oil pipeline 42 inch by 455 km
TRANSCRIPT
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Baku - Tbilisi - Ceyhan (BTC) Oil Pipeline
The Azerbaijan Section of the Project’s Oil Pipeline including valve and pig trap stations, laying of Fiber Optic cable and tie-ins at pumping stations. Much of the terrain is flat and semi-arid.
The Pipeline links the Caspian sea oil wells with the Mediterranean Sea ship tankers port.
The capacity is1 million barrels of crude oil flow per day
Oil Pipeline 42” by 450km.
Photographic Record of Construction
19th June David H Moloney
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Construction of Azerbaijan Oil Pipeline 42” by 450km. Client BTC,
Contents
Overview Surveying & Setting OutClearing & GradingDouble Jointing i.e. welding 2 pipes togetherStringing out PipesBend Pipes for changes in direction sideways and up & downWelding Pipes into a string, Test Weld by X Ray.Anti-corrosion Coat to JointsTrenching i.e. excavate trenchLowering pipe string into trenchBackfilling TrenchReinstatement of Pipeline ROW (Right-of-Way)Reinstatement of River BanksCrossing - Horizontal Directional DrillingCrossing - Thrust BoringCrossing - River Hydrotest & PiggingTie-in i.e. connect to existing pipelineMiscellaneous
Pause Slides to Read
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Construction of Azerbaijan Oil Pipeline 42” by 450km. Client BTC,
Overview Construction Sequence
A typical sequence of activities is- surveying and setting out, preparing the land, stringing out the pipes along the route, excavating the trench, welding and laying the pipes, backfilling the trench with the excavated soil, and reinstating the land to its original condition..
Crossing Railway, Roads, Rivers, etc.Pump Station
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Overview Pipeline Construction Animation
To see animations, view YouTube film.
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Overview Pipeline Crossings Construction Animation
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Construction of Azerbaijan Oil Pipeline 42” by 450km. Client BTC,
Surveying & Setting Out
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Construction of Azerbaijan Oil Pipeline 42” by 450km. Client BTC,
Surveying & Setting Out
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Construction of Azerbaijan Oil Pipeline 42” by 450km. Client BTC,
Surveying & Setting Out
FCI-ROW Set Out
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Construction of Azerbaijan Oil Pipeline 42” by 450km. Client BTC,
Clearing & Grading ROW (Right of Way)
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Construction of Azerbaijan Oil Pipeline 42” by 450km. Client BTC,
Clearing & Grading
Foreign Service Detection
Concrete Slabs Installed For
Foreign Services Protection
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Construction of Azerbaijan Oil Pipeline 42” by 450km. Client BTC,
Clearing & Grading
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Construction of Azerbaijan Oil Pipeline 42” by 450km. Client BTC,
Clearing & Grading
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Construction of Azerbaijan Oil Pipeline 42” by 450km. Client BTC,
Double Jointing Facility
Welding 2 nr 12m long pipes together prior to stringing out.Located at Pipe Storage areas.
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Construction of Azerbaijan Oil Pipeline 42” by 450km. Client BTC,
Double Jointing Facility
Outline Process
1. Single piles 12m long are delivered and stacked.2. At the Bevelling Station. The ends of the pipes are
bevelled. Two pipes are aligned using an internal clamp, the joint is preheated and the root pass weld is done.
3. At the Hot Pass Station. The fill and cap passes will be carried out using Submerged Arc Welding (SAW)
4. The joints will be x-rayed 5. The double pipes 24m long are stored ready for
transportation to the site6. Purpose made dollies will transport the pipes
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Construction of Azerbaijan Oil Pipeline 42” by 450km. Client BTC,
Double Jointing i.e. welding two pipes together
66
Phase 7: Rolling Pipe
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Construction of Azerbaijan Oil Pipeline 42” by 450km. Client BTC,
Stringing out Pipes
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Construction of Azerbaijan Oil Pipeline 42” by 450km. Client BTC,
Stringing out Pipes
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Construction of Azerbaijan Oil Pipeline 42” by 450km. Client BTC,
Stringing out Pipes
Final Product
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Construction of Azerbaijan Oil Pipeline 42” by 450km. Client BTC,
Bending Pipes
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Construction of Azerbaijan Oil Pipeline 42” by 450km. Client BTC,
Bending Pipes
Toolbox Talk
Pipe Will Be Lifted Using Choker
Belts
Choker Belts Placed On
Pipe
Preparation For Lifting
Pipe
Loading Pipe On Bending
Machine
The Bending Machine Uses A
Series Of Clamps And Hydraulic
Pressure To Make A Very
Smooth, Controlled Bend
Bending Start
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Construction of Azerbaijan Oil Pipeline 42” by 450km. Client BTC,
Bending Pipes
Bending
Clamps Pulled Through The Pipe
Maximum Bend angle Is 1.3
Degrees Per Meter
Completed Bends
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Construction of Azerbaijan Oil Pipeline 42” by 450km. Client BTC,
Welding
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Construction of Azerbaijan Oil Pipeline 42” by 450km. Client BTC,
Welding
Beveling
Fit-Up
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Construction of Azerbaijan Oil Pipeline 42” by 450km. Client BTC,
Welding
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Construction of Azerbaijan Oil Pipeline 42” by 450km. Client BTC,
X Ray Pipeline Crawler for testing joint welds
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Construction of Azerbaijan Oil Pipeline 42” by 450km. Client BTC
Joint Field Coating for Anti-corrosion
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Construction of Azerbaijan Oil Pipeline 42” by 450km. Client BTC
Joint Field Coating
1. Toolbox Talk
Preparation For Grit Blasting
Wearing Special Coverall
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Construction of Azerbaijan Oil Pipeline 42” by 450km. Client BTC
Joint Field Coating
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Construction of Azerbaijan Oil Pipeline 42” by 450km. Client BTC
Trenching i.e. excavate trench.
