Start up and Commissioning of the

Pipeline

- B. B. Prasad
 Objective of the commissioning

™To bring the constructed / installed system to

deliver the desired function.

™The Pipeline commissioning means introducing

crude/ product/Gas in the pipeline from originating
station, filling the entire length and then start
delivering to receipt system.
What we need prior to commissioning?

¾ The pipeline and associated facilities are completed in all

respect

¾ All Fire and Safety equipments / facilities are tested and

commissioned

¾ Availability of dedicated communication

¾ Statutory Clearances obtained

What we need prior to commissioning?

¾ Availability of Product (HSD)/ Crude oil – Not less than

line-fill

¾ Required Manpower is placed at all locations

¾ Availability of water and its disposal plan

¾ Availability of a dedicated commissioning team

What will be the procedures to commission a
Water Pipeline?
Critical issues in commissioning a Petroleum
Pipeline
¾ Movement of hydrocarbon in empty pipeline can generate
static current.

¾ Hydrocarbon Vapor mixed with oxygen may lead to explosion.

¾ There may be formation of Air / Vapor pocket that may get

compressed leading to rise in pressure.

¾ Air / vapor pocket may explode in receiving tank leading to

damage of the tank roof seal.

¾ Leakage of any hydrocarbon may lead to fire or damage to

environment .
 Properties of Hydrocarbons

Flash Point:
The flash point of a volatile liquid is the lowest temperature
at which it can vaporize to form an ignitable mixture in air.

Vapor Pressure:
The vapor pressure of a liquid is the pressure exerted by its
vapor when the liquid and vapor are in dynamic equilibrium.

At a given temperature, a substance with higher vapor

pressure vaporizes more readily than a substance with a
lower vapor pressure.
 Properties of Petroleum Products

Products RVP at 37.8 deg C Flash Point 

MS 375‐412 mm Hg. ‐ 43 0C
SKO <0.1 mm Hg > 38 0C
HSD 2.12 to 26 mm Hg. > 42 0C
ATF <0.1 mm Hg > 42 0C
NAPHTHA 450‐472mm Hg. ‐22 0C
CRUDE OIL 230 – 300 mm Hg 37‐620 C
LPG > 1000 mm Hg at 250C ‐600C to ‐1040C
Preferred Liquid for Commissioning

Pipeline Pumping Liquid Preferred Liquid

Multi  MS, SKO, HSD, ATF,  HSD

products LDO, NPHTHA
ATF  ATF SKO
LPG LPG LPG 
NAPHTHA Naphtha Naphtha
CRUDE OIL Crude Oil Crude Oil
What is PIG ?

A device that moves through the inside of 
a pipeline for the purpose of cleaning, 
dimensioning, sealing and inspect.
 Objective of Pigging
New Pipeline 
• Remove debris
• Verify ovality, dent etc
• Water filling & dewatering after hydro‐testing
• Sealing of product or water during commissioning 

In Service Pipeline
• Maintain line efficiency
• Corrosion control
• Check dents, buckles and any other internal abnormality
• To minimize interface generation between two dissimilar 
products
• To avoid cross‐contamination
• To evacuate the pipeline
 Conventional / Utility Pigs – Different types

Guide Disc Sealing Disc

• Various components are 
fitted on mandrel.
• It can be uni‐directional or 
bi‐directional
 Intelligent Pig

• To record bends, 
dents, ovality, bend 
radius & angle.
PIG Launching / Receiving Barrel
 Commissioning of a Multi-products Pipeline

BI-DI PIG Air (2/3 Kg/cm2)

Water (500 to 1000 kL)
Water (1000 to 2000 kL)

¾ Ensure the pipeline is ready in all respects for the commissioning.

¾ Ensure adequate product (HSD) is available for the commissioning

(At least more than line-fill of a Pipeline section).

¾ The pipeline or a section of the pipeline is pressurized with air

(2 to 3 Kg/Sq-cm)

¾ Pump a water column of about 500 kL to 1000 kL

¾Launch a Bi-Di Pig followed by 1000 kL to 2000 kL water

 Commissioning of a Multi-products Pipeline

Air (2/3 Kg/cm2)

HSD BI-DI PIG BI-DI PIG
Water (1000 to 2000 kL) Water (500 to 1000 kL)

¾ Launch second Bi-Di- Pig behind 1000 KL to 2000 KL water

¾ Pump HSD at minimum flow

¾ Track the movement of Pig

¾ Vent the air at receiving end and maintain back pressure 3 to 4

Kg/Sq-cm

¾ Monitor receipt of water at Receiving end – it may be disposed

directly in to a protected pit or in a designated tank.
Commissioning of a Multi Products Pipeline

¾ Receive Ist Bi-Di Pig

¾ Monitor the quantity and quality of water at receiving end

¾ Receive second Bi-Di Pig

¾ Once diesel or diesel mixed with water arrives, switch over to

designated HSD Tank.

