iemr-oil & gas transmission & distribution pipelines

7/28/2019 IEMR-Oil & Gas Transmission & Distribution Pipelines

1/78

INTRODUCTION TOHYDROCARBON PIPELINES


2/78

OIL & GAS PIPELINES

Crude oil is often transported between

continents in large tankers, but oil and natural3

gas is transported (transmitted) across

continents by pipelines.

Transmission pipelines are the main arteries

of the oil and gas business

Pipelines are 40 times safer than rail tanks, and

100 times safer than road tanks for transportingenergy

According to the USA Association of Oil

Pipelines, Oil pipeline spills amount to about 1

gallon per million barrel-miles

Source: Oil & Gas Pipeline By Phil Hophinks (Penspen


3/78

WHY WE ALL SHOULD BE INTERESTED

IN PIPELINES

We rely on pipelines to deliver our energy needs, but everyone is astakeholder in oil and gas transportation:

Pipeline operators (transporters) want a safe, reliable supply, and a

reasonable profit;

The general public (consumers) want cheap gasoline, natural gas, etc.,

delivered reliably and safely, with minimal environmental damage;

Shippers (producers) want cheap, reliable supplies and transportation,

and a reasonable profit;

Regulators want a fair and competitive market;

Government groups want safe, environmentally-friendly, delivery;

Advocacy groups (focussing on environmental, cultural, etc., aspects)

have focussed interests;

The biggest challenge facing the pipeline engineer today and tomorrow is

safetySource: Oil & Gas Pipeline By Phil Hophinks (Penspen


4/78

TYPES OF HYDROCARBON

PIPELINES

These pipelines are made from high quality steel (line pipe steel), constructed

using well-established methods, and operated using procedures developed over

many decades.Source: Oil & Gas Pipeline By Phil Hophinks (Penspe


5/78

PIPELINE COMPONENTS Metallic pipes

Ordinary steel pipe

Corrugated

Cast-iron

Ductile-iron

Stainless steel

Aluminum Copper

Non metallic pipes

Plastic

Rubber and elastomer

Glass

Tubings & pipe designation

Connections

Fittings

Pressure relief and pressure regulating valves


6/78

METALLIC PIPES Metallic pipes are stronger and tougher to break but they have

disadvantages like more sensitive to heat and electricity,

corrosion sensitive

More conductive to heat and electricity.

Following are some of the commercial metal pipelines:

1. Ordinary (Wrought ) steel pipelines seamed or seamless Seamed made up of steel sheets/plates rolled into circular

shape, with edge of each pipe closed by welding

Different types welding are-

1) Butt Welding2) Lap Welding

3) Electric Arc Welding (Single or Double Welded joint)

Source: PE 607 : Oil & Gas pipeline Design, maintenance & Repair


7/78

CORRUGATED STEEL PIPE

Thin-wall, large-diameter, made of galvanized steel sheetshaving either helical or annular corrugations

Used extensively in sewer and drainage systems

Flow is often gravity flow rather than pressure flow.

Have large variety of fittings and great range of sizes.

Some fabricated to have a pecan-shaped instead of circular

cross section



8/78

CAST-IRON PIPE

Two types: ordinary or gray cast-iron pipe, and the ductile-iron pipe.

The ordinary cast-iron pipe made of iron containing 3 to

4% of carbon in the form of graphite flakes.

Gray cast-iron pipe has relatively strong corrosion-resistance ability and long life

Two strength designations: 18/40 and 21/45.

18 means that the min bursting tensile strength is 18,000

and 40 means that the min modules of rupture is 40,000psi.



9/78

DUCTILE-IRON PIPE

Made of iron containing 3.5% carbon in sheroidal ornodular form, and a magnesium alloy

Has the advantage of gray cast-iron pipe (corrosion

resistance and long life) and steel pipe (ductility).

Strength designation is 60/42/10

Min tensile strength of 60,000psi

Min yield strength of 42,000 psi

10% min elongation



10/78

STAINLESS STEEL PIPE

Contains chrome-nickel alloys

300 series such as SS304 or SS316, are the most used stainless

steel pipes.

Corrosion resistant

High price, used only in special applications such as:

When the fluid or environment is corrosive

When no rusting of pipe can be tolerated such as in

pharmaceutical or food industries.