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Construction of Azerbaijan Oil Pipeline 42” by 450km. Client BTC
Trenching
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Construction of Azerbaijan Oil Pipeline 42” by 450km. Client BTC
Lowering Pipe string into Trench
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Construction of Azerbaijan Oil Pipeline 42” by 450km. Client BTC
Lowering Pipe string into Trench
Lifting Belts Supported by Side-Booms Will Be
Utilized For Pipe Handling And Not Placed Over Any
Field Joint Area
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Construction of Azerbaijan Oil Pipeline 42” by 450km. Client BTC
Lowering Pipe string into Trench
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Construction of Azerbaijan Oil Pipeline 42” by 450km. Client BTC
Backfilling
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Construction of Azerbaijan Oil Pipeline 42” by 450km. Client BTC
Backfilling
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Construction of Azerbaijan Oil Pipeline 42” by 450km. Client BTC
Backfilling
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Construction of Azerbaijan Oil Pipeline 42” by 450km. Client BTC
Reinstatement ROW Right-of-Way
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Construction of Azerbaijan Oil Pipeline 42” by 450km. Client BTC
Reinstatement ROW
Spreading Topsoil
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Construction of Azerbaijan Oil Pipeline 42” by 450km. Client BTC
Reinstatement ROW
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Construction of Azerbaijan Oil Pipeline 42” by 450km. Client BTC
Reinstatement ROW
Final Product
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Construction of Azerbaijan Oil Pipeline 42” by 450km. Client BTC
Reinstatement River Bank
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Construction of Azerbaijan Oil Pipeline 42” by 450km. Client BTC
Reinstatement River Bank
Matting
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Construction of Azerbaijan Oil Pipeline 42” by 450km. Client BTC
Reinstatement River Bank
Grass Is Growing On River Banks
Final Product
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Construction of Azerbaijan Oil Pipeline 42” by 450km. Client BTC
Pipeline Crossing by Horizontal Directional Drilling
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Construction of Azerbaijan Oil Pipeline 42” by 450km. Client BTC
Pipeline Crossing by Horizontal Directional Drilling
Rig Anchoring System; During The
Drilling Works, The Rig Will HaveTo
Be Secured To Stop It From Moving
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Construction of Azerbaijan Oil Pipeline 42” by 450km. Client BTC
Pipeline Crossing by Horizontal Directional Drilling
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Construction of Azerbaijan Oil Pipeline 42” by 450km. Client BTC
Pipeline Crossing by Horizontal Directional Drilling
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Construction of Azerbaijan Oil Pipeline 42” by 450km. Client BTC
Pipeline Crossing by Thrust Boring
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Construction of Azerbaijan Oil Pipeline 42” by 450km. Client BTC
Pipeline Crossing by Thrust Boring
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Construction of Azerbaijan Oil Pipeline 42” by 450km. Client BTC
Pipeline Crossing by Thrust Boring
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Construction of Azerbaijan Oil Pipeline 42” by 450km. Client BTC
Pipeline Crossing - River Crossing
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Construction of Azerbaijan Oil Pipeline 42” by 450km. Client BTC
Pipeline Crossing - River Crossing
Sediment Control
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Construction of Azerbaijan Oil Pipeline 42” by 450km. Client BTC
Pipeline Crossing - River Crossing
Lowering In
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Construction of Azerbaijan Oil Pipeline 42” by 450km. Client BTC
Hydrotest, Pigging (clean out pipeline) & Dry Pipeline
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Construction of Azerbaijan Oil Pipeline 42” by 450km. Client BTC
Hydrotest
Block Valve Pre-Testing
Trains Of Brush Pigs With Slugs Of Flushing
Water Are Used For Cleaning The Pipeline Pigs Are Loaded Into Temporary Pig Launchers
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Construction of Azerbaijan Oil Pipeline 42” by 450km. Client BTC
Hydrotest
Pigs Are Received Into Temporary Pig
ReceiverPigs Are Launched With Compressed Air
The Final Pig Is Fitted With An Aluminium
Gauging Plate 95 % Of The Internal Diameter To
Check For Geometrical Defects
Pigs Are Back Loaded Into Test Headers
For Filling And Dewatering Test
Sections
Test Headers Are Then Welded To The
Ends Of Test Section
Water Used For Hydrostatic Testing Is
Filtered To 50 Microns
Water Is Then Passed Through Vented
Break Tanks And Flow Meters
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Construction of Azerbaijan Oil Pipeline 42” by 450km. Client BTC
Hydrotest
Pressurising Pumps And Instrument Control
Container
Filling Spread Showing Fill Pumps,
Chemical Dump And Break Tanks
Pressurising injection Manifold Incorporating
High Pressure Flow Meter
After Hydrotest The Test Section Is
Dewatered And Water Transferred Into The
Next Section
The Dewatered Section Is Then Dried
To -10degC Dewpoing Using
Compressed Air Passed Through
Drying Units
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Construction of Azerbaijan Oil Pipeline 42” by 450km. Client BTC
Tie-in i.e. connecting to existing pipeline
