Oil pipeline 42 inch by 455 km

Baku - Tbilisi - Ceyhan (BTC) Oil Pipeline

The Azerbaijan Section of the Project’s Oil Pipeline including valve and pig trap stations, laying of Fiber Optic cable and tie-ins at pumping stations. Much of the terrain is flat and semi-arid.

The Pipeline links the Caspian sea oil wells with the Mediterranean Sea ship tankers port.

The capacity is1 million barrels of crude oil flow per day

Oil Pipeline 42” by 450km.

Photographic Record of Construction

19th June David H Moloney

Construction of Azerbaijan Oil Pipeline 42” by 450km. Client BTC,

Contents

Overview Surveying & Setting OutClearing & GradingDouble Jointing i.e. welding 2 pipes togetherStringing out PipesBend Pipes for changes in direction sideways and up & downWelding Pipes into a string, Test Weld by X Ray.Anti-corrosion Coat to JointsTrenching i.e. excavate trenchLowering pipe string into trenchBackfilling TrenchReinstatement of Pipeline ROW (Right-of-Way)Reinstatement of River BanksCrossing - Horizontal Directional DrillingCrossing - Thrust BoringCrossing - River Hydrotest & PiggingTie-in i.e. connect to existing pipelineMiscellaneous

Pause Slides to Read


Overview Construction Sequence

A typical sequence of activities is- surveying and setting out, preparing the land, stringing out the pipes along the route, excavating the trench, welding and laying the pipes, backfilling the trench with the excavated soil, and reinstating the land to its original condition..

Crossing Railway, Roads, Rivers, etc.Pump Station

Overview Pipeline Construction Animation

To see animations, view YouTube film.

Overview Pipeline Crossings Construction Animation


Surveying & Setting Out


Surveying & Setting Out

FCI-ROW Set Out


Clearing & Grading ROW (Right of Way)


Clearing & Grading

Foreign Service Detection

Concrete Slabs Installed For

Foreign Services Protection


Clearing & Grading


Double Jointing Facility

Welding 2 nr 12m long pipes together prior to stringing out.Located at Pipe Storage areas.


Double Jointing Facility

Outline Process

1. Single piles 12m long are delivered and stacked.2. At the Bevelling Station. The ends of the pipes are

bevelled. Two pipes are aligned using an internal clamp, the joint is preheated and the root pass weld is done.

3. At the Hot Pass Station. The fill and cap passes will be carried out using Submerged Arc Welding (SAW)

4. The joints will be x-rayed 5. The double pipes 24m long are stored ready for

transportation to the site6. Purpose made dollies will transport the pipes


Double Jointing i.e. welding two pipes together

66

Phase 7: Rolling Pipe


Stringing out Pipes


Stringing out Pipes

Final Product


Bending Pipes


Bending Pipes

Toolbox Talk

Pipe Will Be Lifted Using Choker

Belts

Choker Belts Placed On

Pipe

Preparation For Lifting

Pipe

Loading Pipe On Bending

Machine

The Bending Machine Uses A

Series Of Clamps And Hydraulic

Pressure To Make A Very

Smooth, Controlled Bend

Bending Start


Bending Pipes

Bending

Clamps Pulled Through The Pipe

Maximum Bend angle Is 1.3

Degrees Per Meter

Completed Bends


Welding


Welding

Beveling

Fit-Up


Welding


X Ray Pipeline Crawler for testing joint welds

Construction of Azerbaijan Oil Pipeline 42” by 450km. Client BTC

Joint Field Coating for Anti-corrosion


Joint Field Coating

1. Toolbox Talk

Preparation For Grit Blasting

Wearing Special Coverall


Joint Field Coating


Trenching i.e. excavate trench.


Trenching


Lowering Pipe string into Trench



Lifting Belts Supported by Side-Booms Will Be

Utilized For Pipe Handling And Not Placed Over Any

Field Joint Area


Backfilling


Reinstatement ROW Right-of-Way


Reinstatement ROW

Spreading Topsoil


Reinstatement ROW


Reinstatement ROW

Final Product


Reinstatement River Bank



Matting



Grass Is Growing On River Banks

Final Product


Pipeline Crossing by Horizontal Directional Drilling



Rig Anchoring System; During The

Drilling Works, The Rig Will HaveTo

Be Secured To Stop It From Moving


Pipeline Crossing by Thrust Boring


Pipeline Crossing - River Crossing



Sediment Control



Lowering In


Hydrotest, Pigging (clean out pipeline) & Dry Pipeline


Hydrotest

Block Valve Pre-Testing

Trains Of Brush Pigs With Slugs Of Flushing

Water Are Used For Cleaning The Pipeline Pigs Are Loaded Into Temporary Pig Launchers


