INTRODUCTION

 GAIL is operating 3/4th of India’s natural gas transmission pipelines.

 Producing 1/5th of India’s polyethylene.

 Operating 2/3rd of Liquefied Natural Gas (LNG) stations through alliances.

 Responsible for 1/4th of Liquefied Petroleum Gas (LPG) transmission.

1.1 Background of KG basin pipeline network:

Krishna – Godavari basin of GAIL Rajahmundry started in a modest way,

supplying 0.5 MMSCMD gas to 6 consumers by taking over the ONGCL’s pipeline
network of 136 KMs in Godavari basin in February, 1992.Thereafter, 18’’ x 94 KMs
trunk line was laid from Tatipaka to Kakinada for supplying gas to fertilizer major
NFCL. The line was commissioned in May, 1992 and the network was increased to
230 KMs and supply to 1.8 MMSCMD. Subsequently, another 94 KMs pipeline was
added during the period 1993-1999. The gas supply figure touched 4.2 MMSCMD
and number of Consumers increased to 10.

Based on the indications from ONGCL/Cairn Energy India Ltd[CEIL] regarding

increased availability of Natural gas in the region, GLC has made allocations to the
tune of 15.5 MMSCMD to various consumers. Hence, GAIL started expanding its
network facility in three phases to meet the gas requirement of consumer. In the
phase – I (year 2000), 135 KMs of pipelines have been laid by GAIL. For supplying
additional gas to APGPCL Stage – II (0.82 MMSCMD) 12’’, 63 KMs long pipeline from
Narsapur to APGPCL were laid parallel to the existing lines.

Under Phase – II , i.e., in the year 2001, another 278 KMs of pipeline was laid,
which includes 18’’, 204 KMs long Tatipaka – Kondapalli (near Vijayawada) pipeline
for supplying gas to Lanco Kondapalli power plant &18’’, 10 KMs long pipeline for

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supplying gas to Reliance Energy Ltd, Samalakot.

During the year 2005, another 80 KMs of pipelines was added to supply gas to
four new IPP (Independent Power Producers) and for City gas distribution and CNG
outlets at Vijayawada (through BGL) from the trunk pipeline. All these pipelines were
commissioned and came into operation during the financial year 2005-2006.

Based on the increased availability of RIL D–6 gas, 30 KM P/L was added to
supply more gas. GAIL has started transporting the RIL D–6 gas w.e.f April 2009.

As on current date, KG BASIN PIPELINE NETWORK is operating approx. 870

KMs of pipeline in various sizes ranging from 4’’ to 18’’ diameters to supply to
around 40 consumers in East, West Godavari and Krishna districts with an operating
design capacity of 16.5 MMSCMD for catering uninterrupted gas supplies to various
consumers in the state of Andhra Pradesh.

The pipeline is designed to transport natural gas received from producers to

consumers. Tatipaka is the main gas collection station for M/S ONGCL and Oduru is
the main gas collection centre for RGTIL Gas. From these collection centres i.e.,
Tatipaka&Oduru, gas is being transported through different trunk line pipelines sizes.
There are five major trunk lines.

[1] 18’’ Tatipaka – Kakinada Jn. Point [KKD-1] P/L

[2] 18’’ Tatipaka -Mortha – Lanco P/L

[3] 14’’/12’’ Tatipaka – Narsapur – APGPCL P/L

[4] 18’’ Tatipaka – Kcheruvu [KKD - 2] P/L

[5] 18’’ Kcheruvu – Oduru – KJ Point P/L

Presently, [1] & [2] 18” pipelines are being replaced with 24” new pipelines.

1.2 NATURAL GAS:

COMPOSITION:

Methane : 98.7901

Carbon dioxide : 0.3856

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 Ethane. : 0.2567

Nitrogen : 0.2144

Propane : 0.1305

Hexane : 0.0914

n-Butane : 0.0437

i-Pentane : 0.0225

i-Butane : 0.0192

No traces of Heptane, Octane, Nonane, Decane, H2S, Water, Helium, Oxygen, CO,
Hydrogen and Argon.

