Pipeline Design and Construction

Pipeline Design and Construction

Presented by: Presented by:
Engr Engr. Md. . Md. Sanwar Sanwar Hossain Hossain
Dy Dy. Manager , Operation . Manager , Operation
Gas Transmission Co. Ltd. Gas Transmission Co. Ltd.
Pipeline design
Pipeline design

Q
Q
mmscfd mmscfd
=0.00128084((P
=0.00128084((P
1 1
2 2
-
-
P
P
2 2
2 2
)/L
)/L
miles miles
)
)
0.51 0.51
D
D
2.53 2.53
For successful implementation of a pipeline project,
For successful implementation of a pipeline project,
the following steps are to be considered in general:
the following steps are to be considered in general:
1. Market survey
1. Market survey
-
-
Present & future demand
Present & future demand
2. MAOP & Design pressure
2. MAOP & Design pressure
3. Map of the preliminary selected pipeline route (L)
3. Map of the preliminary selected pipeline route (L)
4. Pipe Size (D)
4. Pipe Size (D)
5. Wall thickness (t)
5. Wall thickness (t)
Pipeline design ( contd.)
Pipeline design ( contd.)
6. Pipe specification / grade
6. Pipe specification / grade
7. Bill of materials
7. Bill of materials
8. Total cost estimate
8. Total cost estimate
9. Selection of ROW
9. Selection of ROW
10. Detailed survey and Preparation of alignment
10. Detailed survey and Preparation of alignment
drawings
drawings
Pipeline design ( contd.)
Pipeline design ( contd.)
Load consideration:
Load consideration:

In earlier days , pipeline design was done

In earlier days , pipeline design was done
considering the present load and 15 to 30%
considering the present load and 15 to 30%
increment of load.
increment of load.

Now
Now
-
-
a days, the use of natural gas increased
a days, the use of natural gas increased
tremendously. As a result the concept of pipeline
tremendously. As a result the concept of pipeline
design has also changed.
design has also changed.

Presently pipeline design is being done considering

Presently pipeline design is being done considering
the present load as well as the assumed gas load of
the present load as well as the assumed gas load of
the that particular area for the next 20 years (
the that particular area for the next 20 years (
effective life of the pipeline)
effective life of the pipeline)
Pipeline design (Contd.)
Pipeline design (Contd.)

Modified Panhandle equation

Modified Panhandle equation
-
-
most useful for
most useful for
transmission pipeline :
transmission pipeline :

Q
Q
mmscfd mmscfd
=0.00128084((P
=0.00128084((P
1 1
2 2
-
-
P
P
2 2
2 2
)/L
)/L
miles miles
)
)
0.51 0.51
D
D
2.53 2.53
where , P
where , P
1 1
=Upstream pressure, PSIA
=Upstream pressure, PSIA
P
P
2 2
=Downstream pressure, PSIA
=Downstream pressure, PSIA
D=Inside pipe
D=Inside pipe
dia
dia
, inch
, inch
Pipeline design (contd.)
Pipeline design (contd.)

t= DP/(2YFL JT)
t= DP/(2YFL JT)
where,
where,
t=Pipe wall thickness, mm
t=Pipe wall thickness, mm
P=design pressure ,psig
P=design pressure ,psig
D=outside
D=outside
dia
dia
of pipe in mm
of pipe in mm
Y=minimum yield strength, psig
Y=minimum yield strength, psig
F=design factor
F=design factor
L= Location factor based on class location
L= Location factor based on class location
J=welding joint factor
J=welding joint factor
T=Temp.
T=Temp.
derating
derating
factor
factor
Line
Line
Pipe
Pipe
: API 5L Grades
: API 5L Grades
Grade
Grade
Minimum yield
Minimum yield
strength(
strength(
MPa
MPa
)
)
Minimum Tensile
Minimum Tensile
strength(
strength(
MPa
MPa
)
)
B
B
241
241
413
413
X42
X42
289
289
413
413
X46
X46
317
317
434
434
X52
X52
358
358
455
455
X56
X56
386
386
489
489
X60
X60
413
413
517
517
X65
X65
448
448
530
530
X70
X70
482
482
565
565
X80
X80
551
551
620
620
Design
Design
and Location Factor
and Location Factor

Canadian Standards association (CSA)