11/78Source: PE 607 : Oil & Gas pipeline Design, maintenance & Repair


12/78

NON METALLIC PIPES

Not as strong as metallic pipes

Light in weight

More economical

Certain advantages such as being more corrosion resistant.

The one used in oil and gas is plastic pipes.



13/78

PLASTIC PIPES 3 types of plastic pipes commonly used

PVC (Polyvinyl chloride) PE (polyethylene)

PP (polypropylene)

Used for

Water Waste water

Natural gas

Other fluids that do not dissolve or chemically interact with

plastics Deform easily

Expand 5 times as much as steel due to temperature

Becomes brittle in very cold weather

Long term performance not known


14/78



15/78

CONNECTIONS (JOINTS)

Bonded joints-welding, brazing or soldering and fusing.

Threaded joints-connecting threaded pipe sections together

Flanges-provide strong joint without permanently joining the

pipe sections.

Mechanical joints-for ease in assembly/disassembly

Bell-and-spigot-used in pressure concrete pipes, glass and

plastic pipes also use

Push-on-connected together simply by pushing two pipe

sections against each other



16/78



17/78

VALVES

Gate valve

Closed/opened by turning handle connected to it Takes many turns to completely open or close a gate valve

Head loss is small when gate fully opened

Maybe a wedge or a disk or a knife

Has a conduit with a full round bore for smooth passage ofpigs



18/78

VALVES

Globe valve

Outside is globe shaped

Flow changes direction as it goes through the valve

Large head loss when valve fully opened

Gives better control or flow than gate valves-good for flow

throttling



19/78

VALVES

Check valves Flow cannot reverse through a check valve, unidirectional

flow

3 types of check valves are swing check, tilt disk, ball check

valve.



20/78



21/78

PIPELINE CONSTRUCTION


22/78

Following are reference/codes followed during Laying ofpipeline & Line-pipe coating:

1. API 1105 : Construction practices for Oil & Productpipelines

2. ASME B 31.4 : Pipeline transportation System for liquidHydrocarbon

3. ASME B 31.8 : Gas Transmission & Distribution PipingSystem

4. OISD B 141 : Design & Construction requirement forcross country Hydro Carbon Pipelines

5. API 6 D : Construction & Inspection of valves

6. API 1104 : For welding of pipeline & related activities

7. DIN 30670 : For 3LPE coating for line pipes

CODES & STANDARDS

Source: eil.co.in/ eil specification


23/78

1. ROU (Right of Use) SURVEY

2. ROU CLEARING AND GRADING3. STRINGING

4. TRENCHING

5. BENDING

6. WELDING7. FIELD JOINT COATING

8. LOWERING

9. BACKFILLING

10.CROSSING

11. HYDROTESTING

12. PIPELINE MARKERS, CLEAN UP & RESTORATION

13. MAGNETIC PIGGING & EGP PRE COMMISSIONINGACTIVITY

PIPELINE LAYING ACTIVITIES



24/78

ROU Survey, ROU Clearing and

Grading, Stringing



25/78

1. ROU (Right of Use) SURVEY:

Installation of Bench Marks, Turning Points

Stake markers in center line of pipeline at a distance of max100m for center line and for horizontal bends 10 m and

reference point for same

Stake two ROU markers at least at every 100m, Painted in Red

and numbers in white in direction of flow

Chainage markers at every 250m

2. ROU CLEARING AND GRADING

All obstacles causing hindrance in construction / laying pipeline

are removed Entire ROU is Graded for movement of equipments and vehicle

Temporary approaches/bridges, if required, are constructed for

movement of equipments, vehicles & personnels



26/78

3. STRINGING

Stringing shall be done after blasting & trenching when

ROU is in rocky area

Coating pipes shall be strung on approved soft earth/sand

filled bag and wedge in such a way that bottom of coated

pipe remain above ground

Pipes shall be supported at minimum two locations

Pipe number, Heat number, coat number & length shall be

transferred and recorded in serial order



27/78

Trenching



28/78

4. TRENCHING

Trench excavation is carried out along staked centerline of

Pipeline.

