Escolar Documentos
Profissional Documentos
Cultura Documentos
OF
CROSS COUNTRY
PIPELINES
TYPES OF PIPELINE
- OFFSHORE SUBMARINE PIPELINE: LAID ON SEA-BED
- ONSHORE CROSS COUNTRY PIPELINE: LAID 1MTR UNDERGROUND
RT- BINA
IP2-SANDAVATA
IPS2- BEWARI
IP1 -SIDHASAR
I. CONSTRUCTION METHODOLOGY
I. CONSTRUCTION METHODOLOGY
LAYING OF PIPELINE
Following are the relevant EIL Specification & Standards for Coating & Laying of Pipeline:
1. 6-71-0001 : Standard specification for Line pipes, Valves, Fittings,
to 6-71-0040 Scrapper Launcher / Receiver, Pig signaller etc.
2. 6-71-0041 : Standard specification for 3LPE Coating
3. 6-71-0042 : Standard specification for CTE Coating Onshore Pipeline.
4. 6-71-0044 : Standard specification for Field Jt. Coating Onshore Pipeline.
5. 6-71-0046 : Standard specification for Conc. Coating Onshore Pipeline.
6. 6-71-0051 : Standard specification for Pipeline Construction (Onshore)
7. 6-71-0052 : Standard specification for Pipeline Construction, Road, Rail,
Minor Water Crossings
8. 6-71-0053 : Standard specification for Major Water Crossings (Conventional)
9. 6-71-0054 : Standard specification for Pipeline River Crossings by HDD
10. 6-71-0055 : Standard specification for Hydro-testing of Onshore Pipelines
11. 6-71-0057 : Standard specification for Pipeline Markers
12. 6-82-1901 : Standard Inspection & Test Plans (ITP’s) for Pipeline Activities
to 6-82-1925
COATING PROCESS:
1) BARE PIPES VISUAL INSPECTION 2) SHOTBLASTING AND VISUAL INSPECTION
- PIPE NO., HEAT NO., LENGTH, DIA, THK ETC. - ROUGHNESS CHECK ON BODY
- BEVEL & BODY DAMAGES E.G. DENTS, GOUGES ETC. - BODY DENTS & GOUGES
COATING PROCESS:
3) PRE-HEATING OF PIPES & PRIMER / EPOXY APPLICATION (PIPES TO BE PREHEATED TO 200 0 C BY
INDUCTION COIL/ GAS OVEN)
- CHECK FOR PIPE TEMP BY DIGITAL TEMPERATURE GUAGE & UNIFORM SPRAY
SPRAY OF EPOXY ON PIPE
COATING PROCESS:
4) COATING APPLICATION
- CHECK TEMP OF EXTRUDERS, PE FILM, ADHESIVE FILM, COAL TAR ENAMEL
ENAMEL ETC.
COATING PROCESS:
5) COOLING OF COATED PIPES IN COOLING TUNNEL & VISUAL INSPECTION OF COATED PIPES
- CHECK COOLING WATER TEMP, VISUAL DAMAGE TO COATING, COATING THK. ETC.
COATED PIPE COOLING TUNNEL 3LPE COATING THICKNESS CHECK CTE COATING THICKNESS CHECK
COATING PROCESS:
6) HOLIDAY TESTING, REPAIR OF COATING & TESTING
- CHECK FOR HOLIDAY AT 25KV FOR 3LPE COATING & 15KV FOR CTE COATING
COATING
- MARK PIPES FOR TESTING E.G. PEEL TEST, AP TEST, IMPACT TEST ETC.
ETC. & COATING REPAIR
COATING PROCESS:
7) EXTERNAL PAINTING (IF REQD) AND STACKING IN YARD
- THK OF PAINT, MARKING ON COATING PIPES, COATING ACCEPTANCE NO., ROW HEIGHT ETC.
ROU SURVEY
ROU CLEARING AND GRADING
STRINGING
TRENCHING
BENDING
WELDING
FIELD JOINT COATING
LOWERING
BACKFILLING
CROSSING
TIE-INS
HYDROTESTING
PIPELINE MARKERS, CLEAN UP & RESTORATION
STATION WORKS
MAGNETIC PIGGING & EGP – PRE COMMISSIONING ACTIVITY
The cut-back areas of Coated Pipes where weld joints are made are to be Coated by Field
Joint Coating.
Field joint coating material is heat shrinkable wraparound sleeve used as anticorrosion
coating of buried onshore pipeline.
Sleeve consist of radiation cross-linked, thermally stabilized, ultraviolet resistant semi-
rigid polyolefin backing with a uniform thickness of high shear strength thermoplastic/co-
melt adhesive
The joint coating system shall consist of a solvent free epoxy primer applied to the pipe
surface prior to sleeve application. The surface area is blast cleaned to SA-2.5 followed by
Pre-heating of pipe surface, application of epoxy primer and application of sleeve by heat
shrinking.
Each sleeve joint is inspected by means of a full circle holiday detector set to DC voltage
at 25 KV (Pipe surface temperature below 50 degree Celsius) and thickness of sleeve
checked.
One out of 50 joints coating or one coating out of every day production shall be tested to
establish peel strength on steel and factory applied coating.
