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 80
0
C
Fusion Bond Epoxy Coatings 110
0
C ~
140
0
C
Polypropylene Coatings 120
0
C
Polymeric Tape Coatings - 60
0
C
Liquid Epoxy Coating - 150
0
C

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
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

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

Tmax
(Pull speed 10N/mm)
N-n S-n
3.5 3.5

1.5 2.5
(50c) (70c)
A B C
10 15 23

2 3 4
(60c) (80c) (90c)
B1
6

-
Impact Strength J/mm @
23c
N-n S-n
5 5
A B C
5 7 10

B1
3
Indentation
-23c
- Tmax
N-n S-n
0.2mm 0.2mm
0.3mm 0.3mm
(50c) (70c)
A B C
0.3mm 0.2mm 0.1mm
0.3mm 0.2mm 0.1mm
-
Cathodic disbondment
65C/24hrs(-3.5V)
20C/28 days(-15V)
65C/28days(-1.5V)


-

7mm
7mm
15mm


-
12mm
DIN-30670 ISO-21809-1 CAS-Z245.21-06
9
THREE LAYER POLYETHYLENE COATING
OPERATING TEMPERATURES
DIN-30670 ISO-21809-1 CAN/CAZ.2451-06
DIN-30670- N
up to 50 C
Class-A : ( )20C to (+) 60C

(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 ; ( )20C to (+)110C

(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 20
th
& 21
st
)
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 20
th
& 21
st
)
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 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.

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