special presentation for national academy of science study team

Special Presentation for National Academy of Science Study Team

For permission to copy or distribute contact [email protected] 1

© 2012 Pipeline Knowledge & Development

Developed and Produced by

Pipeline Knowledge & Developmenthttp://www.pipelineknowledge.com/

Presented by

Tom Miesner

Introduction to Oil PipelinesNational Academy of Science


Instructor –Tom Miesner• Principal Pipeline Knowledge & Development

– Pipeline Education and Training

– Strategy and Project Development

– Expert Testimony and Arbitration

– Appraisals and Independent Opinions

– Management and Improvement Consulting

• Extensive pipeline background

• President Conoco Pipe Line Company

• Numerous JV Boards and Committees

• Author

– Oil and Gas Pipelines in NonTechnical Language

– The Role of Pipelines and Research in the U. S.

– A Practical Guide to US Natural Gas Pipeline Economics

– The Interstate Natural Gas Transmission System: Scale, Physical Complexity,and Business Model

– Pipeline Engineering for McGraw Hill’s Transportation Engineering Handbook

• Currently writing The Final Mile, Natural Gas Distribution Pipelines inNonTechnical Language

2


Copyright and Disclaimer

3

The materials contained in this presentation are copyright Pipeline Knowledge &Development 2012. All rights are reserved. No part of this presentation may bereproduced, distributed, or stored in any form or by an means without prior writtenpermission from Pipeline Knowledge & Development.

Some of the images have been supplied by others . Other information has beentaken from literature or the internet in which case any copyright remains with thoseorganizations or individuals.

The information contained in these materials was secured from sources believed tobe reliable. However, Tom Miesner, Miesner, LLC, and Pipeline Knowledge &Development;1. Make no warranty or representation, expressed or implied regarding the accuracy, completeness,

reliability, or usefulness of the information contained in this presentation2. Assume no liability with respect to the use of the materials contained in these presentations3. Are not responsible for damages resulting from use of the information in these presentations.

For information or to receive permission to copy or reproduce, contact Tom Miesner,[email protected] or +1-281-579-8877


Table of Contents

1) Oil Pipelines2) Fluid Properties3) Pipeline Construction4) Equipment and Components

5) Pipeline Operations

6) Pipeline Maintenance

4




Pipeline Types

• Fluids Transported

– Natural gas

– Crude oil

– Refined products

– LPG and chemicals

– Specialty

• Function

– Gathering

– Transmission, main or trunk line

– Distribution

5 © 2012 Pipeline Knowledge & Development

Pipeline Types

• Fluids Transported

– Natural gas

– Crude oil

– Refined products

– LPG and chemicals

– Specialty

• Function

– Gathering

– Transmission, main or trunk line

– Distribution

6


Pipeline Value Chain

Gas

plant

Crude oil trunk or main line

Gathering stations

Oil and gasGathering lines

Oil products lineProductsterminals

Industrial users

Local distribution

company lines

Underground storage

Underground

& steel storage

Refining center

LPGdistribution

Natural gas transmission or main line

Copyright PennWell Publishing 2006


May replace some of the following series of slides withslides requested from Enbridge showing the actual

assets.

8




Crude Oil Mainline Pump Station

9

Photo by Tom Miesner


Refinery Tank Farm

10


Refinery


Pump station

Flow direction

Lower pressure due togravity

Higher pressure due togravity

Loss ofpressure dueto friction

Pump stationor terminal

Pressure at a point = Pressure at origin –Friction loss + elevation change

Pressure losses due to friction, and/or elevationchanges, require pumping or compression.

Pipeline Hydraulics –The Basics




Fluid Properties

• Density –mass/volume– Specific gravity (density relative to water)

– API gravity for liquids

• Viscosity –internal resistance to flow– Absolute

– Kinematic

• Vapor pressure –pressure above which liquidsbecome gases

• Chemistry– Hydrocarbon molecules– Sulphur (sour vs. sweet)– Other constituents


API Gravity - Liquids

- 131.5API Gravity = 141.5Specific Gravity

API Gravity = 141.5.9

- 131.5 = 25.70 API

• The higher the API gravity the lighter the material• Water has an API gravity of 100

• API gravity is a density measurement used in thepetroleum industry and has no other specialmeaning

14


Viscosity Vs Temperature

15

Courtesy Delrio S.A.


