2020-2021

Duhok polytechnic university

Technical college of engineering
Petrochemical Engineering
Department

COURS: Graduation Project

SUPERVISOR: Dr.Ayad

DELIVERY Jan 30, 2021

DATE:

Name of project:

🅿ipeline Design for Transportation Crude oil

from Atrush field to the importing sea port
of Jihan (Ceyhan)

Submitted 🅱🆈 : ✹ Younis Aziz

✹ Maran Munir
✹Yousif Fadhel

✹ Sazan Luqman
✹ Nahla Abdulkarem

0
TABLE OF CONTENTS

Introduction ________________________________3-10.

Map ________________________________________ 12

Project Data ________________________________________ 13

Calcutation _______________________________________ 14-24

Final data __________________________________________ 25

References ___________________________________ 25

Pipeline Design 1
INTRODUCTION

➲ WHAT IS PIPING ENGINEERING?

Piping engineering is a specialized branch of engineering dealing with design &

layouts of piping network along with the Equipment in a process plant. These
layouts from a complete blueprint of the plant & are used for plant construction
at site. The most important factors to be considered’ are process requirements,
safety, operability, maintenance, compliance with statutory requirements &
economy.

➲ Pipeline Overview

A pipeline is a most economical mean of transporting liquids and gases over

long distances. Although they require high initial capital investment, they far
more than compensate for the expenses made during their construction.

▪ About Pipelines

Pipelines are used for transportation of Gases, Liquids and Solids. Various gases
transported are Natural Gas, LPG and LNG. Most commonly transported liquids
are Crude Oil, Petroleum products and water. Pipelines are also used for
transportation of solids in suspension form e.g. Iron Ore, coal etc. Various
petroleum products like Motor Spirit, HSD, ATF etc. are transported by
pipelines.

Pipeline Design 2
➲ Energy Savings Due to Pipelines:

No. Transportation Mode Energy Consumption in

Percentage of Energy Transported
1 Liquid Pipelines 0.5
2 Liquid -> Coastal Transportation 0.8

3 Liquid ->Trains Transportation 1

4 Liquid -> Trucks Transportation 3.2
5 Coal -> Trains 0.8
6 Coal -> Coastal 1.1
7 Natural Gas Pipelines 2

➲ Types of Pipelines:

❶ Offshore submarine pipeline laid on seabed – Marine offloading Terminals

and Outfalls.
❷ Onshore cross-country pipeline laid 1 meter’s underground – Trunk
Pipelines.
❸ Spur/Branch Pipelines

➲ Major Advantages of Pipelines:

Major advantages of pipelines w.r.t. other modes of material transport are low
cost of transportation, accessibility to remote areas, less time for
transportation. Pipelines are environment friendly, require least energy
requirement and have lowest cost of maintenance. They have minimum impact
on land use pattern with negligible loss of product in transit. Their high
reliability and multi product transportation facility makes them attractive mode
of product transport.

Pipeline Design 3
➲ Disadvantages of Pipelines:

Major disadvantage of pipelines is their high initial cost. Also, there is a

problem of dead stock / inventory in pipelines.

➲ Pipeline Risk Management

❶ The risk associated with the pipeline, in terms of the safety of people,
damage to the environment, and loss of income, depends on the expected
failure frequency and the associated consequence, which is directly related to
the type of fluids transported and the sensitivity of locations of the pipeline.

❷ In this context, pipeline failures are defined as loss of containment.

❸ The potential pipeline failures, causes and their consequences, should be

inventoried and taken into account in the design and the operating philosophy.

➲ Responsibilities of Piping Design Engineer:

▪ Responsibilities piping design engineer begin with:

❶ Preparation of plot plan, equipment layouts piping studies, piping

specification;
❷ Review of process package;
❸ Giving inputs to civil, vessel, electrical / instrumentation groups for various
purposes.

