The function of the pipeline: Gathering pipelines Transportation pipelines, and Distribution pipelines 5 AUGUST 2014... STEEL PIPE SPECIFICATIONSPIPE DIAMETERS Steel pipe up to 12 inc
Trang 1PIPELINES DESIGN, CONSTRUCTION, OPERATION
AND MAINTENANCE
PREPARED BY
dr MOUFFAK TAHA ALI
(dr_mouffak2005@yahoo.com)
Trang 2COURSE OBJECTIVES
1 What is the function of pipelines? Classification of pipelines
2 Pipeline components
3 Pipes & pipe supports
4 Steel pipe specifications, pipe diameters
5 Expansion joints, post installation inspection
6 Pipeline design- Factors that affect the design process
7 Overview of standards that provide guidance on design, construction and
maintenance.
2 AUGUST 2014
Trang 3COURSE OBJECTIVES
8 Pipeline routing process, selection of pipeline route
9 Detailed design parameters
10 Choosing the appropriate material grade for the pipeline
11 Pipeline coating, pipeline protection
12 Pipeline construction and pipeline testing
13 Operation, operation problems
14 Pigging
3 AUGUST 2014
Trang 4WHAT IS THE FUNCTION OF PIPE LINES?
The most common means of transporting liquids and gases
What are the major differences between pipelines and other flow lines?
1.Pipelines have minimum number of curves, they have no sharp bends
2 Often either buried or inaccessible
4 AUGUST 2014
Trang 5CLASSIFICATION OF PIPELINES
Pipeline could be classified with respect to:
1 The fluid in the pipeline
Liquid
Gas
2 The pipeline buried under ground or overland or under the sea (submarine pipeline)
3 The function of the pipeline:
Gathering pipelines
Transportation pipelines, and
Distribution pipelines
5 AUGUST 2014
Trang 6THE TRANSPORTATION OF NATURAL GAS
Natural gas pipeline consist of:
1 The pipeline
2 The compression station
3 Metering station
4 Control valves & isolating valves
5 Control and operating station
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Trang 7PIPELINE COMPONENTS (EITHER LIQUID OR GAS)
1 Initial injection station (supply or inlet station)
2 Compressor / pump station
3 Partial delivery station
4 Block valve station (to isolate any segment of pipeline)
5 Pressure and flow regulating station
6 Final delivery station
7 AUGUST 2014
Trang 8PIPELINE COMPONENTS (EITHER LIQUID OR GAS)
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Pipeline components can be grouped into the following groups:
1 Pipes (include pipe supports, expansion joints etc)
2 Valves (for isolation, control flow rate , control pressure,
prevent reverse flow, and as a safety device)
Trang 9PIPELINE COMPONENTS
1 PIPES & PIPE SUPORTS
PIPE MANUFACTURING METHODS
1 Seamless pipe (pipes with no weld)
2 Electric resistance weld pipe (ERW)
3 Longitudinal-seam submerged –arc welded pipe (LSAW)
4 Spiral submerged arc-welded pipe (SSAW)
9 AUGUST 2014
Trang 10PIPE MANUFACTURING METHODS
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1 Seamless pipe (pipes with no weld)
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Trang 11PIPE MANUFACTURING METHODS
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2 Electric resistance weld pipe (ERW)
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Trang 12PIPE MANUFACTURING METHODS
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3 Longitudinal-seam submerged –arc welded pipe
(LSAW)
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Trang 13PIPE MANUFACTURING METHODS
Trang 14STEEL PIPE SPECIFICATIONS
The elements of steel pipe specification are:
1 Diameter (both external and internal)
2 Pipe nominal size
3 Nominal pipe wall thickness
4 Length of the pipe
5 The weight, the surface area(ASME B 36.10M and B 36.19) for stainless steel pipes
14 AUGUST 2014
Trang 15STEEL PIPE SPECIFICATIONS
PIPE DIAMETERS
Steel pipe up to 12 inches The inside diameter is the nominal size Steel pipe bigger than 12 inches The outside diameter is used as nominal size diameter
15 AUGUST 2014
Trang 16EXPANSION JOINTS
What is the function of expansion joints?
