II Pipeline Design Codes and standards-MSG

PIPELINE DESIGN
Delivering excellence through people

Pipeline Design
Slide Number - 1 of 77
ENGINEERS
INDIA LIMITED
EPC and Total Solutions
Consultancy Organization
Engineers India Ltd Delivering excellence through people
Pipeline Design
Petroleum Refineries
Petrochemicals
Pipelines
Offshore Platforms
Gas Processing
Metallurgy
Ports & Terminals
Highways and Airports
Pipeline Design
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
PIPELINE DESIGN
SERVICES OFFERED BY EIL
Project Implementation Services
Specialist Services
Feasibility Studies
Project Management
Planning & Scheduling
Environment Engineering
Process Design
Information Technology Services
Detailed Engineering
Specialist Materials and
Procurement Services
Construction Management
Plant Operation & Safety
Commissioning and Plant
Risk Analysis
Start-up Assistance
Advanced Control & Optimization
Heat & Mass Transfer Equipment

Design
Maintenance Services
Pipeline Design
PIPELINE DESIGN
EIL EXPERIENCE
1975
First major project

Crude Oil Loop Line for Oil India Ltd.
1979
First major overseas project

150 km Multi Product Pipeline
for Abu Dhabi National Oil Company
1984
First major high pressure Gas Pipeline

Project - 1800 km Gas Transmission Network
for GAIL
Over 40 major pipeline projects completed.

Pipeline Design
PIPELINE DESIGN
Major Onshore Projects (Completed)
DESCRIPTION
CLIENT
YEAR
SIZE
LENGTH
(KM)
GAIL
1989
36/30/24/18
1800
NATURAL GAS
ADNOC
1992
30 /12
166
NATURAL GAS
KANDLA-BHATINDA
IOCL
1996
22/14/10
1443
MULTIPRODUCT
GAS REHABILITATION &

EXPANSION PROJECT
(GREP)
GAIL
1998
36
505
NATURAL GAS
MUMBAI MANMAD
BPCL
1998
18
260
MULTIPRODUCT
VIZAG-VIJAYWADA
HPCL
1998
18
360
MULTIPRODUCT
JAMNAGAR-LONI LPG
PIPELINE
GAIL
2001
16/14/12/8/
6
1235
LPG (LIQUIFIED
PETROLIUM GAS)
PETRONET
2001
18 /14
289
MULTIPRODUCT
HAZIRA-BIJAIPURJAGDISHPUR (HBJ)
MAQTA-AL-AIN PIPELINE
COCHIN KARUR PIPELINE
SERVICES
Pipeline Design
PIPELINE DESIGN
Major Onshore Projects (..contd) (Completed)

DESCRIPTION
CLIENT
YEAR
SIZE
LENGTH
(KM)
VIZAG SECUNDERABAD LPG

PIPELINE
GAIL
2002
12/10
600
LPG (LEQUIFIED
PETROLEUM GAS)
MANMAD-MANGALAYA PIPELINE
BPCL
2003
14
358
MULTIPRODUCT
MANGALORE-BANGLORE
HPCL
2003
24 /20
364
MULTIPRODUCT
DAHEJ VIJAIPUR PIPELINE
GAIL
2003
42
610
REGASIFIED LNG
TAKREER
2004
10
12
16
230
230
208
NAPHTHA,
MULTIPRODUCT & SRR
MANGALAYA-BIJWASAN
PIPELINE
BPCL
2006
16/8
775
MULTIPRODUCT
MUNDRA-DELHI PIPELINE
HPCL
2006
18/16
1050
MULTIPRODUCT
INTER REFINERIES PIPELINES

PROJECT, ABU DHABI
SERVICES
Pipeline Design
PIPELINE DESIGN
Major Onshore Projects (contd)
(Completed)
DESCRIPTION
CLIENT
YEAR
SIZE
LENGTH
(KM)
PUNE SOLAPUR PIPELINE
HPCL
2007
14 / 12
182 / 161
MULTIPRODUCT
DABHOL PANVEL PIPELINE