Pipeline Design 4
▪ Goes through:

❶ Preparation of piping layouts, isometrics, support Drawings;

❷ Stress analysis
❸ Procurement assistance;
❹ Preparation of drawings for statutory approvals;
❺ Preview of vendor drawings;
❻ Coordination with various engineering groups & site. And ends with
completion & commissioning of plant.

➲ Activities of piping design engineer:

▪ Review of process package:

This activity is carried out prior to start the detail engineering to ensure
availability of all the required process data by all engineering groups. This
includes the following:

❶ Process data required converting P & ID’s to piping layouts like a proper
identification of valves, strainers, In-line instruments,
❷ Utility summery giving utility consumption for each equipment with duty
conditions like pressure, temperature etc.,
❸ Conceptual equipment layout drawings for process plant reflecting the
process constraints.
❹ Process data sheets for equipment’s.
❺ Hazardous area classification etc.

Pipeline Design 5
➲ Stages of Pipeline Project:

❶ Conceptualization

▪ Establish Requirement
▪ Evaluate Alternatives
▪ Finalize the Concept

❷ Feasibility Study

▪ Pipeline route Study and Selection

▪ Hydraulic Studies and Optimization
▪ Establish Project Cost
▪ Project Implementation Scheme
▪ Environmental Impact Assessment and Risk Analysis

❸ Basic Engineering

▪ Process Design and Sizing

▪ Optimization Studies
▪ Route Surveys and Investigations

❹ Detailed Engineering

▪ Engineering Design basis

▪ Route Engineering and Engineering Analysis
▪ Specifications and Job Standards
▪ Engineering for Procurement
▪ Installation Engineering and Construction Procedures

➲ what’s the Pumping station:

A pumping station consists of a pump and associated piping with the purpose
of boosting liquid pressure to provide the energy for transmission and
distribution of a liquid.

Pipeline Design 6
➲ Introduction to piping design and projects

There are many commercial and industrial fluid handling applications conveying
fluid from one location to another. At the outset, one must ask the following
questions:

❶ What fluids must be conveyed?

▪ _ Oil, water, gas, steam, air, N2, and others
▪ Are solids present?
▪ What are the rates, pressures, temperatures, and viscosities?

❷ What do we want to do with the fluid?

▪ Move from point A to point B
▪ How far? What are the elevation differences/conditions?

❸ How will we do what? Construction

▪ What “piping?” There is a broad spectrum of goods available.
• What type of pipe is required?
o Note: piping vs. tubing—standard vs. nonstandard sizes
- Nominal pipe side (NPS)¼pipe OD
- Pipe ID varies with wall thickness
• What valves and fittings are required?
• Is pumping/compression required?
• Is heating/cooling required?
• What process equipment is needed?
▪ What materials, size, and thickness are required?
▪ What is the layout? How will the piping be supported?

Final design emerges from familiarity with piping and pipeline systems,
equipment, instrumentation, plant design, and related disciplines.

Pipeline Design 7
➲ Pump station

✓ In each pump station we need:

▪ Electricity (high voltage transformers) for pump

▪ Road for cars and transportation
▪ Engineers and workers
▪ Camp for engineers and workers
▪ Security
▪ Control room
▪ Canal water supply
▪ Land drainage
▪ Sewage systems

✓ For pipelines it should be:

▪ Cathodic protection
▪ Metering system
▪ Leakage detectors
▪ Team for check pipeline
▪ Measurement parameter(sensor)
• Temperature measurement
• Pressure measurement
• Flow measurement
▪ PIG Launchers and PIG Receivers system
▪ Valve

✓ Pump required

▪ PCV (pressure control valve)

▪ Emergency shutdown valve (before and after each pump)
▪ Check valve (before and after each pump)

Pipeline Design 8
➲ Fluid characteristics (Physical properties)

The physical properties of the transported fluid play an important role in

determining the pipe diameter and selecting the pipe material and the
associated equipment. They are also important in determining the power
required to transport the fluid. The most important fluid properties that affect
piping and pipeline design are the following:

▪ Composition
▪ Density
▪ Viscosity
▪ Vapor pressure
▪ Water content
▪ CO2 and H2S content