The width of excavation for trench shall be minimum(pipe diameter

plus 200 mm either side).

Depth of trench shall be specified (Normal =1M;

Road=1.2M;River=1.5M,Rly=1.7M etc.

In case of trenching in rocky areas, blasting is performed with the

guidelines/Safety Rules Of CCOE, Nagpur.

In case where rock/gravel or hard soil is encountered in the bottom

of the trench, padding material(minimum compacted thickness of

150mm) shall be provided.

When up floating of the pipeline after backfilling is anticipitated &

anti-buoyancy measures are provided in such areas e.g. by

installing saddle weight



29/78

Welding

Manual Welding

Automatic WeldingSource: eil.co.in/ eil specification


30/78

5. WELDING

Automated welding involves using mechanical or electronicmeans to control welding conditions such as welding current,

arc length, filler wire, or electrode feed, as well as travelspeeds. Movement and guidance of the electrode, torch orwelding head along the line of weld can be similarlycontrolled.

Advantages of automated welding1. A less experienced operator can handle the welding machine andhave satisfactory end results.

2. A smaller percentage of welding electrodes is lost in stub ends. Amuch shorter arc is uniformly maintained by the automated

welding process than is possible by a manual operator.3. A much higher current can be used with a given size of welding

wire to produce better fusion. A much higher welding speed canalso be obtained.



31/78

6. BENDING

For changes in vertical &

horizontal alignment, prefabricated

coal field bends are provided. Over bends are made in a manner

that centre of bend clears the

highest point of trench bottom. Sag

bend shall fit the bottom of trench.

Side bends shall have specified

clearance to the outside wall of

trench.

The radius of coal field bend shall

be not more than 40 times the dia.of pipe(for 18 and above) and 30

times the dia. of pipe(for 17

below)



32/78

7. FIELD JOINT COATING The cut-back areas of Coated

Pipes where weld joints are

made to be coated by fieldjoint coating.

Field joint coating material isheat shrinkable wraparoundsleeve used as anticorrosioncoating of buried onshorepipeline.

Sleeve consist of radiationcross-linked thermallystabilized, ultraviolet resistantsemi rigid polyolefin backingwith a uniform thickness ofhigh shear strengththermoplastic melt adhesive.



33/78

The joint coating system shall consist of a solvent free epoxy

primer applied to pipe surface prior to sleeve application. The

surface area is blast cleaned to SA-2.5 followed by pre

heating of pipe surface, application of epoxy primer andapplication of sleeve by heat shrinking.

One out of 50 joints coating or one coating out of every day

production shall be tested to establish peel strength on steel

and factory applied coating.



34/78

Lowering



35/78

8. LOWERING

Lowering shall commence after inspection of trench

Lowering shall commence as soon as possible after

completion of joint coating The pipeline must be laid without interruption for the

whole or the length of section available

Ends of the lowered pipeline section shall be closed with

night cap to prevent ingress of water, mud etc.



36/78

9. BACKFILLING

Backfilling shall be carried outimmediately after pipelinelowering in trench after

inspection, so as to provide anatural anchoring for pipeline.

Backfilling material shall notcontain any extraneousmaterial or hard lumps of soilwhich can damage pipeline or

coating or leave the voids inbackfilled trench

If trench are excavated insteep area where the slope ismore than 10%, slopebreakers shall be installed toprevent erosion of backfill,stabilization of backfill shall bedone in sandy area to haveconsolidated cover over thepipeline


37/78

Crossing

CROSSING

Cased & Un-cased

crossings for Roads &

Railways

Open cut & Horizontal

Directional Drilling (HDD) forminor & major river crossing


38/78

11. HYDROTESTING

After the acceptance of gauging operation, uninhabitedwater is pumped into the section using four cup batching

pigs which are launched at specific intervals.After water filling the thermal equilibrium is maintained

between pipeline & environment using thermocouples.

After thermal stabilization, pressurization is carried out in

cycles at 50% test pressure & 75% test pressure andheld for 1 hr at each test pressure and depressurized tozero pressure & then pressurized to final pressure.

