Measurements, Transportation and Storage 504 Eng. Fathi Morgan

MINING STUDIES AND RESEARCH CENTER (MSRC)
FACULTY OF ENGINEERING CAIRO UNIVERSITY

NATURAL GAS ENINEERING DIPLOMA
Measurements,
Transportation &
Storage
NG 504
1
Fathy Ibrahim Emam Morgan
Engineering Consultant
Oil/Gas Piping and Pipelines
Engineering Consultants Group (ECG)
E-mail: fathymorgaan@yahoo.com
Cell No 0122 475 5741
Contact Information
2
MSRC - Natural Gas Engineering Diploma - Measurements, Transportation & Storage NG 504 Eng. Fathy Morgan
For successful implementation of a pipeline project,
the following steps are to be considered in general:
1. Market survey-Present & Future demand
2. Map of the preliminary selected pipeline route(L)
3. Selection of ROW
4. Detailed survey and Preparation of alignment
drawings
5. MAOP & Design pressure
Pipeline Design
3
6. Pipe Size (D)
7. Pipe specification / grade
8. Wall Thickness (t)
9. Bill of Materials
10. Total cost estimate
Pipeline Design (Contd.)
4
Load Consideration:
Presently pipeline design is being done
considering the present load as well as the
assumed gas load of the that particular area for
the next 20 years (effective life of the pipeline)
Now-a days, the use of natural gas increased
tremendously. As a result the concept of
pipeline design has also changed.
5
Line Pipe Wall Thickness Calculation:
t= DP/(2YFLJT)
Where,
t = Pipe wall thickness, mm
P= design pressure, psig
D= outside dia of pipe in mm
Y= minimum yield strength, psig
F= Design factor
L= Location factor based on class location
J= welding joint factor
T= Temp. derating factor
6
Grade Minimumyield
strength (MPa)
Minimum Tensile Strenght
(Mpa)
B 241 413
X42 289 413
X46 317 434
X52 358 455
X56 386 489
X60 413 517
X65 448 530
X70 482 565
X80 551 620
Line Pipe : API 5L Grades
7
Canadian Standards association(CSA) suggests
design factor of 0.8 While location Factors are:
Design and Location Factor
Area Class Location ASME CSA
Deserted 1 0.72 0.80
Village 2 0.60 0.72
City 3 0.50 0.56
Metropolis 4 0.40 0.44
8
Weld type ASME B31.8
Seamless 1
ERW 1
SAW 1
But Welled 0.6
Spiral seam 0.8
Joint Factor
9
Temperature ( F) ASME B31.8
Up to 250 1.00
251-300 0.97
301-400 0.93
401-450 0.91
451 and above 0.87
Temperature Factor
10
DPP
Land acquisition & Requisition
Tender Document Preparation
Tender
Bid Evaluation
Tender Award
Procurement
Mobilization
Clearing, Grading and Stringing
Pipeline Construction Process
11
Welding and NDT
Trenching, Lowering and Backfilling
Tie-in
Hydrostatic Testing
Cleaning
Commissioning
Operation
Pipeline Construction Process
(contd.)
12
Row Acquisition and Requisition
ROW SELECTION
DC Office
Compensation
Crop Compensation
Pre Construction
13
Minimize overall pipe length
Parallel existing utility corridors (Highway, High tension
Electric transmission line).
Avoid areas of high population density
Minimize highways, railways, river, khals, canals, ponds,
hills & mountains corssing to reduce the project cost.
Cross highways, railways, river, khals, canals at or close
to 90 deg. Angle
Minimize crossover of existing facilities
Provide adequate construction area.
Pre Construction (Contd.)
General Guideline For Pipeline Routing
14
Avoid the following areas:
Swamps and Wetlands
Rocky areas
Unstable soil
Populated areas
Historical areas
Environmental sensitive areas ( Forest, Tea garden,
Rubber garden etc.)
Religious sensitive areas ( Mosque, Graveyard, temple
etc.)
General Guideline For Pipeline Routing
15
Land acquisition / Requisition
Normally 10m wide strip along the proposed
pipeline route is to be acquisition and a 15 m
wide strip on one side of the acquisition strip is to
be requisition.
Acquisition is permanent possession for use of
land but requisition is completely a temporary
affair, only for the working period.
