MARGARITA EPF PROJECT

Flow Line & Export Pipelines

Basis of Design
Memorandum

Prepared by :

Consorcio
ICBA

Santa Cruz, Bolivia

July, 2003

TABLE OF CONTENTS

Section No.

Title

Tab No.

1.0

Introduction
1.1 Project
1.2 Location
1.3 Project Number
1.4 Owner
1.5 Client
1.6 Project Description

2.0

Basis of Design
2.1 Client Furnished Data and Assumptions
2.2 Applicable Codes and Standards

3.0

Methodology
3.1 Pipeline Route Location
3.1.1 Pipeline Corridor
3.1.2 Buildings Intended for Human Occupancy
3.1.3 Locations Classes
3.2 Line Lengths
3.3 Right-of-Way and Trench
3.4 Line Sizing
3.5 Wall Thickness Formulae
3.5.1 Line Pipe Cross Country
3.5.2 Railroad and Road Crossing Pipe
3.5.3 River Crossing Pipe
3.5.4 Charpy Values
3.6 Field Bends
3.7 Weld Bevels
3.8 Blowdown Sizing
3.9 Mainline Valve Setting
3.10 Scraper Traps
3.11 River Crossing Location and Design
3.12 Wet Land Area Design
3.13 Meter Stations
3.14 Pressure Alert Valve
3.15 SCADA System
3.16 Cathodic Protection and Monitoring System
3.17 Hydrostatic Test

Section No.

Title

4.0

Calculation Results
4.1 Location Classes and Design Factor, F
4.2 Line Lengths
4.3 Line Sizing
4.4 Wall Thickness Formulas
4.4.1 Maximum Allowed Operation Pressure
4.4.2 Railroad and Road Crossing Pipe
4.4.3 River Crossing Pipe Wall Thickness
4.4.4 Calculated Charpy Valves
4.5 Weld Bevels
4.6 Blowdown Sizing
4.7 Mainline Valve Settings
4.8 Scraper Traps
4.9 River Crossing Design
4.9.1 Major River Crossings
4.9.2 Minor River Crossings
4.9.3 Creek Crossings
4.10 Wetland Areas
4.11 Meter Stations
4.12 Pressure Control
4.13 SCADA
4.14 Cathodic Protection and Monitoring System
4.15 Hydrostatic Test

5.0

Design Data and Calculations

Hydrostatic Calculations
MAWP Pipe
Blowdown Sizing
Stresses in Road Railroad Crossing Pipe
Buoyancy Calculation for wetlands
Ultrasonic Meter Flow rates
Control Valve Sizing
Minor River Scour Calculations|

Tab No.

LIST OF EXHIBITS
Section No.

Title

1a
1b

Preliminary Pipeline Location (Original Route)

Preliminary Pipeline Location (Alternative # 1)
( As per Commercial Document )
Surveyed Route
Pipeline Schematic
Right of Way and trench
Right of Way and trench
Right of Way and trench for Wetlands
Right of Way and trench for Wetlands
Design Flow Diagram
Weld Bevels
Typical Minor River Crossing
Typical Creek Crossing
Fill Water Pipeline Schematic Diagram

2
3
4a
4b
4c
4d
5
6
7
8
9

Tab No.
6
6
6
6
6
6
6
6
6
6
6
6
6

LIST OF TABLES

Table No.

1
2
3
4
5
6
7

Title

House Count and Location Classes Summary

Line Lengths
Hydraulic Calculations Results (Example Only)
Pipe MAWP vs. MAOP
Road and Railroad Crossing pipe
Mainline Valves Settings (Example Only)
Scraper Traps Location

Tab No.

7
7
7
7
7
7
7

BASIS OF DESIGN
1.0 Introduction
1.1 Project Margarita EFP Project - Flow Line & Export Pipelines
1.2 Location

Margarita Fields, South of Bolivia

1.3 Project Number

0670 8300

1.4 Owner/Client

MAXUS Bolivia Inc.

Address:

1.5 Client

Av. Jos Estensssoro # 100

Santa Cruz de la Sierra
Bolivia.

Address:

Consorcio ICBA
Km. 3 Carr. Cbba Casilla : 3616
Telfono Piloto: 352 9270
Fax : 352 3713
Santa Cruz de la Sierra
Bolivia.