Canadian Standards association (CSA)
suggests design factor of 0.8 While location
suggests design factor of 0.8 While location
factors are:
factors are:
Area
Area
Class
Class
Location
Location
ASME
ASME
CSA
CSA
Deserted
Deserted
1
1
0.72
0.72
0.80
0.80
Village
Village
2
2
0.60
0.60
0.72
0.72
City
City
3
3
0.50
0.50
0.56
0.56
Metropolis
Metropolis
4
4
0.40
0.40
0.44
0.44
Joint factor :
Joint factor :
Weld type
Weld type
ASME B31.8
ASME B31.8
Seamless
Seamless
1
1
ERW
ERW
1
1
SAW
SAW
1
1
But Welled
But Welled
0.6
0.6
Spiral seam
Spiral seam
0.8
0.8
Temperature factor:
Temperature factor:
Temperature (
Temperature (
F)
F)
ASME
ASME
-
-
B31.8
B31.8
Up to 250
Up to 250
1.00
1.00
251
251
-
-
300
300
0.97
0.97
301
301
-
-
400
400
0.93
0.93
401
401
-
-
450
450
0.91
0.91
451 and above
451 and above
0.87
0.87
Pipeline Construction Process
Pipeline Construction Process

DPP
DPP

Land acquisition & Requisition

Land acquisition & Requisition

Tender Document Preparation

Tender Document Preparation

Tender
Tender

Bid Evaluation
Bid Evaluation

Tender Award
Tender Award

Procurement
Procurement

Mobilization
Mobilization

Clearing, Grading and Stringing

Clearing, Grading and Stringing
Pipeline Construction Process (contd.)
Pipeline Construction Process (contd.)

Welding and NDT

Welding and NDT

Trenching, Lowering & Backfilling

Trenching, Lowering & Backfilling

Tie
Tie
-
-
in
in

Hydrostatic Testing
Hydrostatic Testing

Cleaning
Cleaning

Commissioning
Commissioning

Operation
Operation
Pre construction
Pre construction

ROW Acquisition & Requisition

ROW Acquisition & Requisition
-
-
ROW Selection
ROW Selection
-
-
DC Office
DC Office
-
-
Compensation
Compensation
-
-
Crop Compensation
Crop Compensation
Pre construction (Contd.)
Pre construction (Contd.)
General Guideline for Pipeline Routing
General Guideline for Pipeline Routing

Minimize overall pipe length.

Minimize overall pipe length.

Parallel existing utility corridors (Highway, High

Parallel existing utility corridors (Highway, High
tension Electric transmission line).
tension Electric transmission line).

Avoid areas of high population density.

Avoid areas of high population density.

Minimize highways, railways, river,

Minimize highways, railways, river,
khals
khals
, canals,
, canals,
ponds, hills & mountains crossing to reduce the
ponds, hills & mountains crossing to reduce the
project cost.
project cost.

Cross highways, railways, river,

Cross highways, railways, river,
khals
khals
, canals at or
, canals at or
close to 90 deg. angle.
close to 90 deg. angle.

Minimize crossover of existing facilities.

Minimize crossover of existing facilities.

Provide adequate construction area.

Provide adequate construction area.
Pre construction (Contd.)
Pre construction (Contd.)
General Guideline for Pipeline Routing
General Guideline for Pipeline Routing

Avoid the following areas:

Avoid the following areas:

Swamps and Wetlands

Swamps and Wetlands

Rocky areas
Rocky areas

Unstable soil
Unstable soil

Populated areas
Populated areas

Historical areas
Historical areas

Environmentally sensitive areas ( Forest, Tea

Environmentally sensitive areas ( Forest, Tea
garden , Rubber garden etc.)
garden , Rubber garden etc.)

Religious sensitive areas ( Mosque , Graveyard,

Religious sensitive areas ( Mosque , Graveyard,
temple etc.)
temple etc.)
Pre construction (Contd.)
Pre construction (Contd.)
Land acquisition / Requisition:
Land acquisition / Requisition:

Normally
Normally
10 m
10 m
wide strip along the proposed
wide strip along the proposed
pipeline route is to be acquisition and a
pipeline route is to be acquisition and a
15 m
15 m
wide
wide
strip on one side of the acquisition strip is to be
strip on one side of the acquisition strip is to be
requisition.
requisition.

Acquisition is permanent possession for use of land

Acquisition is permanent possession for use of land
but requisition is completely a temporary affair , only
but requisition is completely a temporary affair , only
for the working period.
for the working period.

