PEP8 Oil Pipeline 42inch by 455km

Oil Pipeline 42” by 450km.
25th June David H Moloney
Photographic Record of Construction

Baku - Tbilisi - Ceyhan (BTC) Oil Pipeline
The Azerbaijan Section of the Project’s Oil Pipeline including valve and
pig trap stations, laying of Fiber Optic cable and tie-ins at pumping
stations. Much of the terrain is flat and semi-arid.
The Pipeline links the Caspian sea oil wells with the Mediterranean Sea
ship tankers port.
The capacity is1 million barrels of crude oil flow per day
Construction of Azerbaijan Oil Pipeline 42” by 450km. Client BTC,
Contents
Overview
Surveying & Setting Out
Clearing & Grading
Double Jointing i.e. welding 2 pipes together
Stringing out Pipes
Bend Pipes for changes in direction sideways and up & down
Welding Pipes into a string, Test Weld by X Ray.
Anti-corrosion Coat to Joints
Trenching i.e. excavate trench
Lowering pipe string into trench
Backfilling Trench
Reinstatement of Pipeline ROW (Right-of-Way)
Reinstatement of River Banks
Crossing - Horizontal Directional Drilling
Crossing - Thrust Boring
Crossing - River Pause Slides to Read
Hydrotest & Pigging
Tie-in i.e. connect to existing pipeline
Miscellaneous
Overview Construction Sequence
A typical sequence of activities is- surveying and setting out, preparing the land, stringing out the pipes along the
route, excavating the trench, welding and laying the pipes, backfilling the trench with the excavated soil, and
reinstating the land to its original condition.
.
Crossing Railway, Roads, Rivers, etc.

Pump Station
Overview Pipeline Construction Animation
To see animations, view YouTube film.

Overview Pipeline Crossings Construction Animation


FCI-ROW Set Out

Clearing & Grading ROW (Right of Way)

Clearing & Grading
Concrete Slabs Installed For

Foreign Service Detection Foreign Services Protection
Clearing & Grading

Clearing & Grading

Double Jointing Facility
Welding 2 nr 12m long pipes

together prior to stringing out.
Located at Pipe Storage areas.
Double Jointing Facility

Outline Process
1. Single piles 12m long are delivered and stacked.

2. At the Bevelling Station. The ends of the pipes are
bevelled. Two pipes are aligned using an internal
clamp, the joint is preheated and the root pass
weld is done.
3. At the Hot Pass Station. The fill and cap passes
will be carried out using Submerged Arc Welding
(SAW)
4. The joints will be x-rayed
5. The double pipes 24m long are stored ready for
transportation to the site
6. Purpose made dollies will transport the pipes
Double Jointing i.e. welding two pipes together
6
Phase 7: Rolling Pipe
Stringing out Pipes

Stringing out Pipes

Stringing out Pipes
Final Product
Bending Pipes
Bending Pipes
Pipe Will Be Lifted Using Choker Choker Belts Placed On

Toolbox Talk Belts Pipe
The Bending Machine Uses A

Preparation For Lifting Series Of Clamps And Hydraulic
Loading Pipe On Bending Pressure To Make A Very
Pipe Machine Smooth, Controlled Bend Bending Start
Bending Pipes
Bending
Completed Bends
Maximum Bend angle Is 1.3

Clamps Pulled Through The Pipe Degrees Per Meter
Welding
Welding
Fit-Up
Beveling
Welding
X Ray Pipeline Crawler for testing joint welds

Construction of Azerbaijan Oil Pipeline 42” by 450km. Client BTC
Joint Field Coating for Anti-corrosion

Joint Field Coating
Preparation For Grit Blasting

1. Toolbox Talk Wearing Special Coverall
Joint Field Coating

Trenching i.e. excavate trench.

