Pipeline Design and construction

Pipeline Design &ConstructionConstruction

Step by Step

195.401 Generalrequirements (Subpart F)

(c) Except as provided in 195.5, nooperator may operate any part of anyof the following pipelines unless it wasof the following pipelines unless it wasdesigned and constructed asrequired by this part: §195.5 Conversion

to service subject tothis part.

195.401 Generalrequirements (Subpart F)

(c)(1) An interstate pipeline, other thanlow-stress, on which construction waslow-stress, on which construction wasbegun after March 31, 1970, thattransports hazardous liquid.

195.401 Generalrequirements (Subpart F)

(2) An interstate offshore gatheringline, other than low-stress, on whichconstruction was begun after July 31,

(c)

construction was begun after July 31,1977, that transports hazardous liquid.

195.401 Generalrequirements (Subpart F)(c)(3) An intrastate pipeline, other thanlow-stress, on which construction wasbegun after October 20, 1985, thatbegun after October 20, 1985, thattransports hazardous liquid.

(4) A pipeline, on which constructionwas begun after July 11, 1991, thattransports carbon dioxide.

195.401 Generalrequirements (Subpart F)

(c)(5) A low-stress pipeline on whichconstruction was begun after August 10,1994.1994.

Pipelines from theWell to the Refinery and Market

Part 195Subpart C

DesignRequirements

195.100 Scope.

This subpart prescribes minimumdesign requirements for newpipeline systems constructed withsteel pipe and for relocating,steel pipe and for relocating,replacing, or otherwise changingexisting systems …

195.401 Generalrequirements.

(c) Except as provided in 195.5, nooperator may operate any part of anyof the following pipelines unless it was

§195.5 Conversionto service subject to

this part.

of the following pipelines unless it wasdesigned and constructed asrequired by this part:

195.401 Generalrequirements.

(c)(1) An interstate pipeline, other thanlow-stress, on which construction waslow-stress, on which construction wasbegun after March 31, 1970, thattransports hazardous liquid.

195.401 Generalrequirements.

(2) An interstate offshore gatheringline, other than low-stress, on whichconstruction was begun after July 31,

(c)

construction was begun after July 31,1977, that transports hazardous liquid.

195.401 Generalrequirements.(c)(3) An intrastate pipeline, other thanlow-stress, on which construction wasbegun after October 20, 1985, thatbegun after October 20, 1985, thattransports hazardous liquid.

(4) A pipeline, on which constructionwas begun after July 11, 1991, thattransports carbon dioxide.

195.401 Generalrequirements.

(c)(5) A low-stress pipeline on whichconstruction was begun after August 10,1994.1994.

195.106 Internal designpressure.

P = (2 St/OD)* x E x F

* 2 St/O.D. Used to determine low stress

E = seam joint factorF = design factor

Part 195Subpart D

Construction

Pipeline Construction Sequence

195.200 Scope.

This subpart prescribes minimumrequirements for constructing newpipeline systems constructed withsteel pipe and for relocating,steel pipe and for relocating,replacing, or otherwise changingexisting systems …

Pipeline Construction

1. Surveying. The right-of-way isa narrow strip of land thatcontains the pipeline(s) and iswhere all onsite constructionactivities occur. After a planned orproposed route is determined, it isproposed route is determined, it issurveyed to determine theparameters that will be needed tocomplete the project.

§195.210 Pipeline location.

195.210 Pipeline location.

ROW must be selected to avoid,as far as practicable:areas containing private dwellingsindustrial buildingsindustrial buildingsplaces of public

assembly

195.210 Pipeline location.

Pipeline may not be locatedwithin 50 feet of any:private dwellingindustrial buildingindustrial buildingplaces of public assembly

unless 12” of cover is added.

Pipeline Construction

1. Maps & Materials.Once the pipeline issurveyed, ROW ispurchased, alignmentsheets (maps) are drawnsheets (maps) are drawnand material lists aregenerated.

§195.202 Compliance with specifications orstandards.

§195.206 Material inspection.

195.202 Compliance withspecifications or standards.

Each pipeline system must be constructed inaccordance with comprehensive writtenspecifications or standards that are consistentspecifications or standards that are consistentwith the requirementsof this part.

195.206 Materialinspection.

No pipe or other componentmay be installed unless ithas been visually inspected atsite.site.

Pipeline Construction

2. Clearing & Grubbing.The ROW is cleared ofbrush and trees, andleveled to give workersand equipment access toand equipment access tobuild, inspect andmaintain the pipeline.

Track-Type Tractor or Dozer

195.204 Inspection - general.Inspection must be provided to

ensure the installation of pipe orpipeline systems in accordancewith the requirements of thiswith the requirements of thissubpart.

195.204 Inspection - general.No person may be used to

perform inspections unless thatperson has been trained and isqualified in the phase ofqualified in the phase ofconstruction to be inspected.

Pipeline Construction

3. Right-of-way preparation. Theright-of-way will be graded, andpads may be built to allow for themovement of ditchers, additionalequipment, materials and otherpipeline construction activities.pipeline construction activities.

