Start up and Commissioning of Pipelines

Presentation by D. S. Nanaware, Chief Project Manager, IOCL, Noida IiPM, Gurgaon 10th July 2009

Contents

Methodology for Pre-commissioning of new pipelines

Objectives Task Forces Responsibility of Project/Construction Group

Responsibility of O& M Group

Responsibility of Fire & Safety Group Documentation

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Commissioning
Handing/Taking Over Case Study
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Methodology for Pre-commissioning of New Pipelines

10th July 2009

IiPM, Gurgaon

Objectives

Preparation of pre-commissioning and commissioning plan

Safe commissioning of pipeline system

Safe and smooth commissioning operation of pipeline after

Proper handing over & taking over of pipeline system Preparation of check list for all pending activities Liquidation of check list points in a time bound manner
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Task Forces
For efficient startup/commissioning specialized task-force can be formed including specialists from:

Projects/Construction Group
Operations & Maintenance Group

Fire & Safety Group

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Responsibility of Projects/Construction Group

The group will ensure:

Mechanical completion of pipeline system Hydro-testing and pigging of entire pipeline Inertization of pipeline

Ensuring readiness of pipeline system for commissioning

Handing over of pipeline system (including spares, tools, equipment etc) for operation Handing over of relevant documents and certificates to O&M group
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Responsibility of O&M Group

The O&M group will ensure:

Verification and taking over of all contract, project and operation related documents before pre commissioning activities All checks for ensuring system integrity and functionality Verification of all statutory permissions Verification of relevant inspection reports and certificates etc. Verification of venders documents for material supply
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Responsibility of O&M Representative (contd..)

Verification of agreements and MOUs with product suppliers and consumers Preparation of check list with target completion dates for all contracts works and material POs Enlisting of all construction surplus materials, and equipment with all relevant inspection, test certificates and other documents Ensure preparation of check list for balance jobs Verification and taking over the project DFR, concept note and project approvals etc
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Responsibility of Fire & Safety Representative

Verification of Fire network and equipments as per relevant OISD standards Check the adequacy of first aid fire fighting appliance as OISD Std. 117 Ensuring placement of fire fighting equipments/instruments as per OISD Std. 117

Check the compliance of safety audits, OISD audits and Pre-commissioning audits
Check the integrity of fire fighting system before start up and commissioning
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Documentation
The O&M Documentation In-charge shall take over and ensure proper distribution of documents related to: A. Statutory clearances/Permissions

Factory License as per factory act 1948 State Pollution Control Board and Ministry of Environment & Forests (MoEF) clearances State & Central Electricity Authority Permissions (wherever required)

Clearance for frequency in case of Radio set, WalkyTalky/VHF /UHF

Clearance from CCOE
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Documentation
A. Statutory clearances/Permissions (contd..)

Permissions/Agreements executed for Railways, Road (NH & SH), Canal, OFC and any other crossings

Authorization for hazardous waste rule (Management & handling - 1989) B. Revenue and RoU related documents

Detailed RoU Survey Reports with Survey Numbers Tree & Crop compensation details and documents

Land acquisition documents, ROU Cadastral Map

Field management books (FMBs) List of disputes / pending complains with detail status
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Documentation
C. Construction Related Documents

Mechanical Completion Certificate

Hydro testing acceptance certificates

Equipments Commissioning Certificate with commissioning history

Work order copies and Contracts

Construction QA/QC records, Procedures and inspection records

Radiography films and records

MOUs and agreements with product suppliers and consumers (Copies)
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Documentation
C. Construction Related Documents (contd..)

Agreements with contractors, venders, material / Equipment suppliers All taxes and duties statements SAT (Site acceptance Test) of all instruments including certificates and loop testing certificates Process Flow Diagram As-build drawings such as plot plan, cable route drawing, earthing and P&ID etc.
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Commissioning of New Pipelines

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Objective of Commissioning

Commissioning is to bring the constructed / installed system to deliver the desired function.

Pipeline commissioning means introducing crude/ product/Gas in the pipeline from originating station, filling the entire length and then start delivering to the planned receipt system. In case of crude pipeline, there may be intermediate storage stations for operational requirement but ultimate supply is to be made to a refinery In case of product pipeline/Gas pipeline, there may be several intermediate delivery stations before terminal/dispatch station.
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Pre-commissioning
Preparation of commissioning manual

A document describing the procedure to be followed for commissioning is to be prepared by experienced persons The purpose of making the document is to set forth the objectives of commissioning of pipeline system and to establish guidelines for safe commissioning in order to achieve the required goals.

