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PIPELINE DESIGN

Delivering excellence through people
Pipeline Design Slide Number - 1 of 77

ENGINEERS INDIA LIMITED
EPC and Total Solutions Consultancy Organization

Engineers India Ltd – Delivering excellence through people

Pipeline Design Slide Number - 2 of 77

Petroleum Refineries

Petrochemicals
Pipelines Offshore Platforms Gas Processing Metallurgy Ports & Terminals Highways and Airports
Engineers India Ltd – Delivering excellence through people
Pipeline Design Slide Number - 3 of 77

QATAR.EIL OFFICES HEAD OFFICE NEW DELHI REGIONAL OFFICES PROCUREMENT OFFICES VADODARA. LIBYA ABU DHABI. KUWAIT Engineers India Ltd – Delivering excellence through people Pipeline Design Slide Number . ITALY. CHENNAI KOLKATA MUMBAI SITE OFFICES INSPECTION OFFICE OVERSEAS OFFICES 29 LOCATIONS (INDIA) 9 LOCATIONS (OVERSEAS) 10 LOCATIONS LONDON.4 of 77 . SAUDI ARABIA .

PIPELINE DESIGN SERVICES OFFERED BY EIL Project Implementation Services  Feasibility Studies  Project Management  Planning & Scheduling  Process Design  Detailed Engineering  Procurement Services Specialist Services  Heat & Mass Transfer Equipment Design  Environment Engineering  Information Technology Services  Specialist Materials and Maintenance Services  Plant Operation & Safety  Risk Analysis  Construction Management  Commissioning and Plant Start-up Assistance  Advanced Control & Optimization Engineers India Ltd – Delivering excellence through people Pipeline Design Slide Number .5 of 77 .

Engineers India Ltd – Delivering excellence through people Pipeline Design Slide Number .1800 km Gas Transmission Network for GAIL 1984 Over 40 major pipeline projects completed.PIPELINE DESIGN EIL EXPERIENCE 1975 1979 First major project Crude Oil Loop Line for Oil India Ltd. First major overseas project 150 km Multi Product Pipeline for Abu Dhabi National Oil Company First major high pressure Gas Pipeline Project .6 of 77 .

7 of 77 .PIPELINE DESIGN Major Onshore Projects (Completed) DESCRIPTION HAZIRA-BIJAIPURJAGDISHPUR (HBJ) MAQTA-AL-AIN PIPELINE KANDLA-BHATINDA GAS REHABILITATION & EXPANSION PROJECT (GREP) MUMBAI – MANMAD VIZAG-VIJAYWADA JAMNAGAR-LONI LPG PIPELINE CLIENT GAIL ADNOC IOCL GAIL YEAR 1989 1992 1996 1998 SIZE 36“/30”/24”/18” 30 ”/12” 22”/14”/10” 36 ” LENGTH (KM) 1800 166 1443 505 SERVICES NATURAL GAS NATURAL GAS MULTIPRODUCT NATURAL GAS BPCL HPCL GAIL 1998 1998 2001 18 ” 18 ” 16”/14”/12”/8”/ 6 260 360 1235 MULTIPRODUCT MULTIPRODUCT LPG (LIQUIFIED PETROLIUM GAS) COCHIN – KARUR PIPELINE PETRONET 2001 18 ”/14 ” 289 MULTIPRODUCT Engineers India Ltd – Delivering excellence through people Pipeline Design Slide Number .

MULTIPRODUCT & SRR TAKREER 2004 MANGALAYA-BIJWASAN PIPELINE MUNDRA-DELHI PIPELINE BPCL HPCL 2006 2006 16”/8” 18”/16” 775 1050 MULTIPRODUCT MULTIPRODUCT Engineers India Ltd – Delivering excellence through people Pipeline Design Slide Number ..8 of 77 . ABU DHABI GAIL 2003 42” 10” 12” 16” 610 230 230 208 REGASIFIED LNG NAPHTHA.contd) (Completed) DESCRIPTION VIZAG – SECUNDERABAD LPG PIPELINE CLIENT GAIL YEAR 2002 SIZE 12”/10” LENGTH (KM) 600 SERVICES LPG (LEQUIFIED PETROLEUM GAS) MANMAD-MANGALAYA PIPELINE MANGALORE-BANGLORE BPCL HPCL 2003 2003 14 ” 24 ”/20” 358 364 MULTIPRODUCT MULTIPRODUCT DAHEJ – VIJAIPUR PIPELINE INTER REFINERIES PIPELINES PROJECT.PIPELINE DESIGN Major Onshore Projects (.

