Transcript APPROACH PLAN OF DESIGN IN PIPELINES Delivering excellence through people

APPROACH PLAN OF
DESIGN IN PIPELINES
Delivering excellence through people
GAS PIPELINES
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FACILITIES
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DESPATCH STATION
RECEIPT STATION
PIPELINE BETWEEN DESPATCH & RECEIPT STATION
PIGGING STATION
SV (SECTIONALIZING VALVE) STATION
PREPARATION OF DESIGN BASIS DOCUMENT CONTAINING ALL
THE DATA FOR DESIGN OF PIPELINE AS PER CLIENTS
REQUIREMENT
Engineers India Ltd – Delivering excellence through people
CONTENTS OF DESIGN BASIS
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THROUGHPUT DATA : MMSCMD OF GAS
GAS COMPOSITION & TYPE : ASSOCIATED GAS ,
FREE GAS, RLNG, etc.
PIPELINE LENGTH
B/L PRESSURE AT SOURCE & CONSUMER POINTS
LOCATION OF CONSUMERS
CONTRACTED VOLUMES
Engineers India Ltd – Delivering excellence through people
COMMON DESIGN PRACTICES
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600# RATED VALVE & FITTINGS CONSIDERED.
MAWP OF 99.93 KG/CM2 G @ 65 0C
DESIGN LIFE DECIDED BY OWNER GENERALLY 25 -30
YEARS
ASME B31.8 & OISD-226 REFERRED FOR GENERAL
GUIDANCE
Engineers India Ltd – Delivering excellence through people
BASIS OF SIMULATION STUDY
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33% EXTRA CAPACITY OVER CONTRACTED VOLUME
AS PER PNGRB GUIDELINES TO TAKE CARE OF
FUTURE CONSUMPTION / EXPANSION
OPTIMUM NO. OF COMPRESSOR STATIONS DECIDED
ON FOLLOWING BASIS:
MINIMUM SUCTION PRESSURE AS 45 KG/CM2 G
DISCHARGE PRESSURE OF 92-99.93 KG/CM2 G
POWER PLANT PRESSURE REQUIREMENT~ 25-30
KG/CM2 G
FERTILIZER PLANT REQUIRE AT 40-45 KG/CM2G
PETROCHEMICAL PLANT REQUIRE AT 50-55KG/CM2G
Engineers India Ltd – Delivering excellence through people
BASIS OF SIMULATION STUDY
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MAINTAIN VELOCITY LIMIT 10 – 15 m/s
PRESSURE DROP 0.25 – 0.35 Kg/cm2 PER KM
INTER COMPRESSOR DISTANCE 150 – 250 KM
SIMULATION CARRIED TO ESTABLISH HYDRAULICS
FOR THREE LINE SIZES BASED ON ABOVE
GUIDELINES
Engineers India Ltd – Delivering excellence through people
SOFTWARE USED
 PIPELINE STUDIO TGNET FROM ESI
(ENERGY SOLUTION INTERNATIONAL)
 HYSIS FROM HYPROTECH LTD
 WINSIM DESIGN-II
 INHOUSE SOFTWARE ON SPREAD SHEET
Engineers India Ltd – Delivering excellence through people
BROAD EQUIPMENT SPECIFICATIONS
(PREPARED FOR ALL OPTIONS)
CONTENTS
 PIPELINE:SIZE,
LENGTH,
MATERIAL
OF
CONSTRUCTION (MOC), DESIGN PRESSURE &
TEMPERATURE.
 COMPRESSORS:RATED FLOW,
RATIO, RATED BKW, CP/CV, MW
COMPRESSION
 SELECTION OF OPTIMUM CONFIGURATION BASED
ON LOWEST NPV(NET PRESENT VALUE)
Engineers India Ltd – Delivering excellence through people
DETAILED EQUIPMENT SPECS.
(FOR OPTIMUM CASE)
CONTENTS:
 LINE PIPE
 COMPRESSOR INCLUDING AFTER COOLER
 GAS FILTERS
 KNOCK OUT DRUMS
 INSTRUMENTS
• PRESSURE REGULATION SKID.
• METERING
• CONTROL VALVES
• SAFETY VALVES
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Engineers India Ltd – Delivering excellence through people
P&ID DEVELOPMENT
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DETAILS OF PIPING, SIZING & RATING etc.
INSTRUMENTATION
CONTROLS & INTERLOCKS FOR SAFE ,EFFICIENT
& RELIABLE OPERATION OF PIPING SYSTEM
Engineers India Ltd – Delivering excellence through people
UTILITY REQUIRED
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UTILITY SUMMARY PREPARED FOR EACH
FACILITY
UTILITIES REQUIRED
• INSTRUMENT AIR (CONTINUOUS BASIS)
• PLANT AIR FOR CLEANING
(INTERMITTENT BASIS)
• NITROGEN FOR PURGING,INERTIZATION,DRY
GAS SEAL (CONTINUOUS BASIS)
• SERVICE WATER FOR FLUSHING & CLEANING
(INTERMITTENT BASIS)
• POWER (CONTINUOUS BASIS)
Engineers India Ltd – Delivering excellence through people
UTILITY REQUIRED (CONTD.)
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UTILITIES FOR COMPRESSOR ARE ESTIMATED
FROM DATA BASE OF PREVIOUS PROJECTS.
