Pipeline Design and Recent...
Transcript of Pipeline Design and Recent...
PIPELINE DESIGN
Delivering excellence through people
Pipeline Design
Slide Number - 1 of 77
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ENGINEERSENGINEERS
INDIA LIMITEDINDIA LIMITED
EPC and Total Solutions EPC and Total Solutions
Consultancy OrganizationConsultancy Organization
Pipeline Design
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Petroleum Refineries
PetrochemicalsPetrochemicals
Pipelines
Offshore Platforms
Gas Processing
Metallurgy
Pipeline Design
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Metallurgy
Ports & Terminals
Highways and Airports
HEAD OFFICE NEW DELHI
REGIONAL OFFICES VADODARA, CHENNAI
EIL OFFICESEIL OFFICES
REGIONAL OFFICES VADODARA, CHENNAI
KOLKATA
PROCUREMENT OFFICES MUMBAI
SITE OFFICES 29 LOCATIONS (INDIA)
9 LOCATIONS (OVERSEAS)
INSPECTION OFFICE 10 LOCATIONS
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OVERSEAS OFFICES LONDON, LIBYA ABU DHABI,
ITALY, SAUDI ARABIA , QATAR,
KUWAIT
PIPELINE DESIGNPIPELINE DESIGN
SERVICES OFFERED BY EILProject Implementation Services
� Feasibility Studies
� Project Management
Specialist Services
� Heat & Mass Transfer Equipment
Design� Project Management
� Planning & Scheduling
� Process Design
� Detailed Engineering
� Procurement Services
� Construction Management
Design
� Environment Engineering
� Information Technology Services
� Specialist Materials and
Maintenance Services
� Plant Operation & Safety
Pipeline Design
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� Commissioning and Plant
Start-up Assistance
� Risk Analysis
� Advanced Control & Optimization
PIPELINE DESIGNPIPELINE DESIGN
EIL EXPERIENCE
1975 First major project
Crude Oil Loop Line for Oil India Ltd.
1979 First major overseas project
150 km Multi Product Pipeline
for Abu Dhabi National Oil Company
1984 First major high pressure Gas Pipeline
Project - 1800 km Gas Transmission Network
Pipeline Design
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for GAIL
Over 40 major pipeline projects completed.
PIPELINE DESIGNPIPELINE DESIGN
DESCRIPTIONDESCRIPTION CLIENTCLIENT YEARYEAR SIZESIZE LENGTH LENGTH
(KM)(KM)
SERVICESSERVICES
HAZIRAHAZIRA--BIJAIPURBIJAIPUR--
JAGDISHPUR (HBJ)JAGDISHPUR (HBJ)
GAILGAIL 19891989 36“/30”/24”/18”36“/30”/24”/18” 18001800 NATURAL GASNATURAL GAS
Major Onshore Projects (Completed)
JAGDISHPUR (HBJ)JAGDISHPUR (HBJ)
MAQTAMAQTA--ALAL--AIN PIPELINEAIN PIPELINE ADNOCADNOC 19921992 30 ”/12”30 ”/12” 166166 NATURAL GASNATURAL GAS
KANDLAKANDLA--BHATINDABHATINDA IOCLIOCL 19961996 22”/14”/10”22”/14”/10” 14431443 MULTIPRODUCTMULTIPRODUCT
GAS REHABILITATION & GAS REHABILITATION &
EXPANSION PROJECT EXPANSION PROJECT
(GREP)(GREP)
GAILGAIL 19981998 36 ”36 ” 505505 NATURAL GASNATURAL GAS
MUMBAI MUMBAI –– MANMADMANMAD BPCLBPCL 19981998 18 ”18 ” 260260 MULTIPRODUCTMULTIPRODUCT
VIZAGVIZAG--VIJAYWADAVIJAYWADA HPCLHPCL 19981998 18 ”18 ” 360360 MULTIPRODUCTMULTIPRODUCT
Pipeline Design
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VIZAGVIZAG--VIJAYWADAVIJAYWADA HPCLHPCL 19981998 18 ”18 ” 360360 MULTIPRODUCTMULTIPRODUCT
JAMNAGARJAMNAGAR--LONI LPG LONI LPG
PIPELINEPIPELINE
GAILGAIL 20012001 16”/14”/12”/8”/16”/14”/12”/8”/
66
12351235 LPG (LIQUIFIED LPG (LIQUIFIED
PETROLIUM GAS)PETROLIUM GAS)
COCHIN COCHIN –– KARUR PIPELINEKARUR PIPELINE PETRONETPETRONET 20012001 18 ”/14 ”18 ”/14 ” 289289 MULTIPRODUCTMULTIPRODUCT
PIPELINE DESIGNPIPELINE DESIGN
DESCRIPTIONDESCRIPTION CLIENTCLIENT YEARYEAR SIZESIZE LENGTH LENGTH
(KM)(KM)
SERVICESSERVICES
VIZAG VIZAG –– SECUNDERABAD LPG SECUNDERABAD LPG
PIPELINEPIPELINE
GAILGAIL 20022002 12”/10”12”/10” 600600 LPG (LEQUIFIED LPG (LEQUIFIED