PIPELINE DESIGN Major Onshore Projects (…contd) (Completed) DESCRIPTION PUNE SOLAPUR PIPELINE DABHOL PANVEL PIPELINE PROJECT (PH-I) DABHOL PANVEL PIPELINE PROJECT (PH-II) CLIENT HPCL GAIL GAIL YEAR 2007 2007 2007 SIZE 14 ”/ 12” 30” 30” LENGTH (KM) 182 / 161 187 120 SERVICES MULTIPRODUCT REGASIFIED LNG REGASIFIED LNG Engineers India Ltd – Delivering excellence through people Pipeline Design Slide Number .9 of 77 .

HEERA. Engineers India Ltd – Delivering excellence through people Pipeline Design Slide Number .PIPELINE DESIGN Major Offshore Projects (Completed) DESCRIPTION BOMBAY HIGH URAN TRUNKLINE (BUT) SOUTH BASSEIN HAZIRA TRUNKLINE HEERA-URAN TRUNK LINE ICP . GAS CRUDE SECOND BASSEIN HAZIRA TRUNKLINE MUMBAI HIGH URAN TRUNKLINE (MUT) ONGC ONGC 1995 2005 42” 30”/28” 12” to 22” 245 205 x 2 100 GAS CRUDE.HEERA TRUNKLINE CLIENT ONGC ONGC ONGC ONGC YEAR 1979 1986 1996 1996 SIZE 30”/26” 36” 26 ”/24 ” 30”/22” LENGTH (KM) 200 x 2 220 85 x 2 145 SERVICES CRUDE. NEELAM.10 of 77 . GAS GAS CRUDE. BASSEIN. GAS IN-FIELD PIPELINES OF BOMBAY-HIGH. PANNA. MUKTA.

PANNA. NEELAM. MUKTA.11 of 77 . HEERA. BASSEIN. Engineers India Ltd – Delivering excellence through people Pipeline Design Slide Number .PIPELINE DESIGN Major Onshore Projects (Current) DESCRIPTION VIJIPUR DADRI BAWANA PIPELINE (VDBPL) MUNDRA BATHINDA PIPELINE (MBPL) BINA KOTA PIPELINE VADINAR BINA PIPELINE NUMALIGARH SILIGURI PIPELINE COMPRESSOR STATIONS CLIENT GAIL HMPL BPCL BORL OIL GAIL YEAR 2009 2009 2009 2009 2009 --SIZE 48”/ 36”/ 20” 28”/ 30” 18” 24” 16” --LENGTH (KM) 500/ 38/ 55 424/ 590 257 935 400 --SERVICES REGASIFIED LNG CRUDE OIL MULTI PRODUCT CRUDE OIL MULTI PRODUCT REGASIFIED LNG IN-FIELD PIPELINES OF BOMBAY-HIGH.

12 of 77 .PIPELINE DESIGN SECTION-1 Engineers India Ltd – Delivering excellence through people Pipeline Design Slide Number .

13 of 77 .PIPELINE DESIGN CONTENTS INTRODUCTION   Modes of Transportation Benefits of Pipelines PIPELINE DESIGN     Stages of Pipeline Project Codes and Standards Design Installation. Testing & Commissioning Engineers India Ltd – Delivering excellence through people Pipeline Design Slide Number .

OIL. OIL. GAIL. CAIRN. GSPC. RIL) Engineers India Ltd – Delivering excellence through people Pipeline Design Slide Number .14 of 77 . RIL) 33 MMTPA  GAS 115 MMSCMD (ONGC.PIPELINE DESIGN Oil and Gas Production in India  OIL (ONGC.

5 MMT Others.15 of 77 .43.2006-07 NOC – 105.India 350 Capacity .5 MMT 302 300 (MMT) 250 235 200 149 150 100 70 50 0 1998-99 2006-07 2011-12 2016-17 (Actual) Year Engineers India Ltd – Delivering excellence through people Source: Report of Working Group on P&NG Sector for the XI Plan Pipeline Design Slide Number .PIPELINE DESIGN Refining Scenario.

PIPELINE DESIGN Modes of Hydrocarbon Transportation .India 35% 30% Pipelines Road Tankers Rail Tankers Water Carriers 32% 32% 26% 10% 25% 20% 15% 10% 5% 0% % Share Pipelines Road Tankers Rail Tankers Water Carriers Engineers India Ltd – Delivering excellence through people Pipeline Design Slide Number .16 of 77 .

17 of 77 .PIPELINE DESIGN Benefits of Transportation by Pipelines         Safer mode of transportation Environment friendly Least energy requirement Lowest maintenance costs Minimal impact on land use pattern Negligible loss of product in transit High reliability Multi-product Transportation Engineers India Ltd – Delivering excellence through people Pipeline Design Slide Number .