EQUIPMENT / SPECIFICATION & P&ID DEVELOPED
FOR UTILITY SYSTEMS
Engineers India Ltd – Delivering excellence through people
LIQUID PIPELINES
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FACILITIES
DESPATCH STATION
 RECEIPT STATION
 PIPELINE BETWEEN DESPATCH & RECEIPT STATION
 PIGGING STATION
 SV STATION
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PREPARATION OF DESIGN BASIS DOCUMENT
CONTAINING ALL THE DATA FOR DESIGN OF
PIPELINE AS PER CLIENTS REQUIREMENT
Engineers India Ltd – Delivering excellence through people
CONTENTS OF DESIGN BASIS
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THROUGHPUT DATA : MMTPA OF LIQUID
LIQUID TYPE
: CRUDE OIL, HVP LIQUID LIKE
LPG,C2/C3 ,REFINED PETROLEUM PRODUCTS e.g.
MS,SKO,HSD,ATF
SPECIFIC GRAVITY,VISCOSITY AT TWO
TEMPERATURES
PIPELINE LENGTH
B/L PRESSURE AT SOURCE & DESTINATION
LOCATION OF TAP-OFF POINTS
TAP-OFF QUANTITIES
Engineers India Ltd – Delivering excellence through people
COMMON DESIGN PRACTICES




600# RATED VALVE & FITTINGS CONSIDERED.
MAWP OF 99.93 KG/CM2 G @ 65 0C
DESIGN LIFE DECIDED BY OWNER GENERALLY 25 -30
YEARS
ASME B31.4 & OISD-141 REFERRED FOR GENERAL
GUIDANCE
Engineers India Ltd – Delivering excellence through people
BASIS OF SIMULATION STUDY
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8000 HRS (333 DAYS)PUMPING CONSIDERED
PER YEAR
OPTIMUM NO. OF PUMPING STATIONS DECIDED
ON FOLLOWING BASIS:
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MINIMUM SUCTION PRESSURE AS 4-5 KG/CM2 G
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MAXIMUM DISCHARGE PRESSURE OF 90
KG/CM2 G
Engineers India Ltd – Delivering excellence through people
BASIS OF SIMULATION STUDY
(Contd)
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MAINTAIN VELOCITY LIMIT OF 2 m/s
PRESSURE DROP 0.50 Kg/cm2 PER KM
INTER PUMPING DISTANCE ABOUT 200 KM
SIMULATION CARRIED TO ESTABLISH HYDRAULICS
FOR THREE LINE SIZES BASED ON ABOVE
GUIDELINES.
Engineers India Ltd – Delivering excellence through people
SOFTWARE USED
 PIPELINE STUDIO TLNET FROM ESI
(ENERGY SOLUTION INTERNATIONAL)
 INHOUSE SOFTWARE ON SPREAD SHEET
Engineers India Ltd – Delivering excellence through people
SURGE ANALYSYS
 SURGE IN PIPELINE IS PRODUCED DUE TO CHANGE IN
VELOSITY OF MOVING STREAM
 SURGE ANALYSYS CARRIED OUT FOR FOLLOWING
CASES WHICH RESULT IN CHANGE IN VELOCITY:
 CLOSURE OF SECTIONALIZING VALVE ON MAINLINE
 CLOSURE OF INLET VALVE OF STORAGE TANK
 STOPPAGE OF PUMPS AT ORIGINATING /INTERMEDIATE
STATION
 SURGE RELIEF VALVES/INTERLOCKS TO SHUT
PIPELINE THROUGH SCADA PROVIDED TO PROTECT
PIPELINE FROM EXCESS SURGE PRESSURES
Engineers India Ltd – Delivering excellence through people
BROAD EQUIPMENT SPECIFICATIONS
(PREPARED FOR ALL OPTIONS)
CONTENTS
 PIPELINE:SIZE,
LENGTH,
MATERIAL
OF
CONSTRUCTION (MOC), ∆P & ∆T.
 PUMPS: DIFF. HEAD, SHUT OFF PRESSURE,
RATED FLOW, MOC, SP. GRAVITY OF LIQUID
HANDLED, RATED BKW (η = 75%)
 SELECTION OF OPTIMUM CONFIGURATION BASED
ON LOWEST NPV(NET PRESENT VALUE)
Engineers India Ltd – Delivering excellence through people
DETAILED EQUIPMENT SPECS
(FOR OPTIMUM CASE)
 LINE PIPE
 SCRAPER LUNCHER/RECEIVER
 PUMPS
 BASKET FILTERS
 BLOW DOWN DRUMS
 INSTRUMENTS
 METERING
 CONTROL VALVES
 SAFETY VALVES
 SURGE RELIEF VALVE
Engineers India Ltd – Delivering excellence through people
BATCH SIZING AND SEQUENCING
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(FOR OPTIMUM CASE)
MUTUALLY COMPATIBLE PRODUCTS PUMPED FACE
TO FACE (-SKO-HSD-SKO-MS-SKO-ATF-SKO-)
ESTIMATION OF INTERFACE VOLUMES USING
EQUATION BY AUSTIN AND PALFREY
ESTIMATION OF MINIMUM BATCH VOLUMES TO
RESTRICT CONTAMINATION WITHIN PERMISSIBLE
LEVELS (1% SKO IN MS AND 2% SKO IN HSD)
ESTIMATE BATCH CYCLES OF PRODUCTS AND
TANKAGES REQUIRED AT RECEIPT TERMINALS.
Engineers India Ltd – Delivering excellence through people
Engineers India Ltd – Delivering excellence through people
TECHNICAL IMPROVEMENTS
 INTERNAL FLOW IMPROVER EPOXY COATINGS
 REDUCTION IN FRICTION LOSSES,PROJECT COST
AND OPERATIONAL COST
 VFD MACHINES
FLEXIBILITY
LOSSES
IN
OPERATION,REDUCTION
Engineers India Ltd – Delivering excellence through people
IN
POWER
THANK YOU
Engineers India Ltd – Delivering excellence through people