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PIPELINE DESIGN
Delivering excellence through people
Slide Number - 1 of 77
ENGINEERSINDIA LIMITED
EPC and Total SolutionsConsultancy Organization
Pipeline Design
Slide Number - 2 of 77
Engineers India Ltd – Delivering excellence through people
Pipeline Design
Slide Number - 3 of 77
Engineers India Ltd – Delivering excellence through people
Petroleum Refineries
Petrochemicals
PipelinesOffshore PlatformsGas ProcessingMetallurgyPorts & TerminalsHighways and Airports
EIL OFFICES
Pipeline Design
Slide Number - 4 of 77
Engineers India Ltd – Delivering excellence through people
HEAD OFFICE
REGIONAL OFFICES
PROCUREMENT OFFICES
SITE OFFICES
INSPECTION OFFICE
OVERSEAS OFFICES
NEW DELHI
VADODARA, CHENNAIKOLKATA
MUMBAI
29 LOCATIONS (INDIA)9 LOCATIONS (OVERSEAS)
10 LOCATIONS
LONDON, LIBYA ABU DHABI,ITALY, SAUDI ARABIA , QATAR,KUWAIT
PIPELINE DESIGN
SERVICES OFFERED BY EIL
Pipeline Design
Slide Number - 5 of 77
Engineers India Ltd – Delivering excellence through people
Project Implementation Services
Feasibility Studies
Project Management
Planning & Scheduling
Process Design
Detailed Engineering
Procurement Services
Construction Management
Commissioning and Plant
Start-up Assistance
Specialist Services
Heat & Mass Transfer Equipment
Design
Environment Engineering
Information Technology Services
Specialist Materials and
Maintenance Services
Plant Operation & Safety
Risk Analysis
Advanced Control & Optimization
PIPELINE DESIGN
EIL EXPERIENCE1975
1979
1984
First major projectCrude Oil Loop Line for Oil India Ltd.
First major overseas project150 km Multi Product Pipelinefor Abu Dhabi National Oil Company
First major high pressure Gas Pipeline
Pipeline Design
Slide Number - 6 of 77
Engineers India Ltd – Delivering excellence through people
Project - 1800 km Gas Transmission Networkfor GAIL
Over 40 major pipeline projects completed.
DESCRIPTION CLIENT YEAR SIZE LENGTH(KM)
SERVICES
HAZIRAHAZIRA--BIJAIPUR--BIJAIPURJAGDISHPUR (HBJ)
GAIL 1989 36“/30”/24”/18”
1800 NATURAL GAS
MAQTAMAQTA--ALAL--AIN PIPELINE
ADNOC 1992 30 ”/12” 166 NATURAL GAS
KANDLAKANDLA--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
VIZAGVIZAG--VIJAYWADA
HPCL 1998 18 ” 360 MULTIPRODUCT
JAMNAGARJAMNAGAR--LONI LPGPIPELINE
GAIL 2001 16”/14”/12”/8”/6
1235 LPG (LIQUIFIEDPETROLIUM GAS)
COCHIN – KARUR PIPELINE
PETRONET
2001 18 ”/14 ” 289 MULTIPRODUCT
PIPELINE DESIGNMajor Onshore Projects (Completed)
Pipeline Design
Slide Number - 7 of 77
Engineers India Ltd – Delivering excellence through people
DESCRIPTION CLIENT YEAR SIZE LENGTH(KM)
SERVICES
VIZAG – SECUNDERABAD LPGPIPELINE
GAIL 2002 12”/10” 600 LPG (LEQUIFIEDPETROLEUM GAS)
MANMADMANMAD--MANGALAYA PIPELINE
BPCL 2003 14 ” 358 MULTIPRODUCT
MANGALOREMANGALORE--BANGLORE
HPCL 2003 24 ”/20” 364 MULTIPRODUCT
DAHEJ – VIJAIPUR PIPELINE
GAIL 2003 42” 610 REGASIFIED LNG
INTER REFINERIES PIPELINESPROJECT, ABU DHABI
TAKREER 2004 10”
12”
16”
230
230
208
NAPHTHA,MULTIPRODUCT & SRR
MANGALAYAMANGALAYA--BIJWASANPIPELINE
BPCL 2006 16”/8” 775 MULTIPRODUCT
MUNDRAMUNDRA--DELHI PIPELINE
HPCL 2006 18”/16” 1050 MULTIPRODUCT
PIPELINE DESIGNMajor Onshore Projects (..contd) (Completed)
Pipeline Design
Slide Number - 8 of 77
Engineers India Ltd – Delivering excellence through people
DESCRIPTION CLIENT YEAR SIZE LENGTH(KM)
SERVICES
PUNE SOLAPUR PIPELINE HPCL 2007 14 ”/ 12” 182 / 161 MULTIPRODUCT
DABHOL PANVEL PIPELINEPROJECT (PH-(PH-I)
GAIL 2007 30” 187 REGASIFIED LNG
DABHOL PANVEL PIPELINEPROJECT (PH-(PH-II)
GAIL 2007 30” 120 REGASIFIED LNG
PIPELINE DESIGNMajor Onshore Projects ( contd)
(Completed)
Pipeline Design
Slide Number - 9 of 77