5 2 1.1 2 3.18 of 77 .8 0.GasPipelines 0.5 1 0.8 1.5 0 LiquidPipelines LiquidCoastal LiquidTrains LiquidTrucks CoalTrains CoalCoastal N.PIPELINE DESIGN Energy Savings Energy Intensity for Various M odes Energy Consumption in % of energy Transported 4 3.2 Pipelines are the most energy efficient modes of transportation Engineers India Ltd – Delivering excellence through people Pipeline Design Slide Number .5 3 2.5 1 0.

5 % Loss of Total Volume Transported Transmission losses are lowest in Pipelines Engineers India Ltd – Delivering excellence through people Pipeline Design Slide Number .1 0.19 of 77 .2 0.3 0.4 0.ECONOMICS OF PIPELINE TRANSPORTATION Transmission losses Losses During Transportation Rail/Road Pipelines 0 0.

ATF.PIPELINE DESIGN Products Transported       Crude Oil Petroleum Products (MS. HSD. SKO) Water & Effluents LPG Natural Gas Slurries Engineers India Ltd – Delivering excellence through people Pipeline Design Slide Number .20 of 77 .

PIPELINE DESIGN Types of Pipelines ONSHORE (LAND) & OFFSHORE (SUBMARINE) PIPELINES    Trunk Pipelines Spur/ Branch Pipelines Marine Offloading Terminals & Outfalls Engineers India Ltd – Delivering excellence through people Pipeline Design Slide Number .21 of 77 .

2 0. ROW & Compensation Line Pipe Steel Cost Main line materials Coating of Pipes Mainline Construction Cathodic Protection Telecommunication. Sr No.6 0.22 of 77 . prime-overs and construction constitute big ticket items 0 0.4 0. 2 Engineers India Ltd – Delivering excellence through people Pipeline Design Slide Number .PIPELINE DESIGN Capital cost: Typical breakup Percentage of Capital Cost. 1 2 3 4 5 6 7 8 9 10 11 1.8 1 1. 5 Item Description Liquid Lines Survey.5 0 Pipes. SCADA and RCPs Pump / Compressor Stations Delivery Terminal facilities Project Management SubTotal 2% 33% 2% 11% 33% 1% 5% 5% 2% 5% 100% Gas Lines 1% 45% 3% 6% 25% 1% 2% 12% 1% 4% 100% 1 0.

PIPELINE DESIGN Marine Offloading Terminal Engineers India Ltd – Delivering excellence through people Pipeline Design Slide Number .23 of 77 .

PIPELINE DESIGN Open sea Jetty Engineers India Ltd – Delivering excellence through people Pipeline Design Slide Number .24 of 77 .

PIPELINE DESIGN HBJ GAS PIPELINE NETWORK UTTAR PRADESH N DELHI DADRI ANOLA SHAHJAHANPUR RAJASTHAN GADEPAN ANTA BABRALA INDIA AURAIYA JAGDISHPUR GUJARAT JHABUA ARABIAN SEA HAZIRA BIJAIPUR KEY PLAN LEGEND COMPRESSOR STATION RECEIVING TERMINAL DESPATCH STATION MADHYA PRADESH Engineers India Ltd – Delivering excellence through people Pipeline Design Slide Number .25 of 77 .

PIPELINE DESIGN Major Pipelines in India Engineers India Ltd – Delivering excellence through people Pipeline Design Slide Number .26 of 77 .

27 of 77 .PIPELINE DESIGN Pipeline Construction Video Video for Mangalore Bangalore Pipeline Engineers India Ltd – Delivering excellence through people Pipeline Design Slide Number .

PIPELINE DESIGN SECTION-2 PIPELINE DESIGN CODES AND STANDRADS Engineers India Ltd – Delivering excellence through people Pipeline Design Slide Number .28 of 77 .

PIPELINE DESIGN Stages of Pipeline Project  Conceptualization    Establish Requirement Evaluate Alternatives Finalize the Concept  Feasibility Study      Pipeline Route Study and Selection Hydraulic Studies and Optimization Establish Project Cost Project Implementation Scheme Environmental Impact Assessment & Risk Analysis Engineers India Ltd – Delivering excellence through people Pipeline Design Slide Number .29 of 77 .

30 of 77 .PIPELINE DESIGN Stages of Pipeline Project  Basic Engineering    Process Design and Sizing Optimization Studies Route Surveys and Investigations  Detailed Engineering      Engineering Design Basis Route Engineering and Engineering Analysis Specifications and Job Standards Engineering for Procurement Installation Engineering and Construction Procedures Engineers India Ltd – Delivering excellence through people Pipeline Design Slide Number .