PETROLEUM GAS)PETROLEUM GAS)
Major Onshore Projects (..contd) (Completed)
MANMADMANMAD--MANGALAYA PIPELINEMANGALAYA PIPELINE BPCLBPCL 20032003 14 ”14 ” 358358 MULTIPRODUCTMULTIPRODUCT
MANGALOREMANGALORE--BANGLOREBANGLORE HPCLHPCL 20032003 24 ”/20”24 ”/20” 364364 MULTIPRODUCTMULTIPRODUCT
DAHEJ DAHEJ –– VIJAIPUR PIPELINEVIJAIPUR PIPELINE GAILGAIL 20032003 42”42” 610610 REGASIFIED LNGREGASIFIED LNG
INTER REFINERIES PIPELINES INTER REFINERIES PIPELINES
PROJECT, ABU DHABIPROJECT, ABU DHABI TAKREERTAKREER 20042004
10” 10”
12”12”
16”16”
230230
230230
208208
NAPHTHA, NAPHTHA,
MULTIPRODUCT & SRRMULTIPRODUCT & SRR
Pipeline Design
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16”16” 208208
MANGALAYAMANGALAYA--BIJWASAN BIJWASAN
PIPELINEPIPELINE
BPCLBPCL 20062006 16”/8”16”/8” 775775 MULTIPRODUCTMULTIPRODUCT
MUNDRAMUNDRA--DELHI PIPELINEDELHI PIPELINE HPCLHPCL 20062006 18”/16”18”/16” 10501050 MULTIPRODUCTMULTIPRODUCT
DESCRIPTIONDESCRIPTION CLIENTCLIENT YEARYEAR SIZESIZE LENGTH LENGTH
(KM)(KM)
SERVICESSERVICES
PUNE SOLAPUR PIPELINEPUNE SOLAPUR PIPELINE HPCLHPCL 20072007 14 ”/ 12”14 ”/ 12” 182 / 161182 / 161 MULTIPRODUCTMULTIPRODUCT
PIPELINE DESIGNPIPELINE DESIGNMajor Onshore Projects (7contd)
(Completed)
DABHOL PANVEL PIPELINE DABHOL PANVEL PIPELINE
PROJECT (PHPROJECT (PH--I)I)
GAILGAIL 20072007 30”30” 187187 REGASIFIED LNGREGASIFIED LNG
DABHOL PANVEL PIPELINE DABHOL PANVEL PIPELINE
PROJECT (PHPROJECT (PH--II)II)
GAILGAIL 20072007 30”30” 120120 REGASIFIED LNGREGASIFIED LNG
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DESCRIPTIONDESCRIPTION CLIENTCLIENT YEARYEAR SIZESIZE LENGTH LENGTH
(KM)(KM)
SERVICESSERVICES
BOMBAY HIGH URAN TRUNKLINEBOMBAY HIGH URAN TRUNKLINE
(BUT)(BUT)
ONGCONGC 19791979 30”/26”30”/26” 200 x 2200 x 2 CRUDE, GASCRUDE, GAS
PIPELINE DESIGNPIPELINE DESIGNMajor Offshore ProjectsMajor Offshore Projects
(Completed)
(BUT)(BUT)
SOUTH BASSEIN HAZIRA SOUTH BASSEIN HAZIRA
TRUNKLINETRUNKLINE
ONGCONGC 19861986 36”36” 220220 GASGAS
HEERAHEERA--URAN TRUNK LINEURAN TRUNK LINE ONGCONGC 19961996 26 ”/24 ”26 ”/24 ” 85 x 285 x 2 CRUDE, GASCRUDE, GAS
ICP ICP -- HEERA TRUNKLINEHEERA TRUNKLINE ONGCONGC 19961996 30”/22”30”/22” 145145 CRUDECRUDE
SECOND BASSEIN HAZIRA SECOND BASSEIN HAZIRA
TRUNKLINETRUNKLINE
ONGCONGC 19951995 42”42” 245245 GASGAS
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TRUNKLINETRUNKLINE
MUMBAI HIGH URAN TRUNKLINEMUMBAI HIGH URAN TRUNKLINE
(MUT)(MUT)
ONGCONGC 20052005 30”/28”30”/28”
12” to 22”12” to 22”
205 x 2205 x 2
100100
CRUDE, GASCRUDE, GAS
IN-FIELD PIPELINES OF BOMBAY-HIGH, BASSEIN, HEERA, NEELAM, PANNA, MUKTA.
DESCRIPTIONDESCRIPTION CLIENTCLIENT YEARYEAR SIZESIZE LENGTH LENGTH
(KM)(KM)
SERVICESSERVICES
VIJIPUR DADRI BAWANA PIPELINEVIJIPUR DADRI BAWANA PIPELINE
(VDBPL)(VDBPL)
GAILGAIL 20092009 48”/ 36”/ 48”/ 36”/
20”20”
500/ 38/ 55500/ 38/ 55 REGASIFIED LNGREGASIFIED LNG
PIPELINE DESIGNPIPELINE DESIGNMajor Onshore ProjectsMajor Onshore Projects
(Current)
(VDBPL)(VDBPL) 20”20”
MUNDRA BATHINDA PIPELINE MUNDRA BATHINDA PIPELINE
(MBPL)(MBPL)
HMPLHMPL 20092009 28”/ 30”28”/ 30” 424/ 590424/ 590 CRUDE OILCRUDE OIL
BINA KOTA PIPELINEBINA KOTA PIPELINE BPCLBPCL 20092009 18”18” 257257 MULTI PRODUCTMULTI PRODUCT
VADINAR BINA PIPELINEVADINAR BINA PIPELINE BORLBORL 20092009 24”24” 935935 CRUDE OILCRUDE OIL
NUMALIGARH SILIGURI PIPELINENUMALIGARH SILIGURI PIPELINE OILOIL 20092009 16”16” 400400 MULTI PRODUCTMULTI PRODUCT
Pipeline Design
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COMPRESSOR STATIONSCOMPRESSOR STATIONS GAILGAIL ------ ------ ------ REGASIFIED LNGREGASIFIED LNG
IN-FIELD PIPELINES OF BOMBAY-HIGH, BASSEIN, HEERA, NEELAM, PANNA, MUKTA.