Management:
Project Director:

Mel Schulze

Cell Ph.:
Ph.:
Fax:

(591) 716 - 88285

(591) 3 337 7282 / 352 - 9270
(591) 3 337 7283 / 352 - 3713

Project Manager:

Jack Bogan

Engineering Manager:

John Belew

1.6 Project Description

These is EPC Project, where plans the installation of a 8 5/8 O.D.
Gathering System approximately 30.2 Km into its under construction
Margarita EPF Gas Treating Plant Facilities. Gathering System Flow lines
will commence at the existing wellheads, Margarita X1 and X3.
Also, plans the installation of the 6 5/8 O.D. liquid Exporting Pipeline
approximately 54 Km length leaving its under construction Margarita EPF
Gas Treating Plant Facilities and interconnecting at the delivery point to a
6 O.D. Oil Transmission Pipeline.
Also, include the installation of the 10 O.D. Gas Exporting Pipeline
approximately 51 Km in length leaving its under construction Margarita
EPF Gas Treating Plant Facilities and interconnecting at the delivery point
to a Gas Transmission Pipeline. Both delivery point at the Hot Tap fitting
connection.

Basis of Design

2.1

Furnished data and Assumptions

The following data furnished by MAXUS Bolivia Inc. and/or proposed by
INTEC Engineering will be used as a basis of design:

Preliminary Pipeline Location Exhibits 1a & 1b.

Design Code ASME / ANSI B31.4 Pipeline Transportation System for Liquids
Hydrocarbons and B31.8 Gas Transmission & Distribution Pipeline System.

Pipeline Diameters:
W.T. Grade

Design Pressure:

Pipe Lengths:
Gathering Sys.
Export Liquid Line
Export Gas Line

8.625O.D.

6.625O.D.

10.750O.D.

0.375 X60 0.280 X60 0.365 X60

0.500 X60 0.344 X60 0.500 X60
1.900 psi

1.700 psi

1.770 psi

30 Km
54 Km
51 Km

ANSI Class Rating:

1.500 lbs.

900 Lbs.

900 Lbs.

Corrosion Allowance:

3 mm.

3 mm.

3 mm.

Design Factor:
Location Class 1
River Crossing
Fabrication

0.72
0.72
0.72

0.72
0.72
0.72

0.72
0.72
0.72

External Coating:
Internal

3 Layers coating Polyproplyene

None

Joint Coating:

Same as Yard Place Application.

Specify Gravity:

0.600

Standard Conditions:
Temperature
Pressure

60 F
14.73 psia

Rigth-of-Way Width:

15 meters Permanent

Block Valves: Full Opening Ball Type spaced to meet Code requirements


2.2

Meter Stations:
Gas Meter is Multi-path Ultrasonic and Liquid Turbine
Applicable Codes and Standards
The last revision of all codes, standards, and applicable governmental
regulations shall be followed except as modified to be more stringent by these
criteria. Legal requirements shall have preference over these criteria unless the
authorized legal authority grants an exception.
Unless otherwise noted, references made herein to codes, standards and
specifications are to the latest edition.

ASME B31.4, Piping Transportation System for Liquids Hydrocarbons.

ASME B31.8, Gas Transmission and Distribution Piping Systems.
ASME B 31.3, Process Piping Section VII.
American Petroleum Institute, Specification for Pipeline Valves, End Closures
Connectors and Swivels, API 6D.
American National Standards Institute, Steel Pipe Flanges and Flanged
Fittings, ANSI B16.5
American National Standards Institute, Factory-made Wrought Steel ButtWelding Fittings, ANSI B16.9
American Society of Mechanical Engineers, Boiler and Pressure Vessels Code,
Section VIII, Pressure Vessels, Division 1.
American Petroleum Institute, Specification for Line Pipe, API 5L.
American Petroleum Institute, Recommended Practice for Railroad
Transportation of Line Pipe, API RP 5L1.
American Petroleum Institute, Recommended Practice for Marine
Transportation of Line Pipe, API RP 5L5.
American Petroleum Institute, Recommended Practice for Liquid Petroleum
Pipeline Crossing Railroad and Highways, API RP 1102.
American Gas Association, Measurement of Gas by Ultrasonic Meters,
Transmission Measurement Committee Report N 9.
National Corrosion Protection Engineering, Recommended Practice for
Design of Underground Piping Systems, NACE-RP-69.
Manufacturers Standardization Society, Standard Marking System for Valves,
Fittings, Flanges and Unions, MSS SP-25.
Manufacturers Standardization Society, Steel Pipe Line Flanges, MSS SP-44.
Manufacturers Standardization Society, Specifications for High Test Wrought
Butt-Welding Fitting, MS SSP-75.
Manufacturers Standardization Society, Steel Valves Socket Welding and
Threaded Ends, MSS SP-84.
American National Standards Institute, Manual of Petroleum Measurements
Standards, Chapter 14, Section 3, ANSI/API 2530.
American Gas Association, Orifice Metering of Natural Gas, Reports Nos. 3
and 3A.
American Society for Testing and Materials, Fittings of Wrought carbon Steel
and Allow Steel for Moderate and Elevated Temperature, ASTM A234.

American Society for Testing and Materials Standard Specification for

Seamless carbon Steel Pipe ASTM-A106.