PROJECT (PH-I)
GAIL
2007
30
187
REGASIFIED LNG
DABHOL PANVEL PIPELINE

PROJECT (PH-II)
GAIL
2007
30
120
REGASIFIED LNG
SERVICES
Pipeline Design
PIPELINE DESIGN
Major Offshore Projects
(Completed)
DESCRIPTION
CLIENT
YEAR
SIZE
LENGTH
(KM)
SERVICES
BOMBAY HIGH URAN TRUNKLINE

(BUT)
ONGC
1979
30/26
200 x 2
SOUTH BASSEIN HAZIRA

TRUNKLINE
ONGC
1986
36
220
HEERA-URAN TRUNK LINE
ONGC
1996
26 /24
85 x 2
ICP - HEERA TRUNKLINE
ONGC
1996
30/22
145
CRUDE
SECOND BASSEIN HAZIRA

TRUNKLINE
ONGC
1995
42
245
GAS
MUMBAI HIGH URAN TRUNKLINE

(MUT)
ONGC
2005
30/28
12 to 22
205 x 2
100
CRUDE, GAS
GAS
CRUDE, GAS
CRUDE, GAS
IN-FIELD PIPELINES OF BOMBAY-HIGH, BASSEIN, HEERA, NEELAM, PANNA, MUKTA.
Pipeline Design
PIPELINE DESIGN
Major Onshore Projects
(Current)
DESCRIPTION
CLIENT
YEAR
SIZE
LENGTH
(KM)
SERVICES
VIJIPUR DADRI BAWANA PIPELINE

(VDBPL)
GAIL
2009
48/ 36/
20
500/ 38/ 55
REGASIFIED LNG
MUNDRA BATHINDA PIPELINE

(MBPL)
HMPL
2009
28/ 30
424/ 590
CRUDE OIL
BINA KOTA PIPELINE
BPCL
2009
18
257
MULTI PRODUCT
VADINAR BINA PIPELINE
BORL
2009
24
935
CRUDE OIL
NUMALIGARH SILIGURI PIPELINE
OIL
2009
16
400
MULTI PRODUCT
COMPRESSOR STATIONS
GAIL
---
---
---
REGASIFIED LNG
IN-FIELD PIPELINES OF BOMBAY-HIGH, BASSEIN, HEERA, NEELAM, PANNA, MUKTA.
Pipeline Design
PIPELINE DESIGN
SECTION-1
Pipeline Design
PIPELINE DESIGN
CONTENTS
INTRODUCTION
Modes of Transportation
Benefits of Pipelines
PIPELINE DESIGN
Stages of Pipeline Project

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

Environment friendly
Least energy requirement
Lowest maintenance costs
Minimal impact on land use pattern
Negligible loss of product in transit
High reliability
Multi-product Transportation
Pipeline Design
PIPELINE DESIGN
En erg y C o n su m p tio n in % o f en erg y
Tran sp orted
Energy Savings
Ene rgy Intensity for Various M odes
4
3.2
3.5
3
2.5
2
1.5
1
0.5
0.8
0.5
0.8
1.1
0
LiquidPipelines
LiquidCoastal
LiquidTrains
LiquidTrucks
CoalTrains
CoalCoastal
N.GasPipelines
Pipelines are the most energy efficient modes of transportation

Pipeline Design
ECONOMICS OF PIPELINE TRANSPORTATION
Transmission losses
Losses During Transportation
0.1
0.2
0.3
0.4
0.5
% Loss of Total Volum e Transported
Transmission losses are lowest in Pipelines

Pipeline Design
PIPELINE DESIGN
Products Transported
Crude Oil
Petroleum Products (MS, HSD, ATF, SKO)
Water & Effluents
LPG
Natural Gas
Slurries
Pipeline Design
PIPELINE DESIGN
Types of Pipelines
ONSHORE (LAND) & OFFSHORE
(SUBMARINE) PIPELINES
Trunk Pipelines
Spur/ Branch Pipelines
Marine Offloading Terminals & Outfalls
Pipeline Design
PIPELINE DESIGN
Capital cost: Typical breakup

