Start up and Commissioning of the

Pipeline
- B. B. Prasad
Objective of the commissioning
To bring the constructed / installed system to
deliver the desired function.
The Pipeline commissioning means introducing
crude/ product/Gas in the pipeline from originating
station, filling the entire length and then start
delivering to receipt system.
What we need prior to commissioning?
The pipeline and associated facilities are completed in all
respect
All Fire and Safety equipments / facilities are tested and
commissioned
Availability of dedicated communication
Statutory Clearances obtained
What we need prior to commissioning?
Availability of Product (HSD)/ Crude oil Not less than
line-fill
Required Manpower is placed at all locations
Availability of water and its disposal plan
Availability of a dedicated commissioning team
What will be the procedures to commission a
Water Pipeline?
Critical issues in commissioning a Petroleum
Pipeline
Movement of hydrocarbon in empty pipeline can generate
static current.
Hydrocarbon Vapor mixed with oxygen may lead to explosion.
There may be formation of Air / Vapor pocket that may get
compressed leading to rise in pressure.
Air / vapor pocket may explode in receiving tank leading to
damage of the tank roof seal.
Leakage of any hydrocarbon may lead to fire or damage to
environment .
Flash Point:
The flash point of a volatile liquid is the lowest temperature
at which it can vaporize to form an ignitable mixture in air.
Vapor Pressure:
The vapor pressure of a liquid is the pressure exerted by its
vapor when the liquid and vapor are in dynamic equilibrium.
At a given temperature, a substance with higher vapor
pressure vaporizes more readily than a substance with a
lower vapor pressure.
Properties of Hydrocarbons
Properties of Petroleum Products
Products RVPat37.8degC FlashPoint
MS 375412mmHg. 43
0
C
SKO <0.1mmHg >38
0
C
HSD 2.12to26mmHg. >42
0
C
ATF <0.1mmHg >42
0
C
NAPHTHA 450472mmHg. 22
0
C
CRUDEOIL 230 300mmHg 3762
0
C
LPG >1000mmHgat25
0
C 60
0
Cto104
0
C
Preferred Liquid for Commissioning
Pipeline PumpingLiquid PreferredLiquid
Multi
products
MS,SKO,HSD,ATF,
LDO,NPHTHA
HSD
ATF ATF SKO
LPG LPG LPG
NAPHTHA Naphtha Naphtha
CRUDEOIL CrudeOil CrudeOil
WhatisPIG?
Adevicethatmovesthroughtheinsideof
apipelineforthepurposeofcleaning,
dimensioning,sealingandinspect.
ObjectiveofPigging
NewPipeline
Removedebris
Verifyovality,dentetc
Waterfilling&dewateringafterhydrotesting
Sealingofproductorwaterduringcommissioning
InServicePipeline
Maintainlineefficiency
Corrosioncontrol
Checkdents,bucklesandanyotherinternalabnormality
Tominimizeinterfacegenerationbetweentwodissimilar
products
Toavoidcrosscontamination
Toevacuatethepipeline
Conventional/UtilityPigs Differenttypes
Variouscomponentsare
fittedonmandrel.
Itcanbeunidirectionalor
bidirectional
Sealing Disc Guide Disc
IntelligentPig
Torecordbends,
dents,ovality,bend
radius&angle.
PIGLaunching/ReceivingBarrel
Commissioning of a Multi-products Pipeline
Ensure the pipeline is ready in all respects for the commissioning.
Ensure adequate product (HSD) is available for the commissioning
(At least more than line-fill of a Pipeline section).
The pipeline or a section of the pipeline is pressurized with air
(2 to 3 Kg/Sq-cm)
Pump a water column of about 500 kL to 1000 kL
Launch a Bi-Di Pig followed by 1000 kL to 2000 kL water
Water (1000 to 2000 kL)
Air (2/3 Kg/cm
2
)
Water (500 to 1000 kL)
BI-DI PIG
Commissioning of a Multi-products Pipeline
Launch second Bi-Di- Pig behind 1000 KL to 2000 KL water
Pump HSD at minimum flow
Track the movement of Pig
Vent the air at receiving end and maintain back pressure 3 to 4
Kg/Sq-cm
Monitor receipt of water at Receiving end it may be disposed
directly in to a protected pit or in a designated tank.