Pre-commissioning check list

A check list is prepared, which covers the technical, safety as well as statutory requirement before the pipeline and associated facilities is declared ready for commissioning.
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Pre-commissioning (contd..)
Constituting a pre-commissioning team: A committee of experienced engineers is constituted to audit the construction as per pre-commissioning check list and report to the management regarding readiness of the system or any shortcomings to be complied before commissioning. Procurement of consumable/tools/pigs etc: As mentioned in the Commissioning Manual, required consumables, tools, pigs, spares and safety equipments are to be made available prior to commissioning. Availability of product/ crude: As per line fill calculation, the availability of crude oil or the product, as the case may be, is to be ensured at originating / pumping station in coordination with Refinery and Marketing.
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Commissioning

Pipeline sections are generally commissioned in phased manner / in totality based on the situation and preparedness.

After hydro-testing and caliper pigging it is expected that the sections are in a fairly clean condition.

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Commissioning action plan

Constituting a commissioning team: A committee of experienced engineers is constituted to perform the objective of commissioning. Scrutiny of audited pre-commissioning check list: The committee to ensure the compliance of any shortcomings reported in the pre-commissioning check list. Identification and deployment of manpower at new stations Deployment of security personnel at stations Arrangement of water and disposal plan
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Commissioning steps

Pressurization of pipeline section with compressed air up to 3-5 Kg/sq cm. Injection of about 500 to 1000 KL water into the section from launching barrel end Launching of cleaning (bi-di) pig after introduction of water in the line Maintaining 5-10 kg/sq.Cm back pressure at other end by venting the air

Introducing about 1000 to 3000 KL of water behind the cleaning pig

Launching batching (bi-di) pig
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Commissioning steps (contd..)

Introducing HSD / Crude in the line and maintaining 5 to 10 Kg/sq.cm back pressure at other end. Draining dirty water to storm water drain / pre-fixed drain outlet at the receiving end Receiving cleaning pig Again draining dirty water to storm water drain

Receiving batching pig

Lining up marketing HSD receipt tank /Refinery or Pipeline crude receipt tank

Flow to be diverted to HSD / Crude receipt tank as soon as oil traces are observed. Temporary facility for water draining to be dismantled & permanent blinding put
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Commissioning steps (contd..)

Since, before pumping water, line is filled with air at a predetermined pressure, so monitoring and air draining facility is kept ready at receiving end to maintain back pressure of air at 5 to 10 Kg/sq.cm
Pumping into an empty line will cause excessive flow rate & current in the motors resulting in frequent tripping. May result in increase of interface length.

As the pig reaches at receiving end, it is taken out. The muck & dirt quantity is collected and after analysis it is disposed off. Handing over the system to operating group
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Commissioning steps (contd..)

Specific check points/procedure for

Gas Pipelines LPG Pipelines ATF Pipelines

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Handing/Taking Over
HANDING / TAKING OVER FORMAT
NAME OF PROJECT LOCATION PROJECT IDENTIFICATION : ______________________ : ______________________ : ______________________

PROJECT COST
PMC CONTRACTOR DATE OF COMMISSIONING
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: ______________________
: ______________________ : ______________________ : ______________________

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Handing/Taking Over
I.
1.

DETAILS OF FACILITIES TO BE HANDED OVER

_____ INCH DIA. P/L FROM _______ TO ______ (ALONGWITH OFC) HAVING DESIGNED CAPACITY OF ______ MMT/MMSCMD AT PRESSURE _________KG/CM

2.

ORIGINAL/DISPATCH TERMINAL/ STATION AT : ______________________

3.
4. 5. 6.

