The document provides details about pipeline activities such as survey, trench excavation, pipe laying and joining, backfilling, and hydrotesting. It discusses various types of pipes used in pipelines like mild steel, GRP, ductile iron, cast iron, HDPE, and PVC. The document describes techniques for lowering, laying and joining different pipe materials including MS, CI, DI, GRP, and HDPE pipes. It also discusses trench excavation methods, transportation of materials, and pipe handling procedures.

1. PIPELINE ACTIVITIES
BY
V.BHANU CHANDERV.BHANU CHANDER
TIRUPATI,
INDIA

2. Pi liPi liPipe line :Pipe line :
TransportationTransportation ofof liquidsliquids andand gasesgases fromfrom oneone
placeplace toto anotheranother placeplaceplaceplace toto anotheranother placeplace..

3. Survey
Pipe line activity :
Unloading & stocking of pipes at site
Marking
Trench excavation
Blasting
contd…

4. Sand bedding
Pi l iPipe lowering
Laying, joining
Back filling
Sand encasing
S i l fi iSpecials fixing
contd…

5. Pedestals, thrust blocks & valve chambers
Hydro testing
i i iCommissioning
Final measurement
Reconciliation

6. TYPE OF PIPES

7. Mild steel (MS)
Glass reinforcement plastic (GRP)Glass reinforcement plastic (GRP)
Ductile iron (DI)( )
Cast iron (CI)
High density poly ethylene (HDPE)
Poly vinyl chloride (PVC)
ContdContd…

8. Pre stressed concrete (PSC)
Reinforcement cement concrete (RCC)
Asbestos cement pressure (AC)Asbestos cement pressure (AC)
Bar wrapped steel cylinder (BWSC)pp y ( )
Galvanized iron (GI)
Low alloy pipe (LA)

9. PVC pipe MS pipe GI pipe
GRP pipe BWSC pipe CI pipeGRP pipe BWSC pipe CI pipe

10. HDPE i RCC i DI iHDPE pipe RCC pipe DI pipe
LA pipe PSC pipe AC pipeLA pipe PSC pipe AC pipe

11. TRENCH EXCAVATION

12. Obtain work permit before starting excavation work.
Marking is to be made
Excavate trench up to required level with free working
The side slopes of cutting shall generally have the followingThe side slopes of cutting shall generally have the following
slopes for stability.
slope for excavation inslope for excavation in
1:1 clay, muram & boulders etc
1:2 hard muram
NOTE: Slope not required for soft & hard rock

13. TRANSPORTATIONTRANSPORTATION
OF
MATERIAL TO SITE

14. Pipes shall be transported to the site of laying and stacked
along the routealong the route
Padding shall be placed between coated pipes and timber toPadding shall be placed between coated pipes and timber to
avoid damage to the coating
Suitable gap during pipe stacking should be left at proper
intervals to permit access from one side to the other

15. Unloading & stocking of material :Unloading & stocking of material :
Each pipe & special should be properly stacked at
site in such a manner so as not to distort their circularity orsite in such a manner so as not to distort their circularity or
cause any damage to their outer coating.

17. PIPE HANDLING

18. manual pipe handling :
B f h dli th iBefore handling the pipe,
work men should wear
helmet and gloveshelmet and gloves
1. Ropes used to lift the material must be in good condition,p g ,
and it should not be let over sharp edges
2. Ensure that the persons are moved away from the pit while
placing the pipe (if it is heavy)
3. while handling materials in the wet season, ensure that the
materials are free from slush as it may cause slipping.

19. Pipe handling by machinery
Slings should be in good condition and free from defects,
Ensure proper clamping of slings, these are provided on
same direction on free lengthg
Ensure proper visibility for the crane.p p y

20. C.I & D.I PIPES
LOWERING, LAYING &JOINING

21. Pipes should be lowered slowly in to the trench by means of
chain pulley block and tripod stand or cranes or with thep y p
help of ropes.
Rubber gaskets shall be inserted into the groove in theRubber gaskets shall be inserted into the groove in the
socket. Spigot end shall be lubricated with good quality of
grease or oil, then the spigot shall be slipped into socket by
means of jack on the other endmeans of jack on the other end.
Spigot ends of all pipes shall face up stream irrespective ofp g p p p p
the direction of water flow.

23. GRP PIPESGRP PIPES
LOWERING, LAYING
AND
JOININGJOINING

24. Lowering and laying :
Pi h ll b l id i d diti d d i tPipe shall be laid in dry condition and under no circumstances
they shall rest on sludgy bedding. Pipes shall rest continuously
on the bottom of the trench.
Clearance of approximately 100mm in depth and width equal
l h f h ll l 30 b h id h ll bto length of the collar plus 30mm on both sides shall be
provided at the joint which shall be refilled from sides after the
joint is made.j
The pipe should be lowered in to the trenches either by pulley
or by means of two ropes. For road crossing or river crossing
the pipe shall laid 2.0mtr. Below the bed level. The pipe
should be encased with 300mm thick sand.

