal- N.Gas-
Pipelines Coastal Trains Trucks Trains Coastal Pipelines

Pipelines are the most energy efficient modes of transportation


Pipeline Design
Engineers India Ltd – Delivering excellence through people
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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


Pipeline Design
Engineers India Ltd – Delivering excellence through people
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PIPELINE DESIGN
Products Transported
 Crude Oil
 Petroleum Products (MS, HSD, ATF, SKO)
 Water & Effluents
 LPG
 Natural Gas
 Slurries

Pipeline Design
Engineers India Ltd – Delivering excellence through people
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PIPELINE DESIGN
Types of Pipelines

ONSHORE (LAND) & OFFSHORE


(SUBMARINE) PIPELINES
 Trunk Pipelines

 Spur/ Branch Pipelines

 Marine Offloading Terminals & Outfalls

Pipeline Design
Engineers India Ltd – Delivering excellence through people
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PIPELINE DESIGN
Capital cost: Typical breakup
P e r c e ntag e of C a p ita l Cos t.
S r o. Ite m D e s cription
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


Pipeline Design
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

DADRI ANOLA
DELHI

RAJASTHAN BABRALA SHAHJAHANPUR


INDIA
GADEPAN AURAIYA JAGDISHPUR
ANTA

GUJARAT BIJAIPUR
KEY PLAN
JHABUA LEGEND
COMPRESSOR STATION
ARABIAN MADHYA PRADESH
SEA RECEIVING TERMINAL
HAZIRA
DESPATCH STATION

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Engineers India Ltd – Delivering excellence through people
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PIPELINE DESIGN
Major Pipelines in India

Pipeline Design
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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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Engineers India Ltd – Delivering excellence through people
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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
 Installation Engineering and Construction Procedures

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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 OS-
OS-F101 Submarine pipeline systems
Other References Applicable Standards / Specs of ASME, API, NACE, MSS, BS and
DIN

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Engineers India Ltd – Delivering excellence through people
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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 Irrigation/Canal Authority

Pipeline Design
Engineers India Ltd – Delivering excellence through people
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LIST OF SOFTWARES USED IN PIPELINE
ENGINEERING

 CAESAR-II
CAESAR-  PIPELINE STUDIO
 AUTOPIPE TGNET
 IPMCS TLNET
 MRPACK  HYSIS
 SORPS
 PIPECALC
 OFFPIPE
 PRISE
 PIPECROSS
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Engineers India Ltd – Delivering excellence through people
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PIPELINE DESIGN
Optimal sizes of various capacities

Economy of scale
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PIPELINE DESIGN
Route Selection
Routing Considerations
 Pipeline length
 Obstructions & Sensitive areas
 Installation Limitations
 Crossings
Surveys
 Topographical
 Geo-technical
 Population Density Index
 Soil Resistivity
 Cadastral
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Engineers India Ltd – Delivering excellence through people
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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


IPS-1
RECEIPT TERMINAL 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. IPS-F
2. CHAINAGES INDICATED ARE APPROXIMATE. JHEKDA
Ch. 226.72 km

MUNDRA
Ch. 0.00 km

Pipeline Design
Engineers India Ltd – Delivering excellence through people
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PIPELINE DESIGN

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PIPELINE DESIGN
Material Selection & Corrosion Control
Assessment Materials
 Nature of the Product  Carbon Steel (CS)
 Design Life  NACE Carbon Steel
 Product Temperature  CRA Clad CS
Corrosion Protection  CS with internal
 Material Chemistry Coatings
 Internal Coatings  Non-Metallic
Materials
 Product Conditioning
 Corrosion inhibitors
 Corrosion Allowance

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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
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 P = 2St FET


2.S D

where where
Pi Internal design pressure P Design pressure
S allowable stress S Specified minimum yield
= 0.72 x E x SMYS strength
D Outside Diameter of pipe D Nominal OD of pipe
t pressure design wall t Nominal wall thickness
thickness F Design factor
E Weld joint factor E Longitudinal joint factor
T Temperature de-rating factor

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Engineers India Ltd – Delivering excellence through people
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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 : ≤ 10 buildings
Location Class 2 : > 10 and < 46 buildings
Location Class 3 : ≥ 46 buildings
Location Class 4 : Multistory buildings