For scraper station and Valve station separate
block lands of required size have to be
acquisition.
16
Submission of proposal for land acquisition & requisition:
The company submit the proposal with requisite no. of
drawings ( Normally mouza map) showing acquisition
& requisition strip in two distinct colors (red for
acquisition & green for requisition) to DC office.
The process of acquisition and requisition in our
country is done through the DC office of the particular
distinct.
The whole process continues in accordance with
Ordinance, Arts, Rules and Regulation issued by the
government from time to time.
17
Tender
Floating
Bid Receiving & Evaluation
Contract Award & Contract Management
Procurement
Mobilization
18
Cleaning & Grading the ROW
Stringing the pipe along ROW
Welding the pipe joints together
NDT of welding joints
Coating and Wrapping
Ditching / Trenching
Holiday test
Lowering & backfilling
Pigging
Hydro Test
Commissioning
Major steps for pipeline
Construction
19
Bulldozer- Used to clearing & grading of ROW.
Excavator- Used to trenching, pipe lifting, pulling
the welding machine etc.
Side boom- Used to lift the pipe during welding
and lay the pipeline in the trench.
Crane- Used to handle heavy equipment and
machineries.
Welding generator
Trailer/ Truck- used to carry the line pipe from
store yard to the working site.
Equipment used for Pipeline
Construction
20
Pipeline Construction
Equipment
21
ROW is cleared of barriers and
graded for movement of
construction equipment,
materials and ultimately
construction of pipeline.
ROW Clearing and Grading
22
Welders test- an example for the welders
before going to production weld.
Selection Criterion- Visual inspection & NDT
(API 1104)
PQR / WPS Test
Tensile strength test
Face bend test
Root bend test
Charpy V notch test
Pre Welding Activities
23
Stringing is aligning the pipe
along the ROW ready for
welding.
Trailer, Side boom etc. are
used to stringing the pipe.
Stringing
24
Root pass/ Stringer pass
Hot pass
Filling pass
Cap pass
Cleaning the welds
Welding
25
Dye penetrant test
Magnetic particle test
Eddy current test
Radiographic test
Ultrasonic test
NDT personnel certification ( level 1, 2
&3)
NDT (Non Destructive Test)
26
Radiographic test
Equipment
Method
Source
Film examination as Per API 1104
Standard
27
Ultrasonic test
Equipment
Method
Source
Weld examination
28
Porosity
Cluster porosity
Slag inclusion
Lack of fusion
Lack of penetration
Internal concavity
Burn through
Crack
Common welding defects
29
Welding defects:
30
The final weld to join two separate
section together.
Should be properly aligned without
use of jacks or any external force.
Should be done within operating
temp (5-30 deg. Celsius).
NDT test.
Tie-in welds
31
Two different ways
Thurst boring/ horizontal boring method
Drill a hole under the roadway without disturbing
the road / rail surface.
A casing pipe is placed through the hole and then
the pipeline is placed inside the casing.
Spacer is used to center the pipeline within the
casing pipe.
Open Cut method.
Roads and Railway Crossing
32
All except a portion (about 6 inch) of each pipe is
often coated in the factory before deliver to the
site
Three types of coating
3LPE coating
FBE coating
Polyethylene coating
3LPE coating
Apply adhesive on clean pipe surface
Epoxy paint (40-100 micron)
Pipe Coating
33
Bare pipe
34
Features:
Cleaning (sand Blasting)
Apply Adhesive
Apply epoxy paint ( 40 100
micron thick)
3 LPE Coated Pipe
35
Apply 3LPE Coating
Set wire mesh above 3LPE
Coating
Apply Concrete coating
Provide Ve buoyancy force
Apply on ditch, canal, pond, khal,
small river
Features:
Concrete Coated Pipe
36
Put on above 3LPE
coated pipe
One on each pipe
Provide Ve buoyancy
force
Apply on Marchy area
Features:
Set-on-Weight
37
Heat shrink sleeves
Approx. 14 inch length and dia
larger than pipe dia.
Shrink on applying heat and fitted
to the pipe.
Joint coating
38
Ditching
Holyday test
Apply 10 KV on coated pipe surface
Any coating defect will result an audible
sound.
Lowering
Lay pipeline on Trench of approx. 1.2m depth
Put set-on-weight on buried pipe for anti
buoyancy force.
