IndianOil

Pipeline – Laying , Maintenance &

Inspection.
IndianOil

TYPES OF PIPELINE

WHAT IS A PIPE?
It is a pressure tight cylinder which is used to convey a
fluid like water, any liquid petroleum products etc.
IndianOil

TYPES OF PIPELINE

A) SPIRAL WELDED PIPE:

Pipe having helical seam with butt or lap seam joint and is
welded using either a electrical resistance, electric fusion
or double submerged arc welding.

B) SEAMLESS PIPE:
In this process a round billet of high quality steel is heated
to a high forging temperature and forced by revolving rolls
over rounded nose of a piercing mandrel which results a
thick- walled seamless pipe.
IndianOilABOVE GROUND PIPELINE LAYING
• P/L to be routed through shortest route.
• P/L should run in groups.
• Inherent flexibility for expansion/ contraction should
be used.
• Expansion loops to be provided wherever necessary.
• Accessibility for maintenance.
• Clearance between parallel P/L min 1.5 times
diameter of largest P/L.
• Minimum nos. of bends in pump suction line.
IndianOil

ABOVE GROUND PIPELINE LAYING

• Eccentric reducers to be used in Pump suction line

with flat side aligned with top of suction of pump.
• No stress is imposed on flange or casing of pump.
• Minimum ground clearance 300 mm to be
maintained.
• Supports should be of concrete / masonry / steel and
on top of it pipe piece or rod to be embedded for
providing point contact.
• Saddle plates may also be used for support and their
periphery should be welded with the Pipe to prevent
water ingress.
IndianOil
ABOVE GROUND PIPELINE
LAYING
• Good quality jointing material to be used for flanged
joints.
• Nuts in flanges to be tightened uniformly.
• Whenever P/L go through walls, concrete / steel
pipes to be provided for proper plugging and sealing.
• Inlet / Outlet of P/L of tanks should be provided with
pressure release lines.
• Line blind to be used for definite shut off.
• Permanent platform to be used for safe access for
operation of valves.
 UNDERGROUND PIPELINE LAYING
IndianOil
• Install only when it is absolutely necessary.
• Should be adequately protected to prevent corrosion.
As far as possible flange joint to be avoided in U/G
Pipeline. If unavoidable inspection chamber to be
provided at flange joint position.
• Wrapping / coating should be done as per painting
manual.
• Carry out the “peel off Test” to ensure proper
adhesion of coating.
IndianOil

UNDERGROUND PIPELINE LAYING

• Ensure coating is free from holiday using voltage of

15 KV max.
• Entire network to be hydro tested at 1.5 times of
design pressure.
• Depending upon type of soil and length of P/L,
Cathodic Protection system to be installed
 NECESSITY OF INSPECTION
IndianOil

1. To evaluate the present physical condition of the

pipelines for their soundness to continue in service.

2. To keep the concerned operating and maintenance

personnel fully informed the condition of various
pipelines.

3. To determine the causes of deterioration and advise

economical best solution to the problem.

4. To recommend short term and long term repairs.

 NECESSITY OF INSPECTION
IndianOil

/replacement to ensure safe and economical operations of

pipelines.

5. To initiate procurement action of materials to meet repair

and replacement needs.

6. To advise preventive maintenance actions to enhance life

span of pipelines.

7. To advise wrapping/coating, painting, cathodic protection

etc for the enhancement of service life.
IndianOil

EXTERNAL CORROSION

1. Above ground p/ls are prone to atmospheric corrosion.

2. Pipelines touch the damp soil or partly embeded
in soil or supports.
3. At the gaps between p/l and support where water deposits
on p/ls.
4. Material loss is observed at the pipe support locations
where relative movement between pipe and pipe support
takes place.
5. U/G pipelines are subjected to external corrosion due to
improper wrapping and coating.
IndianOil

EXTERNAL CORROSION

6. Lines passing through the culverts, strom water, drains,

marshy lands etc. prone to corrosion due to presence of
moisture, acidic, basic, sulphide rich environment.

