PIPELINE ACTIVITIES

BY
V.BHANU CHANDER V.BHANU CHANDER
TIRUPATI,
INDIA
Pi li Pi li Pipe line : Pipe line :
Transportation Transportation of of liquids liquids and and gases gases from from one one
place placeto toanother another place place place placeto toanother another place place..
Survey
Pipe line activity :
Unloading & stocking of pipes at site
Marking
Trench excavation
Blasting
contd
Sand bedding
Pi l i Pipe lowering
Laying, joining
Back filling
Sand encasing
S i l fi i Specials fixing
contd
Pedestals, thrust blocks & valve chambers
Hydro testing
i i i Commissioning
Final measurement
Reconciliation
TYPE OF PIPES
Mild steel (MS)
Glassreinforcement plastic(GRP) Glass reinforcement plastic (GRP)
Ductile iron (DI) ( )
Cast iron (CI)
High density poly ethylene (HDPE)
Poly vinyl chloride (PVC)
Contd Contd
Pre stressed concrete (PSC)
Reinforcement cement concrete (RCC)
Asbestoscement pressure(AC) Asbestos cement pressure (AC)
Bar wrapped steel cylinder (BWSC) pp y ( )
Galvanized iron (GI)
Low alloy pipe (LA)
PVC pipe MS pipe GI pipe
GRP pipe BWSC pipe CI pipe GRP pipe BWSC pipe CI pipe
HDPE i RCC i DI i HDPE pipe RCC pipe DI pipe
LA pipe PSC pipe AC pipe LA pipe PSC pipe AC pipe
TRENCH EXCAVATION
Obtain work permit before starting excavation work.
Marking is to be made
Excavate trench up to required level with free working
Thesideslopesof cuttingshall generallyhavethe following The side slopes of cutting shall generally have the following
slopes for stability.
slope for excavation in slope for excavation in
1:1 clay, muram & boulders etc
1:2 hard muram
NOTE: Slope not required for soft & hard rock
TRANSPORTATION TRANSPORTATION
OF
MATERIAL TO SITE
Pipes shall be transported to the site of laying and stacked
alongtheroute along the route
Padding shall beplacedbetweencoatedpipesandtimber to Padding shall be placed between coated pipes and timber to
avoid damage to the coating
Suitable gap during pipe stacking should be left at proper
intervals to permit access from one side to the other
Unloading & stocking of material : Unloading & stocking of material :
Each pipe & special should be properly stacked at
siteinsuchamanner soasnot todistort their circularity or site in such a manner so as not to distort their circularity or
cause any damage to their outer coating.
PIPE HANDLING
manual pipe handling :
B f h dli th i Before handling the pipe,
work men should wear
helmet andgloves helmet and gloves
1. Ropes used to lift the material must be in good condition, p g ,
and it should not be let over sharp edges
2. Ensure that the persons are moved away from the pit while
placing the pipe (if it is heavy)
3. while handling materials in the wet season, ensure that the
materials are free from slush as it may cause slipping.
Pipe handling by machinery
Slings should be in good condition and free from defects,
Ensure proper clamping of slings, these are provided on
same direction on free length g
Ensure proper visibility for the crane. p p y
C.I & D.I PIPES
LOWERING, LAYING &JOINING
Pipes should be lowered slowly in to the trench by means of
chain pulley block and tripod stand or cranes or with the p y p
help of ropes.
Rubber gaskets shall be inserted into the groove in the Rubber gaskets shall be inserted into the groove in the
socket. Spigot end shall be lubricated with good quality of
greaseor oil, then thespigot shall beslipped into socket by
meansof jackontheother end meansof jackontheother end.
Spigot ends of all pipes shall face up stream irrespective of pg pp p p
the direction of water flow.
GRP PIPES GRP PIPES
LOWERING, LAYING
AND
JOINING JOINING
Lowering and laying :
Pi h ll b l idi d diti d d i t Pipeshall belaidindry conditionandunder nocircumstances
they shall rest onsludgy bedding. Pipesshall rest continuously
onthebottomof thetrench.
Clearance of approximately 100mm in depth and width equal
l h f h ll l 30 b h id h ll b to length of the collar plus 30mm on both sides shall be
providedat thejoint whichshall berefilledfromsidesafter the
joint ismade. j
Thepipeshouldbeloweredinto thetrenches either by pulley
or by means of two ropes. For roadcrossingor river crossing
the pipe shall laid 2.0mtr. Below the bed level. The pipe
shouldbeencasedwith300mm thick sand.
