1. PIPELINE DESIGN Delivering excellence through people
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Delivering excellence through people
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2. EPC and Total Solutions
ENGINEERS
INDIA LIMITED
EPC and Total Solutions
Consultancy Organization
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Pipeline Design
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3. Petroleum Refineries Petrochemicals Pipelines Offshore Platforms
Gas Processing
Metallurgy
Ports & Terminals
Highways and Airports
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Pipeline Design
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4. 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
Engineers India Ltd – Delivering excellence through people
Pipeline Design
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5. SERVICES OFFERED BY EIL
PIPELINE DESIGN
SERVICES OFFERED BY EIL
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
Engineers India Ltd – Delivering excellence through people
Pipeline Design
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6. PIPELINE DESIGN EIL EXPERIENCE 1975 1979 1984 First major project
Crude Oil Loop Line for Oil India Ltd.
First major overseas project
150 km Multi Product Pipeline
for Abu Dhabi National Oil Company
First major high pressure Gas Pipeline
Project km Gas Transmission Network
for GAIL
Over 40 major pipeline projects completed.
Engineers India Ltd – Delivering excellence through people
Pipeline Design
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7. Major Onshore Projects (Completed)
PIPELINE DESIGN
Major Onshore Projects (Completed)
DESCRIPTION
CLIENT
YEAR
SIZE
LENGTH
(KM)
SERVICES
HAZIRAHAZIRA--BIJAIPUR--BIJAIPUR
JAGDISHPUR (HBJ)
GAIL
1989
36“/30”/24”/18”
1800
NATURAL GAS
MAQTAMAQTA--ALAL--AIN PIPELINE
ADNOC
1992
30 ”/12”
166
KANDLAKANDLA--BHATINDA
IOCL
1996
22”/14”/10”
1443
MULTIPRODUCT
GAS REHABILITATION &
EXPANSION PROJECT
(GREP)
1998
36 ”
505
MUMBAI – MANMAD
BPCL
18 ”
260
VIZAGVIZAG--VIJAYWADA
HPCL
360
JAMNAGARJAMNAGAR--LONI LPG
PIPELINE
2001
16”/14”/12”/8”/ 6
1235
LPG (LIQUIFIED
PETROLIUM GAS)
COCHIN – KARUR PIPELINE
PETRONET
18 ”/14 ”
289
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Pipeline Design
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8. Major Onshore Projects (..contd) (Completed)
PIPELINE DESIGN
Major Onshore Projects (..contd) (Completed)
DESCRIPTION
CLIENT
YEAR
SIZE
LENGTH
(KM)
SERVICES
VIZAG – SECUNDERABAD LPG
PIPELINE
GAIL
2002
12”/10”
600
LPG (LEQUIFIED
PETROLEUM GAS)
MANMADMANMAD--MANGALAYA PIPELINE
BPCL
2003
14 ”
358
MULTIPRODUCT
MANGALOREMANGALORE--BANGLORE
HPCL
24 ”/20”
364
DAHEJ – VIJAIPUR PIPELINE
42”
610
REGASIFIED LNG
INTER REFINERIES PIPELINES
PROJECT, ABU DHABI
TAKREER
2004
10”
12”
16”
230
208
NAPHTHA,
MULTIPRODUCT & SRR
MANGALAYAMANGALAYA--BIJWASAN
2006
16”/8”
775
MUNDRAMUNDRA--DELHI PIPELINE
18”/16”
1050
Engineers India Ltd – Delivering excellence through people
Pipeline Design
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9. Major Onshore Projects ( contd) (Completed)
PIPELINE DESIGN
Major Onshore Projects ( contd)
(Completed)
DESCRIPTION
CLIENT
YEAR
SIZE
LENGTH
(KM)
SERVICES
PUNE SOLAPUR PIPELINE
HPCL
2007
14 ”/ 12”
182 / 161
MULTIPRODUCT
DABHOL PANVEL PIPELINE
PROJECT (PH-(PH-I)
GAIL
30”
187
REGASIFIED LNG
PROJECT (PH-(PH-II)
120
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10. Major Offshore Projects
PIPELINE DESIGN
Major Offshore Projects
(Completed)
IN-FIELD PIPELINES OF BOMBAY-HIGH, BASSEIN, HEERA, NEELAM, PANNA, MUKTA.
DESCRIPTION
CLIENT
YEAR
SIZE
LENGTH
(KM)
SERVICES
BOMBAY HIGH URAN TRUNKLINE
(BUT)
ONGC
1979
30”/26”
200 x 2
CRUDE, GAS
SOUTH BASSEIN HAZIRA
TRUNKLINE
1986
36”
220
GAS
HEERAHEERA--URAN TRUNK LINE
1996
26 ”/24 ”
85 x 2
ICP - HEERA TRUNKLINE
30”/22”
145
CRUDE
SECOND BASSEIN HAZIRA
1995
42”
245
MUMBAI HIGH URAN TRUNKLINE
(MUT)
2005
30”/28”
12” to 22”
205 x 2
100
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Pipeline Design
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11. Major Onshore Projects
PIPELINE DESIGN
Major Onshore Projects
(Current)
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
28”/ 30”
424/ 590
CRUDE OIL
BINA KOTA PIPELINE
BPCL
18”
257
MULTI PRODUCT
VADINAR BINA PIPELINE
BORL