Lowering shall commence after inspection of trench. Trench bottom shall be free from
pipe supports, stones, roots, debris, stakes, and rigid material. Padding shall be provided
in rocky/ murram area.
Lowering shall commence as soon as possible after completion of joint coating, Before
lowering in, complete check by a full circle holiday detector for pipe coating and field joint
coating at 15 KV is carried out (Speed 300mm /sec). Any damage shall be repaired.
Support/ skid points shall be thoroughly checked.
The pipeline must be laid without interruption for the whole or the length of section
available
Ends of the lowered pipeline section shall be closed with night cap to prevent ingress of
water, mud etc.
TIE-IN IN PROGRESS
Hydrostatic test commence only after completion of all welding works so as to avoid/
minimize untested hydro-test joints/ Golden joints.
Hydro test includes all those sections which are tested earlier for Road, rail road crossings,
major water crossings etc.
Duration of hydrostatic test is minimum 24 hours after thermal stabilization. Hydro-static test
pressure for pipeline handling hydrocarbon in gaseous phase is 1.25 times the design
pressure in pipeline located in Class-1 & 2 locations and 1.4 times the design pressure if
pipeline located in Class-3 & 4 locations.
Before water filling, pipeline shall be cleaned with air driven pigs with spring loaded brushes
and chiseled to remove all mill scale, rust, sand etc. from the internal pipe section.
After successful cleaning and acceptance, gauging is carried out using gauging pig.
After water filling operation, thermal equilibrium between pipeline and environment shall be
checked with thermocouples installed on the pipeline.
After thermal stabilization pressurization is carried out in cycles of 50% test pressure & 75%
test pressure and held for 1 hour at each test pressure and depressurized to zero pressure and
then pressurized to final test pressure. During each test pressure, two test shall be carried out
for calculation of air volume in the pipeline under test and on acceptance of air volume test the
section is held for 24 hours at Final test pressure and pressure and temperature recorded on
chart.
The hydrostatic test shall be considered positive if pressure has kept a constant value
throughout the test duration, except for change due to temperature effects. The pressure value
thus added shall be compared with initial value and the test shall be considered as acceptable
if the difference is less than or equal to 0.3 bar.
After positive test results, test shall be terminated . The pipeline shall be depressurized at
constant rate. Dewatering shall be carried out by using four cup pigs driven by compressed air.
Foam pigs shall be passed to complete the dewatering.
CONSTRUCTION OF CROSS COUNTRY PIPELINES
Engineers India Ltd – Delivering excellence through people
Slide Number - ___of 50
CROSS COUNTRY PIPELINE WORKS
PIPELINE ACTIVITIES Contd.:
PIPELINE MARKERS, CLEAN-UP AND RESTORATION
Following type of markers shall be fabricated and installed along the pipeline route such
that they do not cause any hindrance to the regular land user or traffic
− Aerial Markers : At every 5 Kms.
− Kilometer Markers : At every 1 Km. & as per Alignment sheet
− Pipeline Warning Markers : At Road / Railway / River Crossings & Stations / Terminals
− ROU Boundary Markers : At every 750 Mtrs. & as per Alignment sheet
− Direction Markers : At significant turning points
− Navigational Markers : At bank of Navigational Course
− OFC Markers : At OFC Joints
ROU and all sites used for construction of pipeline , water crossing and other structures
shall be restored as per satisfaction of authority having jurisdiction over it.
Damages to roads, bridges, fences etc. damaged during construction shall be restored to
original.
The bed of water course shall be restore to the original level. The banks and any
excavated area shall be restored to original levels . The banks shall also be stabilized.
On completion of clean-up, the ROU shall be restored to such stable and usable condition
as may be reasonably consistent with the condition of the ROU prior to laying the
pipeline. The release note from the land owner s regarding satisfactory indemnification
and restoration of land shall be obtained from land owner.
Intermediate Pigging (IP) stations are installed at regular intervals (as per design ~ 150
Kms.) having a Pig Launcher and a Pig Receiver with Control room, Sump tank, Basket
Filters, guard room, boundary wall etc. to facilitate pigging of pipeline during routine
Operation and Maintenance.
Dispatch Terminal (DT), Pump Station (PS) & Receipt Terminals are provided at start,
intermediate & end locations of the Pipeline to facilitate handling and pumping of the
product through the pipeline. It comprises of Pig Launcher / Pig Receiver with Control
room, Mainline & Booster Pumps (DT/PS), Sump tank, Basket Filters, guard room, Firewater
system, boundary wall etc.
Magnetic PIG loaded with high capacity magnets spread uniformly with high density
polythene four cup PIG is launched to remove ferrous debris, mill scale, electrode pieces
etc. The accumulated weight of this ferrous debris is checked after running the PIG through
pipeline section. When the collected weight of ferrous debris is within limit for specific
length of pipeline section, the line is ready for launching EGP tool.
After successful completion of magnetic pig run EGP tool is launched. This tool is mounted
with battery operated battery device, which gives the reduction in pipeline Dia. at specific
location in electronic form.
Any defect /deformity more than 3% of internal diameter of pipe (dent or ovality) is
physically verified at site. Defect of more than 5% internal diameter of pipe are repaired by
cutting the suitable length of pipe and re-welding and accepted after radiography.