design, construction & simulation aspects of offshore …

.

DONG gas pipeline 187 Km, Denmark, Contractor: Per Aarsleff A/s

DESIGN, CONSTRUCTION & SIMULATION ASPECTS OF OFFSHORE AND ONSHORE CRUDE OIL PIPELINE

SYSTEM

-RAVI SHANKARDate: June 2006.

1. CONTENTS

PART – A Reservoir basics

1 Reservoir engineering2 Recovery methods – water injection

PART – B Pipeline engineering & construction

3 Design data4 Mechanical works inspection5 Design & construction6 Pigging operations7 Commissioning8 Materials & corrosion9 Computational fluid dynamics10 Risk, safety and hazard

hA

Area, Top chalk

-6500

-6400

-6300

-6200

-6100

-6000

-59000 5 10 15 20 25

Area, Km*2

m

Series1Linear (Series1)

1. RESERVOIR ENGINEERING

Total oil reserves, N or

STOIIP = 1.07E+08 barrels

2. WATER INJECTION

- Water discharge at offshore

- Water injection system, design for 10 years

2. WATER DISPOSAL SYSTEM

2. WATER INJECTION SYSTEM

Water injection Vs Production

-50000000

50000001000000015000000200000002500000030000000

0 2 4 6 8 10 12

Year

Flow

[bar

rels

Series1

Series2

CALCULATED



Production rate = 73000BPD

> 20 years

ASSUMED



Production rate = 73000BPD

= 10 years

Boi = 1.3

Bo = 1.33

PIPELINE ENGINEERING

PART - B

DESIGN & CONSTRUCTION

- Project management

- Mechanical configuration

- Material Selection

- Pigging operations

- Hydrostatic testing

- Cathodic protection

- Corrosion defect risk

assessment

- Control system

SIMULATION

- Flow configuration

- K7O using PRO II

- CFD, Heat conduction TDMA, Central differencing method

- Safety and hazard

- Pipeline toolbox 2006

E&CContractor

Per Aarsleff A/S

Pipe SupplierManufacturer

Sub-ContractorConsultant

ClientDONG

USERMaersk

PIPE

BOOK

ConsultantBureau

B

A

PROJECT MANAGEMENT

EXAMPLE:

User: Maersk Olie og GasClient: DONG, owner of pipelineConsultant: Aalborg UniversityMain contractor: Ex: Per Aarsleff A/s


PART - B









assessment

- Control system

SIMULATION


- K7O using PRO II


- Safety and hazard


MECHANICAL CONFIGURATION

D/t ratio of 16in., API X60 Pipeline

01020304050607080

0.00 5.00 10.00 15.00 20.00 25.00

Wall thickness, mm

D /

t

5.56

6.35

7.14

7.92

8.74

9.53

11.13

12.70

19.05

F = 0.72

MECHANICAL CONFIGURATION- Pipeline alignment sheet


PART - B









assessment

- Control system

SIMULATION


- K7O using PRO II


- Safety and hazard


FLOW CONFIGURATION


PART - B









assessment

- Control system

SIMULATION


- K7O using PRO II


- Safety and hazard


- Money,- Market availability,- Life,- Operating conditions, pressure, temperature and flow,- Weight,- Environment, air, water, earth and soil.

MATERIALS

Hardness Test

0100200300400500600700800

0 1 2 3 4 5

1-Hardness; 2-Tempered; 3-Untreated; 4-Corss section

Vick

er re

adin

Series1

Hardness of a martensitic steel

0100200300400500600700800900

0 0.5 1 1.5

% of carbon

Vic

ker's

Har

dne

Series1

Offshore pipeline:-

1. Mo is a good sea water resistant, expected to use in small amount which acts as passivating layer on surface.

2. Mn is good sulphur catcher, which is required to remove sulphur from a raw material while manufacturing.

3. Carbon =< 0.3% in order to be attain good weldability.4. Small amounts of Ni is added along with Mo which gives

flexibility and brittleness while laying pipeline.5. Composition - ASTM, AISI, API etc.