Ditching, Holyday test, Lowering
and Backfilling
39
Bruch/ cup pig
Clean internal rust
Gauge pig
To check pipe ovality
Foam Pig
To dry internal surface
Testing:
40
Natural Gas Equipment
Distribution System
Each time the pressure is reduced,
over pressure protection is provided
by a relief valve or automatic shut off
A relief valve venting gas to the atmosphere is
performing its proper function and should never be
cut off or restricted until the gas company arrives
and makes corrections to the system
41
Properties of Natural Gas
Odorless Colorless - Tasteless
Methyl Mercaptan is added to give it its
distinguishable rotten egg odor
Odorized natural gas is detectable at
concentrations significantly less than 1%
42
Distribution System
Type of System Pressure
Transmission Line
(High Pressure)
300 1000 psig
Distribution Main
(High Pressure)
60 300 psig
Distribution Main
(Modified High Pressure)
5 60 psig
Distribution Main
(Low Pressure)
psig
Service / Customer Line
psig
43
Material Color Size Pressure
Bare Steel - - - - - - 2 6 Up to 60 psi
Wrapped Steel Yellow / brown
20
Up to 1000 psi
Wrought Iron - - - - - - 2 6 Up to 60 psi
Polyethylene Plastic
Black / orange /
yellow
6
Up to 60 psi
Cast Iron - - - - - - 4 20
psi
Copper - - - - - -
-
psi
Piping
44
Polyethylene pipe is buried with a 12 gauge
wire for ease of locating it has nothing to
do with grounding or bonding
POLYETHYLENE PIPE
Piping
45
Distribution piping is normally buried between 12 and 18
below ground level
Piping
46
Shut-off Valves
Square - Handle
L - Handle
T - Handle
Side View
47
Shut-off Valves
Closed Position
Open Position
Top View
48
Typical Residential Installation
49
Regulator
Relief Valve
Valve
50
Meter
51
Commercial Installation
Meter
Valve
Regulator
52
Natural Gas Emergencies
Types of Emergencies
Odors / Leaks
Fire
53
Emergency Response
Odors / Leaks
Inside:
1) Approach incident from upwind, if possible.
2) Position apparatus at least 150 from scene.
3) Investigate for the source of the odor with the GasTrac & Mini-Gas.
4) If a strong odor is encountered or leak is confirmed, evacuate the
bldg. of all occupants.
54
Emergency Response
Odors / Leaks
Inside:
5) Notify BC GAS - Gas Op's to respond.
6) Ventilate the bldg. by opening doors & windows. Remember to
open windows on top.
7) Do not operate electrical switches / telephones.
55
Emergency Response
Odors / Leaks
9) If a leak is confirmed, the IC should determine if it can be stopped
or if the gas needs to be shut off at the valve.
Inside
8) Use only intrinsically safe radios / handlights.
56
Emergency Response
Odors / Leaks
11) Gas valves turned OFF by FD personnel SHOULD NEVER be turned
back on without BC GAS - Gas Op's on scene.
12) No one should re enter the bldg. until BC GAS - Gas Op's has
secured the leak and determined that it is safe to enter.
Inside
10) Hand tools should be spark-proof (1663 /
1665).
57
Emergency Response
Odors / Leaks
Outside
1) If unignited gas is escaping from the ground, either from an
excavation site or from an open pipe outside of a bldg., notify BC
GAS - Gas Op's immediately.
2) Establish a safe area around the incident scene.
3) Extinguish all open flames.
4) Check surrounding bldgs., especially basements, for the presence
of gas.
Gas can migrate through the ground, following pipes or natural
stratifications in the earth.
58
Emergency Response
Odors / Leaks
Outside
5) Restrict or re-route traffic until BC GAS - Gas Op's personnel can
bring the gas flow under control.
6) Although water fog streams can be used to disperse escaping
vapors, they are usually ineffective since the lighter-than-air gas
naturally rises.
7) If water fog is used, caution must be exercised to avoid filling
excavation sites with water.
59
Emergency Response
Odors / Leaks
Outside
8) FD personnel should never clamp or crimp a gas line. Static
electricity could ignite escaping gas, resulting in a sudden
and violent ignition.
9) Hand tools should be spark-proof (1663 / 1665).
