1. PIPELINE DESIGN

2. ENGINEERS INDIA LIMITED
EPC and Total Solutions Consultancy Organization

3. ENGINEERS INDIA LTD. - AREAS OF OPERATION
Petroleum Refineries
Petrochemicals
Pipelines
Offshore Platforms
Gas Processing
Metallurgy
Ports & Terminals
Highways and Airports

4. EIL OFFICES HEAD OFFICE NEW DELHI REGIONAL OFFICES VADODARA, CHENNAI
KOLKATA
PROCUREMENT OFFICES MUMBAI
SITE OFFICES LOCATIONS (INDIA)
9 LOCATIONS (OVERSEAS)
INSPECTION OFFICE 10 LOCATIONS
OVERSEAS OFFICES LONDON, LIBYA ABU DHABI,
ITALY, SAUDI ARABIA , QATAR,
KUWAIT

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

6. PIPELINE DESIGN EIL EXPERIENCE
1975 First major project Crude Oil Loop Line for Oil India Ltd.
1979 First major overseas project km Multi Product Pipeline for Abu Dhabi National Oil Company
1984 First major high pressure Gas Pipeline Project km Gas Transmission Network for GAIL
Over 40 major pipeline projects completed.

7. Major Onshore Projects (Completed)
PIPELINE DESIGN
Major Onshore Projects (Completed)
DESCRIPTION
CLIENT
YEAR
SIZE
LENGTH (KM)
SERVICES
HAZIRA-BIJAIPUR-JAGDISHPUR (HBJ)
GAIL
1989
36“/30”/24”/18”
1800
NATURAL GAS
MAQTA-AL-AIN PIPELINE
ADNOC
1992
30 ”/12”
166
KANDLA-BHATINDA
IOCL
1996
22”/14”/10”
1443
MULTIPRODUCT
GAS REHABILITATION & EXPANSION PROJECT (GREP)
1998
36 ”
505
MUMBAI – MANMAD
BPCL
18 ”
260
VIZAG-VIJAYWADA
HPCL
360
JAMNAGAR-LONI LPG PIPELINE
2001
16”/14”/12”/8”/6
1235
LPG (LIQUIFIED PETROLIUM GAS)
COCHIN – KARUR PIPELINE
PETRONET
18 ”/14 ”
289

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)
MANMAD-MANGALAYA PIPELINE
BPCL
2003
14 ”
358
MULTIPRODUCT
MANGALORE-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
MANGALAYA-BIJWASAN PIPELINE
2006
16”/8”
775
MUNDRA-DELHI PIPELINE
18”/16”
1050

9. Major Onshore Projects (…contd)
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-I)
GAIL
30”
187
REGASIFIED LNG
DABHOL PANVEL PIPELINE PROJECT (PH-II)
120

10. Major Offshore Projects
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
CRUDE, GAS
SOUTH BASSEIN HAZIRA TRUNKLINE
1986
36”
220
GAS
HEERA-URAN TRUNK LINE
1996
26 ”/24 ”
85 x 2
ICP - HEERA TRUNKLINE
30”/22”
145
CRUDE
SECOND BASSEIN HAZIRA TRUNKLINE
1995
42”
245
MUMBAI HIGH URAN TRUNKLINE
(MUT)
2005
30”/28”
12” to 22”
205 x 2
100
IN-FIELD PIPELINES OF BOMBAY-HIGH, BASSEIN, HEERA, NEELAM, PANNA, MUKTA. 10

11. Major Onshore Projects
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
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
---
IN-FIELD PIPELINES OF BOMBAY-HIGH, BASSEIN, HEERA, NEELAM, PANNA, MUKTA. 11

12. PIPELINE DESIGN
SECTION-1

13. PIPELINE DESIGN CONTENTS INTRODUCTION PIPELINE DESIGN
Modes of Transportation
Benefits of Pipelines
PIPELINE DESIGN
Stages of Pipeline Project
Codes and Standards
Design
Installation, Testing & Commissioning

14. Oil and Gas Production in India
PIPELINE DESIGN
Oil and Gas Production in India
OIL MMTPA
(ONGC, OIL, CAIRN, RIL)
GAS MMSCMD
(ONGC, GAIL, OIL, GSPC, RIL)

15. Refining Scenario- India
PIPELINE DESIGN
Refining Scenario- India
Capacity
NOC – MMT
Others MMT
(MMT)
As per the Hydrocarbon Vision 2025 document released in February 2000, the demand for petroleum products in the country is expected to reach over 350 million tonnes by The subsequent short-term documents (like the X Plan document of the Government of India) have assessed the demand to grow slightly at a lower rate. As per this document, the demand is projected as 124 MMT in base case and 134 MMT in upper case for compared to 148 MMT in as in HCV However, based on the experience of the recent past, the oil industry is poised for significant growth in India.
(Actual)
Year
Source: Report of Working Group on P&NG Sector for the XI Plan 15

16. Modes of Hydrocarbon Transportation - India
PIPELINE DESIGN
Modes of Hydrocarbon Transportation - India
Pipelines 32%
Road Tankers 32%
Rail Tankers 26%
Water Carriers 10%

17. Benefits of Transportation by Pipelines
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

18. Pipelines are the most energy efficient modes of transportation
PIPELINE DESIGN
Energy Savings
Pipelines are the most energy efficient modes of transportation

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

20. PIPELINE DESIGN Products Transported Crude Oil
Petroleum Products (MS, HSD, ATF, SKO)
Water & Effluents
LPG
Natural Gas
Slurries