Engineers India Ltd – Delivering excellence through people
DESCRIPTION CLIENT YEAR SIZE LENGTH(KM)
SERVICES
BOMBAY HIGH URAN TRUNKLINE
(BUT)
ONGC 1979 30”/26” 200 x 2 CRUDE, GAS
SOUTH BASSEIN HAZIRATRUNKLINE
ONGC 1986 36” 220 GAS
HEERAHEERA--URAN TRUNK LINE
ONGC 1996 26 ”/24 ” 85 x 2 CRUDE, GAS
ICP - HEERA TRUNKLINE ONGC 1996 30”/22” 145 CRUDE
SECOND BASSEIN HAZIRATRUNKLINE
ONGC 1995 42” 245 GAS
MUMBAI HIGH URAN TRUNKLINE
(MUT)
ONGC 2005 30”/28”
12” to 22”
205 x 2
100
CRUDE, GAS
Pipeline Design
Slide Number - 10 of 77
Engineers India Ltd – Delivering excellence through people
PIPELINE DESIGNMajor Offshore Projects
(Completed)
IN-FIELD PIPELINES OF BOMBAY-HIGH, BASSEIN, HEERA, NEELAM, PANNA, MUKTA.
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
Pipeline Design
Slide Number - 11 of 77
Engineers India Ltd – Delivering excellence through people
PIPELINE DESIGNMajor Onshore Projects
(Current)
IN-FIELD PIPELINES OF BOMBAY-HIGH, BASSEIN, HEERA, NEELAM, PANNA, MUKTA.
PIPELINE DESIGN
SECTION-1
INTRODUCTION
Pipeline Design
Slide Number - 12 of 77
Engineers India Ltd – Delivering excellence through people
PIPELINE DESIGN
CONTENTSINTRODUCTION
Modes of TransportationBenefits of Pipelines
PIPELINE DESIGN
Stages of Pipeline ProjectCodes and StandardsDesignInstallation, Testing & Commissioning
Pipeline Design
Slide Number - 13 of 77
Engineers India Ltd – Delivering excellence through people
PIPELINE DESIGN
Oil and Gas Production in India
33 MMTPAOIL
(ONGC, OIL, CAIRN, RIL)
GAS 115 MMSCMD
Pipeline Design
Slide Number - 14 of 77
Engineers India Ltd – Delivering excellence through people
(ONGC, GAIL, OIL, GSPC, RIL)
(MM
T)
Refining Scenario- India
302300
350
Capacity - 2006-07NOC – 105.5 MMTOthers- 43.5 MMT
PIPELINE DESIGN
70
149
235250
200
150
Pipeline Design
Slide Number - 15 of 77
100
50
0
1998-99 2006-07 2011-12 2016-17
Source: India of –Working Group on P&NG peopleEngineersReport Ltd Delivering excellence throughSector for the XI Plan
(Actual) Year
PIPELINE DESIGN
Modes of Hydrocarbon Transportation - India
35%
30%
Pipelines 32%
Road Tankers
Rail Tankers
Water Carriers
32%
26%
10%
20%
15%
10%
5%
25%
0%% Share
Pipelines
Road Tankers
Rail Tankers
Water Carriers
Pipeline Design
Slide Number - 16 of 77
Engineers India Ltd – Delivering excellence through people
Pipeline Design
Slide Number - 17 of 77
Engineers India Ltd – Delivering excellence through people
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
En
ergy
Con
sum
pti
on in
% o
f en
ergy
Tra
nsp
orte
d
PIPELINE DESIGN
Energy SavingsEnergy Intensity for Various M ode s
4
0.8
0.51
3.2
0.81.1
2
0
1.5
1
0.5
3.5
3
2.5
2
Pipeline Design
Slide Number - 18 of 77
Engineers India Ltd – Delivering excellence through people
Liquid-
Pipelines
Liquid-
Coastal
Liquid-
Trains
Liquid-
Trucks
Coal-
Trains
Coal-
Coastal
N.Gas-
Pipelines
Pipelines are the most energy efficient modes of transportation
ECONOMICS OF PIPELINE TRANSPORTATION
Transmission lossesLosses During Transportation
Rail/Road
Pipelines
Pipeline Design
Slide Number - 19 of 77
Engineers India Ltd – Delivering excellence through people
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
Products Transported
Crude Oil
Petroleum Products (MS, HSD, ATF, SKO)
Water & Effluents
LPG
Natural Gas
Slurries
Pipeline Design
Slide Number - 20 of 77
Engineers India Ltd – Delivering excellence through people
PIPELINE DESIGN
Types of Pipelines
ONSHORE (LAND) & OFFSHORE(SUBMARINE) PIPELINES
Trunk Pipelines
Spur/ Branch Pipelines
Marine Offloading Terminals & Outfalls
Pipeline Design
Slide Number - 21 of 77
Engineers India Ltd – Delivering excellence through people
Liquid Line s Gas Line sIte m D e s criptionSr o.