Methodology
3.1 Pipeline Route Location
3.1.1

Pipeline Corridor
The Gathering & Export Pipelines will be located in a corridor
extending 500 meters each side of the pipeline location supplied by
MAXUS Bolivia Inc.
A map showing the preliminary route location is included as Exhibits
1a and 1b.
Any pipeline relocation outside of this corridor will be submitted to
MAXUS Bolivia Inc. for approval. Explanations for the recommended
relocation are to given.

3.1.2

Buildings Intended for Human Occupancy

The numbers of the buildings intended for human occupancy in a zone
400 meters wide along the pipeline centerline will be determined by
field investigation and will be plotted on the alignment sheets.

3.1.3

Location Classes
Gas pipeline will be divided into random sections of 1.5 Km. in length
such that the sections will include the maximum number of buildings
intended for human occupancy.
The location Class and Design Factor F will then be determined in
accordance with ASME B31.4 & B31.8.

3.2 Line Lengths

The line lengths used in the preliminary design work were determined by
scaling the lengths from the Owners furnished maps and adding a
roughness factor to provide for bends and minor line changes. These
lengths will be replaced by the slack chain surveyed distances as they
become available.
3.3 Right-of-Way and Trench
The Right-of-Way and trench configuration proposed for the project is
included as Exhibit 4a and 4b. The minimum cover depth for Normal Soil
will be 0.80 meter except in rock and wetlands. For rock the minimum
cover depth will be 0.45 meters, and for wetlands 1.5 meters from the top
of the concrete coating pipe.

3.4 Line Sizing

Hydraulic calculations to confirm the 6; 8 &10 line sizes will be made
using the American Gas Association (AGA) flow equation modified by the
Colebrook-White transmission factor as showed below,
6

Q (38.774)(10 )(d

Where:

2.5

T
)( F ) b
Pb

P12 P22

(G )(T f )( Z avg )( L)

0 .5

Q = Flow rate (MMSCFD)

T b = base temperature (520 R)
P b = base pressure (14.73 psia)
P 1 = upstream pressure (psia)
P 2 = downstream pressure (psia)
G = gas specific gravity ( air = 1.0 )
T f = flowing gas temperature (R, R = F + 460)
Z avg = gas compressibility factor
L = pipe length (miles)
d = pipe inside diameter (inches)
F = transmission factor = 4 Log 10 (3.71 d/K e )
K e = effective roughness (inches)

INTEC Engineering uses GASMOD Version 4.0, Gas Pipeline Hydraulic

Simulation for Windows for gas flow calculation. Model scenarios for the
Gathering & Export Pipelines will be made for the volumes, using the
following parameters :

Pipeline Efficiency 98%

Pipe Burial Depth 1 meter
Gas Specific Heat Radio 1.29
Gas Specific Gravity 0.600
Maximum Gas Velocity 50 ft/sec
Base Temperature 60 F
Base Pressure 14.73 psia
Pipe Thermal conductivity 29 Btu/hr/ft/degF
Soil Thermal Conductivity 0.800 Btu/hr/ft/degF

3.5 Wall Thickness Formulae

3.5.1

Line Pipe

INTEC Engineering uses the Steel Piping Design Formula from ASME
B31.4 & B31.8 to determinate the appropriate wall thickness and/or
maximum allowable working pressure/design pressure of the line in
accordance with ASME B31.4 & B31.8 requirements.
The formula is as follows:
P=
Where:

3.5.2

P
S

=
=

D
T
F
E
T

=
=
=
=
=

2S t
FET
D

Design pressure, psig

Specified minimum yield strength, psi.
Stipulated in the specifications under which the
pipe was purchased from the manufacturer.
Nominal outside diameter of pipe, inches
Nominal wall thickness, inches
Design factor
Longitudinal joint factor
Temperature rating factor

Railroad and Road Crossing Pipe

API RP 1102 will be followed to determinate the minimum wall
thickness for line pipe installed for railroad and road crossing.
INTEC Engineering uses PC-Pisces, personal Computer pipeline Soil
Crossing Evaluation System to determinate the stresses on uncased
pipe on crossings. Cornell University developed this software under
the sponsorship of the Gas Research Institute. A flow diagram of the
design procedure is included as Exhibit 4.

3.5.3

River Crossing Pipe

Wall thickness calculations for major river crossings will be based a
Design Factor of 0.60. The pipe is to be manufactured by the sumerged
arc process. Calculations will be based on river water with a specific
gravity of 1.25. Consideration will be given to horizontal directional
drilling the major river crossings.
Wall thickness calculations for minor river crossing will be based on a
Design Factor of 0.72. The pipe is to be manufactured by the ERW
process. Calculations will be based on river water with a specific
gravity of 1.25. Special construction pipe provided with a continuous
concrete coating will be used on the minor river crossing.
Regular line pipe will be used on the creek crossing. Concrete bolt-on
weights to be installed where negative buoyancy is required or as
instructed by the Company.

