DESIGN OF OF LONG DISTANCE DISTANCE OIL OIL PIPELINE AND ITS COMPONENTS. K HA H A W A JA J A H AS A S EE EE B
2 01 0 1 33 - ME M E -1 - 1 25 25
ROHAAN AAMER
2013-ME-113
MUNEEB AHMED
2013-ME-118
ALI IMRAN
2013-ME-191
PROJECT OVERVIEW •
Project Description and design basis
•
Project Schematic and drawings
•
Design of long distance oil pipeline on given conditions
•
Stress analysis of oil pipeline on CAESAR II
•
Design of storage tanks for crude oil
•
Hydraulic design of pumps
•
Design of scrapper launcher and receiver
•
Cost estimation
PIPELINE OVERVIEW •
Part of Badra oil field project by GAZPROM
•
Oilfield is located in Wasit governerate, Republic of Iraq
•
Pipeline runs between CPF of Badra field and tie-in at Gharraf- An Nassiriyah
•
Length of pipeline is approx. 165 km
•
LOTS with a total capacity of 284,000 BOPD
SCHEMATIC
Pipeline construction •
Scraper launcher at GBTA with closed drain vessel
•
Pressure control device at upstream of NASA
•
Block valve stations along the pipeline
•
28” pipeline for approximate length of 94.3 km
•
CP system
•
Leak detection system
•
SCADA system
Pipeline route and components •
Explain the diagram
•
Discuss different components
•
Block valve stations
•
Pig launchers
•
Types of valves used
Badra In-field lines •
17 production wells connected to one of three in-field manifolds
•
Three in-field manifolds
•
Three trunk lines connected with the CPF
•
Two mobile pigging facilities for the flow and trunk lines
Badra Export Pipeline •
One oil export pipeline
•
Block Valve Station (six stations)
•
Pigging facilities
•
Tie-In facility
Codes and Standards •
ASME B31.4 (Liquid transportations system for hydrocarbons)
•
ASME B31.3 (Process piping)
•
API 5L (Specification for pipeline)
•
API RP 5L5 (Recommended practice for Marine transportation of pipelines)
•
API RP 1102 (Recommended practice for pipeline crossing railroad & Highways)
•
API RP 1110 (Recommended practice for pressure testing of pipeline)
•
NACE-RP-02-74 (High voltage inspection of pipeline before installation)
Codes and Standards •
ASTM A82 (Standard specifications for steel wire for concrete reinforcement)
•
ASTM C150 (Standard specifications for Portland cement)
•
ASTM E165 (Standard practice for liquid penetrant Inspection method)
•
ISO 9001:2000 (Quality management system requirments)
•
ISO 8501-1 ( Prepration of steel before paint application and rust grade)
Environmental and Geo-technical data •
Max. summer temperature in shade : 34.7 oC
•
Min. winter temperature : 9.7 oC
•
Sub-Soil temperature at 1m depth in summer : 32 oC
•
Sub-Soil temperature at 1m depth in winters : 18 oC
•
Avg. Barometric pressure : 0.98-1.01 bar
•
Max. annual rainfall : 30.3mm
•
Max. wind speed : 160 km/h
Pipeline mechanical design •
Pipeline corridors & design factors
•
Pipeline wall thickness calculation methodology
•
Combined stress check methodology
•
Pipeline stability analysis
•
Upheaval buckling analysis
•
Hot and cold bending analysis
•
Seismic analysis
Combined stress check methodology •
Internal and external loads
•
Soil pressure and weight of pipe
•
According to standard ASME B31.4 section 402
•
Software used for stress analysis is CAESAR II
Description
GARRAF
BADRA
15.6/15.6 °C
0.8466
0.85
API Gravity
35.6
35
SC
Crude oil specifications
of
residual
Units oil
at
Sulphur
wt %
1.85
H2S < 50 ppm wt
Asphaltenes
wt %
0.3
N/A
Pour Point
°C
-40
-38
cSt
[email protected] °C
14.8@0 °C
cSt
[email protected] °C
9.8@15 °C
cSt
[email protected] °C
6.7@30 °C
cSt
3@60 °C
4.8@45 °C
Kinematic Viscosity