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PIPELINE DESIGN
Line Pipe Selection

Line Pipe Selection Parameters Type of Line Pipes


 Thickness and Grade  Seamless
Selection  Electric Welded
 Handling and  Longitudinal Seam
Transportation (d/t ratio) Submerged--Arc Welded
Submerged
 Type of LinePipe (LSAW)

 Installation Requirements  Helical Seam Submerged-


Submerged-
Arc Welded
(HSAW)

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PIPELINE DESIGN
Line Pipe Application
Submarine Pipelines Onshore Pipelines

 Seamless Pipes  Seamless Pipes


(upto & including 16”) (upto & including 8”)
 LSAW Pipes  LSAW Pipes
(18” & above) (16” & above)
 HSAW Pipes
(18” & above)
 EW Pipes
(4” - 18”)

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Pipeline Design
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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)
 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
350-
 600--800 micron thick dual layer coating
600

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Engineers India Ltd – Delivering excellence through people
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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 Gas Pipelines
 ASME B 31.8 for Gas Location Class 1 32 km (20 miles)
pipelines Location Class 2 24 km (15 miles)
 ASME B 31.4 for Liquid
Pipelines Location Class 3 16 km (10 miles)
Location Class 4 8 km (5 miles)
Location
 Pollution Concerns LPG Pipelines
 Statutory Requirements Industrial, 12 km (7.5 miles)
 Prevention of Inventory Commercial &
Loss
Residential Areas
 Approachability of Valve
Station

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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
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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 Drawings


Design Basis Route Map
Route Selection Report Pipeline Schematic
Wall Thickness Report Alignment Sheets
Seismic Design Report SV Station Layout
Crossing Design Report Equipment Layout
Piping General
Arrangement Drawings

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PIPELINE DESIGN
Typical Pipeline Alignment Sheet
INTERSECTION POINTS(IP/TP) TP50 IP50/1 TP51 IP51/1 TP52 TP53 TP54 TP55 TP56 TP57 TP58 IP58/1 TP59 TP60 TP61 IP61/1 TP62 TP63 TP64 IP64/1 TP65

DEFLECTION ANGLE 38°4'58''(R) 29°8'20''(L) 5°18'55''(R) 8°2'3''(L) 37°0'54''(L) 13°54'57''(R) 11°25'7''(L) 1°21'55''(L) 8°24'45''(R) 2°8'32''(L) 14°0'19''(R) 8°30'18''(L) 15°2'57''(L) 10°4'42''(L) 10°25'50''(L) 5°18'12''(R)

DISTANCE BETWEEN TP & IP's(m)


67.046 25.199 85.000 187.855 76.544 339.096 176.463 38.749 322.708 141.760 45.000 104.113 224.969 393.395 218.000 348.437 326.642 237.677 65.521 90.164

DISTANCE AS PER GROUND PROFILE 67.049 25.200 85.284 187.993 76.618 339.126 176.478 38.853 322.772 141.845 45.093 104.624 225.022 393.407 218.014 348.444 326.679 237.707 65.728 90.390

STATE , DISTRICT AND MANDAL


TO IRUVADA
TP65
M
RA CH. 14134.896m TELEPHONE LINECH.14134.896m
PU IP64/1
A
RIT CH.14044.732m
AM TP64
METALLED ROAD(ASPHALTIC)
TBMW40 (RL 37.514m) A CH.14115.309m
TP50 ND CH. 13979.211m
PE EARTHEN EMBANKMENT ELEC. LINE 440V
CH. 10620.558m TO CH.14132.231m

TO PE
IP50/1

MATCH LINE FOR CONT. REFER DWG


TP51 CH. 10687.604m
LOW LYING AREA

NDA
TP63
CH. 10712.803m
IP51/1 RAIWADA LEFT CANAL CH. 13741.534m

AMRU
CH. 10797.803m (UNLINED) TO
CH. 10691.604m EARTHEN EMBANKMENT TBMW57(RL42.533m) ST
AT

THAP
TP58 TP60
0m E

NO.4529-10-16-71-9005
HIG
.71 TP57
CH. 12080.978m
AIN 664 CH. 12455.060m TP62 HW

CH.1184 IC LINE

UR
TP52 TP59
DR H.10 CH. 11939.218m IP58/1 TP61
IP61/1
CH. 13414.892m RAIWADA LEFT CANAL AY

8.88m

AM
-SA

C H.11824.629m
C CH. 10985.658m CH. 12230.091m (UNLINED)
CH. 12125.978m CH. 13066.455m BB
TP53 CH. 12848.455m CH.14027.732m AV