PIPELINE DESIGNPIPELINE DESIGN
SECTION-1
INTRODUCTIONINTRODUCTION
Pipeline Design
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PIPELINE DESIGNPIPELINE DESIGN
CONTENTS
INTRODUCTION
� Modes of TransportationBenefits of Pipelines� Benefits of Pipelines
PIPELINE DESIGN
� Stages of Pipeline Project� Codes and Standards� Design� Installation, Testing & Commissioning
Pipeline Design
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� Installation, Testing & Commissioning
PIPELINE DESIGNPIPELINE DESIGN
Oil and Gas Production in India
� OIL 33 MMTPA� OIL 33 MMTPA
(ONGC, OIL, CAIRN, RIL)
� GAS 115 MMSCMD
Pipeline Design
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(ONGC, GAIL, OIL, GSPC, RIL)
Refining Scenario- India
302300
350
Capacity - 2006-07
NOC – 105.5 MMT
Others- 43.5 MMT
PIPELINE DESIGNPIPELINE DESIGN
70
149
235
100
150
200
250
300
(MMT)
Pipeline Design
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0
50
1998-99 2006-07 2011-12 2016-17
Source: Report of Working Group on P&NG Sector for the XI Plan
(Actual) Year
PIPELINE DESIGNPIPELINE DESIGN
Modes of Hydrocarbon Transportation - India
30%
35%
Pipelines 32%
Road Tankers 32%
Rail Tankers 26%
Water Carriers 10%0%
5%
10%
15%
20%
25%
30%
% Share
Pipelines
Road Tankers
Rail Tankers
Water Carriers
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% Share
PIPELINE DESIGNPIPELINE DESIGN
Benefits of Transportation by Pipelines
� Safer mode of transportation
� Environment friendly� Environment friendly
� Least energy requirement
� Lowest maintenance costs
� Minimal impact on land use pattern
� Negligible loss of product in transit
High reliability
Pipeline Design
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� High reliability
� Multi-product Transportation
PIPELINE DESIGNPIPELINE DESIGN
Energy Savings
Energy Intensity for Various Modes
4
Energy Consumption in % of energy
0.8
0.51
3.2
0.81.1
2
0
0.5
1
1.5
2
2.5
3
3.5
4
Energy Consumption in % of energy
Transported
Pipeline Design
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0
Liquid-
Pipelines
Liquid-
Coastal
Liquid-
Trains
Liquid-
Trucks
Coal-
Trains
Coal-
Coastal
N.Gas-
Pipelines
Energy Consumption in % of energy
Pipelines are the most energy efficient modes of transportation
ECONOMICS OF PIPELINE TRANSPORTATIONECONOMICS OF PIPELINE TRANSPORTATION
Transmission losses
Losses During Transportation
Pipelines
Rail/Road
Pipeline Design
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0 0.1 0.2 0.3 0.4 0.5
% Loss of Total Volume Transported
Transmission losses are lowest in Pipelines
PIPELINE DESIGNPIPELINE DESIGN
Products Transported
� Crude Oil
� Petroleum Products (MS, HSD, ATF, SKO)� Petroleum Products (MS, HSD, ATF, SKO)
� Water & Effluents
� LPG
� Natural Gas
� Slurries
Pipeline Design
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PIPELINE DESIGNPIPELINE DESIGN
Types of Pipelines
ONSHORE (LAND) & OFFSHORE
(SUBMARINE) PIPELINES(SUBMARINE) PIPELINES
� Trunk Pipelines
� Spur/ Branch Pipelines
� Marine Offloading Terminals & Outfalls
Pipeline Design
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PIPELINE DESIGNPIPELINE DESIGN
Capital cost: Typical breakup
Liquid Lines Gas Lines
1 Su rv ey , ROW & Compen s atio n 2% 1%
Ite m D e scriptionS r �o.Percentag e of Cap ita l Cos t.
1 Su rv ey , ROW & Compen s atio n 2% 1%
2 Lin e Pip e Steel Co s t 33% 45%
3 M ain lin e materia ls 2% 3%
4 Coating o f Pip es 11% 6%
5 M ain lin e Con s tru ctio n 33% 25%
6 Cathod ic Pro tectio n 1% 1%
7 Telecommun ication , SCADA and RCPs 5% 2%
8 Pump / Compres s o r Station s 5% 12%
Pipeline Design
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9 Deliv ery Terminal facilities 2% 1%
10 Pro ject M anag emen t 5% 4%
1 1 S ubTotal 100% 100%
Pipes, prime-overs and construction constitute big ticket items
PIPELINE DESIGNPIPELINE DESIGN
Marine Offloading Terminal
Pipeline Design
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PIPELINE DESIGNPIPELINE DESIGN
Open sea Jetty
Pipeline Design
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PIPELINE DESIGNPIPELINE DESIGN
UTTAR PRADESHN
HBJ GAS PIPELINE NETWORK
KEY PLAN
RAJASTHAN
DADRI
JAGDISHPUR
ANOLA
SHAHJAHANPUR
AURAIYA
BABRALA
ANTA
BIJAIPUR
INDIA
GUJARAT
DELHI
N
GADEPAN
Pipeline Design
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LEGEND
MADHYA PRADESH
JHABUA
COMPRESSOR STATION
RECEIVING TERMINAL
DESPATCH STATIONHAZIRA
ARABIAN
SEA
PIPELINE DESIGNPIPELINE DESIGN
Major Pipelines in India
Pipeline Design
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PIPELINE DESIGNPIPELINE DESIGN
Pipeline Construction Video
Video for Mangalore Bangalore Pipeline
Pipeline Design
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PIPELINE DESIGNPIPELINE DESIGN
SECTION-2
PIPELINE DESIGNPIPELINE DESIGN
Pipeline Design
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PIPELINE DESIGNPIPELINE DESIGN
Stages of Pipeline Project
�� ConceptualizationConceptualization
�� Establish RequirementEstablish Requirement�� Establish RequirementEstablish Requirement