Pressure –PSI vs. Feet

16

WaterSg = 1

43.3 psi

GasolineSg = 0.6929.9 psi

Diesel FuelSg = .8436.4 psi

10

0F

t.




The Important Concepts

• Resistance to flow causes friction

• Faster flow produces more friction

• Size and pattern of the opening determine pressureloss and therefore velocity

• As flow starts to stop the pressures in the systemchange

• Starting or stopping suddenly causes pressure surges(water hammer)

• Changing one variable changes the others


Basic Flow Principles

• Pressure differentials cause fluids to flow

• As fluids move along they must overcome friction– From the pipe wall

– From the fluid’s internal resistance to flow

• Going up hill uses pressure as pressure battlesgravity

• Going down hill increases pressure as gravityhelps pull the material down the hill.

• In most cases friction loss is significantly largerthan elevation loss

18


Pump station

Flow direction

Lower pressure due togravity

Higher pressure due togravity

Loss ofpressure dueto friction

Pump stationor terminal

Pressure at a point = Pressure at origin –Friction loss + elevation change

Pressure losses due to friction, and/or elevationchanges, require pumping or compression.

Pipeline Hydraulics –The Basics


Flow direction

Hydraulic Gradient and Profile

Feet

of

head

Miles

Pre

ssure

inth

elin

e




Profile and Gradient Screen

Pressure in the line

Pressure in the line


Pipeline Construction Spread

22

Courtesy Vanderpool Pipeline Engineers Inc.


Welder Testing and Qualification


Stripping Top Soil

Courtesy U. S. Pipeline, Inc.; photo by Adam Aronson

24




Stringing 3



Ditching 2


26


Internal Alignment Clamps 1



Internal Alignment Clamps 2


28




Welding



Stringer Bead


30


Grinding to Clean the Weld



Weld Bead

32

Prior to weld

Post Weld

Cap bead

Root or stringer bead

Filler beads




Finished Weld



Girth Weld Testing with Ultrasonics

34


Welded Pipe Ready for X-Ray

35


MLLC 1


Developed Films Ready for Reading

36





Girth Weld –Ready for Coating



Coated Girth Weld


38


Lowering



Testing Coating Anomalies –Jeeping


40




Field Bending



Directional Drill –Going In


42


Directional Drill –Changing Drill Pipe



Direction Drill –The Other End


44




Directional Drill –Hole Reamer



Ready to Pull the Pipe


46


Cradling As It Goes



The Other End


48




Bored Crossing

49



Hydrotesting


50


Test Equipment



Off Test –Relieving Pressure


52




Tieing In



Station Site

54

Used with permission


Prefabbing

55



Ready to be Assembled

56





Lowering the Pump Skid

57



Setting the Pump Skid

58



Pump Piping Layout

59



Hydrotesting Station Piping

60





Finished Pump Station

61



Control Building

62



Switch Gear

63



Electrical Terminations

64





Testing and Checkout

65



Startup and Trouble Shooting

66



Line Pipe

• Manufacturing methods– Electric resistance welded (ERW)

– Seamless

– Submerged arc welded (DSAW)

– Gas arc welded

– Spiral wound

• Properties– Metallurgy

– Strength

– Ductility

• API 5L SPECIFICATION FOR LINE PIPE

67

Common Pipe Grades and Their Specified

Minimum Yield Strength

GradeSMYS(psi)

X42 42,000

X-46 46,000

X52 52,000

X56 56,000

X60 60,000

X65 65,000

X70 70,000

X80 80,000


DSAW Pipe

Weld Seam





DSAW Weld

69

Source NTSB


ERW Pipe

70

Weld Seam


Spiral Wound Pipe


Weld Seam


Pipe Labeling

72




Coatings

• Fusion Bond Epoxy (FBE)

• Coal Tar Enamel (TGF 3)

• Multi layer

• Plastic

• Tapes

• Shrink sleeves

• Two part cold epoxy

• Abrasion Resistant Overcoatings (ARO)

• Concrete coating


Fittings and Flanges


-20 0F to 100 0F

AnsiRating

(#)

WorkingPressure (psi)

TestPressure

(psi)

150 285 450

300 740 1125

400 990 1500

600 1480 2225

900 2220 3350


Valves

•Types

–Gate

–Ball

–Plug

–Check

–Globe

•Functions

–Block orisloate

–Control

–Relief

• Supplier

–M & J

–Cameron

–GeneralTwin Seal

–Valvitalia

–PetrolValves

–DynaSeal


Multistage Horizontal Split Case

Courtesy Sulzer Pump




Electric Motors

77



Operations vs. Maintenance

• Operations cause the pipeline to function such that itperforms its intended purpose.