3.5.4

Charpy Valves
In detail design description in Project Execution Plan.

3.6

Field Bends
Large angle bends shall be broken down into several smaller angles to insure
the maximum allowable bend per joint of pipe is not exceeded. The maximum
field bend per joint of pipe shall not exceed 1- degrees per pipe diameter
length after allowance for leading and trailing tangents required by bending
machine. An internal mandrel will be specified for all field bends. All bends
shall be located within the right of way. Wrinkle or mitre bends will not be
allowed.

3.7

Weld Bevels
All joints will be designed for a 100% joint efficiency. Bevels and transitions
will comply with B31.4 & B31.8 requirements.

3.8

Blowdown Sizing
The following formula will be used for determining valve sizing for pipeline
blowdown time:
(0.0588)( P1 )1 / 3 (G )1 / 2 ( D 2 )( L )( Fc )
Tm=
( d ) 2 ( n)

Where:

T m = Blowdown time, minutes

P 1 = Initial pipeline static pressure, psig
G = Specific gravity of gas
d = Inside diameter of blowdown riser, inches
L = Length of pipeline, miles
D = inside diameter of pipeline, inches
n = Number of risers blowing
F c = Choke factor, depend of type of valve

Valves for F c

Fc

Thru port Gate or Ball

Regular Gate
Plug Valve, Regular Pattern
Plug valve, Venturi Pattern

1.6
1.8
2.0
3.2

3.9 Mainline Valve Settings

Mainline Line Block Valves (MLVs) will be installed to meet ASME B31.4 &
B31.8. Code requirements. The valves are to be full opening to permit the
passage of scrapers. All valves will be gear operated.
Final locations of the MLVs will be field determined with due consideration
to accessibility at intervals to meet code requirements.
3.8 Scraper Traps
Scraper traps will be installed at the beginning and terminal of each pipelines.
The scraper traps will be designed to handle an electronic inspection device
(intelligent pig). The scraper barrel will be designed with extruded outlets and
scraper trap assembly will be designed with a maximum design factor, F of
0.60.
Tees will be provided with guidebars.
3.9 River Crossing Location and Design
The design of the pipeline river crossings will consider the following
activities:

Regime analysis
-

Historical behavior of the channel, over a period, based on conditions

of water and sediment discharge, width, depth, slope, meander form
and progress and degradation of the riverbed.

Hydrology
-

Estimate of Standard Project Storm (SPS). The Standard Project

Storm estimate for the specific drainage area above the crossing and
season of the year representative of should represent the most severe
flood-producing rainfall depth-area-duration relationship.

Estimate of Standard Project Flood (SPF) representing flood

discharges that may be expected from the most severe combination of
meteorological and hydrologic conditions that are considered
reasonability characteristic of the geographical area, excluding
extremely rare or unlikely combinations.

Derivation of Project Design Flood (PDF) representing flood

hydrograph or peak discharge value to be used as the basis for design

after full considerations has been given to flood characteristics,

frequencies, and potentialities, and the economics and continuity of
service considerations and other practical considerations entering into
the selection of the design discharge criteria.
-

Delineation of the floodplain boundaries.

Routing the SPF and/or the PDF through the stream crossing. All
routing will use Mannings Equation:

Q=
Where:

1.486
(A)(R 2 / 3 )(S 1 / 2 )
n

Q = Discharge in cubic feet per second

A = Area of flow in square feet
R = Hydraulic Radius A/WP in feet
WP = Wetted Perimeter
S = Slope of water surface in feet per foot
n = Manning roughness coefficient

Field Reconnaissance
Potential problem areas will be studied in detail including potential cutoffs,
evidence of valley wall instabilities and crossing constructability.

Stream Surveys
Stream surveys consisting of:
-

Floodplain bank and bed topography

Vegetation and surface materials
Observed high water levels at bank full and design flood conditions
Longitudinal survey of channel noting water level and high water
marks and minimum bed elevation
Velocity and discharge at the crossing section
Particle size distribution of bed and bank material samples
Core samples and river bed analysis at crossing site

Channel Hydraulics
Depth of scour will be calculated by using Blenchs equations for regime
depth:
dr =

Q2
Fb

Where:

Q=

Qscour
= Unit discharge
bavg

d r = regime depth
b = channel breadth
F b = bed factor = F bo ( 1 + 0.12C )
F bo = zero bed factor
C = bed load charge
The value of F bo is determined from one of the following equations
(whichever is greater):
F bo = 48

D 0.5
d

or
F bo = 7.3 D 0.25
Where:

d=
D=

maximum depth of water below design water surface.