4 (2006) OISD-141 (2003) OISD-214 (2006) OISD-226 (2007) API 5L / ISO 3183 : 2007 API RP1102 API 1104 API 6D / ISO 14313 DNV OS-F101 Other References Title Gas Transportation and Distribution Piping Systems Pipeline Transportation Systems for Liquid Hydrocarbons and other Liquids Design and Construction Requirements for Cross-Country Hydrocarbon Pipelines Cross-Country LPG Pipelines Natural Gas Transmission Pipelines and City Gas Distribution Networks Specification for Line Pipe Recommended practice for Rail and Highway crossings Standard for welding pipeline and related facilities Pipeline Valves Submarine pipeline systems Applicable Standards / Specs of ASME. MSS.8 (2003) ASME B 31.PIPELINE DESIGN Major Codes & Standards Code/Standard ASME B 31. BS and DIN Pipeline Design Slide Number .31 of 77 Engineers India Ltd – Delivering excellence through people . API. NACE.

32 of 77 .PIPELINE DESIGN Major Codes & Standards Type of Crossing ROU & Land Acquisition Approval Authority Central/State Govt. as applicable (As per PMP Act 1962) NHAI National Highway Crossings SH/ MDR/ ODR Crossings Railway Track crossings Crossing through Forest land PWD Indian Railways Forest Authority River/Canal crossings Irrigation/Canal Authority Engineers India Ltd – Delivering excellence through people Pipeline Design Slide Number .

33 of 77 .LIST OF SOFTWARES USED IN PIPELINE ENGINEERING          CAESAR-II AUTOPIPE IPMCS MRPACK SORPS PIPECALC OFFPIPE PRISE PIPECROSS   PIPELINE STUDIO TGNET TLNET HYSIS Engineers India Ltd – Delivering excellence through people Pipeline Design Slide Number .

PIPELINE DESIGN Optimal sizes of various capacities

Economy of scale
Engineers India Ltd – Delivering excellence through people
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PIPELINE DESIGN
Route Selection
Routing Considerations
    

Pipeline length Obstructions & Sensitive areas Installation Limitations Crossings Topographical Geo-technical Population Density Index Soil Resistivity Cadastral
Engineers India Ltd – Delivering excellence through people
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Surveys

  

PIPELINE DESIGN
Typical Pipeline Route Map
The drawing, design and details given on this format are the property of ENGINEERS INDIA LIMITED. They are merely loaned on the borrower's express agreement that they will not be reproduced, copied, exhibited or used, except in the limited way permitted by a written consent given by the lender to the borrower for the intended use.

BHATINDA
Ch. 1012.67 km

RANSISAR Ch. 855.01 km

IP-1 & IPS-F

PROPOSED PIPELINE
IPS-2

JUD Ch. 593.88 km

IPS-F

GAILAWAS Ch. 527.87 km

LEGEND:
PROPOSED MUNDRA-BHATINDA PIPELINE (28" NB) DESPATCH TERMINAL AND PUMPING STATION RECEIPT TERMINAL INTERMEDIATE PUMPING STATION (IPS) INTERMEDIATE PIGGING STATION (IP) FUTURE PUMPING STATION (IPS-F) NOTES: 1. PIPELINE ROUTE SHOWN IS INDICATIVE ONLY. 2. CHAINAGES INDICATED ARE APPROXIMATE.

JORAWARPURA Ch. 313.63 km

IPS-1

JHEKDA Ch. 226.72 km

IPS-F

MUNDRA
Ch. 0.00 km

PROJECT : ENGINEERS INDIA LIMITED
NEW DELHI

REV. OVERALL PIPELINE ROUTE MAP
AC RK VM REV. DATE REVISION BY CHK APPROVED APPROVED

Engineers India Ltd – Delivering excellence through people

CLIENT JOB NO

: M/s GGSRL : 6812

Pipeline Design
1-1641-0503 REV.0 A3-420x297

Slide Number - 36 of 77

37 of 77 .PIPELINE DESIGN Engineers India Ltd – Delivering excellence through people Pipeline Design Slide Number .

PIPELINE DESIGN Material Selection & Corrosion Control Assessment   Materials    Nature of the Product Design Life Product Temperature Material Chemistry Internal Coatings Product Conditioning Corrosion inhibitors Corrosion Allowance    Corrosion Protection      Carbon Steel (CS) NACE Carbon Steel CRA Clad CS CS with internal Coatings Non-Metallic Materials Engineers India Ltd – Delivering excellence through people Pipeline Design Slide Number .38 of 77 .

