II Pipeline Design Codes and Standards-MSG

PIPELINE DESIGN
Delivering excellence through people

Pipeline Design Slide Number - * of 77
ENGINEERS INDIA LIMITED

EPC and Total Solutions Consultancy Organization
Engineers India Ltd Delivering
excellence
through people
ENGINEERS INDIA LTD. - AREAS OF OPERATION
Petroleum Refineries
Petrochemicals
Pipelines Offshore Platforms Gas Processing Metallurgy Ports & Terminals Highways and Airports
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EIL OFFICES
HEAD OFFICE REGIONAL OFFICES PROCUREMENT OFFICES SITE OFFICES INSPECTION OFFICE OVERSEAS OFFICES NEW DELHI VADODARA, CHENNAI KOLKATA MUMBAI 29 LOCATIONS (INDIA) 9 LOCATIONS (OVERSEAS) 10 LOCATIONS LONDON, LIBYA ABU DHABI, ITALY, SAUDI ARABIA , QATAR, KUWAIT
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PIPELINE DESIGN
SERVICES OFFERED BY EIL
Project Implementation Services
Feasibility Studies Project Management Specialist Services Heat & Mass Transfer
Equipment
Design Environment Engineering Information Technology Services
Planning & Scheduling

Process Design Detailed Engineering Procurement Services Construction Management Commissioning and Plant Start-up Assistance
Specialist Materials and

Maintenance Services Plant Operation & Safety Risk Analysis Advanced Control & Optimization
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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.
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Major Onshore Projects (Completed)

DESCRIPTION HAZIRA-BIJAIPURJAGDISHPUR (HBJ) MAQTA-AL-AIN PIPELINE KANDLA-BHATINDA GAS REHABILITATION & EXPANSION PROJECT (GREP) CLIENT GAIL ADNOC IOCL GAIL YEAR 1989 1992 1996 1998 SIZE
PIPELINE DESIGN
LENGTH (KM) 1800 166 1443 505 SERVICES NATURAL GAS NATURAL GAS MULTIPRODUCT NATURAL GAS
36/30/24/18 30 /12 22/14/10 36
MUMBAI MANMAD
VIZAG-VIJAYWADA JAMNAGAR-LONI LPG PIPELINE COCHIN KARUR PIPELINE
BPCL
HPCL GAIL PETRONET
1998
1998 2001 2001
18
18 16/14/12/8/ 6 18 /14
260
360 1235 289
MULTIPRODUCT
MULTIPRODUCT LPG (LIQUIFIED PETROLIUM GAS) MULTIPRODUCT
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PIPELINE DESIGN
Major Onshore Projects (..contd) (Completed)
DESCRIPTION VIZAG SECUNDERABAD LPG PIPELINE MANMAD-MANGALAYA PIPELINE MANGALORE-BANGLORE DAHEJ VIJAIPUR PIPELINE INTER REFINERIES PIPELINES PROJECT, ABU DHABI MANGALAYA-BIJWASAN PIPELINE CLIENT GAIL BPCL HPCL GAIL YEAR 2002 2003 2003 2003 SIZE 12/10 14 24 /20 42 10 12 16 16/8 LENGTH (KM) 600 358 364 610 230 230 208 775 SERVICES LPG (LEQUIFIED PETROLEUM GAS) MULTIPRODUCT MULTIPRODUCT REGASIFIED LNG NAPHTHA, MULTIPRODUCT & SRR MULTIPRODUCT
TAKREER BPCL
2004 2006
MUNDRA-DELHI PIPELINE
HPCL
2006
18/16
1050
MULTIPRODUCT
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PIPELINE DESIGN
Major Onshore Projects (contd) (Completed)
DESCRIPTION CLIENT YEAR SIZE LENGTH (KM) SERVICES
PUNE SOLAPUR PIPELINE

