Cross-country pipelines help transfer natural resources such as oil and gas over long distances. Their development projects are typically complicated and often require the coordinated efforts of interdisciplinary engineering teams to ensure success.

This blog will discuss the major factors of cross-country pipeline design by multidisciplinary engineering firms, such as Rishabh Engineering, highlighting the critical phases and activities involved in such projects.

They are pivotal in transporting essential resources across vast distances, such as natural gas, oil, and water.

Various important large projects are operating around the globe. Listed below are a few examples:

• TAPS carries crude oil from Prudhoe Bay to the Alaskan port of Valdez across an 800-mile route. It was built in the 1970s and is still one of the world’s largest networks.
• The Keystone Pipeline System transports crude oil from Canada to US refineries over a distance of 1,200 miles. It has been controversial because of environmental concerns and has faced numerous legal and regulatory challenges.
• The Nord Stream Pipeline stretches 1,200 kilometers and carries natural gas from Russia to Germany over the Baltic Sea. It was completed in 2011 and has drawn criticism from certain European countries for Russia’s control over energy supplies.
• The West-East Gas Pipeline spans 4,000 kilometers, transporting natural gas from western to eastern China. It was completed in 2004 and is also one of the world’s longest networks.
• Trans-Saharan Gas Pipeline is a proposed 4,400-kilometer channel that would transmit natural gas from Nigeria to Europe through Algeria. The project has been delayed due to political and economic constraints.

These projects require thorough preparation, engineering knowledge, and strict respect for safety and environmental regulations. Each area requires careful thought and attention to detail, from the early feasibility studies to the building and operation phases.

Listed below are the core phases involved in this process;

Project Planning and Feasibility Analysis

Feasibility Studies

It examines the project’s economic, technical, and environmental viability. Key components of feasibility studies include:

• Economic Analysis: Evaluating the project’s cost-effectiveness, including capital and operational expenditures.
• Technical Feasibility: Assessing the technical requirements and challenges associated with the project, including route selection, material specifications, and construction methodologies.
• Environmental Impact Assessment: Identifying potential environmental impacts and developing mitigation strategies to minimize adverse effects.

Front End Engineering Design (FEED)

It provides a precise structure for the project, from conception to completion. It includes:

• Project Scope Definition: Clearly define the project’s objectives, deliverables, and boundaries.
• Cost Estimation: Providing a preliminary budget that accounts for all anticipated expenses.
• Timeline Development: Outlines a realistic project schedule, including major milestones and deadlines.

Detailed Engineering and Design

This process translates the FEED framework into actionable plans and specifications. It covers various engineering disciplines:

Civil and Structural Engineering

• Geotechnical and Geophysical Data Review: Analyzing soil and subsoil conditions to inform design decisions.
• Pipeline Construction Procedures: Developing step-by-step procedures for construction to ensure precision and safety.
• Foundation and Structure Layouts: Designing layouts for pipeline supports and structures.
• Material Specifications: Defining the materials and methods for constructing durable foundations and structures, including reinforced concrete and steel work.
• Earthwork and Excavation Procedures: Preparing the terrain for piping installation.
• Design Basis for Civil and Structural Components: Establish standards for all elements.

Mechanical Engineering

• Pipeline Profile and Alignment Drawings: Create detailed drawings depicting the pipeline’s route and alignment.
• Mechanical Design Reports: Providing comprehensive reports on the mechanical aspects of the pipeline, including stress analysis and material selection.
• Cathodic Protection Design: Implementing measures to prevent corrosion and extend the pipeline’s lifespan.
• Buoyancy Control Measures: Ensuring the pipeline remains stable in water-saturated environments through buoyancy control measures.

Electrical Engineering

• Electrical System Design: Developing the electrical infrastructure necessary for pipeline operations, including power supply and distribution.
• Grounding and Cable Management: Ensuring proper grounding and cable management to enhance safety and operational efficiency.
• Lighting and Electrical Layouts: Designing adequate lighting systems and electrical layouts for facilities and control rooms.