PIPELINE DESIGN Design and Analysis    Wall Thickness Calculations Anti-Buoyancy Measures Piping Stress Analysis   Buried Pipeline Analysis Crossing Design Engineers India Ltd – Delivering excellence through people Pipeline Design Slide Number .39 of 77 .

PIPELINE DESIGN Steel Pipe Wall Thickness Calculation LIQUID PIPELINE (ASME B 31. 841.1.8. 404.72 x E x SMYS D Outside Diameter of pipe t pressure design wall thickness E Weld joint factor 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 E Longitudinal joint factor T Temperature de-rating factor Engineers India Ltd – Delivering excellence through people Pipeline Design Slide Number .11) t = PiD 2. Cl.40 of 77 . Cl.4.2) GAS PIPELINE (ASME B 31.S where Pi Internal design pressure S allowable stress = 0.

40  10 buildings > 10 and < 46 buildings  46 buildings Multistory buildings Engineers India Ltd – Delivering excellence through people Pipeline Design Slide Number . F 0.PIPELINE DESIGN Basic Design Factor for Gas Pipelines LOCATION CLASS Location Class 1 Location Class 2 Location Class 3 DESIGN FACTOR.60 0.72 0.41 of 77 .50 Location Class 4 Location Class Classification Location Class 1 : Location Class 2 : Location Class 3 : Location Class 4 : 0.

PIPELINE DESIGN Line Pipe Selection Line Pipe Selection Parameters  Type of Line Pipes    Thickness and Grade Selection Handling and Transportation (d/t ratio) Type of LinePipe Installation Requirements Seamless Electric Welded Longitudinal Seam Submerged-Arc Welded (LSAW) Helical Seam SubmergedArc Welded (HSAW)     Engineers India Ltd – Delivering excellence through people Pipeline Design Slide Number .42 of 77 .

43 of 77 .18”) Engineers India Ltd – Delivering excellence through people Pipeline Design Slide Number .PIPELINE 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 (4” .

44 of 77 .PIPELINE DESIGN Manufacturing of Helical Pipes Engineers India Ltd – Delivering excellence through people Pipeline Design Slide Number .

7 mm 350-500 micron thick single layer coating 600-800 micron thick dual layer coating  3 Layer PE/ PP Coating (DIN 30670)      Fusion Bonded Epoxy Coating (CSA Z245.0 to 3.45 of 77 .7mm First layer of Fusion bonded epoxy Second layer of extruded adhesive Third layer of extruded PE/ PP Coating thickness 2. AWWA C203)     Primer Two layers of coal tar enamel & glass fibre Inner wrap One layer of coal tar impregnated outer wrap Coating thickness 4.20)   Engineers India Ltd – Delivering excellence through people Pipeline Design Slide Number .PIPELINE DESIGN Anti-corrosive Coatings  Coal Tar Enamel Coating (BS 4164.

46 of 77 .PIPELINE DESIGN 3 Layer PE Coating Application Engineers India Ltd – Delivering excellence through people Pipeline Design Slide Number .

PIPELINE DESIGN Major Pipeline Components         Line Pipe & Coatings Scraper Traps & Pig Signallers Long Radius (LR) Bends Insulating Joints Flow Tees Sectionalizing Valves Pumps / Compressors Filters & Meters Engineers India Ltd – Delivering excellence through people Pipeline Design Slide Number .47 of 77 .

PIPELINE DESIGN Scraper traps Engineers India Ltd – Delivering excellence through people Pipeline Design Slide Number .48 of 77 .

PIPELINE DESIGN Sectionalizing Valve Spacing  ASME B 31. 12 km (7.8 for Gas pipelines  ASME B 31.4 for Liquid Pipelines Location  Pollution Concerns  Statutory Requirements  Prevention of Inventory Loss  Approachability of Valve Station Gas Pipelines Location Class 1 32 km (20 miles) Location Class 2 Location Class 3 Location Class 4 LPG Pipelines 24 km (15 miles) 16 km (10 miles) 8 km (5 miles) Industrial.5 miles) Commercial & Residential Areas Engineers India Ltd – Delivering excellence through people Pipeline Design Slide Number .49 of 77 .

BS EN ISO 17292:2004. BS EN ISO 15761:2002. BS 5353 Engineers India Ltd – Delivering excellence through people Pipeline Design Slide Number .50 of 77 . API 602.PIPELINE DESIGN Type of Valves   Full Bore Ball Valves Through Conduit Gate Valves   Plug and Check Valves Valve Standard : API 6D/ISO14313 Other Valve Standards: API 600.