PROPERTIES:

Specific gravity : 0.63619

Viscosity : 0.01026 cp

Heating value : 37.95 MJ/m3

1.3 TATIPAKA BASE:

PIPELINES:

S.NO SECTION LINE SIZE LENGTH

(Inches) (KM)

1. TATIPAKA-KAKINADA JN POINT 18(24) 74.600

2. TATIPAKA-MORTHA 18(24) 64..500

3. TATIPAKA-NARASAPUR 14 25.600

4. NARASAPUR-APSEB 12 61.900

5. TATIPAKA-KCHERUVU 18 44.500

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6. ADAVIPALEM-KADALI 8 10.500

7. KADALI- TATIPAKA 10 5.000

8. SYANAM-GUDALA 16 9.800

9. MORI-DINDI 12 9.000

10. MUKTESWARAM-KONASEEMA 12 22.500

11. S YANAM-GUDALA 8 9.800

12. NARASAPUR-KOVURU 8 61.900

13. PONNAMANDA-KADALI 10 3.660

14. KSP(W)-PONNAMANDA 10 4.500

15. VATSASA POWER 4 2.000

16. ONGC PNMDA - GAIL PNMDA 10 0.330

17. KSP(E)-PSP 8 12.660

18. PSP-BODASKURU 12 0.300

19. ONGCL TPK-GAIL TPK 14 0.210

20. GOPAVARAM-CHALLAPALLI 4 1.600

21. STEEL EXCHANGE 4 1.360

22. HITECH 4 0.460

23. RCL-2 4 3.800

24. YV LANKA-NARASAPUR 14 7.000

25. TATIPAKA-DINDI 14 17.000

26. ONGC TPK-GAIL TPK 6 0.210

Table 1 : List of pipeline Sections

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1.4 TERMINALS:

1. TATIPAKA RECEIVING TERMINAL

2. SV-1 PASARLAPUDI

3. BODASKURU RECEIVING TERMINAL

4. ODALAREVU RECEIVING TERMINAL

5. SV-2 ALLAVARAM

6.S.YANAM RECEIVING TERMINAL

7. GOPAVARAM RECEIVING TERMINAL

8. GUDALA JUNCTION POINT

9. SV-3 TOTTARAMUDI

10. KGPL TAP-OFF

11. KGPL RECEIVING TERMINAL

12. SEIL

13. HITECH

14. RCL

15. MANDAPETA RECEIVING TERMINAL

16. PONAMANDA RECEIVING TERMINAL

17. ADAVIPALEM RECEIVING TERMINAL

18. KADALI JUNCTION POINT

19. CHINTAPALLI TAP-OFF

20. SVPPL

21. SV-1 DINDI& JUNCTION POINT

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 22. MORI RECEIVING TERMINAL

23. SV-2 YV LANKA(LANCO LINE)

24. SV-2 CHINCHINADA(NSP LINE)

25. NARASAPUR RECEIVING TERMINAL

1.5 ONGC daily Gas supply (Approx) at KG Basin (SCM/Day) :

MORI : 938818

MANDAPETA(HP &LP) : 302370

MANDAPETA(W) : 35267

ODALARAVU : 784413

GMA : 32623

PSP#8 : 323772

KAIKALURU : 1872

LINGALA (LP) : 9500

NSP : 65482

NANDHIGAM : 21735

TOTAL : 25158582 SCM/Day

1.6 CONSUMER NOMINATIONS at TATIPAKA Base (SCM/Day):

HITECH : 15190

SVPPL : 36748

SEIL-I : 22784

SEIL-II : 31566

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Figure 1: process flow diagram of Tatipaka terminal

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Figure 2: key map showing incoming sources of Tatipaka terminal

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 FIRE & SAFETY

2.1 Fire Protection system:

Major Gas Receiving terminals are provided with the following fire protection system
as per OISD guidelines:

a). Fire hydrants and monitors

b). Portable fire extinguishers like DCP & CO2

Minor Gas Receiving Terminals are provide with portable fire extinguishers as per the
OISD 116 guidelines.

2.2 Procedure for Handling Fire

Case-1: Fire at Terminals area

1) Locate the fire affected area

2) Evaluate the magnitude of fire

3) Isolate the affected section from the remaining area

4) Extinguish the fire by suitable fire extinguisher if required seek the

assistance of consumer tender and fire men

5) Inform the MCR/OIC GAIL officers and the customer control room & fire
station

6) Inform the MCR/OIC GAIL Rajahmundry according to the nature of fir

Case-2: Fire at pipeline area

1) As the message comes confirm about the identity of P/L location

particulars and quantum of fire

2) Immediately inform BIC / GAIL officers and customer control room

3) BIC shall rush to the site with necessary fire extinguishers, retaining one

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 coordinator at the terminal and extinguish the fire

4) Ensure that P/L section is isolated if required

5) BIC shall asses the nature of fire and accordingly inform the MCR/OIC
GAIL Rajahmundry & State Govt. Authorities

6) Once the fire is extinguished a detailed report on the incident shall be

submitted to OIC, GAIL Rajahmundry

2.3 PROCEDURE FOR HANDLING ACCIDENTS

1) In case of any accidents occurred in the installation provide the first aid to the
injured person immediately

2) If the accident is of major in nature provide first aid to the person and then
refer him 1 the customer dispensary or to the hospital

3) All minor/Major accidents shall be reported to the safety officer and BIC.