PIPELINE DESIGN
Capital cost: Typical breakupP e r c e ntag e of C a p ita l Cos t.
Pipeline Design
Slide Number - 22 of 77
Engineers India Ltd – Delivering excellence through people
1
2
3
4
5
6
7
8
9
10
11
Su rv e y , ROW & Co mp e n s a tio n
Lin e Pip e Ste e l Co s t
M a in lin e ma te ria ls
Co a tin g o f Pip e s
M a in lin e Co n s tru c tio n
Ca th o d ic Pro te c tio n
T e le c o mmu n ic a tio n , SCA DA a n d RCPs
Pu mp / Co mp re s s o r Sta tio n s
De liv e ry T e rmin a l fa c ilitie s
Pro je c t M a n a g e me n t
S ubTotal
2%
33%
2%
11%
33%
1%
5%
5%
2%
5%
100%
1%
45%
3%
6%
25%
1%
2%
12%
1%
4%
100%
Pipes, prime-overs and construction constitute big ticket items
PIPELINE DESIGN
Marine Offloading Terminal
Pipeline Design
Slide Number - 23 of 77
Engineers India Ltd – Delivering excellence through people
PIPELINE DESIGN
Open sea Jetty
Pipeline Design
Slide Number - 24 of 77
Engineers India Ltd – Delivering excellence through people
PIPELINE DESIGN
HBJ GAS PIPELINE NETWORK
UTTAR PRADESH
N
DADRI ANOLA
SHAHJAHANPUR
AURAIYA JAGDISHPUR
BABRALA
ANTA
INDIA
DELHI
RAJASTHAN
GADEPAN
BIJAIPUR
MADHYA PRADESH
JHABUA
KEY PLAN
LEGENDCOMPRESSOR STATION
RECEIVING TERMINAL
DESPATCH STATION
Pipeline Design
Slide Number - 25 of 77
HAZIRA
Engineers India Ltd – Delivering excellence through people
GUJARAT
ARABIANSEA
PIPELINE DESIGN
Major Pipelines in India
Pipeline Design
Slide Number - 26 of 77
Engineers India Ltd – Delivering excellence through people
PIPELINE DESIGN
Pipeline Construction Video
Video for Mangalore Bangalore Pipeline
Pipeline Design
Slide Number - 27 of 77
Engineers India Ltd – Delivering excellence through people
PIPELINE DESIGN
SECTION-2
PIPELINE DESIGN
Pipeline Design
Slide Number - 28 of 77
Engineers India Ltd – Delivering excellence through people
Pipeline Design
Slide Number - 29 of 77
Engineers India Ltd – Delivering excellence through people
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
Pipeline Design
Slide Number - 30 of 77
Engineers India Ltd – Delivering excellence through people
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
Code/Standard TitleASME B 31.8 (2003) Gas Transportation and Distribution Piping Systems
ASME B 31.4 (2006) Pipeline Transportation Systems for Liquid Hydrocarbons and otherLiquids
OISDOISD--141 (2003) Design and Construction Requirements for CrossCross--CountryHydrocarbon Pipelines
OISDOISD--214 (2006) CrossCross--Country LPG Pipelines
OISDOISD--226 (2007) Natural Gas Transmission Pipelines and City Gas DistributionNetworks
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 andDIN
PIPELINE DESIGNMajor Codes & Standards
Pipeline Design
Slide Number - 31 of 77
Engineers India Ltd – Delivering excellence through people
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 DESIGNMajor Codes & Standards
Pipeline Design
Slide Number - 32 of 77
Engineers India Ltd – Delivering excellence through people
LIST OF SOFTWARES USED IN PIPELINEENGINEERING
PIPELINE STUDIO
TGNET
TLNET
HYSIS
Pipeline Design
Slide Number - 33 of 77
Engineers India Ltd – Delivering excellence through people
CAESAR--II
AUTOPIPE
IPMCS
MRPACK
SORPS
PIPECALC
OFFPIPE
PRISE
PIPECROSS
Pipeline Design
Slide Number - 34 of 77
Engineers India Ltd – Delivering excellence through people
PIPELINE DESIGN
Optimal sizes of various capacities
Economy of scale
Pipeline Design
Slide Number - 35 of 77