Percentage of Capital Cost.
Item Description
Sr No.
Liquid Lines
Gas Lines
Survey, ROW & Compensation
2%
1%
Line Pipe Steel Cost
33%
45%
Main line materials
2%
3%
Coating of Pipes
11%
6%
Mainline Construction
33%
25%
Cathodic Protection
1%
1%
Telecommunication, SCADA and RCPs
5%
2%
Pump / Compressor Stations
5%
12%
Delivery Terminal facilities
2%
1%
10
Project Management
5%
4%
11
SubTotal
100%
100%
Pipes, prime-overs and construction constitute big ticket items

E le c tric a l C o st V a ria tn - P u mp S ta tio n
1. 5
1
0. 5
0
0.2
0. 4
0.6
0. 8
1. 2
Pipeline Design
PIPELINE DESIGN
Marine Offloading Terminal
Pipeline Design
PIPELINE DESIGN
Open sea Jetty
Pipeline Design
PIPELINE DESIGN
HBJ GAS PIPELINE NETWORK
UTTAR PRADESH
N
DELHI
RAJASTHAN
GADEPAN
DADRI
ANOLA
SHAHJAHANPUR
BABRALA
INDIA
ANTA
AURAIYA JAGDISHPUR
BIJAIPUR
GUJARAT
JHABUA
ARABIAN SEA
MADHYA PRADESH
HAZIRA
KEY PLAN
LEGEND
COMPRESSOR STATION
RECEIVING TERMINAL
DESPATCH STATION
Pipeline Design
PIPELINE DESIGN
Major Pipelines in India
Pipeline Design
PIPELINE DESIGN
Pipeline Construction Video
Video for Mangalore Bangalore Pipeline
Pipeline Design
PIPELINE DESIGN
SECTION-2
PIPELINE DESIGN CODES AND STANDRADS
Pipeline Design
PIPELINE DESIGN
Conceptualization
Establish Requirement
Evaluate Alternatives
Finalize the Concept
Feasibility Study
Pipeline Route Study and Selection

Hydraulic Studies and Optimization
Establish Project Cost
Project Implementation Scheme
Environmental Impact Assessment & Risk Analysis
Pipeline Design
PIPELINE DESIGN
Basic Engineering
Process Design and Sizing

Optimization Studies
Route Surveys and Investigations
Detailed Engineering
Engineering Design Basis

Route Engineering and Engineering Analysis
Specifications and Job Standards
Engineering for Procurement
Installation Engineering and Construction Procedures
Pipeline Design
PIPELINE DESIGN
Major Codes & Standards
Code/Standard
Title
ASME B 31.8 (2003)
Gas Transportation and Distribution Piping Systems
ASME B 31.4 (2006)
Pipeline Transportation Systems for Liquid Hydrocarbons and other

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

Hydrocarbon Pipelines
OISD-214 (2006)
Cross-Country LPG Pipelines
OISD-226 (2007)
Natural Gas Transmission Pipelines and City Gas Distribution

Networks
API 5L / ISO 3183 : 2007
Specification for Line Pipe
API RP1102
Recommended practice for Rail and Highway crossings
API 1104
Standard for welding pipeline and related facilities
API 6D / ISO 14313
Pipeline Valves
DNV OS-F101
Submarine pipeline systems
Other References
Applicable Standards / Specs of ASME, API, NACE, MSS, BS and

DIN
Pipeline Design
PIPELINE DESIGN
Major Codes & Standards
Type of Crossing
Approval Authority
ROU & Land Acquisition
Central/State Govt. as applicable

(As per PMP Act 1962)
National Highway Crossings
NHAI
SH/ MDR/ ODR Crossings
PWD
Railway Track crossings
Indian Railways
Crossing through Forest land Forest Authority