60
Emergency Response
Fires Inside:
1) Notify BC GAS - Gas Op's immediately upon receipt of alarm.
2) The IC should determine if the gas can safely be shut off inside the
bldg. or at the meter.
61
Emergency Response
Fires
Inside:
3) In certain industrial / commercial settings, turning off the gas supply
can seriously interrupt important and costly industrial processes and
should only be done upon evaluation with company personnel and BC
GAS - Gas Op's.
4) If the gas supply cannot be shut off, the surrounding combustibles
should be kept wet with a fog stream.
62
Emergency Response
Fires
Outside:
1) Notify BC GAS - Gas Op's immediately upon receipt of alarm.
2) The best method of controlling outdoor gas fires is to shut off the
gas flow.
3) In most cases, FD personnel should not attempt to extinguish the
fire while the gas is still escaping.
4) BURNING GAS WILL NOT EXPLODE.
63
Emergency Response
Fires
Outside:
5) Secure the area and protect exposures, if necessary.
6) IF it is necessary to extinguish the fire before the gas flow can be
stopped, use a Dry Chem extinguisher aimed at the base of the
flame and wet the surrounding area with water fog to prevent the
re-ignition of combustibles.
64
Natural Gas
An Operational
Perspective
65
EXPLORATION AND
PRODUCTION
66
GATHERING AND
PROCESSING
67
Natural gas has to go from
Point A to Point B.
Point Ainvolves getting the gas out
of the ground and into the pipeline.
Point B is where the gas eventually
ends up, so you can cook your food and
heat your home.
The line that connects Point A to Point B is
where the midstream industry takes over.
68 MSRC - Natural Gas Engineering Diploma - Measurements, Transportation & Storage NG 504 Eng. Fathy Morgan
Gas Processing connecting
A to B
Raw natural Gas consists of hydrocarbons:
Methane
Propane
Butane
Pentane
plus many more
It also contains undesired materials: sulfur compounds,
water, mercury, etc.
69
That raw natural gas must be purified, or
processed, to meet quality standards and
specifications set by the major pipeline and
distribution companies
70
A more detailed view
71
72
TRANSMISSION AND
STORAGE
73
74
Distribution piping is normally buried between 12 and
18 below ground level
Piping
75
Agenda
Transporting Gas
Interruptible
Pipeline Map
Basic Rules of Interstate Transportation
Services
Business Processes
76
What is Gas Transportation?
Gas Transportation - service provided by the pipeline
for the party that has requested the transportation
service. The pipeline is the link between the gas
supplies and the markets.
Involves the receipt of the gas by the transporter, the
movement of gas through the transporters system and
the delivery of gas by the transporter for the shippers
account.
Service can be firm or interruptible.
77
Interruptible Service
Firm Service is a service that is offered on a guaranteed basis. The
pipeline, also known as the Transportation Service Provider (TSP),
warrants that it will make the service available on every day of the
contract unless prevented by an act of Force Majeure.
For this firm service, the customer, also known as the Service Requester
(SR), will generally pay a demand and a commodity charge. The total
charge is generally higher than interruptible services.
Firm services have a higher priority than interruptible services. Firm
service contracts generally have a term of over a year.
78
Interruptible Service
Interruptible Service is a service that is not a guaranteed service. The
TSP can generally cease the performance of the service with short or no
notice. The TSP will interrupt if the pipeline space used for interruptible
service is required to serve a higher priority customer.
The SR of the interruptible service will generally pay only a commodity
charge when the service is utilized. The total cost of the service is usually
less than the cost of a firm service. The interruptible service is less
reliable by definition.
79
80
Basic Rules of Interstate Transportation
When Crosses state boundaries.
As such, the service:
- Must be offered on a non-discriminatory basis.
- Must allow firm contract holders to release to other parties so some of the
reservation costs paid by the firm shipper ma be recovered when the capacity
would otherwise not be used.
- Customers must be able to change their firm receipt and delivery points. All
other receipt points must be made available to the customers on an interruptible
basis.
- Customers have rights beyond their contract path but within the same rate zone.
81
Services Offered by Pipelines
Firm Transportation
The highest quality transportation service offered to customers under a filed rate schedule
that anticipates no planned interruption.