Engineers India Ltd – Delivering excellence through people
PIPELINE DESIGN
Route Selection
Routing ConsiderationsPipeline lengthObstructions & Sensitive areasInstallation LimitationsCrossings
SurveysTopographicalGeo-technicalPopulation Density IndexSoil ResistivityCadastral
Pipeline Design
Slide Number - 36 of 77
Engineers India Ltd – Delivering excellence through people
PIPELINE DESIGN
Typical Pipeline Route Map
BHATINDACh. 1012.67 km
IP-1 & IPS-FRANSISARCh. 855.01 km
PROPOSED PIPELINE
IPS-2JUDCh. 593.88 km
IPS-FGAILAWASCh. 527.87 km
LEGEND:
PROPOSED MUNDRA-BHATINDA PIPELINE (28" NB)
DESPATCH TERMINAL AND PUMPING STATION
IPS-1JORAWARPURACh. 313.63 km
IPS-FJHEKDACh. 226.72 km
RECEIPT TERMINAL
INTERMEDIATE PUMPING STATION (IPS)
INTERMEDIATE PIGGING STATION (IP)
FUTURE PUMPING STATION (IPS-F)
NOTES:
1. PIPELINE ROUTE SHOWN IS INDICATIVE ONLY.2. CHAINAGES INDICATED ARE APPROXIMATE.
MUNDRACh. 0.00 km
PIPELINE DESIGN
Pipeline Design
Slide Number - 37 of 77
Engineers India Ltd – Delivering excellence through people
PIPELINE DESIGN
Material Selection & Corrosion Control
MaterialsCarbon Steel (CS)
NACE Carbon Steel
CRA Clad CS
CS with internalCoatings
Non-MetallicMaterials
Pipeline Design
Slide Number - 38 of 77
Engineers India Ltd – Delivering excellence through people
AssessmentNature of the Product
Design Life
Product Temperature
Corrosion ProtectionMaterial Chemistry
Internal Coatings
Product Conditioning
Corrosion inhibitors
Corrosion Allowance
PIPELINE DESIGN
Design and Analysis
Wall Thickness Calculations
Anti-Buoyancy Measures
Piping Stress Analysis
Buried Pipeline Analysis
Crossing Design
Pipeline Design
Slide Number - 39 of 77
Engineers India Ltd – Delivering excellence through people
PIPELINE DESIGN
Steel Pipe Wall Thickness Calculation
LIQUID PIPELINE
(ASME B 31.4, Cl. 404.1.2)
t = PiD2.S
where
Pi Internal design pressureS allowable stress
= 0.72 x E x SMYSD Outside Diameter of pipet pressure design wall
thickness
GAS PIPELINE
(ASME B 31.8, Cl. 841.11)
P = 2St FETD
whereP Design pressureS Specified minimum yield
strengthD Nominal OD of pipet Nominal wall thickness
F Design factor
Pipeline Design
Slide Number - 40 of 77
Engineers India Ltd – Delivering excellence through people
E Weld joint factor E Longitudinal joint factorT Temperature de-rating factor
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 buildingsLocation Class 2 : > 10 and < 46 buildings
Location Class 3 : ≥46 buildingsLocation Class 4 : Multistory buildings
PIPELINE DESIGN
Basic Design Factor for Gas Pipelines
Pipeline Design
Slide Number - 41 of 77
Engineers India Ltd – Delivering excellence through people
PIPELINE DESIGN
Line Pipe Selection
Line Pipe Selection Parameters
Thickness and Grade
Selection
Handling and
Transportation (d/t ratio)
Type of LinePipe
Installation Requirements
Pipeline Design
Slide Number - 42 of 77
Engineers India Ltd – Delivering excellence through people
Type of Line Pipes
Seamless
Electric Welded
Longitudinal Seam
Submerged-Arc Welded
(LSAW)
Helical Seam Submerged-
Arc Welded
(HSAW)
PIPELINE DESIGN
Line Pipe Application
Submarine Pipelines
Seamless Pipes(upto & including 16”)
LSAW Pipes(18” & above)
Pipeline Design
Slide Number - 43 of 77
Engineers India Ltd – Delivering excellence through people
Onshore Pipelines
Seamless Pipes(upto & including 8”)
LSAW Pipes(16” & above)
HSAW Pipes(18” & above)