• Maintenance keeps the pipeline in operating conditionat its current capacity.

• Field operations are those conducted along or nearthe pipeline’s route

• Control room operations are conducted at limitednumbers of locations remote from the pipeline

• Some maintenance activities such as planning areconducted remote from the pipeline but mostmaintenance activities are conducted along the route

• Operations and maintenance are often performed bythe same people

78


Operating Tasks

• Line Control

– Starting and stopping the entire line

– Changing flow rates

– Starting, stopping or diverting flow

– Optimizing line operations

• Measurement and Testing

– Flows and quantities

– Quality

• Indirect Operating Tasks

– Healthy, Safety, and Environmental

– Education of and relations with the various publics

– Emergency response preparation and training

79© 2012 Pipeline Knowledge & Development

Public Relations

• Landowners along the ROW

• Local officials

– Planning commission

– Emergency response

– County commission

• Excavators

– Contractors

– Other underground utilities

• Environmental and other special interest groups

80




HSE and Response

• Health, safety, and environmental

– Conducting safety training

– Monitoring discharge levels

– Completing discharge reports

• Emergency response

– Preparing response plans

– Training

•Employees

•Contractors

•Local officials

– Conducting drills

– Responding to emergencies

81© 2012 Pipeline Knowledge & Development

Typical Pipeline Control Room 2/2

82



Control Room Operations

Nominations Dispatching Controlling ReportingScheduling

Functions

Receipts Delivery

Pipeline

Storage

Flow


Direction of Flow

PremiumGasoline

MidgradeGasoline

RegularGasoline

End ofcycle

Typical Refined Products Cycle

DieselJetFuelDiesel

MidgradeGasoline

RegularGasoline

Beginningof cycle

Lightsweet

LighthighSulfur

HeavyhighSulfur

Lightsweet

Lighthighsulfur

Heavyhighsulfur

Butane

Complex Crude Oil Cycle

Batching Sequence




Station Schematic 1

85

Miesner Station


At what pressure will a pipe leak?

•It depends on…– Wall thickness– Diameter

– Steel strength

Burst Pressure = 2t X USD

t = Wall thicknessUS = Ultimate strengthD = Average diameter

MAOP = 2t X SMYS X SFD

86

SMYS = Specified Minimum Yield Strength


Stress Strain Curve

Stress –Amount offorceStrain –Length ofchange1 - Ultimate Strength2 - Yield Strength3 - Rupture4 - Strain hardening

region5 - Necking region


The Reinforcing Effect

Pipe Wall 1

Pipe Wall 2

Pipe wall 2 will rupture at lower pressure thanpipe wall 1 because of the reinforcing effect.

How to resolve the geometry of wall 3.

88

Pipe Wall 3




Internal Microbial Induced Corrosion

Source: National Transportation Safety Board


Corrosion

• Galvanic– External

– Internal

• AC –induced current from foreign sources

• Microbial induced or assisted corrosion (MIC, MAC)– Anaerobic sulfate-reducing bacteria –sporovibrio

desulfuricans

– Aerobic sulfate-oxidizing –thiobaccilus thioxidans

– Gallionella and iron bacteria

• Acid assisted– Carbonic

– Sulfuric

• Stress Corrosion Cracking (SCC)

90


Corrosion Mitigation

• External –Cathodic Protection– Coating

•Fusion bond

•Coal tar

•Extruded plastic

•Tape

•Shrink Sleeves

– Galvanic– Impressed current

• Internal– Maintenance pigging– Corrosion inhibiting chemicals

• Stress Corrosion Cracking - coating

• AC induced –AC mitigation with cathodic decoupler


Preventing Internal Corrosion

•Effective design and construction

–Limit accumulation of water and other liquids

–Provide means to remove contaminants

•Maintenance Pigging

•Chemical cleaning

•Corrosion inhibitors

92




Low flow velocities, low spots in the line, orsteep slopes can allow debris to collectblocking flow and shielding microbes fromcorrosion inhibitors.