�� Evaluate AlternativesEvaluate Alternatives
�� Finalize the ConceptFinalize the Concept
�� Feasibility StudyFeasibility Study
�� Pipeline Route Study and SelectionPipeline Route Study and Selection
�� Hydraulic Studies and OptimizationHydraulic Studies and Optimization
Establish Project CostEstablish Project Cost
Pipeline Design
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�� Establish Project CostEstablish Project Cost
�� Project Implementation SchemeProject Implementation Scheme
�� Environmental Impact Assessment & Risk AnalysisEnvironmental Impact Assessment & Risk Analysis
PIPELINE DESIGNPIPELINE DESIGN
Stages of Pipeline Project
�� Basic EngineeringBasic Engineering
�� Process Design and SizingProcess Design and Sizing�� Process Design and SizingProcess Design and Sizing
�� Optimization StudiesOptimization Studies
�� Route Surveys and InvestigationsRoute Surveys and Investigations
�� Detailed EngineeringDetailed Engineering
�� Engineering Design BasisEngineering Design Basis
�� Route Engineering and Engineering AnalysisRoute Engineering and Engineering Analysis
Specifications and Job StandardsSpecifications and Job Standards
Pipeline Design
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�� Specifications and Job StandardsSpecifications and Job Standards
�� Engineering for ProcurementEngineering for Procurement
�� Installation Engineering and Construction ProceduresInstallation Engineering and Construction Procedures
PIPELINE DESIGNPIPELINE DESIGNMajor Codes & Standards
Code/StandardCode/Standard TitleTitle
ASME B 31.8 (2003)ASME B 31.8 (2003) Gas Transportation and Distribution Piping SystemsGas Transportation and Distribution Piping Systems
ASME B 31.4 (2006)ASME B 31.4 (2006) Pipeline Transportation Systems for Liquid Hydrocarbons and other Pipeline Transportation Systems for Liquid Hydrocarbons and other
LiquidsLiquids
OISDOISD--141 (2003)141 (2003) Design and Construction Requirements for CrossDesign and Construction Requirements for Cross--Country Country
Hydrocarbon PipelinesHydrocarbon Pipelines
OISDOISD--214 (2006)214 (2006) CrossCross--Country LPG PipelinesCountry LPG Pipelines
OISDOISD--226 (2007)226 (2007) Natural Gas Transmission Pipelines and City Gas Distribution Natural Gas Transmission Pipelines and City Gas Distribution
NetworksNetworks
API 5L / ISO 3183 : 2007API 5L / ISO 3183 : 2007 Specification for Line PipeSpecification for Line Pipe
API RP1102API RP1102 Recommended practice for Rail and Highway crossingsRecommended practice for Rail and Highway crossings
Pipeline Design
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API 1104API 1104 Standard for welding pipeline and related facilitiesStandard for welding pipeline and related facilities
API 6D / ISO 14313API 6D / ISO 14313 Pipeline ValvesPipeline Valves
DNV OSDNV OS--F101F101 Submarine pipeline systemsSubmarine pipeline systems
Other References Other References Applicable Standards / Specs of ASME, API, NACE, MSS, BS and Applicable Standards / Specs of ASME, API, NACE, MSS, BS and
DINDIN
PIPELINE DESIGNPIPELINE DESIGN
Major Codes & Standards
Type of CrossingType of Crossing Approval AuthorityApproval Authority
ROU & Land AcquisitionROU & Land Acquisition Central/State Govt. as applicableCentral/State Govt. as applicable
(As per PMP Act 1962)(As per PMP Act 1962)(As per PMP Act 1962)(As per PMP Act 1962)
National Highway CrossingsNational Highway Crossings NHAINHAI
SH/ MDR/ ODR CrossingsSH/ MDR/ ODR Crossings PWDPWD
Railway Track crossings Railway Track crossings Indian RailwaysIndian Railways
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Crossing through Forest landCrossing through Forest land Forest AuthorityForest Authority
River/Canal crossingsRiver/Canal crossings Irrigation/Canal AuthorityIrrigation/Canal Authority
�� CAESARCAESAR--IIII
�� AUTOPIPEAUTOPIPE
LIST OF SOFTWARES USED IN PIPELINE
ENGINEERING
�� PIPELINE STUDIOPIPELINE STUDIO�� AUTOPIPEAUTOPIPE
�� IPMCSIPMCS
�� MRPACKMRPACK
�� SORPSSORPS
�� PIPECALCPIPECALC
OFFPIPEOFFPIPE
TGNETTGNET
TLNETTLNET
�� HYSISHYSIS
Pipeline Design
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�� OFFPIPEOFFPIPE
�� PRISEPRISE
�� PIPECROSSPIPECROSS
Optimal sizes of various capacities
PIPELINE DESIGNPIPELINE DESIGN
Pipeline Design
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Economy of scale
PIPELINE DESIGNPIPELINE DESIGN
Route Selection
Routing Considerations
� Pipeline length
� Obstructions & Sensitive areas� Obstructions & Sensitive areas
� Installation Limitations
� Crossings
Surveys
� Topographical
� Geo-technical
Pipeline Design
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� Geo-technical
� Population Density Index
� Soil Resistivity
� Cadastral
BHATINDACh. 1012.67 km
PIPELINE DESIGNPIPELINE DESIGN
Typical Pipeline Route Map
LEGEND:
PROPOSED PIPELINE
JUDCh. 593.88 km
RANSISARCh. 855.01 km
GAILAWASCh. 527.87 km
IPS-F
IPS-2
IP-1 & IPS-F
Pipeline Design
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1. PIPELINE ROUTE SHOWN IS INDICATIVE ONLY.