Joining :
1. Spigot andsocket andsocket joint withdoublewater tight
bb i k t ki rubber ringgasket packing
2. Double socket coupling joint with water tight rubber ring p gj g g
gasket packing
3. Flanged joint is used for connecting the valves, the flanged
joint is made from the same materials as the pipe
4. End pipes should not kept open, the ends shall be covered up
either by suitable cap or plug or double layer of gunny bags.
GRP joint with Spigot & socket end
M.S PIPES
LOWERING, LAYING, JOINING &
PAINTING PAINTING
Before Laying, M.S pipes should be coated with cement or
Painting Painting
1. surface cleaning :
The pipe should be cleaned before painting with special
epoxy thinner. This avoids oil, Greece marks on the pipe.
Duetothesemarks thepaint wasn't sticking. Insidedust can
beremovedbyusingcompressedair beremovedbyusingcompressedair.
2. primary coating
After surfacecleaning, first primer coating isnecessary. For
this purpose zinc phosphate primer is combined with
activator in6:1ratio. Zinc phosphateprimer is component a
& i i b & activator iscomponent b, so
primer = component a + component
3. Out side coating :
After primary coating, out side of pipe painted with
l hi h i bi d i h i i 41 epoxy coal tar which is combined with activator in 4:1
ratio.
4. Inside
:
d d d f i id i i i Food grade epoxy used for inside painting resists
corrosion, this is thecombinationof resin & cure in1:1
ratio.
Lowering, laying and joining of MS pipes: Lowering, laying and joining of MS pipes:
Before welding the pipe faces shall be cleaned by scraping Before welding the pipe faces shall be cleaned by scraping
by wire brushes by wire brushes
MSpipeprovidedwithcement mortar / apoxypainting MSpipeprovidedwithcement mortar / apoxypainting MS pipe provided with cement mortar / apoxy painting MS pipe provided with cement mortar / apoxy painting
in lining and coating in lining and coating
Th d f MS i h ll h b l d d f ldi Th d f MS i h ll h b l d d f ldi The ends of MS pipes shall have beveled ends for welding The ends of MS pipes shall have beveled ends for welding
Whileassembling thepipesshall beclosetouniformgap Whileassembling thepipesshall beclosetouniformgap While assembling, the pipes shall be close to uniform gap. While assembling, the pipes shall be close to uniform gap.
(Gap depends up on thickness) electrodes shall be conform (Gap depends up on thickness) electrodes shall be conform
to is 814 to is 814--1991 i.e, e 1991 i.e, e--6013 6013
MS MSpipes pipesare aremanufactured manufacturedeither either by byelectro electroresistance resistance
welding weldingor or submerged submergedarc arcwelding weldingprocess processlongitudinally longitudinallyor or gg gg ggpp g y g y
spirally spirallywelded welded
Manual metal arcweldingwithcoveredelectrodes Manual metal arcweldingwithcoveredelectrodes Manual metal arc welding with covered electrodes. Manual metal arc welding with covered electrodes.
What is metal arc welding :
In metal arc welding a metal rod is used as one
electrode during the welding operation this metal electrode is
meltedbytheheat of thearcandisfusedwiththebasemetal.
Welding defects :
1. Lack of penetration,
2. Slag inclusion,
3. Under cut,
4 P f i 4. Poor fusion,
5. Porosity,
6 Weldcrack 6. Weld crack,
7. Spatter,
8. Wrapping & distortion. pp g
HDPE PIPE
LAYING & JOINING
Fusion Fusion welding welding is is commonly commonly used used in in HDPE HDPE and and is is a a
permanent permanent type typeof of joint joint
The Thepipes pipesshall shall be bebrushed brushedthrough throughout out to toremove remove any anysoil soil
deposited depositedor or stone stonetheir their in in
Pipes Pipes shall shall be be laid laid in in dry dry condition condition and and under under no no
circumstances circumstancesthey theyshall shall rest rest on onslushy slushybedding bedding yy yy gg
Clearance Clearance of of required required depth depth & & width width on on both both sides sides shall shall
be be provided provided at at the the joint joint which which shall shall be be refilled refilled from fromsides sides be be provided, provided, at at the the joint joint which which shall shall be be refilled refilled from fromsides sides
after after the thejoint joint is ismade made
For For road road crossing crossing or or river river crossing crossing the the pipe pipe shall shall be be laid laid 2 2
meter meter below belowthe thebed bedlevel level and andencasing encasingshould shouldbe bedone done meter meter below belowthe thebed bedlevel level and andencasing encasingshould shouldbe bedone done
Pipe Pipeafter after transporting transportingto to the theexact exact place placeshould shouldbe becut cut square square
by bythe thehacksaw hacksawblade blade
TThe he face face of of the the pipe pipe should should be be slightly slightly scrapped scrapped prior prior to to the the pp pp g y g y pp pp pp
fusion fusionwelding weldingto toremove removeoxidized oxidizedlayer layer