It is used to provide some flexibility
1 The flexibility could be in axial direction to accept the thermal expansion
3 Main applications in compressor station and pumping stations, and rarely used in over ground pipelines
4 Flexible rubber joint is used also to eliminate transmission of vibration
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Trang 17METALLIC EXPANSION JOINTS
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Trang 18FLEXIBLE RUBBER EXPANSION JOINTS
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Trang 19FLEXIBLE RUBBER EXPANSION JOINTS
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Trang 20FLEXIBLE RUBBER EXPANSION JOINTS
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Trang 21FLEXIBLE RUBBER EXPANSION JOINTS
21 AUGUST 2014
Trang 22PIPE SUPPORTS
What is the function of pipe supports?
1 Carry the weight of the pipeline + the fluid inside
2 Allow for thermal expansion in the pipeline
Types of pipe supports:
1 Fixed point supports (does not allow for any movement)
2 Floating point pipe supports
3 Hanged pipe supports which divided to:
Fixed height
22 AUGUST 2014
Trang 23PIPE SUPPORTS
Pipe supports are used to carry the pipe in the following cases:
1 Inside the pumping /compression stations
2 In over-ground pipe lines
For buried pipe lines (under ground pipelines) no supports are needed The pipeline is supported completely on soft fine sand
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Trang 24FLOATING PIPE SUPPORT
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Metal clamp on support
AUGUST 2014
Trang 25HANGED PIPE SUPPORTS – SPRING HANGERS
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Spring hangers:
1 Allow for the pipe to move in the vertical direction when
it is filled with liquid
2 Damp any vibration could happen during operation
Trang 27PIPE SUPPORTS
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Trang 28PRINCIPLES OF PIPELINE DESIGN
The following points should be covered during
the design of pipeline:
1 Effect of the environment
2 Routing process
3 Approval and legal considerations
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Trang 29PRINCIPLES OF PIPELINE DESIGN
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Trang 30PRINCIPLES OF PIPELINE DESIGN
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Trang 31PRINCIPLES OF PIPELINE DESIGN
31 Environmental considerations for onshore pipelines
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Trang 32PRINCIPLES OF PIPELINE DESIGN
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Environmental considerations for offshore pipelines
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Trang 33PRINCIPLES OF PIPELINE DESIGN
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ROUTING PROCESS
1 Pipeline route should be as short as possible
2 Onshore pipelines the route must take into consideration:
A Sensitive areas (Areas of populations, national parks, …etc)
B Environment (wildlife, archaeological);
C Geography (rocky areas, fault lines, areas of erosion)
D Crossing (road, rail ways, rivers)
E Location of compressor / pumping stations
F Location of above-ground installations
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Trang 34PRINCIPLES OF PIPELINE DESIGN
34
ROUTING PROCESS
In addition, the route of pipeline should avoid:
1 Running parallel with high-density traffic routes
2 Running parallel to electrical power lines and other oil or
gas pipelines
3 If crossing is required, the pipeline should cross
perpendicular to the road/ railway
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Trang 35PRINCIPLES OF PIPELINE DESIGN
35 Pipeline routing corridor
ROUTING PROCESS
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Trang 36PRINCIPLES OF PIPELINE DESIGN
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ROUTING PROCESS
Transmission pipeline routing
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Trang 37DETAILED DESIGN PARAMETERS
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The following points should be taken into consideration when determining the route of a pipeline:
1 Pipeline diameter (nominal size)
2 Find out the wall thickness (from the standard tables)
3 Material grade (suitable for the environment)
4 Maximum operating pressure and flow conditions
5 Operating temperature (fluid& environment temp.)
6 Pressure drop
7 Corrosion protection which is suitable for this route.
AUGUST 2014
Trang 38FACTORS THAT INFLUNCE THE LENGTH OF A
4 Wall thickness, and
5 The temperature profile
AUGUST 2014
Trang 39EQUATIONS USED IN CALCULATING THE BASIC FLOW PARAMETERS FOR GAS AND LIQUID PIPELINES
39
Trang 40CHOOSING THE WALL THICKNESS FOR THE
PIPELINE
40 AUGUST 2014
Trang 41PIPELINE COATING
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Why we coat pipelines?
