PIPELINES –

Types , Operation and Maintenance

S.S SUDHI ,GM(P)
I/c HSE-Well Services
ONGC Mehsana
 PIPELINES SYSTEM IN ONGC
ONGC operates with
• 14 seismic crews,
• manages 262 onshore production installations,
• 268 offshore installations,
• 69 drilling (plus 37 hired) and 54 work-over rigs (plus 37 hired),
• Owns and operates more than 25,500 kilometers of pipeline in
India, including 4,500 kilometers of sub-sea pipelines.
 PIPELINES SYSTEM
1. Gathering System
2. Trunk Line System
3. Distribution System
 PIPELINES SYSTEM
1. Gathering System a. Line size varies from 4” to 12”

b. Used to gather oil/gas from different wells to GGS/GCS

2. Trunk Line System Oil at different GGS is brought to a central point called C.T.F. (Central Tank Farm). It is

collected there in huge tanks for dispatching it to refinery. The size of trunk / collector lines

depends upon quantity of oil to be transported and pressure required.

3. Distribution System After refining the refined oil is transported to distributors for marketing. The so-called

pipeline is also known as Product Lines.

PIPELINES COLOUR CODING SYSTEM
 Construction of Pipelines
 
1. Size of pipe Size of pipe is analyzed by:
a. Volume to be transported
b. Delivery pressure

2. Specification Specification being followed API:

A.API 5L- Seamless & longitudinally welded pipe in Grade A& B

B.API 5LX- High-test line pipe seamless+ERW

Gd X42 to X70
X-42=>Y.5=42000 psi

C. API5LU Utm high-test heat-treated seamless

A welded pipes to U100 Gds.
U-80 to U-100 Gds

D. API 5LS Spiral welded pipes Gd. A & B x.42 to x.70

 PROCEDURE
 
FOR LAYING
A. Once the size & specification has been decided the planning for laying is done. Planning
consists of:

A1. a. Route Survey 1.Aerial

2. Padestrial
3. Tracing of route on maps
b. Acquisition of row
-Permission of various crossing
i.e. Highways, Canals, Railways etc.

A2.Handling: Houling and stringing

A3.Welding: position Arc Welding Retting

 
 4. PRCEDURE FOR LAYING
 
A4.Coatig and Wrapping

1.Manual
2.Yard coating
3.Tube coating

Coating and wrapping: a) Cleaning of pipe

b) Application of primer
c) Molten Coal for enamel
d) F/Glass – Reinforcement
e) K.Papen – Bacterial effect

A5. Welding and Holiday test 4 KV/mm thicknesses

-Lowering in trench
-Tieing in
-Backfilling
-Testing
CORROSION
Current flows +ve to negative, i.e.
cathode to anode
Electron flows from anode to cathode.
Requirement of corrosion

1.The metal must be in contact with electrolytes containing ionized molecules including
some water molecules. Water molecules break down into H+ & OH- ions,
Fe Fe++ + 2 e
Usually soil moisture or water surrounding the pipeline is electrolyte.

2. A portion of wetted portion must be anodic and another portion cathodic.

3. There must be electrical potential between anode and cathode. There are so many
factors that causes it i.e.:
a) Dissimilar metal
b) Deficiency of oxygen in soil etc.
4. There must be solid conductor between anode and cathode. The pipes itself act as a
conductor.
5. There must be continuous electrolytic path between anode and cathode. The moisture
provides this path.
2.A. PREVENTIVE MAINTENANCE
 
AIR SURVEILLANCE AND GROUND PATROLLING

PREVENTION AND REMOVAL OF ENCROACHMENTS

WASH OUT REPAIRS

DEMARKATION OF ROU BY PROVIDING BOUNDARY STONES AND PIPE LINE MARKERS.

RECONDITIONING OF PIPELINES BASED ON PEARSON AND CORROSION SURVEY

ROUTINE MAINTENANCE OF PIPILINES UNDER PINNED TO ROAD AND RAILWAY BRIDGES

PAINTING OF OVER GROUND LINES AND VALVE PLATFORMS

MAINTENANCE OF C.P. SYSTEM

 
BREAKDOWN MAINTENANCE
 
PLUGING AND CLAMPING
 
SLEEVE WELDING
 
REPLACEMENT OF CORRODED PIPE LINE
Cathodic protection
 HOT TAPPING

Operation -Lowering in and retracting, the cutter is provided through operation of lower –in-
crank

-Both the main boring and retainer rod are equipped with HP/H. Temp. Cheuron type
packing. Both the packing is spring loaded and self-engineered and no adjustment for wear.

-Both packing assemblies can be replaced by unscrewing

Minimum air pressure – 105 CFM at 90 psi

RPM varies from 35-45 depending upon size of tap.
Preparation for tapping

1. Select the correct cutter, cutter holder and pilot

2. Assemble cutter holder and pilot
3. Select a valve for tapping (which will allow the cutter through the bore without damaging the cutte
4. Assemble adaptor to tapping machine
5. Attach cutter assembly to boring bar of tapping machine.
6. Measure length of welding fittings and tapping valve. This length should be short enough as the
maximum traveling is limited to 24”
7. M0unt the tapping machine on the closed valve.
8. Open the valve and extend boring bar until pilot touches the pipe.
9. Attach air hoses.
10. Check the bleeder valve. It is in open position.
11. Set stop collar on measuring rod for depth of cut.
12. Engage the clutches slowly.
13. Start tapping slowly by opening air motor control.
14. When the pilot penetrates the pipe purge air from valve and fitting and close the bleeder valve.
15. When the measuring mark indicates that tap is complete. Retract the cutter and close the valve.
 Pour Point Depressants

Pour point depressants are used to allow the use of petroleum based mineral oils
at lower temperatures.

The lowest temperature at which a fuel or oil will pour is called a pour point. Wax
crystals, which form at lower temperatures, may interfere with lubrication of
mechanical equipment.

High-quality pour point depressants can lower a pour point of an oil additive by as
much as 40°C.
Introduction to Pigging in Pipeline
Pigging in pipeline is a process in pipeline maintenance that involves the
use of devices known as pigs, which clean pipelines and are capable of
checking pipeline condition without necessarily stopping or interfering with
the flow of product in the pipeline.
The primary purpose of pipeline pigs is to make sure that the pipe is clean
and free from obstruction. The pig is usually cylindrical or spherical to aid
movement and efficient cleaning. As the pig moves through the pipeline, it
can possibly detect and remove any build-ups within the pipe which can
often lead to reduced performance, increased energy costs and cause
corrosion, which could lead to disastrous leaks and cracks in the pipeline.
Pipeline pigging is used in number of industries including oil & gas, lube oil,
chemical plants and hygienic applications such as pharmaceutical or food.
Working Principle of Pigging