Design of Gas Transport Systems

October 10, 2012

Elin Kristin Dale

ekrd@statoil.com

1- Classification: Internal 2011-02-21

TPG4140 – NATURGASS, NTNU
 Design of gas transport systems

• Part 1:
− Intro Transport technology
− Gas/condensate fields- and infrastructure development
− System design of pipelines – terms and definitions

• Part 2:
− Design premises included examples
− System design of multiphase pipelines
− Pipeline pressure protection and leak detection

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 Part 1

Intro Transport technology

3- Classification: Internal 2011-02-21

Photo credit: Manfred Jarisch / StatoilHydro TPG4140 – NATURGASS
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 Transport technology

“Development of total transport solutions - from Reservoir to Market”

Responsible for Transport technology in Statoil:
• Multiphase system and flow assurance (FA)
• Transport optimisation and design (TS)

Our job is to secure and optimize transport of oil

and gas in pipeline systems

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 Reservoir
conditions
Transport technology Market
conditions

 System definition
 Hydraulic analysis
 Optimisation of flow in pipeline network wrt
capacity and gas quality management
 Principles for pressure control and pressure
protection
 Interface management
 Supervision, consultation and daily operation of
leak detection system (PM-vakt)

PLEM

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 Gas/condensate fields- and infrastructure
development

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 Gas transport technology
50
Volume BCM

20 LNG
PIPELINE (Barents sea)
(North sea)
10
Floating LNG

5 GTL/Methanol
CNG

2
Electricity
UNECONOMIC
(HVDC)
1
.50

1000 2000 3000 4000 5000

Distance to market - Km

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 Transport analysis
New fields:
• Volume profiles
• Type gas
• Profitability
• Geography Transport Cost Economical
• Owners Solutions estimation analyse

• Distance • CAPEX • NPV

Overall
Infrastructure • Capacity • OPEX • IRR evaluation
• Spare capacity • Tie-ins • Profit index
• Liquid recov. • Processing • Investment • SDA/SØA economy
• Tariffs • Liquid recov.. equivalent 7% • Strategic fit
• Owners • CO2 removal after tax. • Stakeholders
• Flexibility
Market:
• Supply situation
• Geography
• Pricing

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 The Norwegian Continental Shelf
• Statoil has developed the world’s largest
offshore gas pipeline network
• Technical services are provided by Statoil for
the world's most extensive submarine gas
pipeline system:
− 7800 km pipelines (30” – 44”)
− Long term transport capacity approx.
365 MSm3/d
• Statoil is the leader in the construction of
large-diameter pipelines in deep water.
• On 1st January 2002, Gassco became the
operator for most of the gas pipeline systems
from the Norwegian continental shelf.
• On 1st January 2003, Gassled became the
owner for most of the gas pipeline systems
(Statoil share 5%, Statoil+Petoro share 50,8
%).

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 Gas/condensate fields- and infrastructure
development • Gas supply
− Production profile
− Build-up and plateau level
• Market scenarios
− Volume
− Market opportunities (and flexibility)
− Company based sales
• Existing infrastructure
− Platforms
• Tie-ins and functional
requirements
− Pipelines
• Capacity and ullage
• New infrastructure requirements

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 Existing infrastructure - capacity
• The pipeline between X and Y is
the main link between the A B C
production at A and B and the
terminal E.
• Utilisation of the XY link affects the 14,7 20 20 10
capacity towards E, creating a
bottleneck and a gap between the
actual delivery and the demand. X Y
19,7
• Routing of the gas will determine
the possible transportation capacity 49,7
at a given scenario. 15

• The sum of exit capacity in a

transport system is not necessarily D E
equal the actual transport capacity. Gap: ~15
• Transport capacity is dependent on Production scenario 1 [MSm3/d]

volume scenario, bottlenecks and Producers Exit terminals

dependencies. A B C D E

30 40 10 15 65

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 Overall field architecture case – Johan Sverdrup
• Example of business case:
− New field discovery Johan Sverdrup,
largest finding in the world this year.
500-1200 Mill barrels oil equivalents, 140
km offshore, 112 meter depth, 1900
meter below the seabed.
− Which field architecture will you
recommend to your management ?

