Onshore Pipeline Design

Course
Jakarta 2-days,
29-30 June, 2019
By
HAMID SOBIRIN
PIPELINE ENGINEER
OUTLINE

 OVERVIEW
 PIPING VS PIPELINE
 PIPELINE CODE AND STANDARDS
 PIPELINE ROUTE DESIGN
 PIPELINE MECHANICAL DESIGN
 PIPELINE CONSTRUCBILITY
 PIPELINE STRESS ANALYSIS
OVERVIEW
 The ‘Aim’ of this course is to provide you with the knowledge,
understanding and practical skills necessary to participate in Pipeline
design.

 The ‘Objectives’ by the end of the course you will be able to:
• Understand the fundamentals of Pipeline Design
• Have an understanding of pipeline standards
• Describe the importance of route selection
• Demonstrate good Pipeline design practices.
• Demonstrate engineering and design practical experience.
PIPING VS PIPELINE
Pipeline Piping

Series of straight pipe welded together for a long Complex network of pipe & fittings within the defined
distance boundaries of the plant

underground, aboveground and underwater such

Mostly above ground with very few underground services.
as subsea pipeline

Mostly large diameter Can be from ½” to 80” in diameter

Use of pipefittings are limited. Very wide range of pipefittings are used.

Few equipment are used within the Pipeline

Verity of equipment used within the piping system
system

Design in accordance with ASME B31.4, ASME

ASME B31.3 , ASME B3
B31.8
PIPELINE DESIGN CODE AND STANDARDS
 Design Code Pipeline

ASME B31.8 Gas Transmissions and Distribution Piping Systems

ASME B31.4 Pipeline Transportation Systems for Liquid
Hydrocarbons and Other Liquids

 Standard Specification of pipeline component

ASME B 16.5, Pipe Flanges and flanged fittings- up to including NPS 24”
ASME B 16.47, Large diameter steel flanges- NPS 26” through 60”
ASME B 16.20, Metallic gaskets for pipe flanges- Ring Joint, Spiral wound and
Jacketed
ASME B 36.10M, Welded and seamless wrought steel pipe
ASME B 36.19M Stainless Steel pipe
 Indonesian Law and Regulation:
Peraturan Menteri Energi dan Sumber Daya Mineral No.15 tahun 2008 tentang
Pemberlakuan Standar Nasional Indonesia Mengenai Sistem Transportasi Cairan
Untuk Hidrocarbon dan Standar Nasional Indonesia Mengenai Sistem Perpipaan
Transmisi dan Distribusi Gas Sebagai Standar Wajib

Minister of Mines and Energy Decree No.300.K/1997 on Oil and Gas Pipeline
Occupational Safety

Law No. 32 year 2009 on Environmental Protection and Management

PIPELINE ROUTE DESIGN

• conducted by
SITE SURVEY Engineer and
Designer

• Conducted by third
TOPOGRAPHY party ( contractor)

• Conducted
ALIGMENT by Designer
SHEET , review by
engineer
ROUTE SELECTION STUDY
 The purpose of the study was to assess multiple pipeline route options in
order to ensure selection of the optimal route for successful pipeline design,
construction, and overall project execution.
Final design routes shall be established with the following considerations:
 Onshore pipeline route shall comply with government regulation and authority
permits.

 The crossing of existing pipelines, cables, power lines, roads, railways, and
waterways should be at an angle between 60 and 90 degrees.

 Where crossing existing pipeline is necessary, the crossing must be performed

underneath the existing pipeline.
 Optimization of pipeline length and installation cost.

 Minimization of failure during operational (i.e. ground slide) or during

installation (i.e. slope too steep)

 Pipeline minimum curve radius.

Location Class
 Determined classification of location for stringing pipeline as per KEPMEN No
300.K/38/M.PE/1997 and ASME B31.8

Number of Building in the Area

Class
Along 1.6 km width 0.4 km
1 0 up to 10
2 > 10 up to 46
3 > 46
4 > 46 & Stairs
Location Condition
Forest, mountain, sea, land/
agricultural land.
Agricultural land, settlement.
Market, settlement, small town.
Dense settlement, big city, cable
network location
 Determined classification of location for stringing pipeline as per ASME B31.8
Depth of Burial

 Based On the Minister of Mining and Energy Number: 300.K/38/M.PE/1997,

The flowline and trunkline shall be buried along the entire route with a
minimum depth of 1.5m
 Buried depth for pipeline shall be assess by UPHEAVEL BUCKLING calculation
 ROAD CROSSING
 Pipelines across road and river shall be buried at least 2 meters depth,
measured from the top of the pipe to the original grade elevation unless
greater depths are required by Government Regulatory Authorities.
 Buried depth for pipeline under road crossing condition is established based
on API RP 1102 calculation.
MINIMUM VERTICAL CLEARENCE DISTANCE
 A minimum vertical separation of 0.6 m should be kept between the pipeline
and any other buried structure, and shall be separated 2 m nearest wall to
wall another buried pipeline.
 The pipeline route crossings with existing pipeline must be designed in such
way as to avoid the interference of cathodic protection current between both
proposed and existing pipelines to prevent loss of corrosion protection.
MINIMUM SEPARATION DISTANCE BETWEEN PARALEL
PIPELINE

