PIPELINE DESIGN & CONSTRUCTION: A Practical...

PIPELINE DESIGN &CONSTRUCTION:

A Practical Approach

Third Edition

By

M. MohitpourH. GolshanA. Murray

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Library of Congress Cataloging-in-Publication Data

Mohitpour, Mo

Pipeline design & construction : a practical approach / by M. Mohitpour, H.

Golshan, A. Murray. –3rd ed.

p. cm.

ISBN 0-7918-0257-4

1. Pipelines–Design and construction. I. Golshan, H. (Hossein) II. Murray, A.

(Matthew Alan) III. Title

TJ930 .M57 2007

621.8’672–dc21 2007057760

#

ii


TABLE OF CONTENTS

Acknowledgments ix

Foreword xiii

Dedication xv

Preface xvii

Metric Conversion Table xix

Chapter 1 Elements of Pipeline Design 1

Introduction 1

Fluid Properties 2

Environment 2

Effects of Pressure and Temperature 3

Supply/Demand Scenario, Route Selection 7

Codes and Standards 8

Environmental and Hydrological Considerations 8

Economics 12

Materials/Construction 15

Operation 16

Pipeline Protection 17

Pipeline Integrity Monitoring 19

References 21

Chapter 2 Pipeline Route Selection, Survey, and Geotechnical Guidelines 23

Introduction 23

Preliminary Route Selection 23

Key Factors for Route Selection 24

Engineering Survey 31

Legal Survey 36

Construction/As-Built Survey 36

Geotechnical Design 44

References 55

iii


Chapter 3 Natural Gas Transmission 57

Introduction 57

General Flow Equation — Steady State 57

Natural Gas Higher and Lower Heating Values 66

Impact of Gas Molecular Weight and Compressibility Factor on Flow Capacity 72

Flow Regimes 75

Widely Used Steady-State Flow Equations 79

Summary of the Impact of Different Gas and Pipeline Parameters on the Gas

Flow Efficiency 84

Pressure Drop Calculation for Pipelines in Series and Parallel 84

Pipeline Gas Velocity 93

Erosional Velocity 95

Optimum Pressure Drop for Design Purposes 97

Pipeline Packing 97

Determining Gas Leakage Using Pressure Drop Method 98

Wall Thickness/Pipe Grade 101

Temperature Profile 107

Optimization Process 111

Gas Transmission Solved Problems 119

References 128

Chapter 4 Gas Compression and Coolers 129

Introduction 129

Types of Compressors 129

Compressor Drivers 131

Compressor Station Configuration 135

Thermodynamics of Isothermal and Adiabatic Gas Compression 137

Temperature Change in Adiabatic Gas Compression 144

Thermodynamics of Polytropic Gas Compression 149

Gas Compressors in Series 153

Centrifugal Compressor Horsepower 162

Enthalpy/Entropy Charts (Mollier Diagram) 166

Centrifugal Compressor Performance Curve 169

Influence of Pipeline Resistance on Centrifugal Compressor Performance 174

Reciprocating Compressors 188

Gas Compression Solved Problems 191

Gas Coolers 215

Introduction 215

Air-Cooled Heat Exchangers 215

Cooler Heat Transfer Equations 216

Fan Air Mass Flow Rate 221

Required Fan Power 221

iv A Table of Contents


Gas Pressure Drop in Coolers 222

Iterative Procedure for Calculations Based on Unknown T2 224

References 225

Chapter 5 Liquid Flow and Pumps 227

Introduction 227

Fully Developed Laminar Flow in a Pipe 227

Turbulent Flow 231

Centrifugal Pumps 239

Retrofitting for Centrifugal Pumps (Radial-Flow) 258

Pump Station Control 259

Pump Station Piping Design 261

References 261

Chapter 6 Transient Flow in Liquid and Gas Pipelines 263

Purpose of Transient Analysis 263

Background 263

Theoretical Fundamentals and Transient Solution Technique 265

Applications 268

Computer Applications 282

References 311

Chapter 7 Pipeline Mechanical Design 313

Introduction 313

Codes and Standards 313

Location Classification 313

Pipeline Design Formula 314

Expansion and Flexibility 320