7. Insulated or concreted lined pipelines where weather

shield/insulation is damaged or concrete is found cracked,
pipelines subjected to external corrosion due to water
ingress in the insulation or cracked concrete.
IndianOil

INTERNAL CORROSION
1. Greater loss of metal usually observed near
restrictions in the line or change in flow direction
of fluid due to turbulent flow. such areas are Elbow,
tee, orifice etc.

2. Where condensation of water or accumulated

water is observed.

3. At dead ends where liquid to vapour interface

or condensation occurs.
IndianOil

INTERNAL CORROSION
6. Areas near flanges or near welded attachment
acts as cooling fins, causes local corrosion
because of slight temperature difference.

7. Port terminal pipelines which have chance of

carrying sea water/ ballast water.
IndianOil

Inspection frequency of Location P/L

• Quarterly by Location.
• Yearly by M&I during Indexing.
• 3 Yearly by M&I including thickness survey.
For all categories of pipelines.(Critical
pipelines/non critical pipelines for all product
& fire water /Railway siding pipelines.
• Pressure testing as per schedule (By User
Deptt.) as per M&I circular no. HO/M&I/33/41
Dated 03.02.14.
IndianOil

Pressure testing of P/L

U/G P/L inside premises to be pressure tested every 5 years
(Including internal railway siding)
Critical P/L to be pressure tested every 3 years
Jetty line/cross country p/l to be tested every year)
Above ground product pipeline –No Pressure testing required.
Test pressure of U/G pipelines : 1.5 times working pressure when
(Non Critical) test fluid is water.
1.1 times working pressure when
test fluid is product .
Testing Time : U/G pipeline- 4 Hours
Hydrant Line-24 Hours
 Annexure-VII-A
INDIAN OIL CORPORATION LIMITED

SUMMARY SHEET OF PIPELINE PRESSURE TESTING RECORD

Location: _______________________

Sr. Pipeline identity Service Test Test Test Date Test Carried Certificate Signature
No. Pressure Holding Medium Out By Reference &
kg/cm² Time Date
1

6
IndianOil NO SPACE BELOW HYDRANT
LINE FOR PAINTING /
MAINTENANCE
 Blistering of paint
IndianOil

Effects:
Corrosion marks are
visible which, if allowed
to continue, may lead to
pipe failure.
Remedial Measure:
Paint the pipe properly
after thorough surface
preparation.
 Dense pitting in pipeline
IndianOil

Effects:
If corrective actions are
not taken immediately,
may lead to Failure of
the pipeline.
Remedial Measure:
Replace / repair the
pipeline with weld build
up.
 Dense pitting in pipeline
IndianOil

Effects:
Failure of pipeline
may occur at any
time.
Remedial
Measure:
Replace the pipeline
immediately.
IndianOil
Vegetation around
pipeline.
Effects:
Rain water from
vegetation falling on
pipeline will damage the
pipeline painting and
lead to failure. Area
becomes inaccessible.
Remedial Measure:
Clean vegetation in and
around pipeline. Brick
pitching / carpeting
below the pipeline to
avoid vegetation
growth.
 Aboveground pipelines
IndianOil

semiburied
Effects:
Severe corrosion will take
place in the buried portion.
Remedial Measure:
Make the pipeline above
ground since flange and
valves are connected with it
in nearby portion.
Pipelines can be made
totally aboveground or totally
underground. Underground
pipelines should be provided
with proper wrapping coating
but in no case flange, valves
etc. should be made
underground.
IndianOil
Valves partly buried

Effects:
Corrosion in valve body and
prone to failure.
Remedial Measure:
Make the valve totally above
ground.
As per norms valves should
always be placed
aboveground for ease of
operation, inspection,
maintenance and also to
avoid corrosion and related
safety hazards.
IndianOil

CORROSION UNDER INSULATION

IndianOil
Under ground pipeline
coating damage
IndianOil

CORROSION UNDER INSULATION

IndianOil

INSPECTION OF UNDERGROUND LINES

IndianOil
VISUAL INSPECTION OF
PIPELINES
IndianOil
PIPELINE WASHOUT
IndianOil
Underground Pipeline
IndianOil
Damage of Wrapping Coating
IndianOil
PIPE LINE RUPTURE