River/Canal crossings
Irrigation/Canal Authority
Pipeline Design
LIST OF SOFTWARES USED IN PIPELINE

ENGINEERING
CAESAR-II
AUTOPIPE
IPMCS
MRPACK
SORPS
PIPECALC
OFFPIPE
PRISE
PIPECROSS
PIPELINE STUDIO
TGNET
TLNET
HYSIS
Pipeline Design
PIPELINE DESIGN
Optimal sizes of various capacities
Economy of scale
Pipeline Design
PIPELINE DESIGN
Route Selection
Routing Considerations
Pipeline length
Obstructions & Sensitive areas
Installation Limitations
Crossings
Surveys
Topographical
Geo-technical
Population Density Index
Soil Resistivity
Cadastral
Pipeline Design
PIPELINE DESIGN
Typical Pipeline Route Map
Pipeline Design
PIPELINE DESIGN
Pipeline Design
PIPELINE DESIGN
Material Selection & Corrosion Control
Assessment
Nature of the Product

Design Life
Product Temperature
Corrosion Protection
Material Chemistry
Internal Coatings
Product Conditioning
Corrosion inhibitors
Corrosion Allowance
Materials
Carbon Steel (CS)

NACE Carbon Steel
CRA Clad CS
CS with internal
Coatings
Non-Metallic
Materials
Pipeline Design
PIPELINE DESIGN
Design and Analysis
Wall Thickness Calculations
Anti-Buoyancy Measures
Piping Stress Analysis
Buried Pipeline Analysis
Crossing Design
Pipeline Design
PIPELINE DESIGN
Steel Pipe Wall Thickness Calculation
LIQUID PIPELINE
GAS PIPELINE
(ASME B 31.4, Cl. 404.1.2)
(ASME B 31.8, Cl. 841.11)
t = PiD
2.S
P = 2St FET
D
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
where
P Design pressure
S Specified
minimum
yield
strength
D Nominal OD of pipe
t Nominal wall thickness
F Design factor
E Longitudinal joint factor
T Temperature de-rating factor
Pipeline Design
PIPELINE DESIGN
Basic Design Factor for Gas Pipelines
LOCATION CLASS
DESIGN FACTOR, F
Location Class 1
0.72
Location Class 2
0.60
Location Class 3
0.50
Location Class 4
0.40
Location Class Classification

Location Class 1 :
Location Class 2 :
Location Class 3 :
Location Class 4 :
10 buildings
> 10 and < 46 buildings
46 buildings
Multistory buildings
Pipeline Design
PIPELINE DESIGN
Line Pipe Selection
Line Pipe Selection Parameters
Type of Line Pipes
Thickness and Grade

Selection
Seamless
Electric Welded
Handling and
Transportation (d/t ratio)
Type of LinePipe
Longitudinal Seam
Submerged-Arc Welded
(LSAW)
Installation Requirements
Helical Seam SubmergedArc Welded
(HSAW)
Pipeline Design
PIPELINE DESIGN
Line Pipe Application
Submarine Pipelines
Seamless Pipes
(upto & including 16)
LSAW Pipes
(18 & above)
Onshore Pipelines
Seamless Pipes
(upto & including 8)
LSAW Pipes
(16 & above)
HSAW Pipes
(18 & above)
EW Pipes
(4 - 18)
Pipeline Design
PIPELINE DESIGN
Manufacturing of Helical Pipes
Pipeline Design
PIPELINE DESIGN
Anti-corrosive Coatings
Coal Tar Enamel Coating (BS 4164, AWWA C203)
3 Layer PE/ PP Coating (DIN 30670)
Primer
Two layers of coal tar enamel & glass fibre Inner wrap
One layer of coal tar impregnated outer wrap
Coating thickness 4.7mm
First layer of Fusion bonded epoxy
Second layer of extruded adhesive
Third layer of extruded PE/ PP
Coating thickness 2.0 to 3.7 mm
Fusion Bonded Epoxy Coating (CSA Z245.20)
350-500 micron thick single layer coating