EW Pipes(4” - 18”)
PIPELINE DESIGNManufacturing of Helical Pipes
Pipeline Design
Slide Number - 45 of 77
Engineers India Ltd – Delivering excellence through people
Pipeline Design
Slide Number - 46 of 77
Engineers India Ltd – Delivering excellence through people
PIPELINE DESIGN
Anti-corrosive CoatingsCoal Tar Enamel Coating (BS 4164, AWWA C203)
PrimerTwo layers of coal tar enamel & glass fibre Inner wrapOne layer of coal tar impregnated outer wrapCoating thickness 4.7mm
3 Layer PE/ PP Coating (DIN 30670)First layer of Fusion bonded epoxySecond layer of extruded adhesiveThird layer of extruded PE/ PPCoating thickness 2.0 to 3.7 mm
Fusion Bonded Epoxy Coating (CSA Z245.20)350--500 micron thick single layer coating600--800 micron thick dual layer coating
PIPELINE DESIGN
3 Layer PE Coating Application
Pipeline Design
Slide Number - 47 of 77
Engineers India Ltd – Delivering excellence through people
Pipeline Design
Slide Number - 48 of 77
Engineers India Ltd – Delivering excellence through people
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
Scraper traps
Pipeline Design
Slide Number - 49 of 77
Engineers India Ltd – Delivering excellence through people
PIPELINE DESIGN
Sectionalizing ValveSpacing Gas Pipelines
ASME B 31.8 for GaspipelinesASME B 31.4 for LiquidPipelines
Location
Location Class 1
Location Class 2
Location Class 3
Location Class 4
32 km (20 miles)
24 km (15 miles)
16 km (10 miles)
8 km (5 miles)
Pipeline Design
Slide Number - 50 of 77
Engineers India Ltd – Delivering excellence through people
Pollution ConcernsStatutory RequirementsPrevention of InventoryLossApproachability of ValveStation
LPG Pipelines
Industrial, 12 km (7.5 miles)
Commercial &
Residential Areas
Pipeline Design
Slide Number - 51 of 77
Engineers India Ltd – Delivering excellence through people
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
Ball valves
Pipeline Design
Slide Number - 52 of 77
Engineers India Ltd – Delivering excellence through people
PIPELINE DESIGNPlug valve
Pipeline Design
Slide Number - 53 of 77
Engineers India Ltd – Delivering excellence through people
PIPELINE DESIGNCheck valve
Pipeline Design
Slide Number - 54 of 77
Engineers India Ltd – Delivering excellence through people
PIPELINE DESIGN
Major Engineering Deliverables
Design Reports
Design Basis
Route Selection Report
Wall Thickness Report
Seismic Design Report
Crossing Design Report
Pipeline Design
Slide Number - 55 of 77
Engineers India Ltd – Delivering excellence through people
Drawings
Route Map
Pipeline Schematic
Alignment Sheets
SV Station Layout
Equipment Layout
Piping GeneralArrangement Drawings
MA
TC
H L
INE
FO
R C
ON
T. R
EFE
R D
WG
NO
.452
9-10
-16-
71-9
005
TO
TO
PE
UR
TH
AP
AM
RU
ND
A
EL
EC
TR
CH
.118
4IC
LIN
E
8.88
m
DR
AIN C
H.1
182 4
. 62 9
m
MA
TC
HL
I NE
F OR
CO
NT
.RE
FER
DW
G
NO
.452
9 -1 0
-16-
71-9
0 03
CA
NA
LC
H 1
0691
.6m
/RL
35.
411m
RO
AD
CH
107
87.0
2m/R
L 3
2.58
7m
CA
RT
TR
AC
K
CH
134
92.6
1m/R
L 3
3.62
2m
DR
AIN
CH
106
64.7
1m/R
L 3
3.36
6m
DR
AIN
CH
118
24.6
3m/R
L 2
4.34
1m
RO
AD
CH
120
60.8
8m/R
L 2
4.60
4m
33.3
66
35.4
11
33.5
60
32.5
87
31.4
96
30.3
00
29.8
15
27.3
70
25.3
62
27.9
04
24.8
58
25.1
38
24.3
41
24.6
75
24.8
28
24.6
04
23.6
67
22.1
75D
RA
IN
C H
121
15.3
4m/R
L 2
2.17
5m
25.8
84
30.5
57
29.2
19
29.1
35
28.9
35
30.8
93
32.4
44
33.6
22
37.2
19
40.8
16
39.7
4142
.491
CA
NA
LC
H 1
4027
.73m
/RL
39.