Internal Corrosion Under Deposits


Pipeline Cleaning

•Techniques– Mechanical –cleaning pigs– Chemical

– Combination

•Why clean?– Understand the problem or potential problem –remove and

analyze deposits– Clean wall to improve inhibitor effectiveness– Remove deposits and build up to improve flow– Remove nutrients to limit bacterial growth

– Prevent “under deposit”corrosion

94


Blowing Down a Gas Pig Launcher

95



Opening the Trap

96





Carrying the Pig

97



Loading Close Up

98



Getting Ready to Seat the Pig

99



Seating the Pig

100





Ready to Close the Trap

101



On the Other End

102



Wear on the Disc


Brush Pig Ready to Launch

104




Brush Pig Following a Run


Quite a Bit of Crap

106


Shoveling it in the Barrel for Removal


Corrosion Inhibiters

•Types– Control bacteria –treat with biocides

– Neutralize dissolved oxygen

– Apply a protective coating on the pipe ID

•Manufactured by many companies

•Many “trade secrets”and still somewhat of anart

•Must understand the corrosion mechanism toprescribe the “right”inhibitor

•Proper application is critical

108




Finding Potential Problems

•Internal Inspection Devices•Intrusive Monitoring•Non-intrusive Monitoring•Hydrostatic Testing•Electrical Surveys•Direct Assessment•Modeling


Anomaly In-Line Inspections

110

Extracted June 5, 2011 from http://primis.phmsa.dot.gov/iim/perfmeasures.htm


Smart Pigs

• Purpose

–Caliper or Geometry or Deformation

–Metal Loss Surveys

–Crack Detection

–Inertial Navigation Systems• Technologies

–Deflection

–Magnetic Flux

–Ultrasonic

–Combinations


Geometry Inspection

• Provides information regarding geometrical features– Dents

– Wrinkles– Buckles– Ovality– Valves

– Tees– Girth Welds– Wall Thickness Changes

• Also can provide data about such operating conditions asspeed and temperature.

• Some geometry tools have XYZ mapping to produce threedimensional picture of the pipeline geography

112




Caliper/Geometry Tool


Magnetic Flux Leakage Tool

• Tool generates a magnetic flux in the pipe wall• Sensor heads located on the tool measure the amount

and direction of magnetic flux leaking from the pipe wall• More flux leaking from one area versus the surrounding

pipe indicates an anomaly• Flux leakage is a vector (has direction) so each sensor

heads contain three sensors to measure axial, radial,and circumferential components of the field

• This information is recorded and analyzed to understandthe location and geometry of anomalies

• Widely used to find corrosion wall loss

114


MFL Tools for Metal Loss


Metal Loss Classifications

116

0 1 2 3 4 5 6 7 8 9 10

1

2

3

4

5

6

7

8

9

10

CIR

CU

MF

ER

EN

TIA

LG

RO

OV

E

AXIAL SLOTTING

AXIAL GROOVING

Length x (t)

Wid

thx

(t)

PITTING

GENERAL

PIN-HOLE

t = wall thicknessor 10mm,

whichever isgreater

(10mm = 0.3937”)

METAL LOSSDEFINITIONS




Ultrasonic Tool

• Transducers located around the tool emit high frequencysound pulses perpendicular to the pipe wall

• The sound pulses reflect from (bounce off) any boundarylayer they encounter –in this case the inner and outerpipe walls

• These reflections or echoes are recorded by receiversmounted on the tool

• Algorithms analyze the time interval between the arrivalof reflected echoes from inner surface and outer surfaceto calculate the wall thickness

• Placing more transmitters and receivers increase thetools ability to locate various anomalies

117 © 2012 Pipeline Knowledge & Development118

Three calculation methods for determining the remainingstrength of a corrosion defect:

•ASME B31G•Modified B31G (0.85-dL method)•Effective Area

Kiefner & Associates Pipe Assessment (KAPA), andRSTRENG are two tools to perform these calculations andto determine failure and safe operating pressures

KAPA uses “log-secant”formula, also known as the “NG-18”equation for crack-like effects

Evaluation Techniques

© 2012 Pipeline Knowledge & Development 119

COMPLETE SHADED BLOCKS IN THIS SECTION

N W

Pipe O.D. inches Total Len. inches

W.T. inches Eff. Len. inches Fail Pressure, psi Fail Pressure, psi Fail Pressure, psi

SMYS psi Start Len. inches Factor of Safety Factor of Safety Factor of Safety

MAOP psi Stop Len. inches Safe Op. Pressure Safe Op. Pressure Safe Op. Pressure

Des. Fact. Max. Depth inches

Stress Level dmax/t

Max. Des. Pres. psi Eff. Area Sq. In.