Hydrotest

Pigs Are Received Into Temporary Pig

ReceiverPigs Are Launched With Compressed Air

The Final Pig Is Fitted With An Aluminium

Gauging Plate 95 % Of The Internal Diameter To

Check For Geometrical Defects

Pigs Are Back Loaded Into Test Headers

For Filling And Dewatering Test

Sections

Test Headers Are Then Welded To The

Ends Of Test Section

Water Used For Hydrostatic Testing Is

Filtered To 50 Microns

Water Is Then Passed Through Vented

Break Tanks And Flow Meters


Hydrotest

Pressurising Pumps And Instrument Control

Container

Filling Spread Showing Fill Pumps,

Chemical Dump And Break Tanks

Pressurising injection Manifold Incorporating

High Pressure Flow Meter

After Hydrotest The Test Section Is

Dewatered And Water Transferred Into The

Next Section

The Dewatered Section Is Then Dried

To -10degC Dewpoing Using

Compressed Air Passed Through

Drying Units


Tie-in i.e. connecting to existing pipeline

Welded Joint on the Azerbaijan and Georgia Border


Tie-in


Tie-in

Preparation For Tie-In

Tie-In: Manually Welding Joints In

Trench Between Two Sections

Final Product

Tie-In


MiscellaneousContents

Time Chainage DiagramPipe Spool FabricationTank ConstructionPiperackCrane Heavy LiftSlug CatcherRoad constructionReinforced Concrete WallCrossing under Existing UtilitiesTrench ExcavationLoad & HaulRock excavationQuarry & aggregate ProductionConcrete Batching PlantTemporary Sheet Pile shaftCable LayingFencingBuildings


Time Chainage Diagram The chart has two axis: one for time and the other for location

A legend explains meaning of the colours, symbols and line types

Sample Only


Histograms for Resources & Outputs

Progress Monitoring & Reporting - Dashboard

ⓒ David H Moloney

Brief Description

Dashboard is a single page, graphical representation of current progress and historical trends

Temporary Contractors Site Facilities

ⓒ David H Moloney

Brief Description

Site Offices, Camp Accommodation for 1,250 workers, Canteen, Recreation, Fabrication shops, Stores, Plant Yard. In five locations along the route.

Temporary Contractors Site Facilities - Stores

Brief Description

Pipes ⓒ David H Moloney

Brief Description

Pipes were manufactured in Japan, coated

with a plastic covering in Malaysia, and

shipped to the Georgian ports of Poti.

Transported by Train and trucks across land.

Japan

Georgia

Pipe Spool Fabrication Animation

Post Weld Heat Treatment

Non Destructive Testing

Cut

Bevel

Fit-up

Weld

NDT

PWHT

Blasting

Painting

Pipe Spool Fabrication StepsP

ipe

wo

rk

Tank Construction

Piperack Construction Animation

The Pipe Racks carry pipes and cables between the different processes..

Cranes Heavy Lift Animation

Lift column from the horizontal and

rotate into the vertical

Slug Catcher Construction Sequence Animation

Separates the Gas from the Oil & WaterAlso to dissipate any pressure surges

Road Construction Sequence Animation

Reinforced Concrete Wall Construction Sequence Animation

Crossing Under Buried Utilities & Overhead Power Cables Animation

Trench Excavation with Stepped Faces

Trench Excavation with Battered Faces

Excavate & Load, Cart, Tip & Return

Brief Description

Cycle Time for 7km haulage distance using an Excavator 45 tonne weight and Dumper with a 40 tonne capacity, the cycle time is 34 minutes

Ea

rth

wo

rks

7 minutes

14 minutes

3 minutes

14 minutes 7 km

7 km

Rock - Excavability

Brief Description

The excavability of rock depends

mainly on the rock strength and the

layer thickness. This diagram shows

excavation methods for rock of

various strengths and thicknesses,

with a free face.

ⓒ David H Moloney

Ea

rth

wo

rks

Concrete Batching Plant David H Moloney

ⓒ David H Moloney

Brief Description

.

The mixing is computer controlled

and has a dynamic screen display,

showing the process. The material

storage capacity is, to match two

days concrete production.

Co

ncre

te

Temporary Sheet-pile Shaft

Cable laying 132KVa Electric


ENDMy YouTube Channel link: https://www.youtube.com/channel/UCeJR9J7svhBd-C0ZoAH2fhQ

https://www.youtube.com/channel/UCeJR9J7svhBd-C0ZoAH2fhQ

Oil pipeline 42 inch by 455 km

Engineering

Transcript of Oil pipeline 42 inch by 455 km