DESIGN OF LONG DISTANCE OIL

PIPELINE AND ITS COMPONENTS.

K H AWA J A H A S E E B 2013-ME-125
ROHAAN AAMER 2013-ME-113
MUNEEB AHMED 2013-ME-118
ALI IMRAN 2013-ME-191

Advisor : Dr. Ghulam Moeen uddin

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 Units GARRAF BADRA

SC of residual oil at
15.6/15.6 C 0.8466 0.85

Crude oil API Gravity 35.6 35

specifications
Sulphur wt % 1.85 H2S < 50 ppm wt

Asphaltenes wt % 0.3 N/A

Pour Point C -40 -38

cSt 7.45@21.1 C 14.8@0 C

cSt 4.754@37.8 C 9.8@15 C

Kinematic Viscosity cSt 3.686@48.9 C 6.7@30 C

cSt 3@60 C 4.8@45 C

cSt 3.6@60 C
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
 Steel Property Carbon Steel Design Value

Density, kg/m 7850

API 5L X65 SMYS, MPa 450

Pipeline material
Poissons Ratio 0.3

Youngs Modulsus, MPa 207.0 x 10

Coefficient of Thermal Expansion, per K 11.7 x 10-6

Thermal Conductivity, W/m-K 50

 Piping Class 600# - 061000Y

Code ASME B31.4

Pipeline Pipe Material API 5L X65

thickness
calculation 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 Outside Diameter of Pipe D " ~ 28"

 Internal
Specified Weld Allowable Selected
Design Corrosion Calculated Selected
Nominal Size Pipe OD Minimum Yield Joint Design Factor Stress Thickness
Pressure,P Allowance Thickness Schedule
Material Strength Factor Value (NOTE 1) Remarks
i

(inch) D (mm) (Bar)

(MPa) E (MPa) (Mpa) (mm) t(mm)

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
16 406.4 70 API 5L X52 358 1.0 0.6 214.8 1.5 8.12 WT 8.74 OK
16 406.4 70 API 5L X60 413 1.0 0.6 247.8 1.5 7.24 20 7.92 OK
16 406.4 70 API 5L X65 448 1.0 0.6 268.8 1.5 6.79 WT 6.79 OK

18 457.2 70 ASTM A672 C65 241 1.0 0.6 144.6 1.5 12.57 XS 12.70 OK
 Internal
Specified Allowable Selected
Design Weld Joint Corrosion Calculated Selected
Nominal Size Pipe OD Minimum Design Factor Stress Thickness
Pressure,P Factor Allowance Thickness Schedule
Yield Strength Value (NOTE 1)
i Material Remarks

(inch) D (mm) (Bar)

(MPa) E (MPa) (Mpa) (mm) t(mm)

18 457.2 70 API 5L X52 358 1.0 0.6 214.8 1.5 8.95 STD 9.53 OK

18 457.2 70 API 5L X60 413 1.0 0.6 247.8 1.5 7.96 WT 8.74 OK

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