Pipeline Design Philosophy

FIELD ENGINEERING LIMITED

PROSERVE

OGABIRI GAS GATHERING PROJECT.

THIRTY-SEVEN KILOMETER PIPELINE MATERIAL DATASHEET OF

OGABIRI GATHERING PROJECT.

DCC NUMBER: PROS/OGBR/PIP/RPT/151003

RO2 01/12/2015 IFR A.R.O. A.M. E.C.U.

RO1 04/11/2015 IDC A.R.O. A.M. E.C.U.

Revision Date: Status: Issued by Checked by Approved by COMPANY

Approval

THIRTY-SEVEN KILOMETER PIPELINE MATERIAL DATASHEET OF OGABIRI GAS GATHERING

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TABLE OF CONTENTS

Page

List of Illustrations --------------------------------------------------------------------------------- 3

List of Tables --------------------------------------------------------------------------------------- 3

List of Abbreviations ------------------------------------------------------------------------------ 3

1.0 INTRODUCTION -------------------------------------------------------------------------- 5

1.1 BACKGROUND ----------------------------------------------------------------------- 6

1.2 SCOPE OF WORK --------------------------------------------------------------------- 7

1.3 ACKNOWLEDGEMENT -------------------------------------------------------------- 7

1.4 DESIGN INTERFACE ------------------------------------------------------------------ 8

2.0 FORWARD ------------------------------------------------------------------------------- 10

3.0 TECHNICAL DATA FOR OGABIRI GAS GATHERING PROJECT ---------- 11

3.1 DIMENSION FOR PIPELINES -------------------------------------------------------- 11

3.2 QUANTITIES ---------------------------------------------------------------------------- 12

3.3 ANTICORROSION --------------------------------------------------------------------- 13

3.4 RESULTS OF DETAILED DESIGN AND ENGINEERING --------------------- 14

4.0 CONCLUSION -------------------------------------------------------------------------- 17

REFERENCE DOCUMENT-----------------------------------------------------------------------------17

DOCUMENT HIERARCHY-----------------------------------------------------------------------------17

LIST OF ILLUSTRATION

Fig.1.0 Map Outlay of Ogabiri Gas Gathering Project------------------------------------------------ 6

Fig.1.1 Pipesim Simulation Network of the Ogabiri Gas Gathering Project-----------------------8


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Fig.1.2 Hysis Simulation Network of the Ogabiri Gas Gathering Project----------------------9

LIST OF TABLES

Table.3.1. Dimension for Pipelines -------------------------------------------------------------------8

Table.3.2.Quantities ------------------------------------------------------------------------------------12

Table.3.3.Anti-corrosion -------------------------------------------------------------------------------13

Table.3.4. Result of Detailed Design and Engineering --------------------------------------------14

LIST OF ABBREVIATIONS/ACRONYMS

ASME– American Society of Mechanical Engineering.

ASTM– American Society of Testing and Material.

13 Cr - 13-Chrome

16” - Twenty inches

oC - Degrees Celsius

C/S – Cladded Steel

CFC – Chlorofluorocarbon

CO - Carbon monoxide

CO2 - Carbon dioxide

DNA – Deoxyribonucleic Acid.

DSAW - Double Submerged Arc Welded

ELPS – Escravos Lagos Pipeline System.

ERW - Electric Resistance Welded

FBE - Fusion Bonded Epoxy.

FEED – Front End Engineering Drawing.


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GHG – Greenhouse Gas.

GRE - Glass Reinforced Epoxy

HDPE - High Density Polyethylene

HCFC – Hydrochlorofluocarbon

ISO - International Standard Organization

M/F - Manifold

m/s - meter per second

NGC – Nigerian Gas Company.

NNPC – Nigerian National Petroleum Corporation.

NO2 - Nitrogen dioxide

N2O – Di-nitrogen oxide

NO- Nitrous oxide

NOx – Nitrogen-Oxygen compounds.

OPEC – Organization of Petroleum Exporting Countries.

PVC - Polyvinyl casing

ROW - Right of Way

RTP - Reinforced Thermoplastic

SCF – Standard Cubic Feet.

SPDC - Shell Petroleum Development Company

UNFCCC – United Nations Framework Convention on Climate Change.

NGS– Nigerian Gas Station.

API– American Petroleum Institute.

WAGC– West African Gas Company.


