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De waxing

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De waxing

  1. 1. De-waxing & Cleaning of 212Kmlong Loop Line to make suitable for Pumping Products.
  2. 2. SCHEMATIC DIAGRAM OF PROPOSED NSPL ROUTE SRIRAMPUR 631 KM NJP TERMINAL ASSAM RS 2 832 KM BORDER PS5 172 KM. RS9 RS5 PS4 RS3 ROW 401 KM RS4 512.7 361 260 KM 214.3 194 KM 313.3 KM KM KM KM Existing mainline 112 KM 14 KM. New ROW 100 KM. RGP NRLTERMINAL TERMINAL 204 KM 197 KM ASSAM W.B.
  3. 3.  The De-waxing and cleaning of 16” Loop Line of Oil India Limited pipeline is required to be carried out in view of joining the portion of loop line to the newly constructed product pipeline from Numaligarh Refinery to Siliguri Terminal. – Pipe size of the line 16” (406mm) – Thickness of Pipe 7.9mm – Pipe API 5LX-46,52 – Capacity of Product line 1.72 MMTPA
  4. 4.  The job of cleaning and de-waxing was entrusted to CPTDC (China Petroleum Technology Development Corporation). After preliminary ground work a piece of land of area 3200m2 outside RS-3 Kaziranga was rented to place equipment and machines accordingly. A water storage pond of approximately 800m3 was constructed.
  5. 5. WATER STORAGE
  6. 6. Loop Line Main LineRS-3 Kaziranga PS-4 SekoniLoop Line and Main line between RS3 and PS4
  7. 7. Steps involved in de-waxing and cleaning processPigging with different types of pigs with crude oil as medium Sweeping of Crude oil Hot water Pigging Chemical Cleaning Self Check Chemical Cleaning Acceptance Test
  8. 8. Equipment:1) Compressors – Ingersoll Rand (2 nos) a) Capacity – 45m3/min, Pressure – 1.0 Mpa b) Capacity – 30m3/min, Pressure – 2.4 Mpa2) Water Pump – 4 no’s of various capacity3) Chemical dosing pump – 2 no’s4) Hot water boiler etc.
  9. 9. Equipment Water PumpAir Compressor
  10. 10.  It was decided to start the work in the RS-3 Kaziranga to PS-4 Sekoni sector first. The date of starting of the pigging operation was decided as 22.02.07. General pigging process is decided to be carried out with combined and Bi-Di Pigs.Pig Type :- a) Combined Pig (Brush, Cup & Plate) b) Bi - Di Pig Size :- 105% of I.D of Pipe i.e. 409.7mm ( Pipe I.D 390.2mm)
  11. 11. Pigs Used Foam PigCombined PigB.C.P Bi – Di Pig(Brush, Cup &Plate)
  12. 12. Pigging with different types of pigs with crude oil as medium The first pig was launched at RS-3 Kaziranga for PS-4 Sekoni with a trekking instrument on 22.02.07. Pig was tracked at various locations. Throughput in the line during pigging operation was kept at 150Kls/Hr. Series of pigging operations were carried out subsequently between RS-3 Kaziranga to PS-4 Sekoni from 22.2.07 to 08.04.07 Wax collected & other related information are
  13. 13. Cleaning Pigs B.C.P Pig – Before & after Pigging
