pipeline - .: home - optech engineering pvt. ltd....a cross-country pipeline construction project is...
TRANSCRIPT
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Pipeline Construction Project
• LPG / Propane Piping with Ship Unloading Platform
• Crude Oil, Petrol, Diesel Piping with Platform
• Cross Country Oil/Gas Pipeline
• Ammonia Storage Vessels and Piping
• CO2, H2, N2 and other Industrial Gas Pressure
Vessel
• Stainless Steel Storage Tanks and Vessels
• Fire Water Tanks and Piping
Products
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SCOPE
The detailed scope of work tendered includes design, engineering &
procurement, installation, testing and commissioning along with all
associated works pertaining to complete pipeline system
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CODES, STANDARDS AND SPECIFICATIONS
All welded work, equipment for welding, heat treatment, other auxiliary functions and the welding
personnel shall meet the requirements of the codes, standards and specifications listed with the
latest edition:
• ASME B 31.8 – Gas Transmission and Distribution Piping Systems
• ASME B 16.9 – Wrought steel butt-welding fittings
• ASME B 31.3 Chapter V -Fabrication, Assembly and Erection
• ASME B 31.3 Chapter VI -Examination, Inspection and Testing
• ASME BPVC Sec. II Part C -Welding Rods, Electrodes and Filler Metals
• ASME BPVC Sec. V -Nondestructive Examination
• ASME BPVC Sec. IX -Welding and Blazing Qualifications
• API 5 L – Specification for line pipe
• API 6 D – Specification for steel gate, plug, ball and check valves for pipeline service
• API std 1104 – Standard for welding pipelines and related facilities
• EN 12186 – Gas supply systems – Gas pressure regulating stations for transmission and distribution – Functional requirements
• NACE RPO-0274-93 Recommended Practice, High Voltage Electrical Inspection of Pipeline Coatings Prior to Installations
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1. Design
2. Engineering
3. Planning
4. Procurement
5. Resources
6. Storage & Handling
7. Site Occupation
8. Construction Procedure
Quality Assurance Plan
Painting
Prefabrication
Pipe joint Set up
Welding
NDT Inspection
Joint Wrapping/Painting
Holiday Test
9. Quality
10. Safety
11. Aboveground Piping
12. Underground Pipeline
Pipe section Pre-Fabrication
Excavation for trench
Underground Laying of pipe sections
Field joint fabrication inside trench
Backfilling
Crossing
13. Subsea Pipeline
Barge Selection
Barge Modification
Onshore prefabrication on Rollers
Pushing Pipe sections with floaters
Lifting floating pipe section at barge
Field joint fabrication at barge platform
Unloading from Barge
14. Ship Unloading Platform
15. Offshore/Onshore Tie-in
16. Hydro-test of pipeline
17. Pre-Commissioning
18. Commissioning
INDEX
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Pipeline design includes:
• Selection of the route traversed by the pipe
• Determination of required rate of fluid/solid
transport The operational velocity
• Calculation of pressure gradient
• Selection of pumps and other equipment
Determination of pipe thickness and material
• Engineering economic analysis
• Safety
• Leak Prevention
• Ease of Maintenance etc
• Government regulations
• Environmental Concern
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Pre-engineering, conceptual engineering, detailed
engineering addressing the economic aspects of
pipelines.
This phase ensures design is correct, safe and cost
effective.
Implementation of design requirement by translating
into technical specification that describe a
system that the engineer is personally responsible for
knowing said correctness and safety of the system.
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We at Optech formulate the project from the owner's
perspective and its effectiveness in project control is
demonstrated. This provides client multiple opportunities
for decision making in continuously changing project
circumstances keeping eye on the completion timeline
and budget.
A methodology is proposed for project control through risk
analysis, contingency allocation and hierarchical planning
models.
A cross-country pipeline construction project is exposed to
an uncertain environment due to its enormous size
(physical, manpower requirement and financial value),
complexity in design technology and involvement of
external factors. These uncertainties can lead to several
changes in project scope during the process of project
execution. Unless the changes are properly controlled, the
time, cost and quality goals of the project may never be
achieved. PLANNING
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The procurement process lies on the projects critical path and therefore it is essential to set up the process
using the approach of strategic procurement. Setting the right strategy shall affect the efficiency of procurement
process hence will bring positive influence to project schedule performance.
As being in core piping domain for several years, Our technical & commercial intelligence in market makes us to
know what is required, where to source, how to mobilise and most importantly ensuring optimum Quality and cost.
Our Customisation, Integration, Innovation and Delivering strategies contribute in project control and significantly
assist client to perform within budget.
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Resources
Mobilizing and providing :
• Equipment’s
• Manpower (skilled and unskilled)
• Material supply
• Consumables
• Services including logistics, power,
liaisioning, and other resources etc.
as required for the execution of
complete work.
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Storage &
Handling
Loading, transportation, unloading,
handling, and stacking of material at
worksite(s)/ workshop till the pipes
are installed in permanent installation.