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1.0 INTRODUCTION

The world as a global village is confronted presently with the threat of extinction as a result of incessant

emission of dangerous gases such as carbon dioxide(CO2), NOx (N2O,NO,NO2), Hydrogen Sulfide(H2S),

Halocarbons(CFCs and HCFCs), methane, HO radicals, etc. These are responsible for the destruction of

the stratospheric ozone layer, that protects the earth from harmful ultraviolet radiation, also known as

Green House Gases (GHG), and has subjected the global community to a disastrous ecological imbalance

known as Ozone Layer Depletion, which resulted to a catastrophic phenomenon called Global Warming,

a precursor of climate change and other pandemic effects, such as the damaging of the DNA of plants and

animals, skin cancers, cataracts, etc.

These gases are mainly anthropogenic in nature (i.e. caused by human factors) and are mostly due to gas

flaring. No wander, the United Nations in the Frame Work Convention on climate change (UNFCCC)

known as Kyoto Protocol, declared the above gases as Green House Gases, and they are mainly caused by

gas flaring. This resulted in the United Nations resolution to stop gas flaring.

A recent data released from the Nigerian National Petroleum Corporation (NNPC), that oil and gas

companies in Nigeria burn over $3.5 to $5 billion yearly from over 257 flow stations in the Niger Delta.

That specifically, the country flared about 17.15 per cent of the 95,471 metric tons of gas produced in

June 2015 alone. Also, the Organization of Petroleum Exporting Countries (OPEC) stated in 2015

Statistical Report, that Nigeria produced 86,325.2 million standard cubic meters in 2014. Also, NNPC

disclosed that Nigeria lost up to $868.8 million, about =N=173.76 billion to gas flaring in 2014.Using the

Nigeria Gas Company’s(NGC) price of $3 per 1000 SCF of gas at the current exchange rate realities,, the

flaring of 289.6 billion SCF of gas translated to a loss of $868.8 million, an equivalent of =N=173.76

billion. Specifically, the oil and gas company produced 2.524 trillion SCF of gas, utilized 2.235 trillion

SCF and flared 289.6 billion SCF.

Against these backdrops and the likes of it, Nigeria came up with a legislation to stop gas flaring. This

gave birth to the present gas monetization process in Nigeria, for which Ogabiri Gas Gathering project is

the nucleus.


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1.1 BACKGROUND

Fig.1.0 Map Outlay of Ogabiri Gas Gathering Project.

Ogabiri Gas Gathering Project is made up of five flow stations/facilities, thus: Ibugben, Ogabiri-1,

Ogabiri-2, Rumokun-1 and Rumokun-2, with the central gas gathering facility located at Ogabiri-1,

gathering gases from Ibugben, Rumokun-1 and 2 respectively, via gas pipelines, existing along the right

of way. Then, en Route Ogabiri-2, where the new Gas Treatment and Compression Facilities are to be

installed. Here, the gas will be treated according to the West African Gas Pipelines’ specification before

exiting to the NGC Excravos-Lagos Pipeline Systems (ELPS) via a 4.5km new right of way.

1.2 SCOPE OF WORK.

The Field Engineering Limited’s Ogabiri Gas Gathering Project contract scope of this work covers the

preparation of Pipelines Material Datasheets for the entire flow stations and their corresponding pipeline

connections, that made up the Ogabiri Gas Gathering Project. To achieve this, the entire Ogabiri Projects’

various streams’gas and water compositons and conditions were simulated using PIPESIM and HYSIS.

The design simulation of the various pipeline systems connecting the entire facilities en route the


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Escravos- Lagos-Pipelines-System (ELPS), was done using PIPESIM and HYSIS simulations, as

presented in the tables below.

The design conditions, compositions, calculation results, codes, etc, of the high pressure gas line systems

of the entire project facilities as shown in the tables below. Pipeline testing is also included to ensure

compliance to ISO, ASME and ASTM specifications.

1.3 ACKNOWLEDGEMENT.

The contractor(our company), Field Engineering Limited, do hereby express their profound gratitude to

Shell Petroleum Development Company(SPDC), Nigeria, and their partner Nestoil Nigeria Limited, for

the opportunity to execute on their behalf, the Ogabiri Gas Gathering Project.

A contract project of this magnitude could not have been satisfactorily executed without the active

support, co-operation and understanding, as well as abiding patience of the SPDC and Nestoil staff that

are intimately connected with the project. In this regard, we sincerely thank Dr. Chris Ucheobi, the Head

of the K2S Engineering Department, Mr. Lovel Omoanreghan and Mrs. Roseline Uzuegbu, of Nestoil

Nigeria Limited, respectively. Also, Adedotun, Taiwo, Oladipo, facilitators of the training consultants to

Nestoil.