600-800 micron thick dual layer coating
Pipeline Design
PIPELINE DESIGN
3 Layer PE Coating Application
Pipeline Design
PIPELINE DESIGN
Major Pipeline Components
Line Pipe & Coatings

Scraper Traps & Pig Signallers
Long Radius (LR) Bends
Insulating Joints
Flow Tees
Sectionalizing Valves
Pumps / Compressors
Filters & Meters
Pipeline Design
PIPELINE DESIGN
Scraper traps
Pipeline Design
PIPELINE DESIGN
Sectionalizing Valve
Spacing
ASME B 31.8 for Gas
pipelines
ASME B 31.4 for Liquid
Pipelines
Location
Pollution Concerns
Statutory Requirements
Prevention of Inventory
Loss
Approachability of Valve
Station
Gas Pipelines
Location Class 1
32 km (20 miles)
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 &
Residential Areas
Pipeline Design
PIPELINE DESIGN
Type of Valves
Full Bore Ball Valves
Through Conduit Gate

Valves
Plug and Check Valves
Valve Standard :
API 6D/ISO14313
Other Valve Standards:
API 600, API 602, BS EN
ISO 17292:2004, BS EN
ISO 15761:2002, BS 5353
Pipeline Design
PIPELINE DESIGN
Ball valves
Pipeline Design
PIPELINE DESIGN
Plug valve
Pipeline Design
PIPELINE DESIGN
Check valve
Pipeline Design
PIPELINE DESIGN
Major Engineering Deliverables
Design Reports
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
Pipeline Design
PIPELINE DESIGN
Typical Pipeline Alignment Sheet
TP50
INTERSECTION POINTS(IP/TP)
IP50/1 TP51
3 84 '58 ''(R)
DEFLECTION ANGLE
DISTANCE BETWEEN TP & IP's(m)
DISTANCE AS PER GROUND PROFILE
IP51/1
TP52
298'20 ''(L)
TP53
TP54
518'55 ' (R) 82'3'' (L)
TP55 TP56
370'54''(L)
1354'57''(R)
TP57
1125'7''(L)
TP58 IP5 8/1
121'55''(L)
TP59
824'45''(R)
TP60
2 8'32''(L)
TP61
140'19''(R)
IP6 1/1
TP62
8 30'18 ''(L)
TP63
152'57 ''(L)
TP64
104'42''(L)
IP6 4/1
TP65
1 025 '50''(L)
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
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
5 18'12''(R)
65.521
90.164
65.728
90.390
STATE , DISTRICT AND MANDAL

TP65
CH. 14134.896m
IP6 4/1
CH.14044.732m
EAR THEN EMBANKMENT
TELEPHONE LINE CH.1 4134.896m

METALLED ROAD(ASPHALTIC)
CH.14115.309m
ELEC. LINE 440V
CH.14132.231m
TP64
CH. 13979.211m
TBM W40 (RL 37.514m)

TP50
CH. 10620.558m
IP50/1
CH. 10687.604m
LOW LYING AREA
TP63
CH. 13741.534m
DRAIN
CH.12903.743m
K
CH14115.31m/RL 43.684m
CANAL
CH14027.73m/RL 39.741m
48.521
237.676
77.714
40.816
CH13492.61m/RL 33.622m
CART TRACK
33.622
32.444
30.893
166.780
28.935
182.117
217.539
29.135
29.219
94.141
299.254
30.557
224.969
25.884
ROAD
CH12060.88m/RL 24.604m
CH12115.34m/RL 22.175m
DRAIN
22.175
24.604
23.667
34.366
20.101
121.660
114.747
CH11824.63m/RL 24.341m
24.828
24.675
24.341
25.138
66.597
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
10.713
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
10.621
10.692
RICE FIELDS
10.665
10.621
KAJU GARDEN
24.246
24.858
141.522
27.904
38.749
25.362
142.134
176.463
27.370
29.815
196.962
31.496
30.300
37.175
39.369
198.636
32.587
33.560
35.411
33.366
37.325
DRAIN
OPEN WELL 6 m DIA

