Oil and Gas Pipelines and Piping Systems. Design, Construction, Management, and Inspection

660 Pages·2017·1.4 MB·English

by  Alireza Bahadori

Oil and Gas Pipelines and
Piping Systems
Oil and Gas Pipelines
and Piping Systems
Design, Construction, Management,
and Inspection
Alireza Bahadori, PhD, CEng, MIChemE, CPEng,
MIEAust, RPEQ
Schoolof Environment, Science &Engineering,
Southern Cross University, Lismore,NSW,Australia
Australian Oil and Gas Services, Pty Ltd, NSW, Australia
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Dedication
Dedicated to the loving memory of my Parents,
grandparents, and to all who contributed so much
to my work over the years
Biography
Alireza Bahadori, PhD, CEng, MIChemE, CPEng, MIEAust, RPEQ,
is an academic staff member in the School of Environment, Science,
and Engineering at Southern Cross University, Lismore, NSW, Australia
and Managing Director of Australian Oil and Gas Services, Pty Ltd,
www.AustralianOilGas.com.au. He received his PhD from Curtin University,
Perth, Western Australia. During the past 20 years, he has held various
process- and petroleum-engineering positions and was involved in
many large-scale projects at National Iranian Oil Co. (NIOC), Petroleum
DevelopmentOman(PDO),andCloughAMECPtyLtd.
He is the author of approximately 300 articles and 14 books. His books
have been published by several major publishers, including Elsevier. He is
the recipient of the highly competitive and prestigious Australian
Government’s Endeavour International Postgraduate Research Award as part
of his research in the oil and gas area. He also received a Top-Up Award
from the State Government of Western Australia through Western Australia
Energy Research Alliance(WA:ERA) in2009. He serves as a member of the
editorial board and reviewer for a large number of journals. He is a chartered
member of the Institution of Chemical Engineers (IChemE, London, United
Kingdom), chartered professional engineer (CPEng), and member of The
Institutionof Engineers Australia.
xxv
Preface
In designing the pipeline and its associated piping systems, due account
should be given to the operation, inspection, and maintenance requirements
for the predicted life cycle and the planned conditions and criteria for the
operation and maintenance of the pipeline. Due regard should also be given
to manning levels, pipeline condition monitoring, and maintenance system,
remote operations, communications, means of access to the right-of-way,
bypass requirements for components needing regular maintenance without
interruption ofthe pipelineoperation, etc.
Moreover, the materials engineer shall establish the preferred materials
selection based on the process requirements such as medium, pressure, tem-
perature, flow, and the environment of the process facility. Design life and
cost considerations shall alsobe taken into accountinthis respect.
This book covers essential requirements for all aspects to be considered
in design of piping for oil, gas, and petrochemical plants to be designed,
which includes, butis notlimited to,the following:
1. Loading andunloading terminals.
2. Crude oil andgas gathering central facilities.
3. Processunits.
4. Package equipment.
5. Pump house and compressor stations(booster stations).
6. Tank farms and oil/gasdepots.
This book outlines requirements for the procedure in handing over, load-
ing, hauling, unloading, keeping an inventory list, and the storing of materi-
als required for installationof pipelines.
This book also covers requirements for trenching operations for buried
pipelines. It explains conditions of trench before pipe is laid, conditions
under which blasting can be performed, staking, and the marking and use of
excavated materials.
This book also covers requirements to be observed in clearing a right-of-
way and trenching operation in terrains containing natural rock, large
boulders, or othermaterials that have tobe removed by a blasting operation.
xxvii
xxviii Preface
This book also deals with manners to be considered in taking pipes from
stockpile and stringing along a right-of-way for subsequent welding, coating,
lowering, and backfilling.
Moreover, this book covers checking to be made in respect of cleaning of
pipe ends and interior of pipes as well as pipe condition. It also emphasizes
the necessity ofrepair beforelining uppipe andweldingintoa string.
It covers requirements for cold field bending. It describes limits to be
observed in field bending in terms of minimum bend radius as well as maxi-
mum stretching orthinning ofthe pipe wall thickness.
In addition, this book covers technical requirements for welding of pipe
over the ditch and double-jointing yard as well as laying pipe in trench,
exposed, and casing sections. The requirements include complementary tren-
ching works, considerations to be given in laying pipe when trench contains
water or mud, and test of pipe coating justbeforelaying.
This book also covers the requirements for backfilling of buried lines that
are carried out immediately after a lowering operation and before hydrostatic
testing. It explains how to check important features before performing back-
filling operation, the quality of backfill material, and considerations to be
given at crossings with waterways, roads, and irrigated lands. This book
covers clean up and restoration activities that need to be performed immedi-
ately after the pipe is backfilled.
This book outlines specific considerations to be given in the construction