Our company’s appreciation and thanks go to the chiefs, community leaders and youths of the respective

communities involved directly or indirectly for the conducive atmosphere enjoyed during the execution of

this project. Our special gratitude also goes to the youth leaders of the respective communities involved,

for their invaluable maturity, assistance and roles towards a hitch-free execution of this project contract.


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1.4 DESIGN INTERFACE.

Fig.1.1 Pipsim Simulation Network of the Ogabiri Gas Gathering Project.


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Fig.1.2 Hysis Simulation Network of the Ogabiri Gas Gathering Project


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The 37 km Ogabiri Gas Gathering Project via existing Right of Way (ROW), en route the bushy/swampy

terrain of the communities involved, thus; Ibugben, Rumokun and Ogabiri, connecting the Ogabiri Gas

Gathering Facility, from where the gas will be transported to NGS Excravos via ELPS pipeline route. The

pipeline will interface at the other end with a Pig Launcher/Receivers, as well as other tie-in integration

requirements.

Pipeline Design Teams will interface with these other teams: Process Engineering, Mechanical

Engineering, Piping, Civil/Structural Engineering as well as Electrical Engineering & Instrumentations

Engineering, for the success of the project and will during the course of this project, exchange inputs with

the afore-mentioned disciplines. The Pipeline teams will also interface with the project management team

for effective and timely delivery of the entire project.

2.0 FORWARD

This document shall be read along with the following documents:

Detailed Pipeline Design Report for Nine Kilometer Pipeline Connecting the Ibugben Flow

Station and Ogabiri-1 Manifold: No. PROS/OGBR/RPT/151/003 and other teams’ reports.


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3.0 TECHNICAL DATA FOR THE GAS PIPELINES

3.1 DIMENSIONS FOR PIPELINES

Table 3.1 Dimension for Pipelines.

PARAMETERS.

GAS REQUIREMENTS.

IBUGBEN

(Ibugben to

Ogabiri-1

M/F)

RUMOKU

N-1

(Rumokun-

1 to

Ogabiri-1

M/F)

RUMOKU

N-2

(Rumokun-

2 to

Ogabiri-1

M/F)

OGABIRI-1

M/F

(Ogabiri-1

M/F passing

through

{Ogabiri-2

M/F} to

CPF)

CPF to

ELPS.

NPS(INCH) 38 38 42 42 28

OUTSIDE DIAMETER(mm)

(B31.8)

1050.8 1000.7 1050.8 1067.3 701.0

WALL THICKNESS(mm) 12.7 12.7 12.7 12.7 12.7

CORROSION

ALLOWANCE(mm)

1.0 1.0 1.0 1.0 1.0

DESIGN TEMPERATURE

MAXIMUM(0C)

29.4 26.7 29.4 26.7 51.3

AVERAGE LENGHT OF

PIPE(M)

9,000.00 12,000.00 8,500.00 3000.00 4,500.00

JOINT FACTOR 0.8 0.8 0.8 0.8 0.8

DIMENSION STANDARD API 5L API 5L API 5L API 5L API 5L

MATERIAL DESCRIPTION API 5L X60 API 5L

X60

API 5L

X60

API 5L X60 API 5L

X60


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3.2 QUANTITIES

Table 3.2 Quantities.

PLAIN END MASS(km) 298.26 298.26 298.26 330.21 218.7

1

PARAMETERS

GAS REQIREMENTS

IBUGBEN

(Ibugben to

Ogabiri-1 M/F)

RUMOKUN-1

(Rumokun-1 to

Ogabiri-1 M/F)

RUMOKUN-2

(Rumokun-2 to

Ogabiri-1 M/F)

OGABIRI-1

M/F

(Ogabiri-1 M/F

passing through

Ogabiri-2

{M/F} to CPF)

CPF TO ELPS.

THICKNESS(mm) 12.7 12.7 12.7 12.7 12.7

REQUIRED

LENGTH(mm)

9,000,000.00 12,000,000.00 8,500,000.00 3,000,000.00 4,500,000.00

ESCALATION

30%(mm)

2,700,000.00 3,600,000.00 2,550,000.00 900,000.00 1,350,000.00

TOTAL

LENGTH(mm)

11,700,000.00 15,600,000.00 11,050000.00 3,900,000.00 5,850,000.00


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3.3 ANTI-CORROSION.

Table 3.3 Anti-corrosion.

PARAMETER PIPE

EXTERNAL COATING 3-LAYER POLYETHYLENE COATING

NOTES:

1. The average length of deliverable pipes shall be 12.0m, though a minimum of 90% of

Pipes between 11m and 12.5m may be allowed.

2. There should be end bevelling of an angle of 30o for plain-end pipes, with respect to

API 5L specification.