LEGEND:
PROPOSED MUNDRA-BHATINDA PIPELINE (28" NB)
RECEIPT TERMINAL
DESPATCH TERMINAL AND PUMPING STATION
NOTES:
INTERMEDIATE PIGGING STATION (IP)
INTERMEDIATE PUMPING STATION (IPS)
IPS-F
Ch. 226.72 km
JORAWARPURACh. 313.63 km
MUNDRACh. 0.00 km
2. CHAINAGES INDICATED ARE APPROXIMATE. JHEKDA
IPS-1
FUTURE PUMPING STATION (IPS-F)
PIPELINE DESIGNPIPELINE DESIGN
Pipeline Design
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PIPELINE DESIGNPIPELINE DESIGN
Material Selection & Corrosion Control
Assessment
� Nature of the Product
Materials
� Carbon Steel (CS)
� Design Life
� Product Temperature
Corrosion Protection
� Material Chemistry
� Internal Coatings
� NACE Carbon Steel
� CRA Clad CS
� CS with internal
Coatings
� Non-Metallic
Materials
Pipeline Design
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� Product Conditioning
� Corrosion inhibitors
� Corrosion Allowance
Materials
PIPELINE DESIGNPIPELINE DESIGN
Design and Analysis
� Wall Thickness Calculations
� Anti-Buoyancy Measures
� Piping Stress Analysis
� Buried Pipeline Analysis
� Crossing Design
Pipeline Design
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� Crossing Design
PIPELINE DESIGNPIPELINE DESIGN
Steel Pipe Wall Thickness Calculation
LIQUID PIPELINE
(ASME B 31.4, Cl. 404.1.2)
GAS PIPELINE
(ASME B 31.8, Cl. 841.11)
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
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
Pipeline Design
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thickness
E Weld joint factor
F Design factor
E Longitudinal joint factor
T Temperature de-rating factor
PIPELINE DESIGNPIPELINE DESIGN
Basic Design Factor for Gas Pipelines
LOCATION CLASS DESIGN FACTOR, F
Location Class 1 0.72
Location Class 2 0.60Location 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
Pipeline Design
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Location Class 3 : ≥≥≥≥ 46 buildings
Location Class 4 : Multistory buildings
PIPELINE DESIGNPIPELINE DESIGN
Line Pipe Selection
Line Pipe Selection Parameters
� Thickness and Grade
Type of Line PipesType of Line Pipes
�� SeamlessSeamless� Thickness and Grade
Selection
� Handling and
Transportation (d/t ratio)
� Type of LinePipe
� Installation Requirements
�� SeamlessSeamless
�� Electric WeldedElectric Welded
�� Longitudinal Seam Longitudinal Seam
SubmergedSubmerged--Arc Welded Arc Welded
(LSAW)(LSAW)
�� Helical Seam SubmergedHelical Seam Submerged--
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� Installation RequirementsArc Welded Arc Welded
(HSAW)(HSAW)
PIPELINE DESIGNPIPELINE DESIGN
Line Pipe Application
Submarine Pipelines Onshore Pipelines
� Seamless Pipes
(upto & including 16”)
� LSAW Pipes
(18” & above)
� Seamless Pipes
(upto & including 8”)
� LSAW Pipes
(16” & above)
� HSAW Pipes
(18” & above)
� EW Pipes
Pipeline Design
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� EW Pipes
(4” - 18”)
Pipeline Design
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Manufacturing of Helical PipesManufacturing of Helical PipesPIPELINE DESIGNPIPELINE DESIGN
Pipeline Design
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PIPELINE DESIGNPIPELINE DESIGN
Anti-corrosive Coatings�� Coal Tar Enamel Coating (BS 4164, AWWA C203)Coal Tar Enamel Coating (BS 4164, AWWA C203)
�� PrimerPrimer
�� Two layers of coal tar enamel & glass fibre Inner wrapTwo layers of coal tar enamel & glass fibre Inner wrap
One layer of coal tar impregnated outer wrapOne layer of coal tar impregnated outer wrap�� One layer of coal tar impregnated outer wrapOne layer of coal tar impregnated outer wrap
�� Coating thickness 4.7mmCoating thickness 4.7mm
�� 3 Layer PE/ PP Coating (DIN 30670)3 Layer PE/ PP Coating (DIN 30670)�� First layer of Fusion bonded epoxyFirst layer of Fusion bonded epoxy
�� Second layer of extruded adhesive Second layer of extruded adhesive
�� Third layer of extruded PE/ PPThird layer of extruded PE/ PP
�� Coating thickness 2.0 to 3.7 mmCoating thickness 2.0 to 3.7 mm
Pipeline Design
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�� Fusion Bonded Epoxy Coating (CSA Z245.20)Fusion Bonded Epoxy Coating (CSA Z245.20)�� 350350--500 micron thick single layer coating500 micron thick single layer coating
�� 600600--800 micron thick dual layer coating800 micron thick dual layer coating
PIPELINE DESIGNPIPELINE DESIGN
3 Layer PE Coating Application
Pipeline Design
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PIPELINE DESIGNPIPELINE DESIGN
Major Pipeline Components