Median particle size
Scour depth, d s = Z x d r
Z= Values for Estimation of Scour Depth

Conditions

PDF

Bankfull

Forced Ridig Bend

Free Eroding Bend
Confluence
Obstruction
Impinging Flow

1.4 2.50
1.4 1.75
1.5 2.00
1.75 2.50
1.75 2.50

1.4 4.0
1.4 2.5
2.0 3.0
2.5 4.0
2.5 4.0

Depth of Pipe
d p =ds +dd +S
Where:

d p = depth of top pipe from the design water surface.

d s = depth of scour from the design water surface.
d d = channel degradation due to downstream channel cutoff,
or washing out or rapids downstream of the crossing.
S f = a safety margin which may be required to account for
uncertainties in the data.

Bank migration potential

Factor to be considered are:
-

The down-valley shifting of the meander pattern

The potential for a downstream cutoff

Bank material composition

Bank vegetation

Natural protrusions or man-made work in the vicinity of the pipeline

crossing

The presence of bedrock

Width of the valley

3.10

Wetlands Area Design

A special design will be used for all the wetlands areas in order to provide
sufficient pipeline negative buoyancy and to mitigate damage to the
environment.

3.11

Meter Stations

Gas Meter is Multi-Path Ultrasonic and Liquid is Turbine will be installed at

terminal of each pipelines.
The metering station will be designed including ultrasonic meter runs sized to
measure the volumes and pressures.
The design shall comply with AGA Report No. 9 Measurement of Gas by
Ultrasonic Meters.
Isolation valves upstream of the meter shall be full opening and self-sealing.
Piping will be sized for a maximum velocity of 2,500 feet per minute utilizing
the following formulas:
A=
Where:

Qf
V

A = Cross sectional area of pipe in square feet

Q f = Gas volume in cubic feet per minute at flowing
temperature and pressure.

Qf =

Tf
Pb
Q
x
x
xZ
P1
1440 Tb

V = Linear Gas Velocity

Q=

Gas volume in cubic feet per day at base temperature

and pressure

1440 = Number of minutes per day

T b = Base temperature in R = 520 R
P b = Base pressure = 14.73 psia
P 1 = Flowing pressure in psia
Z = Gas compressibility factor

The following formula will be used to calculate the maximum capacity at

reference (base) conditions for ultrasonic meters:
Q ref = Q f x
Where:

Pf Tref Z ref
Pref T f Z f

Q ref = flow rate at reference conditions (Scfh)

P ref = absolute pressure at reference conditions (psia)
T ref = absolute temperature at reference conditions (R)
Q f = flow rate at operating conditions (cfh)}
P f = absolute pressure at flowing conditions (psia)
T f = absolute temperature at flowing conditions (R)

Z f = compressibility of gas at flowing conditions

Z ref = compressibility of gas at reference conditions

3.12

Pressure Alert Valve (PAV)

Pressure Alert Valve (PAV) will be sized and installed at terminal of each
pipeline to protect plant from overpressure. Each PAV will have a monitoring
valve, which will be set at a difference range than the PAV and will operate
only when PAV fails to alert the pressure to meet delivery requirements.
The valve sizing will be done using the following formula:
Q=
Where:

3417
520
x C g P 1 SIN
GT
C1

P1

DEG

C 1 = C g /C v
C g = gas sizing coefficient
G = gas specific gravity
P 1 = valve inlet pressure, psia

P = pressure drop across the valve, psi

T = absolute temperature of gas at inlet, deg. Ranking.

3.13

SCADA System

A SCADA System for the acquisitions of measurement data will be designed

utilizing flow computers, Radio Modem and Fiber Optic Cable, and will be
controlled and monitored from the central control room. The Radio Modem
and Fiber Optic Cable will be installed at each meter run location where no
other means of communication is available.
The SCADA system will be consistent with the system to be used in the main
line.

3.14

Cathodic Protection and Monitoring System

A Cathoric Protection (CP) System will be designed and located according to

the results of soil resistivity survey. The system will consist of rectifiers, anode
beds, test leads, and insulated flanges. Rectifiers will be solar powered.
Insulated joints are to be installed at strategic locations to allow segmenting of
CP system and allow isolation of above ground and connected facilities from
the mainline CP system.
A grounding cell consisting of two zinc anodes will be installed at each
insulated joints to reduce danger shock, arcing and burning of insulating
material due to lightning.

Project design drawing will show the type and location of all cathodic
protection test stations to be installed.
Test stations will be installed, where possible, in areas that are reasonably
accessible to collect test data. Property or ownership boundaries will be the
generally preferred locations.
Test Stations will be installed at intervals of two kilometers. The test stations
installed at specific locations as outlined below will be counted toward
achieving this spacing.

SPECIFIC LOCATIONS
-

Type A, current test taps will be used at unusual locations such as

cathodic protection rectifiers and at foreign line crossing where
interference may be expected.

Test stations will be installed at the following locations to the extent

practical.

At public road crossing, cased or uncased, and railroad crossing.