➲ Material Selection

▪ Stainless steel

Stainless steel pipe is used when corrosion resistance is required. The addition
of chromium gives stainless steel its corrosion resistance properties. Austenitic
stainless steels, identified with the 300 series, contain a maximum of 0.15%
carbon and a minimum of 16% chromium, along with nickel and/or manganese.
Austenitic stainless steels are nonmagnetic and have the best high-temperature
strengths of all the stainless steels. Ferritic stainless steels, identified with the
400 series, contain 14-27% chromium and are magnetic. Martensitic stainless
steels contain 11.5-18% chromium and are also magnetic. Martensitic stainless
steels are commonly used in valve components. Austenitic stainless steels are
the most commonly used in piping systems. The most common grades used in
piping are 304 and 316. There are subsets of these that contain lower carbon,
making them less susceptible to carbide precipitation. These are designated by

Pipeline Design 9
the suffix “L.” Stainless steels are susceptible to stress corrosion cracking and
so exposure to chloride compounds should be avoided.

▪ Applications
Stainless steel piping is used whenever iron dissolution cannot be tolerated.
Stainless steel is used whenever corrosion needs to be avoided, as in heat
exchangers and boilers.

▪ Cast iron
Cast iron contains between 2% and 6.67% carbon. These metals are strong but
brittle. They exhibit very low ductility and malleability and cannot be drawn,
rolled, or worked at room temperature. A sharp blow with a hammer can crack
a cast iron pipe. Cast irons melt readily and can be cast into complicated shapes
and machined. This property makes them well suited for some valve bodies.

▪ Applications
Since cast iron is so brittle, it is not often used for pressure piping applications,
although ASME B31.3 contains basic allowable stress data for gray cast iron
pipe. Cast iron pipe is used primarily for drain, waste, and vent applications.

Pipeline Design 10
➲ What are PIG Launchers and PIG Receivers?

In simplest terms the PIG launchers and PIG receivers are the sections of the
pipeline which allow the PIG to enter and exit the pipeline. They are generally
funnel, Y-shaped sections of the pipe which can be pressurized or depressurized
and then safely opened to insert or remove PIGs. Most pigging systems use
bidirectional launchers and receivers that can work in either direction. This is
important to allow the PIG to be retrieved by the launcher if there is a blockage
in the pipeline which prevents it from reaching the receiver.
PIG launchers and receivers come with safety valves and locking system to
prevent accidents. They are also optimized to be suitable to the pressure and
temperature requirements of the pipeline. Launchers and receivers may be
horizontal or vertical depending on the needs of the pipeline.

11
 ❖ Map

➲ About high ways:

I suggest that when the

pipeline passes from the
highway, it passes under the
road with a depth of 1.5 m,
but first a concrete pipe
must be built after that the
steel Pipe passes from inside
the concrete (the concrete
pipe is strong to withstand
all pressure).and about the
small rivers should be build
bridge and pipe passes over
the bridge.

Pipeline Design 12
PROJECT DATA

🖎Case Description:
✹ Transportation of Crude oil from Atrush field to the importing sea port of
Jihan (Ceyhan). The following data are available:

❶ The distance between the field and the importing sea port is 450km.
❷ The pipeline capacity should not exceed 650 000 barrels per day.
❸ There are four pumping boosters working within the pipeline. The
distance between each two pumping boosters is 120km.
❹ The net elevation is 122m.
❺ The pipeline should cross a small river and 8 high ways.
❻ There are 4 valleys that the pipe line should cross. The mean depth of the
valleys are 12m.

NOW:
❶ State the steps that you should be followed to make a perfect design for
such a project.
❷ What are the precautions that should be taken in your consideration?
❸ State a map road for designing such a project.