Transport Capacity •
Badra CPF Max. production will be 170 kbopd
•
Design of pipeline will increase the production to 204 kbopd
•
Garraf FCP Max. production will be 70 kbopd
•
Design of pipeline will increase the production to 80 kbopd
•
Total transport capacity is 284 kbopd
Design temperature and pressure •
Design pressure : 70 bar
•
Design temperature (AG) : 83 oC
•
Design temperature (UG) : 70 oC
•
Pipeline grade : X65
•
Roughness : 0.05mm
Pipeline material
Steel Property
Carbon Steel Design Value
Density, kg/m³
7850
API 5L X65 SMYS, MPa
450
Poisson’s Ratio
0.3
Young’s Modulsus, MPa
207.0 x 10³
Coefficient of Thermal Expansion, per ºK
11.7 x 10-6
Pipeline thickness calculation
Piping Class
600# - 061000Y
Code
ASME B31.4
Pipe Material
API 5L X65
Design Pressure
P
70 barg (1015 psig)
Specified Min. Yield Strength
S
35000 psi OR 65000 psi
Design Factor
F
0.6
Longitudinal Joint Factor
E
1
Corrosion Allowance
CA
1.5mm
Type
Seamless/EFW
Nominal Size
Pipe OD
Internal Design Pressure,P i
Material
Specified Minimum Yield Strength
Weld Joint Factor
Design Factor
Allowable Stress Value
(MPa)
E
(MPa)
(Mpa)
(mm)
t(mm)
Corrosion Allowance
Calculated Thickness
Selected Schedule
Selected Thickness (NOTE 1)
Remarks
(inch)
D (mm)
(Bar)
3/4
26.67
70
ASTM A106 Gr. B
241
1.0
0.6
144.6
1.5
2.15
160
5.56
OK
1
33.4
70
ASTM A106 Gr. B
241
1.0
0.6
144.6
1.5
2.31
XS
4.55
OK
1 1/2
48.26
70
ASTM A106 Gr. B
241
1.0
0.6
144.6
1.5
2.67
XS
5.08
OK
2
60.32
70
ASTM A106 Gr. B
241
1.0
0.6
144.6
1.5
2.96
XS
5.54
OK
3
88.9
70
ASTM A106 Gr. B
241
1.0
0.6
144.6
1.5
3.65
XS
7.62
OK
4
114.3
70
ASTM A106 Gr. B
241
1.0
0.6
144.6
1.5
4.27
XS
8.56
OK
6
168.27
70
ASTM A106 Gr. B
241
1.0
0.6
144.6
1.5
5.57
XS
10.97
OK
8
219.07
70
ASTM A106 Gr. B
241
1.0
0.6
144.6
1.5
6.80
XS
12.70
OK
10
273.05
70
ASTM A106 Gr. B
241
1.0
0.6
144.6
1.5
8.11
80
15.09
OK
12
323.85
70
ASTM A106 Gr. B
241
1.0
0.6
144.6
1.5
9.34
80
17.48
OK
14
355.6
70
ASTM A106 Gr. B
241
1.0
0.6
144.6
1.5
10.11
80
19.05
OK
16
406.4
70
ASTM A672 C65
241
1.0
0.6
144.6
1.5
11.34
WT
11.91
OK
16 16 16
406.4
70
API 5L X52
358
1.0
0.6
214.8
1.5
8.12
WT
8.74
OK
406.4 406.4
70 70
API 5L X60 API 5L X65
413 448
1.0 1.0
0.6 0.6
247.8 268.8
1.5 1.5
7.24 6.79
20 WT
7.92 6.79
OK OK
18
457.2
70
ASTM A672 C65
241
1.0
0.6
144.6
1.5
12.57
XS
12.70
OK
Nominal Size
(inch)
Pipe OD
D (mm)
Internal Design Pressure,P i
Material
Specified Minimum Yield Strength
Weld Joint Factor
Allowable Stress Value
Corrosion Allowance
(MPa)
E
(MPa)
(Mpa)
(mm)
t(mm)
358
1.0
0.6
214.8
1.5
8.95
STD
9.53
OK
413
1.0
0.6
247.8
1.5
7.96
WT
8.74
OK
Design Factor
Calculated Thickness
Selected Schedule
Selected Thickness (NOTE 1)
Remarks
(Bar)
18
457.2
70
API 5L X52
18
457.2
70
API 5L X60
18
457.2
70
API 5L X65
448
1.0
0.6
268.8
1.5
7.45
20
7.92
OK
20
508
70
ASTM A672 C65
241
1.0
0.6
144.6
1.5
13.80
WT
14.27
OK
20
508
70
API 5L X52
358
1.0
0.6
214.8
1.5
9.78
WT
10.31
OK
20
508
70
API 5L X60
413
1.0
0.6
247.8
1.5
8.68
WT
8.74
OK
20
508
70
API 5L X65
448
1.0
0.6
268.8
1.5
8.11
WT
8.74
OK
24
609.6
70
ASTM A672 C65
241
1.0
0.6
144.6
1.5
16.26
40
17.48
OK
24
609.6
70
API 5L X52
358
1.0
0.6
214.8
1.5
11.43
WT
11.91
OK
24
609.6
70
API 5L X60
413
1.0
0.6
247.8
1.5
10.11
WT
10.31
OK
24
609.6
70
API 5L X65
448
1.0
0.6
268.8
1.5
9.44
20
9.53
OK
28
711.2
70
ASTM A672 C65
241
1.0
0.6
144.6
1.5
18.71
WT
19.05
OK
28
711.2
70
API 5L X52
358
1.0
0.6
214.8
1.5
13.09
WT
14.27
OK
28
711.2
70
API 5L X60
413
1.0
0.6
247.8
1.5
11.55
WT
11.91
OK
28
711.2
70
API 5L X65
448
1.0
0.6
268.8
1.5
10.76
WT
11.13
OK