DABHOL PANVEL PIPELINE PROJECT (PH-I) DABHOL PANVEL PIPELINE PROJECT (PH-II)
HPCL
GAIL GAIL
2007
2007 2007
14 / 12
30 30
182 / 161
187 120
MULTIPRODUCT
REGASIFIED LNG REGASIFIED LNG
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PIPELINE DESIGN
Major Offshore Projects (Completed)
DESCRIPTION BOMBAY HIGH URAN TRUNKLINE (BUT) SOUTH BASSEIN HAZIRA TRUNKLINE HEERA-URAN TRUNK LINE ICP - HEERA TRUNKLINE SECOND BASSEIN HAZIRA TRUNKLINE MUMBAI HIGH URAN TRUNKLINE (MUT) CLIENT ONGC ONGC ONGC ONGC ONGC ONGC YEAR 1979 1986 1996 1996 1995 2005 SIZE 30/26 36 26 /24 30/22 42 30/28 12 to 22 LENGTH (KM) 200 x 2 220 85 x 2 145 245 205 x 2 100 SERVICES CRUDE, GAS GAS CRUDE, GAS CRUDE GAS CRUDE, GAS
IN-FIELD PIPELINES OF BOMBAY-HIGH, BASSEIN, HEERA, NEELAM, PANNA, MUKTA.

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PIPELINE DESIGN
Major Onshore Projects (Current)
DESCRIPTION VIJIPUR DADRI BAWANA PIPELINE (VDBPL) MUNDRA BATHINDA PIPELINE (MBPL) BINA KOTA PIPELINE VADINAR BINA PIPELINE NUMALIGARH SILIGURI PIPELINE COMPRESSOR STATIONS CLIENT GAIL HMPL BPCL BORL OIL GAIL YEAR 2009 2009 2009 2009 2009 --SIZE 48/ 36/ 20 28/ 30 18 24 16 --LENGTH (KM) 500/ 38/ 55 424/ 590 257 935 400 --SERVICES REGASIFIED LNG CRUDE OIL MULTI PRODUCT CRUDE OIL MULTI PRODUCT REGASIFIED LNG
IN-FIELD PIPELINES OF BOMBAY-HIGH, BASSEIN, HEERA, NEELAM, PANNA, MUKTA.

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PIPELINE DESIGN
SECTION-1
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PIPELINE DESIGN
CONTENTS
INTRODUCTION

Modes of Transportation Benefits of Pipelines
PIPELINE DESIGN
Stages of Pipeline Project Codes and Standards Design Installation, Testing & Commissioning
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PIPELINE DESIGN
Oil and Gas Production in India
OIL
33 MMTPA
(ONGC, OIL, CAIRN, RIL)
GAS
115 MMSCMD
(ONGC, GAIL, OIL, GSPC, RIL)
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PIPELINE DESIGN
Refining Scenario- India
Capacity - 2006-07 NOC 105.5 MMT Others- 43.5 MMT
(MMT)
(Actual) Year
Source: Report of Working Group on P&NG Sector for the XI Plan Engineers India Ltd Delivering excellence
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PIPELINE DESIGN
Modes of Hydrocarbon Transportation - India
Pipelines Road Tankers Rail Tankers Water Carriers
32% 32% 26% 10%
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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
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PIPELINE DESIGN
Energy Savings
Pipelines are the most energy efficient modes of transportation

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ECONOMICS OF PIPELINE TRANSPORTATION
Transmission losses
Transmission losses are lowest in Pipelines

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PIPELINE DESIGN
Products Transported

Crude Oil Petroleum Products (MS, HSD, ATF, SKO) Water & Effluents LPG Natural Gas Slurries
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PIPELINE DESIGN
Types of Pipelines
ONSHORE (LAND) & OFFSHORE (SUBMARINE) PIPELINES

Trunk Pipelines Spur/ Branch Pipelines Marine Offloading Terminals & Outfalls
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PIPELINE DESIGN
Capital cost: Typical breakup
Pipes, prime-overs and construction constitute big ticket items