24”
935
NUMALIGARH SILIGURI PIPELINE
OIL
16”
400
COMPRESSOR STATIONS
---
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Pipeline Design
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12. INTRODUCTION SECTION-1 PIPELINE DESIGN Pipeline Design
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Pipeline Design
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13. CONTENTS INTRODUCTION Modes of Transportation
PIPELINE DESIGN
CONTENTS
INTRODUCTION
Modes of Transportation
Benefits of Pipelines
Stages of Pipeline Project
Codes and Standards
Design
Installation, Testing & Commissioning
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Pipeline Design
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14. Oil and Gas Production in India
PIPELINE DESIGN
Oil and Gas Production in India
OIL
(ONGC, OIL, CAIRN, RIL)
33 MMTPA
GAS
115 MMSCMD
(ONGC, GAIL, OIL, GSPC, RIL)
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15. PIPELINE DESIGN Refining Scenario- India Capacity - 2006-07
NOC – MMT
Others MMT
350
302
300
250
200
150
235
(MMT)
149
100 50 70
(Actual) Year
Source: India of –Working Group on P&NG people
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Pipeline Design
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16. Modes of Hydrocarbon Transportation - India 35%
PIPELINE DESIGN
Modes of Hydrocarbon Transportation - India
35%
30%
Pipelines
32%
25%
Pipelines
Road Tankers
Rail Tankers
Water Carriers
Road Tankers
Rail Tankers
Water Carriers
32%
26%
10%
20%
15%
10% 5% 0%
% Share
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Pipeline Design
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17. Benefits of Transportation by Pipelines Safer mode of transportation
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
Engineers India Ltd – Delivering excellence through people
Pipeline Design
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18. Energy Intensity for Various M ode s
PIPELINE DESIGN
Energy Savings
Energy Intensity for Various M ode s 4
3.5 3
2.5 2
3.2 2
Energy Consumption in % of energy
Transported
1.5 1
0.5
1.1
0.8
0.8
0.5 1
Liquid-
Pipelines
Liquid-
Coastal
Liquid-
Trains
Liquid-
Trucks
Coal-
Trains
Coal-
Coastal
N.Gas-
Pipelines
Pipelines are the most energy efficient modes of transportation
Engineers India Ltd – Delivering excellence through people
Pipeline Design
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19. Losses During Transportation
ECONOMICS OF PIPELINE TRANSPORTATION
Transmission losses
Losses During Transportation
Rail/Road
Pipelines
0.1
0.2
0.3
0.4
0.5
% Loss of Total Volum e Transported
Transmission losses are lowest in Pipelines
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Pipeline Design
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20. Products Transported Crude Oil Petroleum Products (MS, HSD, ATF, SKO)
PIPELINE DESIGN
Products Transported
Crude Oil
Petroleum Products (MS, HSD, ATF, SKO)
Water & Effluents
LPG
Natural Gas
Slurries
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21. Types of Pipelines ONSHORE (LAND) & OFFSHORE (SUBMARINE) PIPELINES
PIPELINE DESIGN
Types of Pipelines
ONSHORE (LAND) & OFFSHORE
(SUBMARINE) PIPELINES
Trunk Pipelines
Spur/ Branch Pipelines
Marine Offloading Terminals & Outfalls
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22. Capital cost: Typical breakup P e r c e ntag e of C a p ita l Cos t.
PIPELINE DESIGN
Capital cost: Typical breakup
P e r c e ntag e of C a p ita l Cos t. Sr o.
Ite m D e s cription
Liquid Line s
Gas Line s 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%
11% 1% 5%
100% 1%
45% 3% 6%
25% 2%
12% 4%
100%
Pipes, prime-overs and construction constitute big ticket items
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Pipeline Design
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23. Marine Offloading Terminal
PIPELINE DESIGN
Marine Offloading Terminal
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24. PIPELINE DESIGN Open sea Jetty Pipeline Design
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Pipeline Design
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25. HBJ GAS PIPELINE NETWORK
PIPELINE DESIGN
HBJ GAS PIPELINE NETWORK
UTTAR PRADESH N
DADRI
ANOLA
DELHI
RAJASTHAN
GADEPAN
SHAHJAHANPUR
AURAIYA JAGDISHPUR
BABRALA