Instrumentation and Control Engineering

• Control System Design: Developing the control and monitoring systems required for pipeline operations.
• Instrumentation Layouts: Creating detailed layouts for instrumentation, including sensor placement and cable routing.
• Safety Systems: Designing alarm and shutdown systems to ensure safe operation under various conditions.

Corrosion Protection

The said pipelines may be laid underground and will encounter corrosion problems. Careful attention should be given to protect pipelines from being corroded for their long life. Various methods, like pipeline coating like 3LPE, can provide sacrificial anodes and ICCP system, i.e., impressed current cathodic protection.

Construction and Supervision Support

Construction Supervision

It is crucial to ensure that the project adheres to design specifications, timelines, and safety standards. Key activities include:

• On-site monitoring: Overseeing construction activities to ensure compliance with plans and specifications.
• Quality Control: Implementing quality control measures to verify that materials and workmanship meet specified standards.
• Safety Management: Enforcing safety protocols to protect workers and the environment.

Procurement and Supply Chain Management

Efficient processes are essential to source the necessary materials, equipment, and services. Key activities include:

• Vendor Selection and Evaluation: Assessing and selecting vendors based on quality, reliability, and cost.
• Request for Quotation (RFQ) Processes: Managing RFQs to ensure timely and cost-effective procurement.
• Contract Management: Overseeing contracts to ensure compliance with terms and conditions.

Commissioning and Start-Up

It involves testing and validating the pipeline’s performance before it becomes operational. Key activities include:

• System Testing: Conducting rigorous tests to verify the functionality and safety of the pipeline and its associated systems.
• Performance Validation: Ensuring that the pipeline meets all operational requirements and performance standards.
• Handover Procedures: Transferring pipeline control to the operational team, along with detailed documentation and training.

Maintenance and Monitoring

They are crucial to ensure the pipeline’s continued safe and efficient operation. Key activities include:

• Routine Inspections: Conducting regular inspections to identify and address potential issues before they escalate.
• Maintenance Programs: Developing and implementing maintenance programs to ensure the longevity and reliability of the pipeline.
• Monitoring Systems: Utilizing advanced monitoring systems to continuously track the pipeline’s performance and detect any anomalies.

Environmental and Regulatory Compliance

Environmental Protection

Key activities include:

• Environmental Impact Assessments (EIA): Conduct thorough EIAs to identify potential environmental impacts and develop mitigation strategies.
• Sustainable Practices: Implementing sustainable practices throughout the project to minimize environmental footprints, such as using environmentally friendly materials and methods.
• Restoration Plans: Develop plans to restore affected areas to their original state post-construction.

Regulatory Compliance

Key activities include:

• Permitting and Approvals: Obtaining all necessary permits and approvals from relevant authorities.
• Regulatory Reporting: Maintaining accurate records and reporting to regulatory bodies as required.
• Compliance Audits: Conduct regular audits to ensure ongoing compliance with all applicable regulations.

Here are some of the key considerations;
Pipe Thickness:

• Calculate based on standards, codes, and service requirements, including corrosion allowance.
• Use concrete anchor blocks at direction changes to counteract outward thrust from fluid velocity changes.

Parallel Pipelines Clearance:
Ensure minimum clearance is the largest of:

• O.D. of larger pipe dia over insulation.
• Specific requirements for working space, ROW space, road edges, buildings, etc.

Surge Effect:

• Address surge pressure induced by valve shut-off at the receiving end.
• Determine valve closing time with proper communication between supplier and receiver.
• Consider surge tanks or vessels at both ends to mitigate Fluid-Hammer effects.

Pigging:

• Perform pigging for pipelines carrying different products periodically to flush and prepare the line for new fluids.

Pipeline on Brackets Attached to Bridges:

• Assess vibration levels (frequency and amplitudes) from traffic.
• Avoid resonance by ensuring pipe frequencies do not match bridge frequencies.
• Provide lateral spring-loaded supports at random intervals for damping.

Long Expansion Loops:

• Consider thermal expansion and contraction due to temperature variations.
• Perform stress analysis and ensure proper support arrangements.
• Use rollers for free longitudinal movement and loose clamps to prevent slipping.

