Large Diameter Pipelines Challenges

An identity, which traverses the length and width of geographical spans, influencing the live
of flora and fauna of the area it traverses. So it becomes utmost responsibility of pipeline
fraternity to analyze each and every aspect of pipeline design and to lay the pipeline in such a
manner which results in congenial development, without affecting the delicate balance
established by Mother Nature.

In addition, with the increasing difficulties in acquisition of land for pipeline installation, large
diameter pipelines are becoming only viable option.

Large diameter not only eases the operators from meeting the current as well as future
requirement but also saves them from the repeat exercise of installation of multiple pipelines.
Owing to the large diameter, frictional loses are comparatively less which aids in placing
pumping / compressor stations at a larger interval. In addition, CP currents travels longer
distances on large diameter pipelines which further reduces the requirement of land for CP
stations.

Challenges in Pipeline Routing

Preferably, selection of large diameter pipeline route shall be straighter and shall avoid steep
bends & undulations. Large diameter pipelines require higher turning radius for bending the
pipe at the turning points, thus at the location of bends wider ROU is required to install the
pipeline.

Challenges in Pipeline Design

Large diameter pipeline necessitates the requirement for fabrication of thick-walled pipes:

 to limit D/t ratio within 100, as well as

 for sustaining the internal pressure (Barlow's Formula)

Susceptibility of pipe towards flattening, ovality, buckling and denting increases with rise in
D/t ratio (> 100), decreased wall thickness (../ASMEB31/ASMEB31.aspx), decreased yield
strength, and combinations thereof. Therefore, pipe, having a D/t ratio less than 100, shall be
utilized for large diameter pipelines.

With the increasing diameter, the requirements for tighter dimensional tolerances of the line
pipes such as pipe ovality, pipe ends tolerance, straightness, and wall thickness tolerances etc.
Increases exponentially. It is required to ensure that pipe will not only install with ease but
also maintain its durability against all types of loads predicted to be sustained during its
operation. Therefore, tremendous efforts are required from line pipe manufacturers to produce
the high quality line pipes within specified time.

During conceptualization of large diameter pipeline, a study for optimal utilization of pipeline
shall be based on a "Break-even Analysis" of capital gain (due to increased overall throughput)
compared with increased capital investment (due to increased tonnage).

Challenges in Pipe Handling, Stacking & Transportation

The high capacity equipment are required for handling and hauling of large diameter pipes.
Transportation of pipes becomes challenging owing to the high weight and volume of large
diameter pipes.
 Stacking load and stress generated in the line pipes during transportation
 Stacking height of the pipes within the storage height of barge / rail wagon /
trailer.
 Weight carrying capacity of the barge / rail wagon / trailer, limits the number of
tiers of pipe during transportation.

Pipe transportation on Trailer

Diameter of Pipe Number of Tiers Number of Pipe

1422 mm (56"') 1 1
1219 mm (48"') 2 3
910 mm (36"') 2 2
610 mm (24"') 3 12

Due to this, more number of rail wagons / trailers are required for transportation of pipe, thus
increasing the pipe transportation time and cost.
Challenges in Installation

Large diameter pipelines are also thick walled pipes. Consequently, the weld "Inch Meter" is
high and more number of welding passes (e.g. root pass, hot pass, filter pass and capping) are
required for girth welding of pipes on field. This results in high welding time and thus
increased changes of welding defects. Therefore, to mitigate these challenges, semi-automatic
or automatic welding is preferred for large diameter pipelines.

The results of the typical welding time study show the following results:

Pipe Size (NPS) Number of Welds per day

Automatic Welding Semi-automatic Welding
910 mm (36"') 45 25
1422 mm (56"') 20 8

Pipeline Crossings
In case of large diameter pipelines, crossing becomes more complex, especially in the case of
trenchless methods. In case of pipeline crossing by trenchless technique, the chances of hole
collapse increases, as a larger hole needs to be drilled for pipe crossing. Crossing section
becomes vulnerable to hole collapse due to longer drilling time and larger hold diameter
required for pipe crossing.
 With increase in pipe diameter, pulling force required to pull the pipe also
increases due to increase in upwards buoyancy force on the pipe. Therefore,
generally pipe of diameter larger than 30" is pulled in water filled condition
(partially filled / fully filled / pipe-in-pipe). These methods require a higher
degree of expertise for execution.
 High capacity Maxi-rigs are required for large diameter crossings.
 Large diameter hole requires high capacity of mud pumps for maintaining the
pressure and removal of cutting from the hold.
 The overall cost of HDD crossing is also exponentially proportional to the pipe
diameter. A typical HDD of 1000 meter for 24" pipe cost 80 - 85 Lacs (approx.),
whereas same HDD with 48" pipe will cost 210 to 225 Lacs.
 (Note : all data given above are provided to get the comparative idea and can vary
from case to case basis)

Challenges in Hydrostatic Testing, Pre-commissioning and Commissioning

Humongous quantity of water is required for performing hydrostatic testing of large diameter
pipeline. Apart from water quantity during hydrotesting, water needs to be dosed with
corrosion inhibitor to prevent internal corrosion of the pipeline. Corrosion inhibitors pose
threat to environment and shall be disposed-off properly. Arranging for disposal of such large
quantity of corrosion inhibited water is a challenging task.