Joint Design for Pipes of Unequal Wall Thickness 335

Valve Assemblies 363

Scraper Traps 372

Buoyancy Control 380

Crossings 395

Depth of Cover 403

Aerial Markings 404

Warning Signs 404

References 404

Chapter 8 Materials Selection and Quality Management 407

Introduction 407

Elements of Design 407

Table of Contents A v


Materials Designation Standards 427

Quality Management 431

Summary 440

References 440

Chapter 9 Pipeline Construction 443

Introduction 443

Construction 443

Trenchless Crossings 464

Filling and Hydrostatic Testing 488

Dewatering 492

Evaluation of Squeeze Volumes 493

Hydrostatic Test Sections Containing Trapped Air 497

Hydrostatic Water Criteria 500

Hydrostatic Testing at Low Ambient Temperatures 502

Pneumatic Testing of Pipelines 504

Commissioning 506

References 514

Chapter 10 Pipeline Protection 517

Introduction 517

Pipeline Coating 517

Cathodic Protection 524

Cathodic Protection Calculations for Land Pipelines 536

Internal Corrosion 542

References 542

Chapter 11 Pipeline Integrity 543

Introduction 543

References 564

Chapter 12 Specialty Fluid Transmission 565

Introduction 565

Batched Products Pipeline Design & Operational Uses 589

Carbon Dioxide Pipeline Transmission 590

Fundamentals of LPG Pipelining 647

References 677

Glossary of Terms 683

Appendices

A - Route Selection for Project Success: Addressing ‘‘Feeling/Perception’’

Issues 691

vi A Table of Contents


B - Impact of Different Gas and Pipeline Parameters on Flow Efficiency

of the Pipeline 705

C - Temperature Computations in Fluid Transmission Pipelines 711

D - Sample Calculations from Chapter 9 723

p Hydrostatic Yield Plot 723

E - Cathodic Protection Problem Solution 725

Index 727

Table of Contents A vii


ACKNOWLEDGMENTS

There were many contributors who helped with the preparation of this book, and the authors

would very much like to acknowledge and thank all those listed below. First are the sponsors

and the original contributors without whom this book would not have been possible. The

backbone of this book is the material initiated and prepared by the primary author

(M. Mohitpour) for the course "Innovation in Pipeline Design and Construction Course" at

the Faculty of Continuing Education, University of Calgary, Alberta, Canada. This course

was initiated in October 1988 by NOVA Gas International Ltd., now TransCanada

Corporation (due to a merger of NOVA and TransCanada in July 1998), and has been since

offered annually. The funds thus generated by the author from the course were allocated to a

scholarship fund established under the auspices of the American Society of Mechanical

Engineers (ASME), OMAE Calgary Chapter set up at the University of Calgary, Alberta,

Canada. Also authors proceeds from the sale of the 1st edition of the book was directed to

ASME Pipeline Scholarship Fund that as well was set up at the University of Calgary.

PRIMARY SPONSOR (1ST EDITION)

The authors are grateful to TransCanada for sponsorship of the entire project, specifically

for services received, financial sponsorship and above all permission granted for use of

internally developed materials for preparation of the first edition of this book. Special

thanks is due to the leadership of TransCanada (present & former), specifically Ron Turner,

Ms. Shelagh Ricketts, Messrs. Ardean Braun, Andrew Jenkins, David Montemurro, Dave

Cornies, at TransCanada for their continual support of the project.

PROJECT CONTRIBUTORS

Thanks are due to the authors’ colleagues at TransCanada and those of the former NOVA,

who in many ways contributed to the preparation and delivery of the material in this book.