INDIA
ANTA
GUJARAT
ARABIAN
SEA
BIJAIPUR
MADHYA PRADESH
KEY PLAN
LEGEND
COMPRESSOR STATION
RECEIVING TERMINAL
JHABUA
HAZIRA
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DESPATCH STATION
Pipeline Design
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26. Major Pipelines in India
PIPELINE DESIGN
Major Pipelines in India
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Pipeline Design
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27. Pipeline Construction Video
PIPELINE DESIGN
Pipeline Construction Video
Video for Mangalore Bangalore Pipeline
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Pipeline Design
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28. SECTION-2 PIPELINE DESIGN Pipeline Design
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Pipeline Design
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29. Stages of Pipeline Project
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
Engineers India Ltd – Delivering excellence through people
Pipeline Design
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30. Stages of Pipeline Project
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
Engineers India Ltd – Delivering excellence through people
Pipeline Design
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31. Major Codes & Standards
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
OISDOISD--141 (2003)
Design and Construction Requirements for CrossCross--Country
Hydrocarbon Pipelines
OISDOISD--214 (2006)
CrossCross--Country LPG Pipelines
OISDOISD--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-OS-F101
Submarine pipeline systems
Other References
Applicable Standards / Specs of ASME, API, NACE, MSS, BS and
DIN
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32. Major Codes & Standards
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
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33. 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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34. Optimal sizes of various capacities
PIPELINE DESIGN
Optimal sizes of various capacities
Economy of scale
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35. Route Selection Routing Considerations Pipeline length Surveys
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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36. Typical Pipeline Route Map
PIPELINE DESIGN
Typical Pipeline Route Map
BHATINDA
Ch km
IP-1 & IPS-F
Ch km
RANSISAR
PROPOSED PIPELINE
IPS-2
JUD
Ch km
IPS-F
Ch km
GAILAWAS
LEGEND:
PROPOSED MUNDRA-BHATINDA PIPELINE (28" NB)
DESPATCH TERMINAL AND PUMPING STATION
IPS-1
Ch km
JORAWARPURA
IPS-F
Ch km
JHEKDA
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.
MUNDRA
Ch km
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37. PIPELINE DESIGN Pipeline Design
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38. Material Selection & Corrosion Control
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
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39. Design and Analysis Wall Thickness Calculations Anti-Buoyancy Measures
PIPELINE DESIGN
Design and Analysis
Wall Thickness Calculations
Anti-Buoyancy Measures
Piping Stress Analysis
Buried Pipeline Analysis
Crossing Design
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40. Steel Pipe Wall Thickness Calculation
PIPELINE DESIGN
Steel Pipe Wall Thickness Calculation
LIQUID PIPELINE
(ASME B 31.4, Cl )
t = PiD
2.S
where
GAS PIPELINE
(ASME B 31.8, Cl )
P = 2St FET D
where Pi
Internal design pressure
P Design pressure
S allowable stress
= 0.72 x E x SMYS
D Outside Diameter of pipe
t pressure design wall
S Specified minimum yield
strength
D Nominal OD of pipe
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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41. Basic Design Factor for Gas Pipelines
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
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42. PIPELINE DESIGN Line Pipe Selection Line Pipe Selection Parameters
Thickness and Grade
Selection
Handling and
Transportation (d/t ratio)
Type of LinePipe
Installation Requirements
Type of Line Pipes
Seamless
Electric Welded
Longitudinal Seam
Submerged-Arc Welded
(LSAW)
Helical Seam Submerged-
Arc Welded
(HSAW)