The test shall be considered positive if pressure has

kept a constant value throughout the test duration,except for change due to temperature effects. Thepressure value thus added shall be compared with initialvalue and test shall be considered as acceptable ifdifference is less than to 0.3 bar



39/78

Hydro Testing



40/78

12. PIPELINE MARKER, CLEAN UP &

RESTORATION

Following markers shall be installed along pipeline route such that

they do not caught any hindrance to regular land user and traffic.

Aerial Markers - At every 5 Kms

Kilometer Markers - At every 1 Kms as per Alignment

sheet

Pipeline Warning Markers - At Road/Railways/CrossingROU Boundary Markers - At every 750 m as per

alignment sheet

Navigational Markers - At bank of navigational course

On completion clean up of pipelines ROU shall be restored to suchstable and unstable as may be reasonably consistent with the

condition of ROU prior to laying of Pipeline



41/78

13. MAGNETIC PIGGING & ELECTRONIC GEOMETRICPIGGING

This is a part of pre-commissioning activity, which ensure thatthere is no deformity in pipeline. This is done prior to filling line

with the product. Magnetic PIG loaded with high capacity magnets spread uniformly

with high density polyethylene four cup PIG is launched to removeferrous debris, mill scale, electrode pieces etc. The accumulatedweight of ferrous debris is checked after running the PIG throughpipeline section. When the collected weight of ferrous debris iswithin limit for specific length of pipeline section, the line is ready forlaunching Electronic Geometric Pigging (EGP) tool.

After successful completion of magnetic pig run EGP tool islaunched. The tool is mounted with battery operated battery device,which give the reduction in pipeline Dia. At specific location in

electronic form. Defect upto more than 3% internal diameter of pipe is physically

verified at site. Defect of more than 5% internal diameter of pipe arerepaired by cutting suitable length of pipe and re-welding.



42/78

Horizontal Directional Drilling (HDD) is a trenchless excavation processthat provides the installation of pipelines beneath a wide range of

surface obstacles like Rivers, Highways, Railway Xings, and Right ofWays through Developed Areas etc.

It offer a number of benefits over traditional open-cut methods.

It can be implemented with very little disruption to Surface activities,requires less working space, and quicker than Open-cut methods.

Equipm ent required for HDD are -

1. A rig, which provides the physical means thrust and torque, to open thehole and pull in the product.

2. A transmitter/receiver system for tracking the location of the bore.

3. The down-hole equipment - drill pipe, drill bits, and reamers, whichconverts the physical properties of the rig to open the hole and pull in theproduct.

4. The drilling fluid, which serves to stabilize the hole, cool the down-hole5. equipment, and remove the spoils from the hole.

6. The drilling fluid delivery and recovery system made up of tanks, mixingsystems, pumps; and, when recycling fluids, a system of screens, filters,

7. Shakers, cones, etc. to remove spoils brought to the surface from the fluid.

Continue..

HORIZONTAL DIRECTIO NAL DRILLING

Source: Trenchless Technologies Ltd (website)


43/78

The HDD process begins with boring a small, horizontal hole(Pilot Hole) under the crossing obstacle (i.e. a River) with acontinuous string of steel drill rod, using technology thatallows the drill to be steered and tracked from the surface.

When one of the key considerations in the design of the drill-path is creating as large a radius of curvature as possiblewithin the limits of the right-of-way.

The Curvature requirements are dependent on site geometrycrossing length, required depth to provide safe cover, stagingsite location, etc.

The Drilling operation consists of using an appropriate tool toopen the pilot hole to a slightly larger diameter than the

carrier pipeline. The percentage oversize depends on many variables

including soil types, soil stability, depth, drilling mud, boreholehydrostatic pressure, etc. Normal over-sizing Varies from120% to 150% of the carrier pipe diameter

Continued..

HORIZONTAL DIRECTIO NAL DRILLING



44/78

Enlarging the pilot hole is accomplished using pre-reamingpasses prior to pull back.

Pre-reaming tools are typically attached to the drill pipe at theexit point. The reamers are then rotated and drawn to the drillingrig thus enlarging the pilot hole. Drill pipe is added behind thereamers as they progress toward the drill rig in pull backoperation. This insures that a string of pipe is always maintained

in the drilled hole. Reaming tools typically consist of a circulararray of cutters and drilling fluid jets. Drilling fluid is pumpedthrough the reamers to aid in cutting, support the reamed hole,and lubricate the trailing pipe.