741m
R O
AD
C H
140
40.2
7m/R
L 4
2.49
1m
7 5. 0
3 4
37.3
25
1 98 .
6 36
1 96 .
9 62
1 42 .
1 34
1 76 .
4 63
1 14 .
7 47
1 41 .
5 22
1 21 .
6 60
2 24 .
9 69
2 99 .
2 54
2 17 .
5 39
1 82 .
1 17
1 66 .
7 80
2 48 .
9 29
2 37 .
6 76
4 4. 1
5 2
2 6. 8
9 4
2 1. 1
9 9
7 4. 2
1 9
3 9. 3
6 9
3 7. 1
7 5
3 8. 7
4 9
9 0. 3
4 2
6 6. 5
9 7
2 4. 2
4 6
2 0. 1
0 1
3 4. 3
6 6
9 4. 1
4 1
7 7. 7
1 4
4 8. 5
2 1
10.6
21
1 0. 6
6 5
1 1. 9
3 91 1
. 96 0
1 1. 9
7 21 1
. 98 4
1 0. 6
9 2
1 0. 7
1 3
1 0. 7
8 7
1 0. 9
8 6
1 1. 0
2 5
1 1. 0
6 2
1 1. 2
5 9
1 1. 4
0 1
1 1. 5
7 8
1 1. 6
1 7
1 2. 2
3 0
1 2. 0
6 1
1 2. 0
8 1
1 1. 8
2 5
1 1. 8
4 9
1 2. 1
1 5
1 2. 4
5 5
1 1. 7
5 8
1 2. 7
5 4
1 2. 8
4 8
1 3. 0
6 6
1 3. 2
4 8
1 3. 4
1 5
1 3. 4
9 3
1 3. 7
4 2
1 3. 9
7 9
1 2. 5
4 3
1 0. 6
2 1
1 0. 6
6 5
1 0. 6
9 2
1 0. 7
1 3
1 0. 7
8 7
1 0. 9
8 6
1 1. 0
2 5
1 1. 0
6 2
1 1. 2
5 9
1 1. 4
0 1
1 1. 5
7 8
1 1. 6
1 7
1 1. 7
5 8
1 1. 8
2 5
1 1. 8
4 9
1 1. 9
3 9
1 2. 0
6 1
1 2. 0
8 1
1 2. 1
1 5
1 2. 2
3 0
1 2. 4
5 5
1 2. 7
5 4
1 2. 8
4 8
1 3. 0
6 6
1 3. 2
4 8
1 3. 4
1 5
1 3. 4
9 3
1 3. 7
4 2
1 3. 9
7 9
1 4. 0
2 81 4
. 04 0
1 4. 1
1 51 4
. 13 5
1 4. 1
1 51 4
. 13 5
1 4. 0
2 81 4
. 04 0
1 9. 5
8 843
.684
43.0
34
CA
RT
TR
AC
K
CH
141
15.3
1m/R
L 4
3.68
4m
AM
ND
RA
.71
DR H.10
TO CH
GUTL
AT
-SA
TO AMRUT
RAM
TRAC
PIPELINE DESIGN
Typical Pipeline Alignment SheetINTERSECTION POINTS(IP/TP)
DEFLECTION ANGLE38°4'58''(R)
TP50
29°8'20''(L)
IP50/1 TP51 IP51/1 TP52
5°18'55''(R) 8°2'3''(L)
TP53
37°0'54''(L)
TP54
13°54'57''(R) 11°25'7''(L)
TP55 TP56
1°21'55''(L)
TP57
8°24'45''(R)
TP58 IP58/1
2°8'32''(L)
TP59
14°0'19''(R)
TP60
8°30'18''(L)
TP61 IP61/1
15°2'57''(L)
TP62
10°4'42''(L)
TP63
10°25'50''(L)
IP64/1TP64
5°18'12''(R)
TP65
0m
IP50/1
TP51
CH. 10712.803m
CH. 10687.604m
IP51/1
TP63
CH. 13741.534m
TP65
CH. 14134.896m
IP64/1
CH.14044.732m
TP64
CH. 13979.211m
TBMW40 (RL37.514m)
TP50
CH. 10620.558m
RAIWADALEFT CANAL
TOPE
A
RIT
AM
APU
M
EARTHENEMBANKMENT
LOW LYINGAREA
TOST
EHIG
HWAY
BBAV
ARAM
STATE, DISTRICT ANDMANDAL
TO IRUVADA
TELEPHONE LINECH.14134.896m
METALLED ROAD(ASPHALTIC)
CH.14115.309m
ELEC. LINE440VCH.14132.231m
DISTANCE BETWEENTP& IP's(m)
DISTANCE AS PER GROUNDPROFILE
67.046 25.199 85.000
67.049 25.200 85.284
187.855
187.993
76.544
76.618
339.096
339.126
176.463
176.478
38.749
38.853
322.708
322.772
141.760
141.845
45.000
45.093
104.113
104.624
224.969
225.022
393.395
393.407
218.000
218.014
348.437
348.444
326.642
326.679
237.677
237.707
65.521
65.728
90.164
90.390
SCALE:HORIZONTAL 1:5000VERTICAL 1: 500
37
35
33
31
29
27
25
23
21
45
43
41
39
TP54
CH. 11401.298mELECTRICLINE 440V
CH.11018.117m
TP55
CH. 11577.761m
TP56