2.4 EMERGENCY ACTION PLAN

Depending on the intensity & severity of the incident following emergency

action plans are ready & kept in the control room

1) On site emergency action plan

2) Off site emergency action plan

The district crisis group under the chairman of collector has prepared offsite
emergency action plan for east and west districts to meet any off site emergency
occurs due to uncontrolled incidents by a particular gas stations

Detailed emergency action plan may be referred to Disaster Management plan (DMP)

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2.5 On site emergency action plan

The emergency occurring within the plant, which may cause injuries or loss of life or
damage to property the situation thus created is called on site emergency. This type
of emergency is contained to a particular place and doesn’t affect the
neighbourhood & Surrounding places.

2.6 Off site emergency action plan

If the emergency becomes uncontrollable and leads to damage to life and property in
the installation and throughout the pipeline and its neighbourhood and requires the
assistance of outside agencies to handle the situation. That is called off site
emergency. Handle of offsite emergency is within the purview of the district
authorities.

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 THE SEQUENCE OF ACTIVITIES INVOLVED IN LAYING NEW
PIPELINE

The sequence of activities involved in laying new pipeline is as follows :

1.LAND ACQUISATION

2. ROW CLEARANCE

3. GRADING

4. TRENCHING

5. WELDING

6. STRINGING

7. RADIOGRAPHY

8. JOINT COATING

9. HOLIDAY TESTING

10. LOWERING

11. CATHODICALLY PROTECTING

11. BACK FILLING

12. HYDROTESTING

13. DRYING /PIPE CLEANING / PIGGING

14. HOOKUP WITH TERMINAL

3.1 TRENCHING:

 In cultivable land, to strip top soil (30 cm depth) & store separately along ROW
for replacement on top of backfilled ditch.

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  Provide suitable crossings across open ROW for land owners/ public.

 Width of trench: Pipe OD + 300 mm.

 Depth of trench to be measured from original ground/ graded surface/ top of

road/ bottom of rail, whichever is lower.

 Provide 300 mm additional cover where pipeline is within 15 m of private

dwelling, industrial buildings or public places.

 Provide temp. diversions/ bridges at road crossings to allow passage of

normal traffic with min. inconvenience.

 Provide warning/ traffic signs, lights, barricades, fencing, watchmen as

required by local authorities.

 Provide extra depth to fit min. radius of bend at crossings.

3.2 WELDING:

3.2.1 Welding procedure specification

1) For 18” & 24” pipeline (Station piping)

Process : ARC Welding

Pipe Material : API 5L GRX60

Electrode type : low hydrogen

Polarity : DCRP

Length of Electrode : 350 mm

Number of welders : 02(Two)

Filler Material Electrodes

a) Root : E 6010Lincoln 3.20mm dia

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 b) Hot pass : E 8010 Lincoln 4.00mm dia

c) Filler : E 9010 Lincoln 3.20mm dia

d) Capping E 10018 Lincoln 3.20mm dia

Direction of Welding : Up-Down-Up-Up

Cleaning : Power Grinding & Brushing

Grinding wheel : AZ30TBX

Preheating : 200°c

Position : 5G

2) For 18” & 24” pipeline (Buried pipeline)

Process : ARC Welding

Pipe Material : API 5L GRX60

Electrode type : low hydrogen

Polarity : DCRP

Length of Electrode : 350 mm

Number of welders : 02(Two)

Filler Material Electrodes

a) Root : E 6010 Lincoln 3.20mm dia

b) Hot pass : E 8010 Lincoln 4.00mm dia

c) Filler : E 10018 Lincoln 3.20mm dia

d) Capping E 10018 Lincoln 3.20mm dia

Direction of Welding. : Down-Up-Up-Up

Cleaning : Power Grinding & Brushing

Grinding wheel : AZ30TBX

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 Preheating : 200°c

Position : 5G

For pipes of 8” and below, TIG Welding is done followed by ARC Welding.