The two main methods which are commonly
used to protect pipelines are:
1.Coating
2.Cathodic protection
(CP) system
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Trang 42PIPELINE COATING REQUIREMENTS
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Pipeline coating must have the following characteristics:
1.Thermal stability (will not deform under high operating
temperatures)
2.Impermeability to water and moisture;
3.Chemical stability (does not degrade owing to chemical
reaction with soil or surroundings)
4 Ease of use;
5 Economical
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Trang 43TYPICAL PIPELINE COATING METHODS
43 Typical onshore pipeline coatings
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Trang 44TYPICAL PIPELINE COATING METHODS
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Typical offshore pipeline coatings
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Trang 46For onshore pipelines, protection is usually done
through markers or concrete slabs above the pipeline
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Trang 47PIPELINE PROTECTION
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Trang 48PIPELINE CONSTRUCTION
The construction of the pipeline goes through five major steps:
1 Design, specify different component and preparation for all
required drawings
2 Pipeline built up
3 Pipeline pressure test and drain off the water
4 Cleaning, flushing and preparation for start up
5 Filling with the required fluid (crude oil or gas), and start up
48 AUGUST 2014
Trang 49WORLDWIDE PIPELINE CODES AND STANDARDS
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1 ASME B31.4
Liquid transportation systems for hydrocarbons liquid petroleum
gas, Anhydrous, Ammonia &Alcohol
Trang 50WORLDWIDE PIPELINE CODES AND STANDARDS
Trang 51PIPELINE CONSTRUCTION
Steps in the construction process:
1 Clearing, grading and trenching
2 Stringing and welding pipe segments together
3 Depositing the pipeline, backfilling and testing (hydrostatic test)
4 Restoration
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Trang 52PIPELINE CONSTRUCTION
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Clearing the area
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Trang 53PIPELINE CONSTRUCTION
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Trenching
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Trang 54PIPELINE CONSTRUCTION
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Trenching
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Trang 55PIPELINE CONSTRUCTION
55 'Stringing' the Pipe
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Trang 57PIPELINE CONSTRUCTION
57
The arc is struck and the bug
begins traveling down from a
12 o'clock position
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Trang 58PIPELINE CONSTRUCTION
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Trang 59PIPELINE CONSTRUCTION
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Trang 60PIPELINE CONSTRUCTION
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Trang 61PIPELINE CONSTRUCTION
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Trang 62PIPELINE CONSTRUCTION
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Trang 63PIPELINE CONSTRUCTION
63 AUGUST 2014
Trang 64PRESSURE TEST AND HYDROSTATIC TEST
What is the difference between pressure test and hydrostatic test?
2 Some standards keep the pressure test as:
The test which we perform it after construction directly and
before we put the line on service
Hydrostatic test is carried out periodically to be sure that no defects (corrosion)happen in the line.
The pressure value in both cases are given by the standards and codes which is applied in each case
64 AUGUST 2014
Trang 65WHY HDROTEST PIPELINES?
65 AUGUST 2014
Trang 66HYDROSTATIC TESTING
What is hydrostatic leak testing?
Hydrostatic leak testing is used to test components for leaks by pressurizing them with a liquid.
66 AUGUST 2014
Trang 67HYDROSTATIC TESTING
Method of hydrostatic testing:
1 Hydrostatic leak testing requires that a component be
completely filled with a liquid such as water
2 Pressure is slowly applied to the liquid until the required
pressure is reached (1.5 designed pressure)
3 This pressure is held for the required time at which point the component is inspected visually to locate leaks.
some standards apply the test after we put the pipeline in the
trench and covering it completely.
67 AUGUST 2014
Trang 68RECOMMENDED HYDROTEST LEVELS FROM DESIGN CODES
68 AUGUST 2014
Trang 69After the hydro test, the next stage is to dry the pipeline to ensure that no water remains on the internal pipe wall or at low spots along the pipe route.
If water or moisture is left:
1 Formation of hydrates in sweet gas pipelines
Trang 70PIPELINE DRYING & BLOWDOWNS
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Pipeline Blow down's are carried out to remove debris and dry
down the internal atmosphere to a negative due point, leaving the pipe line ready for product service.
Incorporated in the blow down process is target plate inspection and swab testing for burs and other possible contaminations.
This process is carried out for pre commissioning works also for maintenance and following tie-in works.