At crossing of foreign metallic objects, such as pipelines and cables,

where physical locations allow permanency of the test station and the
foreign operator allows the insulation on the foreign facility to be
made.

At high voltage power transmission lines at the point where the power
line crossed the pipeline, or, in the case of a parallel power line, at the
points on the pipeline where the power line becomes and ceases to be
parallel to the pipeline. When practical and the power line towers are
metallic, the test station will be physically located near a tower.

At insulating flanges or other insulating devices installed in the piping

to isolate pipeline segments if the insulating device is not above grade.

At galvanic anode locations where practical, except for hot spot

protection, to enable testing both potential level and current output of
anode (s).

3.15

Hydrostatic Test

The pipeline is to be hydrostatically tested in place after construction to a

minimum pressure of 1.25 x MAOP (1,700 psig for 6 and 10) or 2,125 psig

and 2,375 psig (1,900 psig for 8); and a maximum pressure that will produce
a hoop stress equal to 110 % SMYS.
During the design phase preliminary hydrostatic test sections will be plotted
on the profile sheets to determinate if pipe yielding will occur during test
elevation differential.
Consideration will be given to installing short sections of heavy wall pipe in
low and other critical areas to prevent pipe yielding and/or to reduce the
numbers of test sections.
If the test sections are modified, they shall be submitted to INTEC
Engineering for review and approval.

Calculation Results
4.1 Location Classes and Design Factors F

Initially the entire line is classified as Location Class 1 with a design factor
0.72. The house count and Location Classes are summarized in Table 1.
The House Count performed along with the survey confirmed the Location
Class 1 classification for most of the line.
The pipe for Location Class 1 will be:
o 8.625O.D.
W.T. Grade

6.625O.D.

10.750O.D.

0.375 X60 0.280 X60 0.365 X60

0.500 X60 0.344 X60 0.500 X60.

4.2 Line Lengths

The total line length is 135 km., of which 30.2 Km are 8 O.D. Gathering
System; 54 Km are 6 O.D. Exportation Liquid System, and 51 Km are 10
O.D. Exportation Gas System pipelines.
4.3 Line Sizing
The results of the hydraulic calculations for the 6; 8 and 10 O.D. pipelines
and MAOP, where received from MAXUS Bolivia in Tender Document and
where calculated during the feed study.
Exhibit 2 shows the Pipeline Surveyed Route, and the Exhibit 3 shows the
Pipeline Schematic.
4.4 Wall thickness
4.4.1

Line Pipe

Table 4 summarizes the MAWP of the pipe to be used for the different design
factors in order to achieve the MAOP of 1,700 psig. for 6 & 10, and 1,900
psig for 8.
4.4.2

Road and Railroad Crossing Pipe

Calculations were made to determinate the minimum wall thickness required

to handle the combined stresses for uncased road crossings. Calculations were
based on a minimum cover depth of two meters.
A comparison of the minimum required wall thickness with the proposed wall
thickness is given in Table 5.
The calculations indicate that the proposed thickness are adequate in all cases.
4.4.3 River Crossing Pipe
In detail design description in Project Execution Plan

The pipe proposed for the major river crossings is with:

8.625O.D. x 0.500 W.T. API 5L-Gr.X60 ERW. (Gathering Line)

6.625O.D. x 0.344 W.T. API 5L-Gr.X60 ERW. (Exportation Line)
10.750O.D. x 0.500 W.T. API 5L-Gr.X60 ERW. (Exportation Line)
This pipe provides an actual design factor of 0.40.
4.4.4

Calculated Charpy Valves

In detail design description in Project Execution Plan

4.5 Weld Bevels
Weld bevels shall comply with Exhibit 6.
4.6 Blowdown Sizing
The blowdown time hole line of 30.2 Km. Section using six-inch blowdown
stacks was calculated to be 83.5 hours.
4.7 Main Valve Settings
Table 6 shows the location of the main line valves. Valve operators will be
installed at all main valves close to major river crossing. All other valves will
be equipped with worm gears.
4.8 Scraper Traps
Table 7 shows the location of the scrapers traps. All scraper traps will be
designed to handle an electronic inspection device (intelligent pig).
4.9 River Crossing Design
4.9.4

Major River Crossings

There are major rivers crossings are:

Pilcomayo River (Gathering Line) - Crosses on existing Bridge

Palos Blancos River (Exportation Line)
Isiri River (Exportation Line)
Monos River (Exportation Line)

The crossing of the major rivers will be designed utilizing :

8.625O.D. x 0.500 W.T. API 5L-Gr.X60 ERW. (Gathering Line)

6.625O.D. x 0.344 W.T. API 5L-Gr.X60 ERW. (Exportation Line)
10.750O.D. x 0.500 W.T. API 5L-Gr.X60 ERW. (Exportation Line)