3. The actual quantity is verifiable in the Results of Detailed Design and Engineering below.

4. The length given here represents the preliminary pipe length and bends

requirement. K2S Department of Nestoil Nigeria Limited shall confirm the above

ground, on-ground and underground pipes.


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3.4 RESULTS OF DETAILED DESIGN AND ENGINEERING.

Table 3.4 Results of the Detailed Design and Engineering.

S/N

PARAMETER

DESCRIPTION

DATA

UNIT

1 PROCESS IBUGB

EN(Ibug

ben to

Ogabiri-

1 M/F)

RUMO

KUN-

1(Rumo

kun-1 to

Ogabiri-

1 M/F)

RUMOK

UN-

2(Rumok

un-2 to

Ogabiri-1

M/F)

OGABIRI

-

1(Ogabiri

-1 M/F

passing

through

Ogabiri-

2{M/F}

to CPF)

CPF TO

ELPS.

1.1 Gas Inlet Temperature. 29.44 26.67 29.44 26.67 51.27 OC

1.2 Gas Inlet Pressure. 4000 4200 4000 3938 6000 KPa

1.3 Gas Inlet Molar Flow. 4.98 10.08 28.95 30.82 81.16 MMS

CFD

1.4 Pipeline Temperature

Change.

1.994 0.5568 0.8201 26.00 1.266 OC

1.5 Pipeline Pressure

Drop.

4.785 2.778 62.42 3938 65.09 KPa

1.6 Pipeline Heat-loss. 2.172e+

004

234.3 3.059e+0

04

64.95 1.820e+

005

KJ/h

1.7 Gas Outlet

Temperature.

27.45 28.89 25.85 25.12 50.00 OC

1.8 Gas Outlet Pressure. 3995 4197 3938 3866 5935 KPa

1.9 Gas Outlet Molar

Flow.

4.980 0.2024 28.95 75.01 81.16 MMS

CFD

1.10 Design life 25 25 25 25 25 Yrs

1.11 Minimum Bend

Radius:

1.11.1 Cold Bending Radius 10508 10007 10508 10673 7005 MM


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1.11.2 Hot Bending Radius 4203.2 4002.8 4203.2 4269.2 2802 MM

1.11.3 With Other Bending

Devices

2101.6 2001.4 2101.6 2134.6 1401 MM

1.12 Pipe outside diameter 1050.8 1000.7 1050.8 1067.3 701.0 MM

1.13 Pipe inside diameter 1025.4 975.3 1025.4 1041.9 675.1 MM

1.14 Pipe wall thickness

(Mainline seasonal

swamp/land) section

12.7 12.7 12.7 12.7 12.7 MM


(mainline river/road

crossing) section

NONE NONE NONE NONE NONE MM


(Major barrels)

12.7 12.7 12.7 12.7 12.7 MM

1.17

Pipe Grade API 5L

X60

API 5L

X60

API 5L

X60

API 5L

60

API 5L

60

NA

1.18 Flow Velocity Range 15.24 –

4.27

15.24 –

4.27

15.24 –

4.27

15.24 –

4.27

15.24 –

4.27

M/S

2 TOPOGRAPHICAL

2.1 Pipeline length 9.00 12.00 8.50 3.00 4.50 KM

2.2 River Crossings None None None None None None

2.3 Rivers Crossing Block

Valves

(Upstream/Down

stream of Rivers

Crossings)

None None None None None None

2.4 Creek crossing ≥ 20m None None None None None None

2.5 Creek crossing < 20m None None None None None None

2.6 Road crossing ≥ 15m None None None None None None

2.7 Road crossing < 15m None None None None None None

2.8 Burial depth

(underwater cover @

creeks) - below

mudline.

None None None None None M

2.9 Burial Depth

(underwater cover @

river crossing) – below

mud cut.

None None None None None M

2.10 Burial Depth

(minimum cover) –

1.5 1.5 1.5 1.5 1.5 M


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Rural Road Crossing

by

2.11 Burial Depth

(Minimum cover

below undisturbed

ground surface) –

Major Road Crossing

by Thrust Bore

1.0 1.0 1.0 1.0 1.0 M

3. CORROSION

CONTROL

3.1 Corrosion Allowance 0.1 0.1 0.1 0.1 0.1 MM/

YR

3.2 External Concrete

Coating (Swamp/River

Sections)

80 80 80 80 80 MM

3.3 External Anti-

Corrosion Coating (3-

Layer Polyethylene)

3.2 3.2 3.2 3.2 3.2 MM

3.4 Internal Coating None None None None None -NA-

3.5 Cathodic Protection

(By Impressed

Current)