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43. Line Pipe Application Submarine Pipelines Onshore Pipelines
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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44. Engineers India Ltd – Delivering excellence through people
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45. Manufacturing of Helical Pipes
PIPELINE DESIGN
Manufacturing of Helical Pipes
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46. Anti-corrosive Coatings
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)
micron thick single layer coating
micron thick dual layer coating
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47. 3 Layer PE Coating Application
PIPELINE DESIGN
3 Layer PE Coating Application
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48. Major Pipeline Components
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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49. PIPELINE DESIGN Scraper traps Pipeline Design
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50. Sectionalizing Valve Spacing Gas Pipelines pipelines
PIPELINE DESIGN
Sectionalizing Valve
Spacing
Gas Pipelines
ASME B 31.8 for Gas
pipelines
ASME B 31.4 for Liquid
Pipelines
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)
LPG Pipelines
Industrial, km (7.5 miles)
Commercial &
Residential Areas
Pollution Concerns
Statutory Requirements
Prevention of Inventory
Loss
Approachability of Valve
Station
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51. Type of Valves Full Bore Ball Valves Through Conduit Gate Valves
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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52. PIPELINE DESIGN Ball valves Pipeline Design
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53. PIPELINE DESIGN Plug valve Pipeline Design
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54. PIPELINE DESIGN Check valve Pipeline Design
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55. Major Engineering Deliverables
PIPELINE DESIGN
Major Engineering Deliverables
Design Reports
Design Basis
Route Selection Report
Wall Thickness Report
Seismic Design Report
Crossing Design Report
Drawings
Route Map
Pipeline Schematic
Alignment Sheets
SV Station Layout
Equipment Layout
Piping General
Arrangement Drawings
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56. Typical Pipeline Alignment Sheet
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 AS PER GROUNDPROFILE
DISTANCE BETWEENTP& IP's(m)
76.618
76.544
38.853
38.749
45.093
45.000
65.728
65.521
90.390
90.164
TO IRUVADA
STATE, DISTRICT ANDMANDAL RA M
CH m
TP65 A PU
TP64
CH m
IP64/1
CH m
TELEPHONE LINECH m
METALLED ROAD(ASPHALTIC)
ELEC. LINE440V
CH m
CH m AM
RIT
CH m
TP50
TBMW40 (RL37.514m) PE ND A TO
EARTHENEMBANKMENT
CH m
TP51
IP51/1
CH m
IP50/1
TOPE TO
LOW LYINGAREA
CH m
CH m
A GRAVEL ROAD
(UNLINED)
TP52
CH m
TP53
CH m
CH m
RAIWADALEFT CANAL
CH m
TP63 TO
.71 0m
SV-1 OF GAIL
CH m
TP57
CH m
AMRU
NDA
IP58/1
CH m
TP58
CH m
CH m
TP60
EARTHEN EMBANKMENT
IP61/1
CH m
TBMW57(RL42.533m)
RAIWADALEFT CANAL
CH m
(UNLINED)
CH m
GRAVEL ROAD ST AT C
AIN 664 E K
CH m
TP59 AY HW
HIG
DR H.10
CH.1184ICLINE
THAP
CH m
TP61
CH m
TP62
-SA
MATCHLINEFORCONT.REFERDWG
CH m UR
MATCH LINE FOR CONT. REFER DWG AM AR AV BB
GUTL
CH m
TP55
8.88m AM K
CH m
DRAIN
TO CH
INTA
ELECTR NO
CH m
TP56
DRAIN
TEMP. HUT ONC/L
HPCLCH Km
CH m
TP54
HAPU
CH m
DRAIN
HPCLCH Km
CH m
12.2m HIGH& 550KV
HIGH TENSIONLINE
HPCLCH Km
VILLAGEBOUNDARY
AMRUTAPURAM IRUVADA K
CART m
CH.13
TRAC NO
CH m
ELECTRICLINE 440V K
TO A
MRUT
OPEN WELL 6mDIA
CH m
GRAVEL ROAD
TBMW49 (RL25.138m)
RAM
PUMP HOUSE 4mFROMC/L
7.648mFROMC/L
OPEN WELL 6mDIA
CH m
CH m
8mFROMC/L 41 43 45 39
C H m/RL m
CH m/RL m
CH m/RL m
CART TRACK
R OAD
VERTICAL 1: 500
HORIZONTAL 1:5000
SCALE: 33 35 37 27 29 31 23 25 21
CH m/RL m
CH m/RL m
CH m/RL m
CH m/RL m
CANAL
DRAIN
CANAL
CART TRACK
ROAD
CH m/RL m
CH m/RL m
C H m/RL m
DRAIN
ROAD
DRAIN
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
44.152
26.894
21.199
74.219
KAJUGARDEN
39.369
37.175
38.749
RICEFIELDS
66.597
24.246
90.342
20.101
34.366
94.141
77.714
48.521
12.543
75.034
19.588
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
Engineers India Ltd – Delivering excellence through people
Pipeline Design
Slide Number - 56 of 77