¾ Observe flow and pressure, once these become stable, the

operation may be made normal and the pipeline may be declared
as commissioned and handed over to Operation.
 Commissioning of an ATF Pipeline

Air (2/3 Kg/cm2)

SKO BI-DI PIG BI-DI PIG
Water (1000 to 2000 kL) Water (500 to 1000 kL)

¾ The procedure is similar to multi-products pipeline except the following

• Commissioning liquid is used SKO instead of HSD

• ATF is not used because it is likely to get contaminated with

water and dirt particles.
 Commissioning of an ATF Pipeline

Air (2/3 Kg/cm2)

SKO BI-DI PIG BI-DI PIG
Water (1000 to 2000 kL) Water (500 to 1000 kL)

¾ The procedure is similar to multi-products pipeline except the following

• Commissioning liquid is used SKO instead of HSD

• ATF is not used because it is likely to get contaminated with

water and dirt particles.
 Commissioning of Naphtha Pipeline

Air (2/3 Kg/cm2)

Naphtha BI-DI PIG BI-DI PIG
Nitrogen (10.0 KM) Nitrogen (500 to 1000 kL)

¾ The procedure is similar to multi-products pipeline except the following

• Air from entire Pipeline is displaced with Nitrogen column using a Bi-Di Pig

•Commissioning liquid is used Naphtha instead of HSD

 Commissioning of LPG Pipeline

LPG BI-DI PIG BI-DI PIG Nitrogen

Nitrogen (10.0 KM)

¾ The procedure is similar to multi-products pipeline except the following

• Air from entire Pipeline is displaced with Nitrogen column using a Bi-Di Pig

•Commissioning liquid is used LPG instead of HSD

 Commissioning of a Gas Pipeline

¾ A gas pipeline is treated as Tank.

¾ However, before taking gas in the

Pipeline, it is to be made moisture
and oxygen free.
 Commissioning of a Gas Pipeline

Commissioning Steps:

¾ Drying – Purging of super dry air

Compressed Super dry air is purged using air compressors
with accessories viz. Moisture Separator, Oil Separator and
Dryer. The air shall be supplied in the pipeline at (-) 20 deg.
C dew point.

Super dry air with dew point (-) 20 deg. C will have sufficient
capacity to absorb water vapour to the extent of 30 % of
the desired capacity.
 Commissioning of a Gas Pipeline

Commissioning Steps:

¾ Drying – Purging of super dry air

Compressed Super dry air is purged using air compressors
with accessories viz. Moisture Separator, Oil Separator and
Dryer. The air shall be supplied in the pipeline at (-) 20 deg.
C dew point.

Super dry air with dew point (-) 20 deg. C will have sufficient
capacity to absorb water vapour to the extent of 30 % of
the desired capacity.
 Commissioning of a Gas Pipeline
Commissioning Steps:

¾ Vacuum Drying
The process utilizes high capacity vacuum to reduce
pressure within the Pipeline to a level from 760 Torr to 40
Torr. At this pressure (40 Torr), any water within the
pipeline will start boiling and vaporizing.

Air left inside the Pipeline is subjected to a vacuum of 40

Torr, the water vapor will expand approx. 18.8 times, which
will be displaced using high capacity vacuum booster
pumps (rated capacity 5000 CuM/Hr)

When the vacuum of 7.6-10 Torr is achieved, it is confirmed

that whole pipeline system has been dried to required level.
 Commissioning of a Gas Pipeline
Commissioning Steps:

¾ Nitrogen Purging
At vacuum level 7.6 Torr and dew point (-) 20 deg.C, the
oxygen content inside the Pipeline is 0.20%.

To further dilute the oxygen content, nitrogen purging is

done almost 13 times more than pipeline volume. This will
reduce oxygen content to 0.015%, which is considered
negligible.

Now the Pipeline system is ready to receive Gas.