Water (1000 to 2000 kL)
Air (2/3 Kg/cm
2
)
Water (500 to 1000 kL)
BI-DI PIG BI-DI PIG HSD
Commissioning of a Multi Products Pipeline
Receive Ist Bi-Di Pig
Monitor the quantity and quality of water at receiving end
Receive second Bi-Di Pig
Once diesel or diesel mixed with water arrives, switch over to
designated HSD Tank.
Observe flow and pressure, once these become stable, the
operation may be made normal and the pipeline may be declared
as commissioned and handed over to Operation.
Commissioning of an ATF Pipeline
The procedure is similar to multi-products pipeline except the following
Commissioning liquid is used SKO instead of HSD
ATF is not used because it is likely to get contaminated with
water and dirt particles.
Water (1000 to 2000 kL)
Air (2/3 Kg/cm
2
)
Water (500 to 1000 kL)
BI-DI PIG BI-DI PIG SKO
Commissioning of an ATF Pipeline
The procedure is similar to multi-products pipeline except the following
Commissioning liquid is used SKO instead of HSD
ATF is not used because it is likely to get contaminated with
water and dirt particles.
Water (1000 to 2000 kL)
Air (2/3 Kg/cm
2
)
Water (500 to 1000 kL)
BI-DI PIG BI-DI PIG SKO
Commissioning of Naphtha Pipeline
The procedure is similar to multi-products pipeline except the following
Air from entire Pipeline is displaced with Nitrogen column using a Bi-Di Pig
Commissioning liquid is used Naphtha instead of HSD
Nitrogen (10.0 KM)
Air (2/3 Kg/cm
2
)
Nitrogen (500 to 1000 kL)
BI-DI PIG BI-DI PIG Naphtha
Commissioning of LPG Pipeline
The procedure is similar to multi-products pipeline except the following
Air from entire Pipeline is displaced with Nitrogen column using a Bi-Di Pig
Commissioning liquid is used LPG instead of HSD
Nitrogen (10.0 KM)
Nitrogen
BI-DI PIG BI-DI PIG LPG
Commissioning of a Gas Pipeline
A gas pipeline is treated as Tank.
However, before taking gas in the
Pipeline, it is to be made moisture
and oxygen free.
Commissioning of a Gas Pipeline
Commissioning Steps:
Drying Purging of super dry air
Compressed Super dry air is purged using air compressors
with accessories viz. Moisture Separator, Oil Separator and
Dryer. The air shall be supplied in the pipeline at (-) 20 deg.
C dew point.
Super dry air with dew point (-) 20 deg. C will have sufficient
capacity to absorb water vapour to the extent of 30 % of
the desired capacity.
Commissioning of a Gas Pipeline
Commissioning Steps:
Drying Purging of super dry air
Compressed Super dry air is purged using air compressors
with accessories viz. Moisture Separator, Oil Separator and
Dryer. The air shall be supplied in the pipeline at (-) 20 deg.
C dew point.
Super dry air with dew point (-) 20 deg. C will have sufficient
capacity to absorb water vapour to the extent of 30 % of
the desired capacity.
Commissioning of a Gas Pipeline
Commissioning Steps:
Vacuum Drying
The process utilizes high capacity vacuum to reduce
pressure within the Pipeline to a level from 760 Torr to 40
Torr. At this pressure (40 Torr), any water within the
pipeline will start boiling and vaporizing.
Air left inside the Pipeline is subjected to a vacuum of 40
Torr, the water vapor will expand approx. 18.8 times, which
will be displaced using high capacity vacuum booster
pumps (rated capacity 5000 CuM/Hr)
When the vacuum of 7.6-10 Torr is achieved, it is confirmed
that whole pipeline system has been dried to required level.
Commissioning of a Gas Pipeline
Commissioning Steps:
Nitrogen Purging
At vacuum level 7.6 Torr and dew point (-) 20 deg.C, the
oxygen content inside the Pipeline is 0.20%.
To further dilute the oxygen content, nitrogen purging is
done almost 13 times more than pipeline volume. This will
reduce oxygen content to 0.015%, which is considered
negligible.
Now the Pipeline system is ready to receive Gas.