Pipeline Planning and Construction Field Manual (eBook)

Front Cover 1
Pipeline Planning and Construction Field Manual 4
Copyright 5
Table of Contents 6
List of Contributors 18
Author Biography 20
E. Shashi Menon, Ph.D., P.E. 20
Barry G. Bubar, P.E. 20
William E. Bauer 20
Hal S. Ozanne 20
Glenn A. Wininger 21
Preface 22
Chapter 1. Design Basis 26
Introduction 26
1.1 Units of Measurement 27
1.2 Physical Properties of Liquids and Gases 29
Summary 65
Bibliography 66
Chapter 2. Route Selection 68
Introduction 68
2.1 Community and Local Agencies 70
2.2 Population Density 70
2.3 Technical and Project Necessities 71
2.4 Constructibility 72
2.5 Right-of-Way 73
2.6 Environmental Issues 74
2.7 Route Beginning and Ending Points 75
2.8 Connections 75
2.9 Mapping System 75
2.10 Field Review 76
2.11 Parallel Other Lines 77
2.12 Integrity 78
2.13 Established Corridors 78
Bibliography 81
Chapter 3. Pipeline Regulatory and Environmental Permits 82
Introduction 82
3.1 Regulation of Interstate Pipelines 83
3.2 Regulation of Intrastate Pipelines 84
3.3 Environmental Permits for Interstate Pipelines 85
3.4 Environmental Permits for Intrastate Pipelines 86
3.5 Local Permits 87
Chapter 4. Right-of-Way 92
Introduction 92
4.1 Right-of-Way Deliverables and Requirements 92
4.2 Project Planning 94
4.3 Right-of-Way Budgeting 95
4.4 Right-of-Way Database and Records 96
4.5 Field Support 100
4.6 Right-of-Way Negotiations and Condemnation 100
4.7 Construction Support 102
4.8 Project Completion and Pipeline Operations 103
Chapter 5. Alignment Sheets 106
Introduction 106
5.1 Uses 106
5.2 Alignment Sheet Development 108
5.3 Quantity of Alignment Sheets 109
5.4 Stationing 109
5.5 Survey 109
5.6 Drawing Issuance 111
5.7 Changes to the Route 111
5.8 Federal Energy Regulatory Commission (FERC) Requirements 115
5.9 Existing Systems 115
Bibliography 117
Chapter 6. Overview of Pipeline Materials 118
Introduction 118
6.1 Criteria 118
6.2 Product to Be Transported 119
6.3 Operating Pressure 119
6.4 Operating Temperature 119
6.5 Handling and Welding 120
6.6 Volume or Throughput 120
6.7 Codes and Regulations 121
6.8 Coating 127
6.9 Joint Coating 127
6.10 Fittings 127
Bibliography 128
Chapter 7. Pipe Strength and Wall Thickness 130
Introduction 130
7.1 Allowable Operating Pressure 131
7.2 Barlow’s Equation for Internal Pressure 133
7.3 Derivation of Barlow’s Equation 134
7.4 Modified Barlow’s Equation 135
7.5 Gas Pipelines: Class Locations 137
7.6 Thick-Walled Pipes 139
7.7 Mainline Valves 141
7.8 Blowdown Calculations 141
7.9 Determining Pipe Tonnage 142
Summary 145
Bibliography 146
Chapter 8. Pipeline Hydraulic Analysis 148
Introduction 148
8.1 Velocity of Flow in Liquid Pipelines 149
8.2 Reynolds Number in Liquid Flow 152
8.3 Pressure and Head of a Liquid 156
8.4 Pressure Drop in Liquid Flow 158
8.5 Friction Factor 160
8.6 Colebrook–White Equation 162
8.7 Moody Diagram 163
8.8 Hazen–Williams Equation 166
8.9 Minor Losses 176
8.10 Flow of Gas in Pipelines 178
8.11 Erosional Velocity 183
8.12 Reynolds Number in Gas Flow 185
8.13 Friction Factor in Gas Flow 188
8.14 Colebrook–White Equation for Gas Flow 189
8.15 Transmission Factor 190