of pipelines at crossings. It deals with surveys required to be carried out
beforegiving schedules andtiming for workexecution at crossings.
This book also covers requirements for installation of casings for correct
insertion of carrier pipe where pipeline crosses major public roads, freeways,
and railways. It also explains boring methods for installation of casings in
order to obviate interruption of traffic, test and installation of fabricated
assemblies, such as launchers and receivers, line break valves, isolated
valves,vent,and drain valves.
This book gives technical specifications and minimum requirements for
welding of transportation pipeline and related facilities for use in oil, gas,
and petrochemical industries, the arc welding of butt, fillet, and socket welds
in carbon and low alloy steel for liquid and gas transmission pipelines, and
relatedfacilities,includingpigtraps. The welds may beproducedbyposition
or roll welding or by a combination of position and roll welding. Roll weld-
ing is only acceptable when using a fully automatic welding process.
Oxyacetylene welding (otherwise known as gas welding) and flash butt
welding processesshall notbe used.
The standard also covers the acceptance standards to be applied to pro-
duction welds tested to destruction or inspected by radiographic, ultrasonic,
or magnetic particle techniques. It includes the inspection procedures for
usingthesetechniques.
Preface xxix
This book covers the minimum requirements for welding work to be car-
ried out for installation of on-plot piping in oil, gas, and petrochemical
industries. The book relates to the requirements pertaining to welding techni-
ques to be used, the qualification of welder/welding operators, and welding
procedures together with testing and recording involved. It also deals with
inspection, testing, and the limits of acceptability and heat treatment of pro-
ductionwelds, if required.
Thisworkcovers theminimumrequirementsofpressure testtobecarried
out on plant piping systems. Upon completion of piping systems and before
commissioning, it shall be pressure-tested in order to prove the strength of
the system, its tightness (absence of leaks), and the integrity of weldments
and materials.
This book covers the essential requirements of hydrostatic pressure test to
be carried out on off-plot piping. Upon completion of a pipeline and before
purging and commissioning operations, the line shall be high-pressure tested
in order to prove the strength of the pipeline, its tightness (absence of leaks),
and the integrity of weldments and materials. The test is also intended to
confirmacceptability of pipeline for the service.
It covers the requirements for the internal chemical cleaning of piping
systems on upstream sides of process machineries and lube oil/seal oil sys-
tems for which removal of rust, mill scale, grease, and foreign matter is
essential.
This book covers minimum technical requirements for design, manufac-
ture, quality control, testing, and finishing of pig launching and receiving
traps that are installed in oil, gas, and petrochemical industries under the ser-
vice conditions.
This book also provides technical specifications and general requirements
for the purchase of steel line pipe for use in oil, gas, and petrochemical
industries under nonsour aswell as sour conditions.
Dr.Alireza Bahadori
SouthernCross University,Lismore, NSW, Australia
May 7,2016
Acknowledgments
I would like to thank the Elsevier editorial and production team, Ms. Katie
Hammon and Ms. Kattie Washington of Gulf Professional Publishing, for
their editorial assistance.
xxxi
Chapter 1
Transportation Pipelines
This chapter provides a baseline for minimum technical requirements and
recommendedengineering practices for design ofpipelines used for transpor-
tation ofhydrocarbons inOil, Gas andPetrochemical Industries.
1.1 FLUID CATEGORIES
Based on the hazard potential of a fluid transported in the pipeline, it should
be categorized inone ofthe following four groups (Table 1.1).
1.2 DESIGN
The relevant sections of ANSI/ASME and API codes and standards referred
toandsupplementedbythischaptershouldbeusedfordesignofthepipeline
in which the operating conditions and requirements, ease of inspection and
maintenance, environmental conditions, safety requirements, geographic
location, climatic, geotechnic, and seismic conditions as well as future
changes and expansions should be taken into account over the pipeline entire
projected life cycle, including its final abandonment.
1.2.1 Operational Requirements
In designing the pipeline and its associated piping systems, due account
should be given to the operation, inspection, and maintenance requirements
for the predicted life cycle and the planned conditions and criteria as set by
and/or agreed to in advance with the personnel responsible for the operation
andmaintenanceofthepipeline.Dueregardshouldalsobegiventomanning
levels, pipeline condition monitoring and maintenance system, remote opera-
tions, communications, means of access to the right-of-way, by-pass require-
ments for components needing regular maintenance without interruption of
the pipeline operation, etc.
1.2.2 Economic Considerations (Optimization)
When there are alternatives for designing and constructing a pipeline, an
economic analysis should be carried out to determine the optimum design
OilandGasPipelinesandPipingSystems.DOI:http://dx.doi.org/10.1016/B978-0-12-803777-5.00001-0
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