3.2.2 SHIELDED METAL ARC WELDING (SMAW):

Manual metal arc (MMA) welding, also known as shielded metal
arc welding (SMAW), stick, and electric arc welding is a constant
current drooping arc process. (The arc process is divided into two
types – drooping and flat. This refers to their volt-amp output
characteristics. By using a drooping characteristic, an alteration in arc
length gives a very small change in current.)

In manual metal arc welding the heat source is an electric arc,

which is formed between a consumable electrode and the parent
plate. The arc is formed by momentarily touching the tip of the
electrode unto the plate and then lifting the electrode to give a gap of
3 mm – 6 mm between the tip and the plate. When the electrode
touches the plate, current commences to flow and as it is withdrawn
the current continues to flow in the form of a small spark across the
gap, which will cause the air in the gap to become ionized, or made
conductive. As a result of this the current continues to flow even
when the gap is quite large. The heat generated is sufficient to melt
the parent plate and also melt the end of the electrode – the molten
metal so formed is transferred as small globules across the arc into
the molten pool.

Mode of Operation:

Arc melts parent plate and electrode to form a weld pool that is
protected by the flux cover. Operator adjusts the electrode feed rate,
i.e. hand movement, to keep the arc length constant. Slag must be
removed after depositing each bead. Normally a small degree of
penetration, requiring plate edge preparation. Butt welds in thick plate

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 or large fillets are deposited in a number of passes. The process can
also be used to deposit metal to form a surface with alternative
properties.

Equipment:

a. Welding Sets:
Manual metal arc sets are manufactured in a range of sizes,
usually distinguished by current – note the duty cycle at which the
current is quoted when comparing sets. Engine powered generators
allow operation away from mains supplies. Electrical input is single-
phase at 240 volts for smaller sets, and 415 volts (2 live phases of a
three-phase supply) for larger sets.

Output is AC or DC. AC only sets need an open circuit voltage of

80 volts to run all electrodes. 50 volts is safer and allows more
current to be drawn, but is limited to general purpose rutile electrodes
only. A control on the set adjusts current – the current is shown
either on a simple scale, or for accurate work, on a meter.

b. Power Source:
The welding machine consists of a power source with welding
lead and an electrode holder. The function of the power source is to
provide the voltage necessary to maintain an arc between the work
piece and the end of the electrode. The amount of current provided by
the power source can be altered by a control to suit different welding
conditions. Power source may supply direct current or alternating
current to the electrode. AC transformers and DC generators supply
only one type of current, but transformer-rectifiers can be switched
between AC and DC output.

c. Welding Cables:
The welding current is conducted from the power source to the
work by multi-strand, insulated flexible copper or aluminium cables. A
return cable is required to complete the welding circuit between the
work and the power source. The size of the cable must be sufficient

16
 for the maximum output of the welding power source. The earth
cable is a third cable, which acts as a safety device in the event of an
electrical fault.

d. Electrode Holder:
The holder should be relatively light, fully insulated and rated for
at least maximum power source output.

e. Return Clamp:
This is fastened to the work or bench on which the work is
placed and completes the welding circuit. The surface clamped
should be clean enough to allow good metal-to-metal contact.

f. Welding Shield or Helmet:

A welding shield or helmet is necessary for protection from arc
ray and heat, and the spatter from the molten metal. The arc is
viewed through a filter that reduces the intensity of the radiation, but
allows a safe amount of light to pass for viewing the weld pool and
the end of the electrode.

3.2.3 DEFECTS IN WELDING:

1. Porosity
2. Slag inclusions
3. Incomplete Fusion
4. Lack of penetration

3.3 RADIOGRAPHY TEST:

Equipment:

X-ray tube. Stand and control gear. Lightproof

cassette.Photographic development facilities.Dark room and
illumination for assessment.

Mode of Operation:

X-rays are emitted from the tube and pass through the work to

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 be inspected. Parts of the work presenting less obstruction to X-rays,
such as cavities or inclusions, allow increased exposure of the film.
The film is developed to form a radiograph with cavities or inclusions
indicated by darker images. Section thickness increases (such as
weld under-bead) appear as less dense images.

