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
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Methodology for
Pre-commissioning of
New Pipelines
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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
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operation
IiPM, Gurgaon
of
pipeline
after
4
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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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
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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, 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
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: _____________________
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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 & 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
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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
: 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
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
Sidhpur - Kot
: 28500 Kl

Kot - Baghsuri
: 30500 Kl

Baghsuri - Sanganer
: 20840 Kl
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Thank You
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