Trenching
Lowering Pipe string into Trench

Lifting Belts Supported by Side-Booms Will Be

Utilized For Pipe Handling And Not Placed Over Any
Field Joint Area

Backfilling
Backfilling
Backfilling
Reinstatement ROW Right-of-Way

Reinstatement ROW
Spreading Topsoil
Reinstatement ROW
Reinstatement ROW
Final Product
Reinstatement River Bank

Matting
Grass Is Growing On River Banks Final Product

Pipeline Crossing by Horizontal Directional Drilling

Rig Anchoring System; During The

Drilling Works, The Rig Will HaveTo
Be Secured To Stop It From Moving


Pipeline Crossing by Thrust Boring



Pipeline Crossing - River Crossing

Sediment Control
Lowering In
Hydrotest, Pigging (clean out pipeline) & Dry Pipeline

Hydrotest
Trains Of Brush Pigs With Slugs Of Flushing

Water Are Used For Cleaning The Pipeline Pigs Are Loaded Into Temporary Pig Launchers
Block Valve Pre-Testing
Hydrotest
The Final Pig Is Fitted With An Aluminium

Pigs Are Received Into Temporary Pig Gauging Plate 95 % Of The Internal Diameter To
Pigs Are Launched With Compressed Air Receiver Check For Geometrical Defects
Water Used For Hydrostatic Testing Is Water Is Then Passed Through Vented
Pigs Are Back Loaded Into Test Headers Break Tanks And Flow Meters
For Filling And Dewatering Test Test Headers Are Then Welded To The Filtered To 50 Microns
Sections Ends Of Test Section
Hydrotest
Filling Spread Showing Fill Pumps, Pressurising Pumps And Instrument Control
Chemical Dump And Break Tanks Container
The Dewatered Section Is Then Dried

To -10degC Dewpoing Using
Compressed Air Passed Through
Drying Units
After Hydrotest The Test Section Is

Pressurising injection Manifold Incorporating Dewatered And Water Transferred Into The
High Pressure Flow Meter Next Section
Tie-in i.e. connecting to existing pipeline
Welded Joint on the Azerbaijan and Georgia Border

Tie-in
Tie-in
Tie-In: Manually Welding Joints In

Preparation For Tie-In Trench Between Two Sections
Tie-In Final Product

Miscellaneous
Contents
Time Chainage Diagram

Pipe Spool Fabrication
Tank Construction
Piperack
Crane Heavy Lift
Slug Catcher
Road construction
Reinforced Concrete Wall
Crossing under Existing Utilities
Trench Excavation
Load & Haul
Rock excavation
Quarry & aggregate Production
Concrete Batching Plant
Temporary Sheet Pile shaft
Cable Laying
Fencing
Buildings
Time Chainage Diagram The chart has two axis: one for time and the other for location
A legend explains meaning of the colours, symbols and line types
Sample Only
Histograms for Resources & Outputs

Dashboard is a single page, graphical representation of current
Progress Monitoring & Reporting - Dashboard progress and historical trends
Dashboard is a single page, graphical representation of
HSE Monitoring & Reporting - Dashboard current HSE Issues and historical trends
Plant & Equipment List & Worker’s Job Titles
ⓒ David H Moloney
Temporary Contractors Site Facilities
Brief Description
Site Offices, Camp Accommodation for

1,250 workers, Canteen, Recreation,
Fabrication shops, Stores, Plant Yard. In five
locations along the route.
ⓒ David H Moloney
Temporary Contractors Site Facilities - Stores
Brief Description
Pipes Delivery ⓒ David H Moloney
Brief Description
Pipes were manufactured in Japan, coated

with a plastic covering in Malaysia, and
shipped to the Georgian ports of Poti.
Transported by Train and trucks across land.
Georgia
Train
Japan
Pipe Spool Fabrication Animation
Pipe Spool Fabrication Steps
Pipework
NDT
Cut Non Destructive
Testing
Bevel PWHT
Post Weld Heat
Treatment
Fit-up Blasting
Weld Painting
Tank Construction
Piperack Construction Animation
The Pipe Racks carry pipes and cables

between the different processes..
Cranes Heavy Lift Animation
Lift column from the horizontal and

rotate into the vertical
Slug Catcher Construction Sequence Animation
Separates the Gas from the Oil & Water

Also to dissipate any pressure surges
Road Construction Sequence Animation
Reinforced Concrete Wall Construction Sequence Animation
Existing Underground Utilities
Earthworks
Brief Description
Before digging
establish the location
and route of
underground utilities.
Locator to find Utilities