Acknowledgment is due to Marezban Canteenwalla, Dr. Iain Colquhoun, Dave Detchka,

Bob De Wolff, John Kazakoff, Michael McManus, Cliff Mitchel, Mark Wright, Neal

Russell, Tom Slimmon, Keith Coulson, Rick Spittal, William Thompson, Bill Trefanenko,

Trent Van Egmond, Doug Waslen, Robert Worthingham, and Chuck Middleton. Without

their initial contributions, the original lecture series at the University of Calgary, which led

to the eventual preparation of this book, would not have occurred.

GRAPHICS DESIGNER AND TECHNICAL WRITER/EDITOR

A project such as this, of course, owes its completeness to the technical writer/editor and

reviewers, who kept a quality check on the timeliness of content and accuracy of the

information included.

ix


Therefore, it is with deep gratitude that the authors acknowledge ASME publications,

specifically Mr. Philip DiVietro, Ms. Mary Grace Stefanchik and Ms. Tara Smith for their

tremendous encouragement and commitment toward completion of this work.

We are also grateful to Ms. Daphne McIntyre and Ms. Karla Ferbey for their diligence

and technical know-how in preparing the text. We would like to thankMs. CamillaWilliams

(Robinson) of TransCanada for her detailed review of the book’s content and Joel

Brimacombe (University of Saskatchewan) for creating many of the figures appearing in

this book.

ERRATA

Acknowledgment is due to many colleagues and associates whom have reported

typographical errors and omissions noted in the 1st edition of the book. We are grateful

to Messrs E.J. Seiders, Doug James, Bill Leighty, Chia Hong Kiat, Marina Marchenkova,

Keith Coulson, and Bill Tyson.

M. Mohitpour, Ph.D., P.E., F.I.Mech.Eng, Fellow.EIC, FASME

[email protected]

H. Golshan, Ph.D, P.Eng.

[email protected]

A.Murray, Ph.D, P.Eng.

[email protected]

x A Acknowledgments


PERMISSIONSACKNOWLEDGMENT

The authors wish to thank all of the organizations that kindly granted their permission to

reprint their figures and tables in this book. Details regarding these items and their formal

acknowledgment appear below:

Chapters 3, 4 The McGraw-Hill Companies

and 8 Figures 3–3, 4–14 and 4–26: From Handbook of Natural Gas

Engineering by D. Katz, et al. copyright 1990. Figure 8–14 From

book ‘‘Profitable Procurement Strategies’’, 1998. These figure are

‘‘reproduced with the permission of The McGraw-Hill Companies’’.

Chapter 5 Marcel Dekker, Inc.

Figure 5–7: Reprinted from Chemical Engineering Fluid Mechanics,

p. 239, by R. Darby, courtesy of Marcel Dekker, Inc.

Chapter 7 CSA International

and 11 Chapter 7 tables (7–1, 7–2, 7–3, 7–4 ) and Figures 7–11, 7–18 as

well as Chapter 11, figures 11–6 and 11–7. With the permission of

CSA International, material is reproduced from CSA Standard CAN/

CSA-Z662, Oil and Gas Pipeline Systems, which is copyrighted by

CSA International, 178 Rexdale Blvd., Etobicoke, Ontario, M9W 1R3.

Chapter 12 Elsevier Science

Figures 12–34 a and b: Reprinted from PHYSICA, Vol. 25, Michels

et al, ‘‘Compressibility Isotherms of hydrogren...’’, T-S Diagrams,

pp. 25, Copyright 1959, with permission from Elsevier Science.

The authors also gratefully acknowledge the following organizations for permission

granted to reproduce various items that appear in the text:

American Gas Association—PRCI

American Petroleum Institute

CRC Press LLC

Crane Company

Daniel Industries Canada

David Brown Union Pumps (Canada) Limited Entec Inc.

Gas Processors and Suppliers Association (GPSA)

xi


Hydraulic Institute

John M. Campbell & Co.

