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EQUIPMENT & MANPOWER PLANNING FOR PIPELINE CONSTRUCTN

3 replies [Last post]
SANJEEV KOUL
User offline. Last seen 6 years 18 weeks ago. Offline
Joined: 2 Mar 2007
Posts: 18
WE HAVE TO EXECUTE A 56 INCH DIA ONSHORE U/G GAS PIPELINE 690 KM LONG.WE HAVE PREPARED AN EPC MASTERSHEDULE FOR THIS PROJECT.WE HAVE A TOTAL DURATION OF 42 MONTHS FOR THIS EPC WORK.WE ARE PLANNING TO GET THE WORK OF CONSTRUCTION EXECUTED THROUGH 2 CONSTRUCTION SUBCONTRACTORS FOR PIPELINE CONSTRUCTION AND SEPARATE SUBCONTRACTS FOR TERMINAL CONSTRUCTION.

THE CONSTRUCTION SCHEDULE FOR THE PIPELINE IS AS UNDER ;-

***********************************************************

ACTIVITY DESCRIPTION FROM TO


Mobilization of manpower ,
machinery etc 07/12/09 04/02/10


ROW survey and marking ,
Clearing and ROW grading 06/01/10 18/02/11


Trenching 05/02/10 14/06/11

Stringing 19/02/10 08/08/11

Bending 26/02/10 22/08/11

Welding O5/03/10 17/09/11


X- ray / NDT ( above ground) 12/03/10 25/09/11
, Joint Repair ,
Joint Coating


Trench bottom padding ,
Lowering, top padding ,
backfilling 19/03/10 09/10/11


Tie - in - joints and
mainline valaves, welding,
X-ray and repair , joint
coating 31/03/10 23/10/11

Tie - in - Joint top
padding and backfilling 14/04/10 06/11/11


Hydrotesting 14/07/10 06/12/11

Restoration of ROW 12/09/10 17/12/11

***********************************************************

NOW BASED ON THE ABOVE CONSTRUCTION SCHEDULE , THE EQUIPMENT AND MANPWER PLANNING PLANNING ie THE PLANNING FOR RESOURCE ASSIGNMENT IS TO BE DONE FOR THE ABOVE PIPELINE SCHEDULE.

FIRSTLY FOR THE PURPOSE OF EXECUTION THE PIPELINE IS TO BE DIVIDED INTO SECTIONS OF APPROPRIATE LENGTHS KNOWN AS SPREADS.I REQUEST YOUR ASSISTANCE IN FIRSTLY FIXING THE PROPER LENGTH , NUMBER AND ARRANGEMENT OF SPREADS ALONG THE PIPELINE.I HAVE ALSO TO LOGICALLY PRESENT TO MY MANAGEMENT THE JUSTIFICATION (PREFERABLY CALCULATION TOO - IF APPLICABLE) FOR FIXING THIS SPREAD LENGTH.

THEREAFTER THE RECOMMENDED DISTRIBUTION OF EQUIPMENT FOR EACH SPREAD (WITH RATINGS ie TONNAGE ETC OF THE EQUIPMENT) IE NO DOZERS , GRADERS , EXCAVATORS / POCLAIN ,ROCK - BREAKERS WITH HYDRAULICALLY OPERATED CHISELS,PIPE BENDING MACHINES PIPELAYERS/SIDEBOOMS , ETC IS REQUIRED TO BE PROVIDED.THIS DISTRIBUTION OF EQUIPMENT HAS TO BE LOGICALLY WORKED OUT AND IS TO BE BASED ON RECOMMENDED EQUIPMENT RATING , STANDARD MACHINEHOUR NORMS , AND TOTAL ESTIMATED QUANTUM OF WORK eg EARTHWORK / GRADING AREA ETC.

LIKEWISE RECOMMENDED DISTRIBUTION OF MANPOWER , WELDERS , RIGGERS , INSULATORS , ETC IS TO BE WORKED OUT BASED ON ESTIMATED QUANTITY OF WELDING LENGTH AND WELD VOLUME ETC AND STANDARD MANHOUR NORMS FOR PIPELINE WELDING ETC.

IT IS ALSO REQUIRED TO WORK OUT THE RATING AND DISTRIBUTION OF WELDING MACHINES FOR THE SPREADS SO CONSIDERED.

ALL THE MANPOWER AND EQUIPMENT PLANNING ABOVE IS TO BE PRODUCED IN A SYSTEMMATIC ,TRACEABLE AND VERIFYABLE MANNER.

ANY HELP FROM PEOPLE EXPERIENCED IN THIS FIELD SHALL BE HIGHLY APPRECIATED. ESPACIALLY I REQUEST HELP FOR FIXING OF SPREAD LENGTHS ,NO OF SPREADS, RECOMMEN
-DATION FOR RATING OF EQUIPMENT , MACHINEHOUR NORMS FOR EQPT WITH SPECIFIC RATING AND MANHOUR NORMS ESP FOR WELDERS.

IN ABSENCE OF DETAILS REGARDING HARD ROCK / ROCK STRATA AND SLOPE (IE TERRAIN)THE SAME CAN BE SUITABLY ASSUMED AT PRESENT AND THE ASSUMPTION SO MADE HAS TO BE CLEARLY MENTIONED.THE SAME CAN ME MODIFIED AT A LATER STAGE AS MORE AND ACTUAL DETAILS COME WITH SOIL INVESTIGATION AND TOPOGRAPHIC SURVEY.