Wall thickness calculations for major river crossings will be based a Design
Factor of 0.60. The pipe is to be manufactured by the ERW process.
Calculations will be based on river water with a specific gravity of 1.25.
Wall thickness calculations for minor river crossing will be based on a Design
Factor of 0.72. The pipe is to be manufactured by the ERW process.
Calculations will be based on river water with a specific gravity of 1.25.
Special construction pipe provided with a continuous concrete coating will be
used on the minor river crossing.
The pipe will be installed at a minimum depth of 10 ft. (3 meters) from the
lowest point of the river bed. These crossings will be open cut.
Pilcomayo River
Gathering Line will crosses on the existing bridge.
Palos Blancos River
Exportation Line will installed at a minimum depth of 10 ft. (3 meters)
from the lowest point of the river bed. These crossings will be open cut.
Exact location of the crossing will be show in the Typical Major River
Crossing Exhibit.
Isiri River
Exportation Line will installed at a minimum depth of 10 ft. (3 meters)
from the lowest point of the river bed. These crossings will be open cut.
Exact location of the crossing will be show in the Typical Major River
Crossing Exhibit.
Los Monos River
Exportation Line will installed at a minimum depth of 10 ft. (3 meters)
from the lowest point of the river bed. These crossings will be open cut.
Exact location of the crossing will be show in the Typical Major River
Crossing Exhibit.

4.9.5

Minor River Crossings

Crossing of minor rivers will be as show on Exhibit 8 utilizing 0.500

wall thickness - API 5L-X60 pipe.
Negative buoyancy will be provided by the use of continuous concrete
coating. The concrete coating should have a minimum thickness of 1.5
inches and with a minimum specific weight concrete of 2.240 Kg/m 3 .
Minor rivers will be installed with double sag bends with a minimum
cover of four meters. The sag bends will have a setback of three meters
minimum from the lower edge of the river bank.
4.9.6

Creek Crossings

Creek crossings will installed as shows on Exhibit 9 with single stress

free sag bends with a minimum cover depth of two meters.
4.10 Wetland Areas
Line pipe coated with continuous concrete coating, one-and-a-half inches
thick, with a minimum specific weight concrete of 2.240 Kg/m 3 . Per
cubic meter will be installed on wetlands. The minimum cover depth for
wetlands areas is 1.50 meters from the top the concrete coating.
Pipeline Buoyancy Negative Calculation details are included in the
Appendix # 5 (Design Data & Calculations), also as show on Exhibit 4b.
4.11 Meter Station
Gas Meter is Multi-Path Ultrasonic and Liquid Turbine Meter will be
installed at terminal of each pipelines. The metering station will be
designed including ultrasonic meter runs sized to measure the volumes
and pressures. And their proving facilities shall be design and installed in
accordance with the API Manual of Petroleum Measurement Standards.
Also shall comply with AGA Report No. 9 Measurement of Gas by
Ultrasonic Meters.
Pressure and temperature transmitters will be installed in order to
communicate the flow conditions to a flow computer.
4.12

Pressure Alert Valve (PAV)

Pressure Alert Valve (PAV) will be sized and installed at terminal of each
pipeline to protect plant from overpressure. Each PAV will have a
monitoring valve, which will be set at a difference range than the PAV and
will operate only when PAV fails to alert the pressure to meet delivery
requirements.

4.13

SCADA System

The flow computers at the meter stations will be linked to the SCADA
system. All the meter runs will be monitored from the central control room
located in Santa Cruz. Where no telephone, radio or cellular
communication is available at the meter station sites, a V-SAT unit will be
installed.
4.14

Cathodic Protection System

Rectifiers will be installed throughout the pipeline. One rectifier will be
installed at the beginning of the each pipelines, and one at the terminus of
those pipelines.
Rectifiers with solar panels and batteries will be installed at all locations
where power is not available. Test leads will be installed every two
kilometers.

4.15

Hydrostatic Test
The pipeline will be hydrostatically tested to a minimum pressure of 1.25 x
MAOP (1,700 psig for 6 & 10) or 2,125 psig and 2,375 psig (1,900 psig
for 8); and a maximum pressure the lesser of 0.2 % deviation on a P-V
plot. A pressure that will produce a hoop stress equal to 110 % SMYS.
The minimum hold period will be four (4) hours.

Table 1
House Count and Location Classes Summary

LOCATION

Location Design
Section
Class Factor F

From

To

KP

KP

30

54

E.

51

E.

PIPE

MAOP

Lines

O.D.

W.T.

API 5L

MAWP

inches

Inches

grade

psig

psig

0,72

0,375 / 0,500

X-60

4050 / 5400

3757 / 5009

Gathering

0,72

0,280 / 0,344

X-60

4032 / 4954

3652 / 4486

Export. Liq

0,72

10

0,365 / 0,500

X-60

3154 / 4320

2934 / 4019

Export. Gas

Table 2
Line Lengths

O.D.

