Start up and Commissioning of Pipelines

Presentation by
D. S. Nanaware,
Chief Project Manager, IOCL,
Noida
IiPM, Gurgaon

10th July 2009

Contents

Methodology for Pre-commissioning of

new pipelines

Objectives

Task Forces

Responsibility of Project/Construction
Group

Responsibility of O& M Group

Responsibility of Fire & Safety Group

Documentation

Commissioning

Handing/Taking Over

Case Study

10th July 2009

IiPM, Gurgaon

Methodology for
Pre-commissioning of
New Pipelines

10th July 2009

IiPM, Gurgaon

Objectives

Preparation of pre-commissioning and commissioning

plan

Safe commissioning of pipeline system

Safe and smooth

commissioning

Proper handing over & taking over of pipeline system

Preparation of check list for all pending activities

Liquidation of check list points in a time bound manner

10th July 2009

operation

of

IiPM, Gurgaon

pipeline

after

Task Forces
For efficient startup/commissioning specialized task-force
can be formed including specialists from:

Projects/Construction Group

Operations & Maintenance Group

Fire & Safety Group

10th July 2009

IiPM, Gurgaon

Responsibility of Projects/Construction
Group
The group will ensure:

Mechanical completion of pipeline system

Hydro-testing and pigging of entire pipeline

Inertization of pipeline

Ensuring readiness of pipeline system for commissioning

Handing over of pipeline system (including spares, tools,

equipment etc) for operation

Handing over of relevant documents and certificates to

O&M group
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IiPM, Gurgaon

Responsibility of O&M Group

The O&M group will ensure:

Verification and taking over of all contract, project and

operation related documents before pre commissioning
activities

All checks for ensuring system integrity and functionality

Verification of all statutory permissions

Verification of relevant inspection reports and certificates

etc.

Verification of venders documents for material supply

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IiPM, Gurgaon

Responsibility of O&M Representative

(contd..)

Verification of agreements and MOUs with product

suppliers and consumers

Preparation of check list with target completion dates for all

contracts works and material POs

Enlisting of all construction surplus materials, and

equipment with all relevant inspection, test certificates and
other documents

Ensure preparation of check list for balance jobs

Verification and taking over the project DFR, concept note

and project approvals etc
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Responsibility of Fire & Safety

Representative

Verification of Fire network and equipments as per relevant

OISD standards

Check the adequacy of first aid fire fighting appliance as

OISD Std. 117

Ensuring placement of fire fighting equipments/instruments

as per OISD Std. 117

Check the compliance of safety audits, OISD audits and

Pre-commissioning audits

Check the integrity of fire fighting system before start up

and commissioning
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Documentation
The O&M Documentation In-charge shall take over and
ensure proper distribution of documents related to:
A. Statutory clearances/Permissions

Factory License as per factory act 1948

State Pollution Control Board and Ministry of Environment &

Forests (MoEF) clearances

State & Central Electricity Authority Permissions (wherever

required)

Clearance for frequency in case of Radio set, WalkyTalky/VHF /UHF

Clearance from CCOE

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Documentation
A. Statutory clearances/Permissions (contd..)

Permissions/Agreements executed for Railways, Road

(NH & SH), Canal, OFC and any other crossings

Authorization for hazardous waste rule (Management &

handling - 1989)
B. Revenue and RoU related documents

Detailed RoU Survey Reports with Survey Numbers

Tree & Crop compensation details and documents

Land acquisition documents, ROU Cadastral Map

Field management books (FMBs)

List of disputes / pending complains with detail status

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Documentation
C. Construction Related Documents

Mechanical Completion Certificate

Hydro testing acceptance certificates

Equipments Commissioning Certificate with commissioning

history

Work order copies and Contracts

Construction QA/QC records, Procedures and inspection

records

Radiography films and records

MOUs and agreements with product suppliers and

consumers (Copies)
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Documentation
C. Construction Related Documents (contd..)

Agreements with contractors, venders, material / Equipment

suppliers

All taxes and duties statements

SAT (Site acceptance Test) of all instruments including

certificates and loop

testing certificates

Process Flow Diagram

As-build drawings such as plot plan, cable route drawing,

earthing and P&ID etc.
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Commissioning of
New Pipelines

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Objective of Commissioning

Commissioning is to bring the constructed / installed

system to deliver the desired function.

Pipeline commissioning means introducing crude/

product/Gas in the pipeline from originating station, filling
the entire length and then start delivering to the planned
receipt system.