Operating Parameters:

Tube voltage : 10 - 500 kV

Tube current : 10 - 250 mA

Power consumption: 1 - 10 kW

Portability : fair

Exposure time : 1 sec - 10 min

Thickness range : up to 100 mm

Minimum defect size : 0.1% of thickness X 0.05 mm

3.4 FIELD JOINT COATING:

Figure 2 :Field joint coatings are carried out using Heat Shrinkable Sleeves

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 A. Materials :

Heat shrinkable wraparound sleeve consists of radiation cross-linked,

thermally stabilised, ultraviolet resistant semi-rigid polyolefin backing with a uniform
thickness of high shear strength thermoplastic/copolymer hot melt adhesive. The
joint coating system may consist of a solvent free epoxy primer applied to the pipe
surface prior to sleeve application. The backing is coated with thermo chrome paint
which will change colour when the desired heat during shrinking is attained. The
wraparound sleeve is supplied in pre-cut sizes to suit the pipe diameter and the
requirements of overlap.

The thickness of field joint coating material is such that an average thickness
of 2.0 mm is guaranteed on the complete finished field joint coating.

B. Field Joint Coating procedure:

1) Surface Preparation :

Oil, grease, salts and other contamination are removed from steel
surface by wiping with rags soaked with suitable solvents such as naphtha or
benzene. Solvent cleaning procedure is in accordance with SSPC-SP 1.
Surface is then blast cleaned to a finish equivalent to SA 2½ of Swedish
Standard SIS-055900. The ends of existing pipe protective coating are
inspected and chamfered prior to application and cleaned as necessary. Joint
coating shall be applied immediately after completion of surface preparation.

2) Application of Joint Coating :

The wrap around sleeve of size such that a minimum overlap of 100
mm is ensured (after shrinking) on both sides of the yard applied corrosion
coating of pipe is selected. Before centring the wraparound sleeve, the bare
steel surface shall be preheated over the surface to remove the moisture. The
minimum preheat temperature as recommended by the manufacturer and
shall be checked by means of pyrometer or temperature crayons. The solvent

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 free epoxy primer (if applicable) is applied prior to sleeve application.

The wraparound sleeve is then entirely wrapped around the pipe

positioning the closure patch off to one side of the pipe in 10 o’clock or 2
o’clock position, and the edge of the undergoing layer facing upward. A heat
shrinking procedure is applied to shrink the sleeve in a manner such that all
entrapped air is removed using gloved hands and hand rollers. Heating is
carried out until the thermo chrome paint has completely changed its colour.
Resulting coating must be free of wrinkles, cold spots and weld profile visible
on the sleeve.

3) Inspection:

A visual inspection is carried out for the following:

 Mastic extrusion on either ends of the sleeve.

 Punctures or pinholes or bend failure. The external appearance of the

sleeve shall be smooth, free of dimples, air entrapment or void
formation.

 Weld bead profile shall be visible through the sleeve.

 The entire closure patch shall have changed colour uniformly.

3.5 EXTERNAL PIPE COATINGS:

To protect the buried line pipes from external corrosion, the line pipes
are coated. A good quality pipeline coating shall have following
characteristics:

 Adherence to pipe

 Non-porous

 Free of defects, pores, flaws, holidays.

 Should act as an insulating barrier.

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  Should be inert to environment.

 Coefficient of thermal expansion of the coating film > that of

pipe metal.

 High resistance to abrasion.

 Resistance to UV degradation.

Following types of coatings are mainly used for coating of line pipes:

i. Coal Tar Enamel Coating

ii. 3 Layer Polyethylene Coating

iii. Fusion Bonded Epoxy Coating

3.6 COAL TAR ENAMEL COATING

Primer : Fast drying synthetic primer Type B for cold application.

Coal Tar : The coal tar enamel shall consist of a uniform mixture of a specially
modified coal tar and inert non-fibrous filler.

Wrapper : The inner wrap glass fibre reinforcement material and outer wrap
material is coal tar impregnated asbestos felt or glass fibre felt.

3.7 LAYER POLYETHYLENE COATING

It consists of 3 layers such as

I. Electrostatic application of epoxy powder (100 - 175 micro meter thick )

II. Crystalline Co-polymer Adhesive applied by extrusion (min. 0.20 mm thick)

III. Polyethylene coating by extrusion.

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3.8 FUSION BONDED EPOXY COATING

The FBE is an electro statically charged powder, which is pneumatically

sprayed onto the hot pipe, and contains excellent passive corrosion protection
properties. It is deposited by electrostatic spray to thickness of 305 micron.

3.9 HOLIDAY TEST:

Holiday test is one of the non destructive test methods applied on
protective coatings to detect unacceptable discontinuities such as pin holes
and voids.

 The test involves checking of an electric circuit to see if current flows to

complete the electric circuit.