Pull-Back Operation - Involves pulling the entire pipeline lengthin one segment

back through the drilling mud along the reamed-hole pathway.Axial tension force readings, constant insertion velocity, mud flowcirculation/exit rates, and footage length installed should berecorded. The pullback speed ranges usually between 1 to 2 feetper minute. A swivel is utilized to connect the pull section to theleading reamers to minimize torsion transmitted to the pipeline.

HORIZONTAL DISTANCE DRILLING



45/78

PIGGING, INSPECTION

&CORROSION CONTROL


46/78

PIG stands for Pipeline Intervention Gadget/ PipelineInspection Guage

A pig is a device inserted into a pipeline which travels

freely through it, driven by the product flow to do a specific

task within the pipeline Functional Classification of pigs:

(a) Utility pigs which perform a function such as cleaning,

separating products in-line or dewatering the line

(b) Inline inspection pigs which are used to provideinformation on the condition of the pipeline and the extent and

location of any problem (such as corrosion for example) and

(c) Special Duty Pigs such as plugs for isolating pipelines.

PIGGING

Source: www.ppsa-online.com


47/78

Pigging is a maintenance tool

During the construction of the line, pigs can be used toremove debris that accumulates

During Hydro-testing, pigs are used to fill the line withwater and subsequently to dewater the line after the

successful test During operation, pigs can be used to remove liquid

hold-up in the line, clean wax off the pipe wall or applycorrosion inhibitors

Inspection pigs are used to assess the remaining wallthickness and extent of corrosion in the line, thusproviding timely information for the operator regardingthe safety and operability of the line

PURPOSE OF PIGGING



48/78

Offshore pipelines are of thicker wall than onshore-sometimes up to

35mm thick. Offshore pipelines can have greater operating pressures, particularly

the deepwater pipelines - Maximum operating pressures onshore cabe 100bar(GP) but offshore can be 300bar(GP)

Flow rates of products both onshore and offshore are the samedependant upon the type of pipeline or its position with regard totransporting product either between offshore platforms or fromplatform to shore.

Offshore pipelines tend to be protected by a concrete outer coatingand sacrificial anodes fitted to the pipeline every 100 metres so theoutside of offshore pipelines tend not to suffer corrosion but may get

damaged by sea bed movement or anchors from ships Generally running pigs in offshore pipelines is very similar to running

in onshore lines

One very important thing to realise with offshore inspection is that thepig must not get stuck in the pipeline as retrieving it will be muchmore expensive than from an onshore pipeline

ONLINE & OFFLINE PIPELINE PIGGING



49/78

The main inspection techniques used are

Magnetic Flux Leakage1. MFL is an inferred method where a strong magnetic flux is

induced into the pipeline wall. Sensors then pick up any leakage

of this flux and the extent of this leakage indicates a flaw in the

pipe wall. For instance, internal material loss in the line will cause

flux leakage that will be picked up by the sensors.2. Defect libraries are built up to distinguish one defect from another.

Ultrasonic Inspection

1. Ultrasonic inspection is a direct measurement of the thickness of the pipe

wall. A transducer emits a pulse of ultrasonic sound that travels at a

known speed. The time taken for the echo to return to the sensor is a

measurement of the thickness of the pipe wall.

2. The technique needs a liquid through which the pulse can travel. The

presence of any gas will affect the output.

INSPECTION TECHNIQUES

Ultrasonic can inspect very thick wall pipe but magnetic flux is limited because

of how strong the magnets need to be to get enough magnetism in the wall

of the pipe to enable good results to be obtained.


50/78

Corrosion is an electrochemical reaction requiring

the following conditions to be met :

1. There must be an anode and a cathode.

2. There must be an electrical potential between the anode

and the cathode.

3. There must be a metallic path between the anode and the

cathode. Normally this will be the pipeline itself.

4. The anode and the cathode must be immersed in an

electrically conductive electrolyte which is ionized -

meaning that some of the water molecules are brokendown intp positively charged hydrogen ions (H+) and

negatively charged hydroxyl ions (OH-).The usual soil

moisture surrounding pipelines normally fulfils this

condition.