CH. 11616.510m
AIN 664
C
(UNLINED)
CH. 10691.604m
TP52
CH. 10985.658mTP53
CH. 11062.202m
TP60
CH. 12455.060m
K
CART 492.606mCH.13
TP61
CH. 12848.455m
TP62
CH. 13414.892m
TP58
CH. 12080.978m
IP58/1
CH. 12125.978m
EARTHEN EMBANKMENT
IP61/1
CH. 13066.455m
KAJUGARDEN RICEFIELDS
TBMW49 (RL25.138m)
TEMP. HUT ONC/L
HPCLCH. 15.00Km HPCLCH. 16.00Km
HPCLCH. 17.00Km
VILLAGEBOUNDARY
AMRUTAPURAM IRUVADA
INTA
CH. 10797.803m
A GRAVEL ROAD
CH.10787.022m
TP57
CH. 11939.218m
SV-1 OF GAIL
CH.11960.218 m
DRAIN
CH.12115.344m
HAPU
TP59
CH. 12230.091m
K
K
GRAVEL ROAD
CH.12060.877mOPEN WELL 6mDIA
7.648mFROMC/L
CH.11648.136m
OPEN WELL 6mDIA
8mFROMC/L
CH11577.761m
PUMP HOUSE 4mFROMC/L
HIGH TENSIONLINE
12.2m HIGH& 550KV
CH.12747.397m
DRAIN
CH.12903.743m
K
TBMW57(RL42.533m)
RAIWADALEFT CANAL
(UNLINED)
CH.14027.732mGRAVEL ROAD
CH.14040.275m
Pipeline Design
Slide Number - 56 of 77
Engineers India Ltd – Delivering excellence through people
PIPELINE DESIGN
Typical P&ID
Pipeline Design
Slide Number - 57 of 77
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PIPELINE DESIGNTypical GA DRAWING
Pipeline Design
Slide Number - 58 of 77
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Pipeline Design
Slide Number - 59 of 77
Engineers India Ltd – Delivering excellence through people
PIPELINE DESIGNMajor Engineering Deliverables
TendersSurvey TenderPipe Coating TenderPipeline Installation Tender
Material ProcurementLine PipesValves & ActuatorsScraper Traps, QOEC, Pig SignallersFlow Tees & Insulating JointsInduction BendsFlow metersPumps & CompressorsOFC cables
PIPELINE DESIGN
Installation, Testing & Commissioning
RoU Grading & Trenching Stringing of Linepipe
Pipeline Design
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PIPELINE DESIGN
Installation, Testing & Commissioning
Welding & NDT :Edge PreparationInternal / External Line-up ClampsManual / Automatic WeldingNDT (X-Ray / UT / MPI etc.)
Pipeline Design
Slide Number - 61 of 77
Engineers India Ltd – Delivering excellence through people
PIPELINE DESIGN
Installation, Testing & Commissioning
Lowering & BackfillingField Joint CoatingHeat Shrink SleevesCold applied tapes
Pipeline Design
Slide Number - 62 of 77
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Pipeline Design
Slide Number - 63 of 77
Engineers India Ltd – Delivering excellence through people
PIPELINE DESIGN
Pipeline Crossings
Crossing Installation
CrossingsRiver, Canal, Road & RailUtility Crossing
MethodologiesOpen-Cut MethodTrench-less Method
HorizontalDirectional DrillingJacking and BoringMicro tunneling
PIPELINE DESIGN
The conventional HDD operations for river crossings.