51 of 77 .PIPELINE DESIGN Ball valves Engineers India Ltd – Delivering excellence through people Pipeline Design Slide Number .

52 of 77 .PIPELINE DESIGN Plug valve Engineers India Ltd – Delivering excellence through people Pipeline Design Slide Number .

53 of 77 .PIPELINE DESIGN Check valve Engineers India Ltd – Delivering excellence through people Pipeline Design Slide Number .

PIPELINE DESIGN Major Engineering Deliverables Design Reports Design Route Wall Drawings Route Basis Map Schematic Sheets Layout Selection Report Pipeline Thickness Report Alignment Seismic Design Report Design Report SV Station Layout Crossing Equipment Piping General Arrangement Drawings Engineers India Ltd – Delivering excellence through people Pipeline Design Slide Number .54 of 77 .

040 14.849 11.493 13.73m/RL 39.543 75.617 11.742 13.825 11.00Km HIGH TENSION LINE 12. 10985.060m TP61 CH.962 142. 12848.803m IP51/1 CH.629m LOW LYING AREA TP63 CH.642 326.747 224.14115.780 248.219 39.677 237.55 of 77 . 17.692 10.758 11.369 37.034 C ART TRACK GRAVEL ROAD CH.11848.390 38°4'58''(R) 5°18'55''(R) 8°2'3''(L) 76.061 12.986 11.828 24.231m MATC H LINE FOR C ONT.588 43.040 10. 11939.11648.138m) C ANAL C H 10691.022m TP55 CH.000 45.10787.741m CH.849 11.604 23.713 10.772 TP57 1°21'55''(L) 141.929 237.732m GRAVEL ROAD CH.11824.972 11.254 217.587m PUMP HOUSE 4m FROM C/L 45 43 41 SCALE: HORIZONTAL 1:5000 VERTICAL 1: 500 35 33 31 29 27 25 23 21 37.014 348.478 11°25'7''(L) 322.025 11.135 28.939 12.046 25.02m/RL 32.622 C ART TRACK OPEN WELL 6m DIA 8m FROM C/L CH 11577.533m) TP62 CH.754 12.455m IP61/1 CH.648m FROM C/L CH.12747.510m HPCL CH. 10712.11960. 14134.815 27.218 m RAIWADA LEFT CANAL (UNLINED) CH.877m C ANAL C H 14027.884 30.713 10.2m HIGH & 550KV HPCL CH.587 31.362 27.544 76. 11401.259 11.660 114.113 104.11018.939 11.455m DRAIN CH.34m/RL 22.138 24. LINE 440V CH.12060.444 IP61/1 TP62 15°2'57''(L) 326.858 25.126 TP55 TP56 13°54'57''(R) 176.708 322.175m R OAD 39 37 C H 11824.219 40.845 TP58 IP58/1 8°24'45''(R) 45.63m/RL 24.115 12.298m K SV-1 OF GAIL CH.202m GRAVEL ROAD CH.787 10.714 48.13 Pipeline Design Slide Number .27m/RL 42.000 67.115 14.45 29-1 0-16 -71-9003 TO CH INTA A GUTL CH.175 38.606 CH.853 STATE .134 176.062 11.848 13.066 13.993 IP51/1 TP52 TP53 TP54 37°0'54''(L) 339.14027.578 11.496 30.979 14.366m C H 10787.728 IP64/1 TP65 5°18'12''(R) 90. DISTRICT AND MANDAL TO IRUVADA PU R M A TP65 CH.309m ELEC.761m TP56 CH.848 13.101 34.397m VILLAGE BOUNDARY R OAD C H 14040.31m/RL 43.248 13.152 21.034 KAJU GARDEN RICE FIELDS 10. 13741.557 29.760 141.892m ST AT E CH.407 TP61 8°30'18''(L) 218.758 11.341 24.370 25.816 39.675 24.218m MATC H LINE FOR C ONT.463 141. R EFER DWG NO.081 12.679 TP63 10°4'42''(L) 237.707 TP64 10°25'50''(L) 65.028 14.341m DRAIN C H 12060.514m) TP50 CH.969 299.00Km ELECTRIC LINE 440V CH. 11616.14132.093 104. 11062.061 12.71m/RL 33. 12455.749 66. 13979.091m TP60 CH.741 42.200 85.14040.8 8m TP57 TP58 CH. 10687.88m/RL 24.248 13.025 11.415 13.411m UR AM AMRUTAPURAM IRUVADA DRAIN C H 10664.636 196.211m A R M IT A TELEPHONE LINE CH. 10691.096 339.803m .081 12.491m C H 14115.560 32.825 11.199 74.115 12.275m TEMP.342 20. 12230.049 25.618 67. 13066.300 29.604m RAIWADA LEFT CANAL (UNLINED) CH.12115.978m TP59 IP58/1 CH.219 29.175 C H 12115.855 187.062 11.141 77.415 13.259 11.135 19.14044.455 12. 15.344m TO AM RUTH AP HPCL CH.667 22.1 C 10 m T O PE D N A EARTHEN EMBANKMENT ND TO PE CH.199 85.578 11.7 IN 4 A 6 R 06 D H.539 182.621 10.135 14.463 176.984 12.284 38.230 12.604m TP52 CH.6m/RL 35.665 10.732m TP64 CH. 10620.935 30. HUT ON C/L HIG H TBM W49 (RL 25.894 44.115 14.896m IP64/1 CH.395 393. 16.00Km K TRAC m CART 492.622m OPEN WELL 6m DIA 7.658m TP53 DRAIN C H.743m K K TBM W57(RL 42.979 14.066 13.411 33.624 TP59 2°8'32''(L) 224.401 11. 10797.521 12.534m EARTHEN EMBANKMENT RU A AM TH AP TO ELEC TRIC LINE C H.676 26.12903.PIPELINE DESIGN Typical Pipeline Alignment Sheet INTERSECTION POINTS(IP/TP) DEFLECTION ANGLE DISTANCE BETWEEN TP & IP's(m) DISTANCE AS PER GROUND PROFILE TP50 IP50/1 TP51 29°8'20''(L) 187.904 24.692 10.558m IP50/1 TP51 CH.164 90.366 35.754 12.761m C H 13492.444 33.787 10.597 24.749 38.986 11.437 348.604m R OAD DRAIN 25.028 14.117m TP54 CH.000 218.022 TP60 14°0'19''(R) 393.522 121.742 13. 12125.117 166. 13414.230 12.665 10.684m Engineers India Ltd – Delivering excellence through people UR AM W A Y-S A BB AV AR AM DRAIN CH.960 11.246 90.45 29-1 0-16 -71-9005 TBM W40 (RL 37.325 33.14134.493 13.621 10.893 32.617 11. R EFER DWG NO.455 12.136m 37.491 198.978m CH.684 43.969 225.521 65. 12080.401 11.61m/RL 33.896m METALLED ROAD(ASPHALTIC) CH. 11577.366 94.