CORROSION

Source: VC Pipeline Protection Ltd.

CORROSION


51/78

Once these conditions are met , an electric current will flow and metal will

be consumed .

The pressure exerted by the potential difference between the anode and

the cathode results in migration of electrons from the anode to the

cathode along the metallic connection between the anode and cathode.

Anode Loss of electrons positive charged iron atom combine with

OH- FE(OH)2 Further reacts to form Fe2(OH)3 which is familiar

RUST.

At the cathode , a surplus of electrons arrives from the anode. These

surplus negatively charged electrons combine with positively charged

hydrogen ions from the environment to form hydrogen (H2).

CORROSION



52/78

CORROSION


53/78

Earth buried pipelines are usually expensive investments . In order

to defend against the threat of corrosion they are protected by

coatings and coverings.

However, the smallest damage of the coating or any cracks in the

covering steadily lead to pitting corrosion.

Corrosion causes an electrochemical reaction which leads to loss of

metal. As a result pipelines become leaky and can cause enormousdamage to property and environment.

The expected lifespan of a pipeline network is, depending on the

transport medium, a minimum of 50 years. However, a pipeline

should be functional for up to 100 years. Cathodic corrosion

protection offers an optimum of safety and efficiency because

With a cathodic protection system pipelines can be operated even in

critical soils reliably.

CORROSION


PRINCIPLES OF CORROSION CONTROL


54/78

There are two possibilities for designing an activecorrosion

protection system of earth buried pipelines:

1. Cathodic protection with impressed current.

2. Cathodic Corrosion Protection with a galvanic anodes

system.

PRINCIPLES OF CORROSION CONTROL


Cathodic Protection with an


55/78

Current is produced by a RECTIFIER and transmitted by foreign current

anodes to the earth buried object to be protected.

The advantage of this method lies primarily in the possibility that the

output voltage can be regulated depending on the soil resistance and the

protecting current requirements of the pipeline.

Furthermore cathodic corrosion protection with an impressed currentsystem enables automatic recording of the state of the pipeline and thereby

possible irregularities can be immediately recognised and remedied .

Cathodic Protection with an

Impressed Current Protection System


Cathodic Protection with an Impressed


56/78

The anodes which are used for the protective current Supply

can be built horizontally or vertically in the ground.

Primarily FeSi anodes used, either single or pre-finished as

canister anode with backfill.

The effectiveness of the cathodic protection system is

monitored through potential mapping through permanent

reference cells at measuring points and then sent to the

rectifier station for an internal comparison with preset

thresholds.

The cable connections of the pipeline, rectifier and reference

electrode come together at the measuring station too.

Cathodic Protection with an Impressed

Current Protection System


Cathodic Corrosion Protection With a


57/78

For smaller objects or those where a power supply with rectifier is difficult

(e.g. in less conductive grounds) cathodic protection with galvanic anodesis used.

The method is based on the difference between the anode material and the

object to be protected.

Current flows automatically from the anode to the pipeline because of the

voltage gradient.

The required number and size of anodes depend on the size of the object to

be protected, the specific soil resistance and the planned term of protection.

Galvanic anodes have a lifetime of maximum 20 years and have to be

changed at the end of this time. However, in contrast to impressed current systems galvanic anode systems

are less expensive.

Cathodic Corrosion Protection With a

Galvanic Anode System



58/78

TELECOMMUNICATION,

INSTRUMENTATION& SCADA

Flow of Data:


59/78

Flow of Data:

PAS

SCADA-MCS

SCADA-SCC

PLC BASED CONTROL SYSTEM

FIELD INSTRUMENTATION

Source: http://petrofed.winwinhosting.net

Modes of communication in pipelines:


60/78

p p

H.F. Communication system

V.H.F. Communication system

Public leased circuits on hire

Line of Sight Communication system

Optical fiber Communication system

Satellite Communication system


VHF Communication:


61/78

VHF Communication:

Used for communication in a pipeline station / tank farm

Base stations and hand held trans-receivers available

Suitable for short range - typically 2 km to 25 km

Cannot be used for inter station communication in pipelines

Supports voice, data, fax, computer networking and SCADA

systems

Comparable cost with other modes


Optical Fibre Communication:


62/78

p

Works by sending signals down hair thin strands of glass fiber.