8.16 Pressure Drop in Gas Flow 193
8.17 Effect of Pipe Elevations 196
8.18 The Average Gas Pressure 197
Summary 199
Bibliography 200
Chapter 9. Series and Parallel Piping and Power Required 202
Introduction 202
9.1 Total Pressure Required to Transport Liquids 203
9.2 Hydraulic Pressure Gradient in Liquids 206
9.3 Series Piping in Liquid Pipelines 210
9.4 Parallel Piping in Liquid Pipelines 212
9.5 Transporting High Vapor Pressure Liquids 215
9.6 Pumping Power Required in Liquid Pipelines 215
9.7 System Head Curves – Liquid Pipelines 218
9.8 Injections and Deliveries – Liquid Pipelines 221
9.9 Pipe Loops in Liquid Pipelines 222
9.10 Gas Pipelines 223
9.11 Hydraulic Pressure Gradient in Gas Pipeline 224
9.12 Series Piping in Gas Pipelines 225
9.13 Parallel Piping in Gas Pipelines 226
Summary 228
Bibliography 229
Chapter 10. Valve Stations 230
Introduction 230
10.1 What to Expect 231
10.2 Valve Usage 231
10.3 Some Other Valves Not Listed by API-6D 235
10.4 Valve Pressure Class 236
10.5 Pipeline Design and Valve Selection 236
10.6 Mainline Valve Locations 237
10.7 Valve Station Design 237
10.8 Buried Valve Vaults 239
10.9 Direct Burial of Valves 241
10.10 Natural Gas Pipeline Valves 241
10.11 Valve Placement on Gas Pipelines 242
10.12 Block Valve Spacing on Gas Transmission Lines 242
10.13 Valve Maintenance for Liquid and Gas Pipelines as per Code 243
10.14 Overpressure Safety Valves and Pressure Limiting Devices for Hazardous Liquid Pipelines 243
10.15 Natural Gas Pipeline Valves Maintenance 244
10.16 Pressure Limiting and Regulating Stations for Gas Pipelines 244
10.17 General Valve Station Protection 244
10.18 Pipeline Valve Selection – Ball or Gate? 244
References 247
Bibliography 247
Chapter 11. Pump Stations 248
Introduction 248
11.1 Multipump Station Pipelines 249
11.2 Hydraulic Balance and Pump Stations Required 249
11.3 Telescoping Pipe Wall Thickness 253
11.4 Change of Pipe Grade – Grade Tapering 254
11.5 Slack Line and Open Channel Flow 254
11.6 Batching Different Liquids 255
11.7 Centrifugal Pumps Versus Reciprocating Pumps 257
11.8 Centrifugal Pump Head and Efficiency Versus Flow Rate 261
11.9 BHP Versus Flow Rate 264
11.10 NPSH Versus Flow Rate 265
11.11 Specific Speed 266
11.12 Affinity Laws for Centrifugal Pumps 267
11.13 Effect of Specific Gravity and Viscosity on Pump Performance 269
11.14 Pump Configuration – Series and Parallel 271
11.15 Pump Head Curve Versus System Head Curve 274
11.16 Multiple Pumps Versus System Head Curve 275
11.17 NPSH Required Versus NPSH Available 275
11.18 Pump Station Configuration 278
11.19 Control Pressure and Throttle Pressure 279
11.20 Variable Speed Pumps 280
11.21 VSD Pump Versus Control Valve 280
Summary 283
Bibliography 283
Chapter 12. Compressor Stations 284
Introduction 284
12.1 Compressor Station Locations 285
12.2 Hydraulic Balance 290
12.3 Isothermal Compression 291
12.4 Adiabatic Compression 293
12.5 Polytropic Compression 295
12.6 Discharge Temperature of Compressed Gas 296
12.7 Compression Power Required 297
12.8 Optimum Compressor Locations 301
12.9 Compressors in Series and Parallel 306
12.10 Types of Compressors – Centrifugal and Positive Displacement 309