For scraper station and Valve station separate block

For scraper station and Valve station separate block
lands of required size have to be acquisition.
lands of required size have to be acquisition.
Pre construction (Contd.)
Pre construction (Contd.)
Submission of proposal for land acquisition & requisition:
Submission of proposal for land acquisition & requisition:

The company submit the proposal with requisite no. of

The company submit the proposal with requisite no. of
drawings (Normally
drawings (Normally
mouza
mouza
map) showing acquisition &
map) showing acquisition &
requisition strip in two distinct colors (red for
requisition strip in two distinct colors (red for
acquisition & green for requisition) to DC office.
acquisition & green for requisition) to DC office.

The process of acquisition & requisition in our country

The process of acquisition & requisition in our country
is done through the DC office of the particular district.
is done through the DC office of the particular district.

The whole process continues in accordance with

The whole process continues in accordance with
Ordinance, Acts, Rules & Regulations issued by the
Ordinance, Acts, Rules & Regulations issued by the
government from time to time.
government from time to time.
Pre construction (contd.)
Pre construction (contd.)

Tender
Tender
-
-
Floating
Floating
-
-
Bid Receiving & Evaluation
Bid Receiving & Evaluation
-
-
Contract Award & Contract Management
Contract Award & Contract Management

Procurement
Procurement

Mobilization
Mobilization
Major steps for pipeline Construction
Major steps for pipeline Construction

Cleaning & Grading the ROW

Cleaning & Grading the ROW

Stringing the pipe along ROW

Stringing the pipe along ROW

Welding the pipe joints together

Welding the pipe joints together

NDT of welding joints

NDT of welding joints

Coating & Wrapping

Coating & Wrapping

Ditching / Trenching
Ditching / Trenching

Holiday test
Holiday test

Lowering & backfilling

Lowering & backfilling

Pigging
Pigging

Hydro Test
Hydro Test

Commissioning
Commissioning
Equipment used for Pipeline Construction:
Equipment used for Pipeline Construction:

Bulldozer
Bulldozer
-
-
Used to clearing & grading of ROW.
Used to clearing & grading of ROW.

Excavator
Excavator
-
-
Used to trenching , pipe lifting, pulling the
Used to trenching , pipe lifting, pulling the
welding machine etc.
welding machine etc.

Side boom
Side boom
-
-
Used to lift the pipe during welding and
Used to lift the pipe during welding and
lay the pipeline in the trench.
lay the pipeline in the trench.

Crane
Crane

Used to handle heavy equipments and

Used to handle heavy equipments and
machineries.
machineries.

Welding generator
Welding generator

Trailer/ Truck
Trailer/ Truck
-
-
used to carry the line pipe from store
used to carry the line pipe from store
yard to the working site.
yard to the working site.
Pipeline construction Equipment
Pipeline construction Equipment
Excavator Excavator
Side boom Side boom
ROW Clearing & Grading
ROW Clearing & Grading

ROW is cleared of barriers and graded for

ROW is cleared of barriers and graded for
movement of construction equipment, materials
movement of construction equipment, materials
and ultimately construction of pipeline.
and ultimately construction of pipeline.
Pre Welding Activities
Pre Welding Activities

Welders test
Welders test
-
-
an exam for the welders before
an exam for the welders before
going to production weld.
going to production weld.

Selection Criterion
Selection Criterion
-
-
Visual inspection & NDT (
Visual inspection & NDT (
API
API
1104)
1104)

PQR / WPS Test

PQR / WPS Test
-
-
Tensile strength test
Tensile strength test
-
-
Face bend test
Face bend test
-
-
Root bend test
Root bend test
-
-
Charpy V notch test
Charpy V notch test
Stringing
Stringing

Stringing is aligning the
Stringing is aligning the
pipe along the ROW
pipe along the ROW
ready for welding .
ready for welding .

Trailer, Side boom etc
Trailer, Side boom etc
are used to stringing the
are used to stringing the
pipe.
pipe.
Welding
Welding

Root pass/ Stringer pass

Root pass/ Stringer pass

Hot pass
Hot pass

Filling pass
Filling pass

Cap Pass
Cap Pass

Cleaning the welds

Cleaning the welds
NDT ( Non Destructive Test)
NDT ( Non Destructive Test)

Dye
Dye
penetrant
penetrant
test
test

Magnetic Particle test

Magnetic Particle test

Eddy current test

Eddy current test

Radiographic test
Radiographic test

Ultrasonic test
Ultrasonic test

NDT personnel certification ( Level 1,2 & 3)

NDT personnel certification ( Level 1,2 & 3)
NDT ( Non Destructive Test)
NDT ( Non Destructive Test)