  14. 14. RS3-PS4 (Kaziranga-Sekoni) Crude Oil De-Waxing Work Sheet Times of Pigging:66 Wax quantity:20267KGSL.NO. Type of Pig Launching Time Receiving Time Wax quantity/Kg 1. Cup Pig 22/02/07, 10:15 23/02.07, 18:10 1200 2. Cup Pig 24/02.07, 11:20 25.02.07, 18:30 1000 3. Bi-Di Pig 27.02.07, 11:45 01.03.07, 10:40 2000 4. Bi-Di-Pig 03.03.07, 08:44 04.03.07, 15:00 800 5 Bi-Di Pig 03.03.09, 16:15 04.03.07, 22:10 600 6. Bi-Di Pig 05.03.07, 08:40 06.03.07, 14:30 300 7 Brush Pig 05.03.07, 12:30 06.03.07, 19:30 700 8. Brush Pig 05.03.07, 16:30 06.03.07, 23:45 600 9. Brush Pig 08.03.07, 09:15 09.03.07, 16:30 900 10. Brush Pig 08.03.07, 13:00 09.03.07, 20:00 350 11. Brush Pig 08.03.07, 16:45 09.03.07, 22:30 300 12. Brush Pig 10.03.07, 08:45 11.03.07, 20:45 400 13. Brush Pig 10.03.07, 11:45 12.03.07, 02:10 400 14. Brush Pig 10.03.07, 14:45 12.03.07, 09:30 100 15. Brush Pig 10.03.07, 17:45 12.03.07, 10:50 75 16. Brush Pig 13.03.07, 08:45 14.03.07, 16:45 100 17. Brush Pig 13.03.07, 11:45 14.03.07, 18:50 400 18. Brush Pig 13.03.07, 14:45 14.03.07, 21:30 75 19. Brush Pig 13.03.07, 17:45 15.03.07, 01:15 2
  15. 15. SL.NO. Type of Pig Launching Time Receiving Time Wax quantity 20. Brush Pig 15.03.07, 08:40 17.03.07, 11:45 300 21. Gauging Pig 15.03.07, 11:30 17.03.07, 13:00 0 22. Brush Pig 18.03.07, 08:45 19.03.07, 17:00 700 23. Brush Pig 18.03.07, 11:35 19.03.07, 20:30 40 24. Brush Pig 18.03.07, 14:30 19.03.07, 21:45 10 25. Brush Pig 18.03.07, 17:30 19.03.07, 23:45 120 26. Brush Pig 20.03.07, 08:45 21.03.07, 10:50 75 27. Brush Pig 20.03.07, 11:35 21.03.07, 13:40 20 28. Brush Pig 20.03.07, 14:25 21.03.07, 16:45 350 29. Brush Pig 20.03.07, 17:15 21.03.07, 19:25 120 30. Brush Pig 22.03.07, 08:35 23.03.07, 12:40 900 31. Brush Pig 22.03.07, 11:30 23.03.07, 17:30 10 32. Brush Pig 22.03.07, 14:30 23.03.07, 17:30 10 33. Brush Pig 22.03.07, 16:30 23.03.07, 20:10 10 34. Brush Pig 24.03.07, 08:30 25.03.07, 12:50 150 35. Brush Pig 24.03.07, 11:30 25.03.07, 16:25 30 36. Brush Pig 24.03.07, 14:00 25.03.07, 19:35 200 37. Brush Pig 24.03.07, 16:30 25.03.07, 22:40 500 38. Brush Pig 26.03.07, 08:50 27.03.07, 12:00 700 39. Brush Pig 26.03.07, 11:20 27.03.07, 15:00 0 40. Brush Pig 26.03.07, 13:50 27.03.07, 16:15 10 41 Brush Pig 26.03.07, 16:20 27.03.07, 18:45 10 42 Brush Pig 28.03.07, 8:35 29.03.07, 11:10 700
  16. 16. SL.NO. Type of Pig Launching Time Receiving Time Wax quantity/Kg 43. Brush Pig 28.03.07, 11:05 29.03.07, 14:00 100 44. Brush Pig 28.03.07, 13:30 29.03.07, 16:20 0 45. Brush Pig 28.03.07, 16:00 29.03.07, 19:00 0 46. Brush Pig 30.03.07, 08:40 31.03.07, 08:30 0 47. Brush Pig 30.03.07, 11:05 31.03.07, 11:05 250 48. Brush Pig 30.03.07, 13:30 31.03.07, 16:00 150 49. Brush Pig 30.03.07, 16:00 31.03.07, 18:00 200 50. Brush Pig 01.04.07, 08:35 02.04.07, 19:30 600 51. Brush Pig 01.04.07, 11:00 02.04.07, 21:55 5 52. Brush Pig 03.04.07, 09:15 04.04.07, 13:00 450 53. Brush Pig 03.04.07, 11:40 04.04.07, 15:20 350 54. Brush Pig 03.04.07, 14:10 04.04.07, 18:00 200 55. Brush Pig 03.04.07, 16:10 04.04.07, 20:00 450 56. Brush Pig 05.04.07, 08:55 06.04.07, 17:00 20 57. Brush Pig 05.04.07, 12:55 06.04.07, 21:00 350 58. Brush Pig 05.04.07, 16:55 07.04.07, 01:15 100 59. Brush Pig 05.04.07, 20:55 07.04.07, 04:55 350 60. Brush Pig 06.04.07, 00:55 07.04.07, 09:20 5 61. Brush Pig 06.04.07, 04:55 07.04.07, 13:00 400 62. Brush Pig 08.04.07, 08:10 09.04.07, 11:10 50 63. Brush Pig 08.04.07, 10:10 09.04.07, 12:45 250 64. Brush Pig 08.04.07, 12:10 09.04.07, 14:00 250 65. Brush Pig 08.04.07, 14:10 09.04.07, 15:40 400 66. Brush Pig 08.04.07, 16:10 10.04.07, 16:45 20