25. Joining :
1. Spigot and socket and socket joint with double water tight
bb i k t kirubber ring gasket packing
2. Double socket coupling joint with water tight rubber ringp g j g g
gasket packing
3. Flanged joint is used for connecting the valves, the flanged
joint is made from the same materials as the pipe
4. End pipes should not kept open, the ends shall be covered up
either by suitable cap or plug or double layer of gunny bags.

26. GRP joint with Spigot & socket end

27. M.S PIPES
LOWERING, LAYING, JOINING &
PAINTINGPAINTING

28. Before Laying, M.S pipes should be coated with cement or
PaintingPainting
1. surface cleaning :
The pipe should be cleaned before painting with special
epoxy thinner. This avoids oil, Greece marks on the pipe.
Due to these marks the paint wasn't sticking. Inside dust can
be removed by using compressed airbe removed by using compressed air.
2. primary coating
After surface cleaning, first primer coating is necessary. For
this purpose zinc phosphate primer is combined with
activator in 6:1 ratio. Zinc phosphate primer is component a
& i i b& activator is component b, so
primer = component a + component

29. 3. Out side coating :
After primary coating, out side of pipe painted with
l hi h i bi d i h i i 4 1epoxy coal tar which is combined with activator in 4:1
ratio.
4. Inside :
d d d f i id i i iFood grade epoxy used for inside painting resists
corrosion, this is the combination of resin & cure in 1:1
ratio.

30. Lowering, laying and joining of MS pipes:Lowering, laying and joining of MS pipes:
Before welding the pipe faces shall be cleaned by scrapingBefore welding the pipe faces shall be cleaned by scraping
by wire brushesby wire brushes
MS pipe provided with cement mortar / apoxy paintingMS pipe provided with cement mortar / apoxy paintingMS pipe provided with cement mortar / apoxy paintingMS pipe provided with cement mortar / apoxy painting
in lining and coatingin lining and coating
Th d f MS i h ll h b l d d f ldiTh d f MS i h ll h b l d d f ldiThe ends of MS pipes shall have beveled ends for weldingThe ends of MS pipes shall have beveled ends for welding

31. While assembling the pipes shall be close to uniform gapWhile assembling the pipes shall be close to uniform gapWhile assembling, the pipes shall be close to uniform gap.While assembling, the pipes shall be close to uniform gap.
(Gap depends up on thickness) electrodes shall be conform(Gap depends up on thickness) electrodes shall be conform
to is 814to is 814--1991 i.e, e1991 i.e, e--60136013
MSMS pipespipes areare manufacturedmanufactured eithereither byby electroelectro resistanceresistance
weldingwelding oror submergedsubmerged arcarc weldingwelding processprocess longitudinallylongitudinally ororgg gg gg pp g yg y
spirallyspirally weldedwelded
Manual metal arc welding with covered electrodesManual metal arc welding with covered electrodesManual metal arc welding with covered electrodes.Manual metal arc welding with covered electrodes.

32. What is metal arc welding :
In metal arc welding a metal rod is used as one
electrode during the welding operation this metal electrode is
melted by the heat of the arc and is fused with the base metal.
Welding defects :
1. Lack of penetration,
2. Slag inclusion,
3. Under cut,
4 P f i4. Poor fusion,
5. Porosity,
6 Weld crack6. Weld crack,
7. Spatter,
8. Wrapping & distortion.pp g

33. HDPE PIPE
LAYING & JOINING

34. FusionFusion weldingwelding isis commonlycommonly usedused inin HDPEHDPE andand isis aa
permanentpermanent typetype ofof jointjoint
TheThe pipespipes shallshall bebe brushedbrushed throughthrough outout toto removeremove anyany soilsoil
depositeddeposited oror stonestone theirtheir inin
PipesPipes shallshall bebe laidlaid inin drydry conditioncondition andand underunder nono
circumstancescircumstances theythey shallshall restrest onon slushyslushy beddingbeddingyy yy gg
ClearanceClearance ofof requiredrequired depthdepth && widthwidth onon bothboth sidessides shallshall
bebe providedprovided atat thethe jointjoint whichwhich shallshall bebe refilledrefilled fromfrom sidessidesbebe provided,provided, atat thethe jointjoint whichwhich shallshall bebe refilledrefilled fromfrom sidessides
afterafter thethe jointjoint isis mademade

35. ForFor roadroad crossingcrossing oror riverriver crossingcrossing thethe pipepipe shallshall bebe laidlaid 22
metermeter belowbelow thethe bedbed levellevel andand encasingencasing shouldshould bebe donedonemetermeter belowbelow thethe bedbed levellevel andand encasingencasing shouldshould bebe donedone
PipePipe afterafter transportingtransporting toto thethe exactexact placeplace shouldshould bebe cutcut squaresquare
byby thethe hacksawhacksaw bladeblade
TThehe faceface ofof thethe pipepipe shouldshould bebe slightlyslightly scrappedscrapped priorprior toto thethep pp p g yg y pppp pp
fusionfusion weldingwelding toto removeremove oxidizedoxidized layerlayer
EnsureEnsure thethe levelingleveling ofof pipespipes isis maintainedmaintained atat thethe timetime ofof fusionfusionEnsureEnsure thethe levelingleveling ofof pipespipes isis maintainedmaintained atat thethe timetime ofof fusionfusion
weldingwelding