57. PIPELINE DESIGN Typical P&ID Pipeline Design
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Pipeline Design
Slide Number - 57 of 77

58. Typical GA DRAWING PIPELINE DESIGN Pipeline Design
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Pipeline Design
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59. Major Engineering Deliverables
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
Engineers India Ltd – Delivering excellence through people
Pipeline Design
Slide Number - 59 of 77

60. Installation, Testing & Commissioning
PIPELINE DESIGN
Installation, Testing & Commissioning
RoU Grading & Trenching
Stringing of Linepipe
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Pipeline Design
Slide Number - 60 of 77

61. Installation, Testing & Commissioning
PIPELINE DESIGN
Installation, Testing & Commissioning
Welding & NDT :
Edge Preparation
Internal / External Line-up Clamps
Manual / Automatic Welding
NDT (X-Ray / UT / MPI etc.)
Engineers India Ltd – Delivering excellence through people
Pipeline Design
Slide Number - 61 of 77

62. Installation, Testing & Commissioning
PIPELINE DESIGN
Installation, Testing & Commissioning
Field Joint Coating
Heat Shrink Sleeves
Cold applied tapes
Lowering & Backfilling
Engineers India Ltd – Delivering excellence through people
Pipeline Design
Slide Number - 62 of 77

63. Pipeline Crossings Crossing Installation Crossings
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
Engineers India Ltd – Delivering excellence through people
Pipeline Design
Slide Number - 63 of 77