In case of crude pipeline, there may be intermediate

storage stations for operational requirement but ultimate
supply is to be made to a refinery

In case of product pipeline/Gas pipeline, there may be

several
intermediate
delivery
stations
before
terminal/dispatch station.
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Pre-commissioning
Preparation of commissioning manual

A document describing the procedure to be followed for

commissioning is to be prepared by experienced persons

The purpose of making the document is to set forth the

objectives of commissioning of pipeline system and to
establish guidelines for safe commissioning in order to
achieve the required goals.

Pre-commissioning check list

A check list is prepared, which covers the technical, safety

as well as statutory requirement before the pipeline and
associated facilities is declared ready for commissioning.
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Pre-commissioning (contd..)
Constituting a pre-commissioning team:
A committee of experienced engineers is constituted to
audit the construction as per pre-commissioning check list
and report to the management regarding readiness of the
system or any shortcomings to be complied before
commissioning.
Procurement of consumable/tools/pigs etc:
As mentioned in the Commissioning Manual, required
consumables, tools, pigs, spares and safety equipments
are to be made available prior to commissioning.
Availability of product/ crude:
As per line fill calculation, the availability of crude oil or the
product, as the case may be, is to be ensured at originating
/ pumping station in coordination with Refinery and
Marketing.
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Commissioning

Pipeline sections are generally commissioned in phased

manner / in totality based on the situation and
preparedness.

After hydro-testing and caliper pigging it is expected that

the sections are in a fairly clean condition.

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Commissioning action plan

Constituting a commissioning team:

A committee of experienced engineers is constituted to
perform the objective of commissioning.

Scrutiny of audited pre-commissioning check

list:
The committee to ensure the compliance of any
shortcomings reported in the pre-commissioning check list.

Identification and deployment of manpower

at new stations

Deployment of security personnel at stations

Arrangement of water and disposal plan

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Commissioning steps

Pressurization of pipeline section with compressed air up

to 3-5 Kg/sq cm.

Injection of about 500 to 1000 KL water into the section

from launching barrel end

Launching of cleaning (bi-di) pig after introduction of water

in the line

Maintaining 5-10 kg/sq.Cm back pressure at other end by

venting the air

Introducing about 1000 to 3000 KL of water behind the

cleaning pig

Launching batching (bi-di) pig

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Commissioning steps (contd..)

Introducing HSD / Crude in the line and maintaining 5 to 10

Kg/sq.cm back pressure at other end.

Draining dirty water to storm water drain / pre-fixed drain

outlet at the receiving end

Receiving cleaning pig

Again draining dirty water to storm water drain

Receiving batching pig

Lining up marketing HSD receipt tank /Refinery or Pipeline

crude receipt tank

Flow to be diverted to HSD / Crude receipt tank as soon as

oil traces are observed. Temporary facility for water
draining to be dismantled & permanent blinding put
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Commissioning steps (contd..)

Since, before pumping water, line is filled with air at a predetermined pressure, so monitoring and air draining facility
is kept ready at receiving end to maintain back pressure of
air at 5 to 10 Kg/sq.cm

Pumping into an empty line will cause excessive flow rate &
current in the motors resulting in frequent tripping. May
result in increase of interface length.

As the pig reaches at receiving end, it is taken out. The

muck & dirt quantity is collected and after analysis it is
disposed off.

Handing over the system to operating group

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Commissioning steps (contd..)

Specific check points/procedure for

Gas Pipelines

LPG Pipelines

ATF Pipelines

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Handing/Taking Over
HANDING / TAKING OVER FORMAT
NAME OF PROJECT

: ______________________

LOCATION

: ______________________

PROJECT IDENTIFICATION

: ______________________

PROJECT COST

: ______________________

PMC

: ______________________

CONTRACTOR

: ______________________

DATE OF COMMISSIONING

: ______________________

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Handing/Taking Over
I.
1.

DETAILS OF FACILITIES TO BE HANDED OVER

_____ INCH DIA. P/L FROM _______ TO ______ (ALONGWITH OFC)

HAVING DESIGNED CAPACITY OF ______ MMT/MMSCMD AT PRESSURE
_________KG/CM

2.

ORIGINAL/DISPATCH TERMINAL/ STATION AT : ______________________

3.

RECEIVING TERMINAL AT

: ______________________

4.

SV/IP STATIONS ALONG PIPELINE AT

: ______________________

5.

ANY OTHER FACILITIES (IF APPLICABLE)

: ______________________

6.

