Start up and Commissioning of Pipelines IiPM, Gurgaon10 th July 2009 Presentation by D. S. Nanaware, Chief Project Manager, IOCL, Noida.

Start up and Commissioning of Pipelines

IiPM, Gurgaon 10th July 2009

Presentation by

D. S. Nanaware,

Chief Project Manager, IOCL, Noida

10th July 2009 IiPM, Gurgaon 2

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

Contents


Methodology for Pre-commissioning of

New Pipelines


Preparation of pre-commissioning and commissioning plan

Safe commissioning of pipeline system

Safe and smooth operation of pipeline after 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

Objectives


Task Forces

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

Projects/Construction Group

Operations & Maintenance Group

Fire & Safety Group


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


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 vender’s documents for material supply


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


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


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, Walky-Talky/VHF /UHF

Clearance from CCOE


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


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)


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.


Commissioning of New Pipelines


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.

Objective of 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.

Pre-commissioning


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.

Pre-commissioning (contd..)


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.

Commissioning


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

Commissioning action plan


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

Commissioning steps


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

Commissioning steps (contd..)


Since, before pumping water, line is filled with air at a pre-determined 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



Specific check points/procedure for

Gas Pipelines

LPG Pipelines

ATF Pipelines



HANDING / TAKING OVER FORMAT

NAME OF PROJECT : ______________________

LOCATION : ______________________

PROJECT IDENTIFICATION : ______________________

PROJECT COST : ______________________

PMC : ______________________

CONTRACTOR : ______________________

DATE OF COMMISSIONING : ______________________

Handing/Taking Over


I. DETAILS OF FACILITIES TO BE HANDED OVER

1. _____ 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 : _____________________

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 : __________

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 & by—pass 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 Yes / No

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

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

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 Done / Not Done

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

Handing/Taking Over


Case Study: Commissioning of SSPL

Name of Pipeline : Sidhpur- Sanganer Pipeline

Length : 517 km

Pipe Size & Thickness: 18’ OD x 0.250” WT

Pipe Grade : API 5L-X65

Capacity : 3.4 MMTPA (5.7 Max)

MAOP : 92 Kg/cm2

Line fill : 79840 Kl Sidhpur - Kot : 28500 Kl

Kot - Baghsuri : 30500 Kl

Baghsuri - Sanganer : 20840 Kl


Thank You

Start up and Commissioning of Pipelines IiPM, Gurgaon10 th July 2009 Presentation by D. S. Nanaware, Chief Project Manager, IOCL, Noida.

Documents

commissioning slide

om group slide

safety group slide

precommissioning audits

gurgaon10 th

noida slide

readiness of pipeline

pre commissioning activities