 Minimum distance for pipeline route as per KEPMEN No 300.K/38/M.PE/1997

are tabulated in the Table:

Construction /
Minimum Distance (m)
Diameter of Pipe

Pressure 4 up to 16 Pressure > 16 Up Pressure > 50

Inch
Bars to 50 Bars Up to 100 Bars

8 2 3 3

10 2 3 3.5

12 - 3.5 4
TOPOGRAPHY
ALIGMENT SHEET
PIPELINE MECHANICAL DESIGN
WALL THICKNESS ANALYSIS
Based on ASME B31.8 the nominal wall thickness is determined by equation
below:
The pressure containment check is governed by the hoop stress equation which
includes inclusive of both internal and external pressures for operating and
hydrotest conditions, as given by the following equations:

t1 : Nominal Required Wall Thickness

Pd : Design Pressure
D : Outside Diameter of the Line Pipe
S : SMYS
F : Design Factor
E : Longitudinal Joint Factor
T : Temperature De-rating Factor
CA : Corrosion Allowance
FREE END THERMAL EXPANSION ANALYSIS
The purpose of the thermal expansion calculations is to obtain the net thermal
expansions at both ends of the pipeline.

The displacement at both ends of the pipeline is the summation of the deformations
along the restrained length of the pipeline :

Where:
y0 = expansion (thermal growth) (m)
Lanch = virtual anchor length (m)
e = maximum expansion rate (m/mm)
UPHEAVEL BUCKLING ANALYSIS
 Upheaval buckling particularly concern to high temperature buried pipelines
when the pipelines are restrained both laterally and axially, with inadequate
resistance to pipeline upward movement.
 The methodology for the upheaval buckling verification is based on the
methodology developed by Palmer A.C.
 Downward Force

The total available downward force depends on the weight of the pipeline itself,
as well as on the download provided by the backfill cover:

Where:
Wope : weight of the pipeline in operating condition
q : download provided by backfill cover
The download provided by the soil can be expressed as a function of the backfilled
cover H, it isdefined as:

Where:
H : cover thickness above top of pipe
Su : average undrained shear strength of cover material
D : pipe overall external diameter
 Force required due to upheavel buckling

Where:
E : steel Young’s modulus
I : moment of inertia
δ : imperfection height (maximum allowable)
L : profile imperfection length
FA : compressive axial force
W : weight of the pipe

 The result is acceptable if

CROSSING ANALYSIS
 Rail Crossing and Road Crossing shall be check for Longitudinal stress and
circumferential stress based on API 1102
 The consideration made during pipeline crossing analyzis are:
The carrier pipe should be as straight as practicable and should have uniform
soil support.
The carrier pipe should be installed so as to minimize the void between pipe
and adjacent soil.
The angle of intersection between pipeline crossing and rail load or highway
to be crossedshall be as near 90degree as practicable.
 Select type of Crossing

Rail Road Highway

Uncased Installation

Cased Installation

Load Charactaristic

Single axle load Tandem Axle Load

Type of Road

Flexible Pavement No Pavement Rigid pavement

 A Begin
Pipe,operation,installation

External Load Internal Load

Earth Load Live Load

Calc. circumferential stress

due to pressure,S Hi (barlow)
Calc. circumferential Eq. 8a & 8b
Calc w
due to earth
load,SHe Section 4.7.2.2.1
Eq.1;Fig 3,4, 5 Calculate F1,Fig. 7

Check Fails
SHi (barlow) ≤
Allowable
Calc.circumferential Calc. cyclic longitudinal
stress due to live load stress due to live load
∆SH, ∆SL
Eq. 3 or 5; Fig. 8,9,10 Eq. 4 or 6 ; Fig. 11,12,13 or
Fig 16 &17
Calc. circumferential stress
due to pressure
SHi ; Eq.7

E D F
B
A B A

C Calc. principle
Stress S1,S2,S3
Eq. 9,10,11

Calc. Effective Stress,

Seff
Eq.12

Fails Seff Check D Check Allowable Seff

Eq.13

Fails Fatigue Check

E
Check Fatigue Girth Weld,
Table 3, Eq. 15 or 16, Figure `8, or Eq. 17

Check Fatigue in longitudinal Weld

Table 3, Eq..19 or 20

Satisfactory Design

F
Optimal Design

Design
Complete
PIPELINE STRESS ANALYSIS BY AUTOPIPE
(UNDERGROUND PIPELINE)
CONSIDERATION

STRESS CRITERIA

LOAD COMBINATION

SOIL SPRING

INPUT MODELLING AUTOPIPE

FLANGE CHECK
ASSUMPTION AND CONSIDERATION
 The model includes piping with associated valves, flange. Nodes are used to
define the length of the pipe element, and to determine the result (force,
moment and stresses) at the particular location.
 All structural masses of pipeline elements, valves, flanges, isolation joint, and
coatings have been included.
 Internal pressure, fluid content and temperature have been included in the
model.
 The pipe system are assumed to be in fully corroded condition to calculate
sustained, expansion, longitudinal, occasional, and combined stress for design
case. For hydrotest case, it has been analyzed in new condition (using
nominal thickness).
STRESS CRITERIA
LOAD COMBINATION
The static stress analysis has been carried out for two cases: design and
hydrostatic test. The following functional loads have been considered in the
analysis:
 Pipeline internal design pressure and temperature.
 Pipeline self content, steel weight
 Earthquake