�� Line Pipe & CoatingsLine Pipe & Coatings
�� Scraper Traps & Pig SignallersScraper Traps & Pig Signallers�� Scraper Traps & Pig SignallersScraper Traps & Pig Signallers
�� Long Radius (LR) BendsLong Radius (LR) Bends
�� Insulating JointsInsulating Joints
�� Flow TeesFlow Tees
�� Sectionalizing ValvesSectionalizing Valves
�� Pumps / CompressorsPumps / Compressors
Pipeline Design
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�� Pumps / CompressorsPumps / Compressors
�� Filters & MetersFilters & Meters
PIPELINE DESIGNPIPELINE DESIGN
Scraper traps
Pipeline Design
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PIPELINE DESIGNPIPELINE DESIGN
Sectionalizing Valve
Spacing Spacing
� ASME B 31.8 for Gas
pipelines
Gas Pipelines
Location Class 1 32 km (20 miles)
Location Class 2 24 km (15 miles)pipelines
� ASME B 31.4 for Liquid
Pipelines
LocationLocation
� Pollution Concerns
� Statutory Requirements
� Prevention of Inventory
Loss
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 &
Pipeline Design
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Loss
� Approachability of Valve
Station
Residential Areas
PIPELINE DESIGNPIPELINE DESIGN
Type of Valves
� Full Bore Ball Valves
� Through Conduit Gate
Valves
� Plug and Check Valves
� Valve Standard :
API 6D/ISO14313
Other Valve Standards:
Pipeline Design
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API 600, API 602, BS EN
ISO 17292:2004, BS EN
ISO 15761:2002, BS 5353
PIPELINE DESIGNPIPELINE DESIGN
Ball valves
Pipeline Design
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PIPELINE DESIGNPIPELINE DESIGN
Plug valve
Pipeline Design
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PIPELINE DESIGNPIPELINE DESIGN
Check valve
Pipeline Design
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PIPELINE DESIGNPIPELINE DESIGN
Major Engineering Deliverables
Design ReportsDesign Reports
��Design BasisDesign Basis
DrawingsDrawings
��Route MapRoute Map��Design BasisDesign Basis
��Route Selection ReportRoute Selection Report
��Wall Thickness ReportWall Thickness Report
��Seismic Design ReportSeismic Design Report
��Crossing Design ReportCrossing Design Report
��Route MapRoute Map
��Pipeline SchematicPipeline Schematic
��Alignment SheetsAlignment Sheets
��SV Station LayoutSV Station Layout
��Equipment LayoutEquipment Layout
Piping General Piping General
Pipeline Design
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��Piping General Piping General
Arrangement DrawingsArrangement Drawings
PIPELINE DESIGNPIPELINE DESIGN
Typical Pipeline Alignment SheetINTERSECTION POINTS(IP/TP)
DEFLECTION ANGLE
STATE , DISTRICT AND MANDAL
DISTANCE AS PER GROUND PROFILE
38°4'58''(R)
TP50 IP50/1
29°8'20''(L)
TP51 IP51/1
5°18'55''(R)
TP52
8°2'3''(L)
TP53
37°0'54''(L)
TP54
13°54'57''(R)
TP55
11°25'7''(L)
TP56
1°21'55''(L)
TP57
8°24'45''(R)
TP58 IP58/1
2°8'32''(L)
TP59
14°0'19''(R)
TP60
8°30'18''(L)
TP61 IP61/1
15°2'57''(L)
TP62
10°4'42''(L)
TP63
10°25'50''(L)
TP64 IP64/1
5°18'12''(R)
TP65
CH. 10620.558m
CH.10664.710m
CH. 10797.803m
IP50/1
CH. 10687.604mTP51
CH. 10712.803mIP51/1
TP50
TP58 TP60
CH. 13741.534m
TP63
TP65
CH. 14134.896m
CH. 13979.211m
TP64
IP64/1
CH.14044.732m
TBM W40 (RL 37.514m)
TBM W57(RL 42.533m)
RAIWADA LEFT CANAL
(UNLINED)
CH. 10691.604m
TO PENDA AMRITA PURAM
TO PENDA AMRUTHAPURAM
EARTHEN EMBANKMENT
LOW LYING AREA
EARTHEN EMBANKMENT
MATCH LINE FOR CONT. REFER DWG
NO.4529-10-16-71-9005
METALLED ROAD(ASPHALTIC)
CH.14115.309m
TO STATE HIGHWAY-SABBAVARAM
TO IRUVADA
ELEC. LINE 440VCH.14132.231m
TELEPHONE LINE CH.14134.896m
DISTANCE BETWEEN TP & IP's(m)67.046
67.049
25.199
25.200
85.000
85.284
187.855
187.993
76.544
76.618
339.096
339.126
176.463
176.478
38.749
38.853
322.708
322.772
141.760
141.845
45.000
45.093
104.113
104.624
224.969
225.022
393.395
393.407
218.000
218.014
348.437
348.444
326.642
326.679
237.677
237.707
65.521
65.728
90.164
90.390
SCALE:
HORIZONTAL 1:5000
VERTICAL 1: 500
21
23
25
27
29
31
33
35
37
39
41
43
45
10.621
37.325
33.366
35.411
33.560
32.587
31.496
30.300
29.815
27.370
25.362
27.904
24.858
25.138
24.341
24.675
24.828
24.604
23.667
22.175
25.884
30.557
29.219
29.135
28.935
30.893
32.444
33.622
37.219
40.816
39.741
42.491
43.684
43.034
DRAIN
CH 10664.71m/RL 33.366m
CANAL
CH 10691.6m/RL 35.411m
ROAD
CH 10787.02m/RL 32.587m
DRAIN
CH 11824.63m/RL 24.341m
ROAD
CH 12060.88m/RL 24.604m
DRAIN
CH 12115.34m/RL 22.175m
CART TRACK
CH 13492.61m/RL 33.622m
CANAL
CH 14027.73m/RL 39.741m
ROAD
CH 14040.27m/RL 42.491m
CART TRACK
CH 14115.31m/RL 43.684m