12.11 Compressor Performance Curves 311
12.12 Compressor Head and Gas Flow Rate 313
12.13 Compressor Station Piping Losses 313
12.14 Compressor Station Schematic 315
Summary 316
Bibliography 316
Chapter 13. Corrosion Protection 318
Introduction 318
13.1 Corrosion in Pipelines 318
13.2 Causes of Pipeline Failure 319
13.3 Types of Corrosion 322
13.4 Corrosion Control 325
Summary 329
Bibliography 329
Chapter 14. Leak Detection 330
Introduction 330
14.1 Prevention 332
14.2 Pressure Regulation 332
14.3 Cathodic Protection 333
14.4 Corrosion Coupons 333
14.5 Pipeline Markers 333
14.6 Smart Pigging 336
14.7 Pipeline Security 337
14.8 Regulations 337
14.9 Purpose 338
14.10 Intermediate Block Valves 339
14.11 Check Valves 340
14.12 Patrolling 340
14.13 Detection 340
14.14 Measurement 341
14.15 Supervisory Control and Data Acquisition System 341
14.16 Hydrostatic Testing 342
Bibliography 343
Chapter 15. Pipeline Pigging and Inspection 344
Introduction 344
15.1 Pig Use 345
15.2 Pipeline Pigging 345
15.3 Problem Pipelines 346
15.4 Piggable Pipelines 347
15.5 Pig Propulsion 348
15.6 Utility Pigs 349
15.7 Selecting Pigs for Small Bore and Double Diameter Pipelines 351
15.8 Poly Pigs 352
15.9 My First Experience with Poly Pigs 353
15.10 Pig Trains 353
15.11 Smart Pigs 354
15.12 Smart Pig Types 355
15.13 Crack Detection 357
15.14 Preparation for Smart Pig Inspection 357
15.15 MFL Smart Pig 358
15.16 Post Smart Pig Inspection 360
15.17 Expert Data Evaluation 360
15.18 External Corrosion 361
15.19 Internal Corrosion 362
15.20 Postinspection Criteria 363
Summary 363
References 364
Bibliography 364
Chapter 16. Pipeline Construction 366
Introduction 366
16.1 Pipeline Construction Sequence 367
16.2 Restoration of Disturbed Construction R.O.W. 380
Chapter 17. Welding and NDT 382
Introduction 382
17.1 Pipeline Welding Procedures 383
17.2 Specimen Preparation 384
17.3 Testing 384
17.4 Criteria for Weld Acceptance 384
17.5 Classic Pipeline Welding 386
17.6 Double Joints 387
17.7 Using Higher X-Grade Pipe 389
17.8 Welders’ Qualification 391
17.9 Welders’ Responsibility 392
17.10 Automatic Pipeline Welding 393
17.11 Verifying Automatic Weld Integrity 395
17.12 Semiautomatic Welding 395
17.13 Strength of Welded Pipelines 397
17.14 Nondestructive Testing of Pipe Girth Welds 398
17.15 Radiographic NDT 399
17.16 Repair of Defect 399
17.17 Welding Rejection Criteria 399
References 402
Bibliography 403
Chapter 18. Hydrostatic Testing 404
Introduction, Including Risk-Based Alternatives to Testing 404
18.1 Testing Pipe 407
18.2 Classifying in Service Pipelines 408
18.3 Intrastate Pipelines 408
18.4 Pretest Planning for an Intrastate Pipeline 409
18.5 Test Water Disposal 414
18.6 Safety and Equipment Procedures During Test 414
18.7 Turning and Operating Valves 414
18.8 Training and Judgment 414
18.9 Back to Test Procedure 415
18.10 Pressurization 416
18.11 List of Equipment for Hydrostatic Test 417
18.12 Test On 418
18.13 Posttest Results 418
18.14 Posttest Leak Analysis 419
18.15 Entrained Air and Vapor 421
18.16 Leaking Isolation Valves and Fittings 421
18.17 Changing Test Water Temperature 422