Has incredibly high transmission capacity i.e. bandwidth.

Immune to Noise.

Freedom from Cross talk.


OFC:


63/78

Overall Cable diameter : 13 14 mm

Wavelengths used: 1310 nm/ 1550 nm

Attenuation @ 1310 nm : 0.36 dB/km

Attenuation @ 1550 nm : 0.23 dB/km


Telecommunication Equipment:


64/78

q p

SDH:Synchronous_Digital_Hierarchy

SDH

D/I MUX

EP

A

B

X

ConferenceSet

Subscriber

Lines

FCBC

48V

Battery

Bank

PC

Printer


Instrumentation Equipments:


65/78

q p

Pressure Indicators

Pressure Switches

Pressure Transmitters

Flow Meters/ Flow Computers

Temperature Transmitter

Temperature Indicator

Level Switches

Flow Switches

Density Meters

Control Valve

Tank Gauging System

Emergency Shutdown System


Instrumenation Equipments:


66/78

q p

PRESSURE

SWITCHES

LEVEL SWITCHES

FLOW SWITCHES TEMP. SWITCHES

FLOW METERS

LEVEL

TRANSMITTERS

PRESSURE

TRANSMITTERSDENSITY METERS


Hazardous Area Classification & Protection Standards:
http://www2.emersonprocess.com/en-US/brands/micromotion/density-viscosity-meters/7835-liquid-concentration-density-meters/Pages/index.aspx


67/78

Hazardous environments exist in oil refineries, pipeline installations, offshore platforms,

chemical plants, mines etc.

Electrical equipment must be suitable for the environment in which they are to be used.

Hazardous areas are classified with respect to the potential danger of explosion and the

areas are divided into zones according to the probability of the hazardous atmosphere-

Zone 0, Zone 1, Zone 2.


Hazardous Area Classification & Protection Standards :


68/78

Instruments, Equipments in pipeline installations are deployed keeping in view

the hazardous area classification.

Protections like Flameproof-Explosion proof, Intrinsic Safety and are ensured

while selection of instruments & equipments.

Each chemical gas or vapour used in industry is classified into a gas group.

Also, to ensure that there is no risk of ignition due to hot surfaces, the

equipments/ instruments are classified with regard to the maximum surface

temperature of any part of the equipment.


Hazardous Area Classification & Protection Standards :


69/78

Explosion Protection Methods/ equipment- common types

Flameproof - (Ex d)

Increased Safety - (Ex e)

Pressurisation - (Ex p)

Intrinsically Safe - (Ex i)


SCADA:


70/78

Dedicated SCADA system is installed to provide effective and efficient monitoring

and control of the entire pipeline from Master Control Station (MCS).

SCADA system has a MCS and Station Control Centres (SCCs) at attended stations viz.

pump stations/ delivery stations/ pump - cum - delivery stations.


State Control Centre & Master Control centre:


71/78

Designed to provide effective & efficient monitoring, safe operation and control

of local station and scraper station/ block valves under its control.

Acquires data from local PLC and scraper station/ block valves under its control in

real time and transmits the same to MCC.

Configured with dual redundant hot standby computer systems.

Programmable Logic Controllers (PLCs) are installed at attended stations/ scraper

stations for interfacing the field devices.

Remote Terminal Units (RTUs) are installed at unattended block valve stations for

interfacing the field devices.


Typical SCC Configuration:


72/78


Typical MCS Configuration:


73/78



74/78

Case Study

Mallavaram-Bhopal-Bhilwara-Vijaipur Gas Pipeline(MBBVPL)

Being built by the consortium of Gujarat State

Petronet Limited (GSPL), IOC, HPCL and BPCL


75/78

Case Study The pipeline is being laid by the consortium through a separate JV company.

GSPL is the lead partner of the consortium with 52% equity holding, followed by IOC with26% and HPCL and BPCL holding 11% each.

Elaborate due diligence has shown that the pipeline will be viable under a sensitivity analysisthrough different parametric conditions. The total investment for constructing the pipeline hasbeen pegged at INR 7,257 crore.