• Some of the parameters to be evaluated :

− Technical: Choice of installation (floater, fixed structure), store or transport, processing,
naval architecture, sensitivity to weather/sea conditions (hurricane, waves, tide,
temperature etc), fluid properties (wax, hydrates, corrosion etc.), pigging, ship transport
path, design codes, infrastructure (helicopter base, logistics, storage equipment/fluids,
accommodation) and pressure protection and leak detection.
− Economic analyses: availability in marked, location of construction, rent or own,
distance from field to market, pipeline transport fee, country laws and regulations,
personnel availability, company philosophy.

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 Pipeline system design
Terms and definitions

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 Pipeline system design – terms and definitions

• Pipeline system
Petroleum and natural gas industries
− A pipeline with compressors or pump stations Pipeline transportation systems, ISO
13623
− Pressure reduction stations
− Metering
− Tankage
− Supervisory control and data acquisition system (SCADA)
− Safety systems
− Corrosion protection systems
− And other equipment, facility or building used in the transportation of fluids
• Pipeline
− Those facilities through which fluids are conveyed, including pipe, pig traps,
components and appurtenances, up to and including the isolation valve.

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 Pipeline system design – system definition

• The extent of the pipeline system, its functional requirements and applicable legislation
should be defined and documented.
• The extent of the system should be defined by describing the system, including the
facilities with their general locations and demarcations and interfaces with other facilities.
• The functional requirements should define the required design life and design conditions.
Foreseeable normal, extreme and shut-in operating conditions with their possible ranges
in flow rates, pressures, temperatures, fluid compositions and fluid qualities should be
identified and considered when defining the design conditions.

Petroleum and natural gas industries

Pipeline transportation systems, ISO 13623 OS F-101: Submarine Pipeline
Systems

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 Pipeline systems
Subsea Production Systems (ISO 13628) and
Platform/Floater
Pipeline Transportation Systems (ISO 13623)
PIG TRAP
ESV

PIG TRAP
SUBSEA ESV
PROCESSING
UNIT
Subsea isolation
Subsea
HIPPS SSIV
Production
MANIFOLD
X-MAS CHOKE RISER BASE
BRANCH
TREE
PWV SSIV
PMV
CHECK
CHOKE TEMPLATE AND
MODULE MANIFOLD Onshore
LANDFALL
SCSSV
PIG TRAP
ESV

TEE
Pipeline Systems: Subsea connection
Single phase; Gas, Oil, condensate CHECK + BLOCK

Multiphase; PLEM

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 Pipeline Project Organisation (Typical)

Project Manager

Project Control Authority

Procurement HSE

Upstream Downstream
Platform/Terminal Platform/Terminal
Administration EIA

Pipeline Pipeline Preparation for

System/RFO Landfall
Engineering Construction Operation

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 " I draw lines, I don't move trees"

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 Pipeline system design – work process
Thermo- Functional Overall System design
hydraulic requirements; Operational concept
analysis gas routing, Philosophy;
regularity, Control and
gas quality, Safety
agreements System,
Environment,
etc.
Internal diameter, Functional Control and Safety Pipeline System
capacity, pressure requirements, Philosophy Diagram, Process
and temperature Regularity, Flow Diagram
profile, etc. Deliverability

P&ID’s

QA

Boundary conditions and technical interface between platform – pipeline – terminal

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 Part 2

Design premises
Hydraulic capacity and gas quality

20 - Classification: Internal 2011-02-21

Photo credit: Manfred Jarisch / StatoilHydro TPG4140 – NATURGASS
NTNU
 Pipeline system design – Hydraulic analysis 1/2
• The objective of the system design
− develop overall transport solutions for the gas chain from the field
to the market which will maximize the value of the liquid- and gas
products and without any unreasonable external conditions for
any third party (fields or transport systems).

− deliver gas quantities nominated by the buyers within the desired

quality specifications.

− ensure high availability and regularity within reasonable technical

and economical limits and relevant agreements.

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 Pipeline system design – Hydraulic analysis 2/2
• The hydraulics of the pipeline system should be analysed to demonstrate that the
system can safely transport the fluids for the design conditions specified by the
system definition, and to identify and determine the constraints and requirements for
its operation. This analysis should cover steady-state and transient operating
conditions.
• Describe the function loads for the pipeline design
− Pressure profile
− Temperature profile
− Density profile (fluid)
− Velocity profile
• Design cases:
− Normal operation, start-up, planned shut-down, etc.
− Not planned operation, emergency shut-down, depressurisation, etc.
− Emergency preparedness analysis; accidents, pipe rupture, leakage etc.