21. Types of Pipelines PIPELINE DESIGN
ONSHORE (LAND) & OFFSHORE (SUBMARINE) PIPELINES
Trunk Pipelines
Spur/ Branch Pipelines
Marine Offloading Terminals & Outfalls

22. Capital cost: Typical breakup
PIPELINE DESIGN
Capital cost: Typical breakup
Pipes, prime-overs and construction constitute big ticket items

23. Marine Offloading Terminal
PIPELINE DESIGN
Marine Offloading Terminal

24. PIPELINE DESIGN
Open sea Jetty

25. HBJ GAS PIPELINE NETWORK
PIPELINE DESIGN
HBJ GAS PIPELINE NETWORK
UTTAR PRADESH
DADRI
ANOLA
DELHI
RAJASTHAN
SHAHJAHANPUR
BABRALA
INDIA
GADEPAN
AURAIYA
ANTA
JAGDISHPUR
GUJARAT
BIJAIPUR
KEY PLAN
JHABUA
LEGEND
COMPRESSOR STATION
RECEIVING TERMINAL
DESPATCH STATION
ARABIAN SEA
MADHYA PRADESH
HAZIRA

26. Major Pipelines in India
PIPELINE DESIGN
Major Pipelines in India

27. Pipeline Construction Video
PIPELINE DESIGN
Pipeline Construction Video
Video for Mangalore Bangalore Pipeline

28. PIPELINE DESIGN CODES AND STANDRADS
SECTION-2
PIPELINE DESIGN CODES AND STANDRADS

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

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

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
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

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

33. LIST OF SOFTWARES USED IN PIPELINE ENGINEERING
CAESAR-II
AUTOPIPE
IPMCS
MRPACK
SORPS
PIPECALC
OFFPIPE
PRISE
PIPECROSS
PIPELINE STUDIO
TGNET
TLNET
HYSIS

34. Optimal sizes of various capacities
PIPELINE DESIGN
Optimal sizes of various capacities
Economy of scale

35. PIPELINE DESIGN Route Selection Routing Considerations Surveys
Pipeline length
Obstructions & Sensitive areas
Installation Limitations
Crossings
Surveys
Topographical
Geo-technical
Population Density Index
Soil Resistivity
Cadastral

36. Typical Pipeline Route Map
PIPELINE DESIGN
Typical Pipeline Route Map

37. PIPELINE DESIGN

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 Materials

39. PIPELINE DESIGN Design and Analysis Wall Thickness Calculations
Anti-Buoyancy Measures
Piping Stress Analysis
Buried Pipeline Analysis
Crossing Design

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
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
GAS PIPELINE
(ASME B 31.8, Cl )
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

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

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)

43. 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”)

44. Manufacturing of Helical Pipes
PIPELINE DESIGN
Manufacturing of Helical Pipes

45. 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

46. 3 Layer PE Coating Application
PIPELINE DESIGN
3 Layer PE Coating Application

47. 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

48. PIPELINE DESIGN
Scraper traps

49. 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

50. 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

51. PIPELINE DESIGN
Ball valves

52. PIPELINE DESIGN
Plug valve

53. PIPELINE DESIGN
Check valve

54. 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

55. Typical Pipeline Alignment Sheet
PIPELINE DESIGN
Typical Pipeline Alignment Sheet

56. PIPELINE DESIGN
Typical P&ID

57. PIPELINE DESIGN
Typical GA DRAWING

58. 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

59. Installation, Testing & Commissioning
PIPELINE DESIGN
Installation, Testing & Commissioning
RoU Grading & Trenching Stringing of Linepipe

60. 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.)

61. Installation, Testing & Commissioning
PIPELINE DESIGN
Installation, Testing & Commissioning
Field Joint Coating Lowering & Backfilling
Heat Shrink Sleeves
Cold applied tapes

62. 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

63. The conventional HDD operations for river crossings.
PIPELINE DESIGN
The conventional HDD operations for river crossings.

64. 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

65. Pipeline Installation using Micro-tunnelling
PIPELINE DESIGN
Pipeline Installation using Micro-tunnelling
Long Distance Micro Tunnelling

66. Overview of Micro tunneling
PIPELINE DESIGN
Overview of Micro tunneling

67. Testing & Commissioning
PIPELINE DESIGN
Testing & Commissioning
TESTING
Gauging and Pigging
Test Pressure
Test Medium
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
DRYING
Swabbing
Methanol Drying
Super Dry Air Method
Vacuum Drying
COMMISSIONING
Nitrogen Purging
Product Charging

68. PIPELINE DESIGN Pigging Requirements Types of Pigs Pipeline Cleaning
Displacement
Internal Inspection
Batching
Types of Pigs
Brush pigs
Gauge Pigs
Spheres
Intelligent Pigs
Cleaning pigs
Gauge Pigs
Spheres
Intelligent Pig (MFL)

69. 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

70. 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 15-20%
Geometry
Controlled to the desired level with cold expansion
Controlled during forming only and no cold expansion is carried out

71. PIPELINE DESIGN Coating Comparison CTE 3LPE 3LPP FBE
Service Conditions
Temperature, o C
Upto 45
Upto 65
Upto 110
Anti-corrosion Properties
Resistance to Moisture
Good
Very Good
Excellent
Cathodic Disbondment
Fair
Electrical Properties
Coating Resistance

72. PIPELINE DESIGN Coating Comparison CTE 3LPE 3LPP FBE
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

73. Cumbersome for larger repair
PIPELINE DESIGN
Coating Comparison
CTE
3LPE
3LPP
FBE
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

74. Thank You 18 4 4