Pipeline Coatings

PIPELINE COATINGS /

FIELD JOINT COATING

EXTERNAL

1

TYPE OF MAIN LINE COATINGS

3 LPE (2 to 3.5mm thk)

DFBE (0.7mm thk) FBE (0.45mm thk)

3 LPP (2 to 3.5mm thk)

2

PIPELINE COATINGS

DFBE ANTI CORROSION COATING

HDPU THERMAL INSULATION (90mm thk)

HDPE JACKET 5mm thk

CTE COATING – 4.8mm thk

3

PIPELINE OPERATING TEMPERATURE

PIPELINE DESIGN LIFE

PIPELINE DIAMETER

TYPE OF SOIL

AMBIENT TEMPERATURE

ROW CONDITIONS

CONSTRUCTION PERFORMANCE

BASIS OF SELECTION OF MAIN LINE COATINGS (NEW)

4

Polyethylene Coatings – 800C

Fusion Bond Epoxy Coatings – 1100C ~

1400C

Polypropylene Coatings – 1200C

Polymeric Tape Coatings - 600C

Liquid Epoxy Coating - 1500C

BASIS OF SELECTION OF MAIN LINE COATING –

OPERATING TEMPERATURE

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

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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

N-Normal

S-Special

n- normal thickness

v- reinforced thickness

Coating classes are based on expected field duty - Operating Temperature - Transport -Handling -Layer conditions - Operating conditions - Soil Conditions - Expected Environmental Conditions

8


FUNCTIONAL PROPERTIES

Peel Strength(N/mm)

@23°c

Tmax

(Pull speed 10N/mm)

N-n S-n

3.5 3.5

1.5 2.5

(50°c) (70°c)

A B C

10 15 23

2 3 4

(60°c) (80°c) (90°c)

B1

6

-

Impact Strength J/mm @

23°c

N-n S-n

5 5

A B C

5 7 10

B1

3

Indentation

-23°c

- Tmax

N-n S-n

≤ 0.2mm 0.2mm

≤ 0.3mm ≤ 0.3mm

(50°c) (70°c)

A B C

≤ 0.3mm ≤ 0.2mm ≤ 0.1mm

≤ 0.3mm ≤ 0.2mm ≤ 0.1mm

-

Cathodic disbondment

65°C/24hrs(-3.5V)

20°C/28 days(-15V)

65°C/28days(-1.5V)

-

≤ 7mm

≤ 7mm

≤ 15mm

-

≤ 12mm

DIN-30670 ISO-21809-1 CAS-Z245.21-06

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OPERATING TEMPERATURES

DIN-30670 ISO-21809-1 CAN/CAZ.2451-06

DIN-30670- N up to 50° C

Class-A : (– )20°C to (+) 60°C

(LDPE)

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

design temp.

Class-B : (– )40° C to (+) 80 °C

(MDPE/HDPE)

DIN-30670- S up to 70° C

Class-C ; (– )20°C to (+)110°C

(PP)

10

VIPUL KUMAR, PEng,

Deputy General Manager-

Engineering

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




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 flow-lines 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.




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




Achievements

Anti-buoyancy Method

Original design concept for concrete coating

Recommended in coating yard to achieve desired density

Innovative Technique

Geo text bags filled with gravel material used

Advantages

Saving on time

Saving in logistics and cost Vipul Kumar, 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

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




Achievements




Achievements

Documents

Pipeline Coatings