8m FROM C/L
CH 11577.761m
90.342
CANAL
CH10691.6m/RL 35.411m
CH10787.02m/RL 32.587m
ROAD
DRAIN
CH10664.71m/RL 33.366m
PUMP HOUSE 4m FROM C/L
74.219
21.199
44.152
26.894
SCALE:
HORIZONTAL 1:5000
VERTICAL 1: 500
GRAVEL ROAD
CH.12060.877m
OPEN WELL 6 m DIA

7.648m FROM C/L
CH.11648.136m
CART TRACK
VILLAGE BOUNDARY
AMRUTAPURAM
IRUVADA
CH.12747.397m
ROAD
CH14040.27m/RL 42.491m
HIGH TENSION LINE

1 2.2m HIGH & 550KV
TBM W49 (RL 25.138m)
45
43
41
39
37
35
33
31
29
27
25
23
21
TEMP. HUT ON C/L

HPCL CH. 17.00Km
HPCL CH. 16.00Km
TP54
CH. 11401.298m
43.684
43.034
C H. 11616.510m
HPCL CH. 15 .00Km
19.588
CH. 11577.761m
TP56
ELECTRIC LINE 440V

CH.11018.117m
RAIWADA LEFT CANAL

(UNLINED)
CH.14027.732m
GRAVEL ROAD
CH.14040.275m
C H. 13066.455m
CH. 12848.455m
39.741
42.491
TP55
TP62
CH. 13414.892m
IP61/1
TP61
CH. 12230.091m
CH. 12125.978m
SV-1 OF GAIL
CH.11960.218 m
CH. 11062.202m
GRAVEL ROAD
C H.10787.022m
CH. 12455.060m
TP59
IP58/1
CH. 11939.218m
TBM W57(RL 42.533m)
TP60
75.034
TP57
TP52
CH. 10985.658m
TP53
EARTHEN EMBANKMENT
TP58
CH. 12080.978m
12.543
RAIWADA LEFT CANAL

(UNLINED)
CH. 10691.604m
248.929
IP51/1
CH. 10797.803m
37.219
TP51
CH. 10712.803m
Pipeline Design
PIPELINE DESIGN
Typical P&ID
Pipeline Design
PIPELINE DESIGN
Typical GA DRAWING
Pipeline Design
PIPELINE DESIGN
Major Engineering Deliverables
Tenders
Survey Tender
Pipe Coating Tender
Pipeline Installation Tender
Material Procurement
Line Pipes
Valves & Actuators
Scraper Traps, QOEC, Pig Signallers
Flow Tees & Insulating Joints
Induction Bends
Flow meters
Pumps & Compressors
OFC cables
Pipeline Design
PIPELINE DESIGN
RoU Grading & Trenching
Stringing of Linepipe
Pipeline Design
PIPELINE DESIGN
Welding & NDT :
Edge Preparation
Internal / External Line-up Clamps
Manual / Automatic Welding
NDT (X-Ray / UT / MPI etc.)
Pipeline Design
PIPELINE DESIGN
Field Joint Coating
Lowering & Backfilling
Heat Shrink Sleeves

Cold applied tapes
Pipeline Design
PIPELINE DESIGN
Pipeline Crossings
Crossing Installation
Crossings
River, Canal, Road & Rail
Utility Crossing
Methodologies
Open-Cut Method
Trench-less Method
Horizontal Directiona
l Drilling
Jacking and Boring
Micro tunneling
Pipeline Design
PIPELINE DESIGN
The conventional HDD operations for river crossings.
Pipeline Design
PIPELINE DESIGN
Pipeline Installation using Micro-tunnelling
MICRO-TUNNELLING:
Micro Tunneling process uses a Micro Tunnel Boring Machine

