Pipeline
Pipeline
Long series of Pipes usually of large diameter often underground with few fittings & equipment’s mostly Pumps & Valves mainly to control the flow, that are laid with an intention to transport any fluid whether liquid or gas over long distances.
- The design of pipeline is governed by ASME B31.4 that is code for Liquid Transportation Systems for Hydrocarbons, Liquid Petroleum Gas, Anhydrous Ammonia, and Alcohol and ASME B31.8 that is a code for Gas Transmission and Distribution Piping Systems.
- The constructions drawing here are termed as alignment sheet.
- Pipeline design generally involves river crossing, highway crossing, rail line crossing etc.
- The pipeline is Series of straight pipe welded together over a long distance.
- The pipeline can run underground, aboveground and underwater such as a subsea pipeline.
- Pipelines are mostly large diameter that transport bulk liquid or gas from one place to other sometimes 1000s of miles in distance.
- In pipeline few equipment are used within the Pipeline system such as pumps, valves & instruments that support the function of the system to transport fluid safely over a long distance.
Piping
Piping
Large series & networks of Pipes within the well-defined boundaries of the plant/plot with all fittings & equipment’s like Pump, Valves, Unions & other Miscellaneous items with an intention to transfer fluid from one facility to another within those boundaries as required.
- Piping is designed in accordance with ASME B31.3 that is Process Piping code and for power plant piping ASME B31.1 that is code for Power Piping.
- The construction drawings here are termed as isometric drawings.
- Piping is a Complex network of pipe & fittings within the defined boundaries of the plant.
- Piping is mostly above ground with very few underground services.
- Piping can be from ½” to 80” as per the plant design requirements that transfer fluid from on equipment to another within the plant boundary.
- Variety of equipment such as a pump, valves, filter vessel, column, heat exchanger, instruments are used within the piping system that supports the function of the plant to produce finish product.
Onshore System
| SL. NO. | Onshore PIPELINE | Onshore PIPING | |
| 1 | Design Codes | ||
| · ASME B31.4 : Pipeline Transportation Systems for Liquids and Slurries · ASME B31.8 : Gas Transmission and Distribution Piping Systems | · ASME B31.3 : Process Piping | ||
| 2 | Scope | ||
| Outside plant boundary Cross-country (i.e. villages, fields, river, canal, railway, highway, cities, deserts, forests, hills, Ghats etc.) | Within plant boundary (up to all nozzles/ equipment terminal points) | ||
| 3 | Type of pipe | ||
| Line pipes as per following code: · API Spec 5L: Specification for Line pipes | Assorted pipes as per following code: · ASTMs · BS · API 5L | ||
| 4 | Valves | ||
| Valves are procured as per following code: · API 6D: Specification for Pipeline and Piping Valves Full Bore (FB) Ball Valves are used for smooth passage of pigs. | Valves are procured as per following code: · BS · API Standard Full bore (FB) and Reduced bore (RB) both types of valves are used as per respective valve standards. There is no requirement for pigging. | ||
| 5 | Welding | ||
| Welding code: · API Std. 1104: Welding of Pipelines and Related Facilities Type of welding: | Welding code: · ASME Sec. IX: Standard for Welding and Brazing Procedures, Welders, Brazers and Welding and Brazing Operators Type of welding: | ||
| 6 | Weld joint inspection (NDT requirements) | ||
| 100% by Automatic UT or RT (by using X-Ray) | 5% to 100% (mostly by using gamma ray source) | ||
| 7 | Analyses | ||
| – Wall Thickness Analysis – Elastic Bend Radius Analysis – Stability Analysis for Water Bodies/ Marshy Areas – Horizontal directional drilling design analysis – Railroad/ Highway Crossing Analysis – Casing Pipe Analysis for Crossings – Seismic Analysis | – Piping wall thickness calculation [as input to Piping Material Specification (PMS)]
– Piping Stress Analysis (by Caesar II). Following analyses are performed on CAESAR II· Static Analysis· Dynamic Analysis · Wind Analysis · Flange Leakage Analysis · Seismic Analysis | ||
| 8 | Installation | ||
| Buried (mostly) | Above ground/ On rack/ slippers/ T-postal etc. | ||
| 9 | Special Installations | ||
| Across rivers · Horizontal Directional Drilling (HDD) method · Micro-tunneling method Across road/ rail/ highway · Auger boring/ jacking boring method · Shallow HDD Ghats/ Hills – Special equipment used | Special fabrication methods: · Modular installations · Finning · Studding · Jacketing · Spooling inside warehouse · U/G piping for cooling water | ||
| 10 | Special Equipments | ||
| · Sectionalizing Valves (Remote operated) · Insulating Joints · Scraper Launcher/ Receiver · Stem Extended Valves (for buried valves) · Flow Tee · Long Radius bends (R=6D) · Cold field bends (R = 30D or 40D) | · Expansion Joints · Motor Operator Valves (MOV) · Cryogenic Valves · Springs | ||
| 11 | Survey | ||
| · Topographical Survey (all along the pipeline route) · Geotechnical investigation (all along the pipeline route) · Soil resistivity survey (all along the pipeline route) · Hydrological Survey for water bodies (for scour depth calculation) · Cadastral Survey (for RoU acquisition) | · Wind profile from meteorology · Seismic study of plot | ||