Pipeline Design 13
CALCULATION

➲ Assumption:

❶ Crude oil physical data:

𝑘𝑔 𝑘𝑔
▪ Density = 870 to 920 3 (we will assume 900 3 for our project)
𝑚 𝑚
▪ Viscosity =4 cp

❷ Pipe Material and Grade:

▪ Steel pipe
▪ Spec No: API 5L
▪ Grade: A25
▪ Roughness = 0.05 mm

❸ We will assume that the elevation of the pipe will increase gradually, so we
will divide it between four pumping stations, each will be (30.5 m)

➲ Design steps:

❶ Velocity constraints: According to (API RP 145)

(API RP 145 is a standard reding to minimum and maximum velocity of crude oil
in pipelines)

𝑚
▪ Maximum velocity in the pipe= 3.0 to 4.5 (To avoid erosion)
𝑠
𝑚
▪ Minimum velocity in the pipe= 0.9 to 1.2 (To avoid sediment settling)
𝑠

𝑏𝑏𝑙(𝐶𝑟𝑢𝑑𝑒 𝑜𝑖𝑙) 𝑚3 (𝐶𝑟𝑢𝑑𝑒 𝑜𝑖𝑙)

- Flow rate= 650,000 𝑑
= 1.19608
𝑠

Pipeline Design 14
 𝑄 1.19608
𝑄 = 𝐴𝑉 A= = = 0.3986 𝑚2
𝑉 3
𝑑= 0.7124 𝑚
𝜋
= 28 in A= 𝑑 2
4
𝑚3
✹ Q = Flow rate ( 𝑠
)
✹ 𝐴 = Area of pipe (𝑚2 )
𝑚
✹ 𝑉 = Velocity of crude oil ( )
𝑠
✹ 𝑑 =Diameter of pipe (𝑚, 𝑖𝑛)

▪ So, we will start are design from NPS 30 in, then we will test 32 in, 34 in, 36
in also.

❷ Pressure Drop:

▪ Apply Bernoulli’s equation from suction of pump No.❶ To suction of pump

No.❷ (We will keep 5 bar suction for each pump)

𝑝1 𝑉12 𝑝2 𝑉22
𝜌𝑔
+
2𝑔
+ 𝑍1 + ℎ𝑝 − ℎ𝑓= + + 𝑍2
𝜌𝑔 2𝑔

ℎ𝑝 = 𝑍2 + ℎ𝑓

✹ Z1 & Z2 are elevation, so Z1=0, Z2=30.5 m (122/4)

✹ P1=P2 (we keep the same section pressure for all pumps)
✹ V1=V2 (Because the pipe diameter is same)

✹ ℎ𝑝 is pump required head

✹ ℎ𝑓 is friction head loss

Pipeline Design 15
▪ As we assumed before that the elevation increase gradually, we will put
elevation for each section to be = 30.5 m

120 km

30.5 m
Pumping station No.➀ Pumping station No.➁

🅿1 🅿2

𝑝1 𝑉12 𝑝2 𝑉22
𝜌𝑔
+
2𝑔
+ 𝑍1 + ℎ𝑝 − ℎ𝑓= + + 𝑍2
𝜌𝑔 2𝑔

▪ So, Final equation will be: ℎ𝑝 = 𝑍2 + ℎ𝑓

▪ Both ℎ𝑝 and ℎ𝑓 are unknown, we will use moody chart and Reynolds
number (Re) and Relative roughness(r) to find friction factor(𝑓).
- So, we will start by the following steps:

1) Assume Diameter
2) Find ℎ𝑓 from moody chart
3) Find pump required head (ℎ𝑝)

Pipeline Design 16
▪ The bigger the pipe diameter, the smaller pump head will be, so we will test
30 in, 32 in, 34 in, 36 in pipes and make selection and optimizing according
to the cost.