Radiography Test
Radiography Test
o
o
Equipment
Equipment
o
o
Method
Method
o
o
Source
Source
o
o
Film examination as Per API 1104 Standard
Film examination as Per API 1104 Standard
NDT ( Non Destructive Test)
NDT ( Non Destructive Test)

Ultrasonic Test
Ultrasonic Test
o
o
Equipment
Equipment
o
o
Method
Method
o
o
Source
Source
o
o
Weld examination
Weld examination
Common welding defects
Common welding defects

Porosity
Porosity

Cluster porosity
Cluster porosity

Slag inclusion
Slag inclusion

Lack of fusion
Lack of fusion

Lack of penetration
Lack of penetration

Internal concavity
Internal concavity

Burn through
Burn through

Crack
Crack
Welding defects:
Welding defects:
Welding defects:
Welding defects:
Tie
Tie
-
-
in welds
in welds

The final weld to join two separate section

The final weld to join two separate section
together.
together.

Should be properly aligned without use of

Should be properly aligned without use of
jacks or any external force.
jacks or any external force.

Should be done within operating temp ( 5

Should be done within operating temp ( 5
-
-
30
30
deg. Celsius).
deg. Celsius).

NDT test.
NDT test.
Roads and Railway Crossing
Roads and Railway Crossing
Two different ways
Two different ways

Thrust boring/ Horizontal boring method

Thrust boring/ Horizontal boring method
-
-
Drill a hole under the roadway without disturbing
Drill a hole under the roadway without disturbing
the road/ rail surface.
the road/ rail surface.

A casing pipe is placed through the hole and then

A casing pipe is placed through the hole and then
the pipeline is placed inside the casing.
the pipeline is placed inside the casing.

Spacer is used to center the pipeline within the

Spacer is used to center the pipeline within the
casing pipe.
casing pipe.

Open Cut method

Open Cut method
Pipe Coating
Pipe Coating

All except a portion ( about 6 inch ) of each pipe is

All except a portion ( about 6 inch ) of each pipe is
often coated in the factory before deliver to the site.
often coated in the factory before deliver to the site.

Three types of coating

Three types of coating
-
-
3LPE coating
3LPE coating
-
-
FBE coating
FBE coating
-
-
Polyethylene coating
Polyethylene coating

3LPE coating
3LPE coating
-
-
Apply adhesive on clean pipe surface
Apply adhesive on clean pipe surface
-
-
Epoxy paint ( 40
Epoxy paint ( 40
-
-
100 micron)
100 micron)
-
-
Polyethylene coating
Polyethylene coating
Bare pipe
Bare pipe
Steel Pipe without coating
Steel Pipe without coating
3 LPE Coated Pipe
3 LPE Coated Pipe

Features:
Features:
-
-
Cleaning ( sand
Cleaning ( sand
Blasting)
Blasting)
-
-
Apply Adhesive
Apply Adhesive
-
-
Apply epoxy paint ( 40
Apply epoxy paint ( 40
-
-
100 micron thick)
100 micron thick)
-
-
Polyethylene coating
Polyethylene coating
Concrete Coated Pipe
Concrete Coated Pipe

Features:
Features:
-
-
Apply 3LPE Coating
Apply 3LPE Coating
-
-
Set wire mesh above 3LPE
Set wire mesh above 3LPE
Coating
Coating
-
-
Apply Concrete coating
Apply Concrete coating
-
-
Provide
Provide

Ve
Ve
buoyancy
buoyancy
force
force
-
-
Apply on ditch, canal ,
Apply on ditch, canal ,
pond,
pond,
khal
khal
, small river
, small river
Set
Set
-
-
on
on
-
-
Weight
Weight

Features:
Features:
-
-
Put on above 3LPE coated
Put on above 3LPE coated
pipe
pipe
-
-
one on each pipe
one on each pipe
-
-
Provide
Provide

Ve
Ve
buoyancy
buoyancy
force
force
-
-
Apply on marshy area
Apply on marshy area
Joint coating
Joint coating

Heat shrink sleeves

Heat shrink sleeves
-
-
Approx. 14 inch length and
Approx. 14 inch length and
dia
dia
larger than pipe
larger than pipe
dia
dia
.
.
-
-
Shrink on applying heat and fitted to the pipe.
Shrink on applying heat and fitted to the pipe.
Ditching, Holyday test, Lowering & Backfilling
Ditching, Holyday test, Lowering & Backfilling

Ditching
Ditching

Holyday test
Holyday test
-
-
Apply 10 KV on coated pipe surface
Apply 10 KV on coated pipe surface
-
-
Any coating defect will result an audible sound.
Any coating defect will result an audible sound.