Replies

Ben Robertson
User offline. Last seen 6 years 17 weeks ago. Offline
Joined: 24 Sep 2007
Posts: 4
To Mr. Sanjeev Koul.

I read your posts with interest. I have been involved in laying over 9,000 miles of pipelines on five continents in the last 52-years. I have worked as a spread engineer (for the contractors’ planning), as a pipeline bending engineer/bending foreman, as a pipeline superintendent and as a pipeline consultant.

Could you supply the following information?
What country and area of that country is the job in?
What is the expected weather?
What are the different pipe thicknesses?
What pipe yield-X-65 (?), X-70(?) or X-80(?) or what?
Does the contractor have a choice of welding procedures-Manual (stick rod or Semiautomatic-maybe a combination of both) or pure automatic?
Have you figured in two double-jointing yards? This is dependent on conditions (and widths) of roads to allow 24 meters to be hauled? Weight capabilities and weigh limits of bridges are also a consideration.
Also running double-jointing yards assumes there will be a timely supply of single length joints to the yards.
Can you estimate what per cent of total job are flat or rolling hills, swamps, sand or sand dunes, land requiring de-watering, sharp hills and mountains?
What percent is normal dirt (easily cut by excavators or wheel trenchers), soft rock (like sandstone, sedimentary rock) or aggregate rock (like American caliche or African Laterite) or very hard rock (like granite, chert)?
What is the countryside like? Open, deserts, farmers fields, lightly forested, heavily forested, rice fields, swamps or rainforest and jungles?
What type of coating will be used?

Some points: Automatic welding would be my first choice. These pipe gangs can make more (and better) welds, per day, than a stick or semiautomatic crew. That is with a lower number of welders. They are expensive to rent the automatic welding equipment and to run due to a greater number of men in the crew. There is a lot more equipment (and operators) on the right-of-way. There are pipe facing- machine carrier side booms and many more Pay welder machines.

We did 1,000 kilometers of 40-inch crude oil line across Turkey out of Iraq in 1975& 1976. We used only one spread (or you might say a “Super Spread). The pipe was hauled from the Mediterranean Sea port to various stock piles near road crossings by 100 cab-over Daf stringing trucks. Pipe was loaded on off-road trailers that were pulled by dozers, big front loaders and ex-Swiss Army 6x6 trucks down the right-of-way... The stringing crew ran day and night (with special lighting) and could get on an average of 1,000 single pipes strung in 24 hours.

The welding crews, of which there were three on one spread, could weld an average of 450-40-inch welds daily (if every thing worked well, with no major breakdowns of welding gear). I ran two bending crews, with one running 24-hours a day (with special lighting) and one running 16 hours a day. All crews worked seven 16-hour days, counting travel times.

The biggest pipe I have been involved with was a 400-kilometer of 48” job in Southern Mexico. There may be some differences in laying 56-inch pipe, compared to 48-inch.pipe

I have good friend that has many years of experience in laying 56-inch pipelines. I will ask him how he would rig this up as far as number of spreads, equipment in each crew, etc. My thoughts would be by using 2 Super Spreads for the 690 kilometers, with the use of two double jointing yards. One should put two bending machines on each spread. That would be a total of 4 bending machines and 8 big (cat 594 or Cat 589 pipelayers or Komatsu D-355 or Converted-to-side boom, dozers- Komatsu D-375 pipelayers.

I would rig up two pipe gangs on each spread... If any other crew needs more equipment or people to stay ahead, it can be easily added. Instead of running 4 spreads with the need to have multiple camps for each spread, these cuts down the cost of buying them and the bother of moving them.

There are several pieces of equipment new on the market, but not too well known. If you will send me an e-mail to ben.robertson@sbcglobal.net, I will attach the details of some of them, in a return e-mail.

For instance, there is a new Multi Ripper excavator bucket (several models) that can break up and remove rock from the trench. It makes 4 to 5 times more progress than a hydraulic rock pick, each day and sometimes eliminates the need for an expensive rock saw trencher (and eliminates the hassle of moving each) or rock blasting.

Regards,
..
Ben
SANJEEV KOUL
User offline. Last seen 6 years 18 weeks ago. Offline
Joined: 2 Mar 2007
Posts: 18
Ashraf
Thanks for the valuable tips.I need some cofirmation / clarification from you in connection with spread lengths etc and i shall write a mail to in this connection separately.
ragards
Sanjeev
Ashraf Jahangeer
User offline. Last seen 2 years 43 weeks ago. Offline
Joined: 8 May 2007
Posts: 144
SANJEEV,

The productivity norms must be available with your company if they are in the business. Do not hesitae to ask for it as this will save lots of time for you.

Once you have it the steps for planning are as follows.

1) The number of teams to work simultaneously shall be calculated based on your companies productivity norms and the schedule.

2) Study the route of pippeline. It is recommnded to choose all town/habitataed location for setting up of base camps.

3) The distance between spreads must be optimized to minimize transportation time and the effort in setting-up a base camp.

4) The method generally followed is that say we start form point A and move upto 50 km forward then the next camp shall be 100 km from A as to cover 50 km forward and 50 km backward.

5) I am not sure about your pipeline sub-contract but it is recommended to have different stretch for both these sub-contractors to avoid conflict.


Hope the above are useful to you.


Regards,


Ashraf