Ensure Ensurethe theleveling levelingof of pipes pipesis ismaintained maintainedat at the thetime timeof of fusion fusion Ensure Ensurethe theleveling levelingof of pipes pipesis ismaintained maintainedat at the thetime timeof of fusion fusion
welding welding
The Theheating heating mirror mirror / / pan pan should should be beheated heated up up to to 200 200 deg deg.. cc
and andthe thesurface surfaceof of the thepan panshould shouldbe be210 210++or or 55deg deg.. CC
The Theheating heatingpan panshould shouldbe bemetallic metallic plate platewhich whichis is heated heatedup up
to to the the required required temperature temperature either either by by electrical electrical coil coil embedded embedded to to the the required required temperature temperature either either by by electrical electrical coil coil embedded embedded
inside insideor or by byblow blowtorch torch
The The fusion fusion welding welding of of pipe pipe should should be be held held in in either either side side of of The The fusion fusion welding welding of of pipe pipe should should be be held held in in either either side side of of
the theheating heatingmirror mirror / / pan panwith withTeflon Teflonpaper paper on oneach eachside side
The Thecontact contact pressure pressureof of 00..22kg/cm kg/cm2 2in ineither either side sideif if the thepipe pipe
should shouldbe bemaintained maintained
Initial Initial heating heatingtime timefor for achieving achievingthe themolten moltenrim, rim, varies varies from from
11 to to 5 5 min min depending dependingon onthe thepipe pipewall wall thick thick&& size size..
Pipes Pipesshould shouldbe beremoved removedfrom fromthe theheating heatingmirror mirror // pan, pan, when when Pipes Pipesshould shouldbe beremoved removedfrom fromthe theheating heatingmirror mirror // pan, pan, when when
the therim rimof of the themolten molten material material is is formed formed and and ensure ensurethat that the therim rim
formation formationis isnot not excessive excessive..
Immediate Immediate joint joint should should be be made made by by the the application application of of
moderate moderatepressure pressureof of approx approx.. 11 to to 2 2 kg/cm kg/cm2 2 for for 22 to to 3 3 sec sec..
while while joining, joining, the the pressure pressure should should be be maintained maintained until until the the
joint joint is isluke lukewarm warm.. joint joint is isluke lukewarm warm..
After After the the pressure pressure is is relieved, relieved, the the joint joint should should be be allowed allowed to to
cool cool completely completely cool cool completely completely
Back Filling : Back Filling : Back Filling : Back Filling :
Back Back fill fill with with excavated excavated soil soil should should be be free free from from
i d i d hh ll ff bbi h bbi h t bl t bl ii cinders, cinders, ashes, ashes, slag, slag, refuse, refuse, rubbish, rubbish, vegetable vegetable or or organic organic
metal, metal, lumpy lumpy or or frozen frozen metal, metal, boulders boulders rocks, rocks, other other materials materials
which whichin inthe theopinion opinionof of any anyauthority, authority, is isdeleterious deleterious..
Concrete slabs over pipes : Concrete slabs over pipes :
when when pipes pipes are are laid laid below below roads roads (which (which may may be be
subjected subjected to to heavy heavy traffic traffic loads), loads), trenches trenches should should be be covered covered
ith ith i f d i f d tt l b l b with withreinforced reinforced concrete concrete slabs slabs
GRP Lamination Details
Materials used in the process: Materials used in the process:
1. Grinding wheels, (machine)
2. Surface,
3. Robin,
4. Matt, ,
5. Resin,
6. Hardener,
7 Aerosol powder 7. Aerosol powder,
L i ti P Lamination Process :
1. First, grind the damaged portion with grinding wheel. , g g p g g
2. After that , mix the aerosol powder with hardener, this
mixture has tobeput ondamagedportion hardener is mixture has to be put on damaged portion, hardener is
used to set quickly that joint.
3. Surface is very soft material, this has to put on that portion
& paste with resin which is used for sticking & hardening.
4. Matt & robin are the strength of that lamination
process
these both used one by one on damaged portion.
5. The robin & matt used up to 7 times
6. Resin pour on robin & matt
Hydro Testing:
1. After Completionof eachsectionof pipeline, it shall be
testedfor water tightness beforebeingcoveredin testedfor water tightness beforebeingcoveredin.
2. Thiscanbedonebyclosingeachendbymeansof
valve, blankflange, capor plugandfillingthepipewith
water.
3. The pressure shall be raised gradually by means of a hydro
testing pump till the pressure is at least one and half times
th ki the working pressure.
4. A pressure to be specified by the authority for a duration of
one hour.
NOTE : In the test pressure drops after one hour
THANK U.....