Pipeline Construction

4. Hauling and stringing thepipe. Lengths of pipe are movedfrom stockpile sites to the right-of-way. They are lined up along theright-of-way, ready for welding.right-of-way, ready for welding.

Stringing

Stringing is the delivery and distribution of linepipe where it is needed on the right-of-way andwhen it is needed

Pipeline Construction5. Bending the pipe. A pipeline mustcross over hills and curve aroundspecial places such as lakes andsacred sites. A specialized pipe-bending machine is used to bendsome pipe to the shape of the land.some pipe to the shape of the land.The pipe retains its strength andremains circular where it is bentbecause of the characteristics of steeland the bending techniques used.

Bending

Hydraulic Pipe BendingMachines

PneumaticBendingMandrel

Bent to Fit

The pipe must be bent to reflect the generalcontours of the right-of-way.

195.212 Bending of pipe.

Pipe may not have a wrinkle bend. Each field bend must comply withthe following:

195.212 Bending of pipe.

not impair serviceability have a smooth contour pipe with longitudinal weld, must bein neutral axis unless--in neutral axis unless--made with internalmandrel

pipe is <12” or hasdiameter to w.t. ratio<70

Pipeline Construction

6. Welding. A technique whereanother metal is melted and usedto join lengths of pipe. Automaticwelding machines are used wherepossible and some hand weldingalso takes place. A rigorous qualityalso takes place. A rigorous qualityassurance and quality controlprogram is followed to ensure thestrength and quality of the welding.

Welding

External Line-upClampsBeveling

Machine

PneumaticInternal

Lineup Clamp

Automatic External Welder

Automatic Internal Welder

Pipe Facing Machine

Welding Truck Rig

Welder Tractor

The Pipe Gang

The workers responsible forpositioning the pipe, aligning it, andmaking the initial welds.

Firing Line

The workers responsible for the filler pass and thecap bead, which complete the joint

195.208 Welding ofsupports and braces.

May NOT be welded to pipe whichoperates over 100 psig.

Good Weld?

Radiography

195.234 Welds:Nondestructive testing.

Field Joint Coating

195.561 Whenmust I inspect pipecoating used for

Mill coated pipe has a cutback of 6-9 inches at theend of the pipe to not interfere with welding. Thiscutback must be coated once the weld is complete.

195.557 Whichpipelines must

coating used forexternal corrosioncontrol?195.581 Whichpipelines must Iprotect againstatmosphericcorrosion and whatcoating materialmay I use?

pipelines musthave coating forexternal corrosioncontrol?195.559 Whatcoating materialmay I use forexternal corrosioncontrol?

Pipeline Construction

7. Digging the trench. The waythe trench or ditch is dug, andwhat equipment is used,depends mainly on the type ofsoil. Alternates include bucketsoil. Alternates include bucketwheel trenchers. Other diggingequipment will includebackhoes or trackhoes

195.246 Installation of pipe in a ditch.195.248 Cover over buried pipeline.195.250 Clearance between pipe andunderground structures.

Hydraulic Excavator orTrackhoe

Backhoe or Rubber-Tired Hoe

Trencher or Ditching Machine

Ditching or Trenching

First Rule of Holes:

When you’re in one . . . STOPDIGGING!!!

Trench Boxes

TAPSTrans-Alaska Pipeline System

In thiscase the

pipeline isnot

loweredin-It’s

Supported aboveground by vertical support members

loweredup!

Pipeline Construction

8. Lowering the pipe.Tractors with special arms calledsidebooms are used to lower the pipeinto the trench. Care is taken to avoiddamaging the pipe and its exteriordamaging the pipe and its exteriorcoating.

Pipeline Construction

8. Lowering the pipe.Different tools are used to helpfacilitate the lowering in process.These include slings, rollers, cradlesand pipe tongs. As the pipe isand pipe tongs. As the pipe islowered in, a holiday detector or“jeep” is used to locate voids in thecoating.

Pipelayer or Sideboom

Lowering In

195.246 Installation of pipe in a ditch.195.248 Cover over buried pipeline.195.250 Clearance between pipe andunderground structures.

Fabrication

9. Installing valves and specialfittings. Valves and otherconnections are part of a pipeline.These assemblies are installed asthe pipeline is constructed. Theythe pipeline is constructed. Theyinclude shut-off valves that canblock off sections of the pipelinefor maintenance.

195.254 Aboveground components.195.256 Crossing of railroads and highways.195.258 Valves: General.195.260 Valves: Location.

Pipeline Construction

10. Crossings. A pipeline will needto cross rivers and streams, roads,railroads and other pipelines. Plansare developed in advance. Watercrossings can be completed either by"open cut" techniques or by horizontal"open cut" techniques or by horizontaldirectional drilling.

Pipeline Construction

10. Crossings. (CONTINUED)The selection of a crossing methoddepends upon site specific criteriasuch as fish habitat, water flow, andsoil conditions such as rocks and boulders. Generally,horizontal directional drilling is selected for major riverhorizontal directional drilling is selected for major rivercrossings where local soil conditions permit the technique.