Table Below is the list of code and non-code load combination used in the
analysis.
Non Code Combination

No. Load Case Load Description

1. GR Gravity

2. T1 Thermal

3. P1 Operating Pressure

4. Functional (GRT1P1) Gravity + Thermal + Operating Pressure

Gravity + Thermal + Operating Pressure +

5. Functional (GRT1P1+E1)
Earthquake
Gravity + Thermal + Operating Pressure -
6. Functional (GRT1P1-E1)
Earthquake
Code Combination
No. Load Case Category Loading Combination

1. Hoop Hoop Max Pressure

Longitudinal
2. Rest Fun GR + Temp + Pressure
GRT1P1
Combination
3. Rest Fun GR + Temp + Pressure
GRT1P1
Longitudinal Gravity + Thermal + Operating
4. Rest Env
GRT1P1 + E1 Pressure + Earthquake
Combination Gravity + Thermal + Operating
5. Rest Env
GRT1P1+E1 Pressure + Earthquake
Longitudinal Gravity + Thermal + Operating
6. Rest Env
GRT1P1 +-E1 Pressure - Earthquake
Combination Gravity + Thermal + Operating
7. Rest Env
GRT1P1-E1 Pressure - Earthquake
INPUT MODELLING AND ANALYSIS
AUTOPIPE
 Pipeline Global Coordinate

 The model global coordinate system adopts the following orientation:

 Y-axis: north

 X-axis:east
 Z-axis: vertical (upward)

 The local coordinate system in AUTOPIPE model is defined as below figure:


 Input Data Proses

Description Unit Value

Design Pressure @ Ref erence Height (1) MPa (psig) 4.14 (600)
Design Temperature(1) C (F) 65.6 (150)
Operating Pressure @ Ref erence Height (1) MPa (psig) 2.78 (402.91)
Operating Temperature(1) C (F) 48.74 (119.74)
Installation Temperature(2) C (F) 15 (59)
Pipeline Hydrostatic Test Pressure(3) MPa (psig) 5.175 (750)

Riser and Tie-in Spool Hydrostatic Test Pressure(4) MPa (psig) 5.796 (840)

Pressure Ref erence Height (M.S.L) m (f t) 10.97 (36)

6.73 ~ 21.14
Product Density (1) kg/m3 (lb/f t 3)
(0.42 ~ 1.32)
Pressure Rating f or Pipeline Components 600#
 Input Pipe Properties
Description Unit Value
Outside Diameter mm (in.) 273.1 (10.75)
Wall Thickness mm (in.) 12.7 (0.5)
Fabrication (f or Pipeline) - HF-ERW/SMLS
Fabrication (f or Riser and Tie-in Spool) SMLS

Description Unit Value

Material Grade - API 5L X65 PSL2
Carbon Steel Density kg/m3 (lb/f t 3) 7850 (490)
Young’s Modulus MPa (psi) 2.07105 (30.0106)
Poisson’s Ratio - 0.3
Coef f icient of Linear Expansion /C (/F) 11.710-6 (6.510-6)
Structural Damping Ratio - 0.005
Internal Corrosion Allowance1) mm (in.) 3.2 (0.126)

Description Unit Value

Anti-corrosion Coating Material(1) - AE
Anti-corrosion Coating Thickness (1) mm (in.) 5.5 (0.217)
Anti-corrosion Coating Density (1) kg/m3 (lb/f t 3) 1280 (79.9)
Anti-corrosion Coating Cut Back Length(1) mm (in.) 225±12 (8.86±0.5)
Concrete Coating Density kg/m3 (lb/f t 3) 3044 (190)
Concrete Coating Compressive Strength MPa (psi) 31. 4496)
Concrete Coating Cut Back Length mm (in.) 350±10 (13.78±0.4)
Input Pipe Properties
 Input Soil Properties
 Set Static Analysis Load Cases
 Modify Load Combination
 CURICULUM VITAE
HAMID SOBIRIN
PIPELINE ENGINEER
Address : Jl. Mess AL Perum Graha Cibubur View
Blok C No. 10 RT.02 RW.03 Kel. Jati Raden
Kec. Jati Sampurna Kota Bekasi – Indonesia
Place, Date Of Birth : Lumajang, 8 Nov 1989
Phone : (+62) 81 216 360 930,
Email : hamidsobirin0811@gmail.com
hamid_sobirin@yahoo.com

EXPERIENCE
1. PT SINGGAR MULIA (Jan 2013 – Jun 2019)
2. PT INTI KARYA PERSADA TEKNIK (Aug 2011 – Dec 2012)