HDD (IF ANY) DETAIL

10th July 2009

: _____________________
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Handing/Taking Over
II. IMPORTANT PARAMETERS AND DATES
1. MECHANICAL COMPLETION DATE OF MAIN LINE WORKS: __________
2. PIGGING (FOAM, GAUGE, CLEANING PIG & EGP)

: __________

3. HYDRO TEST & DESIGN PRESSURE OF MAIN LINE

: __________

4. MECHANICAL COMPLETION DATE OF RECEIVING

: __________

& ORIGINATING TERMINALS

5. INSTRUMENTATION COMPLETION DATE

: __________

OF TERMINAL STATION
6. COMMUNICATION SYSTEM COMPLETION DATE

: __________

7. SCADA AND TELEMETRY COMMISSIONING DATE

: __________

8. DATE FOR PRODUCT/GAS CHARGING IN THE SYSTEM

: __________

9. FINAL DATE OF COMMISSIONING

: __________

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Handing/Taking Over
III. STATUS OF SYSTEMS / FACILITIES TO BE RECORDED
BEFORE TAKING OVER
(A) Pipeline & CP
1. Status of ROU, CP test points and Markers

OK/ Not OK

2. Checking of mainline & bypass line valves & Actuator

OK / Not OK

3. Physical Status of SV/IP, receiving & Pump stations OK / Not OK

4. Performance test of SVs/IP station

Done / Not Done

5. Checking of casing shorting at crossings.

Done / Not Done

6. Status of Temporary CP

Removed./ Not Rmd

7. Status of captive power system

Comm / Not comm.

with battery bank (wherever applicable)

8. if pipeline is not charged, is it dried & filled with inert gas
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Yes / No
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Handing/Taking Over

(B) COMMUNICATION & SCADA

1. Status of communication system

Comm / Not comm.

2. OFC Checking

Done/Not Done

3. Status of SCADA and telemetry system

Comm / Not comm.

(If applicable)
4. Communication between the RTU

OK/ Not OK

at maintenance bases
5. Communication between the flow

OK/ Not OK

computers to RTU/SCADA for Master Control Centre

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Handing/Taking Over
(C) INSTRUMENTATION & METERING
1. Status of metering systems (If applicable)

Yes/NO

2. Checking of Instrumentation Panel (If Applicable)

Comm/Not comm.

3. Status of Chromatographs (If applicable)

Done / Not Done

4. Status of Instruments at SVs/RRs/IPs

comm/Not comm.

5. Remote operation of Valves at SVs & Terminals.

OK/NOTOK

6. Status of UPS

Comm. /Not comm.

(D) ELECTRICAL SYSTEM

1. Checking of Electrical Panel & battery backup (If Applicable) Comm/Not comm
2. Electricity at terminals/distribution stations from S.E. Board

OK/NOTOK

3. Earthings system

Comm/Not comm.

3. Lighting

Comm/Not comm.

4. Lightening Protection System

OK/NOTOK

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Handing/Taking Over
(E) FIRE & SAFETY
1. Status of Fire fighting Systems

OK / Not OK

2. Status of fire detection system at SVs/RRs/lPs & Terminals Comm/Not comm.

3. Status of on line extinguishing system at SVs/RRs/lPs

Comm./Not comm.

4. Safety audit by Fire & Safety personal from O&M

Done/ Not Done

(F) GENERAL
1. Status Control Buildings Construction

Comp./Not Comp.

2. Status of basic amenities for security guards at the

Done / Not Done

permanent establishment
(Security rest room, water, lighting arrangement)
3. Preparation of final checklist before taking over

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Done / Not Done

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Handing/Taking Over
(G) DOCUMENTATION
1. Listing & handing over of all procedures, reports,

Done / Not Done

certificates, vender manuals, drawings and

related documents which are to be handed
over as per Contractual obligation with the venders
2. Listing & handing over of As builds, Alignment

Done / Not Done

sheet, hydro test report, Pigging report,

pipeline route map, pipe book, crossing
details (Hard copy & soft copy)
3. Revenue records & records for permanent land acquisition Done! Not Done
4. Certificates related to Metering system

Done I Not Done

(H) SPARES
1. Commissioning spares

Handed over/not handed over

2. Two years spares

Handed over/not handed over

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Case Study: Commissioning of SSPL

Name of Pipeline : Sidhpur- Sanganer Pipeline

Length

Pipe Size & Thickness: 18 OD x 0.250 WT

Pipe Grade

Capacity

MAOP

: 92 Kg/cm2

Line fill

: 79840 Kl

: 517 km

: API 5L-X65
: 3.4 MMTPA (5.7 Max)

Sidhpur - Kot

: 28500 Kl

Kot - Baghsuri

: 30500 Kl

Baghsuri - Sanganer

: 20840 Kl

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Thank You

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