CH. 12848.455m
HIGH TENSION LINE
TP57
CH.11848.88m
ELECTRIC LINE
CH.11824.629m
CH. 11062.202m
CH. 11401.298m
TP54
CH.11018.117m
ELECTRIC LINE 440V CH.12115.344m
CH. 11577.761m
TP55
TP56
CH. 11616.510m
CH.12060.877m
GRAVEL ROAD
CH. 11939.218m
DRAI N
DRAIN
CH.12747.397m
MATCH LINE FOR C
ONT. REFER DWG
NO.4529-10-16-71-9003
DRAIN
CH.10664.710m
CH. 10985.658m
GRAVEL ROAD
CH.10787.022m
TP52
TP53
CH. 12080.978m
TP58
CH. 12455.060m
TP60
CH. 12230.091m
TP59
DRAIN
CH.12903.743m
CH.13492
.606mCART TR
ACK
TP61
TP62
CH. 13414.892m
CH.14027.732m
RAIWADA LEFT CANAL IP58/1
CH. 12125.978m CH. 13066.455m
IP61/1
KAJU GARDEN RICE FIELDS
VILLAGE BOUNDARY
AMRUTAPURAM IRUVADATBM W49 (RL 25.138m)
TEMP. HUT ON C/L
HPCL CH. 15.00Km HPCL CH. 16.00KmHPCL CH. 17.00Km
TO CHIN
TA GUTL
A
SV-1 OF GAIL
CH.11960.218 m
TO PENDA AMRUTHAPURAM
TO AMRUTHAPURAM
K
K
OPEN WELL 6m DIA
7.648m FROM C/L
CH.11648.136m
OPEN WELL 6m DIA
8m FROM C/L
CH 11577.761m
PUMP HOUSE 4m FROM C/L
12.2m HIGH & 550KV
K
(UNLINED)
GRAVEL ROAD
CH.14040.275m
MATCH LINE FOR CONT. REFER DWG
NO.4529-10-16-71-9005
TO STATE HIGHWAY-SABBAVARAM
10.665
44.152
10.692
26.894
10.713
21.199
10.787
74.219
10.986
198.636
11.025
39.369
11.062
37.175
11.259
196.962
11.401
142.134
11.578
176.463
11.617
38.749
11.758
141.522
11.825
66.597
11.849
24.246
11.939
90.342
12.061
121.660
12.081
20.101
12.115
34.366
12.230
114.747
12.455
224.969
12.754
299.254
12.848
94.141
13.066
217.539
13.248
182.117
13.415
166.780
13.493
77.714
13.742
248.929
13.979
237.676
14.028
48.521
14.040
12.543
14.115
75.034
14.135
19.588
10.621
10.665
10.692
10.713
10.787
10.986
11.025
11.062
11.259
11.401
11.578
11.617
11.758
11.825
11.849
11.939
12.061
12.081
12.115
12.230
12.455
12.754
12.848
13.066
13.248
13.415
13.493
13.742
13.979
14.028
14.040
14.115
14.135
11.960
11.972
11.984
Pipeline Design
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Typical P&ID
PIPELINE DESIGNPIPELINE DESIGN
Pipeline Design
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PIPELINE DESIGNPIPELINE DESIGNTypical GA DRAWING
Pipeline Design
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PIPELINE DESIGNPIPELINE DESIGN
Major Engineering Deliverables
TendersTenders
�� Survey TenderSurvey Tender
�� Pipe Coating TenderPipe Coating Tender
�� Pipeline Installation TenderPipeline Installation Tender
Material Procurement Material Procurement
�� Line PipesLine Pipes
�� Valves & ActuatorsValves & Actuators
�� Scraper Traps, QOEC, Pig Scraper Traps, QOEC, Pig SignallersSignallers
�� Flow Tees & Insulating JointsFlow Tees & Insulating Joints
Pipeline Design
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�� Flow Tees & Insulating JointsFlow Tees & Insulating Joints
�� Induction BendsInduction Bends
�� Flow metersFlow meters
�� Pumps & CompressorsPumps & Compressors
�� OFC cablesOFC cables
PIPELINE DESIGNPIPELINE DESIGN
Installation, Testing & Commissioning
RoU Grading & Trenching Stringing of Linepipe
Pipeline Design
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PIPELINE DESIGNPIPELINE DESIGN
Installation, Testing & Commissioning
Welding & NDT :� Edge Preparation
� Internal / External Line-up Clamps� Internal / External Line-up Clamps
� Manual / Automatic Welding
� NDT (X-Ray / UT / MPI etc.)
Pipeline Design
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PIPELINE DESIGNPIPELINE DESIGN
Installation, Testing & Commissioning
Field Joint Coating Lowering & Backfilling� Heat Shrink Sleeves
� Cold applied tapes� Cold applied tapes
Pipeline Design
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PIPELINE DESIGNPIPELINE DESIGN
Pipeline Crossings
Crossing Installation
CrossingsCrossings
� River, Canal, Road & Rail
� Utility Crossing
Methodologies
� Open-Cut Method
� Trench-less Method
� Horizontal
Directional Drilling
Pipeline Design
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Directional Drilling
� Jacking and Boring
� Micro tunneling
PIPELINE DESIGNPIPELINE DESIGN
The conventional HDD operations for river crossings.
Pipeline Design
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Boring Across Road crossings.
Pipeline Design
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Boring Across Road crossings, showing Auger used for Boring
Pipeline Design
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PIPELINE DESIGNPIPELINE DESIGN
Pipeline Installation using Micro-tunnellingMICRO-TUNNELLING:� Micro Tunneling process uses a Micro Tunnel Boring Machine
(MTBM) combined with pipe jacking technique.