  17. 17. Same process started for the sector PS-4 Sekoni to RS-4 Ghani on 26.02.07Wax collected in this sector is much more less than the previous sector.Total quantity of wax collected in both the sector is around 26400Kgs approx.
  18. 18. Sweeping of crude oilVery critical job.Compressed air is used.Safety precautions to be taken  Static electricity / Earthing.  Nitrogen Purging.
  19. 19. Arrangements of Equipment in Sweeping operation Water Pump Air Compressor Air compressor --1 --2 Loop Line Main Line RS-3 Kaziranga PS-4 Sekoni
  20. 20. M/L is isolated from the Loop Line.M/L was kept pressurized at 35Kg/cm2.The first pig was a combined pig, launched at 1210hrs.The second pig was Bi-Di, launched at 1410hrsThe third pig was also Bi-Di, launched at 1610hrsThe fourth pig was also a Bi-Di launched at 1820hrs followed by 30Kl of water and again followed by a Bi-Di pig, and the whole train of pigs was driven by compressed air
  21. 21. Sweeping Operation Bi – Di Bi – Di Bi – Di Bi – Di B.C.P Pig Pig Pig Pig Pig Crude Water Crude Crude CrudeAir -30 Kls
  22. 22. The oil from the loop line was taken into the balance tank at PS-4 and normal pumping from PS-4 Sekoni was continued.The fourth pig which was the last pig in contact with the crude oil was received on 9.4.07 at 1855 hrs and sweeping operation completed.The line is immediately isolated from all the crude oil connections.
  23. 23. Sweeping process (PS-4 Sekoni to RS-4 Ghani) In PS4 – RS4 sector the oil column in front of the sweeping pig was very long which was from PS-4 Sekoni to PS-5 Noonmati of 140Km long. The length of the oil column to be swept is only 53Km. After completing sweeping operation in both the sectors, multiple pigging with air started and considerable amount of cleaning is achieved.
  24. 24. PS-4 Sekoni RS-4 Ghani L/L M/L M/L under Pressure Loop Line between PS4 Sekoni & RS4 Ghani
  25. 25. Hot water PiggingDecided to carry out hot water pigging.Hot water plug of 200mtrs was driven between one combination pig and a Bi-Di pig with the help of air.The water temperature at the inlet is 80’CThis process continued for a few days and foam pigs were also driven along with air until certain level of cleaning is achieved.
  26. 26. Arrangement for Hot Water Pigging 16” Loop Line underHot cleaningWater4” Line HOT WATER
  27. 27. Chemical CleaningChemical mixed with H.S.D in a ratio of 1:12 is used.The H.S.D and the chemical mixture is plugged between two pigs, of which one is a combination pig and other a Bi-Di pig, and the plug is followed by 30Kl of water.The whole train is driven by compressed air.Initially 12Kl of H.S.D was mixed with 1Kl of chemical.