Lowering
Lowering
-
-
Lay pipeline on Trench of approx. 1.2 m depth
Lay pipeline on Trench of approx. 1.2 m depth
-
-
Put
Put
Set
Set
-
-
on
on
-
-
weight
weight
on
on
burried
burried
pipe for anti
pipe for anti
-
-
buoyancy
buoyancy
force
force
Testing :
Testing :

Brush / cup pig

Brush / cup pig
-
-
Clean internal rust
Clean internal rust

Gauge pig
Gauge pig
-
-
To check pipe
To check pipe
ovality
ovality

Foam Pig
Foam Pig
-
-
To dry internal surface
To dry internal surface
Pig Receiver
Pig Receiver

To receive pig at the

To receive pig at the
terminal point
terminal point
Pig Traps
Pig Traps
Pig Receiver connected with pipeline Pig Receiver connected with pipeline
Hydro test
Hydro test

After mechanical completion of pipeline

After mechanical completion of pipeline

Min test pressure should be 1.5 times of design

Min test pressure should be 1.5 times of design
pressure.
pressure.

Conventional hydro test pressure for high pressure

Conventional hydro test pressure for high pressure
pipeline= 1.5 X 1135
pipeline= 1.5 X 1135
psi
psi
= 1703
= 1703
psi
psi

Before commencing pressurization need to obtain

Before commencing pressurization need to obtain
necessary permission from the competent authority
necessary permission from the competent authority
.As per Gas Safety rules Department of explosive is
.As per Gas Safety rules Department of explosive is
the competent authority in Bangladesh.
the competent authority in Bangladesh.

Prior notification of testing should be given, in

Prior notification of testing should be given, in
writing to persons in the vicinity of the pipeline .
writing to persons in the vicinity of the pipeline .
Hydro test (contd.)
Hydro test (contd.)

Prior notification of testing should be given to local

Prior notification of testing should be given to local
police and other authorities, who may be affected.
police and other authorities, who may be affected.

Warning notice stating Warning

Warning notice stating Warning
-
-
PipeLine
PipeLine
Under
Under
Test and No Parking should be placed at
Test and No Parking should be placed at
appropriate locations for the duration of the test.
appropriate locations for the duration of the test.

Patrols should be provided to watch special points of

Patrols should be provided to watch special points of
hazard during the test, in particular road, rail and
hazard during the test, in particular road, rail and
water crossing and points of public access.
water crossing and points of public access.

Standby emergency crew should be available to deal

Standby emergency crew should be available to deal
any unwanted situation.
any unwanted situation.
Commissioning
Commissioning

Prior to the commissioning the pipeline should be dry

Prior to the commissioning the pipeline should be dry
up.
up.

Methods available for drying up are:

Methods available for drying up are:
-
-
Using dry air (compressor) push a series of foam
Using dry air (compressor) push a series of foam
pigs through the pipeline collecting water until the
pigs through the pipeline collecting water until the
required dryness is achieved.
required dryness is achieved.

The pipeline should be purged of before the

The pipeline should be purged of before the
admission of the gas to be transmitted .
admission of the gas to be transmitted .

Use inert gas to purge of air.

Use inert gas to purge of air.

After drying up a pipeline can be commissioned

After drying up a pipeline can be commissioned
straight to gas.
straight to gas.
Codes and Standards
Codes and Standards

ASME B31.8 ( Onshore & Offshore)

ASME B31.8 ( Onshore & Offshore)

ASME B16.5 (Flange & Flange Fittings)

ASME B16.5 (Flange & Flange Fittings)

ASME B16.21 ( Gaskets for Flanges)

ASME B16.21 ( Gaskets for Flanges)

API 5L ( Line Pipe)

API 5L ( Line Pipe)

API 6D (Valves)
API 6D (Valves)

API 1104 (Welding Inspection)

API 1104 (Welding Inspection)

ASME U
ASME U
-
-
Stamp ( Pig Traps & Launcher)
Stamp ( Pig Traps & Launcher)

ASME Boiler & Pressure Vessel Code ( Scrubber, KOD

ASME Boiler & Pressure Vessel Code ( Scrubber, KOD
and Other pressure Vessels)
and Other pressure Vessels)