| 12 | Corrosion Protection Coating | ||
| · Three Layer Polyethylene (3LPE) coating · Three Layer Polypropylene (3LPP) coating · Fusion bonded epoxy (FBE) coating · Coal tar enamel (CTE) Coating | · Painting | ||
| 13 | Cathodic Protection System | ||
| · Impressed Current Cathodic Protection (ICCP) system · Sacrificial Anode (limited locations) | · Not applicable | ||
| 14 | Hydrostatic testing | ||
| Gauge Plate run of 95% of ID of highest thickness of pipes Test Pressure · 1.25 times of Design Pressure (for liquid pipelines) · 1.25 to 1.5 times of Design Pressure (for gas pipelines) Maximum: · Pressure equivalent to Hoop stress of 95% of SMYS of pipe material Hold period: 24 hours (generally) Selection of hydrostatic test section based on elevation difference of ground profile | No gauge plate run is done. Generally card-board blasting is done to clean the piping. Test Pressure · 1.5 × Design Pressure × Temperature Factor Maximum: · based on line schedule Hold period: 2 – 6 hours | ||
| 15 | Preservation | ||
| Preservation of pipeline with corrosion inhibited water or by filling of inert gas (N2) | Not applicable | ||
| 16 | Communication System | ||
| Telecom/ SCADA | Not applicable | ||
| 17 | Pigging | ||
| Intelligent Pigging | Not applicable | ||
| 18 | Machines/ Equipments required for installation | ||
| · Trencher · Backhoe/ Excavator · Side Boom · Cold field bending machine · Holiday Detection Machines · Pneumatic/ Hydraulic Internal Clamps | |||
Offshore System
| SL. NO. | Offshore PIPELINE | Offshore PIPING | |
| 1 | Design Codes | ||
| · DNVGL-ST-F101 : Submarine pipeline systems · API RP 1111 : Design, Construction, Operation and Maintenance of Offshore Hydrocarbon Pipelines (Limit state design) | · ASME B31.3 : Process Piping | ||
| 2 | Installation | ||
| Subsea (in water on seabed or buried in seabed) | Deck Platform Piping (similar to plant) | ||
| 3 | Survey (Subsea) | ||
| · Geophysical survey/ Bathymetric Survey by using side scan sonar, sub-bottom profiler and echo-sounder · Met-Ocean data collection · Geo-technical data of the pipeline route | Not Applicable | ||
| 4 | Pipes | ||
| Line pipes are utilized as per following specs: · API Spec 5L : Specification for Line pipes · DNVGL-ST-F101 : Submarine Pipeline Systems | Assorted Pipes are utilized as per following specs: · ASTM Standards | ||
| 5 | Valves | ||
| Full bore Valves for smooth passage of intelligent pigs are utilized as per spec: · API 6D SS : Specification on Subsea Pipeline Valves | Reduced bore valves are utilized (as there is no requirement for pigging) as per spec: · BS/API standards | ||
| 6 | Analyses | ||
| · Wall thickness Analysis · On-bottom Stability · Span Analysis · Global Buckling – Lateral and Upheaval · Pipeline Expansion Analysis · Riser Design (Span , Stress & Flexibility Analysis) · Riser Clamp Design · Pipeline Crossing Design and Analysis · Installation Analyses such as :- Pipelay Analyses in OFFPIPE, Shore approach installation design & Analyses, Riser/ Expansion Spool installation analyses, Hoses lifting & installation analyses | · Deck piping stress analysis using CAESAR II | ||
| 7 | Environmental Loads (Met-ocean Parameters) | ||
| Wave, current and external pressure and buoyancy | Wind load | ||
| 8 | Corrosion Protection Coating | ||
| Coatings such as:– · Coal Tar Enamel Coating (CTE) · Three layer polyethylene coating (3LPE) · Three layer poly-propylene coating (3LPP) · Double layer fusion bonded epoxy coating (DLFBE) | Painting | ||
| 9 | Cathodic Protection System | ||
| Sacrificial Anodic Cathodic Protection (SACP) system | Not Applicable | ||
| 10 | Welding | ||
| Welding is performed as per specification: · API Std. 1104 : Welding of Pipelines and Related Facilities Mostly automatic welding on pipelay barge. | Welding is performed as per specification: · ASME Sec. IX : Standard for Welding and Brazing Procedures, Welders, Brazers and Welding and Brazing Operators Manual welding at fabrication yard. | ||
| 11 | Weld joint inspection (NDT requirements) | ||
| 100% by Automatic UT | Mostly by using gamma ray source. | ||
| 12 | Special Equipments | ||
| · Subsea Isolation Valve (SSIV) · LR Bends · Flow tee · Pipeline End Manifold (PLEM) · Single Point Mooring (SPM) system · Submarine hoses · Floating hoses · Cables and umbilical installation · Piggy-back pipelines | Not Applicable | ||
| 13 | Installation Equipment | ||
| · Pipelay Barge · Derrick Barge · Diving support vessel · Dynamic Positioning (DP) barge (for deep-water) | · Pre-fabricated deck piping | ||
| 14 | Installation Methods | ||
| · S-lay Method (for shallow water installation) · J-Lay Method (for deep water installation) · Shore pull/ barge pull near Land Fall Point (LFP) | · Along with deck structure | ||
| 15 | Hydrostatic testing | ||
| Gauge Plate run of 95% of ID of highest thickness of pipeline. Test Pressure· Minimum : 1.25 times x Design PressureHold period · 24 hours | No gauging is done. Test Pressure· Maximum : As per line scheduleHold period · 2 hours | ||
| 16 | NDT requirements | ||
| 100% weld joints by RT or AUT | Varies from 10% to 100% depending upon service. | ||
| 17 | Intelligent Pigging | ||
| Compliant | Not applicable | ||
[Table source: – From Web]
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