 A holiday test or continuity test is performed by applying low voltage across

the chosen path

 It is connected in series with an LED or noise producing component such as

piezoelectric speaker.

 If the electric flow is detected then the test area is termed as conductive
indicating presence of discontinuities such as pinholes and voids.

 This test is commonly used in the offshore industries where piping and
structures are coated with non conductor coatings.

3.10 HYDROSTATIC TEST :

 Instruments and equipment to be used are with valid calibration and of
required rating.

 Water testing certificate and corrosion inhibitor dosage recommendation

available.

 Gauge plate of 95% id and 10 mm thickness shall be passed through the

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 section after cleaning of the pipe.

 Gauge plate with < 2 mm scratch on side wall and with no dent is acceptable.

 Checking the condition and sequence of pigs in the hydrostatic header.

 Only qualified welder is allowed to perform welding of header.

 Check rating and condition of header fittings.

 Use the filling water from tested water source only.

 Fill 500 meters. Of water before first pig and 1000 meter water between first
and second pig.

 Final filling shall be done with fill rate of 2 km/hrs

 After receipt of pigs at receiver minimum 2 hrs. Water flushing shall be

ensured.

 Turbine meter reading recording shall be preserved.

 Thermal stabilization for 24 hrs. Shall be done and section is said to be

thermally stabilized if difference not higher than 1 degree is attained between
the average value of soil temperature readings

 Pressurize the section not more than 2 bar/min rate.

 Following the sequence mentioned below:-

a) pressure the pipe section to 50%hold for i hr.

b) drop 0.5 bar do air volume calculation.

c) drop pressure to static +1 bar.

d) follow b & c for 75% pressurization.

e) if air volume calculation value is between 1 to 1.06, then filling is accepted.

 Pressure the pipe to 125.18 to 118.55 kg/cm2 (depending upon pipe section
profile) and hold it for 24 hrs.

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  Use dwt and recording system during testing.

 The test is considered acceptable if difference is less or equal to 0.3 bar in

case of doubt testing period shall be extended.

3.11 CATHODIC PROTECTION :

Corrosion :

Corrosion is Loss of metal due to its interaction with environment.

It is an electrochemical process.

The less noble metal become anode (positive electrode) while more noble
metal act a cathode( negative electrode).

Anodic reaction – dissolution of metal .

Cathodic reaction – deposition of ions.

Reaction at anode which causes dissolution of metal leads to corrosion of

metal.

Cathodic Protection:

A technique to reduce the corrosion of a metal surface by making that

surface the cathode of an electrochemical cell.

• Anode: the electrode from which current leaves to the electrolyte Anode gets
corroded

• Cathode: the electrode where current is collected from the electrolyte No

corrosion takes place at the cathode

Cathodic protection can be done in 2 ways.

1. Sacrificial Anode CP

2. Impressed Current CP

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3.11.1 Sacrificial Anode CP :

• No external power requirement

• Suitable in low resistivity soil / marine environment only

• Choice on anode material is limited.;anodes get corroded fast;

• Can protect well coated structures only, protected area is small

Anodematerials:

Zinc Alloy (C-Sentry)

Sea water, low resistivity soil

Aluminum Alloy (Galvalum I, Galvalam II, Galvalum III, Alanode)

Sea water

Magnesium Alloy (Galvomag)

Soil

3.11.2 Impressed Current CP:

• Requires external power supply

• TRU output can be controlled (automatic / manual)

• Can be used in high resistivity soil, can protect uncoated structures

• Wide choice on anode material; anodes have long life

Anode materials:

• Platinum and platinised metals

• High silicon cast iron

• Lead-platinum

• Lead-silver

• Graphite

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 • Cast Iron

Figure 3: schematic of cathodic protection by impressed current

OPERATION:

 Current is fed to the pipeline through a DC rectifier unit.

 Circuit is completed by an Anode bed using a Silicon iron Anode.

 As a result anode is corroded and the pipe remains protected.

 Input to CP rectifier : 1 Phase, 220 V A.C.

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  Output from CP rectifier : 0-50V, 0-50A D.C.

 Pipe is kept at a negative potential w.r.t the soil (Min (-)0.85 V).

 Regular PSP readings are taken using copper sulphate half cell to
ascertain the protection level.

 At CP location PSP readings not to exceed (-)1.2V .(Off potential)

 Spacing of CP units is based on soil conditions, coating conditions

and pipe resistance.

3.11.3 Monitoring of CP:

Monitoring the condition of structures protected by CP is done by two

methods.

