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Start up and Commissioning of Pipelines

IiPM, Gurgaon 10
th
July 2009
Presentation by
D. S. Nanaware,
Chief Project Manager, IOCL, Noida

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th
July 2009

IiPM, Gurgaon

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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

10
th
July 2009

IiPM, Gurgaon

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Methodology for
Pre-commissioning of
New Pipelines

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th
July 2009

IiPM, Gurgaon

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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

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IiPM, Gurgaon

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Task Forces
For efficient startup/commissioning specialized task-force
can be formed including specialists from:
Projects/Construction Group
Operations & Maintenance Group
Fire & Safety Group

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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

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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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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, Walky-
Talky/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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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

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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

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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..)

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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

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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

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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

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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..)

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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
Commissioning steps (contd..)

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Specific check points/procedure for
Gas Pipelines
LPG Pipelines
ATF Pipelines
Commissioning steps (contd..)

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HANDING / TAKING OVER FORMAT

NAME OF PROJECT : ______________________

LOCATION : ______________________

PROJECT IDENTIFICATION : ______________________

PROJECT COST : ______________________

PMC : ______________________

CONTRACTOR : ______________________

DATE OF COMMISSIONING : ______________________

Handing/Taking Over

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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

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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

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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 Yes / No
Handing/Taking Over

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(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

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(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

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(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

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(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

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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

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th
July 2009

IiPM, Gurgaon

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Thank You

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