Institute of Gas Technology

Institute of Materials

KTAB-TV

National Fire Protection Association

Pipeline and Gas Journal, Petroleum Engineer Publishing Company

Standby Systems

Welding Technology Institute of Australia

xii A Permissions Acknowledgment


FOREWORD

"Pipeline Design & Construction - A Practical Approach" was first published in October

2000 at the time of ASME International Pipeline Conference in Calgary, Alberta,

CANADA. The second edition of this book was published in October 2003.

This publication has been a resounding success due to its practical approach in the

development of pipeline systems from inception through to design, construction, operations

and maintenance. The authors have substantially upgraded the book for the 3rd edition.

"Pipeline Design & Construction - A Practical Approach" evolved from training

courses initiated by M. Mohitpour in 1988 in response to the pipeline community’s need

to educate those in the industry’s hierarchy, and the training and development needs of

those entering the profession. These courses have been offered worldwide since that time

by the authors.

The content of the book, generated by the considerable knowledge and experience of

the authors, is augmented by current industry practices, some of which has been made

available by TransCanada Corporation, one of the world’s largest pipeline companies. I am

very pleased that this experience and knowledge continues to be available to the pipeline

industry through the publication of this third edition.

Shelagh Ricketts

Vice President: Systems Design & Operations

TransCanada Corporation

September 2006, Calgary, CANADA

xiii


DEDICATION

This book is dedicated to all those pipeliners who baffle a novice on ‘‘pigging a pipeline.’’

These pipeliners are the real contributors to our technological advancements because

without them progress in the pipelining industry would have been very limited. Where there

is the largest advanced network of pipelines, there is also the most progress in technological

development. It is dedicated to an industry whose breadth of expertise has been a principal

party to these advancements. It is dedicated to the future of the pipeline industry.

xv


PREFACE

"Pipeline Design and Construction: A Practical Approach" is designed to assist the

education and learning of those interested in designing, building and managing pipelines.

The book provides a practical way to learn about the elements that make up a single-phase

liquid and gas pipeline system, as well as a rational way to design, construct, commission,

and assess pipelines and related facilities. It is a reference material for those involved in the

industry and a tool for training new entrants or for refreshing the knowledge of

professionals. Materials for compilation of the book have been gathered from the authors’

collective experience totaling more than 65 years of service in the industry, covering all

aspects of gas and liquid transmission; compression, pumping, protection and integrity;

procurement services; construction, commissioning and operation; as well as management

of pipeline projects. It also draws upon materials researched by the authors from outside

sources and materials developed by the authors’ employer, TransCanada.

The layout of the book generally presents, in a logical manner, the sequential steps in

the design, construction and integrity maintenance of the pipeline.

Where possible, mathematical models are presented from basic principles developed

by the authors or obtained from other sources. Examples and case studies are described in

some detail for illustrative purposes. In some chapters, application - oriented examples,

with sketches and descriptions of systems, are presented and discussed. References and

bibliographical guides are presented to the reader for additional information.

In this book, a mix of imperial and metric units is utilized; however, corresponding

metric conversions are provided for imperial units. The use of both systems is justified

because the industry uses them interchangeably.

While every care has been exercised by the authors to contact copyright holders and

obtain permissions and reference materials, avoid errors and omissions, and provide

information adequately, it is not intended that specific examples, or applications be copied

for turnkey use. Readers are encouraged to check formulations and other details prior to

use. Notifications of corrections, omissions and attributions are welcomed by the authors.