36. TheThe heatingheating mirrormirror // panpan shouldshould bebe heatedheated upup toto 200200 degdeg.. cc
andand thethe surfacesurface ofof thethe panpan shouldshould bebe 210210 ++ oror –– 55 degdeg.. CC
TheThe heatingheating panpan shouldshould bebe metallicmetallic plateplate whichwhich isis heatedheated upup
toto thethe requiredrequired temperaturetemperature eithereither byby electricalelectrical coilcoil embeddedembeddedtoto thethe requiredrequired temperaturetemperature eithereither byby electricalelectrical coilcoil embeddedembedded
insideinside oror byby blowblow torchtorch
TheThe fusionfusion weldingwelding ofof pipepipe shouldshould bebe heldheld inin eithereither sideside ofofTheThe fusionfusion weldingwelding ofof pipepipe shouldshould bebe heldheld inin eithereither sideside ofof
thethe heatingheating mirrormirror // panpan withwith TeflonTeflon paperpaper onon eacheach sideside
TheThe contactcontact pressurepressure ofof 00..22 kg/cmkg/cm22 inin eithereither sideside ifif thethe pipepipe
shouldshould bebe maintainedmaintained

38. InitialInitial heatingheating timetime forfor achievingachieving thethe moltenmolten rim,rim, variesvaries fromfrom
11 toto 55 minmin dependingdepending onon thethe pipepipe wallwall thickthick && sizesize..
PipesPipes shouldshould bebe removedremoved fromfrom thethe heatingheating mirrormirror // pan,pan, whenwhenPipesPipes shouldshould bebe removedremoved fromfrom thethe heatingheating mirrormirror // pan,pan, whenwhen
thethe rimrim ofof thethe moltenmolten materialmaterial isis formedformed andand ensureensure thatthat thethe rimrim
formationformation isis notnot excessiveexcessive..
ImmediateImmediate jointjoint shouldshould bebe mademade byby thethe applicationapplication ofof
moderatemoderate pressurepressure ofof approxapprox.. 11 toto 22 kg/cmkg/cm22 forfor 22 toto 33 secsec..
whilewhile joining,joining, thethe pressurepressure shouldshould bebe maintainedmaintained untiluntil thethe
jointjoint isis lukeluke warmwarm..jointjoint isis lukeluke warmwarm..
AfterAfter thethe pressurepressure isis relieved,relieved, thethe jointjoint shouldshould bebe allowedallowed toto
coolcool completelycompletelycoolcool completelycompletely

39. Back Filling :Back Filling :Back Filling :Back Filling :
BackBack fillfill withwith excavatedexcavated soilsoil shouldshould bebe freefree fromfrom
i di d hh ll ff bbi hbbi h t blt bl iicinders,cinders, ashes,ashes, slag,slag, refuse,refuse, rubbish,rubbish, vegetablevegetable oror organicorganic
metal,metal, lumpylumpy oror frozenfrozen metal,metal, bouldersboulders rocks,rocks, otherother materialsmaterials
whichwhich inin thethe opinionopinion ofof anyany authority,authority, isis deleteriousdeleterious..
Concrete slabs over pipes :Concrete slabs over pipes :
whenwhen pipespipes areare laidlaid belowbelow roadsroads (which(which maymay bebe
subjectedsubjected toto heavyheavy traffictraffic loads),loads), trenchestrenches shouldshould bebe coveredcovered
ithith i f di f d tt l bl bwithwith reinforcedreinforced concreteconcrete slabsslabs

40. GRP Lamination Details
Materials used in the process:Materials used in the process:
1. Grinding wheels, (machine)
2. Surface,
3. Robin,
4. Matt,,
5. Resin,
6. Hardener,
7 Aerosol powder7. Aerosol powder,

41. L i ti PLamination Process :
1. First, grind the damaged portion with grinding wheel., g g p g g
2. After that , mix the aerosol powder with hardener, this
mixture has to be put on damaged portion hardener ismixture has to be put on damaged portion, hardener is
used to set quickly that joint.
3. Surface is very soft material, this has to put on that portion
& paste with resin which is used for sticking & hardening.

42. 4. Matt & robin are the strength of that lamination
process
these both used one by one on damaged portion.
5. The robin & matt used up to 7 times
6. Resin pour on robin & matt

43. Hydro Testing:
1. After Completion of each section of pipeline, it shall be
tested for water tightness before being covered intested for water tightness before being covered in.
2. This can be done by closing each end by means of
valve, blank flange, cap or plug and filling the pipe with
water.

44. 3. The pressure shall be raised gradually by means of a hydro
testing pump till the pressure is at least one and half times
th kithe working pressure.
4. A pressure to be specified by the authority for a duration of
one hour.
NOTE : In the test pressure drops after one hour

45. THANK U.....