56 of 77 .PIPELINE DESIGN Typical P&ID Engineers India Ltd – Delivering excellence through people Pipeline Design Slide Number .

PIPELINE DESIGN Typical GA DRAWING Engineers India Ltd – Delivering excellence through people Pipeline Design Slide Number .57 of 77 .

PIPELINE DESIGN Major Engineering Deliverables Tenders    Survey Tender Pipe Coating Tender Pipeline Installation Tender Line Pipes Valves & Actuators Scraper Traps. Pig Signallers Flow Tees & Insulating Joints Induction Bends Flow meters Pumps & Compressors OFC cables Pipeline Design Slide Number . QOEC.58 of 77 Material Procurement         Engineers India Ltd – Delivering excellence through people .

Testing & Commissioning RoU Grading & Trenching Stringing of Linepipe Engineers India Ltd – Delivering excellence through people Pipeline Design Slide Number .PIPELINE DESIGN Installation.59 of 77 .

Testing & Commissioning Welding & NDT :     Edge Preparation Internal / External Line-up Clamps Manual / Automatic Welding NDT (X-Ray / UT / MPI etc.60 of 77 .) Engineers India Ltd – Delivering excellence through people Pipeline Design Slide Number .PIPELINE DESIGN Installation.

61 of 77 . Testing & Commissioning Field Joint Coating   Lowering & Backfilling Heat Shrink Sleeves Cold applied tapes Engineers India Ltd – Delivering excellence through people Pipeline Design Slide Number .PIPELINE DESIGN Installation.

PIPELINE DESIGN Pipeline Crossings Crossing Installation Crossings  River. Road & Rail  Utility Crossing Methodologies  Open-Cut Method  Trench-less Method  Horizontal Directional Drilling  Jacking and Boring  Micro tunneling Engineers India Ltd – Delivering excellence through people Pipeline Design Slide Number . Canal.62 of 77 .

PIPELINE DESIGN The conventional HDD operations for river crossings.63 of 77 . Engineers India Ltd – Delivering excellence through people Pipeline Design Slide Number .