1. Close Interval Potentials Survey (CIPS)

2. Direct Current Voltage Gradient (DCVG) survey

3.11.4 Close Interval Potentials Survey (CIPS):

 The principle of a CIPS is to record the potential profile of a pipeline

over its entire length by taking potential readings at intervals of around
1 m.

 CIP Surveys are carried out using a high speed data logger with inbuilt
GPS Antenna and stick mounted Cu/CuSO4 reference electrode.

 The most important consideration in the potential readings is the IR, or

ohmic drop error, that is included in the potential measurements when
a CP system is operational.

 For minimization of IR errors, two current interruption criteria used in

practice include a 4-sec ON, 1-sec OFF cycle and a 1.6-sec ON, 0.4-sec
OFF cycle.

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 Figure 4: close interval potential survey

 Fundamentally, these surveys do not indicate the actual severity of

corrosion damage.

3.11.5 Direct Current Voltage Gradient (DCVG) survey:

 DCVG surveys are a more recent methodology to locate defects on coated

buried pipelines and to make an assessment of their severity.

 The potential gradient is measured by an operator between two reference

electrodes (usually of the saturated Cu/CuSO4 type), separated by a distance
of say half a meter.

 The imposed pulsed input signal minimizes interference from other current
sources.

 The presence of a defect is indicated by a increased needle deflection as the

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 defect is approached, no needle deflection when the operator is immediately
above the defect, and a decreasing needle deflection as the operator walks
away from the defect.

 An additional feature of the DCVG technique is that defects can be assigned

approximate size factor.

Figure 5: Direct current voltage gradient survey

An empirically based rating based on the so-called %IR value has been
adopted in general terms as follows:

 0 to 15%IR (“small”): No repair required usually.

 16 to 35%IR (“medium”): Repairs may be recommended.

 36 to 60%IR (“large”): Early repair is recommended.

 61 to 100%IR (“extra large”): Immediate repair is recommended.

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3.12 HORIZONTAL DIRECTIONAL DRILLING (HDD):

Horizontal Directional Drilling (HDD) was the preferred pipeline construction

method to cross major waterways and critical areas where normal trenching
operation is not possible.

Installation of a pipeline by HDD is generally accomplished in three stages.

The first stage consists of directionally drilling a small diameter pilot hole
along a designed directional path.

The second stage involves progressive enlarging this pilot hole to a diameter
suitable for installation of the pipeline.

The third stage consists of pulling the pipeline back into the enlarged hole.

The initial borehole is called a pilot hole. The borehole is drilled using drilling
fluid, which is brought into the borehole by the rotating drilling head.

Bentonite in water forms thixotropic fluid which is used as drilling fluid in HDD.

Enlarging the pilot hole is accomplished using Reaming operation. It was done
by 2 different tools.

1. Fly cutter

2. Reamer

30
 Figure 6: Horizontal directional drilling

After the pilot drill was completed, a hole of 6” can be obtained.

For enlarging the existing hole, a fly cutter and reamer of 12” were connected
to drill pipes and pulled back.

The hole will be further enlarged using 24” reamer in 2nd stage and 36”
reamer in the next stage.

Now the hole of 36” is ready for accommodating 24” pipeline.

On the other side of rig, the pipe of 1600 metres is welded and tested by
Radiography.

The welded pipe is joint coated and tested by Hydrostatic test and Holiday
test.

The pull end of pipe is closed and connected to drill pipe using a swivel.

31
 Entire pipe is placed on rollers for moving the pipe during pulling.

HDD Equipment

Figure 7: HDD Equipment

3.13 PIGGING:
Prior checks list before starting pigging operation:
 Operational checks of valves to be operated during pigging such as
mainline, pig barrel valve, kicker line valve, vent valve.
 Operational conditions of the band end closure of the pig barrel condition
of O-ring of band end closure.
 Operational condition of the QOEC
 Checking the condition and movements of the pig launching/receiving pad
(if available) i.e trolley, receiving try etc, greasing of the same.
 Internal inspection of condition of pig barrel any debris and liquids present

32
 in barrel shall be cleared.
 Arrangement of requisite spares for pigging operation
 Communication system and channel to be establish and ensure for
operation.
 Arrangements for collecting the condensate and transportation.
 Condensate collection shall be made at all possible anticipated locations.
Tanker to be intimated advance in 12hr and stationed at all Varity
locations.
 Temporary pits for collecting water/slug to be prepared in advance.
 Arrangement of fire fighting equipment and PPES.
 Produce of sequence operation for pigging and circulation to all the
concerned.
 Selection of pigs and transportation to the site.
 Tools and tackles for pigging operation.
 Restriction of gas flow for smooth travel 2.5km/hr.