Onland pipeline:-

1. Mn is good sulphur catcher, which is required to remove sulphur from a raw material while manufacturing.

2. Carbon =< 0.3% in order to be attain good weldability.3. Composition - ASTM, AISI, API etc.

MATERIALS


PART - B









assessment

- Control system

SIMULATION


- K7O using PRO II

- CFD, Heat conductionTDMA, Central differencing method

- Safety and hazard


Heat conduction using CFD

- 1 dimensional heat transfer

- Steady state heat conduction

- Heat conduction from pipe-soil-environment

- Linearising the terms


TDMA method using MS excel sheet:

Heat transfer by conduction

020406080

100120140160180200

0 2 4 6 8 10 12Distance, Xi

Tem

pera

ture

,

Series1


Central differencing method using Matlab:

1 2 3 4 5

W P E

wxδ exδ

xδX = 0

X = 5

TA

TB

TW

TE

STaTaTa wwEEPP ++=

W

W

E

EP x

Kx

Kaδδ

+=E

EE x

Ka

δ=

W

WW x

Ka

δ=

.

wEP aaa += xSΔ Ppu TSS +and b = =


PART - B









assessment

- Control system

SIMULATION


- K7O using PRO II

- CFD, Heat conduction

using MatlabTDMA, Central differencing method

- Safety and hazard


PIGGING OPERATIONS


PART - B









assessment

- Control system

SIMULATION


- K7O using PRO II



- Safety and hazard


HYDROSTATIC TESTING

- Cleaning

- Gauging

- Filling

- Pressurising

- Evaluation

- Dewatering

- Swabbing

- Drying

- Commissioning

HYDROSTATIC TESTING

Volume required to fill section, V = 11623.52 m3

Pressure change due to temperature change, = 0.316 bar

Difference between initial and final adjusted pressure = - 0.116 bar

Pδ


PART - B









assessment

- Control system

SIMULATION


- K7O using PRO II



- Safety and hazard

CATHODIC PROTECTION

Net mass of anodes

05000

1000015000

20000250003000035000

0 20 40 60 80 100 120 140 160

Chainage, Km

Mas

s of

ano

d

Series1Series2Impressed current system:

Mass of anodes = 120Kg at K75 and K125 locations

Galvanic system:Mass of anodes = 30000 Kg/Km at all pipe jointing locations


PART - B









assessment

- Control system

SIMULATION


- K7O using PRO II



- Safety and hazard

Corrosion Defect Assessment - PIPELINE TOOLBOX 2006, RSTRENG

PIT measurement

0

50

100

150

200

250

300

0 1 2 3 4 5 6 7Total pit length, in

Pit

dept

h, m

PIT measurement


PART - B









assessment

- Control system

SIMULATION


- K7O using PRO II



- Safety and hazard

CONTROL SYSTEM- GAS PIPELINE

Pressure limiting system

A Operating pressure limiting system

B Safety pressure limiting system

C Thermal pressure safety relief system

1.

2. Compressor piping, SMYS = 3 x MOP

3. Mainline pressure NOT to exceed 10% of MOP = 60.5 bar

OR NOT to exceed 75% of SMYS4. Compressor piping pressure NOT to exceed 10% of MOP = 82.5 bar

CONTROL SYSTEM- GAS PIPELINE


PART - B









assessment

- Control system

SIMULATION


- K7O using PRO II



- Safety and hazard

SAFETY AND HAZARD

• Safety during hydrostatic testing

2. Chemical reaction concepts

3. Turbulance generation due to flame acceleration

4. Explosion in a gas pipeline

25C Temperature

Fuel concentration

0%

100%Vaporpressure

Flash point

AutoIgnitionregion

UFL

LFL

AIT

Flammable mixture

Ignition

Transition to detonation

DetonationSAFETY AND HAZARD

16 inch

Run up distance

Run up distance = 33 m.

Flame velocity, m/s.

Flame velocity = 30 m/s

Time taken to detonate the 16in pipeline carrying propane = 1.1 sec.

END OF PRESENTATIONTHANK YOU

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