RECEIVING TERMINAL AT
SV/IP STATIONS ALONG PIPELINE AT ANY OTHER FACILITIES (IF APPLICABLE) HDD (IF ANY) DETAIL
IiPM, Gurgaon

: ______________________
: ______________________ : ______________________

: _____________________
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Handing/Taking Over
II. IMPORTANT PARAMETERS AND DATES
1. MECHANICAL COMPLETION DATE OF MAIN LINE WORKS: __________ 2. PIGGING (FOAM, GAUGE, CLEANING PIG & EGP) 3. HYDRO TEST & DESIGN PRESSURE OF MAIN LINE 4. MECHANICAL COMPLETION DATE OF RECEIVING & ORIGINATING TERMINALS 5. INSTRUMENTATION COMPLETION DATE OF TERMINAL STATION 6. COMMUNICATION SYSTEM COMPLETION DATE 7. SCADA AND TELEMETRY COMMISSIONING DATE : __________ : __________ : __________ : __________ : __________ : __________

8. DATE FOR PRODUCT/GAS CHARGING IN THE SYSTEM

9. FINAL DATE OF COMMISSIONING
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: __________
: __________
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Handing/Taking Over
III. STATUS OF SYSTEMS / FACILITIES TO BE RECORDED BEFORE TAKING OVER
(A) Pipeline & CP
1. Status of ROU, CP test points and Markers 2. Checking of mainline & bypass line valves & Actuator OK/ Not OK OK / Not OK

3. Physical Status of SV/IP, receiving & Pump stations OK / Not OK 4. Performance test of SVs/IP station 5. Checking of casing shorting at crossings. Done / Not Done Done / Not Done

6. Status of Temporary CP
7. Status of captive power system with battery bank (wherever applicable) 8. if pipeline is not charged, is it dried & filled with inert gas
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Removed./ Not Rmd

Comm / Not comm.

Yes / No
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Handing/Taking Over

(B) COMMUNICATION & SCADA

1. Status of communication system
2. OFC Checking 3. Status of SCADA and telemetry system (If applicable) 4. Communication between the RTU at maintenance bases 5. Communication between the flow computers to RTU/SCADA for Master Control Centre OK/ Not OK OK/ Not OK

Comm / Not comm.

Done/Not Done Comm / Not comm.

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Handing/Taking Over
(C) INSTRUMENTATION & METERING
1. Status of metering systems (If applicable) 2. Checking of Instrumentation Panel (If Applicable) 3. Status of Chromatographs (If applicable) 4. Status of Instruments at SVs/RRs/IPs 5. Remote operation of Valves at SVs & Terminals. Yes/NO Comm/Not comm. Done / Not Done comm/Not comm. OK/NOTOK

6. Status of UPS

Comm. /Not comm.

(D) ELECTRICAL SYSTEM

1. Checking of Electrical Panel & battery backup (If Applicable) Comm/Not comm 2. Electricity at terminals/distribution stations from S.E. Board 3. Earthings system 3. Lighting 4. Lightening Protection System
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OK/NOTOK Comm/Not comm. Comm/Not comm. OK/NOTOK

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Handing/Taking Over
(E) FIRE & SAFETY
1. Status of Fire fighting Systems OK / Not OK 2. Status of fire detection system at SVs/RRs/lPs & Terminals Comm/Not comm. 3. Status of on line extinguishing system at SVs/RRs/lPs 4. Safety audit by Fire & Safety personal from O&M Comm./Not comm. Done/ Not Done

(F) GENERAL
1. Status Control Buildings Construction 2. Status of basic amenities for security guards at the permanent establishment (Security rest room, water, lighting arrangement) 3. Preparation of final checklist before taking over Done / Not Done Comp./Not Comp. Done / Not Done

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Handing/Taking Over
(G) DOCUMENTATION
1. Listing & handing over of all procedures, reports, certificates, vender manuals, drawings and related documents which are to be handed over as per Contractual obligation with the venders 2. Listing & handing over of As builds, Alignment sheet, hydro test report, Pigging report, pipeline route map, pipe book, crossing details (Hard copy & soft copy) 3. Revenue records & records for permanent land acquisition Done! Not Done 4. Certificates related to Metering system Done I Not Done Done / Not Done Done / Not Done

(H) SPARES
1. Commissioning spares 2. Two years spares
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Handed over/not handed over Handed over/not handed over

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Case Study: Commissioning of SSPL

Name of Pipeline Length Pipe Grade Capacity MAOP Line fill

: Sidhpur- Sanganer Pipeline : 517 km

Pipe Size & Thickness: 18 OD x 0.250 WT

: API 5L-X65 : 3.4 MMTPA (5.7 Max) : 92 Kg/cm2 : 79840 Kl
: 28500 Kl : 30500 Kl : 20840 Kl
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Sidhpur - Kot Kot - Baghsuri Baghsuri - Sanganer

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Thank You

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