64. The conventional HDD operations for river crossings.
PIPELINE DESIGN
The conventional HDD operations for river crossings.
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Pipeline Design
Slide Number - 64 of 77

65. Boring Across Road crossings.
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Pipeline Design
Slide Number - 65 of 77

66. Boring Across Road crossings, showing Auger used for Boring
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Pipeline Design
Slide Number - 66 of 77

67. Pipeline Installation using Micro-tunnelling
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
Engineers India Ltd – Delivering excellence through people
Pipeline Design
Slide Number - 67 of 77

68. PIPELINE DESIGN Schematic Diagram Pipeline Design
Engineers India Ltd – Delivering excellence through people
Pipeline Design
Slide Number - 68 of 77

69. Pipeline Installation using Micro-tunnelling
PIPELINE DESIGN
Pipeline Installation using Micro-tunnelling
Long Distance Micro Tunnelling
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Pipeline Design
Slide Number - 69 of 77

70. Overview of Micro tunneling
PIPELINE DESIGN
Overview of Micro tunneling
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Pipeline Design
Slide Number - 70 of 77

71. Testing & Commissioning
PIPELINE DESIGN
Testing & Commissioning
TESTING
DRYING
Gauging and Pigging
Test Pressure
Test Medium
Swabbing
Methanol Drying
Super Dry Air
Method
Vacuum Drying
COMMISSIONING
Nitrogen Purging
Product Charging
TEST PRESSURE
LIQUID PIPELINES
Ref. ASME B 31.4 :
1.25 times design pressure
GAS PIPELINES
Ref. ASME B 31.8 : Table (f)
Class 1 and 2: * des pr
Class 3 and 4: * des pr
Engineers India Ltd – Delivering excellence through people
Pipeline Design
Slide Number - 71 of 77

72. PIPELINE DESIGN Pigging Requirements Pipeline Cleaning Types of Pigs
Displacement
Internal Inspection
Batching
Types of Pigs
Brush pigs
Gauge Pigs
Spheres
Intelligent Pigs
Cleaning pigs
Gauge Pigs
Spheres
Intelligent Pig
(MFL)
Engineers India Ltd – Delivering excellence through people
Pipeline Design
Slide Number - 72 of 77

73. RECENT DEVELOPMENTS TECHNICAL IMPROVEMENTS
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
Engineers India Ltd – Delivering excellence through people
Pipeline Design
Slide Number - 73 of 77

74. Comparison of LSAW & HSAW Pipes
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 %
Geometry
Controlled to the desired level
with cold expansion
Controlled during forming only
and no cold expansion is carried
out
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Pipeline Design
Slide Number - 74 of 77

75. Coating Comparison CTE 3LPE 3LPP FBE PIPELINE DESIGN o Pipeline Design
Service Conditions o
Temperature, C
Upto 45
Upto 65
Upto 110
AntiAnti--corrosion Properties
Resistance to Moisture
Good
Very Good
Excellent
Cathodic Disbondment
Fair
Electrical Properties
Coating Resistance
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Pipeline Design
Slide Number - 75 of 77

76. Coating Comparison CTE 3LPE 3LPP FBE PIPELINE DESIGN Pipeline Design
Cathodic Protection Design
Current Density
High
Low
Mechanical Properties
Resistance to Impact
Fair
Excellent
Superior to PE
Resistance to
Indentation
Poor
Very Good
Resistance to Peel
Superior than PE -
Resistance to Soil
Stresses
Elongation
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Pipeline Design
Slide Number - 76 of 77

77. Coating Comparison CTE 3LPE 3LPP FBE PIPELINE DESIGN Pipeline Design
Long Term Ageing
Heat & Light Ageing
Fair
Very Good
Application & Field Repair
Ease of Application
Easy
Relatively difficult
Damages during
handling &
transportation
High
Low
Ease of Field Repair
Difficult
Easy for small repair,
Cumbersome for
larger repair
Engineers India Ltd – Delivering excellence through people
Pipeline Design
Slide Number - 77 of 77