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 Pipeline system design – Design premises 1/3
Area B - Åsgard Transport, Kårstø temp.
• Pipeline Route
High Rough Likely Rough Low Rough
− Length 5

− Bathymetric profile 3

Temperature, °C
• Environmental Conditions
1

-1
− Air temperature
-3
− Sea bottom temperature 66 68 70 72 74 76 78 80 82 84 86
Hydraulic capacity, MSm³/d
− Ground temperature
− Geo-technical data (soil conditions) Area B - Åsgard Transport, Kårstø pressure
High Rough Likely Rough Low Rough

130
125
120
115

Pressure, barg
110
105
100
95
90
85
80
66 68 70 72 74 76 78 80 82 84 86
Hydraulic capacity, MSm³/d

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 Hydraulic capacity – Sensitivity analysis

Variation of parameters and hydraulic capacity compared to basis

Zeebrugge 69.5 MSm³/d (october)

5 Trenching -200 Km

Length +/-10 Km
4

3 Temperature

10 micron 2 Roughness 1- 3 micron

1 Gas Composition

-2 -1.5 -1 -0.5 0 0.5 1 1.5 2 2.5 3

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 Pipeline system design – Design premises 2/3

• Pipeline Data
− Design pressure
− Design temperature
− Internal diameter
− Wall thickness
− Internal coating
− Concrete coating
− Insulation
− Trenching/dredging
− Gravel/rock dumping

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 Langeled Bredero Shaw i Farsund Sept. 2004
Concrete coating Coating
(330 000 m3) (25 000 t)
= 1,5 Troll A GBS = 3 Eiffel Towers
Total coating “wire”:
Total pipeline steel (51 900km)
(962 000 t) = 1.3 times
= 40 Troll A deck around the equator

Per pipe:
Ca 25 tonns
1200 km a 12m pipes:

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 The largest laying vessels

Solitaire:
The worlds largest pipeline laying
vessel at Nyhamna

Acergy Piper:
At Sleipner T at start-up of the laying
process

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 Pipeline system design – Design premises 3/3
• Gas properties
− Equation of state
• Gas composition
• Friction equation
− Internal roughness
• Transport specification
• Sales gas specifications
• Pressure Control System
− Pressure regulating
− Pressure safety
• Pig trap arrangement
− Pigging philosophy
• Pipeline valve philosophy
• Future requirements

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 Transport of 42” subsea pipeline
valve

• Double expanding gate

• Weight of valve: 80 tons (60 cars..)
• 10m high including activator:
• Total of 100 tons

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 Why gas quality specifications?
• Ensure interoperability /interchangeability (WI)
• Ensure unproblematic transport of gas
− Max/min temperature and pressure
• Prevent corrosion and erosion of equipment
− Water, CO2, H2S content
• Prevent condensation of liquid (HC dew point)
• Prevent gas hydrates (Water dew point)

Hydrocarbon dew-point (-3 C, 69 barg)

Water dew-point (-12 C, 69 barg)
CO2 content (max 2.5 % mol)
H2S content (5 mg/Nm3)
GCV (Gross calorific value)
Wobbe index (WI)
Max/min pressure and temperature

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 Hydrates – main reason for temperature
control in multiphase pipelines
Kristin hydrate curve
900
800
700
Potensial for hydrate formation
Pressure, bar

600
500
400
300
200
Safe operating
100 conditions
0
0 5 10 15 20 25 30 35
Temperature, °C
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 System design of multiphase pipelines

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 The diameter dilemma of long gas-condensate
pipelines
Technical feasibility – for how long can reservoir drive production to shore?
• Minimize pressure drop  large pipe diameter

Operational acceptability – will system availability be high enough?