Yes Yes Yes Yes Yes -NA-

3.6 Corrosion Monitoring

(By Intelligent Pig)


3.7 Electrical Insulation

(By Insulating Joints

@ above/below

ground

transitions)


3.8 Corrosion Inhibition

Yes

Yes Yes Yes Yes Yes

4 ANCILLIARY

EQUIPMENT

4.1 Pig Launcher /

Receiver

Yes Yes Yes Yes Yes NO

4.2 Mixer Yes Yes Yes Yes Yes NO

4.3 Slug Catcher Yes Yes Yes Yes Yes NO

4.4 Water Splitter Yes Yes Yes Yes Yes NO

4.5 Booster Compressor Yes Yes Yes Yes Yes NO

5 ENVIRONMENTAL


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5.1 Maximum Wind

Speed.

20.5 20.5 20.5 20.5 20.5 M/S

5.2 Average Daily

Relative

Humidity(Maximum)

97 97 97 97 97 %

5.3 Average Daily

Relative

Humidity(Minimum)

83 83 83 83 83 %

5.4 Average Daily

Relative

Humidity(Mean)

72 72 72 72 72 %

5.5 Ambient temperature

(Maximum)

29.4 29.4 29.4 29.4 29.4 0C

5.6 Ambient Temperature

(Minimum)

18 18 18 18 18 0C

5.7 Mean Maximum

Hourly Rainfall

100 100 100 100 MM

5.8 Mean Maximum

Monthly

Rainfall(occurs in

September)

355 355 355 355 355 MM

5.9 Average Annual

Rainfall

2800 2800 2800 2800 2800 MM

4.0 CONCLUSION

This project was carefully executed with enough up-to-date science and technology, which guaranteed

strict compliance and attainment to internationally accepted standards of pipeline for transportation of

hydrocarbon natural gas, without compromising the ecological sanctity of the concerned area, being

guided with the Environmental Impact Assessment(E.I.A), conducted before the take off of this project

execution.

REFERENCE DOCUMENTS.


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The choice of material and equipment, design, construction, maintenance as well as repair of equipment

and facilities covered by the industry guidelines shall comply with the latest edition of the references

listed below, unless specifically noted.

DOCUMENT HIERARCHY.

Should there be any conflicts with respect to any/some of the documents used in this project, reference

should be made to the following listed documents arranged in an order of descending priority, thus:

1. Nigerian Law.

2. The contract.

3. Ogabiri FEED approved documents.

4. WAGC Guidelines and Standards.

5. WAGC Design and Engineering Practices.

6. Industry Guidelines and Standards.

7. SPDC’s Kolo Creek – Rumuekpe T/L Replacement EIA Report.

8. The Guardian: www.ngrguardiannews.com>Features>Weekend.

9. Requirements Concerning Pipes and Pressure Vessels.

- International Association of Classification Societies.

10.Welded Steel Pipe Design Manual 2007.

(Merits, Design Standards, Technical and References)

American Iron and Steel Institute.

Publication Number D631-0807-e

11.Gas Transmission System Design and Selection.

Session 3 Gas Transmission System Design Material Selection EP.

12.Guidelines for the Design of Buried Pipe.

American Life Alliance.


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July 2001(with added agenda through February 2005)

13.ASME B31.8: Gas Transmission and Distribution Piping Systems.

49 CFR 192.619 (a) (1) (i)

14.Restoration of Right of Way

8, August 2008. < http://www.ngaa.org/cms/33/1339/65/84.aspx>

15.Trenching for New Pipelines.

8, August, 2008. <http:www.ngaa.org/cms/33/1339/65/73.aspx>

16.Stringing, Welding and Coating Pipe Segments.

8,August, 2008. <http://www.ngaa.org/cms/33/1339/65/70.aspx>

17.Assuring the Integrity of Natural Gas Pipeline.

Posakony, G.J. et al.

Topical Report. GRI-91/0366, Chicago, 1993.

18.The Design and Location of Gas Transmission Pipeline Using Risk Analysis Techniques, Risk and

Reliabilty and Limit State Conference, Aberdeen, May,1996.

Hopkins,P., Hopkins,H.F., I Corder.

19.Pipelines Onland: Design, Construction and Installation, Steel For Oil and Gas, British Standard

Institute, 1992.

Anon. , Code of Practice for Pipelines, BS 8010 Part 2.8.

http://www.ngaa.org/cms/33/1339/65/84.aspx

http://www.ngaa.org/cms/33/1339/65/70.aspx

Pipeline Design Philosophy

Engineering

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