No-Notice Service
A bundled, city-gate service that allows customers to receive gas on demand to meet peak
service needs subject to delivering supplies into the pipeline.
Interruptible Transportation
Transportation service subject to interruption at the option of the pipeline.
Storage Service
A firm or interruptible service that allows customers to store natural gas that has been
transferred from its original location
82
Services offered by Pipelines
(continued)
Pooling Service
A firm or interruptible service that allows customers to aggregate natural gas from many receipt points to
serve a number of contracts without tying a particular receipt point to a particular contract.
Parking Service
An interruptible service which allows a customer to request that the pipeline hold on its system, gas
quantities that have been delivered by the customer under any transportation agreement between the
pipeline and the customer, and then return such gas quantities at thecustomers request.
Loan Service
An interruptible service which allows a customer to receive gas quantities from the pipeline and then
return such loaned quantities of gas to the pipeline at the point in which the gas was borrowed.
83
Local Distribution
84
85
How the Natural Gas Distribution System
Works
Local Gas Distribution Companies Overview
Natural gas distribution is the last step in the delivery process
What is a natural gas LDC?
Generally state regulated entities which operate gas distribution piping systems
that serve
gas locally to homes, businesses and industrial customers
Some are municipally-owned
Operate in defined, exclusive service territories
Statutorily obligated to provide reliable natural gas service to customers at just
and reasonable rates, terms and conditions
Local distribution is exempt from FERC jurisdiction under NGA 1(b)
NGPA definition
86
Where does transportation end and local distribution begin?
No bright line from FERC; but generally movement through large diameter
pipelines at higher pressure (over 350 psia) is considered transportation;
particularly if the line is not regulated by a state PUC
Supreme Court decision in FPC v. East Ohio Gas Co., 338 U.S. 464 (1950)
Congress responded with Hinshaw exemption NGA 1(c)
How the Natural Gas Distribution System
Works contn.
87
Differences from Interstate Pipelines
Generally, LDCs operate at lower pressures, use smaller diameter pipes, and
the distribution pipes directly connect to the house lines of local homes and
businesses
LDC systems differ among themselves, but generally consist of:
high pressure transmission lines, lower pressure mains and service lines,
regulators, a wide variety of meters, and odorization equipment
May include on-system storage, LNG storage, and propane-air
88
LDC Customers and Services
Types of LDC customers: retail, commercial, and industrial
Types of LDC services:
Sales Service to Core/Retail (firm and interruptible services)
Transportation Service (firm and interruptible)
Retail unbundling (customers purchase gas commodity directly from
suppliers/marketers)
LDCs connect to interstate pipelines at citygate points
LDCs purchase natural gas commodity at wholesale from
producers/marketers
Receive the gas from the supplier at the citygate; and/or
Receive the gas at upstream points and move the gas on interstate
pipeline capacity
89
LDC Resources Used to Serve Core
Customers
Typical LDC resources include:
Gas purchased outside of the LDCs service territory
Supplies previously purchased and held in storage facilities outside of the
LDCs service territory
Supplies previously purchased and held in peaking facilities inside the LDC
service territory
Supplies purchased from local production wells in the state
Diversion of supplies from interruptible customers understate-approved tariff
curtailment provisions
90
LDC Operating- System
Movement on LDC systems involves moving smaller volumes of gas at lower
pressures to numerous individual customers.
To ensure flow, gas may be perioducally compressed at compressor stations,
but the pressure required on LCD systems is much lower than on an interstate
pipeline.
Supervisory control and SCADA systems monitor gas flow on the distribution
network.
To detect leaks, gas is odorized at the citygate with mercaptan
Piping system is steel for higher pressure main and polyethylene(plastic) in
lower pressure mains and service lines.
91
LDC Operations - Service
Generally, customers do not make nominations.
Gas consumed at the residance or business is measured by a onsite
meter.
Customers are billed according to use and rate schedule.
Storage or on-system needle peaking storage is used as an additional
resource to meet core needs.
92
LDC Focus on Safety
LDC safety programs include:
Leak detection response
Safety education
One Call Systems
Emergency plans and responsiveness
State statutes and regulations adopt DOT
safety requirements
93

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MINING STUDIES AND RESEARCH CENTER (MSRC)

FACULTY OF ENGINEERING CAIRO UNIVERSITY

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