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Site Occupation:
• As soon as the Contract is signed and permitted, the Optech team will proceed with the setting-
up of the site installation as agreed with the Owner according to relevant approved drawings.
• The site shall be levelled, sealed and hardened with a layer of murrum soil.
• It must be possible to reach the site with trucks and cars from the public road.
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• Painting of pipes & fitting
• Prefabrication
• Pipe Joint Set up
• Pipe Joint Welding
• QA/QC/NDT inspection
• Joint Wrapping/ Coating
• Holiday test for painting/coating
• Aboveground/Underground/
Subsea Field Joint Fabrication
• Hydro-test
CONSTRUCTION
PROCEDURE
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Painting
Pipe are cleaned by surface blasting to
the standard surface finish.
OEPL painters are highly skilled
professionals in optimising the quality
and quantity of paint.
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Prefabrication
Allows to start mechanical
construction from 1st day, without
hindering civil work schedule.
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Joint Set up
Joint set shall meet the standard joint
profile mentioned in Welder Procedure
Qualification.
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Welding
SMAW welding
TIG Welding
SAW welding
MIG/MAG Welding
OEPL has a brigade of Qualified welders
with years of experience in domain at
any point of the time.
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Heat Shrink
Sleeve
Application at
Joint
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Quality
Conformance to the requirement shall
be achieved by :
• Qualification of Man-Material-
Machine
• Work procedures
• Each stage inspection and control
• Well documented Records
• Example, snap shows stage
inspection of Joint set up, welding,
NDt, Holiday test etc
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SAFETY
All work must be performed in
consideration of all risk
assessments, applicable operating
instructions for technical
equipment, work processes and
hazardous substances as well as
environmental aspects.
Before commencing work, an
agreement must be signed with
the client with regard to health,
safety, and environmental
protection.
Optech team believe in safe
system of work is the only shortcut
to hit the target and have
completed such Projects with zero
LTI.
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Aboveground
Piping
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Typical
Aboveground ex.
Common
Uniform
Manifold
Product Mass
flow meter unit
Pig Launcher
Fire Hydrant
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Pipe laying,
Joint Set up,
Welding inside
trench
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Postweld
Pipelay
Inside trench
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Special
provisions at
Road/Culvert
Crossings
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SUBSEA PIPELINE
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Subsea Pipeline will be constructed in two modules:
• Onshore Prefabrication of pipe sections
• Subsea field joint with the help of barge/vessel.
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Barge
Selection
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Barge
Modification
with lower
Level Platform
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Onshore
Prefabrication
On Rollers
• A concrete platform with pipe
roller will be constructed to
facilitate shore to water transition.
• Opening of 1st pipe end will be
sealed with blind and provided
with pulling lug.
• Pipe joints then fabricated on the
roller platform in sequence.
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Pipe Buoyancy
& Floaters
• Pipe Buoyancy is calculated and
Buoyancy force is provide by the
floaters.
• Pipe sections will be pushed in
Ocean during high tide.
• These sections will be carried out
by tug boat to safe parking area
and adequately anchored to
restrict unwanted movement with
waves.
• Part of these sections near shore
rest on bed during low tide
without affecting floaters and
floated again with full tide.
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Pipe Section
Lifting at Barge
Platform
• Barge will positioned at the
location of subsea field joint and
firmly anchored.
• The floating pipe sections will
then be carried by Tug boat and
aligned with barge Platform.
• Pipe end s to be joined are then
lifted by Crane on the barge within
pipe bending limits.
• Barge platform has adequate
facilities to align the pipe end for
fabrication.
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Fabrication
at
Barge Platform
• Tie the pipe ends with chain
pulley and position as required.
• Remove pipe caps by cutting.
• Joint set up
• Welding
• NDT inspection
• Joint coating by Heat Shrink
sleeve Application
• Holiday test
• Final approval by TPIA for
unloading from barge.
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Ship
unloading
platform/
Jetty
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Offshore
&
Onshore
Tie in
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Hydro-test
• The pipeline will tested for
strength and leak at pressure
1.5 times of design pressure.
• Hydro-test will be conducted
in Pipe sections.
• Prior to hydro-test ,line will be
cleaned by air blowing or
pigging.
• Post hydro-test dewatering will
be done by pigging or air
blowing.
• Pipeline will be preserved with
nitrogen purging in case of
delayed commissioning.
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Commissioning
• Pipeline will be intended to commission immediately after the Hydro-test.
• Pre-commissioning is the series of processes carried out on pipeline system to prove its ability to contain final
product without leak.
• Team will inspect all the components installed are correct according to standards, fit for the purpose and
verified with the records.
• A pre commissioning punch list will point out all the non conformities and team will ensure they are acted
upon.
• The process during which the pipeline is made "live" i.e. the product is put in the pipeline, is called pipeline
commissioning or start-up.
• After successful clearance and regulatory approval, line will be made live.
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Thank You!