Suveyed
length

As-builts
Length

Inches

km

km

Gathering Line

30

Exportation Liquid Line

54

Exportation Gas Line

10

51

TOTAL

135

Section

Table 3

Hydraulic Calculation Results ( Example Only, Attached)

6 Liquid Pipeline Hydrostatic Test Profile, Section III.

PERFIL HIDRAULICO OLEODUCTO 6", TRAMO III

Dimetro

: 6 5/8"

Altura Min.

:423

( 602

psig )

Espesor

: 0,280"

Altura Max.

:1.283

( 1.824

psig )

Especificacin

: API-5LX60

Dif. Altura

:860

( 1.223

psig )

Longitud

: 20.000 m

Presin Min.

:2.125

psig

( 1.494

PMO

: 1.700 psig.

Presin Max.

:4.080

psig

( 2.869

Fecha : 31/10/02

Puntos

KP

Altura (m)

1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26

00+000
00+400
00+680
00+800
01+760
01+950
02+620
03+100
03+260
03+420
03+500
03+760
03+920
06+078
06+283
06+945
07+600
08+570
09+619
14+895
19+855
17+000
17+700
18+000
19+000
20+000

597,658
687,098
598,076
663,017
525,000
597,820
500,755
587,527
538,042
558,939
536,070
652,293
570,000
1.283,000
1.265,000
1.249,000
1.198,000
1.234,000
1.261,000
1.096,000
800,000
720,621
690,096
566,811
462,099
423,221

Presin
(m)
2.272
2.182
2.271
2.206
2.344
2.271
2.368
2.282
2.331
2.310
2.333
2.217
2.299
1.586
1.604
1.620
1.671
1.635
1.608
1.773
2.069
2.149
2.179
2.302
2.407
2.446

Table 4
Pipe MAWP vs. MAOP

Presiones Optimizadas
(psig)
3.230
3.103
3.230
3.137
3.333
3.230
3.368
3.245
3.315
3.285
3.318
3.152
3.269
2.256
2.281
2.304
2.376
2.325
2.287
2.521
2.942
3.055
3.099
3.274
3.423
3.478

(m)
2.222
2.132
2.221
2.156
2.294
2.222
2.319
2.232
2.281
2.260
2.283
2.167
2.249
1.536
1.554
1.570
1.621
1.585
1.558
1.723
2.019
2.099
2.129
2.253
2.357
2.396

(psig)
3.159
3.032
3.159
3.066
3.263
3.159
3.297
3.174
3.244
3.214
3.247
3.082
3.199
2.185
2.210
2.233
2.306
2.254
2.216
2.451
2.872
2.984
3.028
3.203
3.352
3.407

MAWP
psig

MAOP
psig

F = 0.72

F = 0.72

8.625" O.D. x 0.375" W.T., API 5L - Gr.X60

4.050

3.757

8.625" O.D. x 0.500" W.T., API 5L - Gr.X60

5.400

5.009

6.625" O.D. x 0.280" W.T., API 5L - Gr.X60

4.032

3.652

6.625" O.D. x 0.344" W.T., API 5L - Gr.X60

4.954

4.486

10.750" O.D. x 0.365" W.T., API 5L - Gr.X60

3.154

2.934

10.750" O.D. x 0.500" W.T., API 5L - Gr.X60

4.320

4.019

Pipe

Table 5
Roads and Railroad Crossing Pipe

Proposed
Section

Gathering
Line

Exportation
Lines

Crossing
O.D.
Inches

W.T.
Inches

API 5L
grade

Process
type

Public Road

8.625

0.375

X-60

ERW

Private Road

8.625

0.375

X-60

ERW

Railroad

8.625

0.500

X-60

ERW

Public Road

6.625 / 10.750

0.280 / 0.365

X-60

ERW

Private Road

6.625 / 10.750

0.280 / 0.365

X-60

ERW

Railroad

6.625 / 10.750

0.280 / 0.500

X-60

ERW

Table 6
Mainline Valve Settings

MLV No.

Line

Use

Location

X-3
By Pass

Header

By Pass

5
6

Plant
8"

Gear

MLV
MLV

MLV

10

Header

X-1

11

Header

X-3

Check

Plant

MLV
6"

MLV

MLV

MLV

Hot Tap

1
2

Ball

MLV
MLV

Operator

X-1

Wellhead Tie in

Valve

Ball

Gear

Ball

Gear

Plant
10"

MLV

MLV
Hot Tap

Table 7
Scraper Traps Location

Location
Km. Post

Type

000

Launching 8

030

Receiving 8

000

Launching 6

000

Launching 10

051

Receiving 6

054

Receiving 10

Section Line

Gathering
Gathering
Exportation
Exportation
Exportation
Exportation