𝑍1 = 0, 𝑍1 = 30.5 𝑚, P1=P2(we will keep 5 bar for all pumps section)

Roughness = 0.05 mm

ℎ𝑝 = 30.5 + ℎ𝑓

𝜋
D= 30 in =0.7624 m, A= 𝑑2 =0.45603 𝑚2
4

𝑄
𝑄 = 𝐴𝑉 𝑉=A
𝑚3
1.19608 𝑚
= 𝑠
= 2.6226 (Acceptable)
0.45603 𝑚2 𝑠

𝑒 0.05 𝑚𝑚
Relative roughness r= (e in mm and d in mm) = = 6.6 ∗ 10−5
𝑑 762.4 𝑚𝑚

𝜌𝑉𝑑 900∗2.6226∗0.7624
• 𝑅𝑒 = = = 449881 turbulent flow
𝜇 4∗10−3

Pipeline Design 17
(From Moody chart 𝑓 = 0.013503)

𝐿𝑉2 120000 ∗ (2.6226)2

ℎ𝑓 = 𝑓 = (0.013503) = 785.59 𝑚
𝐷2𝑔 0.7624 ∗ 2 ∗ 9.81

ℎ𝑝 = 30.5 + 785.59 = 816.1 m

Pipeline Design 18
❸ Maximum Pressure: we have three valleys each one 12 m, so the maximum
pressure will be at the bottom of the valley, we need this pressure to find
maximum pressure in the pipe and to select design pressure (we will assume
that the valleys are exactly behind the pumping station ) .

➀ ➁

12 m
Pumping station No.➀ Bottom of the valley

▪ Apply Bernoulli’s equation from suction of pump to the bottom of valley

(assume valley is just below the pump)

▪ We will try 5 bar pressure to each pump.

𝑃2 = 𝑍1𝜌𝑔 + 𝑃1 + ℎ𝑝𝜌𝑔

𝑃2 = 12 ∗ 900 ∗ 9.81 + 500000 + 816.1 ∗ 900 ∗ 9.81

= 7811294.9 𝑝𝑎𝑠𝑐𝑎𝑙
𝑃2 = 78.11 𝑏𝑎𝑟 (so, we will select 85 bar as a design pressure)

❹ Pipe thickness and schedule No:

Piping codes: The following standards from the American Natl. Standards Inst.
(ANSI) and the American Soc. of Mechanical Engineers (ASME) specify wall-
thickness requirements.
ANSI/ASME Standard B31.1, Power Piping. This standard applies to steam piping
systems.
ANSI/ASME Standard B31.3, Chemical Plant and Petroleum Refinery Piping, this
standard applies to major facilities onshore and offshore worldwide.
Pipeline Design 19
ANSI/ASME Standard B31.4, Liquid Transportation Systems for Hydrocarbons,
Liquid Petroleum Gas, Anhydrous Ammonia, and Alcohols, this standard applies
to onshore oil pipeline facilities.
ANSI/ASME Standard B31.8, Gas Transmission and Distribution Piping Systems.
This standard applies to gas transmission, gathering, and distribution pipelines
onshore.

• Pipelines are designed according to ASME B31.4

The ANSI/ASME Standard B31.4 code is somewhat less stringent than that of
Standard B31.3 because of the lower levels of hazard associated with liquid
pipelines. The code for Standard B31.4 is used often as the standard of design
for crude-oil piping systems in facilities, such as pump stations, pigging facilities,
measurement and regulation stations, and tank farms. The wall-thickness
formula for Standard B31.4 is stated as

Where

t = minimum design wall thickness, in.,

P = internal pressure in pipe, psi,
dO = Outside diameter of pipe, in.,
SY = minimum yield stress for pipe, psi (Table 9.11)
F = design factor (0.72 for all locations),
E = longitudinal weld-joint factor [1.0 seamless, ERW, double submerged
arc weld and flash weld]

Pipeline Design 20
Pipeline Design 21
t = ?
P = internal pressure in pipe, psi, maximum pressure was 78.11 bar, we
will select 85 bar as a design pressure (85 bar *14.5=1232.5 psi)
dO = 30 in.,
SY = 25000 psi from our Grade
F = 0.72 for all locations,
E = 1.0 for ERW welding at 5 f,