xvii


METRIC CONVERSION OF SOMECOMMON UNITS

TO CONVERT FROM

CUSTOMARY UNIT

TO DEFINE UNIT 1 SYMBOL MULTIPLY BY

barrel per hour liters per second L/s 0.044 163

barrel per day cubic meters per day m3/d 0.158 987

MMBOD cubic meters per day m3/d 0.158 987 � 106

Btu/second kilowatt kW 1.055 056

Btu/hour watt W 0.293 071

Btu/lbm kilojoule per kilogram kJ/kg 2.326

Btu/lbm-8F R kilojoule per kilogram-

kelvin

kJ / (kg.K) 4.1868

Btu/lbm-mole-8R joule per mole-kelvin J / (mol.K) 4.1868

Btu/8R kilojoule per kelvin kJ/K 1.8991

Btu/ft2-hr. joule per sq. meter-

second

J / (m2.s) 3.154 591

Btu/ft-hr-8F joule per meter-second-

kelvin

J / (m/s.K) 1.730 735

joule per square meter-

second kelvin

J / (m2.s.k) 5.678 263

foot-pound force (ft. lbf) joule J 1.355 818

foot2 square meter m2 0.092 903

foot3 cubic meter m3 0.028 316 85

foot3/minute liter per second L/s 0.471 947

foot3/hour cubic meter per day m3/d 0.679 604

MMSCFD cubic meter per second m3/s 0.327 774

gallon/minute (GPM) liter per second L/s 0.063 090

inch2 square centimeter cm2 6.451 600

inch3 cubic centimeter cm3 16.387 064

kilowatt-hour (kWh) megajoule MJ 3.6

mile per hour kilometer per hour km/h 1.609 344

pound kilogram kg 0.453 592 37

pound force/foot2 (psf) pascal Pa 47.880 258

pound mass/foot3 (lbm/ft3) kilogram per cubic

meter

kg/m3 16.018 463

pound mass/gallon kilogram per liter kg/L 0.119 826

pound mass/hour kilogram per hour kg/h 0.453 592

psi kilopascal kPa 6.894 757

Btu

ft2 hr F- -8

xix


TO CONVERT FROM

CUSTOMARY UNIT

TO DEFINE UNIT 1 SYMBOL MULTIPLY BY

psi/foot kilopascal per meter kPa/m 22.620 59

psi/mile pascal per meter Pa/m 4.284 203

Watt-hour kilojoule kJ 3.6

yard2 square meter m2 0.836 127

yard3 cubic meter m3 0.764 555

acre square meter m2 4,046.856

atmosphere (std) kilopascal kPa 101.325

barrel (42 gal) cubic meter m3 0.158 987

Btu (International Table) kilojoule kJ 1.055 056

calorie (Thermochemical) joule J 4.184

degree F degree Celsius 8C 5/9 (8F-32)degree R degree kelvin K 5/9

foot meter m 0.3048

gallon (U.S. liquid) liter L 3.785 412

horsepower (U.S.) kilowatt kW 0.7457

inch (U.S.) millimeter mm 25.4

inch of mecury (608F) kilopascal kPa 3.376 85

inch of water (608F) kilopascal kPa 0.248 843

mil micrometer �m 25.4

mile (U.S. statute) kilometer km 1.609 344

ounce (U.S. fluid) milliliter mL 29.573 53

poise pascal-second Pa.s 0.1

stokes square centimeter per

second

cm2/s 1

ton, long (2,240 lbm) ton t 1.016 047

ton, short (2,000 lbm) ton t 0.907 184 74

ton of refrigeration kilowatt kW 3.516 853

yard (U.S.) meter m 0.9144

NOTE: Multiply factors for compounds units. For example:

1. To convert lb/ft3 to kg/m3, multiply

1 lb

ft3� 0:45536 kg

lb� ft3

ð0:3048Þ3 m3

2. To convert a viscosity at 258C of 0.548 centistoke to viscosity in centipoise, obtain

0:548 centistoke

1� 1 cm2=s

1 centistoke� mm2=s

100 cm2=s¼ 0:00548 mm2=s

Now multiply by the flow density �kgmm3 to determine the viscosity in centipoise:

0:00548 mm2

s� �

kg

mm3¼ 0:00548� centipoise

xx A Pipeline Design and Construction: A Practical Approach


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