Erection Stresses:
Anticipate local and excessive stresses in following conditions during handling of pipes:

• Local deformation/bending from crane use.
• Deformation when pulling pipe along trenches or sleeves.
• Submarine portion lowering, causing local deformations.
• Vibrations during hydro testing of unsupported lengths.
• Compression or tension effects when crossing hillocks.

Corrosion Allowance:

• Specify extra corrosion allowance for long-distance pipelines.
• Provide a minimum of 3 mm allowance or as specified, whichever is greater, to prevent leaks.

Cross-Country Pipeline Design Codes

These pipelines must adhere to various codes and standards to ensure their safety, reliability, and environmental protection. Here are some of the key codes and standards commonly used:

• ASME B31.4: Outlines the liquid pipeline design, construction, and operation standards.
• ASME B31.8: Sets the gas pipeline design, construction, and operation standards.
• API 5L: Issued by the American Petroleum Institute (API), this standard governs the manufacture of line pipes that transport oil, gas, and other fluids. It includes material selection and quality management guidelines.
• ISO 3183: This international standard specifies the requirements for producing seamless and welded steel pipes used in pipelines for transporting liquids and gases.
• ANSI/ASNT CP-189: It provides guidelines for the qualification and certification of non-destructive testing (NDT) personnel, which is crucial for pipeline inspections and maintenance.
• API 1169: It sets the standards for the certification of pipeline inspectors, covering aspects such as pipeline construction, operations, and maintenance.
• PHMSA Pipeline Safety Regulations: Published by the Pipeline and Hazardous Materials Safety Administration (PHMSA) in the United States, these regulations establish minimum safety standards for the design, construction, and operation of pipelines.

Our team at Rishabh Engineering was involved in developing one such ambitious pipeline project for a leading cement manufacturer. In this case, the client wanted to use reliable natural gas as a fuel source for their plant operations. It was with delivery through new pipelines, ensuring operational sustainability and cost-effectiveness.

Scope of Work:

• Front End Engineering Design (FEED): Preliminary engineering to establish project scope, cost, and timeline.
• Detailed engineering for constructing a 3km pipeline from the tie-in point at the gas station to the distribution station.
• Construction supervision during the execution phase.
• Procurement support services.

Here’s how we contributed to the project’s success:

• Comprehensive FEED Services: We provided comprehensive FEED services, establishing a solid foundation for the project. It included defining the project scope and estimated costs and, developing a realistic timeline, ensuring all stakeholders clearly understood the project’s objectives and requirements.
• Detailed Engineering and Design: Our multidisciplinary team handled all aspects of detailed engineering and design, including civil, structural, mechanical, electrical, and instrumentation engineering. Their thorough approach ensured that every detail was meticulously planned and executed, from geotechnical data review to electrical system design.
• Construction Supervision: Our team provided on-site supervision support during the construction phase to ensure adherence to compliance with design specifications and safety standards. This proactive approach to quality control and safety management helped prevent issues and keep the project on track.
• Procurement Support: Our team supported the client with managed RFQs, vendor selection, and contract management, ensuring that all materials and equipment were sourced efficiently and cost-effectively. Their expertise in procurement helped avoid delays and ensured the project stayed within budget.

Software Used:

• AutoCAD PLANT 3D,
• TEKLA,
• CADWorx,
• STAAD.Pro Connect,
• CAESAR II
• PV Elite,
• Aspen Hysys

Cross-country pipeline development necessitates the expertise of a multidisciplinary engineering firm – from preliminary planning and design to construction and commissioning, each stage necessitates painstaking attention to detail, flawless coordination, and a dedication to quality. Rishabh Engineering’s help in the cement manufacturer’s transition to lean gas exemplifies how complete engineering and procurement support can drive the success of such complicated programs. Our piping engineering services team supports the successful implementation of cross-country pipeline projects by addressing all important considerations, such as feasibility studies and detailed engineering, procurement, and environmental compliance. These projects improve connection and economic growth while promoting environmental stewardship and energy sustainability.

Our team specializes in designing, welding, corrosion protection, testing, and commissioning of cross-country pipelines.