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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
DADR ANOLA DEL I HI SHAHJAHA BABRALA RAJASTHAN NPUR GADEP AURAIYA JAGDISH ANTA AN PUR
GUJARAT
INDIA
BIJAIPUR JHABUA
ARABI AN SEA
KEY PLAN LEGEND COMPRESSOR STATION

RECEIVING TERMINAL DESPATCH STATION
MADHYA PRADESH
HAZIRA
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PIPELINE DESIGN
Major Pipelines in India
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PIPELINE DESIGN
Pipeline Construction Video
Video for Mangalore Bangalore Pipeline
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PIPELINE DESIGN
SECTION-2
PIPELINE DESIGN CODES AND STANDRADS

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PIPELINE DESIGN
Stages of Pipeline Project
Conceptualization
Establish Requirement Evaluate Alternatives Finalize the Concept
Feasibility Study

Pipeline Route Study and Selection Hydraulic Studies and Optimization Establish Project Cost Project Implementation Scheme Environmental Impact Assessment & Risk Analysis
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PIPELINE DESIGN
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
ASME B 31.8 (2003)
Title
Gas Transportation and Distribution Piping Systems
ASME B 31.4 (2006)

OISD-141 (2003) OISD-214 (2006) OISD-226 (2007) API 5L / ISO 3183 : 2007 API RP1102 API 1104 API 6D / ISO 14313 DNV OS-F101 Other References
Pipeline Transportation Systems for Liquid Hydrocarbons and other Liquids

Design and Construction Requirements for Cross-Country Hydrocarbon Pipelines Cross-Country LPG Pipelines Natural Gas Transmission Pipelines and City Gas Distribution Networks Specification for Line Pipe Recommended practice for Rail and Highway crossings Standard for welding pipeline and related facilities Pipeline Valves Submarine pipeline systems Applicable Standards / Specs of ASME, API, NACE, MSS, BS and DIN
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PIPELINE DESIGN Major Codes & Standards

Type of Crossing
ROU & Land Acquisition
Approval Authority
Central/State Govt. as applicable (As per PMP Act 1962)
National Highway Crossings
NHAI
SH/ MDR/ ODR Crossings
PWD
Railway Track crossings Crossing through Forest land River/Canal crossings
Indian Railways Forest Authority Irrigation/Canal Authority
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LIST OF SOFTWARES USED IN PIPELINE ENGINEERING

CAESAR-II AUTOPIPE IPMCS MRPACK SORPS PIPECALC OFFPIPE PRISE PIPECROSS

PIPELINE STUDIO TGNET TLNET HYSIS
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PIPELINE DESIGN Optimal sizes of various capacities
Economy of scale
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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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PIPELINE DESIGN
Typical Pipeline Route Map
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PIPELINE DESIGN
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PIPELINE DESIGN
Material Selection & Corrosion Control
Assessment

Materials
Nature of the Product Design Life Product Temperature
Corrosion Protection

Material Chemistry Internal Coatings Product Conditioning Corrosion inhibitors Corrosion Allowance
Carbon Steel (CS) NACE Carbon Steel CRA Clad CS CS with internal Coatings Non-Metallic Materials
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PIPELINE DESIGN
Design and Analysis
Wall Thickness Calculations
Anti-Buoyancy Measures
Piping Stress Analysis
Buried Pipeline Analysis

Crossing Design
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PIPELINE DESIGN
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 = 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
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
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PIPELINE DESIGN
Basic Design Factor for Gas Pipelines
LOCATION CLASS Location Class 1 Location Class 2 Location Class 3 Location Class 4 Location Class Classification Location Class 1 : Location Class 2 : Location Class 3 : Location Class 4 : DESIGN FACTOR, F 0.72 0.60 0.50 0.40 10 buildings > 10 and < 46 buildings 46 buildings Multistory buildings
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PIPELINE DESIGN
Line Pipe Selection
Line Pipe Selection Parameters Thickness and Grade Selection
Type of Line Pipes

Seamless Electric Welded
Handling and Transportation (d/t ratio)

