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PIPELINE COATINGS / FIELD JOINT COATING EXTERNAL

1

TYPE OF MAIN LINE COATINGS

3 LPE (2 to 3.5mm thk)

FBE (0.45mm thk)

3 LPP (2 to 3.5mm thk)

DFBE (0.7mm thk) 2

PIPELINE COATINGS

DFBE ANTI CORROSION COATING HDPU THERMAL INSULATION (90mm thk) HDPE JACKET 5mm thk CTE COATING – 4.8mm thk

3

BASIS OF SELECTION OF MAIN LINE COATINGS (NEW)

 PIPELINE OPERATING TEMPERATURE  PIPELINE DESIGN LIFE  PIPELINE DIAMETER  TYPE OF SOIL  AMBIENT TEMPERATURE  ROW CONDITIONS



CONSTRUCTION PERFORMANCE

4

BASIS OF SELECTION OF MAIN LINE COATING – OPERATING TEMPERATURE

 Polyethylene Coatings – 800C  Fusion Bond Epoxy Coatings – 1100C ~ 1400C

 Polypropylene Coatings – 1200C  Polymeric Tape Coatings - 600C

 Liquid Epoxy Coating - 1500C 5

THREE LAYER POLYETHYLENE COATING

DIN-30670 – “POLYETHYLENE COATING FOR STEEL PIPES & FITTINGS.

ISO-21809-1 – “ PETROLEUM & NATURAL GAS INDUSTRIES – EXTERNAL COATINGS FOR BURIED AND SUBMEREGED PIPELINES USED IN PIPELINES TRANSPORTATION SYSTEM PART-1 (3 LAYER PE & 3 LAYER PP) CAN/CAZ-Z245.21-06 – “EXTERNAL POLYETHYLENE COATING FOR PIPES.

6

3LPE COATING PROCESS

7

THREE LAYER POLYETHYLENE COATING DESIGNATION / COATING CLASSIFICATION DIN-30670

ISO-21809-1

CAN/CAZ.2451-06

DIN-30670 - N-n

Class-A

System-B1

DIN-30670 - N-v

Class-B

System-B2

DIN-30670 - S-n

Class-C

DIN-30670 - S-v Coating classes are based on N-Normal expected field duty - Operating Temperature S-Special - Transport -Handling n- normal thickness -Layer conditions - Operating conditions v- reinforced thickness - Soil Conditions - Expected Environmental Conditions

8

THREE LAYER POLYETHYLENE COATING FUNCTIONAL PROPERTIES DIN-30670 Peel Strength(N/mm) @23°c

N-n 3.5

Tmax (Pull speed 10N/mm)

Impact Strength J/mm @ 23°c Indentation -23°c - Tmax Cathodic disbondment 65°C/24hrs(-3.5V) 20°C/28 days(-15V) 65°C/28days(-1.5V)

ISO-21809-1

S-n 3.5

A 10

1.5 (50°c)

2.5 (70°c)

2 (60°c)

N-n 5

S-n 5

N-n ≤ 0.2mm ≤ 0.3mm (50°c)

S-n 0.2mm ≤ 0.3mm (70°c)

-

A 5

B 15

3 (80°c)

B 7

C 23

B1 6

4 (90°c)

-

C 10

A B C ≤ 0.3mm ≤ 0.2mm ≤ 0.1mm ≤ 0.3mm ≤ 0.2mm ≤ 0.1mm

≤ 7mm ≤ 7mm ≤ 15mm

CAS-Z245.21-06

B1 3 -

≤ 12mm

9

THREE LAYER POLYETHYLENE COATING OPERATING TEMPERATURES

DIN-30670

ISO-21809-1

CAN/CAZ.2451-06

Class-A : (– )20°C to (+) 60°C DIN-30670- N up to 50° C

(LDPE) Class-B : (– )40° C to (+) 80 °C

(MDPE/HDPE) DIN-30670- S up to 70° C

Not Clearly Specified. However, the purchaser has to specify the max design temp.

Class-C ; (– )20°C to (+)110°C (PP)

10

VIPUL KUMAR, PEng, Deputy General ManagerEngineering



 





M 1 Infield Pipeline Pressure Class Length Kms  Power Fluid Lines 1500# 10  Water Injection Lines 900# 10  Production Fluid Lines 600# 53 R1 Infield Pipeline 600# 7 MR Pipeline  Gas Line 12” API 5LX60 PSL2 300# 90  Condensate Line 4” API 5LX 65 600# 90 T Pipeline  Water Supply Line 20” API 5LX 65 PSL2 20 Total Pipeline Length

280 Vipul Kumar, PEng



Innovative Techniques Four Cluster of Well pads created to save on Flow lines cost from 18 individual well pads to M Field  Trunk lines laid for Power Fluid & Water Injection in pipeline corridor & connecting well pads to Trunk lines thus saving cost on lines from individual well pads to MPT. 