The MBBVPL will be laid from Mallavaram (Kakinada) to Bhopal, passing through Godavari,Waranagl, Karimnagar, Adilabad and Nagpur. From Bhopal, the line will bifurcate into two.While one line will go northwards to Vijaypur meeting the HVJ pipeline of GAIL there, the

other branch line will go to Bhilwara in Rajasthan. In between the pipeline will cover Sehore,Indore and Chittorgarh.

The pipeline is scheduled to be completed within 36 months in line with PNGRB guidelines.The major project activities to be completed within the following duration are listed below:--12 months: Pipeline route survey, preparation of Emergency Management Plan (EMP),

carrying out Environmental Impact Assessment (EIA) and engineering activities.--Next 6 months: To initiate the bidding process and award contracts--Next 18 months: Completion of detailed engineering, procurement, construction and

commissioning activities

The pipelines would be implemented in a phased manner in line with the development planincorporated in the financial model to improve the internal rate of return (IRR) of the projects.

The consortium has drawn up plans to partly commission the pipeline project in 24 months(Mallavaram to East Godavari district in Andhra Pradesh) instead of one time commissioningof the whole project in 36 months to improve the profitability of the project.

Source: IndianPetro, Jan 22, 2012


76/78

Case Study A maximum period of thirty six months, from the date of issue of the authorization

letter, has been given for commissioning of the gas pipeline project. The pipeline will achieve a total capacity of 76.25 MMSCMD by 25th year of its

operation.

Of this, the extra capacity in the natural gas pipeline, which will be available foruse on a ''common carrier'' basis by any third party on an open-access and non-discriminatory basis, will be 19.06 MMSCMD.

However during the first year of operation, the design capacity will be only 52.87

MMSCMD, which will remain constant till the tenth year of operation. Though the design capacity is 52.87 MMSCMD, the volume considered for

transportation is much lower at 39.65 MMSCMD in the first year of operation.

The MBBVPL will be hooked up with the Mehsana-Bhatinda (MBPL) at Bhilwara(Rajasthan).

The pipeline has been designed in such a way that gas can be injected in thepipeline at both Mallavaram and Bhiwara.

This will help in flowing of volumes from Mehsana into central India and volumesfrom the KG basin (Kakinada) into central as well as north India.



77/78

Case Study Though the design capacity, in the first year of operation (expected in 2014-15),

of the MBBVPL has been pegged at 52.87 MMSCMD, the volume considered fortransportation is much lower at 39.65 MMSCMD. Out of this, as of now, a total of25.5 MMSCMD has been considered for the pipeline from the following sources:

Domest ic sources--Additional gas from RIL's KG basin: 6 MMSCMD--GSPC's KG basin fields; 8 MMSCMD

Gujarat LNG term inals--Another 11.5 MMSCMD is estimated to come from four LNG terminals inGujarat, namely PLL Dahej, Mundra LNG terminal, HLPL Hazira and FSRU(Floating, Storage, Regas and Unloading) facility, Pipavav.

The total share of gas for the MBBVPL -- both from domestic sources and LNGterminals -- adds up to 25.5 MMSCMD in the first year (2014-15) of operationagainst the total anticipated supply of 93.8 MMSCMD.

The total anticipated supply of 93.8 MMSCMD in 2014-15 is expected to go upto

183 MMSCMD by 2020-21. With this, the share of gas to the MBBVPL system will also go up proportionately.



78/78

Case Study: Costs The total investment for constructing the Mallavaram-Bhopal-Bhilwara-Vijaipur

Gas Pipeline (MBBVPL) has been pegged at Rs 7,257 crore The capital expenditure, including IDC (interest during construction period) and

cash deficit in initial years, for the pipeline has been estimated as under:

Land and RoU (including land compensation): Rs 198 crore

Pipelines: Rs 4,338 crore

SCADA and telecom: Rs 78 crore

Buildings: Rs 182 crore Others: Rs 417 crore

Contingency at 10%: Rs 521 crore

Total core project cost: Rs 5,735 crore

IDC and financing charges: Rs 492 crore

Funding of cash deficit: Rs 1029 croreTotal 'As Built' project cost: Rs 7,257 crore

iemr-oil & gas transmission & distribution pipelines

Documents