PIPELINE COATINGS /

FIELD JOINT COATING

EXTERNAL

1
 TYPE OF MAIN LINE COATINGS

3 LPE (2 to 3.5mm thk) 3 LPP (2 to 3.5mm thk)

FBE (0.45mm thk) DFBE (0.7mm thk)

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 PIPELINE COATINGS

DFBE ANTI CORROSION COATING

HDPU THERMAL INSULATION (90mm thk)
HDPE JACKET 5mm thk

CTE COATING – 4.8mm thk

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 BASIS OF SELECTION OF MAIN LINE COATINGS (NEW)

 PIPELINE OPERATING TEMPERATURE

 PIPELINE DESIGN LIFE

 PIPELINE DIAMETER

 TYPE OF SOIL

 AMBIENT TEMPERATURE

 ROW CONDITIONS

 CONSTRUCTION PERFORMANCE

4
 BASIS OF SELECTION OF MAIN LINE COATING –
OPERATING TEMPERATURE

 Polyethylene Coatings – 800C

 Fusion Bond Epoxy Coatings – 1100C ~
1400C

 Polypropylene Coatings – 1200C

 Polymeric Tape Coatings - 600C

 Liquid Epoxy Coating - 1500C

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 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.

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3LPE COATING PROCESS

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 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
Coating classes are based on
N-Normal expected field duty
- Operating Temperature
S-Special - Transport
-Handling
n- normal thickness -Layer conditions
- Operating conditions
v- reinforced thickness - Soil Conditions
- Expected Environmental
Conditions

8
 THREE LAYER POLYETHYLENE COATING
FUNCTIONAL PROPERTIES
DIN-30670 ISO-21809-1 CAS-Z245.21-06
Peel Strength(N/mm) N-n S-n A B C B1
@23°c 3.5 3.5 10 15 23 6

Tmax 1.5 2.5 2 3 4 -

(Pull speed 10N/mm) (50°c) (70°c) (60°c) (80°c) (90°c)

Impact Strength J/mm @ N-n S-n A B C B1

23°c 5 5 5 7 10 3

Indentation N-n S-n A B C -

-23°c ≤ 0.2mm 0.2mm ≤ 0.3mm ≤ 0.2mm ≤ 0.1mm
- Tmax ≤ 0.3mm ≤ 0.3mm ≤ 0.3mm ≤ 0.2mm ≤ 0.1mm
(50°c) (70°c)
Cathodic disbondment
65°C/24hrs(-3.5V) ≤ 7mm
20°C/28 days(-15V) - ≤ 7mm -
65°C/28days(-1.5V) ≤ 15mm ≤ 12mm

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 THREE LAYER POLYETHYLENE COATING
OPERATING TEMPERATURES

DIN-30670 ISO-21809-1 CAN/CAZ.2451-06

Class-A : (– )20°C to (+) 60°C

DIN-30670- N (LDPE)
up to 50° C Not Clearly Specified.
Class-B : (– )40° C to (+) 80 °C
However, the purchaser
has to specify the max
(MDPE/HDPE)
design temp.
Class-C ; (– )20°C to (+)110°C
DIN-30670- S
up to 70° C
(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 20th & 21st)
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 20th & 21st)
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 20th & 21st)
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 20th & 21st)
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 Vipul
andKumar,
costPEng
 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
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
Vipul Kumar, PEng
Cairn India – 2010 Technical Forum
(October 20th & 21st)
Celebrating Our Technical
Achievements
Cairn India – 2010 Technical Forum
(October 20th & 21st)
Celebrating Our Technical
Achievements