PIPELINE DESIGN Pipeline Installation using Micro-tunnelling MICRO-TUNNELLING:     Micro Tunneling process uses a Micro Tunnel Boring Machine (MTBM) combined with pipe jacking technique. cobbles & boulders Installation of more than one pipe in the tunnel Precise installation and Minimum space at both ends Can be done in curved path also Engineers India Ltd – Delivering excellence through people Pipeline Design Slide Number .64 of 77 . 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. Pipe jacking from launch shaft to reception shaft.

PIPELINE DESIGN Pipeline Installation using Micro-tunnelling Long Distance Micro Tunnelling Engineers India Ltd – Delivering excellence through people Pipeline Design Slide Number .65 of 77 .

PIPELINE DESIGN Overview of Micro tunneling Engineers India Ltd – Delivering excellence through people Pipeline Design Slide Number .66 of 77 .

4 * des pr Engineers India Ltd – Delivering excellence through people Pipeline Design Slide Number .322(f) Class 1 and 2: 1.25 * des pr Class 3 and 4: 1.25 times design pressure GAS PIPELINES Ref. ASME B 31.67 of 77 .4. ASME B 31.4 : 437.8 : Table 841.1 1.PIPELINE DESIGN Testing & Commissioning TESTING    Gauging and Pigging Test Pressure Test Medium DRYING Swabbing  Methanol Drying  Super Dry Air Method  Vacuum Drying COMMISSIONING  Nitrogen Purging  Product Charging  TEST PRESSURE LIQUID PIPELINES Ref.

68 of 77 Engineers India Ltd – Delivering excellence through people .PIPELINE DESIGN Pigging Requirements  Types of Pigs     Pipeline Cleaning Displacement Internal Inspection Batching    Brush pigs Gauge Pigs Spheres Intelligent Pigs Cleaning pigs Gauge Pigs Spheres Intelligent Pig (MFL) Pipeline Design Slide Number .

69 of 77 .PIPELINE DESIGN RECENT DEVELOPMENTS TECHNICAL IMPROVEMENTS   Automatic Welding & Automatic UT Micro-Tunneling for pipeline construction   Internal flow coating on line pipes for gas pipelines 3LPP coating on High Temperature pipelines Engineers India Ltd – Delivering excellence through people Pipeline Design Slide Number .

70 of 77 .PIPELINE DESIGN Comparison of LSAW & HSAW Pipes Description Method of Manufacture Weld Length Position of weld LSAW UOE/COE/JCO/3 roll bending Equal to pipe joint length Longitudinal – positioned in upper quadrant during construction HSAW Formed by Twisting of Coil Approximately 1. resulting in proportional increase in coating cost by 15-20% Controlled during forming only and no cold expansion is carried out Geometry Engineers India Ltd – Delivering excellence through people Pipeline Design Slide Number .5 to 2 times the length of pipe joint Spiral – present all around the pipe Corrosion Coating Specified thickness throughout entire body. Weld seam is tracked to ensure coating thickness on weld seam Controlled to the desired level with cold expansion Thickness normally increased all over the body.

PIPELINE DESIGN Coating Comparison CTE Service Conditions Temperature. o C Upto 45 Upto 65 Upto 110 Upto 110 3LPE 3LPP FBE Anti-corrosion Properties Resistance to Moisture Good Very Good Excellent Good Cathodic Disbondment Fair Good Good Good Electrical Properties Coating Resistance Good Excellent Excellent Excellent Engineers India Ltd – Delivering excellence through people Pipeline Design Slide Number .71 of 77 .

PIPELINE DESIGN Coating Comparison CTE Cathodic Protection Design Current Density High Low Low Low 3LPE 3LPP FBE Mechanical Properties Resistance to Impact Fair Excellent Superior to PE Fair Resistance to Indentation Resistance to Peel Poor Very Good Excellent Fair Fair Excellent Superior than PE - Resistance to Soil Stresses Elongation Fair Excellent Excellent Excellent Fair Excellent Excellent Pipeline Design Slide Number .72 of 77 Engineers India Ltd – Delivering excellence through people .

PIPELINE DESIGN Coating Comparison CTE Long Term Ageing Heat & Light Ageing Fair Very Good Very Good Very Good 3LPE 3LPP FBE Application & Field Repair Ease of Application Easy Relatively difficult Relatively difficult Relatively difficult Damages during handling & transportation Ease of Field Repair High Low Low High Difficult Easy for small repair. Cumbersome for larger repair Easy for small repair.73 of 77 . Cumbersome for larger repair Engineers India Ltd – Delivering excellence through people Pipeline Design Slide Number . Cumbersome for larger repair Easy for small repair.

Thank You www.74 of 77 Engineers India Ltd – Delivering excellence through people .engineersindia.com Pipeline Design Slide Number .