• Minimize liquid inventory in pipeline  small pipe diameter
Design
Design rate
50 rate 8000
Pressure drop (bara)

7000 Large

Liquid content (m3)

Large 6000 ID
40 ID
5000
4000
3000 Small
30
2000 ID
Small
ID 1000
20 0
20 22 24 26 28 30 32 34 24 26 28 30 32 34
Gas rate (MSm3/d) Gas rate (MSm3/d)

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 Conventional design of gas-condensate pipelines
Pipeline diameter: small
Troll slug-catcher
• Minimize liquid inventory
 Accept moderate/high pressure drop
Slug-catcher size set by:

Slug-catcher
• Rate increase:

volume
From maximum turndown to design
rate
• Pigging
 Liquid inventory prior to pigging 8000
50
Pressure drop (bara)

7000

Liquid content (m3)

6000 Maximum Steady state
Design pressure turndown
40 liquid content
drop 5000
4000

Maximum 3000
30 Design Design
turndown rate 2000 rate
1000
20 0
20 22 24 26 28 30 32 34 24 26 28 30 32 34
Gas rate (MSm3/d) Gas rate (MSm3/d)

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 New design of gas-condensate pipelines

Pressure drop (bara)

50
Pipeline diameter: large
• Minimize pressure drop Large
40 ID
 Accept relatively large liquid inventory
• If possible, alleviate liquid load
30
 Multi-diameter pipelines/dual lines Small
• Exploit pipeline’s slow response to transients ID
20
 Operational procedures 20 22 24 26 28 30 32 34
Gas rate (MSm3/d)

Slug-catcher design Liquid flow into slug-catcher

300

Volume rate (m3/h)

• Exploit pipeline’s slow response to transients
200
 Reduce slug-catcher size
• Onshore reception system routes liquid to 100
off-spec tank
0
 Optimise slug-catcher design
0 2 4 6 8 10 12 14
Time (days)

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 Pipeline integrity and leak detection

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Deepwater horizon
 Pipeline integrity and leak detection
Probability reduction Consequence reduction

Robust Safe Integrity Leak Emergency

design operation management detection response

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 PPS and PPC

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 Risk reduction
Allocations of risk reducing measures
Acceptable risk Frequency of
Achieved freq of overpressure
(Frequency of
overpressure Without risk reduction
overpressure )

-5
1x10 1 times pr year

Frequency of
Required risk reduction overpressure
•Facilities regulation §33 Actual risk reduction
•ISO 10418 (API 14 C)
•IEC 61508
•IEC 61511 Manuel
PPS -2 PPS -1 PPC
actions

Achieved risk reduction from safety functions

PPC: Independent of the PSS
PPS: Two independent systems activated at different pressure levels, and
with a redundant and fail safe instrumentation and signal transfer system

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 Shut down of receiving facility
Kollsnes export is stopped 0.5 hour later
44" Den Helder. SOP at 2% Opflex. October
Time, hrs
0 2 4 6 8 10 12 14 16 18
210
203 barg (+10m)
200
190
Kollsnes
180
170
Pressure, barg

160 156.8 barg (+10m)

150
140
130
Den Helder
120
110
Danish German
100 Norwegian sector sector Dutch
sector sector
90
0 100 200 300 400 500 600 700 800 900
Distance, km

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 Multi design pressure concept
Normal Design Multi Design Pressure
PD PD1
Low utilisation of pipe material PD2
PD3
Settle out pressure
Normal pressure profile

Upstream end Downstream end Normal pressure profile

• The settle out pressure in a “normal” shut-in situation shall not exceed the lower design
pressure
• The pipeline hydraulics during normal, upset and packing conditions are analysed to
demonstrate that the pressure control and pressure protection system will act satisfactory
• Cost saving material

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 Pipeline pressure protection
Triple redundant

Fiberoptic and
telemetry

PPS-1 PPS-2 PPS-1 PPS-2

PT PT EV EV PT PT

Pipeline
Upstream Downstream
Plant Plant

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 Pipeline integrity and leak detection
Probability reduction Consequence reduction

Robust Safe Integrity Leak Emergency

design operation management detection response

technology
robustness solution
protecting
pressure loss
what?
need reliability mass balance

point sensor
pipeline or
zone? sensitivity
acoustic

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 The risk picture…

Probability

Acceptable risk, but extra

barriers?

Consequence
30” Kvitebjørn gas pipeline damage and leak, 2007

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 Key learning points

• Complexity of field architecture development

• Parameters influencing pipeline infrastructure development
• Pipeline design premises
• How the hydraulic of the pipeline system influence pipeline design
• Pressure protection and leak detection of pipeline systems

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 Thank you

Design of gas transport systems

Elin Kristin Dale
Senior engineer Transport Analysis
ekrd@statoil.com , tel: +47 99 15 73 34
www.statoil.com

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