1304.8 1251.4850

0.425

KAPA 2001-2 DEFECT EVALUATION

11-Jun-07

0.72

39.8%

1537.7

PIPELINE DATA

12.750

0.389

35000 2.74

1675.3

0.266

0.684

0.00

3.00

ASME B31G

1738.1

2.04

METHOD 2

Modified B31G

2.13

METHOD 3

Defect I.D. No.:

Pipe Joint No. :

Date of Eval:

1812.2

METHOD 1

EFFECTIVE AREA

2326.8

CALCULATED PARAMETERS

3.50

3.00

Line Name:

Segment Name:

Crane to McCamey

Crane to McCamey 12" Pipeline

21457.5 Defect Location: MP 0

Eval. By:

Description: Validation of smart pig results

Dawn Halferty

Other

Sta.0

deg. 0 deg.

0

GPS 0

DEFECT PROFILE

079

127

266

157191

600 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 00

50

100

150

200

250

300

350

400

450

500

0.00 0.50 1.00 1.50 2.00 2.50 3.00 3.50 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00

Defect Length, inches

Wall

Th

ickn

ess,

mil

s

IMPORTANT NOTICE! When burst (fail) pressure is less than MOP of pipe, ASME B31.4,

451.7 shall be used to calculate safe operating pressure. (Not calculated by this program!) If

burst (fail) pressure is greater than MOP of pipe, Factor of Safety must always be greater than

1.39 as calculated by the appropriate Method above.

Method 1: No notation indicates defect

may be acceptable using this method.





Summary Screen


Pressure Reduction Warning

120

•If Factor of Safety drops below 1.39 for any ofthe methods, a warning is issued

Pipe O.D. inches Total Len. inches

W.T. inches Eff. Len. inches Fail Pressure, psi Fail Pressure, psi Fail Pressure, psi

SMYS psi Start Len. inches Factor of Safety Factor of Safety Factor of Safety

MAOP psi Stop Len. inches Safe Op. Pressure Safe Op. Pressure Safe Op. Pressure

Des. Fact. Max. Depth inches

Stress Level dmax/t

Max. Des. Pres. psi Eff. Area Sq. In.

846.0 945.2

Lower Operating Pressure!

850

1.103

0.72

39.8%

1537.7

PIPELINE DATA

12.750

0.389

35000 1.95

1190.6

0.300

0.771

0.50

5.50

ASME B31G

1312.8

1.54

METHOD 2

Modified B31G

1.38

METHOD 3

1175.0

METHOD 1

EFFECTIVE AREA

1653.6

CALCULATED PARAMETERS

9.50

5.00

IMPORTANT NOTICE! When burst (fail) pressure is less than MOP of pipe, ASME B31.4,

451.7 shall be used to calculate safe operating pressure. (Not calculated by this program!) If

burst (fail) pressure is greater than MOP of pipe, Factor of Safety must always be greater than

1.39 as calculated by the appropriate Method above.

Method 1: No notation indicates defectmay be acceptable using this method.

Method 2: No notation indicates defectmay be acceptable using this method.






Tool Calibration

121



Other Wall Measurement Techniques

•Intrusive– Corrosion coupons– Electrical resistance probes

•Non-intrusive– Ultrasonic– Acoustic– Fiber optic

– Field signature method

122


Corrosion Coupons

• A small piece of metal is inserted into and left in the line

• After some time it is withdrawn, examined, and weighed

• Corrosion rates and mechanisms for the line are inferredfrom the effects on the coupon

• Advantages– widely used

– well known

– Relatively inexpensive

• Disadvantages– Intrusive –must cut a hole in the line

– Surrogate –not the actual line

– Accessibility –difficult to place in many desired locations

–Monitoring –can not be monitored in real time


Corrision Coupon Tap

Courtesy CenterPoint Energy

124




Preparing to Weld the Fitting

125



30-Inch Stopple Fitting

126



Stopple Cutter Heads

127



Stopple Plug

128





Bypass Connection

129



Piggable Valves

130

Courtesy LineStar Services


Sealing Module

131



Tool Communications vs Stopple Fitting

132


Photo by Tom Miesner Photo by Tom Miesner




Cutting Out the Old Pipe



Lining Up the New Pipe


134


Welding In the New Pipe



Longitudinal weld Circumferential weld

Installing a Steel Sleeve

136

special presentation for national academy of science study team

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