195.256 Crossing of railroads and highways.

BoringMachine

DirectionalDrillingMachine

Horizontal Drilling Rig

Directional Drilling

Pipeline Construction

11. Backfilling the trench.Before testing the pipeline, theditch is backfilled. Sometimes theexcavated soil is used to fill thetrench and sometimes othertrench and sometimes otherselected backfill is used. Care istaken to protect the pipe coatingfrom potential damage.

195.252 Backfilling.

Backfilling

Track-Type Tractor orDozer

Padding Machine

Tie-In12. Tie-in. Collective term for the construction tasksbypassed by regular crews on pipeline construction. Tie-inincludes welding road and river crossing, valves, portions ofthe pipeline left disconnected for hydrostatic testing, andother fabrication assemblies, as well as taping and coatingthe welds.

Pipeline Construction

13. Testing. A variety of methodswill be used to ensure the integrity ofthe assembled pipeline and tocomply with code.

195.304 Test pressure.195.305 Testing of components.195.307 Pressure testing aboveground breakout tanks.195.306 Test medium.195.308 Testing of tie-ins.195.310 Records.

Pipeline Construction

14. Dewatering. If water is used asa test medium, dewatering of thepipeline is done with dewateringpigs. The water should bedisposed of in an environmentallydisposed of in an environmentallysensitive manner.

Pipeline Construction

15. Cleaning up. Thepipeline right-of-way andtemporary facilities such ascamps will be reclaimed.

The continuous growth of energy consumption and the difficultiesin establishing new ROW’s for transmission power lines and metalpipelines increase the tendency to site them along the sameroutes. Consequently, electromagnetic problems can arise.

Electromagnetic InteractionsBetween Power Transmission

Lines and Pipelines

•Electric shocks to people who contact the pipeline

•Damage to pipeline insulating coating, insulatingjoints and cathodic protection systems

The continuous growth of energy consumption and the difficultiesin establishing new ROW’s for transmission power lines and metalpipelines increase the tendency to site them along the sameroutes. Consequently, electromagnetic problems can arise.

Electromagnetic InteractionsBetween Power Transmission

Lines and Pipelines

Induced voltages can beproduced through capacitive,inductive and conductivecouplings with the power line

Intensity depends on the powerline, pipeline and soilcharacteristics… and geometricconfiguration between the powerline and the pipeline.

•Electric shocks to people who contact the pipeline

•Damage to pipeline insulating coating, insulatingjoints and cathodic protection systems

line and the pipeline.

Voltages can be produced undernormal operating conditions andduring short-circuit occurrencesat the power line

Electromagnetic InteractionsBetween Power Transmission

Lines and Pipelines

•Pipeline induced voltages should be compared to safety limitsestablished by industry codes.

•Underground sections of pipeline checked with respect to therisks of damage to pipeline coating.risks of damage to pipeline coating.

•Above-ground sections checked for risks of potential electricshocks to people.

•Voltage across insulating joints compared to the voltagewithstand capability.

•Cathodic protection systems checked for maximum voltages attheir connection to the pipeline.

Other Safety Considerations• When driving on the Right-of-Way - watch out for

HEAVY EQUIPMENT!

Other Safety Considerations

Wild animals are about in the woods – be careful!

Other Safety Considerations

• Overhead power lines and equipment-don’t be incontact with equipment or stand near (water, mudother conductors)

• Wear proper personal protective equipment• Beware of lengths of welded pipe on skids without• Beware of lengths of welded pipe on skids without

proper cribbing• Don’t stand near pipe being lifted from ground• Don’t stand near pipe truck being unloaded

– Note improperly chocked pipe

Other Safety Considerations

• Sideboom A-frames don’t fall up• Sidebooms can flip over when lifting pipe• Sidebooms can roll over backward on an incline• Be aware of worn cables or slings• Hydraulic hoses can break causing unintended• Hydraulic hoses can break causing unintended

equipment movement

Other Safety Considerations

• Be aware of trenching and shoring safety precautions– Don’t stand near the edge of an excavation– Don’t enter an unsafe excavation– Equipment vibrations can cause a cave-in

• Welding can cause a “flash”• Welding can cause a “flash”– Welding at night near glass can reflect the same

damaging radiation• Avoid touching the “tail” of the “jeep”

Pipeline Construction Sequence

• Construction spreads - what’s going on during construction:• Surveying, staking & pre-construction condition documentation• Environmental Mitigation• Relocation/replacement – precautions near/over live lines• Clearing, stumping, grubbing & grading• Stringing & bending• Welding & Coating• Trenching, double ditching/HDD & bores• Trenching, double ditching/HDD & bores• Road and stream x-ings (rip-rap, flume & trench, etc.,)• Lowering-in• Tie-ins• catheading• Coatings, corrosion & backfill• Hydro (pre & post testing), de-water, clean & dry• Purging• Commissioning• Hot taps & stopples• Final clean-up