3.13.1 PIG LAUNCHING:

QOEC

FLOW DI

#1 KICKER VALVE

VENT #3 MAIN LFIlN

owE VALVE

PIG

#2 FULL BORE TEE

33
FLOW
VALVE

Figure 8: Pig Launching

 Ensure pig barrel isolation valve #2 and kicker line valve #1 closed.
 Open the barrel vent and drain to allow the gases displaced or vent to
atmosphere.
 With pig barrel vent and drain valves open position check the pressure gauge
reading and pressure gauge must be zero kg/cm2
 Replace the pressure gauge with nitrogen gas hose and purge the gas upto 2-
3 kg/cm2 into the barrel and open the barrel vent and drain to avoid the gas
explosiveness while opening the barrel end closure.
 Open the pig barrel and insert the pig and pushed forward until the front pig if
firmly in contact with reducer.
 Close and secure the end closure and close drain and vent valves.
 Gradually open the kicker line valve to pressurize the launcher allow the
pressure to equalize.
 When the launcher is pressurized to line pressure then fully open the kicker
line isolation valve.
 Gradually open the pig barrel isolation valve #2. i.e., full bore valve.
 Double ensure that the pig barrel isolation valve is fully open.
 Gradually close main valve #3 thereby increase the flow behind the pig.
 Monitor pig signal for pig passage by hearing manually or through GEO
PHONE.
 Once pig has entered mainline completely first open the mainline valve #3.
 Close pig barrel isolation valve#2.
 Close kicker line valve #1.
 Gradually open the vent and drain valves and depressurize the barrel.
 Repeat the launching sequence for next pigs.

34
 3.13.2 Pig receiver:

QOEC

#1 EQUALISER VALVE

#3 MAINLINE VALVE
FLOW

VENT

PIG FLOW

#2 FULL BORE VALVE TEE

FLOW

Figure 9: Pig Receiver

 Ensure pig barrel isolation valve #2 and kicker line valve #1 closed.
 Gradually pressurize the barrel through equalizer line across the pig barrel
isolation valve.
 When the barrel is fully pressurized to the mainline pressure then open the
equalizer line valve #1 connecting the pig barrel and mainline.
 Open the pig barrel isolation valve #2 i.e., fully bore valve.
 Control the flow of pipeline.
 Collect gas the liquid received from the pipeline in the terminal facilities such
as slug catcher, scrubber, and condensate tank open drain and soak pits etc.
 Ensure the pig speed calculate are updated with current flow and pressures.
 When pig is tentatively near to the receiver, close the mainline valve #3, and
allow the entire flow of gas through the pig barrel and equalizer line.
 When pig is received. First open the mainline valve #3.
 Gradually close the pig barrel valve #2.

35
  Close the equalizer line valve #1.
 Open the barrel vent and drain.
 Ensure the total barrel fully empty and check the pressure gauge reading zero
kg/cm2. Close the vent and drain valves.
 Purge the nitrogen gas through the pressure gauge upto 2-3kg/cm2 and open
the vent and drain valves to allow the gas to atm.
 Remove the pig receiver tray, take the pig and clean the receiver with water
jet.
 After cleaning insert the tray in receiver.
 Close and secure the pig barrel end closures.
 Repeat same operation for receiving pigs.

3.13.3 Types of pigs:

1) Foam pig

2) Gauge pig

3) Brush pig

4) Magnetic pig

5) Electronic geometric pig

6) CDP(corrosion detection pig)

7) Intelligent pig

VALVE LEGENDS:

BALL VALVE FLANGE END

BALL VALVE BW END/UPTO ½” SW END

36
 PLUG VALVE

PLUG VALVE FLANGED END

GLOBE VALVE

GATE VALVE

NON RETURN VALVE (NRV)

NEEDLE VALVE

PIPEBOOK:

Pipeline entitle details are recorded as follows

ma
rks
Re
Date

wate hydr
otes
of

t
dryin
Date
of

g
r

37
 s.n Chi He Act Wall Date Joi Wp Date RT Date Date Date Dat Date
o nag at ual thick of nt s of NO/ of ut of of e of of
e no len ness bend no. no. weld DA field peel low back
gth TE joint test erin fillin
coati g g
ng
38