  28. 28. Chemical Cleaning Bi – Di Bi – Di B.C.P Pig Pig Pig WATER H.S.D (12Kl) +Air 30 Kl CHEMICAL(1Kl) Air Same procedure was followed for the other sector also.
  29. 29. Self CheckAfter cleaning with chemical a self check was required to be carried out and finally 200mtrs of H.S.D was plugged between 350mtrs and 250mtrs of water with separating pigs and the train was driven between RS-3 Kaziranga and PS-4 Sekoni as shown in the figure.
  30. 30. Self Check B.C.P B.C.P B.C.P B.C.P Pig Pig Pig Pig AIR water H.S.D water AIRAir Foam 200 m 200 m 350 m Foam Pig Pig
  31. 31. The above process was also carried out in the other sector and concentration of chemical required is determined to 1:12 only, and the chemical cleaning process is decided to be taken up once again.
  32. 32. Acceptance testThe final acceptance test of the cleaning process is decided to be taken up after self check and the total cleaning process.The process is carried out as follows Bi – Di Bi – Di Bi – Di Bi – Di Pig Pig Pig Pig Water H.S.D WaterAir Air 200 m 300 m 100 m
  33. 33. H.S.D – Euro III was used for testing in the line.When H.S.D reached PS-4 Sekoni various samples were taken in presence of OIL, NRL and CPTDC representatives and tested for colour.For conducting the process of colour test, officers of chemical department of all the three parties carried out the test with respect to the colour code.
  34. 34. The colour code was established by contaminating crude oil and wax with Euro III – H.S.D in the laboratory and they were observed in testing machine.The colour code of Euro III – H.S.D was taken as to be “0”.
  35. 35. Colour code chartContaminated Sample (ppm) Color code with crude Color code with wax 10 0 0 20 0 0 50 1 1 100 2 2 200 3 4 500 6-7 7 1000 9-10 11 5000 17 18 10000 22 28
  36. 36. Samples collected during Acceptance test PS4 – RS4 Sample RS3 – PS4 Sample
  37. 37. It was found in the laboratory that sample with colour code 7 (i.e. up to 500ppm contamination)was within acceptable limit.The following results of colour code were found in the sectors RS3 – PS4 & PS4 – RS4. – RS3 to PS4 0 –1 – PS4 to RS4 4–5
  38. 38. Precaution taken in respect of safety While carrying out sweeping operation with the help of air, nitrogen was purged into the receiving trap at both the location i.e. PS4 and RS4 in a regulated manner. Utmost precautions were taken when sweeping pig was near to the receiving trap to avoid any collision of pig head with the barrel door.
  39. 39.  Cushioning materials were also placed near the door of the receiving trap. The line was completely earthed in three places to discharge any static electricity that may be generated due to numerous numbers of pigging operations. Flame proof equipment were only used inside the repeater stations and pump stations to avoid any incidents.
  40. 40. Precaution taken in respect of Environment To avoid any pollution, spill of oil is totally restricted in Pump Stations and Repeater Stations. Wax and other materials were dumped in a location made with concrete and poly- ethylene lined sheet.
  41. 41.  Water and other liquids coming out of the line is kept reserved in a poly-ethylene lined concrete walled pond made at RS-4 Ghani. An effluent treatment plant (portable) was constructed by the contractor to treat the effluent before disposal which is again tested to avoid any pollution and it was kept under 10mg/Ltr. H.S.D and other chemicals were recycled and reused for the other sectors.
  42. 42. Portable Effluent treatment Plant
  43. 43. Benefits:Construction of a new pipeline of 212Kms long would have cost us Rs 250 crores but the cost of cleaning and de-waxing of existing line was only Rs 27 crores.Construction of pipeline inside Kaziranga sanctuary would have been a difficult job in view of the environmental policy of the Government.
  44. 44. THANK YOU

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