Spray Paint to mark pavement ⓒ David H Moloney
Crossing Under Buried Utilities & Overhead Power Cables Animation
General Items Wheel Wash Drive-through
General Items Weighbridge & Sheeting Access
ⓒ David H Moloney
General Items Dust Suppression
ⓒ David H Moloney
Organogram
Brief Description
Shown are the line and

lateral relationships
between the various team
members and their relative
position in the site
organisation.
Trench Excavation with Stepped Faces
Trench Excavation with Battered Faces
Excavate & Load, Cart, Tip & Return
Earthworks
Brief Description 7 minutes
Cycle Time for 7km haulage distance

using an Excavator 45 tonne weight
and Dumper with a 40 tonne capacity,
the cycle time is 34 minutes
7 km
14 minutes 7 km 14 minutes
3 minutes
Rock - Excavability
Earthworks
Brief Description
The excavability of rock depends

mainly on the rock strength and the
layer thickness. This diagram shows
excavation methods for rock of
various strengths and thicknesses,
with a free face.
ⓒ David H Moloney
Quarry & Aggregate Production
Concrete
ⓒ David H Moloney
Concrete Batching Plant David H Moloney
Concrete
Brief Description
.
The mixing is computer controlled
and has a dynamic screen display,
showing the process. The material
storage capacity is, to match two
days concrete production.
ⓒ David H Moloney
Concrete Batching Plant
Concrete
ⓒ David H Moloney
Temporary Sheet-pile Shaft
Cable laying 132KVa Electric
Fencing
Concrete
ⓒ David H Moloney
Central Control Building for Refinery
Concrete
Cross Sections Horizontal moving upwards
ⓒ David H Moloney
Main Electrical Sub Station
Concrete
Cross Sections Horizontal moving upwards
ⓒ David H Moloney
Main Electrical Sub Station
Concrete
Cross Sections Vertical moving along
ⓒ David H Moloney
END
My YouTube Channel link: https://www.youtube.com/channel/UCeJR9J7svhBd-C0ZoAH2fhQ

PEP8 Oil Pipeline 42inch by 455km

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PEP8 Oil Pipeline 42inch by 455km

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Oil Pipeline 42” by 450km.

25th June David H Moloney

Photographic Record of Construction

Overview Construction Sequence

Crossing Railway, Roads, Rivers, etc.

To see animations, view YouTube film.

Surveying & Setting Out

Surveying & Setting Out

Surveying & Setting Out

FCI-ROW Set Out

Clearing & Grading ROW (Right of Way)

Clearing & Grading

Concrete Slabs Installed For

Clearing & Grading

Clearing & Grading

Double Jointing Facility

Welding 2 nr 12m long pipes

Double Jointing Facility

1. Single piles 12m long are delivered and stacked.

Double Jointing i.e. welding two pipes together

Stringing out Pipes

Stringing out Pipes

Stringing out Pipes

Pipe Will Be Lifted Using Choker Choker Belts Placed On

The Bending Machine Uses A

Maximum Bend angle Is 1.3

X Ray Pipeline Crawler for testing joint welds

Joint Field Coating for Anti-corrosion

Joint Field Coating

Preparation For Grit Blasting

Joint Field Coating

Trenching i.e. excavate trench.

Lowering Pipe string into Trench

Lowering Pipe string into Trench

Lifting Belts Supported by Side-Booms Will Be

Lowering Pipe string into Trench

Reinstatement ROW Right-of-Way

Reinstatement River Bank

Reinstatement River Bank

Reinstatement River Bank

Grass Is Growing On River Banks Final Product

Pipeline Crossing by Horizontal Directional Drilling

Pipeline Crossing by Horizontal Directional Drilling

Rig Anchoring System; During The

Pipeline Crossing by Horizontal Directional Drilling

Pipeline Crossing by Horizontal Directional Drilling

Pipeline Crossing by Thrust Boring

Pipeline Crossing by Thrust Boring

Pipeline Crossing by Thrust Boring

Pipeline Crossing - River Crossing

Pipeline Crossing - River Crossing

Pipeline Crossing - River Crossing

Hydrotest, Pigging (clean out pipeline) & Dry Pipeline

Trains Of Brush Pigs With Slugs Of Flushing

The Final Pig Is Fitted With An Aluminium

The Dewatered Section Is Then Dried

After Hydrotest The Test Section Is

Tie-in i.e. connecting to existing pipeline

Welded Joint on the Azerbaijan and Georgia Border

Tie-In: Manually Welding Joints In

Tie-In Final Product

Time Chainage Diagram

Histograms for Resources & Outputs

Site Offices, Camp Accommodation for