ELECTR
SV-1 OF GAIL
CH. 11062.202m DRAIN GRAVEL ROAD AR
CH.11960.218 m AM

DRAIN
A CH.12903.743m CH.14040.275m
MATCH LINE FOR CONT. REFER DWG

GUTL GRAVEL ROAD TP55


INTA CH.10787.022m K K
TO CH CH. 11577.761m TEMP. HUT ON C/L
TP56
CH. 11616.510m HPCLCH. 17.00Km K
HPCL CH. 16.00Km TRAC
HPCLCH. 15.00Km
TP54 DRAIN HIGH TENSIONLINE CART 2.606m
49

CH 14115.31m/RL 43.684m
CH.12115.344m CH.13
NO.4529-10-16-71-9003

ELECTRIC LINE 440V 12.2m HIGH& 550KV

C H 14040.27m/RL 42.491m
CH. 11401.298m TO A VILLAGE BOUNDARY
CH.11018.117m MRUT CH.12747.397m
K HAPU

CH 14027.73m/RL 39.741m
RAM AMRUTAPURAM IRUVADA
TBMW49 (RL 25.138m)
GRAVEL ROAD

CART TRACK
CH.12060.877m
CH 10691.6m/RL 35.411m

OPEN WELL 6m DIA

CH 13492.61m/RL 33.622m
CH 10664.71m/RL 33.366m

CH 10787.02m/RL 32.587m

PUMP HOUSE 4m FROMC/L 7.648mFROMC/L

R OAD
CH.11648.136m
45

CANAL
43 OPEN WELL 6m DIA

CART TRACK
41 8m FROM C/L

CH 12060.88m/RL 24.604m
CANAL

CH 11824.63m/RL 24.341m
DRAIN

CH11577.761m
39

C H 12115.34m/RL 22.175m
ROAD

SCALE: 37
HORIZONTAL 1:5000 35
VERTICAL 1: 500 33
31

DRAIN

ROAD
29

DRAIN
27
25
23
21
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
198.636

196.962

142.134

176.463

141.522

121.660

114.747

224.969

299.254

217.539

182.117

166.780

248.929

237.676
26.894
21.199
44.152

74.219

39.369

37.175

38.749

66.597

24.246

90.342

20.101
34.366

94.141

77.714

48.521

12.543

75.034

19.588
KAJU GARDEN RICE FIELDS
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
11.960
11.972
11.984

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
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
Pipeline Design
Engineers India Ltd – Delivering excellence through people
Slide Number - 56 of 77
PIPELINE DESIGN
Typical P&ID

Pipeline Design
Engineers India Ltd – Delivering excellence through people
Slide Number - 57 of 77
PIPELINE DESIGN
Typical GA DRAWING

Pipeline Design
Engineers India Ltd – Delivering excellence through people
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
Pipeline Design
Engineers India Ltd – Delivering excellence through people
Slide Number - 59 of 77
PIPELINE DESIGN
Installation, Testing & Commissioning
RoU Grading & Trenching Stringing of Linepipe

Pipeline Design
Engineers India Ltd – Delivering excellence through people
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.)

Pipeline Design
Engineers India Ltd – Delivering excellence through people
Slide Number - 61 of 77
PIPELINE DESIGN
Installation, Testing & Commissioning
Field Joint Coating Lowering & Backfilling
 Heat Shrink Sleeves
 Cold applied tapes

Pipeline Design
Engineers India Ltd – Delivering excellence through people
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

Pipeline Design
Engineers India Ltd – Delivering excellence through people
Slide Number - 63 of 77
PIPELINE DESIGN
The conventional HDD operations for river crossings.