(MTBM) combined with pipe jacking technique.
Pipe jacking from launch shaft to reception shaft.
Hydraulic Jacks used to push Jacking pipes behind a tunnel boring
machine
Carrier pipe inserted in jacking pipe
ADVANTAGES:
Micro-tunnelling can be used wherever HDD cannot be done

Crossing of Rivers with gravels, cobbles & boulders
Installation of more than one pipe in the tunnel
Precise installation and Minimum space at both ends
Can be done in curved path also
Pipeline Design
PIPELINE DESIGN
Pipeline Installation using Micro-tunnelling
Long Distance Micro Tunnelling
Pipeline Design
PIPELINE DESIGN
Overview of Micro tunneling
Pipeline Design
PIPELINE DESIGN
Testing & Commissioning
TESTING
Gauging and Pigging

Test Pressure
Test Medium
TEST PRESSURE
LIQUID PIPELINES
Ref. ASME B 31.4 : 437.4.1
1.25 times design pressure
DRYING
Swabbing
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
Pipeline Design
PIPELINE DESIGN
Pigging
Requirements
Types of Pigs
Pipeline Cleaning
Displacement
Internal Inspection
Batching
Cleaning pigs
Gauge Pigs
Brush pigs
Gauge Pigs
Spheres
Intelligent Pigs
Spheres
Intelligent Pig (MFL)
Pipeline Design
PIPELINE DESIGN
RECENT DEVELOPMENTS
TECHNICAL IMPROVEMENTS
Automatic Welding & Automatic UT

Micro-Tunneling for pipeline construction
Internal flow coating on line pipes for gas pipelines

3LPP coating on High Temperature pipelines
Pipeline Design
PIPELINE DESIGN
Comparison of LSAW & HSAW Pipes
Description
LSAW
HSAW
Method of
Manufacture
UOE/COE/JCO/3 roll bending
Formed by Twisting of Coil
Weld Length
Equal to pipe joint length
Approximately 1.5 to 2 times the

length of pipe joint
Position of weld
Longitudinal positioned in
upper quadrant during
construction
Spiral present all around the

pipe
Corrosion Coating
Specified thickness throughout

entire body.
Weld seam is tracked to ensure
coating thickness on weld seam
Thickness normally increased all

over the body, resulting in
proportional increase in coating
cost by 15-20%
Geometry
Controlled to the desired level

with cold expansion
Controlled during forming only

and no cold expansion is carried
out
Pipeline Design
PIPELINE DESIGN
Coating Comparison
CTE
3LPE
3LPP
FBE
Upto 45
Upto 65
Upto 110
Upto 110
Resistance to Moisture
Good
Very Good
Excellent
Good
Cathodic Disbondment
Fair
Good
Good
Good
Good
Excellent
Excellent
Excellent
Service Conditions
Temperature, o C
Anti-corrosion Properties
Electrical Properties
Coating Resistance
Pipeline Design
PIPELINE DESIGN
Coating Comparison
CTE
3LPE
3LPP
FBE
High
Low
Low
Low
Resistance to Impact
Fair
Excellent
Superior to PE
Fair
Resistance to
Indentation
Poor
Very Good
Excellent
Fair
Resistance to Peel
Fair
Excellent
Superior than PE
Resistance to Soil
Stresses
Fair
Excellent
Excellent
Excellent
Elongation
Fair
Excellent
Excellent
Cathodic Protection Design

Current Density
Mechanical Properties
Pipeline Design
PIPELINE DESIGN
Coating Comparison
CTE
3LPE
3LPP
FBE
Fair
Very Good
Very Good
Very Good
Long Term Ageing

Heat & Light Ageing
Application & Field Repair

Ease of Application
Easy
Relatively difficult
Damages during
handling &
transportation
High
Low
Low
High
Difficult
Easy for small repair,

Cumbersome for
larger repair

Cumbersome for
larger repair

Cumbersome for
larger repair
Ease of Field Repair
Pipeline Design
Thank
You
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Pipeline Design

II Pipeline Design Codes and standards-MSG

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