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Trang 72PIPELINE DRYING METHODS
72 AUGUST 2014
Trang 73PIPELINES DRYING
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Pipelines have to be dried before put into service
This necessitates a thorough drying process because the
slightest amount of residual moisture can create significant
problems for the pipeline:
1 Hydrates can form, leading to a constriction of the pipe
cross-section and
2 In the case of small-diameter branches, blocking can result.
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Trang 74DRYING METHODS
1 Methanol swabbing
Use train of pigs containing a methanol solution, followed by drying
gas such as nitrogen.
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Trang 75DRYING METHODS
2 Drying using air or nitrogen along with foam pigs
Nitrogen or air is often used as a drying gas
Foam pigs are then passed through the pipeline
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Trang 76DRYING METHODS
3 Operational drying (applicable to gas pipelines)
By carefully controlling the pressure, nitrogen gas is introduced into the pipeline along with the product.
This continues until the dew point falls to an acceptable level.
Once this is reached, the pipeline pressure is then raised up to the required operational level
76 AUGUST 2014
Trang 77DRYING METHODS
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Trang 78DRYING METHODS
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Trang 79DRYING METHODS
4 VACUUM DRYING METHOD
The vacuum drying method was applied after the dewatering with pigs
The considerable volume of 102.000 m 3 was evacuated down to 0,3
mbar(a) [29,905 in Hg (V)], which corresponds to the Dew Point of -32° C [-25.6° F] in 6 days only.
79 AUGUST 2014
Trang 80DRYING METHODS
4 VACUUM DRYING METHOD (CONTI.)
Vacuum drying Involves reducing the pressure in the pipeline until the remaining water begins to boil off This pressure is known as vapor pressure.
80 AUGUST 2014
Trang 81DRYING METHODS
VACUUM DRYING METHOD (CONTI.)
Vacuum drying consists of three phases:
Evacuation: The pressure is reduced to a level causing the water to evaporate at the ambient temperature.
Evaporation: Once this pressure is reached, it is maintained to
ensure that all the free water is evaporated.
81 AUGUST 2014
Trang 82DRYING METHODS
VACUUM DRYING METHOD (CONTI.)
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Trang 83DRYING METHODS
Final drying: The final process is to remove all water vapor from the pipeline This is achieved by further reducing the pressure using vacuum equipment, drawing the remaining vapor out of the pipeline.
83 AUGUST 2014
Trang 84PIPELINE PIGGING
Pipeline pigs are devices that are inserted into and travel
throughout the length of a pipeline driven by a product flow
Pipeline pigging is done for the following reasons
1 Pigging process remove any debris left in the line from new construction
2 To periodically remove wax, dirt and water from the pipeline (scraper pigs and brush pigs);
3 To sweep liquids from gas pipelines (spheres)
84 AUGUST 2014
Trang 85PIPELINE PIGGING
4 To separate products to reduce the amount of mixing between
different types of crude oil or refined products;
5 To control liquids in a pipeline, including two-phase pipelines
(spheres and foam pigs);
6 To inspect pipelines for defects such as dents, buckles or corrosion (“intelligent-pigs).
7 To fill lines for hydrostatic testing, dewatering following hydrostatic testing, and drying and purging operations (spheres and foam pigs);
85 AUGUST 2014
Trang 86TYPES OF PIGS
Pigs can be divided into three general categories;
1 The conventional or utility pig for "on stream" or routine
pigging,
2 The geometry pigs for inspection, and
3 The ILI (In Line Inspection) tools for metal loss and corrosion
86 AUGUST 2014
Trang 88CLEANING PIGS
88 Brush cleaning pig
AUGUST 2014
Trang 89THE GEOMETRY PIGS FOR INSPECTION
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Trang 90MAGNETIC INSPECTION TOOLS
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Trang 91ULTRASONIC INSPECTION TOOLS
91 AUGUST 2014
Trang 92COMPRESSION STATION
What is the function of the compression station?
Compression station is a system or arrangement of several
components located at intervals along a main pipeline to
maintain continues flow of the gas.
92 AUGUST 2014
Trang 93COMPRESSION STATION
What is the function of the compression station?
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Trang 94COMPRESSION STATION
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