Pipeline Design
Engineers India Ltd – Delivering excellence through people
Slide Number - 64 of 77
Boring Across Road crossings.

Pipeline Design
Engineers India Ltd – Delivering excellence through people
Slide Number - 65 of 77
Boring Across Road crossings, showing Auger used for Boring

Pipeline Design
Engineers India Ltd – Delivering excellence through people
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

Pipeline Design
Engineers India Ltd – Delivering excellence through people
Slide Number - 67 of 77
PIPELINE DESIGN

Schematic Diagram

Pipeline Design
Engineers India Ltd – Delivering excellence through people
Slide Number - 68 of 77
PIPELINE DESIGN
Pipeline Installation using Micro-tunnelling
Long Distance Micro Tunnelling

Pipeline Design
Engineers India Ltd – Delivering excellence through people
Slide Number - 69 of 77
PIPELINE DESIGN

Overview of Micro tunneling

Pipeline Design
Engineers India Ltd – Delivering excellence through people
Slide Number - 70 of 77
PIPELINE DESIGN
Testing & Commissioning
TESTING
DRYING
 Gauging and Pigging
Swabbing

 Test Pressure
Methanol Drying

 Test Medium
 Super Dry Air
Method
TEST PRESSURE
 Vacuum Drying

LIQUID PIPELINES
COMMISSIONING
Ref. ASME B 31.4 : 437.4.1  Nitrogen Purging
1.25 times design pressure  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

Pipeline Design
Engineers India Ltd – Delivering excellence through people
Slide Number - 71 of 77
PIPELINE DESIGN
Pigging
Requirements Types of Pigs
 Pipeline Cleaning  Brush pigs
 Displacement  Gauge Pigs
 Internal Inspection  Spheres
 Batching  Intelligent Pigs

Cleaning pigs Gauge Pigs Spheres Intelligent Pig


(MFL)

Pipeline Design
Engineers India Ltd – Delivering excellence through people
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

Pipeline Design
Engineers India Ltd – Delivering excellence through people
Slide Number - 73 of 77
PIPELINE DESIGN
Comparison of LSAW & HSAW Pipes
Description LSAW HSAW
Method of UOE/COE/JCO/3 roll bending Formed by Twisting of Coil
Manufacture
Weld Length Equal to pipe joint length Approximately 1.5 to 2 times the
length of pipe joint
Position of weld Longitudinal – positioned in Spiral – present all around the
upper quadrant during pipe
construction
Corrosion Coating Specified thickness throughout Thickness normally increased all
entire body. over the body, resulting in
Weld seam is tracked to ensure proportional increase in coating
coating thickness on weld seam cost by 15-
15-20%

Geometry Controlled to the desired level Controlled during forming only


with cold expansion and no cold expansion is carried
out

Pipeline Design
Engineers India Ltd – Delivering excellence through people
Slide Number - 74 of 77
PIPELINE DESIGN

Coating Comparison

CTE 3LPE 3LPP FBE


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

Anti--corrosion Properties
Anti

Resistance to Moisture Good Very Good Excellent Good

Cathodic Disbondment Fair Good Good Good

Electrical Properties
Coating Resistance Good Excellent Excellent Excellent

Pipeline Design
Engineers India Ltd – Delivering excellence through people
Slide Number - 75 of 77
PIPELINE DESIGN

Coating Comparison
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 Poor Very Good Excellent Fair


Indentation

Resistance to Peel Fair Excellent Superior than PE -

Resistance to Soil Fair Excellent Excellent Excellent


Stresses

Elongation Fair Excellent Excellent -

Pipeline Design
Engineers India Ltd – Delivering excellence through people
Slide Number - 76 of 77
PIPELINE DESIGN

Coating Comparison
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 High Low Low High


handling &
transportation

Ease of Field Repair Difficult Easy for small repair, Easy for small repair, Easy for small repair,
Cumbersome for Cumbersome for Cumbersome for
larger repair larger repair larger repair

Pipeline Design
Engineers India Ltd – Delivering excellence through people
Slide Number - 77 of 77
Thank You

www.engineersindia.com

Pipeline Design
Engineers India Ltd – Delivering excellence through people
Slide Number - 78 of 77