Pipeline Design
Slide Number - 64 of 77
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Boring Across Road crossings.
Pipeline Design
Slide Number - 65 of 77
Engineers India Ltd – Delivering excellence through people
Boring Across Road crossings, showing Auger used for Boring
Pipeline Design
Slide Number - 66 of 77
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Pipeline Design
Slide Number - 67 of 77
Engineers India Ltd – Delivering excellence through people
PIPELINE DESIGN
Pipeline Installation using Micro-tunnellingMICRO-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 boringmachineCarrier pipe inserted in jacking pipe
ADVANTAGES:Micro-tunnelling can be used wherever HDD cannot be doneCrossing of Rivers with gravels, cobbles & bouldersInstallation of more than one pipe in the tunnelPrecise installation and Minimum space at both endsCan be done in curved path also
PIPELINE DESIGN
Schematic Diagram
Pipeline Design
Slide Number - 68 of 77
Engineers India Ltd – Delivering excellence through people
PIPELINE DESIGN
Pipeline Installation using Micro-tunnellingLong Distance Micro Tunnelling
Pipeline Design
Slide Number - 69 of 77
Engineers India Ltd – Delivering excellence through people
PIPELINE DESIGN
Overview of Micro tunneling
Pipeline Design
Slide Number - 70 of 77
Engineers India Ltd – Delivering excellence through people
PIPELINE DESIGN
Testing & CommissioningTESTING
Gauging and PiggingTest PressureTest Medium
DRYINGSwabbingMethanol DryingSuper Dry AirMethodVacuum Drying
COMMISSIONINGNitrogen PurgingProduct Charging
Pipeline Design
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TEST PRESSURE
LIQUID PIPELINESRef. ASME B 31.4 : 437.4.11.25 times design pressure
GAS PIPELINESRef. ASME B 31.8 : Table 841.322(f)Class 1 and 2: 1.25 * des prClass 3 and 4: 1.4 * des pr
PIPELINE DESIGNPigging
RequirementsPipeline Cleaning
Displacement
Internal Inspection
Batching
Types of PigsBrush pigs
Gauge Pigs
Spheres
Intelligent Pigs
Pipeline Design
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Cleaning pigs Gauge Pigs Spheres Intelligent Pig(MFL)
PIPELINE DESIGN
RECENT DEVELOPMENTS
TECHNICAL IMPROVEMENTSAutomatic 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
Slide Number - 73 of 77
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Description LSAW HSAW
Method ofManufacture
UOE/COE/JCO/3 roll bending Formed by Twisting of Coil
Weld Length Equal to pipe joint length Approximately 1.5 to 2 times thelength of pipe joint
Position of weld Longitudinal – positioned inupper quadrant duringconstruction
Spiral – present all around thepipe
Corrosion Coating Specified thickness throughoutentire body.
Weld seam is tracked to ensurecoating thickness on weld seam
Thickness normally increased allover the body, resulting inproportional increase in coatingcost by 15-15-20%
Geometry Controlled to the desired levelwith cold expansion
Controlled during forming onlyand no cold expansion is carriedout
PIPELINE DESIGN
Comparison of LSAW & HSAW Pipes
Pipeline Design
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CTE 3LPE 3LPP FBE
Service Conditions
oTemperature, C Upto 45 Upto 65 Upto 110 Upto 110
AntiAnti--corrosion Properties
Resistance to Moisture Good Very Good Excellent Good
Cathodic Disbondment Fair Good Good Good
Electrical Properties
Coating Resistance Good Excellent Excellent Excellent
PIPELINE DESIGN
Coating Comparison
Pipeline Design
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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 toIndentation
Poor Very Good Excellent Fair
Resistance to Peel Fair Excellent Superior than PE -
Resistance to SoilStresses
Fair Excellent Excellent Excellent
Elongation Fair Excellent Excellent -
PIPELINE DESIGN
Coating Comparison
Pipeline Design
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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 duringhandling &transportation
High Low Low High
Ease of Field Repair Difficult Easy for small repair,
Cumbersome forlarger repair
Easy for small repair,
Cumbersome forlarger repair
Easy for small repair,
Cumbersome forlarger repair
PIPELINE DESIGN
Coating Comparison
Pipeline Design
Slide Number - 77 of 77
Engineers India Ltd – Delivering excellence through people