Cairn India – 2010 Technical Forum (October 20th & 21st) Celebrating Our Technical Achievements



Initial Design Concept Heavy design on Anchor Flanges and Anchor Blocks  Anchor Block Estimated Quantity of RCC=24000 Cum 



Innovative Efforts Improvisation on Basic Design of Anchor Flanges & Blocks  Added bends to reduce total applicable force  Anchor flanges on downstream of Water and gas lines eliminated after review  Above resulted in to Reduction of RCC to 10000 Cum(i.e. reduction of 58 %) 

Vipul Kumar, PEng



ANCHOR FLANGE/ BLOCK DESIGN

Cairn India – 2010 Technical Forum (October 20th & 21st) Celebrating Our Technical Achievements

Vipul Kumar, PEng



Reinstatement of Flow-lines Prior to Re-Start Oil in flow lines likely to congeal in black out/ shut down condition.  Original design envisaged tapping at every 500 meters for flushing congealed oil with hot water.  On design review the arrangement considered of high risk. 



INNOVATIVE TECHNIQUE 

On power black out/ shut down displace oil in flowlines with water to ensure oil will not stay in flow lines.



Installed diesel driven high capacity pump at MPT end itself. Vipul Kumar, PEng



Thumbli Main Header 

Originally header design concept • Horizontal header on sloped graded area • Header of uniform size pipes



Design Review Sloped header to match graded slope  Header of Multiple sizes matching with flow requirement 



Advantages Saving on concrete cost  Saving on pipe cost 

Vipul Kumar, PEng



Sectionalizing Valve Location 

As per ASME B 31.8 Sectionalizing valves provided as per location Class



Original design provided for installation of vents and drains along with Sectionalizing valves. However, various constraints were not permitting this feasible.



On design review, risk assessment and proper interpretation of OISD 141 recommended design was modified to eliminate drains and vents. Cairn India – 2010 Technical Forum (October 20th & 21st) Celebrating Our Technical Achievements



 

Gas and Condensate lines from MPT to RGT(90 Kms) passing through villages and populated area Considered high safety and Security Risks Intrusion detection system introduced 

Multifunctional120 Core Optical Fiber cable • Intrusion Detection System • Access control system • Data Network • Hotline • PAGA System Vipul Kumar, PEng



ZINC RIBBON CONFIGURATION IN CASING

Cairn India – 2010 Technical Forum (October 20th & 21st) Celebrating Our Technical Achievements



Anti-buoyancy Method  



Innovative Technique 



Original design concept for concrete coating Recommended in coating yard to achieve desired density

Geo text bags filled with gravel material used

Advantages  

Saving on time Saving in logistics Vipul andKumar, cost PEng



OPTIONS CONSIDERED All 14 Pipelines on Steel / Concrete structure Bridge  Horizontal Directional Drilling  Bury below soil erosion point 



TECHNO-COMMERCIAL FEASIBLE OPTION IMPLEMENTED 1200 X 25 X 6 meters open excavation  Pipe-layers, cranes, trailers, welding sets etc lowered in excavated trench  All 14 pipelines laid & trench backfilled 



ADAVANTAGES ACCRUED 

Saving on time and cost Vipul Kumar, PEng

Launcher and Receiver skids matching Hot bends and Cold bends Inclusion of Magnetic Pigging TCP and PCP System MIJs GOC OFC Hydro-testing Drying with Compressor Magnetic pigging Nitrogen Packing of Pipelines Vipul Kumar, PEng

Launcher and Receiver skids matching Hot bends and Cold bends Inclusion of Magnetic Pigging TCP and PCP System MIJs GOC OFC Hydro-testing Drying with Compressor Magnetic pigging Nitrogen Packing of Pipelines Vipul Kumar, PEng

Vipul Kumar, PEng

Vipul Kumar, PEng

Cairn India – 2010 Technical Forum (October 20th & 21st) Celebrating Our Technical Achievements

Cairn India – 2010 Technical Forum (October 20th & 21st) Celebrating Our Technical Achievements