1232.5∗30
𝑡= = 1.02708 in
2∗0.72∗1∗25000

▪ We will repeat the same above procedure to other sizes (32,34,36) in then
we will select optimum pipes and schedule:

Size hp Max. Design Thickness Schedule

(in) Pressure Pressure (t)
30 816.1 78.11 85 1.027 Not
available
32 600 59 65 0.838 Not
available
34 440 45 50 0.685 40
Weight (244.77)

36 345 36.51 42 0.575 30

Weight (236.13)

▪ 36 in NPS (nominal pipe size) schedule 30 in weight is less than 34 in NPS

schedule 40 in and also less cost

✹ So our selection will be 36 in NPS schedule 30

This schedule data it depends

on next table.

Pipeline Design 22
• Thickness
• Weight
Pipeline Design 23
➲ double check the calculation with actual inside diameter:
𝐼𝐷 = 𝑂𝐷 − 2 ∗ 𝑡
𝑡 = 0.625 𝑓𝑜𝑟 36 𝑖𝑛 𝑠𝑐ℎ. 30
𝐼𝐷 = 36 − 2 ∗ 0.625 = 34.75 𝑖𝑛
𝑚
Velocity= 2 𝑠
, Re=388128, f= 0.0144
𝐿𝑉 2 120000 ∗ (2)2
ℎ𝑓 = 𝑓 = (0.0144) = 399 𝑚 𝑠𝑎𝑦 400 𝑚
𝐷2𝑔 0.88265 ∗ 2 ∗ 9.81
ℎ𝑝 = 𝑍2 + ℎ𝑓 = 30.5 + 400 = 430.5 𝑚

▪ Maximum pressure:

𝑃2 = 12 ∗ 900 ∗ 9.81 + 500000 + 430.5 ∗ 900 ∗ 9.81

𝑃2 = 44.06 𝑏𝑎𝑟 𝑠𝑒𝑙𝑒𝑐𝑡 𝑑𝑒𝑠𝑔𝑖𝑛 𝑝𝑟𝑒𝑠𝑠𝑢𝑟𝑒 50 𝑏𝑎𝑟

50∗14.5∗36
𝑡= = 0.725 in > 0.625
2∗0.72∗1∗25000

We can’t select sch. 30

✹ Test sch. 40 in t=0.75 in

𝐼𝐷 = 36 − 2 ∗ 0.75 = 34.5 𝑖𝑛
𝑚
Velocity= 2 𝑠
, Re=390940, f= 0.0144
𝐿𝑉 2 120000 ∗ (2)2
ℎ𝑓 = 𝑓 = (0.0144) = 402 𝑚
𝐷2𝑔 0.8763265 ∗ 2 ∗ 9.81
ℎ𝑝 = 𝑍2 + ℎ𝑓 = 30.5 + 402 = 432.5 𝑚 𝑠𝑎𝑦 433 𝑚
▪ Maximum pressure:
𝑃 = 44.3 𝑏𝑎𝑟 (𝑠𝑎𝑦 50 𝑏𝑎𝑟)
𝑡 = 0.725 in < 0.75 in (schedule 40 will be the right choose)

Pipeline Design 24
FINAL DATA

▪ So, we will order Steel pipe: class API 5L Grade= A25 with nominal pipe

size= 36 inch and schedule= 40

▪ Pump head should be = 433 m with available section pressure = 5 bar

REFERENCES
✹ Stewart, M., 2015. Surface Production Operations: Volume III: Facility Piping and
Pipeline Systems. Gulf Professional Publishing.

✹DeGeer, D. and Nessim, M., 2008, January. Arctic pipeline design considerations.
In ASME 2008 27th International Conference on Offshore Mechanics and Arctic
Engineering (pp. 583-590). American Society of Mechanical Engineers Digital Collection.

✹Dinovitzer, A.S. and Smith, R.J., 1998, June. Strain-based pipeline design criteria review.
In 1998 2nd International Pipeline Conference (pp. 763-770). American Society of
Mechanical Engineers Digital Collection.

Pipeline Design 25