Pipe jacking from launch shaft to reception shaft.� 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
Pipeline Design
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� Installation of more than one pipe in the tunnel
� Precise installation and Minimum space at both ends
� Can be done in curved path also
PIPELINE DESIGNPIPELINE DESIGN
Schematic DiagramSchematic Diagram
Pipeline Design
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PIPELINE DESIGNPIPELINE DESIGN
Pipeline Installation using Micro-tunnelling
Long Distance Micro TunnellingLong Distance Micro Tunnelling
Pipeline Design
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PIPELINE DESIGNPIPELINE DESIGN
Overview of Micro tunneling
Pipeline Design
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PIPELINE DESIGNPIPELINE DESIGN
Testing & CommissioningTESTING
� Gauging and Pigging
� Test Pressure
� Test Medium
DRYING
� Swabbing
� Methanol Drying� Test Medium
TEST PRESSURE
LIQUID PIPELINES
Ref. ASME B 31.4 : 437.4.1
1.25 times design pressure
GAS PIPELINES
� Methanol Drying
� Super Dry Air
Method
� Vacuum Drying
COMMISSIONING
� Nitrogen Purging
� Product Charging
Pipeline Design
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GAS PIPELINES
Ref. ASME B 31.8 : Table 841.322(f)
Class 1 and 2: 1.25 * des pr
Class 3 and 4: 1.4 * des pr
PIPELINE DESIGNPIPELINE DESIGN
Pigging
Requirements
� Pipeline Cleaning
� Displacement
Types of Pigs
� Brush pigs
� Gauge Pigs� Displacement
� Internal Inspection
� Batching
� Gauge Pigs
� Spheres
� Intelligent Pigs
Pipeline Design
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Cleaning pigs Gauge Pigs Spheres Intelligent Pig
(MFL)
PIPELINE DESIGNPIPELINE DESIGN
RECENT DEVELOPMENTS
TECHNICAL IMPROVEMENTSTECHNICAL IMPROVEMENTS
�� Automatic Welding & Automatic UTAutomatic Welding & Automatic UT�� Automatic Welding & Automatic UTAutomatic Welding & Automatic UT
�� MicroMicro--Tunneling for pipeline constructionTunneling for pipeline construction
�� Internal flow coating on line pipes for gas pipelinesInternal flow coating on line pipes for gas pipelines
�� 3LPP coating on High Temperature pipelines3LPP coating on High Temperature pipelines
Pipeline Design
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PIPELINE DESIGNPIPELINE DESIGN
Comparison of LSAW & HSAW Pipes
DescriptionDescription LSAWLSAW HSAWHSAW
Method of Method of
ManufactureManufacture
UOE/COE/JCO/3 roll bendingUOE/COE/JCO/3 roll bending Formed by Twisting of CoilFormed by Twisting of Coil
Weld LengthWeld Length Equal to pipe joint lengthEqual to pipe joint length Approximately 1.5 to 2 times the Approximately 1.5 to 2 times the Weld LengthWeld Length Equal to pipe joint lengthEqual to pipe joint length Approximately 1.5 to 2 times the Approximately 1.5 to 2 times the
length of pipe jointlength of pipe joint
Position of weldPosition of weld Longitudinal Longitudinal –– positioned in positioned in
upper quadrant during upper quadrant during
constructionconstruction
Spiral Spiral –– present all around the present all around the
pipepipe
Corrosion Coating Corrosion Coating Specified thickness throughout Specified thickness throughout
entire body. entire body.
Weld seam is tracked to ensure Weld seam is tracked to ensure
coating thickness on weld seamcoating thickness on weld seam
Thickness normally increased all Thickness normally increased all
over the body, resulting in over the body, resulting in
proportional increase in coating proportional increase in coating
cost by 15cost by 15--20%20%
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GeometryGeometry Controlled to the desired level Controlled to the desired level
with cold expansionwith cold expansion
Controlled during forming only Controlled during forming only
and no cold expansion is carried and no cold expansion is carried
outout
PIPELINE DESIGNPIPELINE DESIGN
CTECTE 3LPE3LPE 3LPP3LPP FBEFBE
Coating Comparison
CTECTE 3LPE3LPE 3LPP3LPP FBEFBE
Service ConditionsService Conditions
Temperature, Temperature, oo CC Upto 45Upto 45 Upto 65Upto 65 Upto 110Upto 110 Upto 110Upto 110
AntiAnti--corrosion Propertiescorrosion Properties
Resistance to MoistureResistance to Moisture GoodGood Very GoodVery Good ExcellentExcellent GoodGood
Cathodic DisbondmentCathodic Disbondment FairFair GoodGood GoodGood GoodGood
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Cathodic DisbondmentCathodic Disbondment FairFair GoodGood GoodGood GoodGood
Electrical Properties Electrical Properties
Coating ResistanceCoating Resistance GoodGood ExcellentExcellent ExcellentExcellent ExcellentExcellent
PIPELINE DESIGNPIPELINE DESIGN
CTECTE 3LPE3LPE 3LPP3LPP FBEFBE
Cathodic Protection DesignCathodic Protection Design
Coating Comparison
Cathodic Protection DesignCathodic Protection Design
Current DensityCurrent Density HighHigh LowLow LowLow LowLow
Mechanical PropertiesMechanical Properties
Resistance to ImpactResistance to Impact FairFair ExcellentExcellent Superior to PESuperior to PE FairFair
Resistance to Resistance to
IndentationIndentation
PoorPoor Very GoodVery Good ExcellentExcellent FairFair
Resistance to PeelResistance to Peel FairFair ExcellentExcellent Superior than PESuperior than PE --
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Resistance to PeelResistance to Peel FairFair ExcellentExcellent Superior than PESuperior than PE --
Resistance to Soil Resistance to Soil
StressesStresses
FairFair ExcellentExcellent ExcellentExcellent ExcellentExcellent
ElongationElongation FairFair ExcellentExcellent ExcellentExcellent --
PIPELINE DESIGNPIPELINE DESIGN
CTECTE 3LPE3LPE 3LPP3LPP FBEFBE
Long Term AgeingLong Term Ageing
Coating Comparison
Long Term AgeingLong Term Ageing
Heat & Light AgeingHeat & Light Ageing FairFair Very GoodVery Good Very GoodVery Good Very GoodVery Good
Application & Field RepairApplication & Field Repair
Ease of ApplicationEase of Application Easy Easy Relatively difficultRelatively difficult Relatively difficultRelatively difficult Relatively difficultRelatively difficult
Damages during Damages during
handling & handling &
transportationtransportation
HighHigh LowLow LowLow HighHigh
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transportationtransportation
Ease of Field RepairEase of Field Repair DifficultDifficult Easy for small repair,Easy for small repair,
Cumbersome for Cumbersome for
larger repairlarger repair
Easy for small repair,Easy for small repair,
Cumbersome for Cumbersome for
larger repairlarger repair
Easy for small repair,Easy for small repair,
Cumbersome for Cumbersome for
larger repairlarger repair
Thank YouThank YouThank YouThank You
Pipeline Design
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