Longitudinal Seam Submerged-Arc Welded (LSAW) Helical Seam SubmergedArc Welded
Type of LinePipe Installation Requirements
(HSAW)
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PIPELINE DESIGN
Line Pipe Application
Submarine Pipelines
Seamless Pipes (upto & including 16) LSAW Pipes (18 & above)

Onshore Pipelines
Seamless Pipes (upto & including 8) LSAW Pipes (16 & above) HSAW Pipes (18 & above) EW Pipes (4 - 18)
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PIPELINE DESIGN
Manufacturing of Helical Pipes
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PIPELINE DESIGN
Anti-corrosive Coatings
Coal Tar Enamel Coating (BS 4164, AWWA C203)

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
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PIPELINE DESIGN
3 LAYER PE COATING APPLICATION
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PIPELINE DESIGN
Major Pipeline Components
Line Pipe & Coatings Scraper Traps & Pig Signallers Long Radius (LR) Bends Insulating Joints Flow Tees Sectionalizing Valves Pumps / Compressors Filters & Meters
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PIPELINE DESIGN
Scraper traps
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PIPELINE DESIGN
Sectionalizing Valve
Spacing ASME B 31.8 for Gas pipelines ASME B 31.4 for Liquid Pipelines Location Pollution Concerns Statutory Requirements Prevention of Inventory Loss Approachability of Valve Station Gas Pipelines Location Class 1 miles) Location Class 2 miles) Location Class 3 miles) Location Class 4 LPG Pipelines 8 km (5 miles) 16 km (10 32 km (20 24 km (15
Industrial, 12 km (7.5 miles) Commercial & Residential Areas

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PIPELINE DESIGN
Type of Valves

Full Bore Ball Valves Through Conduit Gate
Valves

Plug and Check Valves Valve Standard : API 6D/ISO14313 Other Valve Standards: API 600, API 602, BS EN
ISO 17292:2004, BS EN ISO

15761:2002, BS 5353
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PIPELINE DESIGN
Ball valves
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PIPELINE DESIGN
Plug valve
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PIPELINE DESIGN
Check valve
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PIPELINE DESIGN
Major Engineering Deliverables
Design Reports
Design
Drawings
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
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PIPELINE DESIGN
Typical Pipeline Alignment Sheet
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PIPELINE DESIGN Typical P&ID
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PIPELINE DESIGN Typical GA DRAWING
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PIPELINE DESIGN Major Engineering Deliverables

Tenders

Survey Tender Pipe Coating Tender Pipeline Installation Tender Line Pipes Valves & Actuators Scraper Traps, QOEC, Pig Signallers Flow Tees & Insulating Joints Induction Bends Flow meters Pumps & Compressors OFC cables
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Material Procurement

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PIPELINE DESIGN
Installation, Testing & Commissioning
RoU Grading & Trenching Stringing of Linepipe
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PIPELINE DESIGN
Welding & NDT :
Edge Preparation Internal / External Line-up Clamps Manual / Automatic Welding NDT (X-Ray / UT / MPI etc.)
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PIPELINE DESIGN
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 Micro tunneling
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PIPELINE DESIGN
The conventional HDD operations for river crossings.
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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 Can be done in curved path also
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PIPELINE DESIGN
Pipeline Installation using Micro-tunnelling
Long Distance Micro Tunnelling
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PIPELINE DESIGN
Overview of Micro tunneling
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PIPELINE DESIGN
Testing & Commissioning
TESTING Gauging and Pigging Test Pressure Test Medium DRYING Swabbing Methanol Drying Super Dry Air Method Vacuum Drying COMMISSIONING Nitrogen Purging Product Charging
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
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PIPELINE DESIGN
Pigging
Requirements

Types of Pigs

Pipeline Cleaning Displacement Internal Inspection Batching
Brush pigs 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-Tunneling for pipeline construction
Internal flow coating on line pipes for gas pipelines 3LPP coating on High Temperature pipelines
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PIPELINE DESIGN Comparison of LSAW & HSAW Pipes