Welded Joint on the Azerbaijan and Georgia Border
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Construction of Azerbaijan Oil Pipeline 42” by 450km. Client BTC
Tie-in
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Construction of Azerbaijan Oil Pipeline 42” by 450km. Client BTC
Tie-in
Preparation For Tie-In
Tie-In: Manually Welding Joints In
Trench Between Two Sections
Final Product
Tie-In
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Construction of Azerbaijan Oil Pipeline 42” by 450km. Client BTC
MiscellaneousContents
Time Chainage DiagramPipe Spool FabricationTank ConstructionPiperackCrane Heavy LiftSlug CatcherRoad constructionReinforced Concrete WallCrossing under Existing UtilitiesTrench ExcavationLoad & HaulRock excavationQuarry & aggregate ProductionConcrete Batching PlantTemporary Sheet Pile shaftCable LayingFencingBuildings
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Construction of Azerbaijan Oil Pipeline 42” by 450km. Client BTC
Time Chainage Diagram The chart has two axis: one for time and the other for location
A legend explains meaning of the colours, symbols and line types
Sample Only
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Construction of Azerbaijan Oil Pipeline 42” by 450km. Client BTC
Histograms for Resources & Outputs
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Progress Monitoring & Reporting - Dashboard
ⓒ David H Moloney
Brief Description
Dashboard is a single page, graphical representation of current progress and historical trends
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Temporary Contractors Site Facilities
ⓒ David H Moloney
Brief Description
Site Offices, Camp Accommodation for 1,250 workers, Canteen, Recreation, Fabrication shops, Stores, Plant Yard. In five locations along the route.
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Temporary Contractors Site Facilities - Stores
Brief Description
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Pipes ⓒ David H Moloney
Brief Description
Pipes were manufactured in Japan, coated
with a plastic covering in Malaysia, and
shipped to the Georgian ports of Poti.
Transported by Train and trucks across land.
Japan
Georgia
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Pipe Spool Fabrication Animation
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Post Weld Heat Treatment
Non Destructive Testing
Cut
Bevel
Fit-up
Weld
NDT
PWHT
Blasting
Painting
Pipe Spool Fabrication StepsP
ipe
wo
rk
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Tank Construction
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Piperack Construction Animation
The Pipe Racks carry pipes and cables between the different processes..
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Cranes Heavy Lift Animation
Lift column from the horizontal and
rotate into the vertical
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Slug Catcher Construction Sequence Animation
Separates the Gas from the Oil & WaterAlso to dissipate any pressure surges
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Road Construction Sequence Animation
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Reinforced Concrete Wall Construction Sequence Animation
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Crossing Under Buried Utilities & Overhead Power Cables Animation
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Trench Excavation with Stepped Faces
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Trench Excavation with Battered Faces
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Excavate & Load, Cart, Tip & Return
Brief Description
Cycle Time for 7km haulage distance using an Excavator 45 tonne weight and Dumper with a 40 tonne capacity, the cycle time is 34 minutes
Ea
rth
wo
rks
7 minutes
14 minutes
3 minutes
14 minutes 7 km
7 km
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Rock - Excavability
Brief Description
The excavability of rock depends
mainly on the rock strength and the
layer thickness. This diagram shows
excavation methods for rock of
various strengths and thicknesses,
with a free face.
ⓒ David H Moloney
Ea
rth
wo
rks
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Quarry & Aggregate Production
ⓒ David H Moloney
Co
ncre
te
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Concrete Batching Plant David H Moloney
ⓒ David H Moloney
Brief Description
.
The mixing is computer controlled
and has a dynamic screen display,
showing the process. The material
storage capacity is, to match two
days concrete production.
Co
ncre
te
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Concrete Batching Plant
ⓒ David H Moloney
Co
ncre
te
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Temporary Sheet-pile Shaft
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Cable laying 132KVa Electric
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Fencing
ⓒ David H Moloney
Co
ncre
te
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ⓒ David H Moloney
Co
ncre
te
Central Control Building for Refinery
Cross Sections Horizontal moving upwards
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Main Electrical Sub Station
ⓒ David H Moloney
Co
ncre
te
Cross Sections Horizontal moving upwards
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Main Electrical Sub Station
ⓒ David H Moloney
Co
ncre
te
Cross Sections Vertical moving along
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Construction of Azerbaijan Oil Pipeline 42” by 450km. Client BTC
ENDMy YouTube Channel link: https://www.youtube.com/channel/UCeJR9J7svhBd-C0ZoAH2fhQ