18.18 Posttest Report 422
18.19 Volume Analysis 422
18.20 Testing Interstate Liquid and Natural Gas Transmissions Lines 423
18.21 Test Section 12 426
18.22 Cross-Country Pipeline Testing 427
18.23 Pipeline Rupture 427
References 429
Chapter 19. Commissioning 430
Introduction 430
19.1 Plan 436
19.2 Plan Sequence 436
19.3 Operations and Maintenance Manuals 437
19.4 Completion of Construction 437
19.5 Sizing or Gauging Pigs 437
19.6 System Checkout 438
19.7 Pipeline Drying 438
19.8 Line Fill 439
Bibliography 445
Chapter 20. Specification Writing, Data Sheet Production, Requisition Development, and Bid Analysis 446
Introduction 446
20.1 Specification Writing 446
20.2 Material Specifications 447
20.3 Construction Specifications 463
20.4 Material Requisition Development 486
20.5 Bid Quotation and Bid Analysis 486
Chapter 21. Operations and Maintenance Manuals 490
Introduction 491
21.1 Operating Manuals 491
21.2 Regulations 491
21.3 Written Emergency Procedures 492
21.4 Training Program 493
21.5 Details 499
21.6 Maintenance Manuals 503
21.7 Preventative Maintenance 503
21.8 Project Data Book 503
21.9 Startup Sequential Process 506
21.10 Shutdown Sequential Process 506
Bibliography 507
Appendix 1. Chapter 1 508
Outline of Design Basis Manual (DBM) 508
Units and Conversions 510
Physical Properties of Liquids and Gases 512
ASTM Method for Viscosity Versus Temperature of Liquids 516
Viscosity of a Mixture of Liquids Using Blending Index 517
Viscosities of Common Hydrocarbon Gases 517
Gas Compressibility Factor Calculation Methods 518
Appendix 2. Chapter 3 520
Underground Utility Permit 520
License Agreement 522
Permit Investigation Report 524
Appendix 3. Chapter 4 526
Right-of-Way Budget 526
Title Research Check List 527
Title Report 529
Survey Permit 533
Pipeline Right of Way Easement 534
Valve Easement 534
Surface Easement 535
General Warranty Deed 537
Pipe and Storage Yard Lease 537
Damage Release 540
Advance Damage Release 541
Appendix 4. Chapter 7 542
Pipe Seam Joint Factors 542
Pipeline Internal Design Pressures and Test Pressures – USCS Units 543
Pipeline Internal Design Pressures and Test Pressures – SI Units 544
Appendix 5. Chapter 8 548
Explicit Friction Factor Equations 548
Hazen–Williams C-Factor 548
Gas Flow Pressure Drop Equations 549
Frictional Pressure Drop in Liquids – USCS Units 555
Frictional Pressure Drop in Liquids – SI Units 556
Appendix 6. Chapter 9 558
Equivalent Length of Series Pipes 559
Equivalent Diameter of Parallel Pipes 560
Brake Power Required for Water 561
Appendix 7. Chapter 11 562
Line Fill Volume per Mile of Pipe – USCS Units 562
Line Fill Volume per Kilometer of Pipe – SI Units 562
Specific Speed of Centrifugal Pumps 563
Suction Specific Speed of Centrifugal Pumps 564
Appendix 8. Chapter 12 520
Compressor Power (USCS Units) 566
Compressor Power (SI Units) 567
Brake Power (HP/MMSCFD) for Reciprocating Compressors – USCS Units 568
Brake Power (kW/Mm3/day) for Reciprocating Compressors – SI Units 568
Appendix 9. Chapters 17 and 18 570
Pipe Hoop Stress and Pipe Longitudinal Stress Formula 570
Pipeline Design 571
Pipeline Design Pressure (Pd) 572
Longitudinal Stress 572
Index 574