Description LSAW HSAW
Formed by Twisting of Coil Approximately 1.5 to 2 times the length of pipe joint Method of Manufacture UOE/COE/JCO/3 roll bending Weld Length Position of weld Equal to pipe joint length
Longitudinal positioned in upper Spiral present all around the pipe quadrant during construction
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 Controlled during forming only and cold expansion no cold expansion is carried out
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PIPELINE DESIGN
Coating Comparison
CTE
Service Conditions
Temperature, o C Upto 45 Upto 65 Upto 110 Upto 110
3LPE
3LPP
FBE
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
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PIPELINE DESIGN
Coating Comparison
CTE
Cathodic Protection Design
Current Density High Low Low Low
3LPE
3LPP
FBE
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 Elongation
Fair
Excellent
Excellent
Excellent
Fair
Excellent
Excellent
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PIPELINE DESIGN
Coating Comparison
CTE
Long Term Ageing
Heat & Light Ageing Fair Very Good Very Good Very Good
3LPE
3LPP
FBE
Application & Field Repair

Ease of Application Easy Relatively difficult Relatively difficult Relatively difficult
Damages during handling & transportation Ease of Field Repair
High
Low
Low
High
Difficult
Easy for small repair, Easy for small repair, Easy for small repair, Cumbersome for larger Cumbersome for larger Cumbersome for larger repair repair repair
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Thank You
www.engineersindia.com
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PIPELINE DESIGN

Delivering excellence through people

ENGINEERS INDIA LIMITED

Engineers India Ltd Delivering

Pipeline Design Slide Number - * of 77

ENGINEERS INDIA LTD. - AREAS OF OPERATION

Pipeline Design Slide Number - * of 77

Engineers India Ltd Delivering

Pipeline Design Slide Number - * of 77

Planning & Scheduling

Specialist Materials and

Engineers India Ltd Delivering

Engineers India Ltd Delivering

Major Onshore Projects (Completed)

36/30/24/18 30 /12 22/14/10 36

Engineers India Ltd Delivering

Pipeline Design Slide Number - * of 77

Engineers India Ltd Delivering

Pipeline Design Slide Number - * of 77

PUNE SOLAPUR PIPELINE

Engineers India Ltd Delivering

Pipeline Design Slide Number - * of 77

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

Pipeline Design Slide Number - * of 77

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

Pipeline Design Slide Number - * of 77

Engineers India Ltd Delivering

Pipeline Design Slide Number - * of 77

Modes of Transportation Benefits of Pipelines

Engineers India Ltd Delivering

Pipeline Design Slide Number - * of 77

(ONGC, OIL, CAIRN, RIL)

(ONGC, GAIL, OIL, GSPC, RIL)

Engineers India Ltd Delivering

Pipeline Design Slide Number - * of 77

Pipelines Road Tankers Rail Tankers Water Carriers

32% 32% 26% 10%

Engineers India Ltd Delivering

Pipeline Design Slide Number - * of 77

Engineers India Ltd Delivering

Pipeline Design Slide Number - * of 77

Pipelines are the most energy efficient modes of transportation

Pipeline Design Slide Number - * of 77

ECONOMICS OF PIPELINE TRANSPORTATION

Transmission losses are lowest in Pipelines

Pipeline Design Slide Number - * of 77

Engineers India Ltd Delivering

Pipeline Design Slide Number - * of 77

Engineers India Ltd Delivering

Pipeline Design Slide Number - * of 77

Capital cost: Typical breakup

Pipes, prime-overs and construction constitute big ticket items

Pipeline Design Slide Number - * of 77

Engineers India Ltd Delivering

Pipeline Design Slide Number - * of 77

Engineers India Ltd Delivering

Pipeline Design Slide Number - * of 77

KEY PLAN LEGEND COMPRESSOR STATION

Engineers India Ltd Delivering

Pipeline Design Slide Number - * of 77

Engineers India Ltd Delivering

Pipeline Design Slide Number - * of 77

Engineers India Ltd Delivering

Pipeline Design Slide Number - * of 77